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

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 inspected 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 - 2nd Ed. 04.2007

Produced by:

B.U. TECHNICAL PUBLISHING

Iveco Technical Publications

Lungo Stura Lazio, 15/19

10156 Turin - Italy

NEF POWER GENERATION ENGINES	3

PRELIMINARY REMARKS

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.

SYMBOLS - WARNINGS

Danger for persons

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

Danger of serious damage for the assembly

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

General danger

!

It includes the dangers of above described signals.

Environment protection

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

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

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4	NEF POWER GENERATION ENGINES

GENERAL WARNINGS

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact

!immediate superiors where a danger situation occurs which is not described.

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

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

Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.

In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position.

Keep personnel not authorised to operations clear of working area.

You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly follow all the safety indications found on the assembly.

Do not leave the running assembly unattended when making repairs.

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

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

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

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

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

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

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NEF POWER GENERATION ENGINES	5

GENERAL WARNINGS

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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6	NEF POWER GENERATION ENGINES

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

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

!always disconnect, as a first one, the chassis bonding cable from batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated.

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

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

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

Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding, bonding, etc.) comply with 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.

To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special truck.

A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries) can cause them to be destroyed.

Disconnect the batteries from the system during their recharging with an external apparatus.

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

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

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

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

Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according to original arrangement.

NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable side.

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NEF POWER GENERATION ENGINES	7

Bonding and screening

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

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

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

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

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

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

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

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

Figure 1

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

Figure 2

88039

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

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

Where accuracy is not particularly needed:

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

1 kgm

= 10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1

1 kg/cm2		= 1 bar.
Temperature
0° C	=	32° 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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2 NEF POWER GENERATION ENGINES

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F4GE NEF ENGINES	1

Part 1

F4GE NEF ENGINES

Section

General specifications

Fuel

1

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 relates to the specific duty and is divided in four separate parts:

1.Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the relating specific duty.

2.Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating specific duty.

3.Maintenance planning and specific overhaul.

4.Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct instructions to identify the cause of the major inconveniences.

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

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2	F4GE NEF ENGINES	F4GE NEF ENGINES

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F4GE NEF ENGINES	3

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

1	Ø 1	= housing for connecting rod small end bush	Tighten to torque
		α	Tighten to torque + angular value
2	Ø 2	= housing for connecting rod bearings

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4	F4GE NEF ENGINES	F4GE NEF ENGINES

SYMBOLS - ASSISTANCE OPERATIONS

Removal

Disconnection

Refitting

Connection

Removal

Disassembly

Fitting in place

Assembly

Tighten to torque

Tighten to torque + angle value

α

Press or caulk

Regulation

Adjustment

Visual inspection

Fitting position check

Measurement

Value to find

Check

Equipment

Surface for machining

Machine finish

Interference

Strained assembly

Thickness

Clearance

Lubrication

Damp

Grease

Sealant

Adhesive

Air bleeding

Replacement

Original spare parts

Intake

Exhaust

Operation

ρCompression ratio

Tolerance

Weight difference

Rolling torque

Rotation

Angle

Angular value

Preload

Number of revolutions

Temperature

Pressure

bar

Oversized

Higher than….

Maximum, peak

Undersized

Less than….

Minimum

Selection

Classes

Oversizing

Temperature < 0 °C

Cold

Winter

Temperature > 0 °C

Hot

Summer

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F4GE NEF ENGINES	5

UPDATING

Section	Description	Page	Date of revision

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6	F4GE NEF ENGINES	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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2	SECTION 1 - GENERAL SPECIFICATIONS	F4GE NEF ENGINES

