2007-2012 Iveco NEF Marine Engine N40 N60 Service & Repair Manual

1 ENGLISH NEF SERIES ELECTRONIC INJECTION SYSTEM N40 ENT (TIER 2) N45 ENT (TIER 3) N60 ENT (TIER 2) N67 ENT (TIER 3) NEF 60 TE2 USE AND MAINTENANCE INTRODUCTION We would like to thank you for buying an IVECO MOTORS product, and compliment you on your choice of engine. Before you carry out any operation involving the engine or its fittings, please read the contents of this manual carefully; compliance with the instructions provided in the manual is the best way to guarantee trouble-free, long term operation of the engine. The contents of this manual refer to the standard configuration of the engine, and the illustrations are purely indicative. Some instructions are provided by giving the sequence of operations to be carried out in order to allow the engine and/or its fittings to perform in a certain way. In some cases they will be dependent on the configuration of the commands and the set-up of the machine on which the engine is installed; for any points that differ from the contents of this manual, please consult the instructions provided by the machine Manufacturer or a specific manual. The information provided below was current at the date of publication. The Manufacturer reserves the right to make modifications at any time without prior notice, for technical or commercial reasons or to update the engines to comply with legal requirements in the various Countries. The Manufacturer declines all liability for any errors or omissions. Please remember that the IVECO MOTORS Technical Service Network is available to offer you its experience and professional skills, wherever you may be.

2 TABLE OF CONTENTS Page GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine technical data N40 ENT - N45 ENT . . . . . . . . . . . . . . . . . . 4 Engine technical data N60 ENT - N67 ENT . . . . . . . . . . . . . . . . . . 6 Engine technical data NEF 60 TE2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Preliminary checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Starting and stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Recognising alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine management and diagnosis from the instrument panel. .15 Engine pre-heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 For proper use of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Special warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CONTROLS AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 19 Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 How to proceed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Moving the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Disposal of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . 31 Preparing the engine for a long period of inactivity . . . . . . . . . . . 31 Restarting the engine after a long period of inactivity . . . . . . . . . 32 Page ENGINE MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 BEHAVIOUR IN AN EMERGENCY. . . . . . . . . . . . . . . . . . . . . . .34 IN APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil viscosity level according to surrounding temperatures . . . . . . .

3 ENGLISH GENERAL INFORMATION GUARANTEE In order to ensure that your engine gives the best possible performance and to take advantage of the IVECO MOTORS guarantee, you must follow the indications provided in this publication with great care; failure to do so may result in invalidation of the guarantee. SPARE PARTS Always use Original IVECO MOTORS Spare parts. This is essential to keep the engine in original running order. The use of non-original spare parts will not only invalidate the guarantee, but will mean that IVECO MOTORS will not be considered liable in any way during the whole working life of the engine. LIABILITY The Manufacturer will only be considered liable subject to performance of the control and maintenance operations indicated and described in this manual; to this effect, proof that these operations have been performed must be provided. Any special maintenance operations that may be necessary must be carried out by qualified technicians from authorised Workshops in the IVECO MOTORS Network, using the instruments and equipment provided for the purpose. SAFETY The following information is intended to encourage caution when using the engine, so as to avoid damage to persons or property as a result of improper or incorrect behaviour. The engines must only be used for the purposes indicated by the Manufacturer. Any tampering, modification and use of non-original spare parts may compromise proper operation and safe use of the engine; never, under any circumstances make modifications to the wiring and to the units equipping the engine, or connect them to other power systems. Pay particular attention to moving parts of the engine, to high temperature components and to circuits containing pressurised fluids; its electrical equipment houses electrical currents and voltage. The exhaust fumes produced by the engine are bad for your health. Tackle, making use of the U-bolts provided on the engine for that purpose. The engine must not be started up and used until the machine in which it installed has satisfied all necessary safety requirements, or until the machine has been guaranteed to comply with local laws and regulations. The operations required to guarantee the best possible use and preservation of the engine must only be carried out by persons of proven experience, equipment with tools considered suitable by IVECO MOTORS. For the purpose of safety, further recommendations are given in the chapter CONTROLS AND MAINTENANCE.

