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Engines Iveco N45, N67. Manual - part 20

IO
N
3

-IN
D

STRIAL

APPL

ATIO

F4
H

NE
F

rin

2D
32N

003G

2006

ANOMALY

POSSIBLE CAUSE

(*) = if available in the equipment

RECOMMENDED TESTS OR

INTERVENTION

REMARKS

Low performance at load request.

Possible exessive smoke.

Possible blink-code 8.1

Insufficient fuel level in the tank.

Check fuel level.

The excessive smoke is due to the fact
that, in case of insufficient fuel feeding, the
engine control module tries to compen-
sate prolonging the injectors working
time.

Fuel tank device partially obstructed by
impurities or deformed because of over-
heating.

Check if the priming pump of the pre-filter
is working correctly.

If the pump plunger is permanently de-
pressed disassemble and check the tank
pick.-up tube. If this is in order, replace the
pre-filter.

Obstructed air filter.

Replace the air filter.

Solve the cause of the filter’s obstruction.

Excessive fuel blow-by from rail boost
valve.

Check the O Rings and the correct con-
nection of the pipe fittings

under the

feeding pump (the lockers must stay out-
side and the fittings must be well locked).
Visually check the low pressure pipeline
integrity.

Unless the leakage is significant, no per-
formance failures will be detected.
To verify O-rings integrity, extract from
the tank the fuel recycling pipeline, seal
the end and activate the priming pump
driving the low pressure circuit.

Excessive fuel blow-by from rail boost
valve.

Disconnect the pipe and visually check if
there are any significant blow-by from the
boost gauge valve; in such case replace
the valve.

The engine suddenly stops (with no previ-
ous problems) and does not start again.

Obstructed fuel filter.

Replace the fuel filter.

Solve the cause of the filter’s obstruction
(empty and clean the tank and the part of
the circuit over the filter, refill with clean
fuel).

TROU

BLES

HOOTIN

IO
N
3

-IN
D

STRIAL

APPL

ATIO

F4
H

NE
F

2006

rin

2D
32N

00G

ANOMALY

POSSIBLE CAUSE

(*) = if available in the equipment

RECOMMENDED TESTS OR

INTERVENTION

REMARKS

The engine disconnects or does not start. (*)

EDC ”burned” by short circuit on the wir-
ing harness of the friction clutch.

Eliminate the short circuit and replace the
EDC.

Verify that the wire line, close to the
pedal, is not exposed to.

Difficult start and low performance in all
conditions.

Inefficient high pressure pump.

After having excluded any other possible
cause, replace the high pressure pump.

Difficult start, low performance and en-
gine running with one cylinder less.

Injector with obstructer or solenoid
(mechanical part) blocked open.

The non-working injector is easily recog-
nisable detecting by feeling the absence of
pulsing within the relevant high pressure
pipe.

In case of low entity blow-by, inficiating
the mechanical working of the injector
but not involving flow limiter activation,
there is no error memorisation in the en-
gine control module.
If the flow limiter is activated. Check error
code memory.

Starting requires in excess of ten seconds,
followed by huge white exhaust fumes,
and a fuel smell.

Injector blocked in open position (with
no return).

The non-working injector is easily recog-
nisable detecting by feeling the absence of
pulsing within the relevant high pressure
pipe.

Usually, whether such symptoms appear,
it is instinctive to give up engine start.
However, by insisting, it is possible to start
the engine.
As a matter of facts, by insisting, if within
the rail the pressure makes the flow li-
miter close up, the engine starts with one
cylinder less and gradually the grade of
fumes reduces and disappears.

Breaking of high pressure pipeline from
pump to rail.

Strange vibrations provoked by slack of
pipe bracket.

Replace the pipeline ensuring the correct
tightening of the anti-vibration bracket
screws.

It is very important, in addition to correct
blocking, to keep the brackets in the orig-
inal position.

The engine works with one cylinder less,
without memorising failure blink codes in
the engine control module.

Injector blocked in closed position.

Identify the injector that is not working
any more and the relating high pressure
filler.

The non-working injector is easily recog-
nisable detecting by feeling the absence of
pulsing within the relevant high pressure
pipe.

MAINTENANCE PLANNING
Recovery

To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions,
checks and setting operations that must be performed on the engine at due planned dates.

The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine
and evaluate replacements and checks.

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.

Regular maintenance and inspection planning

Checks and periodical inspections

Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection presence of water in fuel filter or pre-filter . . . . . . . . . . . . . . . . . . . . . .

Inspection blow-by filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection of belt wear status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and setting of tappet clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of engine’s oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of blow by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacement of belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency (hours)

Daily

4000

When anomaly occurs

500

1000

500

1500

The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic
to determine and evaluate replacements and checks.

The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by
Iveco Motors.

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.

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Print P2D32N003GB

Base - February 2006

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.

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 inconven-
iences, 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.

MAINTENANCE PROCEDURES
Checks and inspections

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) placed on the right hand side of the EDC.

Figure 118

Draw off the rod from its slot and check that the level is within
the etched tags of minimum and maximum level.

Whether it should be difficult to make the evaluation, proceed
cleaning the rod using a clean cloth with no rag grinding and
put it back in its slot. Draw it off again and check the level.

In case the level results being close to the tag showing mini-
mum level, provide filling lubrication of the engine’s compo-
nents.

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”.

Figure 119

The engine oil is highly polluting and harmful.

In case of contact with the skin, rinse well with water
and detergent.

Adequately protect the skin and the eyes, operate in
full compliance with safety regulations.
Disposal must be carried out properly, and in full
compliance with the law and regulations in force.

74174

108540

SECTION 3 - DUTY-INDUSTRIAL APPLICATION

F4HE NEF ENGINES

Base - February 2006

Print P2D32N00GB

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