Iveco GE NEF 45M, GE NEF 60M, GE NEF 75M, GE NEF 85M, GE NEF 100M Service Manual

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NEF TIER 2 SERIES

Power generation application

NEF 45

GE NEF 45M GE NEF 60M GE NEF 75M GE NEF 85M

GE NEF 100M

GS NEF 45M GS NEF 60M GS NEF 75M GS NEF 85M

GS NEF 100M

NEF 60

GE NEF 200E

GS NEF 200E

NEF 67

GE NEF 125M GE NEF 130M GE NEF 160M

GS NEF 125M GS NEF 130M GS NEF 160M

Technical and Repair manual

This publication describes the characteristics, data and correct methods for repair operations on each component of the vehicle.

If the instructions provided are followed and the specified equipment is used, correct repair operations in the programmed time will be ensured, safeguarding against possible accidents.

Before starting to perform whatever type of repair, ensure that all accident prevention equipment is available and efficient.

All protections specified by safety regulations, i.e.: goggles, helmet, gloves, boot, etc. must be checked and worn.

All machining, lifting and conveying equipment should be i nspected before use.

The data contained in this publication was correct at the time of going to press but due to possible modifications made by the Manufacturer for reasons of a technical or commercial nature or for adaptation to the legal requirements of the different countries, some changes may have occurred.

No part of this publication, including the pictures, may be reproduced in any form or by any means.

Publication edited by Iveco Motors Iveco SpA PowerTrain Mkt. Advertising & Promotion Viale dell’Industria, 15/17 20010 Pregnana Milanese Milano (Italy)

Print P4D32N001 E -2

Ed. 04.2007

Produced by:

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

RYR

NEF POWER GENERATION ENGINES

PRELIMINA

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. 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.

EMARKS

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.

NOTE

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.

It indicates an additional explanation for a piece of information.

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GENERAL WARNINGS

Warnings shown cannot be representativeof all dangersituations possiblyoccurring. Therefore, it issuggested 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.

NEF POWER GENERATION ENGINES

Do not leave the running assembly unattended when making repairs.

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

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

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

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

Worn out, damaged or consumable parts must be replaced by IVECO Motors 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 repair interventions must meet safety rules.

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NEF POWER GENERATION ENGINES

GENERALWARNINGS

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

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

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

Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.

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

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

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

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

Tightening screws and nuts must always be according to prescriptions; IVECO Motors 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 ON THE ELECTRIC SYSTEM

If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,

always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.

Before connecting the batteries to the system, make sure that the system is wel l 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 IVECO Motors 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.

NEF POWER GENERATION ENGINES

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 presentmust be seen from cable side. Connectors views contained in the manualare representative of cable side.

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NEF POWER GENERATION ENGINES

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 c onnected both to a system bonding point such as the dashboard opening bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.

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

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

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

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

Figure 1

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

Figure 2

88039

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

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NEF POWER GENERATION ENGINES

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

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

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

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

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.

according to ratio 1:1

Temperature

0° C=32° F 1° C = (1 x 1.8 + 32) ° F

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NEF POWER GENERATION ENGINES 1

NEF POWER GENERATION ENGINES

F4GE NEF engines Part 1

F4AE NEF engines Part 2

Main electrical power and Troubleshooting Part 3

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NEF POWER GENERATION ENGINES

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F4GE NEF ENGINES

Part 1 F4GE NEF ENGINES

Section

General specifications

Fuel 2

Power Generation application 3

Overhaul and technical specifications 4

Tools 5

Safety prescriptions Appendix

PREFACE TO USER’S GUIDELINE MANUAL

Section 1 describes the NEF engine illustrating its features and working in general.

Section 2 describes the type of fuel feed.

Section 3 relatesto 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 directinstructions to identify the cause of the major inconveniences.

Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such operations.

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F4GE NEF ENGINES

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F4GE NEF ENGINES

SPECIAL REMARKS

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

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

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F4GE NEF ENGINES

SYMBOLS - ASSISTANCE OPERATIONS

F4GE NEF ENGINES

Removal Disconnection

Refitting Connection

Removal Disassembly

Fitting in place Assembly

Tighten to torque

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Regulation Adjustment

Visual inspection Fitting position check

Intake

Exhaust

Operation

Compression ratio

Tolerance Weight difference

Angle Angular value

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

Replacement Original spare parts

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F4GE NEF ENGINES

UPDATING

Section Description Page Date of revision

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F4GE NEF ENGINES

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F4GE NEF ENGINES

SECTION 1 - GENERAL SPECIFICATIONS 1

SECTION 1

General specifications

Page

ELECTRICAL SPECIFICATIONS

OF THE GENERATING SETS 3............

CORRESPONDENCE BETWEEN TECHNICAL

CODE AND COMMERCIAL CODE 4.......

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

OIL VAPOUR RECIRCULATING SYSTEM 6.....

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

AIR INDUCTION BOOST DIAGRAM 8........

- Description 8...........................

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SECTION 1 - GENERAL SPECIFICATIONS

F4GE NEF ENGINES

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F4GE NEF ENGINES

ggR

ating

GENEF45MNEF45AM

GENEF60MNEF45SM

GENEF75MNEF45SM

GENEF85MNEF45TM

GENEF100MNEF45TM2

GENEF125MNEF67SM1

GENEF130MNEF67TM2

GENEF160MNEF67TM3

GSNEF45MNEF45AM

GSNEF60MNEF45SM

GSNEF75MNEF45SM

GSNEF85MNEF45TM

GSNEF100MNEF45TM2

GSNEF125MNEF67SM1

GSNEF130MNEF67TM2

GSNEF160MNEF67TM3

ELECTRICAL SPECIFICATIONS OF THE GENERATING SETS

Electrical specifications

Generating set Assembled Engine

Prime 45 36 50 40

Stand By 50 40 55 44

Prime 60 48 66 53

Stand By 66 53 73 58

Prime 75 60 75 60

Stand By 82 66 82 66

Prime 85 68 100 80

Stand By 94 75 110 88

Prime 100 80 110 88

Stand By 110 88 121 97

Prime 125 100 145 116

Stand By 138 110 160 128

Prime 130 104 145 116

Stand By 143 114 160 128

Prime 160 128 170 136

Stand By 176 141 187 150

Prime 45 36 50 40

Stand By 50 40 55 44

Prime 60 48 66 53

Stand By 66 53 73 58

Prime 75 60 75 60

Stand By 82 66 82 66

Prime 85 68 100 80

Stand By 94 75 110 88

Prime 100 80 110 88

Stand By 110 88 121 97

Prime 125 100 145 116

Stand By 138 110 160 128

Prime 130 104 145 116

Stand By 143 114 160 128

Prime 160 128 170 136

Stand By 176 141 187 150

50 Hz 60 Hz

kVA kW (*) kVA kW (*)

SECTION 1 - GENERAL SPECIFICATIONS 3

(*) Power factor 0.8.

Prime Power

The Prime Power is the maximum power available with varying loads for an unlimited number of hours. The average power output during a 24 h period of operationmust not exceed 80% of the declared prime power between the prescribed maintenance intervals and at standard environmental conditions. A 10% overload is permissible for 1 hour every 12 hours of operation.

Stand-by Power

This is the maximumpower available for a period of 500 hours/year with a mean loadfactor of 90% of the declared stand-by power. No kind of overload is permissible for this use.

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SECTION 1 - GENERAL SPECIFICATIONS

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

Technical Code Commercial Code

F4GE0405A*F600 GE NEF 45M F4GE0405B*F600 GE NEF 45M F4GE0455A*F600 GE NEF 75M F4GE0455B*F600 GE NEF 75M F4GE0455C*F600 GE NEF 60M F4GE0485C*F600 GE NEF 85M F4GE0485A*F600 GE NEF 100M F4GE0655B*B600 GE NEF 125M F4GE0685D*F601 GE NEF 130M F4GE0685B*F601 GE NEF 160M

F4GE NEF ENGINES

Technical Code Commercial Code

F4GE0405A*F600 GS NEF 45M F4GE0405B*F600 GS NEF 45M F4GE0455A*F600 GS NEF 75M F4GE0455B*F600 GS NEF 75M F4GE0455C*F600 GS NEF 60M F4GE0485C*F600 GS NEF 85M F4GE0485A*F600 GS NEF 100M F4GE0655B*B600 GS NEF 125M F4GE0685D*F601 GS NEF 130M F4GE0685B*F601 GS NEF 160M

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F4GE NEF ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

LUBRICATION

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

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

Figure 1

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

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

Lubrication delivery oil

106533

Oil returning to sump

LUBRICATION SYSTEM LAYOUT (6 cyl. engines)

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SECTION 1 - GENERAL SPECIFICATIONS

OIL VAPOUR RECIRCULATING SYSTEM

Figure 2

F4GE NEF ENGINES

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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F4GE NEF ENGINES

SECTION 1 - GENERAL SPECIFICATIONS

COOLING SYSTEM

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

- expansion tank; placement, shape and dimensions are

subject to change according to the engine’s equipment;

- radiator, which has the duty to dissipate the heat

subtracted to the engine by the cooling liquid. Also th is 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

- heatexchange

o coolthe lubrication oil: eventhis

component is part of the engine’s specific equipment;

- centrifugal water pump, placed in the front part of the

engine block;

- thermostat regulating the circulation of the cooling

liquid;

- the circuit may eventu ally be extended to the

compressor, if this is included in the equipment.