4 ENGINE TECHNICAL DATA N40 ENT - N45 ENT The technical code and serial number are indicated on a plate, which is located on different parts of the engine, according to the model: flywheel casing, tappet cover, other. (*)Net power to the flywheel in compliance with ISO 3046-1. Test conditions: temperature 25 °C; atmospheric pressure 100 kPa; relative humidity 30%. Code N40 ENT N45 ENT Engine family F4 Cycle 4-stroke diesel Number and arrangement of cylinders 4, in line Bore x stroke 102 x 120 mm 104 x 132 mm Total displacement 3,900 cm 3 4,500 cm 3 Air system Supercharged aftercooled Injection type Common Rail, electronically managed Engine direction of rotation Anticlockwise (seen from flywheel side) Dry weight 410 kg 410 kg Electrical system 24 V Accumulator/s - capacity - discharge current 130 Ah or above 500 A or above Performance: Maximum power (*) Maximum torque N40 ENT 107 kW (145 CV) @ 2300 rpm 490 Nm (50 Kgm) @ 1200 rpm N45 ENT 104 kW (141 CV) @ 2200 rpm 560 Nm (57 Kgm) @ 1400 rpm WARNING Any alteration of the above mentioned characteristics, in particular modification of the data stored in the injection system electronic units or the characteristics of the engine and its fittings, is strictly prohibited, penalty invalidation of the guarantee and absence of all liability on the part of IVECO MOTORS.

5 ENGLISH Engine N40 ENT - N45 ENT 1. Auxiliary member drive belt - 2. Engine air inlet - 3. Fuel inlet manifold from tank - 4. Common rail - 5. Lifting U-bolt - 6. Common rail high pressure pump - 7. Fuel outlet connector to tank - 8. Fuel filter - 9. Oil drainage plug - 10. Oil dipstick - 11. Engine electronic control unit - 12. Sensor on drive shaft phonic wheel. Engine N40 ENT - N45 ENT 1. Turbocharger air intake - 2. Turbocharger - 3. Turbocharging air outlet to after-cooler - 4. Exhaust manifold - 5. Turbocharger exhaust outlet - 6. Lifting U-bolt - 7. Oil filler cap - 8. Coolant outlet to heat exchanger - 9. Thermostat valve location - 10. Alternator - 11. Coolant inlet from heat exchanger - 12. Lubricant oil filter - 13. Electrical starter motor. 05_573_N 05_574_N

6 ENGINE TECHNICAL DATA N60 ENT - N67 ENT The technical code and serial number are indicated on a plate, which is located on different parts of the engine, according to the model: flywheel casing, tappet cover, other. (*)Net power to the flywheel in compliance with ISO 3046-1. Test conditions: temperature 25 °C; atmospheric pressure 100 kPa; relative humidity 30%. Code N60 ENT N67 ENT Engine family F4 Cycle 4-stroke diesel Number and arrangement of cylinders 6, in line Bore x stroke 102 x 120 mm 104 x 132 mm Total displacement 5,900 cm 3 6,700 cm 3 Air system Supercharged aftercooled Injection type Common Rail, electronically managed Engine direction of rotation Anticlockwise (seen from flywheel side) Dry weight 520 kg 520 kg Electrical system 24 V Accumulator/s - capacity - discharge current 130 Ah or above 500 A or above Performance: Maximum power (*) Maximum torque N60 ENT 169 kW (230 CV) @ 2300 rpm 810 Nm ( 83 Kgm) @ 1200 rpm N67 ENT 175 kW (238 CV) @ 2200 rpm 1020 Nm (104 Kgm) @ 1400 rpm WARNING Any alteration of the above mentioned characteristics, in particular modification of the data stored in the injection system electronic units or the characteristics of the engine and its fittings, is strictly prohibited, penalty invalidation of the guarantee and absence of all liability on the part of IVECO MOTORS.

