Iveco NEF Engine N60 ENT M37 Full Service Repair Manual

NEF ENGINE N40 ENT M25 N60 ENT M37 N60 ENT M40 TECHNICAL AND REPAIR MANUAL MARCH 2007 EDITION TECHNOLOGICAL EXCELLENCE

1.2 MARCH 2007 N40 ENT M25 N60 ENT M37-M40 FOREWORD We strongly recommend that you carefully read the indications contained in this document: compliance with them protects the engine against irregular operation and assures its reliability, safeguarding sea-going and maintenance personnel against accident hazards. The indications contained in this document pertain to the N40 ENT M25, N60 ENT M37 e N60 ENT M40 marine engine and complement the IVECO MOTORS-FPT publication of “Marine Diesel Engines Installation Handbook” that the reader should refer to for anything that is not explained herein. Technical engineers and fitters are required to comply with safety regulations on work. They have to implement and adopt the device required for individual personal safeguard while carrying out maintenance or checks. Safety rules are reported in Section 9 of this publication. Regulations on handling engine are reported at the end of Section 6 of this publication. In order to start the engine, strictly follow the procedure stated at the end of Section 5 of this publication. To get the best possible performance out of the engine, it is mandatory to conform with its intended mission profile. The engine must not be used for purposes other than those stated by the manufacturer. IVECO MOTORS-FPT is available beforehand to examine requirements for special installations, if any. In particular o Use of unsuitable fuels and oils may compromise the engine’s regular operation, reducing its performance, reliability and working life; o Exclusive use of IVECO Original Parts is a necessary condition to maintain the engine in its original integrity; o Any tampering, modifications, or use of non-original parts may jeopardize the safety of service personnel and boat users. To obtain spare parts, you must indicate: - Commercial code, serial number and indications shown on the engine tag; - Part number of the spare as per spare part catalog. The information provided below refer to engine characteristics that are current as of the publication date. IVECO MOTORS-FPT reserves the right to make modifications at any time and without advance notice, to meet technical or commercial requirements or to comply with local legal and regulatory requirements. We refuse all liability for any errors and omissions. The reader is reminded that the IVECO MOTORS-FPT Technical Assistance Network is always at the Customer’s side with its competence and professionalism. Publication IVECO MOTORS-FPT edited by: IVECO PowerTrain Advertising & Promotion Pregnana Milanese (MI) www.ivecomotors.com Printed P3D32N001 E - March 2007 Edition

1. MARCH 2007 N40 ENT M25 N60 ENT M37-M40 SECTION CONTENTS 1. OVERVIEW 5 2. TECHNICAL DATA 53 3. ELECTRICAL EQUIPMENT 59 4. DIAGNOSTICS 95 5. MAINTENANCE 121 6. SERVICING OPERATIONS ON INSTALLED ENGINE 127 7. TOOLS 141 8. OVERHAUL 149 9. SAFETY REGULATIONS 217 Section Page Indications for consultation The different engine versions are usually explained with common images and descriptions. In cases of considerable differences, they are explained separately. Sections 1-2-3 are intended for sales personnel, to provide them with exact knowledge of the product’s characteristics and enable them to meet the Customer’s demands with precision. The remaining sections are meant for personnel in charge of carrying out ordinary and extraordinary maintenance; with an attentive consultation of the chapter devoted to diagnos- ing, they will also be able to provide an effective technical assistance service. CAUTION During the year 2005, some modifications were made to the internal circuits of the relay box and to the wiring. These modifications make incompatible and harmful the use of the components supplied now together with the components supplied before. Please refer to the instruc- tion shown in Chapter 8.

MARCH 2007 N40 ENT M25 N60 ENT M37-M40 4 PAGE LEFT INTENTIONALLY BLANK

OVERVIEW 1.5 MARCH 2007 N40 ENT M25 N60 ENT M37-M40 SECTION 1 IDENTIFYING DATA 7 COMMERCIAL CODE 8 PRODUCT MODEL NUMBER 9 ENGINE PARTS AND COMPONENTS 10 ENGINE ARCHITECTURE 12 Crankcase 12 Crankshaft 13 Connecting Rods 13 Pistons 14 Timing system driving gear 14 Cylinder head 16 Valves and valve seats 17 Ancillary machine members drive 17 COMBUSTION AIR INTAKE AND EXHAUST SYSTEM 18 Comburent air filter 19 Turbocompressor 19 Air/sea-water heat exchanger 19 COOLING FRESH WATER CLOSED-LOOP 20 Exhaust manifold cooling 21 Thermostatic valve 22 Water pump 22 Additional expansion tank 22 SEA-WATER OPEN COOLING LOOP 23 Sea-water pump 24 Sea-water/coolant heat exchanger 24 OVERVIEW Page (continues on next page)

