Iveco F4ge PDF

N SERIES
F4G TIER 3
Agricultural applications (Hyundai)
F4GE9484F*J608
F4GE9454J*J604
Technical and Repair manual

This publication contains data, features, instructions and
methods for performing repair interventions on the assembly
and its components.
This publication is addressed to qualified, specialised person-
nel.
Check that you have the publication related to the assembly
on which you are about to work available before you start.
Make sure that you have all the necessary safety apparatuses,
such as, for example, protective eyewear, helmet, gloves, foot-
wear, etc. Check that the working, lifting and transport equip-
ment etc. is available and in working order. Make sure that the
group is prepared and secured.
Proceed by carefully observing the instructions contained
herein and use the indicated specific tools to ensure correct
repair procedures, observance of time schedules and safety of
operators.
All repair interventions are aimed at restoring the conditions
of operation, efficiency and safety contemplated by FPT.
All on-group interventions, aimed at implementing changes,
alterations or other not authorised by FPT will relieve FPT
from responsibility. Specifically, the warranty (where appli-
cable) will be immediately cancelled.
FPT cannot be held responsible for repair interventions.
FPT is available to provide any additional information needed
for performing the inventions and indications in the cases and
situations not contemplated in this publication.
The data contained in this publication may not be up-to-date
if changes are made by the manufacturer at any time for techni-
cal or commercial reasons or if required to meet legal require-
ments of countries worldwide.
Contact a FPT dealership before proceeding in the event of dif-
ferences between the contents of this publication and the
actual assembly.
Reproduction, even partial, of this text and the illustrations
contained herein is prohibited.
Produced by:
Publication edited by
FIAT Powertrain Technologies
Mkt. Advertising & Promotion
Viale dell’Industria, 15/17 B.U. TECHNICAL PUBLISHING
20010 Pregnana Milanese Iveco Technical Publications
Milano (Italy) Lungo Stura Lazio, 15/19
Print P2D32N010 E - 1st Ed. 02.2009 10156 Turin - Italy
F4GE N SERIES 1
F4GE N SERIES
F4GE N Series Part 1
Print P2D32N010 E Base - Febraury 2009

2 F4GE N SERIES
Base - Febraury 2009 Print P2D32N010 E

F4GE N SERIES INTRODUCTION 1
Introduction
Page
PREFACE TO USER’S GUIDELINE MANUAL . . . . 3
SYMBOLS ............................... 5
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . . . 7
- Bonding and screening . . . . . . . . . . . . . . . . . . . 8
CONVERSIONS BETWEEN THE MAIN UNITS

OF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND MOST USED DERIVED
QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
KEY OF LECTURE OF THE HEADINGS

AND FOOTNOTES . . . . . . . . . . . . . . . . . . . . . 10

2 INTRODUCTION F4GE N SERIES

PREFACE TO USER’S GUIDELINE MANUAL

Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
Section 1 describes the engine illustrating its features and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four separate parts:
1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the relating
specific duty.
2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating
specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct
instructions to identify the cause of the major inconveniences.
Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such
operations.
The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order
to prevent serious accidents taking place.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - Warnings
Danger for persons

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

Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may
sometimes cause the warranty to become null and void.
General danger
! It includes the dangers of above described signals.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
NOTE It indicates an additional explanation for a piece of information.

Service operations
Example
∅1 Ø 1 = housing for connecting rod small end bush

Tighten to torque
Tighten to torque + angular value
α
∅ 2 Ø 2 = housing for connecting rod bearings

Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

α
Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Surface for machining

bar
Pressure
Machine finish
Oversized
Interference
Higher than….
Strained assembly
Maximum, peak
Undersized
Thickness
Less than….
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0 °C
Sealant
Cold
Adhesive
Winter
Temperature > 0 °C
Air bleeding Hot
Summer

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 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.

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; FPT commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

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 FPT system and are carefully recovered after repair or maintenance interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
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.

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

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

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES
Type of Section Page

vehicle title number
Printout Language Basic edition referred to When month - year update

number Publication month - year editorial is present (revi) to the
phase closing basic edition

F4GE N SERIES 1
Part 1
F4GE N SERIES
Section
General specifications 1
Fuel 2
Agricultural applications 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
Print P2D32N010 E Base - February 2009

2 F4GE N SERIES
Base - February 2009 Print P2D32N010 E

F4GE N SERIES 3
UPDATING
Section Description Page Date of revision

4 F4GE N SERIES

F4GE N SERIES SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General Specifications
Page
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OIL VAPOUR RECIRCULATING SYSTEM . . . . . . . 4
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR INDUCTION BOOST DIAGRAM . . . . . . . . . . 6
- Boosting version engines . . . . . . . . . . . . . . . . . 6
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Inter-cooled engine version . . . . . . . . . . . . . . . 7
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) 8

2 SECTION 1 - GENERAL SPECIFICATIONS F4GE N SERIES

LUBRICATION Lubrication involves the heat exchanger and the turboblower.

Lubrication by forced circulation is achieved through oil rotary All these components may often vary according to the specific
expansion pump, placed in the front part of the basement, duty.
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
Routing of oil under

pressure
Routing of oil return
by gravity to sump
132102
Introduction of oil
LUBRICATION SYSTEM LAYOUT

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

OIL VAPOUR RECIRCULATING SYSTEM
Figure 2
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 (con-
nection towards these vapours shall be designed by the Engineer).

COOLING SYSTEM - Heat exchanger to cool the lubrication oil: even this
The engine cooling system, closed circuit forced circulation component is part of the engine’s specific equipment.
type, generally incorporates the following components: - Centrifugal water pump, placed in the front part of the
- Expansion tank; placement, shape and dimensions are engine block.
subject to change according to the engine’s equipment. - Thermostat regulating the circulation of the cooling liquid.
- Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.
- Visc pusher fan, having the duty to increase the heat
dissipating power of the radiator. This component as well
will be specifically equipped based on the engine’s
development.
Figure 3
TO RADIATOR
FROM RADIATOR
Water coming out from thermostat
Water recirculating in engine

127129
Water coming into pump
COOLING SYSTEM LAYOUT

AIR INDUCTION BOOST DIAGRAM

Boosting version engines
Figure 4
AIR FILTER TURBOCHARGER
EXHAUST
88208
Description The turbocharger is equipped with a transforming valve to

The turbocharger is composed by the following main parts: regulate the pressure , that is located on the exhaust collector
one turbine, one transforming valve to regulate the boost before the turbine and connected by piping to the induction
feeding pressure , one main body and one compressor. collector.
During engine working process, the exhaust emission flow It’s duty is to choke the exhaust of the emissions , releasing part
through the body of the turbine, provoking the turbine disk of them directly to the exhaust tube when the boost feeding
wheel’s rotation. pressure, over the compressor, reaches the prescribed bar
value.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates, The cooling process and the lubrication of the turbocharger
compressing the sucked air through the air filter. and of the bearings is made by the oil of the engine.
The air coming out of the compressor is sent via the intake
manifold directly to the pistons.

Inter-cooled engine version

Figure 5
AIR FILTER TURBOCHARGER
EXHAUST
RADIATOR
74195
4 cylinders version
Description
The turbocharger is composed by the following main parts: The turbocharger is equipped with a transforming valve to
one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust collector
feeding pressure , one main body and one compressor. before the turbine and connected by piping to the induction
collector.
During engine working process, the exhaust emission flow
through the body of the turbine, provoking the turbine disk It’s duty is to choke the exhaust of the emissions , releasing part
wheel’s rotation. of them directly to the exhaust tube when the boost feeding
pressure, over the compressor, reaches the prescribed bar
The compressor rotor, being connected by shaft to the
value.
turbine disk wheel, rotates as long as this last one rotates,
compressing the sucked air through the air filter. The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.

EXHAUST GAS RE-CIRCULATION SYSTEM The internal EGR system is not equipped with any
(EGR) electronically controlled elements: the system is always active.
In the TIER 3 version, the profile of the exhaust cam has been Its configuration does not need additional elements
modified in order to allow the partial opening of the relative i.e.checking valves, piping or heat exchangers.
valve during the aspiration phase (re-circulation of EGR The exhaust cam (B) has another lobe apart from the major
exhaust gas) with the subsequent re-introduction of part of lobe (see Section. A-A fig.) with respects to the configuration
the exhaust gas into the engine cylinders. without EGR.
The exhaust gases can partially be re-directed into the The additional lobe, during the aspiration phase in the cylinder
cylinders so as to reduce the maximum combustion in question, allows a brief opening of the exhaust valve
temperature values responsible for the production of nitric generating re-circulation due to the intake of the exhaust gases
acid (NOx). caused by depression which is created in the aspiration phase
The exhaust gas re-circulation system (EGR), reducing the inside the cylinder.
combustion temperature by means of the diminishing of the
concentration of oxygen in the combustion chamber,
represents therefore an efficient control system of the
emission of NOx .
Figure 6
114789
A. Aspiration valve control - B. Exhaust valve control.

F4GE N SERIES SECTION 2 - FUEL 1
SECTION 2
Fuel
Page
4-CYLINDER ENGINES WITH BOSCH VE 4/12 F

ROTARY MECHANICAL PUMP . . . . . . . . . . . . 3
- General information . . . . . . . . . . . . . . . . . . . . . 3
- Description of working principles . . . . . . . . . . . 4
FEED PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Example of identification . . . . . . . . . . . . . . . . . 5
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 SECTION 2 - FUEL F4GE N SERIES

4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTARY MECHANICAL PUMP

General information
Fuel feed system is composed by:
- Fuel tank (placed on the machine)
- Fuel delivery and back-flow to tank
- Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame)
- Priming pump, assembled to the engine and driven by the camshaft
- Fuel filter (assembled to the engine in different positions according to equipment application and duty)
- Fuel feed rotary pump
- Injector feed pipeline (from fuel feed pump to injectors)
- Injectors
Figure 1
2
1
4
74168
1. Injector feed pipes - 2. Fuel exhaust pipes from injectors - 3. Fuel feed rotary pump - 4. Connector for LDA pressure
gauge pipe within suction collector - 5. KSB thermal bulb - 6. Electro-valve - 7. Injector.

Figure 2
3
2
75807
1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump.
Description of working principles
Fuel is sucked from the fuel tank by the priming pump. This The fuel arrives therefore to the valve gauging the pressure
last one is placed on the engine basement and is driven by inside feed pump.
the camshaft.
The distribution plunger further increases this pressure and
Throughout the filter, the fuel is piped to the union fitting delivers fuel throughout the delivery pipe fitting to the
vacuum chamber of the transfer pump. (For applications to injectors.
be equipped in cold climate areas, the fuel filter is provided
The fuel drawing from the injectors is recovered and delivered
with heater).
to the tank again.
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.

FEED PUMP
The rotary type pump is driven by a gear mating the camshaft’s one.
Example of identification
V = Distribution rotary plunger
E = Pump dimensions
4 = 4 cylinders engine
12 = Distribution plunger in mm.
1150 = N°. of pump revolutions per minute
LV = Left direction of rotation
Figure 3
1
15
2
14
3
5
13
12
7
8
9
11
10
30454
Injection pump longitudinal section

1. Diagram - 2. Locking nut - 3. Pivot - 4. Drive lever - 5. Speed gauge - 6. Transfer pump - 7. Drive shaft - 8. Cam disk -
9. Advance converter - 10. Distribution plunger - 11. Delivery pipe fitting - 12. Hydraulic head - 13. Drive plate -
14. Gauge pin - 15. Counteracting spring.

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 4
88209
1. Priming pump - 2. Drive lever - 3. Camshaft.