117585

COOLING SYSTEM LAYOUT (6 cyl. engines)

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SECTION 1 - GENERAL SPECIFICATIONS

AIRINDUCTION BOOST DIAGRAM

Figure 4

F4GE NEF ENGINES

AIR FILTER

RADIATOR

4 cylinders version

TURBOCHARGER

EXHAUST

74195

TURBOCHARGER

EXHAUST

RADIATOR

6 cylinders version

Description

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

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

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

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

74195

The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector before the turbine and connected by piping to the induction c ollec t or.

It’s duty is to choke the exhaust of the emissions , releasing part of them directly to the exhaust tube when the boost feeding pressure, over the compressor, reaches the prescribed bar value.

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

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F4GE NEF ENGINES

SECTION 2 - FUEL 1

SECTION 2

Fuel

Page

INJECTION FEED SYSTEM BY MECHANICAL

ROTARY PUMP 3.......................

- General information 3.....................

- Description of working principles 3...........

FEED PUMP 4............................

- STANADYNE DB4 pump 4................

- Description of operation 4.................

PRIMING PUMP 5.........................

FUEL FILTER 6............................

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SECTION 2 - FUEL

F4GE NEF ENGINES

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F4GE NEF ENGINES

INJECTION FEED SYSTEM BY MECHANICAL ROTARY PUMP General information

Fuel feed system is composed by:

- Fuel tank

- Fuel delivery and back-flow to tank

- Fuel pre-filter

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

- Fuel filter

- Fuel feed rotary pump

- Injector feed pipeline

- Injectors

SECTION 2 - FUEL

Figure 1

(6-cylinder version)

106534

Description of working principles

Fuel is sucked from the fuel tank by the priming pump. This last one is placed on the engine basement and is driven by the camshaft.

Throughout the filter, the fuel is piped to the union fitting vacuum chamber of the tran sfer pump.

Transfer pump is placed inside the feed pump, and is bladed

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.

type; its duty is to increase fuel pressure in co rrespondence with the increase of the number of revolutions.

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SECTION 2 - FUEL

FEED PUMP

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

STANADYNE DB4 pump

Figure 2

F4GE NEF ENGINES

1. Camshaft - 2. Distributor rotor - 3. Transfer pump vanes - 4. Pump element pistons (4) -

5. Cam - 6. Hydraulic head - 7. Pressure regulator unit - 8. Regulator - 9. Automatic advance - 10. Casing -

11. Metering valve- 12. Delivery valve - 13. Electrical power cut-off solenoid.

Description of operation

The main rotating components are propeller shaft (1), distributor rotor (2), transfer pump vanes (3) and regulato r (8). With reference to the Figure 2, the propeller shaft engages the distributor rotor inside the hydraulic head.

The four pistons are driven simultaneously, one towards the other, by a cam by means of rollers and pads positioned on the peripheral part of the rotor. There is one cam lobe for each engine cylinder.

The transfer pump, positioned on the rear part of the rotor, is sealed inside by the end cap. This also contains the filter mesh and the transfer pump pressure regulator.

106514

The upper part of the regulat or unit is pressed against the distributor rotor and acts as a seal for the transfer pump.

The distributor rotor incorporates two fuel inputs, an axial hole and an exhaust that serves all the outputs to the injection ports.

The hydraulic head contains the head in which the rotor turns, the metering valve seat, the fuel inputs and the connectors to the injectors. The high pressure injection pumps, connected to the injectors, are fastened to the above connectors.

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F4GE NEF ENGINES

SECTION 2 - FUEL

PRIMING PUMP

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

Figure 3

Figure 4

1. Priming pump - 2. Camshaft.

3246t

88209

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

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SECTION 2 - FUEL

F4GE NEF ENGINES

FUEL FILTER

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

On the filter cartridge base there is a water dump screw, th roughout which it is possible to provide regular drainage; on the bearing for th ose 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

106515

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

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F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

SECTION 3

Power Generation application

Page

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

- Clearance data - 4 cyl. 4...................

- Clearance data - 6 cyl. 7...................

PART ONE - MECHANICAL COMPONENTS 9

REMOVING AND REFITTING

THE SOUND-PROOFING UNIT 11.........

- Removal 11.............................

- Refitting 12..............................

REMOVING AND REFITTING THE ENGINE/

GENERATOR 13.........................

- Removal 13.............................

- Refitting 13..............................

SEPARATING THE GENERATOR FROM

THE ENGINE 14.........................

DETACHING THE TANK FROM THE BASE 15..

OVERHAULING THE 6-CYLINDER ENGINE 16..

- Introduction 16..........................

- Operations of preparing the engine for assembly

on the rotary stand 16.....................

- Installation of rear components 25............

- Flywheel installation 28.....................

- Installation of front components 28...........

- Completing the engine 37..................

- Rotary feed pump disassembly and assembly

procedure 39............................

- Disassembly 40...........................

- Rotary feed pump setting check 41...........

- Assembly 41.............................

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SECTION 3 - POWER GENERATION APPLICATION

Page

ASSEMBLY PROCEDURE OF THE ”ADC100” ELEC-

TRONIC ACTIVATOR ON STANADYNE SERIES ”D”

INJECTION PUMPS 43....................

- Assembly of the actuator 44................

PASSAGE FROM 50 HZ TO 60 HZ FOR NEF MOTORS

WITH STANADYNE PUMP 45..............

- Passage from 50 Hz to 60 Hz 45.............

- Passage from 60 Hz to 50 Hz 47.............

- Stabilization of t h e rotation regime 47.........

- Identification tag 47........................

REPLACEMENT OF THE ELECTRO-VALVE AND THE

SOLENOID VALVE THROTTLE ON STANADYNE

PUMPS 48..............................

- Electro-valve replacement 49................

- Replacement of the soleno id valve throttle 51...

- Checks and controls 52....................

F4GE NEF ENGINES

PART FOUR -

MAINTENANCE PLANNING 53...........

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

- Recovery 55.............................

- Planning of controls and periodical intervention 55

- Checks not included in maintenance

planning-daily checks 56....................

MAINTENANCE PROCEDURES 56............

- Checks and controls 56....................

- Engine oil level check. 56...............

- Check of fuel system 57................

- Cooling system check 57...............

- Lubricating system check 57.............

- Check for any water in the fuel filter 57....

- Check of drive belt tensioning 58.........

- Check of belt’s tear and wear status 58....

- Check and setting of tappet clearance 58...

- Oil motor and filter replacement 59.......

- Changing the coolant 59................

- Fuel filter replacement 60...............

- Alternator belt replacement 60...........

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

GENERAL INFORMATION

Figure 1

SECTION 3 - POWER GENERATION APPLICATION 3

ENGINE WITH 6 CYLINDERS

The NEF engines have been specifically designed by Iveco Motors for the power generation application.

They are internal combustion engines, with a 4-stroke Diesel cycle, 4 or 6 cylinders and 2 valves per cylinder.

They are fueled by a rotary mechanical pump.

Data, technical specifications and performances granted shall be valid only if the Setter will follow and

comply with all installation prescriptions provided by Iveco Motors.

Furthermore, the expanders assembled by the Setter must always comply with couple, power and number of revolutions based on which the engine has been designed.

106522

The section herein described is composed or four directories:

- directory of mechanical overhaul prescribed i n

accordance to the engine’s specific duty, illustrating all necessary operations to remove and assembly the external components of the engine, including cylinder heads, gearbox of the timing system and of the front part cover;

- electrical directory, describing the connections of the

different components, of the pre-post heating gearbox (only for some versions) and of the sensors assembled to the engine;

- troubleshooting directory;

- directory of preventive and regular maintenance

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

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

Clearance data - 4 cyl.

F4GE NEF ENGINES

bar

Type

Compression ratio 17.5:1

Working power kW

rpm

Working torque Nm

rpm

Loadless engine idling rpm

Loadless engine peak rpm rpm

Borexstroke mm Displacement cm

LUBRICATION

Oil pressure (warm engine)

F4GE0405A*F600 F4GE0405B*F600

1500

318

1500

. -

- 104 x 132

4485

Forced by gear pump, relief valve single action

oil filter

1800

15W40 ACEA E3

- idling bar

- peak rpm bar

COOLING

Water pump control Thermostat

- start of opening ºC

FILLING

engine sump liters engine sump + filter liters

0.70

3.50

By centrifugal pump, regulating thermostat, heat

exchanger, intercooler

Through belt

81 ± 2

NOTE

Base - April 2007 Print P4D32N001 E

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

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

F4GE NEF ENGINES

Clearance data - 4 cyl.

