Engine Iveco Vector 8. Manual - part 26

 

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Engine Iveco Vector 8. Manual - part 26

 

 

74

SECTION 3 - INDUSTRIAL APPLICATION

VECTOR 8 ENGINES

Base - April 2006

Print P2D32V001E

Sym

p

to

m

Visible

tr

ouble

Po

ssib

le

c

au

se

Repair

Not

es

At

tr

ib

u

tab

le

to

mech

an

ical

malf

u

n

ct

ion

in

g:

No

star

ti

n

g

si

gn

Low

p

res

su

re

p

u

mp

op

era

ting

d

efect

C

h

eck

the

d

e

gr

ee

of

the

troub

le

an

d

rep

la

ce

th

e

d

am

age

o

r

in

e

ff

ic

ie

n

t

p

ar

ts

ch

e

cki

n

g

w

ith

a

p

res

su

re

ga

u

ge

th

at

th

e

p

res

su

res

exceed

4.5

b

ar

H

igh

pr

e

ssu

re

pu

mp

damage

d

Ch

an

ge

th

e

h

ig

h

pr

e

ssu

re

pu

m

p

No

vi

sible

sig

n

Inefficient

h

ig

h

p

res

si

on

pump

A

fter

check

ing

and

exclud

ing

an

y

o

ther

p

o

ss

ib

ilit

y

rep

la

ce

th

e

p

ump

Sta

rting

difficult.

Sta

rtup

requires

at

lea

st

2

0

second

s,

la

rg

e

amount

of

while

sm

ok

e

from

e

x

ha

us

t,

fuel

sm

ell.

In

ject

or

ja

mmed

o

p

e

n

(irrev

e

rs

ib

ly).

Without

any

d

ia

gn

os

is

ins

trument,

the

injector

tha

t

d

o

es

not

w

ork

ca

n

b

e

found

b

e

ca

us

e

the

relev

an

t

h

ig

h

p

res

su

re

p

ip

e

s

are

not

h

ea

ted

CAU

T

ION

h

o

t

e

n

gi

n

e

par

ts

m

ay

ca

u

se

se

ve

re

injuries

N

o

rm

al

ly

w

ith

th

e

se

sy

m

pto

m

s

it

is

n

atu

ral

to

abandon

the

attempt

o

f

star

ti

n

g

the

e

n

gi

n

e

.

B

e

cau

se

in

si

sti

n

g

th

e

e

n

gi

n

e

star

ts

wit

h

one

cylind

e

r

les

s

and

sl

owly

th

e

smok

e

di

mi

n

ish

e

s

an

d

d

is

appe

ar

s

e

x

h

au

st

,f

u

e

l

sm

e

ll.

C

h

eck

tha

t

the

relev

an

t

e

ng

ine

-inject

or

ca

bl

e

cy

lin

de

r

n

u

m

be

r

m

atc

h

C

h

eck

ca

b

le

p

o

si

ti

oning

and

if

req

u

ired

connect

th

e

e

ng

ine

ca

b

le

p

rop

erly

D

ifficult

st

ar

tup

and

poor

performa

nce

in

al

l

conditions

Inefficient

low

or

h

igh

pr

e

ssu

re

pu

mp

A

fter

check

ing

and

exclud

ing

an

y

o

ther

p

o

ss

ib

ilit

y

and

check

ing

ra

il

p

res

su

re

tr

end

,

rep

la

ce

the

hig

h

or

low

p

res

su

re

p

u

mp

accord

ing

to

w

hich

comp

onent

is

d

am

ag

e

d

D

ifficult

st

ar

tup,

poor

performa

nces

an

d

e

ng

ine

runs

wit

h

one

cylind

e

r

mi

ssi

n

g

Inj

e

ct

or

wi

th

shutte

r

o

r

solenoid

core

(mecha

nica

l

p

ar

t)

lock

ed

op

en.

Without

any

d

ia

gn

os

is

ins

trument,

the

in

je

ct

or

th

at

doe

s

n

o

t

w

or

k

can

be

fou

n

d

by

feeling

if

there

is

no

p

u

ls

at

ion

o

n

the

hig

h

pr

e

ssu

re

pi

pi

n

g

Wit

h

slig

ht

b

low

-b

y

tha

t

jeop

ard

is

es

th

e

mecha

n

ica

l

op

era

tion

o

f

the

inject

or

b

u

t

d

o

es

not

e

na

b

le

the

flow

limiter

SECTION 3 - INDUSTRIAL APPLICATION

75

VECTOR 8 ENGINES

Print P2D32V001E

Base - April 2006

Sym

p

to

m

Visible

tr

ouble

Po

ssib

le

c

au

se

Repair

Not

es

A

ttri

buta

b

le

to

m

al

func

ti

oni

n

g

in

the

fuel

suppl

y:

In

su

fficient

fuel

lev

el

d

u

ring

op

era

tion

C

h

eck

fuel

lev

el

The

la

ck

o

f

fuel

ca

u

se

s

troub

le

to

norma

l

sy

ste

m

ope

rati

o

n

m

ostl

y

w

h

e

n

th

e

re

is

a

rema

rk

ab

le

req

u

es

t

o

f

fuel.

