SATIZ CNG NEF Series Operating instructions

CNG NEF SERIES
Vehicle application
N60
N60 ENT G
Technical and Repair manual

Publication edited by
Iveco Motors
Iveco SpA
PowerTrain
Mkt. Advertising & Promotion
Viale dell’Industria, 15/17
20010 Pregnana Milanese
Milano (Italy)
Print P1C32N001GB -1
st Ed. 04.2005
This publication describes the characteristics, data and correct
methods for repair operations on each component of the ve-
hicle.
If the instructions provided are followed and the specified
equipment is used, correct repair operations in the pro-
grammed time will be ensured, safeguarding against possible
accidents.
Before starting to perform whatever type of repair, ensure that
all accident prevention equipment is available and efficient.
All protections specified by safety regulations, i.e.: goggles,
helmet, gloves, boot, etc. must be checked and worn.
All machining, lifting and conveying equipment should be in-
spected before use.
The data contained in this publication was correct at the time
of going to press but due to possible modifications made by
the Manufacturer for reasons of a technical or commercial na-
ture or for adaptation to the legal requirements of the differ-
ent countries, some changes may have occurred.
No part of this publication, including the pictures, may be re-
produced in any form or by any means.
B.U. TECHNICAL PUBLISHING
Iveco Technical Publications
Lungo Stura Lazio, 15/19
10156 Turin - Italy
Produced by:

F4B Engines Part 1
CNG NEF ENGINES
1
CNG NEF ENGINES

2CNG NEF ENGINES

Where possible, the same sequence of procedures has been followed for easy reference.
Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see
next page) instead of giving descriptions of some operations or procedures.
Example
Ø 1 = housing for connecting rod small end bush
Ø 2 = housing for connecting rod bearings
α
Tighten to torque
Tighten to torque + angular value
1
∅
∅2
3
CNG NEF ENGINES
SPECIAL REMARKS

Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated
in the general table of contents.
Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.).
Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections — disconnections of
units to/from the vehicle, overhauls at the bench and relating troubleshooting.
On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electric
schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the
electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
PRELIMINARY REMARKS
General danger
It includes the dangers of above described signals.
Danger of serious damage for the vehicle
Partial or complete non observance of these prescriptions can cause serious damages to the vehicle and sometimes
guarantee lapse too.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
SYMBOLS - WARNINGS
It indicates an additional explanation for a piece of information.
!
NOTE
4CNG NEF ENGINES

5
CNG NEF ENGINES
Graph and symbols
Removal
Disconnection Intake
Refitting
Connection Exhaust
Removal
Disassembly Operation
Fitting in place
Assembly ρCompression ratio
Tighten to torque Tolerance
Weight difference
α
Tighten to torque + angle value Rolling torque
Press or caulk Replacement
Original spare parts
Regulation
Adjustment Rotation
!Warning
Note
Angle
Angular value
Visual inspection
Fitting position check Preload
Measurement
Value to find
Check
Number of revolutions
Equipment Temperature
Surface for machining
Machine finish bar Pressure
Interference
Strained assembly
Oversized
Higher than….
Maximum, peak
Thickness
Clearance
Undersized
Less than….
Minimum
Lubrication
Damp
Grease
Selection
Classes
Oversizing
Sealant
Adhesive
Temperature < 0 °C
Cold
Winter
Air bleeding
Temperature > 0 °C
Hot
Summer

6CNG NEF ENGINES

Section
General specifications 1
Fuel 2
Use 3
General overhaul 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the F4B 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 sepa-
rate 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 incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
Installation general prescriptions are reported within the ap-
pendix.
The appendix reports general safety prescriptions to be follo-
wed by all operators whether being in-charge of installation or
maintenance, in order to avoid serious injury.
Part 1
F4B ENGINES
1
CNG NEF ENGINES

2CNG NEF ENGINES

3
CNG NEF ENGINES
UPDATING
Section Description Page Date of revision

4CNG NEF ENGINES

SECTION 1 - GENERAL SPECIFICATIONS 1
CNG NEF ENGINES
SECTION 1
General specifications
Page
CORRESPONDENCE BETWEEN TECHNICAL CODE
AND COMMERCIAL CODE 3.............
LUBRICATION 5..........................
OIL VAPOUR RECIRCULATING SYSTEM 6.....
COOLING SYSTEM 7......................
AIR INDUCTION BOOST DIAGRAM 8........
-Description 8............................