SECTION 3 - POWER GENERATION APPLICATION 5

Type

Compression ratio 17.5:1

Working power kW

rpm

Working torque Nm

rpm

Loadless engine idling rpm

Loadless engine peak rpm rpm

Borexstroke mm Displacement cm

SUPERCHARGING

Turbocharger type HOLSET HX25 HOLSET HX25W HOLSET HX25

F4GE0455A*F600 F4GE0455B*F600 F4GE0455C*F600

1500

471

1500

. - -

- - -

Without intercooler

1800

393

1800

104 x 132

4485

direct injection

1500

382

1500

bar

15W40 ACEA E3

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

Forced by gear pump, relief valve single action

oil filter

0.70

3.50

By centrifugal pump, regulating thermostat, heat

exchanger, intercooler

Through belt

81 ± 2

NOTE

Print P4D32N001 E Base - April 2007

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

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

SECTION 3 - POWER GENERATION APPLICATION

Clearance data - 4 cyl.

F4GE NEF ENGINES

Type

Compression ratio 17.5:1

Working power kW

rpm

Working torque Nm

rpm

Loadless engine idling rpm

Loadless engine peak rpm rpm

Borexstroke mm Displacement cm

SUPERCHARGING

Turbocharger type HOLSET HX27W

F4GE0485A*F600 F4GE0485C*F600

1500

471

1500

. -

- 104 x 132

4485

With intercooler

direct injection

1500

554

1500

bar

15W40 ACEA E3

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

Forced by gear pump, relief valve single action

oil filter

0.70

3.50

By centrifugal pump, regulating thermostat, heat

exchanger, intercooler

Through belt

81 ± 2

NOTE

Base - April 2007 Print P4D32N001 E

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

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

F4GE NEF ENGINES

ype

Typ

F4GE065

Clearance data - 6 cyl.

SECTION 3 - POWER GENERATION APPLICATION 7

bar

Compression ratio 17.5:1

Working power kW

rpm

Working torque Nm

rpm

Loadless engine idling rpm

Loadless engine peak rpm

Borexstroke mm Displacement cm

SUPERCHARGING

Turbocharger type HOLSET HX35W

LUBRICATION

Oil pressure (warm engine)

F4GE0655

B*B600

125

1500

796

1500

- - -

Without

intercooler

direct injection

Forced by gear pump, relief valve single action

D*F601 B*F601

104 x 132

oil filter

F4GE0685

130

1500

815

1500

6728

With intercooler

direct injection

156

1500

969

1500

NOTE

- idling bar

- peak rpm bar

COOLING Water pump control

Thermostat

- start of opening ºC

15W40 ACEA E3

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

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

FILLING

engine sump* liters

engine sump + filter* liters

* First filling operation

0.70

3.50

Liquid

Through belt

81 ± 2

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION 9

PART ONE - MECHANICAL COMPONENTS

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

REMOVING AND REFITTING THE SOUND-PROOFING UNIT

Removal

Figure 2

Figure 3

115047

Operate inside the soundproofing unit and move back the exhaust pipe cover (1) in order to reach the stop collar (2), then loosen the fastening screw (3).

114332

Operate from the control board side and disconnect the electric connection (1) from the stop button.

Figure 4

114334

Operate from the exhaust pipes side and loosen the covering panel (2) fastening nuts (1) and remove it.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 5

Remove pipe (1) from its seat.

114335

Figure 7

114337

Secure hooks with c h ain catches (1) into the slots (2) provided for the purpose and, by means of a proper hoisting device, lift the soundproofing unit (3) and remove it with the aid of another operator.

NOTE

Figure 6

When removing pipe (1), pay attention not to damage the coolin g unit air ducts (2).

NOTE

Make su re that the rods have all the same length in order to lift the soundproofing unit along the vertical axis, thus reducing interferences.

Refitting

To refit, reverse the removal in structions.

114336

Operate along the perimeter and loosen the soundproofing unit (2) fastening screws (1).

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

REMOVING AND REFITTING THE ENGINE/GENERATOR

Figure 8

SECTION 3 - POWER GENERATION APPLICATION

107479

Removal

Disconnect the electrical system by detaching the cables from the battery. Disconnect the positive and negative cables from any clamps, detach them from their attachments on the starter motor, then remove them. Remove the fan safety grilles (4) by undoing the relevant fasteners. Place a container under the cock (10) to collect the coolant. Disconnect and remove the pipes (1) and (16) together with the sleeves by undoing the clamps. Block the radiator suitably and remove it from its seat after disconnec ting the brackets (3) from the engine and the nuts (12) from the support (11). Disconnect the diesel pipes (6) from the engine and fromthe

Disconnect the air hose (19) from the turbocharger of the turbine and the oil vapour recovery pipe from the cover of the cylinder head. Remove the air cleaner (18) by undoing the fasteners (← ) and remove it from its seat together with the support (17). Fit a lifting tool onto the specific h ooks on the engine and keep it under tension. Remove the fixing nuts from the four supports (5) of the engine/generator assembly. Separate the engine/generator assembly from the crankcase.

Refitting

To refit, reverse the removal instructions; restore the coolant system as described in the procedure on page 49.

tank, taking care to collect any diesel coming down, then remove them from their seat. Disconnect the electrical c onnection (7) of the diesel level signal (8) and earth (9).

NOTE

Check the integrity of the rubber-type blocks in the supports (5) of the pipes and electrical connections.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

SEPARATING THE GENERATOR FROM THE ENGINE

Figure 9

F4GE NEF ENGINES

107480

Remove the fan (1), the brackets of the supports (4) and the support (3).

Separate the generator from the engine as follows:

- disconnect the wiring (10) from the engine at each of its

points of connection with the parts of the engine: starter

- removethe safety grilles (5) by u ndoing the fasteners (7),

unscrew all the nuts (6) connecting the generator (8) to thehousingoftheengineflywheel;

- block the generator suitably and separate it from the

engine.

motor, alternator, various sensors, etc. Then fasten it appropriately to the control panel (9) so as not to hinder operations when separating the two assemblies;

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

DETACHING THE TANK FROM THE BASE

Figure 10

SECTION 3 - POWER GENERATION APPLICATION

107477

The tank is blocked inside the base (1) with angular brackets (3). To remove the tank (2) from its seat, remove the brackets (3) by undoing the relevant fasteners.

NOTE

At the time of assembly, check that the adhesive rubber blocks (4) are sound and positioned by the brackets (3).

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

OVERHAULING THE 6-CYLINDER ENGINE Introduction

The following description concerns the operations of overhauling the engine restricted to the components that differentiate it acco rding to its specific use.

NOTE

Due to requirements dictated by the application, some assemblies may be located on the engine in different positions.

The “General Overhaul” section contains all the operations of overhauling t h e engine block and this sect ion is therefore to be considered as following this topic.

NOTE

The operations of removing the engine, as those for overhauling, must be performed by skilled personnel with specific tools.

Operations of preparing the engine for assembly on the rotary stand

Figure 11

108987

- Remove the intake manifold (1) and the sleeve (6).

- Remove the fuel hoses (2).

- Place a container under the diesel filter and unscrew the

condensation bleed cock located under the filter; drain

- Remove the fuel filter mounting (4) from the bracket

secured to the cylinder head.

- Remove the priming pump (5).

- Disconnect the pipes (3) from the injection pump.

off all the diesel it contains.

- Fully unscrew the cock and, using tool 99360076,

remove the diesel filter (4).

Base - April 2007 Print P4D32N001 E

NOTE

Removing the injection pump requires a specific procedure described in this section.

F4GE NEF ENGINES

Figure 12

SECTION 3 - POWER GENERATION APPLICATION

- Disconnect the pipe (1) delivering oil to the turbine (3).

- Disconnect the pipe (4) returning oil to the turbine (3).

- Remove the turbine (3).

- Remove the oil filter (6) with tool 99360076.

- Remove the starter motor (5).

- Remove the exhau st manifold (2).

NOTE

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

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

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

Figure 13

NOTE

108988

70126

To disconnect fuel pipelines (2, Figure 11), 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.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 14

76147

- Assemble th e bracket bearing 99361037 using the four

screw threaded ports (1).

Figure 16

88143

- Disconnect the supply pipe unit from the injectors (1).

- Remove fuel exhaust pipe (2) from the injectors by

removing screw (4) and seal (3).

Figure 15

106554

- Assemble the second bracket 99361037 throughout the

screw-threaded ports (1).

- Lift the engine usin g the rocker arm 99360595 and put

it on the turning stand 99322205.

- Remove the oil level rod together with guide pipe;

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

- Drain the oil through the c ap underneath the plug.

Figure 17

(Demonstration)

76150

- Loosen the screws (1) holding the fixing brackets of such

pipelines; pipe the pipeline ends.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Figure 18

(Demonstration)

76149

- Remove tappet caps: loosen the fixing sc rews (1) and lift

the caps (2); remove the gaskets.

NOTE

On the tappet cap there is a blow-by valve for t he lubrication oil vapours. All the gaskets shall always be replaced durin g assembly.

Figure 20

(Demonstration)

76151

- Disassemble suction and exhaust manifolds: loosen the

screws (1) fixing the suction manifold plate to the cylinder head (some of them have already been screwed-out sinc e fixing the pipe brackets to the injectors). From the exhaust manifold side loosen the (2) fixing screws; remove the gaskets.

Figure 19

84082

- Remove injectors (2) with tool 99340205 (1) and take

out the cylinder head.