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
1
5
4
4
3
3
3243t
3244t
1. Fuel filter bearing- 2. Heater - 3. Water dump screw- 4. Filter cartridge -

5. Temperature sensor.


F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION 1
SECTION 3
Agricultural application
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . . . 4
PART ONE -
MECHANICAL COMPONENTS . . . . . . . . . . . 7
OVERHAUL OF THE ENGINE . . . . . . . . . . . . . . . 9
- Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Engine setting operations for the assembly on

turning stand . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Disassembly of application components . . . . . 11
- Installation of rear components . . . . . . . . . . . . 19
- Flywheel installation . . . . . . . . . . . . . . . . . . . . . 22
- Installation of front components . . . . . . . . . . . 23
- Completion of engine . . . . . . . . . . . . . . . . . . . 33
- Rotary feed pump disassembly and assembly pro-

cedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Power take-off disassembly and assembly

procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Feed system bleed procedure . . . . . . . . . . . . . 38
- Checks and inspections . . . . . . . . . . . . . . . . . . 39
PART TWO -
ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . 41
ELECTRICAL COMPONENT LAYOUT . . . . . . . . 43
- Cooling liquid temperature sensor . . . . . . . . . 44
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
- KSB Water temperature sensor . . . . . . . . . . . 44
- Electromagnets assembled to feed pump . . . . 45
- Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . 45
- Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
- Pre-post heating resistor . . . . . . . . . . . . . . . . . 45

2 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES
Page
PART THREE - TROUBLESHOOTING . . . . . . . . 47
PART FOUR -
MAINTENANCE PLANNING . . . . . . . . . . . . . 55
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . 57
- Checks not included in maintenance planning-daily

checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . 58
- Checks and controls . . . . . . . . . . . . . . . . . . . . 58
- Engine oil level check . . . . . . . . . . . . . . . . 58
- Check of fuel system . . . . . . . . . . . . . . . . 59
- Cooling system check . . . . . . . . . . . . . . . 59
- Lubricating system check . . . . . . . . . . . . . 59
- Check of water presence within fuel filter or

pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . 59
- Check of drive belt tensioning . . . . . . . . . 60
- Check of belt’s tear and wear status . . . . 60
- Check and setting of tappet clearance . . . 60
- Oil motor and filter replacement . . . . . . . 60
- Fuel filter replacement . . . . . . . . . . . . . . . 61
- Alternator belt replacement . . . . . . . . . . . 62

GENERAL INFORMATION
Figure 1
132103
NEF engines have been designed and developed by FPT

specifically for transportation by land and farming equipment NOTE Data, technical specifications and performances
in general. granted shall be valid only if the Setter will follow and
comply with all installation prescriptions provided
They are characteristed by diesel cycle 4 stroke atmospheric by FPT.
or supercharged 4 and 6 cylinders each with 2 valves. Furthermore, the expanders assembled by the
Setter must always comply with couple, power and
Feed is provided by rotary mechanical pump or on line number of revolutions based on which the engine
according to the equipment application. has been designed.
It differ from other applications because of the provision of The section herein described is composed or four directories:
different power, power take-off for the different collector
- directory of mechanical overhaul prescribed in accordan-
configuration, priming pump, oil pan and boost turbine ce to the engine’s specific duty, illustrating all necessary
operations to remove and assembly the external compo-
NOTE nents of the engine, including cylinder heads, gearbox of
The picture shows application designed for 4 the timing system and of the front part cover;
cylinders version, 2 valves per cylinder, having fuel - electrical directory, describing the connections of the
feed mechanical pump. different components, of the pre-post heating gearbox
(only for some versions) and of the sensors assembled to
the engine;
- troubleshooting directory;
- directory of preventive and regular maintenance opera-
tions, providing instructions for the execution of the main
operations.
CLEARANCE DATA
Type F4GE9454J*604
ρ Compression ratio 17.5:1
Max. output kW 66
(HP) (90)
rpm 2200
Max. torque Nm 400

(kgm) (40.0)
rpm 1250
Loadless engine
idling rpm
950
Loadless engine
peak rpm rpm
2430
Bore x stroke mm 104 X 132
Displacement cm3 4485
SUPERCHARGING without intercooler
Direct injection
Turbocharger type HOLSET HX25
LUBRICATION Forced by gear pump, relief valve single action
oil filter
Oil pressure
bar (warm engine)
- idling bar > 0.70

- peak rpm bar 3.1
COOLING By centrifugal pump, regulating thermostat, heat
exchanger, intercooler
Water pump control Through belt
Thermostat
- start of opening ºC 81 ± 2
ACEA: E3, E5, E7 FILLING
URANIA LD7
20W40: 0°C to 40°C engine sump*
(Very hot countries, heavy liters 13
mission)
15W40: -10°C to 40°C engine sump + filter*
(Europa/Nord American liters 14
mission)
10W30: -28°C to 35°C
(Cold mission)
* First filling operation
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.

Type F4GE9484F*J608
ρ Compression ratio 17.5:1

Max. output kW 74
(HP) (101)
rpm 2200
Max. torque Nm 430
(kgm) (43.0)
rpm 1250
Loadless engine
idling rpm 800

Loadless engine
peak rpm rpm
2430
Bore x stroke mm 104 X 132
Displacement cm3 4485
SUPERCHARGING With intercooler
Turbocharger type HOLSET HX25

Forced by gear pump, relief valve single action
LUBRICATION oil filter
bar Oil pressure

(warm engine)
- idling bar > 0.70

- peak rpm bar 3.1
COOLING By centrifugal pump, regulating thermostat, heat
exchanger, intercooler
Water pump control Through belt
Thermostat
- start of opening ºC 81 ± 2
ACEA: E3, E5, E7 FILLING
URANIA LD7
20W40: 0°C to 40°C engine sump*
(Very hot countries, heavy liters 13
mission)
15W40: -10°C to 40°C engine sump + filter*
(Europa/Nord American liters 14
mission)
10W30: -28°C to 35°C
(Cold mission)
* First filling operation
NOTE Data, features and performances are valid only if the setter fully complies with all the installation prescriptions provided
by FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns
based on which the engine has been designed.


PART ONE - MECHANICAL COMPONENTS


OVERHAUL OF THE ENGINE Figure 3

Preface
Part of the operations illustrated within this section can be
partially executed while the engine is assembled on the
vehicle, depending on the room available for access to the
engine and on the equipment application as well.
2
NOTE With regard to the engine disassembly operations,
please apply for information consulting the specific
manual. All operations of engine disassembly
operations as well as overhaul operations must be
executed by qualified engineers provided with the
specific tooling and equipment required.
3
The following information relate to the engine overhaul
operations only for what concerns the different components 4
customising the engine, according to its specific duties.
NOTE For specific application exigencies, some units can

be assembled to the engine in different positions. 1
Within ”General overhaul” section, all the operations of 5

engine block overhaul have been contemplated. Therefore
the above mentioned section is to be considered as following
the part hereby described.
Engine setting operations for the assembly on 75671
turning stand
Figure 2 - disassemble lubrication oil exhaust pipe from the
turbo-blower:
Underneath the turbo-blower loosen the two screws
(2), loosen the screw (3) fixing the pipe throughout the
stop collar (4) fixing the block; finally loosen and remove
the union (5) from the block; plug the pipe ends and the
exhaust of the turbo-blower.
Figure 4
116386 3
In order to apply the brackets 99361037 to the engine block
to fix it on to the stand 99322205 for the overhaul, it is
necessary to perform the following operations:
On the right hand side:
- disassemble pipes (1) from the union (2) fitting the
lubrication oil filter (assembled on the opposite side):
2
unlock the nuts fixing the pipes (1) and remove them from
the union (2); drain the oil eventually still inside the pipes
and plug them properly in order to avoid impurity inlet.
1
NOTE For some versions, the oil filter (3) is directly 75672
assembled on to the heat exchanger:in such case
it shall be disassembled using tool 99360076.
- Disassemble the starter;
Warning: the oil filter contains inside aprx. 1 kg. of
Properly hold the starter (2) and loosen the fixing screws
engine oil. Provide for oil recovery and disposal in
(1);
compliance with the law and regulations in force.
assemble the supporting bracket (99361037) using the
threaded ports on the basement.
Figure 5 Figure 6
1
3
2
75673
75674
On the left hand side: - Assemble the second bracket 99361037 throughout the
screw-threaded ports (1).
- Disassemble oil filter (1) and bracket as well (for versions
with engine oil filter not directly assembled on to the - Lift the engine using the rocker arm 99360595 and put
exchanger); it on the turning stand 99322205.
Using tool 99360076 operate on oil filter; - Drain the oil through the cap underneath the plug.
Loosen the screws (3) removing the bracket together
with the filter bearing (4 and 5).
Warning: the oil filter contains inside aprx. 1 kg. of Warning: avoid contact of engine oil with the skin:
engine oil. in case of skin contamination, rinse in running water.
Provide tank with sufficient capacity to contain the Engine oil is highly pollutant: provide for disposal in
liquid. compliance with the law and regulations in force.
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
- The plug and the oil filler pipe (for versions with the
engine oil filter fitted directly on the heat exchanger).
- Seal the opening to prevent foreign bodies from
entering.
- Remove the oil level rod together with guide pipe (2);
(loosen the guide pipe disassembling from the block);
properly pipe the screw-threaded port to avoid inlet of
foreign matters.

Disassembly of application components - Place a container under the fuel filter and screw out the
condense drain faucet underneath said filter. Carry out
Figure 7 complete drainage of the fuel contained therein.
- Screw out completely the faucet and, using equipment
1 99360076 disassemble oil filter (1).
- Disconnect fuel pipelines (2 and 3) respectively from
priming pump to filter bearing and from this last one to
the feed pump.
- Remove the fuel filter bearing (4) from the bracket fixed
to the engine head.
75675
Proceed disassembling the supercharger:

- loosen the fixing nut (1) and remove the lubrication pipe
from the supercharger. Analogously carry out the same
operation on the other end of the pipe and remove it
from the upper part of the heat exchanger.
- Loosen the screw nuts fixing the supercharger on the Figure 9
exhaust manifold.
- Hold up the supercharger and after lifting it remove the
gasket.
Figure 8
70126
NOTE To disconnect fuel pipelines (2 and 3, Figure 8), in

low pressure from the relating pipe fittings, it is
Necessary to press the locking fastener (1) as
shown in picture B.
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.
123024
NOTE In some versions, the fuel filter has a heater

interposed between filter support and filtering
cartridge.
For the versions requiring it, disconnect the
electrical connections of such electrical
component before removing the fuel filter.

BOSCH VE 4/12 F Pump Figure 11

Figure 10
1 1
75679
75677
- Disconnect the pipelines (1) and (2) that provide feed
and fuel recovery between pump and injectors; screw
- Disconnect the LDA pipe (1) from the head and from
the feed pump. Pipe the ends of the pipelines as well as out the nuts fixing the pipes to the pumping elements;
the feed pump and the engine head. loosen the fuel recovery pipe collar on the injection
pump; operate on the nuts assembled to the injectors
and loosen the screws fixing the fuel recovery pipeline;
loosen the screws holding the fixing brackets of such
pipelines (1,6, and 7, Figure 12); pipe the pipeline ends.
- Disassemble the injectors and remove them from their
slot: remove the gaskets.
Figure 12
3
7
4
6 5
75680
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side- 7. Front bracket fixing
screw (on suction collector plate).

Figure 13 Figure 15
87409
88102
- Disassemble suction and exhaust manifolds: loosen the
- Loosen the two fixing screws (2) and disassemble 8 screws (1) fixing the suction manifold plate to the
priming pump (1). cylinder head (two of them have already been
screwed-out since fixing the pipe brackets to the
injectors); from the exhaust manifold side;
loosen the (2) fixing screws; remove the gaskets.
Figure 14
Figure 16
87406
- Remove tappet caps:

Loosen the four fixing screws (1) and lift the caps (2);
remove the gaskets.
125114
- Disassemble rocker arm bearings; loosen the two fixing

NOTE On the cap there is a blow-by valve for the screws (2) and remove the complete rocker arm bearing;
lubrication oil vapours. withdraw tappet rods. Repeat the operation for all the
All the gaskets shall always be replaced during remaining rocker arm bearings.
assembly.
- Disassemble water temperature transmitter (1).

Figure 17 Figure 19
1 2
123023
- Disassemble thermostat unit; loosen the three fixing 75686
screws (1) and disassemble the thermostat unit (2)

together with the bracket (5); remove the gasket (3) and - Properly hold the alternator (1) separating it from its
the thermostat (4). bearing by loosening the screw (2); remove screw nut
and washer.
- Assemble the bracket in the original position fixing it with
the screws of the thermostat unit.
NOTE The shape and the size of the thermostat casing

vary according to the usage of the engine.
The illustrations therefore provide a general
guideline for the operation to be carried out.
The procedures described are therefore applicable.
Figure 18 Figure 20
108545
88555
Release on the drive belt tensioner (1) and extract the belt
(2) from the belt pulleys from the water pump ones and from Unscrew the fixing screws (1) and disassemble the pipeline
union (2).
the belt rebound pulleys.
Disassemble the belt tensioner (1).
Loosen the screws fixing the alternator to the support and
disassemble it.

Figure 21 Figure 23
1
107275
- Loosen the screws (5) and disassemble the oil filter/heat 88140
(2) exchanger bearing (4), interlayer plate (3) and
relating gaskets (1). Fit tool 99360330 (2) in the starter motor housing to be able
to rotate the flywheel.
- Disassemble injection pump (see specific procedure)
and the power take-off underneath.
Figure 24
Figure 22
3
84071
Turn the flywheel until, when pushing the pin 99360616 (1),
it blocks the gear (2).
4 Figure 25
75688
- 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.
90504
- Loosen the screws (1) and disassemble the pulley (2).

Figure 26 Figure 28
116242
- Loosen the screws (1 and 3) and remove the front cover

(2).
78256 NOTE Take note of the screw (1 and 3) assembly position,

since the screws have different length.
- 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 Figure 29
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).
75811
Figure 27 - Loosen the screws (1) and remove oil pump (2).
Figure 30
75695
- Screw out the opposite screws (2) from the ports where
00904t the withdrawal pins shall be introduced (see picture
following).
- Using the specially provided tie rod (3) for the tool - Loosen remaining flywheel fixing screws (1) to the
99363204 and the lever (4), withdraw the external engine drive shaft.
holding ring (2) from the front cover (1). - Remove the flywheel block tool (2).
Figure 31 (Demonstrative) Figure 33
1 4
84077
75690
- Screw up two medium length screws in the ports (4) to - Loosen the screws (2) and remove the flywheel cover
sling the flywheel with a hoist. box (1).
Throughout two guide pins (2) previously screwed up
into the engine drive shaft ports (3) control the engine NOTE Take note of the screw (1) assembly position, since
flywheel withdrawal by means of a hoist. the screws have different length.
Figure 34
Figure 32
132104
- Turn the engine upside-down.