2SECTION 1 - GENERAL SPECIFICATIONS CNG NEF ENGINES

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
SECTION 1 - GENERAL SPECIFICATIONS 3
CNG NEF ENGINES
Technical Code Commercial Code
F4BE0641A*G102 N60 ENT G
F4BE0641A*G103 N60 ENT G
F4BE0641A*G105 N60 ENT G

4SECTION 1 - GENERAL SPECIFICATIONS CNG NEF ENGINES

Figure 1
LUBRICATION
Lubrication by forced circulation is achieved through oil rotary
expansion pump, placed in the front part of the basement,
driven by the straight-tooth gear splined to the shaft’s bar hold.
From the pan, the lubrication oil flows to the driving shaft, to
the camshaft and to the valve drive.
Lubrication involves the heat exchanger (2,3), the
turboblower for turbocompressed versions, and for any
compressed air system.
All these components may often vary according to the specific
duty.
Routing of oil under pressure
Routing of oil return by gravity
to sump
Introduction of oil
76212
LUBRICATION SYSTEM LAYOUT
1. Lubrication oil pipe to supercharger - 2. Heat exchanger body - 3. Heat exchanger - 4. Oil rotary expansion pump -
5. Oil filter.
(Demonstrative)
SECTION 1 - GENERAL SPECIFICATIONS 5
CNG NEF ENGINES

3240t
Figure 2
OIL VAPOUR RECIRCULATING SYSTEM
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).
1
2
3
6SECTION 1 - GENERAL SPECIFICATIONS CNG NEF ENGINES

Figure 3
COOLING SYSTEM
The engine cooling system, closed circuit forced circulation
type, generally incorporates the following components:
-Expansion tank; placement, shape and dimensions are
subject to change according to the engine’s equipment.
-Radiator, which has the duty to dissipate the heat
subtracted to the engine by the cooling liquid. Also this
component will have specific peculiarities based on the
equipment developed, both for what concerns the
placement and the dimensions.
-Visc
p
ushe
r
f
an, ha
v
in
g
t
he du
t
y
t
oinc
r
ease
t
he hea
t
dissipating power of the radiator. This component as well
will be specifically equipped based on the engine’s
development.
-Heat exchanger to cool the lubrication oil: even this
component is part of the engine’s specific equipment.
-Centrifugal water pump, placed in the front part of the
engine block.
-Thermostat regulating the circulation of the cooling liquid.
-The circuit may eventually be extended to the
compressor, if this is included in the equipment.
Water coming out from thermostat
Water recirculating in engine
Water coming into pump
COOLING SYSTEM LAYOUT
FROM RADIATOR
TO RADIATOR
76216
SECTION 1 - GENERAL SPECIFICATIONS 7
CNG NEF ENGINES

Figure 4
The turbocharger is composed by the following main parts:
one turbine, one transforming valve to regulate the boost
feeding pressure , one main body and one compressor.
During engine working process, the exhaust emission flow
through the body of the turbine, provoking the turbine disk
wheel’s rotation.
The compressor rotor, being connected by shaft to the
turbine disk wheel, rotates as long as this last one rotates,
compressing the sucked air through the air filter.
The above mentioned air is then cooled by the radiator and
flown through the piston induction collector.
The turbocharger is equipped with a transforming valve to
regulate the pressure , that is located on the exhaust collector
before the turbine and connected by piping to the induction
collector.
It’s duty is to choke the exhaust of the emissions , releasing part
of them directly to the exhaust tube when the boost feeding
pressure,overthecompressor,reachestheprescribedbar
value.
The cooling process and the lubrication of the turbocharger
and of the bearings is made by the oil of the engine.
Description
74195
RADIATOR
AIR FILTER TURBOCHARGER
EXHAUST
AIR INDUCTION BOOST DIAGRAM
8SECTION 1 - GENERAL SPECIFICATIONS CNG NEF ENGINES