OVERVIEW 1. MARCH 2007 N40 ENT M25 N60 ENT M37-M40 Page ENGINE OIL LUBRICATION LOOP 25 Gear pump 26 Filter bracket 26 Oil vapour recirculation 26 FUEL LINE 27 Fuel supply system scheme 28 Fuel pre-filter 29 Fuel filter 30 Pump assembly 31 Low pressure feed pump 32 Pressure control solenoid valve 34 Low pressure limiter valve 34 Pressure control with engine at maximum rating 35 Pressure control with engine at minimum rating 36 High pressure pump 37 Rail and high pressure piping 39 Two-stage overpressure valve 39 Electro-injectors 40 Pressurization valve of the electro-injector backflow 42 EDC 7 SYSTEM ELECTRONIC AND ELECTRIC MAIN COMPONENTS 43 EDC 7 Electronic Central Unit 44 Air pressure/temperature sensor 44 Atmospheric pressure sensor 44 Oil pressure/temperature sensor 45 Crankshaft sensor 45 Camshaft sensor 46 Coolant temperature sensor 46 Fuel temperature sensor 47 Fuel pressure sensor 47 Pressure control solenoid 48 Throttle lever position 48 Page SYSTEM FUNCTIONS 49 Run up 49 Starting 49 Metering and fuel injection 49 Injection advance management 49 Pre-injection 50 Injection pressure modulation 50 Idling adjusting 50 Self-diagnosis 50 EDC indicator light 50 Fuel heating 50 Linearization of the acceleration gradient 50 Balance of the cylinder torque delivery 50 Rotation speed control 50 Top speed limitation 50 Cut off 50 Derating 51 Recovery 51 After run 51

OVERVIEW 1.7 MARCH 2007 N40 ENT M25 N60 ENT M37-M40 IDENTIFYING DATA IDENTIFYING DATA (from January 2004) 04_004_N Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY ENGINE TYPE ENGINE DWG ENGINE S/N COMMERC. TYPE / VERSION POWER SET CODE HOMOLOGATION N° ENGINE FAMILY POWER (KW) AND SPEED (RPM) YEAR OF BUILD S. p. A. 04_002_N Figure 2 Figure 1 Figure  (up to December 2003) 04_007_N 1 1 2

OVERVIEW 1.8 MARCH 2007 N40 ENT M25 N60 ENT M37-M40 COMMERCIAL CODE The purpose of the commercial code is to make the characteristics of the product easier to understand, categorizing the engines according to their family, origins and intended application. The commercial code, therefore, cannot be used for the technical purpose of recognizing the engine’s components, which is served by the “ENGINE S/N”. N 60 E N T M 37 . 1 0 ENGINE FAMILY IDENTIFIER: N = NEF DISPLACEMENT: 60 = 6000 cc NOMINAL FUEL SUPPLY: E = ELECTRONIC INJECTION BASE: N = NON STRUCTURAL AIR INTAKE: T = INTERCOOLED SUPERCHARGED APPLICATION: M = MARINE MAXIMUM PERFORMANCE LEVEL ACHIEVABLE 37 = 370 HP VERSION: TURBOCHARGED: 1 = COOLED 2 = NOT COOLED VERSION

OVERVIEW 1. MARCH 2007 N40 ENT M25 N60 ENT M37-M40 PRODUCT MODEL NUMBER The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to character- ize its application and power output level. It is stamped on a side of crank-case, close to oil filter. F 4 A E 0 6 8 6 B * E 1 0 3 ENGINE FAMILY IDENTIFIER DESIGN ITERATION ENGINE NO. OF STROKES AND CYLINDER DISPOSITION (0 = 4 STROKES, VERTICAL) NO. OF CYLINDERS FUEL + INJECTION (8 = DIESEL, TCA, DIRECT INJECTION) INTENDED USE (6 = MARINE) POWER RANGE: B = MAXIMUM POWER 370 HP E = EMISSION FOR MARINE APPLICATION VARIANTS TO BASIC ENGINE

OVERVIEW 1.10 MARCH 2007 N40 ENT M25 N60 ENT M37-M40 ENGINE PARTS AND COMPONENTS Figure 4 1. Engine coolant discharge cap - 2. Electric starter motor - 3. Tube bundle engine coolant/sea-water heat exchanger - 4. Location of sacrificial anode - 5. Cooled exhaust manifold - 6. Exhaust gas and sea-water discharge pipeline - 7. Cap for engine coolant outlet to sanitary water heating system - 8. Lifting eyebolts - 9. Rocker arm cover - 10. Oil refill cap - 11. Coolant refill cap - 12. Location of thermostatic valve - 13. Engine coolant tank - 14. Auxiliary belt automatic tensioner - 15. Alternator - 16. Cap for engine coolant discharge and recirculation from sanitary water heating system - 17. Oil filter. 17 16 2 3 4 5 6 9 10 11 8 12 13 15 14 1 04_006_N 7

Iveco NEF Engine N60 ENT M37 Full Service Repair Manual

You're Reading a Preview

Recently Viewed