- Loosen the screws (2), disassemble the plate (3) and
remove the oil pan (1).
NOTE The shape and the size of the sump vary according
to the usage of the engine.
00903t
- Remove the flywheel cover box fixing ring using the

tool 99340056 (3) to operate on the back tang (5) of
the engine drive shaft. Throughout the tool guide ports,
drill the internal holding ring using Ø 3,5 mm drill for
a 5mm depth.
- Fix the tool 99340056 (3) to the ring (1) tightening the
6 screws specially provided (4).
- Proceed with drawing the ring (1) tightening the screw
(2).
- Using 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 35 Figure 36
99222
- Loosen the screws (1) and disassemble the oil suction 87655
rose pipe (3).
- Loosen the screws (2) and remove the stiffening - Remove the gear (1) transmitting motion to the ignition
plate (4). pump and the relevant support.
Figure 37
87424
- Remove the screws (1) and disassemble the gears (3)

and (4) from the camshaft (2).

Figure 38 Installation of rear components

Figure 39
70157
- Loosen the screws (2) and disassemble the timing

gearbox (1).
70210
NOTE Take note of the screw (2) assembly position, since DIAGRAM SHOWING SCREW
the screws have different length. TIGHTENING TO FIX REAR GEARBOX
- Accurately clean the timing gearbox (1) and the engine
block.
- Reassemble to box (1) to the engine block.
- Tighten the fixing screws in the same position as found
out during disassembly and fix the screws to the locking
couples listed here below, following the order as shown
in the picture.
Screws M8 20 ÷ 28 Nm
Screws M10 44 ÷ 54 Nm
It is necessary and essential to clean the surface to

! be sealed in order to achieve excellent tight seal.
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 40 Figure 42
87653
- Place the dial gauge (1) on the timing gear (2) and check
70211
that the slack between the gears (2) and (3) is included
in the range between 0,076 ÷ 0,280 mm.
- Use a felt pen to mark the driving gear (1) tooth fitted
on the output shaft (2) having the mark (→) for timing
on the side surface. Figure 43
NOTE Screw up two pins to facilitate operation of engine

drive shaft rotation.
87654
- Fit the screws (1) fastening the gears (2) to the camshaft
Figure 41 (3) and tighten them to the prescribed pair.
Figure 44
116355
- Turn the engine shaft (3) and the distribution shaft (4)
so that by mounting the bevel gear on the latter (1) the 87655
stencilled mark on the gear (1) coincides with the groove
on the gear tooth (2). - Spline the gear (1) transferring motion to the ignition
pump.
Figure 45 Figure 46
122588
84077
DIAGRAM SHOWING SEALING LOCTITE 5205
APPLICATION - Re-assemble the box (1) to the engine basement.
- Tighten the fastening screws (2) to the same position
NOTE It is necessary and essential to clean the surface to detected before disassembly.
be sealed in order to achieve excellent tight seal.
Apply sealing LOCTITE 5205 on the box in order
to form a kerbstone of a few mm. Diameter. It must
be uniform (no crumbs), with no air blisters, thinner tear and wear nor dirt.
or irregular zones.
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 the joint and obstruct lubricant passages. Figure 47
Couplings must be assembled within 10 minutes

after completing the sealing operation.
87659
- Apply to the rear tongs hold (3) of the engine drive shaft
the part (6) of the tool 99346253, fix it with the screws
(1) and spline the new tight ring to it (2).
- Place the part (5) on the part (6), tighten the nut (4)
until tight ring assembly (2) into the flywheel box is
completed.

Flywheel installation Figure 50

Figure 48 (Demonstration)
1 4
75690
- Screw up two hooks or trail rings in the flywheel (1)

84071
threaded ports (4) for handling .
- Using a hoist, handle the flywheel to place it in its housing Turn the flywheel until, when pushing the pin 99360616 (1),
inside the flywheel cover box. it blocks the gear (2).
- Screw up to pins (2) having appropriate length, in the
shaft ports (3) and using them as guide, assemble the
engine flywheel (1) properly placing it inside the flywheel
cover box.
- Tighten the screws (4) fixing the engine flywheel (3) to
the engine shaft.
Figure 49 Figure 51
α 1
75695
1
Tighten the engine flywheel (1) fixing screws (2) in two
phases:
88140
- 1st phase; tightening by means of dynamometric wrench
Fit tool 99360330 (2) in the starter motor housing to be able to couple 30 ± 4 Nm;
to rotate the flywheel.
- 2nd phase, 60º ± 5º angle dwell with tool 99395216.

tear and wear nor dirt.

Installation of front components Figure 55

Figure 52
106549
- Remove the fixing ring (2) from the front cover (1),
accurately clean the plug surface.
70220
- Assemble oil pump (1).
- Tighten fixing screws (2) and lock them to the prescribed
couple.
Figure 53
Figure 56
70221
- Apply to the water pump (1) a new fixing ring (2).
Figure 54
75710
- Accurately clean the contact surface of engine block and

76112
- Assemble the water pump (1). apply sealing LOCTITE 5205 on it in order to form a
uniform and continuous kerbstone with no crumbs.
- Tighten the screws (2) and lock them to the prescribed
couple.
Figure 57 Figure 59
106550 99222
- Assemble the front cover (2) to the block and tighten - Assemble the plate (4), the rose pipe (3), tighten the
the screws (1) fixing them to the prescribed couple. fixing screws (1, 2 and 4) and fix them to the prescribed
couple.
Figure 58
00902t

Figure 60 Figure 62
119123
Set the gasket (1) on the oil sump (2).

3
NOTE The shape and the size of the sump vary according
to the usage of the engine.
1 2
75697
- Assemble the pulley (1) to the engine drive shaft , and

the distance ring (3).
- Tighten the fixing screws (2) and lock them to the 110
± 5 Nm couple.
Figure 63
Figure 61
107275
132104
- Assemble the following elements to the block: new
- Assemble oil pan (1), apply the plate over it (2). Tighten gasket (1), heat exchanger (2), new gasket (3), oil filter
the screws (2) and lock them to the prescribed couple. bearing (4).
Tighten the screws (5) and lock them to the prescribed
couple.
NOTE Before assembly, always check that the threads of NOTE Before assembly, always check that the threads of
the ports and of the screws have no evidence of the ports and of the screws have no evidence of
tear and wear nor dirt. tear and wear nor dirt.

Figure 64 Figure 66
1 2
75686
122589 - Connect the alternator (1) to the support.

- Tighten the screw without locking it (2).
- Lubricate the fixing ring (4) using engine oil and place it
on the oil filter (2).
- Tighten the oil filter (2) manually on the connector for
the support (1) until it is in the end of travel position,
tighten the oil filter (2) a further ¾ of a turn (for versions
with the engine oil filter fitted directly on the heat
exchanger).
- Place a new fixing ring on the block housing (3). Figure 67
Figure 65
87759
- Place the gasket (1) over the block.

The choice of the gasket’s thickness shall be made in
consideration of the cylinder protrusion measured with
respect to the block’s upper surface.
NOTE Verify that the engine block stand is clean.

88587
Do not grease the gasket. It is recommended to
Assemble pipeline union (1) and tighten screws (2) up to the keep the gasket inside packaging until assembly to
prescribed torque. the cylinder head.
Gasket assembly shall be made following the
direction of wording printed on the gasket itself so
NOTE Before any assembly operation always verify that that this will be readable as indicated in the picture.
the hole and screw threads have no evidence of
wear or dirt.

Figure 68 Figure 70
1
4
2
1
3
3
2
2
1 3
4 75705
75688
- Place the head (3) over the block and insert screws (1) - Carry out the assembly of the rocker arms after previous
and (2). check of the components.
ROCKER ARM UNIT COMPONENTS:
1. Elastic ring - 2. Spacer- 3. Rocker arms-
NOTE If the valves have been removed from the head, it 4. Support.
is necessary to assemble them before assembling
the head itself on the engine block.
Figure 71
18.975
NOTE Before using the fixing screws again, measure them 18.963
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 > 0,1 mm the screw must be replaced.
D2 D1
19.000 19.000
19.026 19.026
75703
75704
Figure 69 SHAFT AND ROCKER ARM BASIC DATA

Check the coupling surfaces of bearing and shaft: no evidence
of excessive wear shall be detected or damages.
Replace if necessary.
10 4 1 5 11
α Figure 72
13 7 2 8 14
9 3 6 12
76115
- Lubricate cylinder head bolts and install to head.
- Bolts must be torqued using stitching pattern starting
13.00
with the centre bolts and moving out. Bolts to be 11.00
torqued in stages: all bolts torqued to snug torque, then
90 degrees rotation for all bolts. Then a further 90 116391
degrees for the M12 x 140 and M12 x 180.
ROCKER ARM ADJUSTMENT SCREW
M12 x 70 50 Nm + 90 deg’s
M12 x 140 40 Nm + 180 deg’s If unscrewed, check adjustment quota.
M12 x 180 70 Nm + 180 deg’s Tighten the screw-threaded nut (1) to the i 4 ÷ 6 Nm couple.

Figure 73 Figure 76
2 1
122587
Before executing assembly, check the Rocker Arm driving

rods: these shall not be deformed; the spherical ends in
75806
contact with the Rocker Arm adjustment screw and with the
tappet (arrows) shall not present evidence of seizure or wear:
in case of detection proceed replacing them. On TIER 3 engines, due to the additional lobe for the
The rods driving the suction and exhaust valves are identical INTERNAL E.G.R., it is not possible to use the valve clearance
and therefore interchangeable. adjustment procedure that requires adjusting the clearance
of all the valves by positioning the crankshaft 2 times only.
Figure 74 Each cylinder must be checked by taking it to the T.D.C. (top
dead centre) at the end of compression and adjusting the
clearance of both valves on the cylinder in question.
D2 D1 Remove the rocker covers of the cylinder; remove the
injector and place the tool 99395097(see Figure 98) to set
the cylinder top dead centre position (end-of-compression
phase). Pre-load the gauge.
The searched condition is obtained by rotating the engine
75703
shaft properly until you find the maximum value on the
comparator and then checking that the intake and exhaust
valves are both closed.
- Insert the tappet driving rods and the Rocker Arm unit.
Before using the fixing screws again, measure them twice Adjust the slack between rocker arms and valves using socket
as indicated in the picture, checking D1 and D2 wrench (1), point wrench (3) and feeler gauge (2).
diameters: Correct slack is:
if D1 - D2 < 0,1 mm the screw can be utilised again; - suction valves 0.25  0.05 mm
if D1 - D2 > 0,1 mm the screw must be replaced; - exhaust valves 0.50  0.05 mm.
Figure 75
IGNITION SEQUENCE: 1 - 3 - 4 - 2
Engine shaft Bilance Adjust intake and

starting and valves exhaust valves
rotation cylinder n° clearance cylinder
n°
1° al PMS 1 1
180° 3 3
180° 4 4
180° 2 2
125114
- Tighten the screws (2) to the prescribed couple and

assemble water temperature sensor (1).

Figure 77 Figure 79
1
75707
- Assemble injectors after having replaced the sealing 123025

gasket (1).
- Assemble exhaust manifold (1) providing new gaskets
(2).
NOTE During assembly of injectors, verify that the injector
sphere is correctly positioned on the head housing.
NOTE The illustration of exhaust manifold may be not
matching your model. Anyhow, described
procedure is applicable.
Figure 78 (Demonstrative) Figure 80
123023
- Assemble thermostat unit (2) including thermostat (4)

and gasket (3).
- Tighten the screws to the prescribed couple.
87406
- Assemble cylinder covers (2) with the respective gaskets; NOTE The screws (1) have been have been utilised to fix
the bracket (3).
- Fit the seal nods and tighten the screws fixing them to
the prescribed couple. Disassemble the bracket and reassemble
components from 1 to 5 as shown in the picture.
The gasket must be new.
NOTE Always replace the gaskets using new ones.
Check the threads of the fixing screws: there shall
be no evidence of wear or dirt deposit. NOTE The shape and the size of the thermostat casing
vary according to the usage of the engine.
Seal nods shall have no visible deformation. In such The illustrations therefore provide a general
case provide for replacement with new nods. guideline for the operation to be carried out.
The procedures described are therefore applicable.

Figure 81 Figure 82
1 7
2
6
75701
86571
- Apply on the surface joining the suction manifold plate
(1) a sufficient coat of Loctite 5999 and provide. fixing
- Assemble the pulley fan bearing (8) tightening the screws the screws to the prescribed couple.
to the prescribed couple. - If the duct (6) from the intake manifold plate (1) has been
- Assemble the alternator (1) tensioning bracket. removed, refit it after having fitted a new gasket (5) and
components (3) and (4).
- Mount pulley (5) and secure it to support through
screws. - Tighten the screws (7) to the prescribed couple.
- Assemble the transmission pulley (7).

- Refit the automatic belt tensioner (2), tightening the
fixing bolt to the recommended torque.
- Assemble belt Poli-V (4) on the pulley (5) of the engine
shaft, on the jockey pulley, on the water pump (6) and
on the alternator (3), tighten (syn.: tension) the belt by
means of the automatic belt tensioner (2).
NOTE If the old belt is to be reassembled examine it

carefully in order to see if there may be incisions or
evident signs of yielding.

Figure 83 Figure 84
1 88102
- Assemble priming pump (1) providing new gasket and

tighten the screws (2) to the prescribed couple.
- Also assemble feed pump (see specific procedure) and
the power take-off underneath.
NOTE Pump mounting requires specific procedure

contained in this section.
75700
- Assemble the brackets (1) fixing the fuel pipelines to the

injectors: use the same screws (2) fixing the manifold
plate as shown in the picture.
BOSCH VE 4/12 F pump

Figure 85
3
7
4
6 5
75680
1. Rear bracket fixing screw (on suction collector plate) - 2. Fuel recovery pipeline to pump - 3. Rotary feed pump -
4. Connection nut to pumping elements - 5. Injector - 6. Bracket fixing screw to injection pump side- 7. Front bracket fixing
screw (on suction collector plate).