Figure 21

75683

- Disassemble rocker arm bearings; loosen the two fixing

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

- Disassemble water temperature transmitter (1).

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 22

88089

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

bracket (3).

- Loosen screw (2) in order to slide out POLY-V belt (2).

- Remove belt stretcher bracket (3).

- Remove the coolin g fan.

- Disassemble the control pipe pulleys and the guide

rollers.

Figure 24

75686

- Properly hold the alternator (1) separating it from its

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

Figure 23

117588

- Disassemble thermostat unit; loosen the three fixing

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

- In order to facilitate head overhauling operations at the

test bench keep bracket (3) assembled on it by fixing it with the thermostat unit screws.

Figure 25

106544

- Loosen the screws (1) and withdraw the alternator

bearing (2).

NOTE

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

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Figure 26

106545

- Loosen the screws (4) and disassemble the oil

pressure/temperature sensor (3) (if fitted).

- Disassemble injection pump (see specific procedure).

Figure 28

75692

- Apply the suitable tool (2) on the flywheel covering box

(1) in order to lock flywheel (3) rotation. (use the starting motor fixing nuts and studs).

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

shaft.

Figure 27

- Disassemble cylinder head;

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

76152

Figure 29

106546

- Unloose the screws (3) and disassemble the damping

flywheel (2) and the pulley (1).

- The engine flywheel lock tool can facilitate the removal

of damper flywheel (2) installed on pulley (1).

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 30

106547

- Remove the screws (1) and disconnect the water pump

(2).

- Remove the screw (3) and the roller (4).

- Remove the screw (5) and disconnect the engine speed

sensor (6).

Figure 32

00904t

- Using the specially provided tie rod (3) for the tool

99363204 and the lever (4), withdraw the external holding ring (2) from the front cover (1).

Figure 33

Figure 31

00900t

- Remove the engine drive shaft fixing ring from the front

cover. Use the tool 99340055 (4) to operate on the front tang (2) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring (1) using Ø 3,5 mm drill for a 5mm depth. Fix the tool to the ring tightening the 6 screws specially provided. Proceed withdrawing the ring (1) tightening the screw (3).

70149

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

NOTE

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

Figure 34

75811

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

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Figure 35

75691

- Screw out the opposite screws (1) from the ports where

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

- Loosen remaining flywheel fixing screws (3) to the

engine drive shaft (4).

- Remove the flywheel block tool (2).

Figure 37

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 t he tool guide ports, drill the internal holding ring using Ø 3,5 mm drill for a 5mm depth.

- Fix the tool 99340056 (3) to the ring (1) tightening the

6 screws specially provided (4).

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

(2).

- Using the specially provided tie rod (3) for the tool

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

Figure 36

Figure 38

75690

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

slingtheflywheelwithahoist.

- Loosen the screws (2) and remove the flywheel cover

box (1).

70153

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.

NOTE

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

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 39

88076

- Turntheengineupside-down.

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

remove the oil pan (1).

NOTE

The shape and dimensions of the pan and of the rose pipe may vary according to the engine application. The relating illu strations provide general guidelines of the operation to be performed. The procedures described are applicable anyway.

Figure 41

70156

- Loosen the screws (1) and disassemble the gear from the

camshaft (2).

Figure 40

87261

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

rose pipe (3).

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

(4).

Figure 42

106540

- 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.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Installation of rear components

Figure 43

75712

DIAGRAM SHOWING SEALING LOCTITE 5205

APPLICATION WITHIN GEARBOX AREAS

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

block.

NOTE

It is necessary and essential to clean th e 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, thinneror irregularzones.

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 minu t es after completing the sealing operation.

Figure 44

910

75711

DIAGRAM SHOWING SCREW

TIGHTENING TO FIX REAR GEARBOX

- Reassemble to box (1) to the engine block.

- Tighten the fixing screws in the same position as found

out during disassembly and fix the sc rews to the locking couples listed here below, following the order as shown in the picture.

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

NOTE

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

Figure 45

70211

- With a pen marker, mark the tooth (1) of the driving gear

assembled to the engine drive shaft with (2) (→) timing notch.

NOTE

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

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 46

106541

- Orient enginedrive shaft (3) and camshaft (4) taking care

that in phase o f assembly of the driving gear (2) to the camshaft, the notches marked on the gears (1 and 2) shall match.

Figure 48

106543

- Tighten the screws (1) fixing the gear to the camshaft (3)

and lock them to the prescribed couple.

Figure 47

106542

- Position comparator (1) on timing system gear (2) and

check that the clearance between gears (2) and (3) is within 0.076 ÷ 0.280 mm range.

Figure 49

75708

DIAGRAM SHOWING SEALING LOCTITE 5205

APPLICATION.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

NOTE

It is necessary and essential to clean th e surface to

Figure 51

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, thinneror irregularzones.

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 minu t es after completing the sealing operation.

0901t

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

of the tool 99346252, fix it tightening the screws (4) and key the new holding ring on it (3).

- Place detail (1) on detail (5), tighten the screw nu t (2)

until complete assembly of the fixing ring (3) into th e flywheel cover box (7).

Figure 50

75709

DIAGRAM SHOWING SCREW

TIGHTENING TO FIX FLYWHEEL COVER BOX.

- Reassemble the box (1) to the engine block, tighten the

fixing screws in the same position as found out during disassembly and fix the screws to the locking couples listed here below, following the order as sh own in the picture.

Screws M12 75 ÷ 95 Nm Screws M10 44 ÷ 53 Nm

Figure 52

75696

- Check the conditions of the rim tooth (2). Whether

tooth break or excessive wear is detected, disassemble the rim from the engine flywheel using a common willow and replace with a new one, previously heated to 150º C degrees for 15’ ÷ 20’; seconds; bevelling must be made towards engine flywheel direction.

NOTE

Tightening to angle is performed using tool

99395216.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Flywheel installation

Figure 53

- Screw up two hooks or trail rings in the flywheel (1)

threaded ports (4) for handling .

- Usinga hoist, handle the flywheel to place it in its housing

inside the flywheel cover box.

- Screw up to pins (2) having appropriate length, in the

shaft ports (3) and using them as guide, assemble the engine flywheel (1) properly placing it inside the flywheel cover box.

75690

Figure 55

75695

Tighten the engine flywheel (1) fixing screws (2) in two phases:

- 1stphase; tightening by means of dynamometric wrench

to couple 30 ± 4 Nm;

- 2nd phase, 60º ± 5º angle dwell.

NOTE

Angle dwell shall always be performed using 99395216 tool. Before assembly, always check that the threads of the ports and of the screws have no evidence of tear and wear nor dirt.

Figure 54

75692

- Tighte n the screws (4) fixing the engine flywheel (3) to

the engine shaft. Use tool 99360339 (2) to operate on the flywheel cover box (1) to block engine flywheel rotation.

Installation of front components

Figure 56

70220

- Assemble oil pump (1).

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

couple.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Figure 57

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

Figure 58

Figure 60

70221

75710

76112

- Assemble the water pump (1).

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

couple.

Figure 59

- Accurately clean the contact surface of engine block and

apply sealing LOCTITE 5205 on it in order to form a uniform and continuous kerbstone with no crumbs.

Figure 61

106550

106549

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

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

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

accurately clean the plug surface.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 62

00902t

- Apply on engine drive shaft front tang (6) the detail (4)

of the tool 99346252, fix it with the screws (5) and key the new holding ring on it (7).

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

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

Figure 64

88075

- Providefor new gasket replacement (1) of the oil pan (2).

NOTE

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

Figure 63

88074

- Assembleplate (4),suction rose (3) andtighten the fixing

screws (2 and 1) locking them on the prescribed torque.

Figure 65

88076

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

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

NOTE

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

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Figure 66

106546

- Assemble the pulley (1) and the dumping flywheel (2) to

the driving shaft.

- Tighten the fixing screws (3) and clamp them to the

couple 68 ± 7 Nm.

Figure 68

106552

- Lubricate the fixing ring (2) using engine oil and place it

on the oil filter (3).

- Manually start the oil filter (3) on the bearing union (1)

until counter-boring, further screw up the oil filter (3) by 3/4 turn.

- Place a new fixing ring on the block housing (4).

Figure 67

106551

- Assemble the following elements to the block: new

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

NOTE

In some applications, the bearing of the exchanger shall be assembled to a screw t hreaded union connected to the filter on the opposite side of the engine, throughout two pipelines.

Figure 69

106553

- Assemble the alternator bearing (1) ensuring that the

pins (3 and 4) are against the engine block.

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

couple.

NOTE

Before assembly, always check that the threads of

NOTE

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

Print P4D32N001 E Base - April 2007

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

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 70

- Connect the alternator (1) to the support.

- Tighten without locking th e screw (2).

75686

Figure 72

- Place the gasket (1) over the block.

The choice of the gasket’s thickness shall be made i n consideration of the cylinder protrusion measured w ith 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 to the cylinder head.

88092

Figure 71

88090

To refit the POLY-V belt, perform the steps described in Figure 22 in reverse order.

NOTE

For belt stretching rotate the alternator as indicated in the figure, lock screw (1) and screw (2, Figure 70).