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F4GE NEF ENGINES					SECTION 1 - GENERAL SPECIFICATIONS 3
ELECTRICAL SPECIFICATIONS OF THE GENERATING SETS
			Electrical specifications
Generating set	Assembled Engine	Ratings		50 Hz			60 Hz
			kVA		kW (*)	kVA		kW (*)
GE NEF 45M	NEF 45 AM1	Prime	45		36	50		40
		Stand By	50		40	55		44
GE NEF 60M	NEF 45 SM1	Prime	60		48	66		53
		Stand By	66		53	73		58
GE NEF 75M	NEF 45 SM2	Prime	75		60	75		60
		Stand By	82		66	82		66
GE NEF 85M	NEF 45 TM1	Prime	85		68	100		80
		Stand By	94		75	110		88
GE NEF 100M	NEF 45 TM2	Prime	100		80	110		88
		Stand By	110		88	121		97
GE NEF 125M	NEF 67 SM1	Prime	125		100	145		116
		Stand By	138		110	160		128
GE NEF 130M	NEF 67 TM2	Prime	130		104	145		116
		Stand By	143		114	160		128
GE NEF 160M	NEF 67 TM3	Prime	160		128	170		136
		Stand By	176		141	187		150
GS NEF 45M	NEF 45 AM1	Prime	45		36	50		40
		Stand By	50		40	55		44
GS NEF 60M	NEF 45 SM1	Prime	60		48	66		53
		Stand By	66		53	73		58
GS NEF 75M	NEF 45 SM2	Prime	75		60	75		60
		Stand By	82		66	82		66
GS NEF 85M	NEF 45 TM1	Prime	85		68	100		80
		Stand By	94		75	110		88
GS NEF 100M	NEF 45 TM2	Prime	100		80	110		88
		Stand By	110		88	121		97
GS NEF 125M	NEF 67 SM1	Prime	125		100	145		116
		Stand By	138		110	160		128
GS NEF 130M	NEF 67 TM2	Prime	130		104	145		116
		Stand By	143		114	160		128
GS NEF 160M	NEF 67 TM3	Prime	160		128	170		136
		Stand By	176		141	187		150

(*) 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 operation must 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 maximum power available for a period of 500 hours/year with a mean load factor of 90% of the declared stand-by power. No kind of overload is permissible for this use.

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4	SECTION 1 - GENERAL SPECIFICATIONS	F4GE NEF ENGINES

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

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	5

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 any 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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6	SECTION 1 - GENERAL SPECIFICATIONS	F4GE NEF ENGINES

OIL VAPOUR RECIRCULATING SYSTEM

Figure 2

1

2

3

3240t

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

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

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

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F4GE NEF ENGINES	SECTION 1 - GENERAL SPECIFICATIONS	7

COOLING SYSTEM

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

-expansion tank; placement, shape and dimensions are subject to change according to the engine’s equipment;

-radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions;

-visc pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine’s development;

Figure 3

-heat exchanger to cool the lubrication oil: even this component is part of the engine’s specific equipment;

-centrifugal water pump, placed in the front part of the engine block;

-thermostat regulating the circulation of the cooling liquid;

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

117585

COOLING SYSTEM LAYOUT (6 cyl. engines)

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8	SECTION 1 - GENERAL SPECIFICATIONS	F4GE NEF ENGINES

AIR INDUCTION BOOST DIAGRAM

Figure 4

AIR FILTER

AIR FILTER

TURBOCHARGER

EXHAUST

RADIATOR

4 cylinders version

TURBOCHARGER

EXHAUST

RADIATOR

6 cylinders version

74195

74195

Description

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

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

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

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

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

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

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

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F4GE 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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F4GE NEF ENGINES	SECTION 2 - FUEL	3

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

Figure 1 (6-cylinder version)

Description of working principles

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

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

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

106534

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.

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4	SECTION 2 - FUEL	F4GE NEF ENGINES

FEED PUMP

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

STANADYNE DB4 pump

Figure 2

106514

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 valve12. 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 regulator

(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.

The upper part of the regulator 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

5

PRIMING PUMP

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

Figure 3

1

2

3246t

1. Priming pump - 2. Camshaft.

Figure 4

88209

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

Print P4D32N001 E

Base - April 2007

6	SECTION 2 - FUEL	F4GE NEF ENGINES

FUEL FILTER

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

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

Figure 5

106515

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

Base - April 2007

Print P4D32N001 E