Figure 86 Figure 88
1 1
75679 123024
- Assemble the fuel filter bearing (4) to the bracket fixed

- Assemble the pipes (1) and (2) providing fuel feed and
to the engine head.
recovery between pump and injectors;
Screw up the locking nuts and tighten the screws fixing - Connect the fuel pipelines (2 and 3) respectively from
the fuel recovery manifold; fix the pipes to the injectors priming pump to filter bearing and from this last one to
throughout the brackets previously assembled. feed pump.
- Using 99360076 equipment assemble fuel filter (1).
NOTE The filter shall be priory filled with fuel to facilitate

feed system bleed operations.
Figure 89
Figure 87
70126
75677
NOTE To connect fuel pipelines (3 and 4, Figure 89) in
low pressure from the relating connection unions
it is necessary to press the locking fastener (1) as
- Fix the LDA pipeline (1) to the engine head and to the shown in picture B.
feed pump. After having connected the pipeline, reset the
fastener (1) into block position as shown in
pictur A.

Figure 90 Completion of engine

Figure 91
1
75675
116386
Proceed assembling the turbocharger: On the right hand side:
- Hold the turbocharger and place it on the exhaust - reassemble the pipes (1) from the union (2) to the
manifold after having interposed the gasket. lubrication oil filter (placed on the opposite side): tighten
the pipe rings (1) and connect them to the union
- Screw up the fixing nuts of the turbocharger to the
exhaust manifold tightening them to the prescribed
couple.
NOTE In some cases, the oil filter (3) is directly placed on
- Tighten the lubrication pipe fixing ring. Operate in the the heat exchanger: in this case it shall be
same way on the other end of the pipe. Connect it to assembled using tool 99360076.
the upper part of the heat exchanger.
To complete engine assembly it is necessary to remove it
from the turning stand. Figure 92
- Using rocker arm 99360595 hold the engine and loosen
the screws fixing the brackets to the turning stand
99322205.
- Disassemble the brackets 99361037 from the engine
after having properly put it on a wooden bearing. 2
75671
- Reassemble the lubrication oil exhaust pipeline (1) from

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

Figure 93 Figure 94
2
75673
On the left hand side:

- Assemble oil filter (1) together with bracket (for the
87712
versions with engine oil filter not directly assembled to
the exchanger); tighten the screws (3) assembling the
bracket (4) including filter bearing (5).
- Reassemble the starter; Using tool 99360076 screw up oil filter;
properly hold the starter (2) and tighten the fixing screws
(1) to the prescribed couple. - The plug and the oil filler pipe (for versions with the
engine oil filter fitted directly on the heat exchanger);
- Assemble oil level rod together with guide pipe (2).
- Fill up engine oil.
- Install the engine on the machine (for installation
operations please apply to specific issue).

Rotary feed pump disassembly and assembly Find the top dead centre with the tool (99395097) - False
procedure injector
Figure 96
NOTE This procedure prescribes that:
- the fuel pipes (from the pumping elements to
the injectors, recovering blow-by from the
injectors to the pump and the supply from the
priming pump) have all been removed;
- the electrical connections have been
disconnected.
- Accelerator cable shall be disconnected.
1
Figure 95
88141
Remove the rocker covers of the 1st cylinder; remove the 1st
injector and place the tool (1) to set the 1st cylinder top dead
centre position (end-of-compression phase). Pre-load the
gauge.
The searched condition is obtained by rotating the engine
shaft properly until you find the maximum value on the
valves are both closed.
1 Figure 97
88140
Disassemble the starter from the flywheel box and use tool
99360330 to rotate the flywheel.
In case feed pump replacement is necessary, this shall be
supplied pre-set already as spare part.
On the other hand, in case the pump shall be disassembled
and reassembled later on without being repaired it will be
necessary to pr-set it while it is still assembled to the engine
and disassemble it only afterwards.
The following procedure analyses this second hypothesis
since it is the more complex.
84071
Turn the flywheel until, when pushing the pin 99360616 (1),
it blocks the gear (2) obtaining the TDC of the 1° cylinder.

BOSCH VE 4/12 F Pump Figure 100

Figure 98
1
2 1
75694
75721
- Unscrew the side screw that locks the pump shaft - From the pump side, loosen the fixing nuts (1) without
partially (1) and remove spacer (2). This must be kept on removing them in order to enable moving the pump
a side (we recommend to fix it on the pump with a wire backwards using 99340035 extractor.
or a clip).
- Assemble the 99340035 extractor throughout the two
- Tighten the lateral screw (1) blocking rotation of the threaded ports (4, Figure 99) and withdraw the gear from
pump shaft. the pump shaft.
- Properly hold the feed pump and loosen completely the
fixing nuts.
- Withdraw the pump from the studs, together with the
gasket.
When the supply pump is to be assembled on the engine the
P.M.S. conditions at compression end stage cylinder No. 1
Figure 99 must be carried out.
1 4 NOTE Hold the pump driving gear to avoid interference

or crawling during timing gear rotation.
2 3
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.

Figure 101 Figure 103
1 2
75721
- Loosen screw (1) that prevents pump shaft rotation and
75694 insert spacer (2). Tighten screw (1)so that it locks spacer
(2): in this way the supply pump shaft will be able to rotate
- Assemble the pump pre-set in its housing on the engine, freely.
fitting the shaft into the gear port (not provided with - Assemble the cover (2, Figure 102) including gasket and
wrench). tighten the screws (1, Figure 102).
- Disassemble the flywheel rotation/locking tool 99360330;
- Tighten the fixing nuts (1) locking the pump flange in the arrange the starting motor in its seat.
slot centre. - Connect all pipelines (from pumping elements to injectors,
bleeding recovery pipes from injectors to pump, LDA
pipeline and feed provided by priming pump).
- Connect electrical connections to electro-magnets on the
NOTE The gasket removed during pump disassembly shall hydraulic head and on KSB.
not be utilised again.
Always use original spare parts. NOTE If the pump has been removed with the engine
mounted, connect the accelerator cable, if present
in the application.
Ignition pump control and timing
Figure 102
1 4
2 3
87720
75693 - With the injection pump inserted in relating seat and secur-
ing screws loosened, mount comparator 99395603 (2) and
99395100 gauge tool (1), preloading the rod by 2.5 mm.
- On the timing side, throughout the specially appointed - Rotate the engine derive shaft to shift from the condition
port, fit the washer and screw up the fixing nut (3) to the of the first cylinder to TDC end of compression phase.
pump shaft. Lock the nut to the 90-95 Nm couple. Reset the dial gauges and rotate the engine drive shaft into
the opposite direction until recovering the condition of the
1st cylinder to TDC in phase of compression (see
Figure 97).
From this position on the comparator applied on the pump
it must be possible to read the value listed on the pumping
element pre-lift table. Section 4.
- Rotate the pump in anti-clockwise direction if the stroke is
shorter or in clockwise direction if the stroke is longer, until
obtaining the stroke prescribed.
- Checking these conditions, lock the pump by tightening the
relevant nuts to the prescribed pair.
Feed system bleed procedure Power take-off disassembly and assembly

procedure
Figure 105 Figure 106 (Demonstration)
1 4 3
76211 2 75720
In case any operation has been executed on the components

of the feed circuit, it is necessary to execute bleeding of air
within the system. Where designed, there is a power take-off able to transmit
- Loosen the air bleed screw (3) on the fuel filter (1) and motion to different auxiliary parts.
operate the bleed lever for the priming pump (2) Disassembly of such mechanism shall be executed as
repeatedly. following:
- Continue executing this operation until when fuel drains - Loosen the two screws (3) and after having removed the
from the bleeder vent screw. cover (1) with a specially provided extractor, withdraw
- Tighten the air bleed screw (3) to a torque of 7 ÷ 9 Nm. the power take-off (2).
- The two gaskets (4) shall be replaced in phase of
reassemble.
- Vary out the assembly fitting the power take-off in its
housing, providing new gasket and checking the sprocket
gear meshing.
- Assemble cover and gasket and tighten the screws to the
prescribed couple.

Checks and inspections
NOTE The following tests shall be made after engine

assembly to the vehicle.
Preventively check that the liquid levels have been
correctly restored.
Start the engine, let it run at revolution regimen

slightly higher than idling and wait that the cooling
liquid temperature reaches the value enabling
thermostat opening, then check that:
- There is no water bleeding from the manifolds

connecting engine cooling circuit pipelines and cabin
internal heating, eventually providing to further tighten
the locking rings.
- Carefully check the fuel connection pipes to the
respective unions.
- There is no oil leakage from the lubrication circuit of the
various pipelines connecting cover and cylinder head, oil
pan and bearing, oil filter and heat exchanger as well as
relating housings.
- There is no fuel leakage from fuel pipelines.
- There is no blow-by from pneumatic pipes (if provided).
- Verify correct working of the lighting leds of the
dashboard containing the tools as well as of the
equipment that was disconnected during engine
disconnection.
- Check and blow by with care the engine cooling system,
carrying out frequent drainage.


PART TWO -
ELECTRICAL EQUIPMENT


ELECTRICAL COMPONENT LAYOUT

Figure 107
132105
Below there are listed the electric components which are

present on F4GE94--- engines.
1. Cooling liquid temperature sensor;
2. Alternator;
3. Starter;
4. (A) Engine STOP solenoid,
(B) KSB electromagnet;
5. Oil pressure sensor;
6. Fuel heater (where provided for);
7. KSB Water temperature sensor;
8. Resistance for cold start up;

Cooling liquid temperature sensor Starter
88314
Starter is usually driven by starting unit placed on the vehicle

dashboard and provides positive tension to the tele-switch as-
C sembled to the starter itself.
Specifications:
A B BOSCH 3 kW - 12V
A C
B
KSB Water temperature sensor
75718 Figure 110
It is a component integrating a temperature sensor.

It is assembled to the engine head close to the thermostat unit
and its duty is to detect engine cooling liquid temperature.
Specifications:
Range of working temperatures:
Connection side -40 ÷ 130 °C/(+150 °C for
< 10 min.)
Bulb side on engine: -40 ÷ 140 °C
Working tensions: 6 ÷ 28 V
Settings:
80 °C 0.304 ÷ 0.342 kΩ
75719
20 °C 2.262 ÷ 2.760 kΩ
-10 °C 8.244 ÷ 10.661 kΩ It is assembled to the cylinder head on the engine left hand si-
de.
Specifications:
Working tensions:12 ÷ 24 V
Electrical Power load: 2.5 A (induction)
5.0 A (resistance)
Setting: 63±3 ºC Contact opening
upon increasing temperature
53±3 ºC Contact closure
upon decreasing temperature

Electromagnets assembled to feed pump Alternator

75725
It is place front view on the right hand side of the engine, and
is driven by tooth belt.
2
Specifications:
75724a
Working tension: 12 V
1 - Engine STOP solenoid; Current delivered: 90A (at 6000 rpm)
2 - KSB Electro-magnet Absorption in stand-by: ≤ 1mA
Sense of rotation: clockwices
Oil pressure sensor
Figure 112 Pre-post heating resistor
Figure 114
75723
75722
It is a resistor assembled to the suction collector and is utilised

It is assembled to the block on the engine’s left hand side. to heat the air during pre-post heating operations.
Specifications: It is fed by a tele-switch usually placed very close to the engine.
Working tensions: 12 ÷ 24 V Specifications:
Contact closure Working tension: 12 V
upon lower pressure: 0.6 bar Maximum possible
air flow: 2 cc / min
Contact opening (pressure 138 kPa)
upon higher pressure: 0.9 bar


PART THREE - TROUBLESHOOTING


ANOMALY POSSIBLE CAUSE REMEDY NOTE
The engine does not start Battery flat or faulty. Check and recharge battery. Replace bat-
tery if necessary.
F4GE N SERIES
Print P2D32N010 E
Connections to battery terminals cor- Clean, examine and tighten the nuts on
roded or loose. the battery terminals. Replace the cable
terminals and the nuts if excessively cor-
roded.
Incorrect timing of injection pump. Check and correctly time the injection See your FPT dealer.
pump.
Deposits or water in the fuel tank. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air.
Dismantle and clean the injection pump.
Remove water from tank and refuel.
No fuel in tank. Refuel.
No power supply. Overhaul or replace the fuel or transfer
pump.
Air bubbles in the fuel lines or injection Check the hoses to ensure that air is in
pump. fact present and also check the fuel pump.
Eliminate the air from the injection pump
by unscrewing the cap and working the
fuel pump by hand.
Faulty starter motor. Repair or replace the starter motor.
SECTION 3 - AGRICULTURAL APPLICATION
49
Base - February 2009

50

The engine does not start at low tem- Fuel system clogged with paraffin crystals Replace the fuel with fuel suitable for use
peratures forming due to the use of unsuitable fuel. at low temperatures. Replace the fuel fil-

ters.
K.S.B. device for cold spark advance con- Check or replace the injection pump. See your FPT dealer.
trol operating incorrectly.
The engine cuts out. Idle rpm too low. Adjust with adjustment screw.
Irregular flow of injection pump. Adjust flow. See your FPT dealer.
Impurities or water in the fuel lines. Disconnect the hoses and clean them Drain feed system.
using a jet of compressed air. Dismantle
and clean the injection pump. Remove
water from fuel tank and refuel.
Clogged fuel filter. Dismantle and replace if necessary.