7 ENGLISH Engine N60 ENT - N67 ENT 1. Auxiliary member drive belt - 2. Engine air inlet - 3. Fuel inlet manifold from tank - 4. Common rail - 5. Lifting U-bolt - 6. Common rail high pressure pump - 7. Fuel outlet connector to tank - 8. Fuel filter - 9. Oil dipstick - 10. Oil drainage plug- 11. Engine electronic control unit - 12. Sensor on drive shaft phonic wheel. Engine N60 ENT - N67 ENT 1. Turbocharger air intake - 2. Turbocharger - 3. Turbocharging air outlet to after-cooler - 4. Turbocharger exhaust outlet - 5. Exhaust manifold - 6. Lifting U-bolt - 7. Oil filler cap - 8. Coolant outlet to heat exchanger - 9. Thermostat valve location - 10. Alternator - 11. Coolant inlet from heat exchanger - 12. Lubricant oil filter - 13. Electrical starter motor. 05_575_N 05_576_N

8 ENGINE TECHNICAL DATA NEF 60 TE2 The technical code and serial number are indicated on a plate, which is located on different parts of the engine, according to the model: flywheel casing, tappet cover, other. (*)Values in compliance with ISO 8528. SELECTING THE RUNNING SPEED The running speed can be preselected (1500 or 1800 rpm) by inserting a resistor between terminals 87 and 32 of the 89-pin connector on the engine's electronic control unit. The prescribed resistor values are as follows: - 1500 rpm : 1330 Ohm - 1800 rpm : 820 Ohm For incorrect values or in the total absence of a resistor the running speed will be kept at minimum, equivalent to 800 rpm. Code NEF 60 TE2 Engine family F4 Cycle 4-stroke diesel Number and arrangement of cylinders 6, in line Bore x stroke 102 x 120 mm Total displacement 5.900 cm 3 Air system Supercharged aftercooled Injection type Common rail, electronically managed Engine direction of rotation Anticlockwise (seen from flywheel side) Isochronous speed regulator Electronically controlled Dry weight 630 kg Electrical system 12 V Accumulator/s - capacity - discharge current 185 Ah or above 1200 A or above Performance (*) (50 Hz) Prime 175 kWm @ 1500 rpm Stand by 193 kWm @ 1500 rpm (60 Hz) Prime 195 kWm @ 1800 rpm Stand by 215 kWm @ 1800 rpm WARNING Any alteration of the above mentioned characteristics, in particular modification of the data stored in the injection system electronic units or the characteristics of the engine and its fittings, is strictly prohibited, penalty invalidation of the guarantee and absence of all liability on the part of IVECO MOTORS.

9 ENGLISH NEF 60 TE2 1. Coolant filler cap - 2. Heat exchangers - 3. Oil filler cap - 4. Engine air inlet - 5. Common rail - 6. Lifting U-bolt - 7. Air filter - 8. Common rail high pressure pump - 9. Fuel outlet connector to tank - 10. Fuel filter - 11. Fuel prefilter - 12. Fuel inlet manifold from tank - 13. Oil drainage plug - 14. Oil dipstick - 15. Engine electronic control unit NEF 60 TE2 1. Exhaust manifold - 2. Turbocharger air inlet - 3. Turbocharging air outlet to after-cooler - 4. Turbocharger - 5. Turbocharger exhaust outlet - 6. Lifting U-bolt - 7. Coolant outlet to heat exchanger - 8. Thermostat valve location - 9. Radiator fan - 10. Alternator - 11. Coolant inlet sleeve from heat exchanger - 12. Oil filter - 13. Electric starter motor. 05_577_N 05_578_N

2007-2012 Iveco NEF Marine Engine N40 N60 Service & Repair Manual

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