NOTE

In case the same belt priory removed is assembled again, proceed examining it carefully to check there

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F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Figure 74

76152

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

and (2).

NOTE Before using the fixing screws again, measure them

twice as indicated in the picture, c h eckin g D1 and D2 diameters: if D1 - D2 < 0,1 mmthe screw can be utilised again; if D1-D2>0,1mmthescrewmustbereplaced.

D1D2

Figure 73

4 cylinder engine

13 14

76115

6 cylinder engine

76214

- Lubricate c ylinder 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.

NOTE

75703

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

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

Figure 75

75705

ROCKER ARM UNIT COMPONENTS:

1. Elastic ring - 2. Spacer- 3. Rocker arms-

4. Support.

- Carry out the assembly of the rocker arms after previous

check of the components.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 76

18.975

18.963

19.000

19.026

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 77

19.000

19.026

75704

Figure 79

D1D2

75703

Insert the tappet driving rods and the Rocker Arm unit. Before using the fixin g 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 80

13.00

11.00

116391

ROCKER ARM ADJUSTMENT SCREW

If the adjuster screw has been removed, check the adjustment distance. Tighten the screw-threaded nut (1) to the 4 - 6 Nm couple.

Figure 78

75683

- Tighten the screws (2) to the prescribed couple and

assemble water temperature sensor (1).

32655

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

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Figure 81

75806

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

Correct slack is:

- su ction valves 0.25  0.05 mm

- exhaust valves 0.50  0.05 mm.

NOTE

In order carry out a quicker adjustment of the working slack between rocker arms and valves, proceed as following:

6 cylinder engine

Rotate the engine drive shaft, balance the valves of cylinder 1 and adjust the valves identified by star symbol, as indicated in the following table:

Cylinder n. Suction Exhaust

234

Rotate the engine drive shaft, balance the valves of cylinder 6 and adjust the valves identified by star symbol, as indicated in the following table:

Figure 82

75707

- Assemble injectors after having replaced the sealing

gasket (1).

NOTE

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

Figure 83

(Demonstration)

Cylinder n. Suction Exhaust

234

** -

*- *

4 cylinder engine

Rotate the engine drive shaft, balance the valves of cylinder 1 and adjust the valves identified by star

76149

symbol, as indicated in the following table:

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

Cylinder n. Suction Exhaust

-*-

234

- Fit the seal nods and tighten the screws (1) fixing them

to the prescribed couple.

Rotate the engine drive shaft, balance the valves of cylinder 4 and adjust the valves identified by star symbol, as indicated in the following table:

NOTE

Always replace the gaskets using new ones.

Check the threads of the fixing screws: there shall

Cylinder n.

Suction

1 *

Exhaust

Print P4D32N001 E Base - April 2007

234

be no evidence of wear or dirt deposit.

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

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Figure 84

(Demonstration)

117588

- Assemble thermostat unit (2) including thermostat (5)

and gasket (4).

- Tighten the screws to the prescribed couple.

NOTE

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

Disassemble the bracket (3) and reassemble components from 1 to 5 as shown in the picture.

The gasket (4) must be new.

Figure 86

(Demonstration)

76208

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

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

Figure 87

Figure 85

106555

- Apply on the surface joining the suction manifold plate

(1) the gasket (3) and provide. Fixing the screws (2) t o the prescribed couple.

- If you have removed the pipe (7) and the spacer (5) from

the intake manifold plate (1) fit it back on after inserting two new gaskets (4-6).

- Tighten the screws (8) to the prescribed couple.

107

- Fix the fuel pipes (1) to the injectors (2) and to the

connectors (3) previously fitted.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

Completing the engine

Figure 88

SECTION 3 - POWER GENERATION APPLICATION

108988

- Fit the starter motor (5).

- Fit the oil filter (6) with tool 99360076.

- Fit the exhaust manifold (2).

- Fit the turbine (3).

- Fit the pipe (4) returning oil from the turbine (3).

- Fit the pipe (1) delivering oil to the turbine (3).

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

Figure 89

F4GE NEF ENGINES

Fitting the injection pump requires a specific procedure described in this section.NOTE

- Fit the pipes (3) to the injection pump.

- Fit the priming pump (5).

- Fit the fuel filter mounting (4).

- Fit the diesel filter (4) with tool 99360076.

NOTE

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

- Fit the fuel pipes (2).

- Fit the intake manifold (1) and the sleeve (6).

Figure 90

NOTE

108987

70126

To connect fuel pipelines (3, Figure 89) in low pressure from the relating connection unions it is necessary to press the locking fastener (1) as showninpictureB. After having connected the pipeline, reset the fastener (1) into block position as shown in picture A.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Rotary feed pump disassembly and assembly procedure

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.

Engine versions with tool (99360330)

Figure 91

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 th e engine and disassemble it only afterwards.

The following procedure analyses this second hypothesis since it is the more complex.

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

Figure 93

88140

Disassemblethestarterfromtheflywheelboxandusetool 99360330 to rotate the flyw heel.

Engine versions with tool (99360339)

Figure 92

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 then checking that the intake and exhaust valves are both c l osed. Once PMS has been obtained, lock the flywheel by means of tool 99360339 (Figure 93).

Searching for the top dead centre with timing gear blocking pin

Figure 94

75714

Disassemble the starter from the flywheel box (1) and use tool 99360339 (2) to rotate the flywheel.

Print P4D32N001 E Base - April 2007

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

84071

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Disassembly

Figure 95

106659

- Partially unlock pump shaft retaining screw (1) and move

spacer with slot (2) in area with lager size h ole for complete screw passage.

- Lock applying a torque ranging between 11,9 and 12,4

Nm retaining screw (1) till reaching spacer, thus locking pump shaft rotation.

Figure 97

106658

- From the pump side, loosen the fixing nuts (1) without

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

- Assemble the 99340035 extractor throughout the two

threaded ports (4, Figure 96) 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.

Figure 96

75693

- From timing side, remove the cover (2) loosening the

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

- Loosen the fixing nut (3) and remove the relating

washer.

NOTE

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

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F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Rotary feed pump setting check

Figure 98

106660

1. Slot on the hub of the hydraulic rotor -

2. Synchronization pin 99365196 - 3. Plate.

The synchronization pin 99365196 (2) has been designed for use in the event of the rotor shaft being inadvertently released. The correct synchronization of the pump with the engine is obtained when the synchronization pin 99365196 (2), fitted in the hole on the plate (3), enters the slot (1) on the exterior of the hydraulic rotor hub.

Assembly

Figure 99

106658

When installing supplì pump on engine, cylinder no.1 must be at TDC, end of compression phase.

- Assemble the pump pre-set in its housing on the engine,

fitting the shaft into the gear port (not provided with wrench).

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

slot centre.

NOTE

The gasket removed during pump disassembly shall not be utilised again. Always u s e original spare parts.

Therefore:

- Remove the screw cap (3) at the centre of the plate.

- Insert the s ynchroniz a tion pin (1) 99365196 in the hole

on the plate (3). The synchronization position is obtained when the synchronization pin (2) enters the slot on the hydraulic rotor hub.

- Lock the control shaft in the correct position by means

of the screw (1, Figure 95).

- Remove the synchronization pin and fit the screw cap of

the plate (3). Tighten the cap using a torque of 2.3 ÷ 3.4 Nm.

NOTE

Support the pump gear to prevent interference or sticking when the timing system gears turn.

Figure 100

75693

- On the timing side, throughout the specially appointed

port, fit the washer and screw up the fixing nut (3) to the pump shaft. Lock the nut to the 190-203 Nm couple.

- Assemble the cover (2) including gasket and tighten the

screws (1).

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

Figure 101

106659

- - Svitare, senza rimuovere, la vite (1) di bloccaggio

rotazione dell’alberino della pompa e spostare il distanziale con asola nella zona del foro di dimensioni minori. Avvitare fino a battuta la vite bloccando il suddetto distanziale: in questo modo l’alberino della pompa di alimentazione è libero di ruotare.

- Disassemble the flywheel rotation/locking tool

99360339 or 99360330; arrange the starting motor in its seat.

- Connect all thepipes (fromthe pumpingelements to the

injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump).

- Connect the electrical connections.

F4GE NEF ENGINES

NOTE

In case pump removal has been carried out while the engine was assembled, connect acceleration cable.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

ASSEMBLY PROCEDURE OF THE ”ADC100” ELECTRONIC ACTIVATOR ON STANADYNE SERIES ”D” INJECTION PUMPS

Figure 102

Before proceeding in the removal of the Injection Pump cover and then to the replacement with the electronic actuator, it is important to clean the external part of the pump, if necessary, using solvents. This prevents contamination of the internal part of the pump.

- Disconnect the wire of the stop electro-valve from the

clamp (I) positioned on the pump cover, being careful to isolate it.

- Remove the fuel return pipe from the connection (2).

116978

- Remove the three screws (3) of the pump cover. The

screws will then be replaced assembling the screws supplied with th e ADC100 actuator.

- Remove the cover of the injection pump very carefully

so that the dirt won’t penetrate inside the pump.