Presence of air in the fuel and injection Check that the hoses are not cracked or
system. the unions loose. Replace worn parts, re-
move the air from the hoses and deaerate
the injection pump and fuel filter by un-
screwing the caps and working the primer
pump by hand.
Broken injection pump controls. Replace the faulty parts.
Abnormal clearance between camshaft Adjust clearance by replacing shims.
cams and tappets.
Burnt, corroded or chalky valves. Replace the valves, rectify or replace the
cylinder head seatings.
F4GE N SERIES
Print P2D32N010 E
The engine overheats Faulty water pump. Check the unit and replace if necessary.
Replace the gasket.
F4GE N SERIES
Print P2D32N010 E
Malfunctioning thermostat. Replace the thermostat.
Fouling in coolant openings in the cylinder Wash following the standards specified
head and cylinder groups. for the type of descaling product used.
Water pump drive belt slack. Check and adjust the tightness of the belt. On applications provided with automatic
tensioner, check corret worching of such
device.
Coolant level too low. Top-up radiator with coolant.
Incorrect engine timing. Check timing and tune correctly.
Incorrect calibration of injection pump. Correct the delivery rate of the pump on See your FPT dealer.
a bench so that the injection is at the
specified rate.
Dry air cleaner blocked. Clean the air filter or replace if necessary.
Engine operation is irregular and lacks Incorrect timing of injection pump. Check timing and correctly set pump.
power
Faulty automatic advance variator Check operation on injection pump test See your FPT Dealer
setup; if values found do not correspond
to requirements, change variator spring.
K.S.B. automatic cold advance device mal- Check or replace injection pump.
functioning.
Excessive piston wear. Check or replace injection pump.
Incorrect calibration of speed regulator. Check and correctly calibrate the regula- See your FPT Dealer
tor.
51

52

Engine operation is irregular and lacks Partial blockage of nozzles or faulty oper- Clean the nozzles of the atomisers using
power ation of injectors. the appropriate tools and completely

overhaul the injectors.
Impurities or water in the fuel and injec- Carefully clean the system and refuel. If necessary drain feed system.
tion system.
Incorrect play between camshaft cams Check and correct play
and tappets.
Faulty turbocharger. Replace complete unit.
Air cleaner blocked. Clean or replace air cleaner.
Faulty operation of L.D.A. device Check that the diaphragm is not perfor- See your FPT dealer.
ated, that the counter spring is suitable
and that it has the correct loading (check

on test bench).
Check that there is adequate air pressure
inside the intake manifold in relation to
the engine rpm under full-load conditions.
Tie rods between accelerator pedal and Adjust the tie-rods so that the command
regulation lever incorrectly adjusted. lever can be moved to the full delivery
position.
Engine running with abnormal knocking Faulty operation of injectors. Replace all injectors.
Fuel lines blocked. Dismantle the hoses, clean them and re-
place those that are seriously dented.
Incorrect set-up of injection pump. Correct the set-up of the pump so that in- See your FPT dealer.
jection occurs at the specified angle.
F4GE N SERIES
Print P2D32N010 E
Engine running with abnormal knocking Knocking of crankshaft causing excessive Rectify the pins of the crankshaft and in-
play on one or more main or rod bearings stall smaller bearings. Replace the thrust
F4GE N SERIES
Print P2D32N010 E
or excessive play on shoulders. half-rings.
Crankshaft unbalanced. Check alignment of crankshaft.
Loosening of screws securing flywheel. Replace the loosened screws and tighten
all the screws to the specified torque.
Misalignment of rods. Replace the rods.
Noise from piston journals due to excess- Replace the piston journal and/or the pis-
ive play of piston hubs and in the rod ton and rod bushing.
bushing.
Loose bushings in the rod seatings. Replace with new bushings.
Noisy timing. Adjust the play between camshaft cams
and tappets and check that there are no
broken springs, that there is no excessive
play between the valve stems and the
valve guides, tappets and seatings.
The engine smokes abnormally. Black or Excessive maximum pump output. Disconnect the pump and adjust delivery See your FPT dealer.
dark grey smoke. in accordance with the data given in the
calibration table.
K.S.B. device out of calibration or malfunc- Check operation by a tester and adjust
tioning. correctly as described in the manual.
There is an excessive delay on the injec- Correct the set-up.
tion pump.
53

54

The engine smokes abnormally. Black or The injection pump has an excessive ad- Correct the set-up.
dark grey smoke. vance.

The holes in the atomisers (or some of Replace the injectors with a series of new
them) are partially or entirely blocked. injectors or clean and rectify the original
ones using suitable equipment.
Air cleaner blocked or deteriorated. Clean or replace the filter element.
Loss of compression in the engine due to: Overhaul the engine or limit the interven-
tions to the relative parts.
stuck or worn flexible rings;
worn cylinder liners;
valves deteriorated or badly adjusted.
Unsuitable injectors, different types of in- Replace or calibrate the injectors.
jectors or incorrectly calibrated.

Injection hoses with an unsuitable internal Check conditions of the end or unions
diameter, end of hoses pinched due to re- and where necessary replace the hoses.
peated blocking.
Blue, grey-blue, grey smoke tending to Excessive delay in injection pump. Correct the set-up of the pump. See your Iveco dealer.
white.
K.S.B. automatic cold advance device mal- Check or replace injection pump. See your Iveco dealer.
functioning.
Faulty injector. Replace the injector.
Leaking of oil from the piston rings caused Overhaul the engine.
by glued or worn rings or wearing of cylin-
der liner walls.
Engine oil passing through the intake Recondition the cylinder head.
guides-valves following wearing of guides
or valve stems.
Engine too cold (thermostat blocked or Replace the thermostat.
inefficient).
F4GE N SERIES
Print P2D32N010 E
PART FOUR - MAINTENANCE PLANNING


MAINTENANCE SCHEDULE
On purpose to guarantee the right engine use please follow the below indicated maintenance schedule.
It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance
and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense
and by the specific conditions in which the engine is run.
Maintenance operations Frequency (hours)
Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily

Check presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . Daily
Check of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -
Check and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600
Oil and filter replacement . 600
Fuel filter and prefilter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600
Belt replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800

Checks not included in maintenance planning-daily checks

It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid
inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.
- Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.
- Notify the maintenance if any inconvenience is detected of if any filling is necessary.
After engine start and while engine is running, proceed with the following checks and controls:
- check presence of any eventual leakage from the fuel, cooling and lubricating circuits.
- Verify absence of noise or unusual rattle during engine working.
- Verify, using the vehicle devices, the prescribed pressure temperature and other parameters.
- Visual check of fumes (colour of exhaust emissions)
- Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES Figure 116

Checks and controls
Engine oil level check

The check must be executed when the engine is disconnected
and possibly cool.
The check can be made using the specially provided flexible

rod (1).
132106
MAX 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”.
MIN Some applications are equipped with a level transmitter
alerting dashboard instruments in case of insufficient
lubrication oil within the pan.
1 75748 The engine oil is highly polluting and harmful.
Draw off the rod from its slot and check that the level is within In case of contact with the skin, rinse well with water
and detergent.
the etched tags of minimum and maximum level.
Whether it should be difficult to make the evaluation, proceed Adequately protect the skin and the eyes, operate in
cleaning the rod using a clean cloth with no rag grinding and full compliance with safety regulations.
put it back in its slot. Draw it off again and check the level.
Disposal must be carried out properly, and in full
In case the level results being close to the tag showing compliance with the law and regulations in force.
minimum level, provide filling lubrication of the engine’s
components.

Check of fuel system Lubricating system check

The check must be executed both when the engine The check must be executed both when the engine
disconnected and when it is running. disconnected and when it is running.
The check operation consists in examining the fuel pipelines
running from the tank to the pre-filter (if provided in the Verify the presence of any oil leakage or blow-by from the
specific equipment), to the filter, to the injection pump and to head, from the engine pan of from the heat exchanger.
the injectors.
The engine oil is highly polluting and harmful.

Cooling system check
In case of contact with the skin, rinse well with water
The check must be executed both when the engine
and detergent.
disconnected and when it is running.
Adequately protect the skin and the eyes, operate in
Check the pipelines from the engine to the radiator, from the full compliance with safety regulations.
expansion tank and vice-versa. Find out any blow-by, verify the
status of the pipes specially close to the holding strips. Disposal must be carried out properly, and in full
Verify that the radiator is clean, the correct working of the fan
flywheels, the presence of any leakage from the connectors,
from the manifold and from the radiating unit.
Check of water presence within fuel filter or pre-filter

Due to the high temperatures achieved by the
system, do not operate immediately after the engine’s
disconnection, but wait for the time deemed NOTE The components of the system can be damaged
necessary for the cooling. very quickly in presence of water or impurity within
Protect the eyes and the skin from any eventual high the fuel.
pressure jet of cooling liquid.
Timely proceed operating on the pre-filter (not
available on the engine block) to carry out the
drainage of the water within the feed circuit.
The coolant should be checked every year before the winter,
assessing the density and it should be changed every two years.
There is a bleed screw at the base of the fuel filter for draining
any water in the filter.
Place a container underneath the filter and slightly loosen the
In case of new filling, proceed bleeding system, screw. Drain the water eventually contained in the filter’s
through the bleeds on the engine. bottom.
If bleeding of the system is not carried out, serious Lock the screw (max 0.5 Nm locking couple) as soon as fuel
inconvenience might be caused to the engine due starts bleeding.
to the presence of air pockets in the engine’s head.

Check of drive belt tensioning Adjust the slack between rocker arms and valves using socket
There is an automatic tensioner which corrects the belt wrench (1), point wrench (3) and feeler gauge (2).
tension.
Correct slack is:
Check of belt’s tear and wear status - suction valves 0.25  0.05 mm
Carefully verify the belt’s surface in order to detect any sign of - exhaust valves 0.50  0.05 mm.
incision, crack, excessive wear in correspondence of toothing;
check end and surface grinding.
IGNITION SEQUENCE: 1 - 3 - 4 - 2
Danger: if the engine is switched off but is still hot, Bilance Adjust intake and
unexpected motion of the belt may occur. Engine shaft
starting and valves exhaust valves
Wait for engine temperature cooling as a precaution rotation cylinder n° clearance cylinder
n°
in order to avoid serious danger injury.
1° al PMS 1 1
180° 3 3
180° 4 4
180° 2 2
Check and setting of tappet clearance
Figure 117
2 1 Oil motor and filter replacement
3 Warning: We recommend to wear proper protec-

tions because of high motor service temperature.
The motor oil reaches very high temperature: you
must always wear protection gloves.
Due to the several applications, the pan shape and the oil
75806 quantity can change slightly. However, the following oper-
ations are valid for all applications.
On TIER 3 engines, due to the additional lobe for the
We recommend to carry out the oil drainage when the motor
INTERNAL E.G.R., it is not possible to use the valve clearance
is hot.
adjustment procedure that requires adjusting the clearance of
all the valves by positioning the crankshaft 2 times only. - Place a proper container for the oil collecting under the
pan connected with the drain plug.
Each cylinder must be checked by taking it to the T.D.C. (top
dead centre) at the end of compression and adjusting the - Unscrew the plug and then take out the control dipsick
clearance of both valves on the cylinder in question. and the inserting plug to ease the downflow of the lubrica-
tion oil.
Remove the rocker covers of the cylinder; remove the injector
and place the tool 99395097(see Figure 98) to set the cylinder
top dead centre position (end-of-compression phase).
Pre-load the gauge. The oil motor is very pollutant and harmful.
The searched condition is obtained by rotating the engine In case of contact with the skin, wash with much water
shaft properly until you find the maximum value on the and detergent.
valves are both closed. Protect properly skin and eyes: operate according to
safety rules.
Dispose of the residual properly following the rules.

- After the complete drainage, screw the plug and carry out Fuel filter replacement
the clean oil filling.
During this operation don’t smoke and don’t use free
flames.
Use only the recommended oil or oil having the re-
quested features for the corrrect motor functioning. Avoid to breathe the vapors coming from filter.
!
In case of topping up, don’t mix oils having different
features.
If you don’t comply with theses rules, the service war-
ranty is no more valid. After filters replacement the supply equipment
! deaeration must be carried out.
- Check the level through the dipsick until when the filling
is next to the maximum level notch indicated on the dip-
sick. According to the applications the filters position and the quan-
tity can change.
However the following operations are valid for all applications.
Whereas you replace the lubrication oil, it is necessary to re- - Drain the fuel inside the filter by operating the water re-
place the filter. lease screw. Collect the fuel in a container without impu-
According to the application the filter can be located in differ- rities.
ent positions: the following procedure is a valid guide for all - Unscrew the cartridge by using the 99360076-tool.
applications.
- Collect the eventual fuel inside the filtering cartridge.
- The filter is composed by a support and a filtering car-
tridge. For the cartridge replacement use the - Clean the gasket seat on the support and oil slightly the
9936076-tool. 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.
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 sup-
port.
- 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 top-
ping up to compensate the quantity of oil used for the fill-
ing of the filtering cartridge.

Alternator belt replacement
Warning: with switched off motor (but still hot) the

belt can operate without advance notice.
Wait for the motor temperature lowering to avoid
very serious accidents.
Figure 118
88544
- By means of a square wrench of proper size act on point

A, indicated on the figure, of the automatic belt tightener
(1) and release the pressure.
- Remove the control belt (2) from the driven and inter-
mediate pulleys.
- Replace the worn belt with a new one.
- Place the belt on the pulleys and the guide rollers.
- Place the automatic tightener in order to key the belt in
the functioning position.
- Check proper position in the races of the pulleys.

F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1
SECTION 4
Overhaul and technical specifications
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . . . . 4
TABLE OF PRE-DELIVERY VALUES FOR BOSCH

INJECTION PUMPS VE 4/12 F . . . . . . . . . . . . . . 10
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . 11
ENGINE REMOVAL AT THE BENCH . . . . . . . . . . 11
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 12
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Checks and measurements . . . . . . . . . . . . . . . 12
- Checking head supporting surface on cylinder unit 13
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Checking cam lift and pin alignment . . . . . . . . 14
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 16
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Fitting tappets — camshaft . . . . . . . . . . . . . . . . 16
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Measuring journals and crankpins . . . . . . . . . . 17
- Replacing oil pump control gear . . . . . . . . . . . 19
- Fitting main bearings . . . . . . . . . . . . . . . . . . . . 19
- Finding journal clearance . . . . . . . . . . . . . . . . . 19
- Checking output shaft shoulder clearance . . . 20
CONNECTING ROD — PISTON ASSEMBLY . . . . 20

2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES
Page Page
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Removing the valves . . . . . . . . . . . . . . . . . . . . 27
- Conditions for proper pin-piston coupling . . . . 22
- Checking cylinder head wet seal . . . . . . . . . . . 28
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 - Checking cylinder head supporting surface . . . 28
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 23 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Removing carbon deposits, checking and grinding

- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Checking clearance between valve stem and valve

- Fitting connecting rod-piston assembly . . . . . . 24 guide and valve centering . . . . . . . . . . . . . . . . . 29
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Connecting rod-piston coupling . . . . . . . . . . . . 24
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Fitting split rings . . . . . . . . . . . . . . . . . . . . . . . . 24
- Regrinding — replacing the valve seats . . . . . . . 30
- Fitting connecting rod-piston assembly into cylinder VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
barrels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FITTING CYLINDER HEAD . . . . . . . . . . . . . . . . . . 31
- Finding crankpin clearance . . . . . . . . . . . . . . . . 25
- Refitting the cylinder head . . . . . . . . . . . . . . . . 32
- Checking piston protrusion . . . . . . . . . . . . . . . 26 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . 33

GENERAL SPECIFICATIONS
Type 4 CYLINDERS
Cycle Four-stroke diesel engine

Power See properties described in Section 3
Injection Direct
Number of cylinders 4
∅
Bore mm 104
Stroke mm 132
+ + +.. = Total displacement cm3 4485
TIMING
start before T.D.C. A 18.5

end after B.D.C. B 29.5
start before B.D.C. D 67

end after T.D.C. C 35
Checking timing
mm 0.25 to 0.05
X X
mm 0.50 to 0.05
FUEL FEED
Injection
Type: Bosch VE 4/12 F
Nozzle type DSLA 145 P
Injection sequence 1-3-4-2

CLEARANCE DATA
Type 4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS mm

∅1
Cylinder barrels ∅1 104.000 to 104.024
X
0.4
Spare pistons
∅1 type:
X Size X 55.9
Outside diameter ∅1 103.714 to 103.732
∅2 Pin housing ∅2 38.010 to 38.016
Piston — cylinder barrels 0.268 to 0.310
Piston diameter ∅1 0.4
X
Piston protrusion X 0.28 to 0.52
∅ 3 Piston pin ∅3 37.994 to 38.000
Piston pin — pin housing 0.010 to 0.022

Type 4 CYLINDERS

X1 2.705 to 2.735
X1 Split ring slots X2 2.440 to 2.460
X2 X3 4.030 to 4.050
X3 * measured on a ∅ of
99.00 mm
S 1 S1 2.560 to 2.605
S 2 Split rings S2 2.350 to 2.380
S 3 S3 3.970 to 3.990
1 0.100 to 0.175
Split rings - slots 2 0.060 to 0.110
3 0.040 to 0.080
Split rings 0.4
X1 Split ring end opening

X 2 in cylinder barrel:
X1 0.30 to 0.40
X3
X2 0.60 to 0.80
X3 0.30 to 0.55
∅1
Small end bush
housing ∅1 40.987 to 41.013
Big end bearing
housing ∅2 72.987 to 73.013
∅ 2
∅ 3 Small end bush diameter
Inside ∅3 38.019 to 38.033

S
Spare big end half
bearings S 1.955 to 1.968
Piston pin — bush 0.037 to 0.016
Big end half bearings 0.250 to 0.500

Type 4 CYLINDERS
82.990 ÷ 83.010
Journals ∅1
68.987 ÷ 69.013
Crankpins ∅2
∅1 ∅2
Main half bearings S1 2.456 to 2.464

Big end half bearings S2 1.955 to 1.968
S 1 S 2
Main bearings
∅ 3 No. 1 — 5 ∅3 87.982 to 88.008
No. 2 — 3 — 4 ∅3 87.977 to 88.013
Half bearings — Journals

No. 1 — 5 0.440 to 0.106
No. 2 — 3 — 4 0.039 to 0.111
Half bearings - Crankpins 0.038 to 0.116
Main half bearings
0.250 to 0.500
Big end half bearings
Shoulder journal X1 37.475 to 37.550
X 1
Shoulder main bearing X2 32.180 to 32.280
X 2
Shoulder half-rings X3 37.28 to 37.38
Output shaft shoulder 0.095 to 0.270

Type 4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM mm

∅ 1
Valve guide seats on

cylinder head ∅1 8.019 to 8.039
∅ 4 Valves:
∅4 7.960 to 7.980
α 60º
∅4 7.960 to 7.980
α α 45º
Valve stem and guide 0.039 to 0.079
Housing on head for
valve seat:
∅1 46.987 to 47.013
∅ 1 ∅1 43.637 to 43.663
Valve seat outside diameter;

∅ 2 valve seat angle on cylinder
head:
∅2 47.063 to 47.089
α 60º
∅2 43.713 to 43.739
α
α 45º
X 0.136 to 0.872
X Sinking X 0.050 to 0.830
0.050 to 0.102
Between valve seat
and head 0.080 to 0.102
Valve seats -

Type 4 CYLINDERS

Valve spring height:
free spring H 63.50 / 65.69*

H H1
H 2 under a load equal to:
329 N H1 49.02
641 N H2 38.20
Injector protrusion X -
X
Camshaft bush
housings No. 1-5 59.222 to 59.248
Camshaft housings
∅ ∅ ∅ No. 2-3-4-5 54.089 to 54.139
1 23 4 5
∅ 2
Camshaft journals:
1⇒5 ∅ 53.995 to 54.045
∅ 1 ∅ 3
Bush inside
∅
diameter ∅ 54.083 to 54.147
Bushes and journals 0.038 to 0.152

Cam lift:
H H -
H -
* Installed as an alternative

Type 4 CYLINDERS

∅1
Tappet cap housing
on block ∅1 16.000 to 16.030
∅2
∅ 3 Tappet cap outside
diameter: ∅2 15.929 to 15.959
∅3 15.965 to 15.980
∅2
Between tappets and housings -
Tappets -
∅ 1
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

TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS VE 4/12 F
Technical Pre-lift
Code (mm)
F4GE9454F*J604 0.7 ± 0.05
4-CYLINDER ENGINES
F4GE9484F*J608 0.8 ± 0.05
NOTE INJECTION PUMP CALIBRATION

Overhaul and calibration interventions are up to BOSCH assistance network.
The contract technical specification containing the data to calibrate the pump at the bench is identified by the code shown
on injection pump body and is available at BOSCH technical assistance network.
Otherwise, refer to FPT Technical Assistance Service.

ENGINE OVERHAUL Figure 3

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.
Figure 1 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
70158
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.
70161
Use tool 99360500 (1) and hoist to remove the output shaft
(2) from the block.
Figure 2
Figure 5
70159
70162
Remove the screws (1) and the main bearing caps (2). Remove the main half-bearings (1).
Remove the screws (2) and remove the oil nozzles (3).

zs
Figure 6 REPAIR OPERATIONS

CYLINDER UNIT
Checks and measurements
Figure 9
70163
Remove the screws (1) and disconnect camshaft (3) retaining

plate (2).
70166
NOTE Take note of plate (2) assembling position. Once engine is disassembled, clean accurately the
cylinder-block assembly.
Use the proper rings to handle the cylinder unit.
The engine block shall not show cracks.
Figure 7
Check operating plug conditions and replace them in case of
uncertain seal or if rusted.
Inspect cylinder barrel surfaces; they shall be free from seizing,
scores, ovalisation, taper or excessive wear.
Inspection of cylinder barrel bore to check ovalisation, taper
and wear shall be performed using the bore dial gauge
99395687 (1) fitted with the dial gauge previously set to zero
on the ring gauge (2) of the cylinder barrel diameter.
NOTE Should the ring gauge be not available, use a

micrometer for zero-setting.
70164
Withdraw carefully the camshaft (1) from the engine block. Figure 10
Figure 8
70167
Measurements shall be performed on each cylinder, at three
different heights in the barrel and on two planes
perpendicular with each other: one parallel to the
longitudinal axis of the engine (A), and the other
perpendicular (B). Maximum wear is usually found on plane
(B) in correspondence with the first measurement.
Should ovalisation, taper or wear be found, bore and grind
70165 the cylinder barrels. Cylinder barrel regrinding shall be
performed according to the spare piston diameter oversized
by 0.4 mm and to the specified assembling clearance.
Withdraw the tappets (1) from the engine block.
Figure 11 Check main bearing housings as follows:

- fit the main bearings caps on the supports without
bearings;
- tighten the fastening screws to the specified torque;
α - use the proper internal gauge to check whether the

housing diameter is falling within the specified value.
Replace if higher value is found.
Checking head supporting surface on cylinder

unit
When finding the distortion areas, replace the cylinder unit.
Planarity error shall not exceed 0.075 mm.
Check cylinder unit operating plug conditions, replace them
in case of uncertain seal or if rusted.
107804
NOTE In case of regrinding, all barrels shall have the same

oversize (0.5 mm).

TIMING SYSTEM
Camshaft
Figure 12
70169
CAMSHAFT MAIN DATA

Specified data refer to pin standard diameter
Camshaft pin and cam surfaces shall be absolutely smooth; BUSHES

if they show any traces of seizing or scoring replace the
camshaft and the bushes.
Figure 14
Checking cam lift and pin alignment

Set the camshaft on the tailstock and using a 1/100 gauge set
on the central support, check whether the alignment error
is not exceeding 0.04 mm, otherwise replace the camshaft.
Figure 13
70172
Camshaft bush (2) shall be pressed into its housing.

Internal surface must not show seizing or wear.
Use bore dial gauge (3) to measure camshaft bush (2) and
intermediate housing (1) diameter.
Measurements shall be performed on two perpendicular
axes.
70171
Check camshaft (2) pin diameter using micrometer (1) on

two perpendicular axes.

Figure 15
Sec. A-A
107399
CAMSHAFT BUSH AND HOUSING MAIN DATA

* Value to be obtained after driving the bushes.

Bush replacement Fitting tappets — camshaft

Figure 16 Figure 18
70176
70174
Lubricate the tappets (1) and fit them into the relevant
To replace front and rear bushes (1), remove and refit them housings on the engine block.
using the beater 99360362 (2) and the handgrip 99370006
(3). Figure 19
NOTE When refitting the bushes (1), direct them to make

the lubricating holes (2) coincide with the holes on
the block housings.
70164
Lubricate the camshaft support bearing and install the

camshaft (1) being careful to ensure that the bearing or the
shaft support seats are not damaged during the operation.
Tappets
Figure 20
Figure 17
70238
84053
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
MAIN DATA CONCERNING THE TAPPETS AND THE then tighten the screws (2) to the specified torque.
RELEVANT HOUSINGS ON THE ENGINE BLOCK
Figure 21 OUTPUT SHAFT

Measuring journals and crankpins
Figure 23
70179
Check camshaft end float (1).

It shall be 0.23 ± 0.13 mm. 70182
Grind journals and crankpins if seizing, scoring or excessive
Figure 22 ovalisation are found. Before grinding the pins (2) measure
them with a micrometer (1) to decide the final diameter to
which the pins are to be ground.
NOTE It is recommended to insert the found values in the

proper table.
See Figure 24.
Undersize classes are: 0.250 - 0.500 mm.
NOTE Journals and crankpins shall always be ground to

70180 the same undersize class.
Journals and crankpins undersize shall be marked
Fit nozzles (2) and tighten the fastening screws (1) to the on the side of the crank arm No.1.
specified torque. For undersized crankpins: letter M
For undersized journals: letter B
For undersized crankpins and journals: letters MB
Figure 24
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Rated value

Figure 25
measured on > 45.5 mm radius
between adjacent journals 70183
OUTPUT SHAFT MAIN TOLERANCES
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Roundness ○
SHAPE
Cilindricity /○/
Parallelism //
DIRECTION Verticality
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION
Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL ©
IMPORTANT ⊕
SECONDARY ⊝
MAIN BEARING ON TIMING INTERMEDIATE MAIN FIRST MAIN BEARING

SYSTEM CONTROL SIDE BEARINGS ON FRONT SIDE
70237

Replacing oil pump control gear Finding journal clearance
Figure 26 Figure 28
70161
Refit the output shaft (2).