- Remove the connection (2) of the fuel return pipe and

the sealing from the injection pump cover. Keep the connection (2) and the sealing that will have to be assembled on t he electronic actuator.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

Figure 103

F4GE NEF ENGINES

A. The injection pump open seen from above - B. Front (carter side) - C Rear (injector side)

I. The ”U” shaped hook of the electronic actuator- 2. Injection pump lever- 3. Droop adjustment screws

Assembly of the actuator

- Reassemble the connection forthe fuel return pipe and

the pump cover’s original dealing, on the ADC 100 electronic actuator.

- Position the electronic actuator on the injection pump

with the highest part slightly titled upwards.

- Slide the electronic actuator towards the rear part of the

pump (injectors’ side) until the ”U” shape hook (I) of the actuator engages the lever of the injection pump (2).Once engaged, align the holes of the pump and the electronic actuator.

116979

NOTE

Couplings mistakes between the actuator’s hook (I) andthe lever (2)of the injection pumpcancause motoroverspeedconditions.

- Tighten the ADC 100 actuator to the injection pump,

using the screws su pplied with the actuator.

- Reconnect the fuel return pipeto the connection placed

on the actuator.

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F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

PASSAGE FROM 50 HZ TO 60 HZ FOR NEF MOTORS WITH STANADYNE PUMP

Figure 104

According to the specific needs of the motor employment it is possible that a request to vary the adjustment of the Stanadyne pump be made to obtain adifferent u se frequency:

- 1500 rpm / 50 Hz

- 1800 rpm / 60 Hz

The necessary procedures will be described in order to execute the following adjustments:

- passage from 50 Hz to 60 Hz and vice versa.

- stabilizing of the rotation regime.

NOTE

If only the Stanadyne identification tag (2) is present, this means that the injection pump presents a setting of 50 Hz.

In case of modification of the setting from 50 Hz to 60 Hz done in the factory, an identification tag (1) is applied by Iveco Motors.

116400

On the Iveco Motors tag (I) reported are:

- the model of the injection pump (4);

- an identification code (3) of the specific application of

the setting ofthe injection pump, forexample: A.S. 7.54 identifies the setting at 1800 rpm of 60 Hz.

Passage from 50 Hz to 60 Hz

To carry out the passage from 50 Hz to 60 Hz you must, first of all:

- identify the code of t h e injection pump from the

Stanadyne tag (2).

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

Figure 105

F4GE NEF ENGINES

116975

Type of injection pump

(Stanadyne tag)

Screw rotations at 50 Hz

from the final position

(clockwise)

DB 4629 - 5927 2 6 4

DB 4629 - 5932 2 9 7

DB 4629 - 5944 2.5 8.5 6

DB 4429 - 5945 3 6 3

DB 4429 - 5954 2 8.5 6.5

DB 4427 - 5955 3 9 6

- Act on the droop setting adjustment screw (2), rotating

it clockwise the number of rotations indicated in the chart figure, starting from the position in which the screw is.

NOTE

In case of doubt you can always unscrew the droop setting register screw (2) counter clockwise till you get to the final position - do n ot force it further in order to not damage the adjustment system. At this point, always referring to the chart figure, rotate the droop setting screw clockwise (2), the number of rotations indicated for the regime of 60 Hz from the final position.

Screw rotations at 60 Hz

from the final position

(clockwise)

Difference of rotations

from 50 Hz to 60 Hz

(clockwise)

If, for example, for a motor with an injection pump with code DB 4429 - 5945, originally set at 50 Hz, you want to pass to 60 Hz, it is sufficient to act on the droop setting adjustment screw (2) rotating it 3 times cloc kwise from the position in which it is, start the motor, loosen the adjustment screw of the maximum regime and accelerate with the accelerator lever, till yo u obtain the empty rotation regime equal to 62 Hz (l860 rpm),

- Then regulate the screw of the minimum regime (4) so

to block the accelerator lever in the newly obtained position and finally block both adjustment screws (I and

4) using the appropriate lock nuts (tightening torque 3,5

- 4 Nm).

- After starting the motor you must operate the maximum

NOTE

(I) and minimum (4) register screws in order to block the accelerator lever (3)in t he position to obtain the desired regime, considering the frequency fall in the passage from empty to full of the motor (about 2 Hz).

Base - April 2007 Print P4D32N001 E

The adjustment screw of the minimum regime (4) does n ot allow the attainment of the minimum intended in the ”classical” meaning of the term because the injection pump regulator imposes a superior rotation regime since it is about an injection pump for the application of a generator.

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Passage from 60 Hz to 50 Hz

To pass from a 60 Hz regime to the 50 Hz regime, operate analogously to what seen above, remembering to act on the droop setting adjustment screw (2, Figure 105), rot ating the same of 3 counter clockwise rotations from the position in which it is for the functioning at 60 Hz.

Stabilization of the rotation regime

In case of instability of the rotation regime, act on the droop setting adjust ment screw (2, Figure 105) rotating lightly the same clockwise/counter clockwise till the stabilization of the motor rotation regime.

NOTE

Attention! Some motors cannot undergo the passage from 50 Hz to 60 Hz and vice versa, as they need a specific injection pump to work at the required regimes.

Make reference to the SI 191 1 ”Service Information” to verify which motors cannot undergo the passage from 50 Hz to 60 Hz and vice versa.

Identification tag

Figure 106

116976

In case the Iveco Motors tag is not present because it is a motor with an injection pump that has a setting of 50 Hz, it is necessary to proceed in the application of a tag in the illustrated area as in Figure 4 stamping it as the figure example.

The blank tag can be ordered at the Part Replacement Service.

Figure 107

116977

If the Iveco Motors tag is already on the injection pump, you must proceed stamping the new identification suffix of the newly obtained setting and strikethrough the identification of the preceding setting, as illustrated in the figure example.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

REPLACEMENT OF THE ELECTRO-VALVE AND THE SOLENOID VALVE THROTTLE ON STANADYNE PUMPS

Figure 108

116980

A. Position of the electro-valve arm - I. E ncapsulated coil - 2. Mobile nucleus of t he electro-valve -3. Electro-valve arm -

4. Isolator - 5. Solenoid valve ends

A. Position of the electro-valve arm - I. E ncapsulated coil - 2. Mobile nucleus of t he electro-valve -3. Electro-valve arm -

4. Isolator - 5. Solenoid valve ends

116981

Two types of electro-valves can be us ed on Stanadyne i njection pumps:

- ETR (Energize To Run)

- ETSO (Energize To Stop).

Please note, in the figure, the different assembling position of the electro-valve according to the ETR - ETSO functions.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Electro-valve replacement

Figure 109

116982

To replace the electro-valve remove the cover of the injection pump loosening and removing the three fixing screws (I and 2) of the cover and the relative washers.

Check the state of wear of the rubber couplings.NOTE

Figure 111

Figure 110

116983

Remove the entire cover of the electro-valve (I), pulling it upwards perpendicularly to the injection pump.

Be careful that nothing falls into the injection pump.

116985

Remove the electro-valve (3) from the cover (2).

NOTE

Since the ends of the component are electrically isolated from the cover, make sure to remember the assembling order of the nuts, of the washers and of the components, for the electrical connection of the electro-valve ends; one end is earthed through an appropriate element (I). Pay attention to the position of the isolating element (4).

Assemble of the new electro-valve on the injection pump’s cover, using the appropriate kits:

- I2 V-ETR

- 24 V-ETR

- I2 V-ETSO

- 24 V-ETSO

The kits contain the indicated type Check the state of wear of the rubber couplings. of electro-valve and all that is needed for its assembling.

The nuts fixing the electro-valve (3) to the cover (2) must be tightened to a I, I ÷ 1,7 Nm torque.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

Figure 112 Figure 113

The repositioning of the cover (2) must be done proceeding in reverse to what described for its disassembling, making sure that it corresponds perfectly to the assembling seat without forcing it (for the ETR version the cover of the pump

116986

will correspond to the assembling seat only after the joint tool has been removed).

F4GE NEF ENGINES

116987

In the electro-valve ETR kit there is the joint tool (I) which must be used to position the electro-valve’s arm (2) and to reassemble the cover on the injection pump.

NOTE

This tool (I) allows to keep in the excitation position the arm of the electro-valve (2), allowing the correct assembling of the cover and avoiding dangerous over rotations at the starting of the motor.

Once the cover is put on the assembling seat and the relative screws are pointed on the injection pump, rotate the joint tool (I) and then pull it carefully from underneath the cover (3), making sure not to move or damage its sealing.

Then tighten the screws with a 4,0 ÷ 5,1 Nm tightening torque, making sure not to damage the connection earth ed element of the electro-valve end.

NOTE

Figure 114

A blue seal is included in the kit and it has to be positioned on the screw (I), after the cover reassembling operations (2): when new, the seal is not blue.

116998

In case the original electro-valve should be replaced and its characteristics modified (different voltage, ETR instead of ETSO, eco), it is necessary the application of an identification tag (I) in the indicated place.

The tag must be stamped (I) as shown in details in the figure.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION

Figure 115

116989

In some cases the tag may already be present. If the tag is already present, it is necessary to strikethrough the old identification elements and stamping the new ones, as shown in the example in the figure.

The electro-valve and the solenoid valve throttle on the same injection pump, must have t he same operating voltage, so in case of a change in the motor’s operating voltage, both must be replaced.

Figure 117

116991

Insert the connection cable socket (I) in the cable group end and screw the nut (I, Figure 116) tightening it to a 5, 7 ÷ 6,8 Nm torque.

Position the socket clamp (2, Figure 116) and screw the fixing nut tightening it to a 7, 9 ÷ 9, 0 Nm torque.

Position the magnet in its seat and screw the self-blocking fixing nut, supplied with the replacement kit, tightening it to a5,1÷5,7Nmtorque.

Replacement of the solenoid valve throttle

Figure 116

116990

Disconnect the linkage connector from the temperature sensor on the motor, and then remove the fixing nut of the socket clamp (2) and the nut (I) of the cable group end, so to release the electrical lead assembly of the solenoid valve throttle.

Remove the fixing nut (3) from the magnet and remove the component from its seat.

NOTE

The operating voltage of the device is easy to find looking at the c olors of the supply wires of the solenoid:

- BLACK: forthe I2V device

- RED: for the 24V device

The electro-valve and the solenoid valve throttle on the same injection pump, must have t he same operating voltage, so in case of a change in the motor’s operating voltage, both must be replaced.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

Checks and controls

The following tests shall be made after engine assembly.

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:

- no coolant leaks from the coupling sleeves of the cooling

circuit piping, tightening the collars further if necessary.

- Carefully check the fuel connection pipes to th e

respective unions.

- There is no oil leakage from the lubrication circuit of the

various pipelines connecting cover and.

- Cylinder head, oil pan an d bearing, oil filter and heat

exchanger as well as relating housings.

- There is no fuel leakage from fuel pipelines.

- 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.

F4GE NEF ENGINES

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION 53

PART FOUR - MAINTENANCE PLANNING

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION 55

MAINTENANCE PLANNING Recovery

To ensure optimised working conditions, in the following pageswe are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates.

The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks.

It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run.

Planning of controls and periodical intervention

Controls and periodical intervention

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

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

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

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

Replacementofengine’soilandfilter .................................

Replacementoffuelfilter ...........................................

Replacementofbelt ..............................................

NOTE

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

Frequency (hours)

Daily

4000

500

1500

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.

- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.

- Notify the maintenance if any inconvenience is detected of if any filling is necessary.

After engine start and while engine is running, proceed with the following checks and controls:

- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.

- Verify absence of noise or unusual rattle during engine working.

- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.

- Visual check of fumes (colour of exhaust emissions)

- Checking the coolant level.

MAINTENANCE PROCEDURES Checks and controls

Engine oil level check.

Figure 118

106668

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

Figure 119

106669

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”.

Thecheckcanbemadeusingthespeciallyprovidedflexible rod (1).

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

Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no rag grinding and put it back in its slot. Draw it off again and check the level.

In case the l evel 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 caseof 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.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION 57

Check of fuel system

The check must be executed both when the engine disconnected and when it is running. The check is made by observing the fuel pipes from the tank to the fuel 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 pipes from the engine to the radiator and vice versa; note any seepage and the state of the pipes especially near the coupling clamps.

Verify that the r adiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the mani fold and from the radiating unit.

Due to the high temperatures achieved by the system, do not operateimmediately 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.

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 for any water in the fuel filter

NOTE

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

Take prompt action on the filter to drain off the water in the fuel circuit.

The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two year.

NOTE

If refilled, bleed the system as described on page 49.

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.

Fuel filter is equipped with pump screw-valve to drain the water eventually mixed with fuel.

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.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

Check of drive belt tensioning

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

Check of belt’s tear and wear status

Carefully verify the belt’s surface in order to detect any sign of incision, crack, excessive wear in correspondence of toothing; check end and surface grinding.

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

NOTE

Cylinder n. Suction Exhaust

F4GE NEF ENGINES

In order to more quickly perform the operating clearance adjustment for rocker arms — valves, proceed as follows:

rotate the drive shaft, balance cylinder 1 valves and adjust the valves marked by the asterisk as shown in the table:

4 cylinder engine

Rotate the drive shaft, balance cylinder 1 valves and adjust the valves marked by the asterisk as shown in the table:

-*-

234

Rotate the drive shaft, balance cylinder 4 valves and adjust the valves marked by the asterisk as shown in the table:

Figure 120

75806

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

Clearance shall be as follows:

- intake valves 0.25 ± 0.05 mm

- exhaust valves 0.50 ± 0.05 mm.

Cylinder n. Suction Exhaust

6 cylinder engine

Rotate the drive shaft, balance cylinder 1 valves and adjust the valves marked by the asterisk as shown in the table:

Cylinder n. Suction Exhaust

Rotate the drive shaft, balance cylinder 6 valves and adjust the valves marked by the asterisk as shown in the table:

Cylinder n. Suction Exhaust

1 *

234

** -

*- *

* *

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 3 - POWER GENERATION APPLICATION 59

Oil motor and filter replacement

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

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

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 caseof 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.

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

- The filter is composed by a support and a filtering car-

tridge. 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.

- Replace the filtering cartidge with a new one and screw

manually until when the gasket is in contact with the support.

- Tigthen by means of the 99360076-tool of three fourth

turn.

- Operate the motor for some minutes and check the level

through the dipsick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.

- After the complete drainage, screw the plug and carry out

the clean oil filling.

Use only the recommended oil or oil having the requested features for the corrrect motor functioning.

In case of topping up, don’t mix oils having different features.

If you don’t comply with theses rules, the service warranty is no more valid.

- Check the level through the dipsick until when the filling

is next to the maximum level notch indicated on the dipsick.

Changing the coolant

- Position a container beneath the radiator tap to r ecover

the coolant.

- Open the tap and allow all the coolant in the radiator to

flow out.

- Charge the coolant for the first time.

- Leave the radiator cap open.

- Start the engine and leave it running for at least a minute

so that all the air in the circuit is completely removed.

- Stop the engine.

- Top up.

NOTE

If the procedure described is not followed, the radiator fluid level will be incorrect.

Print P4D32N001 E Base - April 2007

SECTION 3 - POWER GENERATION APPLICATION

F4GE NEF ENGINES

Fuel filter replacement

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

Avoid to breathe the vapors coming from filter.

NOTE

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

However the following operationsare valid for allapplications.

- Drain the fuel inside the filter by operating the water re-

lease screw. Collect the fuel in a container without impu rities.

- Unscrew the cartridge by using the 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.

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 121

88089

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

bracket (3).

- Loosen the bolt that fixes the alternator to the support.

- Remove the worn Poly-V belt (2) from the pulleys and

driving rollers.

- Fit the new Poly-V belt (2) onto the pulleys and driving

rollers.

- Fit the new POLY-V belt (2) on the pulleys and guide

rollers.

- Stretch POLY-V belt (2).

- Lock screw (1) and the bolt that fi xes the alternator to the

support

- Run the engine for a few hours and check proper belt

stretching.

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

SECTION 4

Overhaul and technical specifications

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

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

ENGINE OVERHAUL 10.....................

ENGINE REMOVAL AT THE BENCH 10........

REPAIR OPERATIONS 11....................

CYLINDER UNIT 11........................

- Checks and measurements 11...............

- Checking head supporting surface

on cylin der unit 12........................

Page

TIMING SYSTEM 13........................

- Camshaft 13.............................

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

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

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

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

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

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

- Measuring journ als and crankpins 17..........

- Replacing oil pump control gear 21...........

- Fitting main bearings 21....................

- Finding journal clearance 21.................

- Checking output shaft shoulder clearance 22...

CONNECTING ROD — PISTON ASSEMBLY 22..

- Pistons 23...............................

- Measuring piston diameter 23...............

- Piston pins 24............................

Print P4D32N001 E Base - April 2007

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4GE NEF ENGINES

- Conditions for proper pin-piston coupling 24....

- Split rings 24.............................

- Connecting rods 25.......................

- Bushes 26...............................

- Checking connecting rods 26................

- Checking torsion 26.......................

- Checking bending 27.......................

- Fitting connecting rod-piston assembly 27......

- Connecting rod-piston coupling 27............

Page

- Checking piston protrusion 30...............

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

- Removing the valves 31....................

- Checking cylinder head wet seal 32...........

- Checking cylinder head supporting surface 32...

VALVES 33................................

- Removing carbon deposits, checking

and grinding valves 33......................

- Checking clearance between valve stem

and valve guide and valve centering 33.........

VALVE GUIDE 34..........................

VALVE SEATS 34...........................

- Regrinding — replacing the valve seats 34.......

- Fitting split rings 28........................

- Fitting connecting rod-piston assembly

into cylinder barrels 28.....................

- Finding crankpin clearance 29................

VALVE SPRINGS 35.........................

FITTING CYLINDER HEAD 35................

- Refitting the cylinder head 36................

TIGHTENING TORQUE 37..................