70184
Check the backlash between output shaft main journals and
Check that gear toothing (1) is not damaged or worn, the relevant bearings as follows:
otherwise remove it using the proper puller (3).
When fitting the new gear, heat it to 180°C for 10 minutes
in an oven and then key it to the output shaft.
Figure 29
Fitting main bearings
Figure 27
128169
- clean accurately the parts and remove any trace of oil;

- fit caps (1), including the half bearings (2) on the relevant
70185
supports.
NOTE Refit the main bearings that have not been

replaced, in the same position found at removal.
NOTE Before using the fixing screws again, measure them
D2 diameters:
Main bearings (1) are supplied spare with 0.250 — 0.500 mm if D1 - D2 < 0,1 mm the screw can be utilised again;
undersize on the internal diameter. if D1 - D2 > 0,1 mm the screw must be replaced.
NOTE Do not try to adapt the bearings.

D2 D1
Clean accurately the main half bearings (1) having the 75703
lubricating hole and fit them into their housings.
The second last main half bearing (1) is fitted with shoulder
half rings.

Figure 30 Checking output shaft shoulder clearance
Figure 32
70187
Tighten the pre-lubricated screws (1) in the following three

successive stages: 70190
- 1st stage, with dynamometric wrench to 50 ± 6 Nm. This check is performed by setting a magnetic-base dial gauge
- 2nd stage, with dynamometric wrench to 80 ± 6 Nm. (2) on the output shaft (3) as shown in the figure, standard
value is 0.068 to 0.41.
Figure 31 If higher value is found, replace main thrust half bearings of

the second last rear support (1) and repeat the clearance
check between output shaft pins and main half bearings.
α
CONNECTING ROD — PISTON ASSEMBLY
70188
Figure 33
- 3rd stage, with tool 99395216 (1) set as shown in the
figure, tighten the screws (2) with 90° ± 5° angle.
70191
CONNECTING ROD — PISTON ASSEMBLY

COMPONENTS
1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws -
6. Half bearings - 7. Connecting rod - 8. Bush.
NOTE The pistons are supplied spare with the following

sizes:
- standard;
- 0.4 mm oversize.

Figure 34 Figure 35
126311 126312
Remove split rings (2) from piston using pliers 99360183 (1). The circlips (2) retaining the gudgeon pin are removed using
round-nose pliers (1).
Figure 36
87730
MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS

Piston pins Figure 40

Figure 37
18857 128140
To measure the piston pin (1) diameter use the micrometer Check the clearance between the sealing rings (3) of the 2nd
(2). and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Conditions for proper pin-piston coupling
Figure 38 Figure 41
32619
41104
Lubricate the pin (1) and its seat on piston hubs with engine DIAGRAM FOR MEASURING THE CLEARANCE X
oil; the pin shall be fitted into the piston with a slight finger BETWEEN THE FIRST PISTON SLOT AND THE
pressure and shall not be withdrawn by gravity. TRAPEZOIDAL RING
Since the first sealing ring section is trapezoidal, the clearance
between the slot and the ring shall be measured as follows:
Split rings make the piston (1) protrude from the engine block so that
Figure 39 the ring (2) protrudes half-way from the cylinder barrel (3).
In this position, use a feeler gauge to check the clearance (X)
between ring and slot: found value shall be the specified one.
16552
Use a micrometer (1) to check split ring (2) thickness.

Figure 42 Figure 44
70194
Use feeler gauge (1) to measure the clearance between the

ends of the split rings (2) fitted into the cylinder barrel (3).
Connecting rods
Figure 43 80339
NOTE Every connecting rod is marked as follows:

- On body and cap with a number showing their
coupling and the corresponding cylinder.
In case of replacement it is therefore necessary
to mark the new connecting rod with the same
numbers of the replaced one.
- On body with a letter showing the weight of
the connecting rod assembled at production:
S V, 1820 to 1860 (yellow marking);
S W, 1861 to 1900 (green marking);
S X, 1901 to 1940 (blue marking);
Spare connecting rods are of the W class with
green marking *.
Material removal is not allowed.
88607
NOTE The surface of connecting rod and rod cap are

knurled to ensure better coupling.
Therefore, it is recommended not to smooth the
knurls.

Bushes Figure 47
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
Removal and refitting shall be performed using the proper
beater.
When refitting take care to make coincide the oil holes set
on the bush with those set on the connecting rod small end.
Grind the bush to obtain the specified diameter.
Fitting connecting rod-piston assembly

Connecting rod-piston coupling
126312
Figure 45
Position the piston on the connecting rod according to the
diagram shown in the figure, fit the pin and stop it by the split
rings (2).
Fitting split rings

Figure 48
70198
The piston crown is marked as follows:

1. Part number and design modification number;
2. Arrow showing piston assembling direction into cylinder
barrel, this arrow shall face the front key of the engine
block;
3. Marking showing 1st slot insert testing;
4. Manufacturing date.
126311
Use pliers 99360183 (1) to fit the split rings (2) on the piston.
Figure 46 Split rings shall be fitted with the marking “TOP” facing
upwards and their openings shall be displaced with each
other by 120°.
NOTE Split rings are supplied spare with the following

sizes:
- standard;
- 0.4 mm oversize.
70199
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
Figure 49 Figure 51
70202
DIAGRAM FOR CONNECTING ROD-PISTON

ASSEMBLY FITTING INTO BARREL
70200 - Split ring openings shall be displaced with each other by
120°;
- connecting rod-piston assemblies shall have the same
Fit half bearings (1) on connecting rod and cap. weight;
- the arrow marked on the piston crown shall be facing the
front side of the engine block or the slot obtained on the
NOTE Refit the main bearings that have not been piston skirt shall be corresponding to the oil nozzle
replaced, in the same position found at removal. position.
Do not try to adapt the half bearings.
Finding crankpin clearance
Figure 52
Fitting connecting rod-piston assembly into

cylinder barrels
Figure 50
128170
To measure the clearance proceed as follows:

- clean the parts accurately and remove any trace of oil;
- fit the connecting rod caps (1) with the relevant half
bearings (2).

D2 diameters:
70201 if D1 - D2 < 0,1 mm the screw can be utilised again;
Lubricate accurately the pistons, including the split rings and
the cylinder barrel inside.
Use band 99360605 (2) to fit the connecting rod-piston D2 D1
assembly (1) into the cylinder barrels and check the following:
- the number of each connecting rod shall correspond to 75703
the cap coupling number.

Figure 53 Figure 55
70204
70207
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the dynamometric
wrench (2). If a different clearance value is found, replace the half bearings
and repeat the check.
Once the specified clearance has been obtained, lubricate
Figure 54
the main half bearings and fit them by tightening the
connecting rod cap fastening screws to the specified torque.
α
Check manually that the connecting rods (1) are sliding
axially on the output shaft pins and that their end float,
measured with feeler gauge (2) is 0.250 to 0.275 mm.
70205
- Apply tool 99395216 (1) to the socket wrench and

tighten screws (2) of 60° ± 5°. Checking piston protrusion
Figure 56
70208
Once connecting rod-piston assemblies refitting is over, use

dial gauge 39395603 (1) fitted with base 99370415 (2) to
check piston (3) protrusion at T.D.C. with respect to the top
of the engine block.
Protrusion shall be 0.28 to 0.52 mm.

CYLINDER HEAD Figure 58

Removing the valves
1 2
Figure 57 3
4
1
2 6
A 75751
Valve removal shall be performed using tool 99360268 (1)

and pressing the cap (3) so that when compressing the
springs (4) the cotters (2) can be removed. Then remove the
75750
cap (3) and the springs (4).
Intake (1) and exhaust (2) valves have heads with the same
diameter. Repeat this operation for all the valves.
The central notch (→) of the exhaust valve (2) head Overturn the cylinder head and withdraw the valves (5).
distinguishes it from the intake valve.
Figure 59
NOTE Should cylinder head valves be not replaced,
number them before removing in order to refit
them in the same position. 2
A = intake side — S = exhaust side
75752
NOTE Sealing rings (1) for intake valves are yellow.

Sealing rings (2) for exhaust valves are green.

Checking cylinder head wet seal Figure 61
Figure 60 D
0,4 C
1 0,025 / ¯ 25,4
A B
0,4 TOTAL C
0,01 / ¯ 50
75756
75753
The rated thickness A for the cylinder head is 95 ± 0.25 mm,
This check shall be performed using the proper tools. max. metal removal shall not exceed thickness B by 0.13 mm.
Use a pump to fill with water heated to approx. 90°C and 2
to 3 bar pressure.
Replace the cup plugs (1) if leaks are found, use the proper NOTE After grinding, check valve sinking. Regrind the
beater for their removal/refitting. valve seats, if required, to obtain the specified value.
NOTE Before refitting, smear the plug surfaces with

water-repellent sealant.
Replace the cylinder head if leaks are found.
Checking cylinder head supporting surface
Distortion found along the whole cylinder head shall not

exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.

VALVES Figure 64
Figure 62
EXHAUST INTAKE
VALVE VALVE
18882
Check the valve stem (1) using a micrometer (2), it shall be

7.943 to 7.963.
116395
INTAKE AND EXHAUST VALVE MAIN DATA
Removing carbon deposits, checking and

grinding valves
Checking clearance between valve stem and
Figure 63 valve guide and valve centering
Figure 65
18625
Remove carbon deposits from valves using the proper metal

brush. 75757
Check that the valves show no signs of seizing, scoring or
cracking. Use a magnetic base dial gauge (1) set as shown in the figure,
Regrind the valve seats, if required, removing as less material the assembling clearance shall be 0.056 ± 0.096 mm.
as possible. Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.

VALVE GUIDE VALVE SEATS

Figure 66 Regrinding — replacing the valve seats
Figure 67
75754
INTAKE EXHAUST Check the valve seats (2). If slight scoring or burnout is found,
70328
regrind seats using adequate tool (1) according to the angle
Use a bore dial gauge to measure the inside diameter of the values shown in Figure 68.
valve guides, the read value shall comply with the value
shown in the figure.
Figure 68
119982
INTAKE EXHAUST
VALVE SEAT MAIN DATA
Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80° - 100°C and using the proper
them with the spare ones. Use adequate tool to remove as beater, fit the new valve seats, previously cooled, into the
much material as possible from the valve seats (take care not cylinder head.
to damage the cylinder head) until they can be extracted
Use adequate tool to regrind the valve seats according to the
from the cylinder head using a punch.
values shown in Figure 68.

Figure 69 FITTING CYLINDER HEAD
Figure 71
1 3 1
2
75758
2
After regrinding, check that valve (3) sinking value is the 75759
specified one by using the base 99370415 (2) and the dial
gauge 99395603 (1). Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and
VALVE SPRINGS sealing rings (3) for exhaust valves are green.
Figure 70
Figure 72
50676
1 2
MAIN DATA TO CHECK INTAKE AND EXHAUST 3
VALVE SPRINGS
Before refitting use adequate tool to check spring flexibility. 4
Compare load and elastic deformation data with those of the
new springs shown in the following table.
6
5
Height Under a load of
mm N
75751
H (free) 63.50/65.69* 0 Position on the cylinder head: the spring (4), the upper cap
H1 49.02 329 (3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
H2 38.20 641
* Installed as an alternative
Refitting the cylinder head

Figure 73 twice as indicated in the picture, checking D1 and
D2 diameters:
if D1 - D2 < 0,1 mm the screw can be utilised again;
D2 D1
75703
87759
Check cleanness of cylinder head and engine block coupling
surface.
Take care not to foul the cylinder head gasket.
Set the cylinder head gasket (1) with the marking “TOP” (1)
facing the head.
The arrow shows the point where the gasket thickness is
given.
Figure 74
88775
There are two types of head seals, for the thickness (1.25
mm Type A and 1.15 mm Type B) take the following
measures:
- for each piston detect, as indicated on Figure 74, at a
distance of 45 mm from the centre of the piston
overhandings S1 and S2 in relation to the engine base
upper plane then calculate the average:
S cil1 = S1 + S2
2
For 4 cylinder versions:
Repeat the operation for pistons 2, 3 and 4 and calculate the
average value.
S cil1 + S cil2 + S cil3 + S cil4