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

GENERAL SPECIFICATIONS

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 3

Type

Cycle Four-stroke diesel engine

Power Supercharged with intercooler

Injection Direct

Number of cylinders 4 in-line 6 in-line

∅

Bore mm 104

Stroke mm 132

+++..=

Total displacement cm

TIMING

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

4 CYLINDERS 6 CYLINDERS

4553 6728

15° 35°

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

69° 21°

Checking timing

Checking operation

0.25 to 0.05

0.50 to 0.05

FUEL FEED

Injection

STANADYNE DB 4

Type: rotary

Nozzle type DSLA 145 P

Injection sequence 1-3-4-2 1-5-3-6-2-4

Print P4D32N001 E Base - April 2007

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

CLEARANCE DATA

F4GE NEF ENGINES

Type

4 CYLINDERS 6 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

∅

Cylinder barrels ∅1

104.000 to 104.024

∅1

∅

Pistons: Size X Outside diameter ∅ 1 Pin housing ∅ 2

103.714 ÷ 103.732 / 103.755 ÷ 103.733 (•)

0.4

55.9 / 52.4 (•)

38.010 to 38.016

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

(•) Applicable to F4GE0405 engines only

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 5

Type

4 CYLINDERS 6 CYLINDERS

CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

X 3

Split ring slots X 2

*measuredona∅ of

X1*

2.705 to 2.735* / 2.600 to 2.620 (•)

2.440 to 2.460 / 2.550 to 2.570 (•)

4.030 to 4.050

99.00 mm

Split rings S 2

S1*

Split rings - slots 2

3.000 (••) / 2.470 to 2.500 (•)

2.350 to 2.380 / 2.478 to 2.490 (•)

3.970 to 3.990

- / 0.100 to 0.150 (•)

0.060 to 0.110 / 0.060 to 0.092 (•)

0.040 to 0.080

Split rings 0.4

Split ring end opening in cylinder barrel:

X1 X2 X3

0.30 to 0.45 / 0.25 to 0.55 (•)

0.60 to 0.80 / 0.30 to 0.55 (•)

0.30 to 0.55

1∅

Small end bush housing ∅ 1 Big end bearing

∅ 2

∅

housing ∅ 2

Small end bush diameter

Inside ∅ 3 Spare big end half bearings S

Piston pin — bush 0.019 to 0.039

Big end half bearings 0.250; 0.500

(•) Applicable to F4GE0405 engines only

(••) Nominal dimension

40.987 to 41.013

72.987 to 73.013

38.019 to 38.033

2.205 to 2.218

Print P4D32N001 E Base - April 2007

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4GE NEF ENGINES

Type

CYLINDER UNIT AND CRANKSHAFT COMPONENTS

Journals ∅ 1 Crankpins ∅ 2

12∅∅

Main half bearings S 1 Big end half bearings S 2

Main bearings

∅

No. 1—5 / 1-7 ∅ 3

No. 2—3—4 / 2-3-4-5-6 ∅ 3

Half bearings — Journals No. 1—5 / 1-7 No. 2—3—4 / 2-3-4-5-6

Half bearings - Crankpins 0.033 to 0.041

Main half bearings Big end half bearings

4 CYLINDERS 6 CYLINDERS

82.99 to 83.01

68.987 to 69.013

2.456 to 2.464

1.955 to 1.968

87.982 to 88.008

87.977 to 88.013

0.064 to 0.095

0.059 to 0.100

0.250; 0.500

Shoulder journal X 1 37.475 to 37.545

Shoulder main bearing X 2 32.180 to 32.280

X 2

Shoulder half-rings X 3 37.28 to 37.38

Output shaft shoulder 0.095 to 0.265

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 7

Type

4 CYLINDERS 6 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM mm

∅

Valve guide seats on

∅α4

cylinder head ∅ 1

Valves:

∅ 4 α

8.019 to 8.039

7.960 to 7.980 60º

7.960 to 7.980 45º

Valve stem and guide 0.039 to 0.076

Housing on head for valve seat:

46.987 to 47.013

43.637 to 43.663

∅ 1

∅1

∅

Valve seat outside diameter;

valve seat angle on cylinder head:

Sinking X

Between valve seat and head

∅ 2 α

47.063 to 47.089 60º

43.713 to 43.739 45º

0.356 to 1.102

0.104 to 0.840

0.050 to 0.102

Valve seats -

Print P4D32N001 E Base - April 2007

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4GE NEF ENGINES

Type

CYLINDER HEAD — TIMING SYSTEM

Valve spring height:

free spring H

under a load equal to:

329 N H1 641 N H2

Injector protrusion X

Camshaft bush housings No. 1 (flywheel side)

∅

1 23 4 5

∅

Camshaft housings No. 2-3-4-5/2-3-4-5-6-7

Camshaft journals: 1 ⇒ 5 ∅ 1 ⇒ 7 ∅

4 CYLINDERS 6 CYLINDERS

63.50

49.02

38.20

59.222 to 59.248

54.089 to 54.139

53.995 to 54.045

∅

Bush inside diameter ∅

54.083 to 54.147

Bushes and journals 0.038 to 0.162

Cam lift:

11.02

10.74

Base - April 2007 Print P4D32N001 E

F4GE NEF ENGINES

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 9

Type

4 CYLINDERS 6 CYLINDERS

CYLINDER HEAD — TIMING SYSTEM mm

∅

Tappet cap housing on block ∅ 1 16.000 to 16.030

∅ 2

∅∅2

Tappet cap outside diameter: ∅ 2

∅ 3

15.929 to 15.959

15.965 to 15.980

Between tappets and housings -

Tappets -

∅

Rocker shaft ∅ 1 18.963 to 18.975

Rockers ∅ 2 19.000 to 19.026

∅ 2

Between rockers and shaft 0.025 to 0.063

Print P4D32N001 E Base - April 2007

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

F4GE NEF ENGINES

ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH

The following instructions are prescribed on the understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well. (See Section 3 of the manual herein).

The section illustrates therefore all the most important engine overhaul procedures.

The following operations are relating to the 6 cylinders engine but are analogously applicable for the 4 cylinders.

Figure 1

70158

Figure 3

70160

The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2).

NOTE

Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal.

Figure 4

Remove the screws (1) fastening the connecting rod caps (2) and remove them.

Withdraw the pistons including the connecting rods from the top of the engine block.

NOTE

Keep the half-bearings into their housings since in case of use they shall be fitted in the same position found at removal.

Figure 2

74774

Use tool 99360500 (1) and hoist to remove the output shaft (2) from the block.

Figure 5

70159

Remove the screws (1) and the main bearing caps (2).

Remove the main half-bearings (1).

70162

Remove the screws (2) and remove the oil nozzles (3).

Base - April 2007 Print P4D32N001 E

Iveco GE NEF 45M, GE NEF 60M, GE NEF 75M, GE NEF 85M, GE NEF 100M Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Technical and Repair manual

SYMBOLS - WARNINGS

GENERAL WARNINGS

GENERALWARNINGS ON THE ELECTRIC SYSTEM

Bonding and screening

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

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

NEF POWER GENERATION ENGINES

SPECIAL REMARKS

SYMBOLS - ASSISTANCE OPERATIONS

UPDATING

SECTION 1 - GENERAL SPECIFICATIONS 1

ELECTRICAL SPECIFICATIONS OF THE GENERATING SETS

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

LUBRICATION

OIL VAPOUR RECIRCULATING SYSTEM

COOLING SYSTEM

AIRINDUCTION BOOST DIAGRAM

Description

SECTION 2 - FUEL 1

Description of working principles

FEED PUMP

STANADYNE DB4 pump

Description of operation

PRIMING PUMP

FUEL FILTER

SECTION 3 - POWER GENERATION APPLICATION

GENERAL INFORMATION

Clearance data - 4 cyl.

Clearance data - 6 cyl.

PART ONE - MECHANICAL COMPONENTS

REMOVING AND REFITTING THE SOUND-PROOFING UNIT

Removal

Refitting

REMOVING AND REFITTING THE ENGINE/GENERATOR

Removal

Refitting

SEPARATING THE GENERATOR FROM THE ENGINE

DETACHING THE TANK FROM THE BASE

Operations of preparing the engine for assembly on the rotary stand

Installation of rear components

Flywheel installation

Installation of front components

Completing the engine

Rotary feed pump disassembly and assembly procedure

Disassembly

Rotary feed pump setting check

Assembly

ASSEMBLY PROCEDURE OF THE ”ADC100” ELECTRONIC ACTIVATOR ON STANADYNE SERIES ”D” INJECTION PUMPS

Assembly of the actuator

PASSAGE FROM 50 HZ TO 60 HZ FOR NEF MOTORS WITH STANADYNE PUMP

Passage from 50 Hz to 60 Hz

Passage from 60 Hz to 50 Hz

Stabilization of the rotation regime

Identification tag

REPLACEMENT OF THE ELECTRO-VALVE AND THE SOLENOID VALVE THROTTLE ON STANADYNE PUMPS

Electro-valve replacement

Replacement of the solenoid valve throttle

Checks and controls

Planning of controls and periodical intervention

Checks not included in maintenance planning-daily checks

Check of fuel system

Cooling system check

Lubricating system check

Check for any water in the fuel filter

Check of drive belt tensioning

Check of belt’s tear and wear status

Check and setting of tappet clearance

Oil motor and filter replacement

Changing the coolant

Fuel filter replacement

Alternator belt replacement

SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CLEARANCE DATA