S=
4

TIGHTENING TORQUE
TORQUE
COMPONENT
Nm kgm
Cooling Nozzles (M8x1.25x10) 15 ± 3 1.5 ± 0.3
Main bearing cap 1st stage 50 ± 6 5.0 ± 0.6
2nd stage 80 ± 6 8.0 ± 0.6
3rd stage 90º ± 5º
Rear gear housing assembly
(M8x1.25x40) 24 ± 4 2.4 ± 0.4
(M8x1.25x25) 24 ± 4 2.4 ± 0.4
(M10x1.5) 49 ± 5 4.9 ± 0.5
Oil pump (M8x1.25x30) 8±1 0.8 ± 0.1
Front cover assembly
(M8x1.25x45) 24 ± 4 2.4 ± 0.4
(M8x1.25x30) 24 ± 4 2.4 ± 0.4
Connecting rod bolts (M11x1.25) 1st stage 30 ± 3 3.0 ± 0.3
2nd stage 60 ± 5 6.0 ± 0.5
3rd stage 60º ± 5º
Ladder frame assembly (M10x1.25x25) 43 ± 5 4.3 ± 0.5
Oil rifle plugs
(M10x1) 6±1 0.6 ± 0.1
(M14x1.5) 11 ± 2 1.1 ± 0.2
Assemble oil suction tube (M8x1.25x20) 24 ± 4 2.4 ± 0.4
Oil pan assembly
(M8x1.25x25) 24 ± 4 2.4 ± 0.4
(M18x1.50) 60 ± 9 6.0 ± 0.9
Set timing pin 5±1 0.5 ± 0.1
Fuel pump assembly
M8 screw 24 ± 4 2.4 ± 0.4
M6 screw 10 ± 1 1.0 ± 0.1
M6 nut 10 ± 1 1.0 ± 0.1
M10x1.5 flange head nuts pre-torque 10 ±15 1.0 ±1.5
final torque 50 ± 55 5.0 ± 5.5
Fuel pump gear (drive gear nut) snug torque 15 ±20 1.5 ± 2.0
final torque 85 ± 90 8.5 ± 9.0
Timing pin cap of fuel pump 30 ± 35 3.0 ± 3.5
Rocker assys (M8) 24 ± 4 2.4 ± 0.4
Cylinder head bolts
(M12x70) 50 + 90º 5.0 + 90º
(M12x140) 40 + 180º 4.0 + 180º
(M12x180) 70 + 180º 7.0 + 180º
Assy rocker covers (M8x1.25x25) 24 ± 4 2.4 ± 0.4
Intake manifold (M8x1.25) 24 ± 4 2.4 ± 0.4
Assy air intake connection (M8x1.25) 24 ± 4 2.4 ± 0.4
Oil bypass valve into lube filter head (M22x1.5x10) 80 ± 8 8.0 ± 0.8
Plug (M12x1.5x12) 10 ± 1 1.0 ± 0.1
Exhaust manifold (M10x1.5x65) 43 ± 6 4.3 ± 0.6
Water pump (M8x1.25x25) 24 ± 4 2.4 ± 0.4
Water outlet connection
(M8x1.25x35) 24 ± 4 2.4 ± 0.4
(M8x1.25x70) 24 ± 4 2.4 ± 0.4
Fan support (M10x1.5x20) 33 ± 5 3.3 ± 0.5
Fan pulley
(M6) 10 ± 2 1.0 ± 0.2
(M10) 43 ± 6 4.3 ± 0.6

TORQUE
COMPONENT
Nm kgm
Rear lifting bracket (M12x1.75x30) 77 ± 12 7.7 ± 1.2
Crankshaft pulley (M12x1.75x10.9) 110 ± 5 11.0 ± 0.5
Flywheel housing
(M12x120) 85 ± 10 8.5 ± 1.0
(M12x80) 85 ± 10 8.5 ± 1.0
(M10x80) 49 ± 5 4.9 ± 0.5
(M10x40) 49 ± 5 4.9 ± 0.5
Flywheel housing (M12x1.25) 1st stage 30 ± 4 3.0 ± 0.4
2nd stage 60º ± 5º
Assy rear cover plate to flywheel housing (M8x1.25x16) 24 ± 4 2.4 ± 0.4
Fuel injectors 60 ± 5 6.0 ± 0.5
Fuel lift pump 24 ± 4 2.4 ± 0.4
Turbocharger to exhaust manifold (M10) 43 ± 6 4.3 ± 0.6
Oil feed to oil filter head 24 ± 4 2.4 ± 0.4
Oil feed to turbocharger (M12x1.5) 35 ± 5 3.5 ± 0.5
Oil drain (M8x1.25x16) 24 ± 4 2.4 ± 0.4
Alternator to alternator support (M8x1.25x30) 24 ± 4 2.4 ± 0.4
Alternator to water inlet conn. assy (M8x1.25x30) 24 ± 4 2.4 ± 0.4
Lower alternator mounting (M10x1.25x25) 24 ± 4 2.4 ± 0.4
Alternator upper pivot to support (M10) 49 ± 5 4.9 ± 0.5
Alternator mounting hardware (M12x1.75x120) 43 ± 6 4.3 ± 0.6
Alternator wiring (M6x1.0 nut) 10 ± 2 1.0 ± 0.2
Automatic belt tensioner mount (M10) 45 ± 5 4.5 ± 0.5
Starter motor to gear case (M10) 49 ± 5 4.9 ± 0.5
Screw M8 for fastening cylinder barrel lubricating nozzles 15 ± 3 1.5 ± 0.3
Screw M12 for fastening output shaft caps 1st stage 50 ± 6 5 ± 0.6
2nd stage 80 ± 6 8 ± 0.6
3rdd stage 90º ± 5º
Screw M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.4 ± 0.4
Screw M8 for fastening camshaft gear 36 ± 4 3.6 ± 0.4
Screw M10 for fastening connecting rod caps 1st stage 60 ± 5 6 ± 0.5
2ndd stage 60º ± 5º

F4GE N SERIES SECTION 5 - TOOLS 1
SECTION 5
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 5 - TOOLS F4GE N SERIES

TOOLS
TOOL NO. DESCRIPTION
Revolving stand for overhauling units (1000 daN capacity, 120 daN/m
99322205 torque)
99340035 Injection pump gear extractor
99340055 Tool to remove output shaft front gasket
99340056 Tool to remove output shaft rear gasket
99340205 Injector pull-our tool
99346252 Tool for fitting output shaft rear gasket

v
99346253 Tool for fitting output shaft rear gasket
99360076 Tool to remove oil filter (engine)
99360183 Pliers for removing/refitting piston rings (65 — 110 mm)
99360268 Tool for removing/refitting engine valves
99360330 Flywheel crank handle
99360344 Adapter, cylinder compression test (use with 99395682)

99360351 Tool for stopping the engine flywheel
Beater for removing/refitting camshaft bushes (to be used with

99360362 99370006)
99360500 Tool for lifting the output shaft
99360595 Lifting rig for engine removal/refitting
99360605 Band for fitting piston into cylinder barrel (60 — 125 mm)
99360616 Engine TDC positioning tool

99361037 Brackets for fastening engine to revolving stand 99322205
99363204 Tool to remove gaskets
99370006 Interchangeable willow handgrip
99370415 Gauge base for different measurements (to be used with 99395603)
99395097 Tool to check top dead centre (use with 99395604)
Dial gauge holder for rotary injection pump timing (use with
99395100 99395603)

99395216 Pair of gauges with ½” and ¾” square head for angle tightening
99395603 Dial gauge (0 — 5 mm)
99395604 Dial gauge (0 — 10 mm)
99395682 Diesel fuel engine cylinder compression control device


F4GE N SERIES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . . 3

2 APPENDIX F4GE N SERIES

F4GE N SERIES APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

Standard safety prescriptions necessary instructions.
Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different
must be followed absolutely in a standard working area and operation from the ones they’ve been designed and
whose non fulfillment will make any other measure useless provided for: serious injury may occur.
or not sufficient to ensure safety to the personnel in-charge
of maintenance. - In case of test or calibration operations requiring engine
running, ensure that the area is sufficiently aerated or
- Be informed and inform personnel as well of the laws in utilize specific vacuum equipment to eliminate exhaust
force regulating safety, providing information docu- gas. Danger: poisoning and death.
mentation available for consultation.
- Keep working areas as clean as possible, ensuring During maintenance
adequate aeration.
- Ensure that working areas are provided with emergency - Never open filler cap of cooling circuit when the engine
boxes, that must be clearly visible and always provided is hot. Operating pressure would provoke high
with adequate sanitary equipment. temperature with serious danger and risk of burn. Wait
unit the temperature decreases under 50ºC.
- Provide for adequate fire extinguishing means, properly
indicated and always having free access. Their efficiency - Never top up an overheated engine with cooler and
must be checked on regular basis and the personnel utilize only appropriate liquids.
must be trained on intervention methods and priorities.
- Always operate when the engine is turned off: whether
- Organize and displace specific exit points to evacuate particular circumstances require maintenance
the areas in case of emergency, providing for adequate intervention on running engine, be aware of all risks
indications of the emergency exit lines. involved with such operation.
- Smoking in working areas subject to fire danger must be - Be equipped with adequate and safe containers for
strictly prohibited. drainage operation of engine liquids and exhaust oil.
- Provide Warnings throughout adequate boards signaling - Keep the engine clean from oil tangles, diesel fuel and or
danger, prohibitions and indications to ensure easy chemical solvents.
comprehension of the instructions even in case of
emergency. - Use of solvents or detergents during maintenance may
originate toxic vapors. Always keep working areas
Prevention of injury aerated. Whenever necessary wear safety mask.
- Do not wear unsuitable cloths for work, with fluttering
ends, nor jewels such as rings and chains when working - Do not leave rags impregnated with flammable
close to engines and equipment in motion. substances close to the engine.
- Wear safety gloves and goggles when performing the - Upon engine start after maintenance, undertake proper
following operations: preventing actions to stop air suction in case of runaway
- filling inhibitors or anti-frost speed rate.
- lubrication oil topping or replacement - Do not utilize fast screw-tightening tools.
- utilization of compressed air or liquids under pressure
(pressure allowed: ≤ 2 bar) - Never disconnect batteries when the engine is running.
- Wear safety helmet when working close to hanging - Disconnect batteries before any intervention on the
loads or equipment working at head height level. electrical system.
- Always wear safety shoes when and cloths adhering to - Disconnect batteries from system aboard to load them
the body, better if provided with elastics at the ends. with the battery loader.
- Use protection cream for hands. - After every intervention, verify that battery clamp
polarity is correct and that the clamps are tight and safe
- Change wet cloths as soon as possible from accidental short circuit and oxidation.
- In presence of current tension exceeding 48-60 V verify - Do not disconnect and connect electrical connections
efficiency of earth and mass electrical connections. in presence of electrical feed.
Ensure that hands and feet are dry and execute working
operations utilizing isolating foot-boards. Do not carry - Before proceeding with pipelines disassembly
out working operations if not trained for. (pneumatic, hydraulic, fuel pipes) verify presence of liquid
or air under pressure. Take all necessary precautions
- Do not smoke nor light up flames close to batteries and bleeding and draining residual pressure or closing dump
to any fuel material. valves. Always wear adequate safety mask or goggles.
- Put the dirty rags with oil, diesel fuel or solvents in Non fulfillment of these prescriptions may cause serious
anti-fire specially provided containers. injury and poisoning.

4 APPENDIX F4GE N SERIES
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

incorrect tightening may seriously damage engine’s
components, affecting engine’s duration. - Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
- Avoid priming from fuel tanks made out of copper alloys personnel’s safety and health shall be adopted.
and/or with ducts not being provided with filters.
- Be informed and inform the personnel as well of laws in
- Do not modify cable wires: their length shall not be force regulating use and exhaust of liquids and engine
changed. exhaust oil. Provide for adequate board indications and
- Do not connect any user to the engine electrical organize specific training courses to ensure that
equipment unless specifically approved by FPT. personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Do not modify fuel systems or hydraulic system unless
FPT specific approval has been released. Any - Collect exhaust oils in adequate specially provided
unauthorized modification will compromise warranty containers with hermetic sealing ensuring that storage is
assistance and furthermore may affect engine correct made in specific, properly identified areas that shall be
working and duration. aerated, far from heat sources and not exposed to fire
danger.
For engines equipped with electronic gearbox:
- Handle the batteries with care, storing them in aerated
- Do not execute electric arc welding without having environment and within anti-acid containers. Warning:
priory removed electronic gearbox. battery exhalation represent serious danger of
- Remove electronic gearbox in case of any intervention intoxication and environment contamination.
requiring heating over 80ºC temperature.
- Do not paint the components and the electronic
connections.
- Do not vary or alter any data filed in the electronic
gearbox driving the engine. Any manipulation or
alteration of electronic components shall totally
compromise engine assistance warranty and
furthermore may affect engine correct working and
duration.

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What safety precautions should be followed when working on the engine?

What safety precautions should be followed when working on the engine?

What are some prohibited actions when working on the engine?

What are some prohibited actions when working on the engine?

N SERIES

Technical and Repair manual

F4GE N Series Part 1

Print P2D32N010 E Base - Febraury 2009

Base - Febraury 2009 Print P2D32N010 E

PREFACE TO USER’S GUIDELINE MANUAL . . . . 3

- Bonding and screening . . . . . . . . . . . . . . . . . . . 8

CONVERSIONS BETWEEN THE MAIN UNITS

KEY OF LECTURE OF THE HEADINGS

Print P2D32N010 E Base - Febraury 2009

Base - Febraury 2009 Print P2D32N010 E

PREFACE TO USER’S GUIDELINE MANUAL

Danger for persons

Danger of serious damage for the assembly

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

∅1 Ø 1 = housing for connecting rod small end bush

Print P2D32N010 E Base - Febraury 2009

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

Base - Febraury 2009 Print P2D32N010 E

Print P2D32N010 E Base - Febraury 2009

Base - Febraury 2009 Print P2D32N010 E

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Print P2D32N010 E Base - Febraury 2009

Bonding and screening

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

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

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

Base - Febraury 2009 Print P2D32N010 E

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Print P2D32N010 E Base - Febraury 2009

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Type of Section Page

Printout Language Basic edition referred to When month - year update

Base - Febraury 2009 Print P2D32N010 E

Overhaul and technical specifications 4

Safety prescriptions Appendix

Print P2D32N010 E Base - February 2009

Base - February 2009 Print P2D32N010 E

Section Description Page Date of revision

Print P2D32N010 E Base - February 2009

Base - February 2009 Print P2D32N010 E

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

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

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

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

EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) 8

Print P2D32N010 E Base - February 2009

Base - February 2009 Print P2D32N010 E

LUBRICATION Lubrication involves the heat exchanger and the turboblower.

Routing of oil under

LUBRICATION SYSTEM LAYOUT

Print P2D32N010 E Base - February 2009

OIL VAPOUR RECIRCULATING SYSTEM