S

car

ce

lo

adi

n

g

Fu

el

sy

st

em

clog

ge

d

b

efore

the

p

refilter

C

h

eck

if

the

p

refilt

er

p

riming

p

ump

w

ork

s

properly.

If

the

kn

ob

of

the

p

ump

rema

ins

aspi

ra

te

d

d

ow

n

w

ar

ds

by

th

e

d

e

p

re

ssi

on

,

d

is

as

se

mb

le

an

d

check

p

refilt

er

int

e

gr

it

y.

If

th

e

troub

le

p

e

rs

is

ts

h

ave

th

e

m

an

u

fac

tu

re

r

check

the

sy

st

em

b

e

tween

the

ta

n

k

and

the

p

refilter.

C

h

eck

accura

tely

an

d

clea

n

fuel

sy

st

em

S

ca

rc

e

lo

ad

in

g

req

u

es

t

pe

rf

or

man

ce

s.

Possi

bl

e

smoke

an

d

roc

kin

g

Fu

e

l

le

aks

fr

o

m

fitti

n

gs

o

r

p

ip

e

s

af

te

r

th

e

low

p

res

su

re

p

u

mp

.

C

h

eck

the

cond

itions

of

the

p

ip

es

an

d

relev

an

t

sea

ls

.

Abn

o

rm

al

pe

rf

or

man

ce

ro

ck

in

g

D

ies

el

fuel

filter

clog

ge

d

C

h

eck

the

p

res

ence

of

errors

(d

etecta

b

le

d

at

a)

w

it

h

the

d

ia

gn

os

is

ins

trument

,

then

rep

la

ce

the

filt

ers

Ai

r

b

lo

w

-by

be

for

e

th

e

low

pr

e

ssu

re

pu

mp

C

h

eck

the

cond

itions

of

the

p

ip

es

an

d

relev

an

t

sea

ls

b

e

tw

een

th

e

p

refilt

er

an

d

the

low

p

res

su

re

p

u

mp

.

C

heck

th

at

th

e

b

leed

sc

rews

on

the

filter

ar

e

tig

htened

.

Wit

h

full

loa

d

pe

rf

or

man

ce

d

e

cay

o

cc

u

rs

O

n

eo

rm

o

rei

n

je

ct

o

rs

b

lo

ck

e

d

.

The

injector

tha

t

d

oes

n

ot

work

ca

n

b

e

found

ev

en

wit

h

out

d

ia

gn

os

is

ins

trument

s

ev

en

if

it

is

comp

let

e

ly

clos

ed

b

e

ca

us

e

the

relev

an

t

h

ig

h

p

res

su

re

p

ip

e

s

w

ould

b

e

cold

.

C

A

UTI

O

N:

hot

e

ng

ine

p

ar

ts

ma

y

ca

u

se

se

ve

re

injuries

.

occurs

.

A

ir

filt

ers

clog

ge

d

as

ind

ica

ted

b

y

th

e

se

n

sor

s.

Req

u

es

t

clea

n

ing

/rep

la

cement

o

f

the

filters

an

d

cl

e

an

th

e

in

take

du

ct

s

b

e

fo

re

th

e

fil

te

rs

76

SECTION 3 - INDUSTRIAL APPLICATION

VECTOR 8 ENGINES

Base - April 2006

Print P2D32V001E

Sym

p

to

m

Visible

tr

ouble

Po

ssib

le

c

au

se

Repair

Not

es

A

ttri

buta

b

le

to

el

ec

tri

ca

l

ma

lf

unc

ti

oni

n

g.

Eng

ine

d

oes

n

ot

accelera

te

PW

M

si

gn

al

n

ot

pl

au

si

bl

e

o

r

m

al

fu

n

cti

on

of

the

ac

ce

le

ra

tor

p

otenti

ometer

.

C

h

eck

act

iv

e

d

ia

gn

os

is

an

d

any

ca

b

ling

cont

rol.

Rep

la

ce,

if

req

u

ired

The

ra

il

p

res

su

re

d

o

es

not

corres

p

ond

to

the

o

ne

wa

nted

Ch

e

ck

ac

ti

ve

d

iagn

o

si

s

an

d

an

y

adj

u

stabl

e

flo

w

co

n

tr

o

l

val

ve

re

pl

ac

e

m

e

n

t.

If

repla

cement

d

oes

n

ot

resolv

e

the

trouble,

wi

th

a

m

ul

ti

meter

chec

k

that

ca

bl

in

g

w

or

ks

pr

ope

rl

y

Pow

e

r

re

d

u

cti

on

R

ai

l

pr

e

ssu

re

se

n

sor

doe

s

n

o

t

w

or

k

pr

ope

rl

y

C

h

eck

act

iv

e

d

ia

gn

os

is

an

d

any

se

ns

or

rep

la

cement

If

repla

cement

d

oes

n

ot

resolv

e

the

trouble,

wi

th

a

m

ul

ti

meter

chec

k

that

ca

bl

in

g

w

or

ks

pr

ope

rl

y

Abn

o

rm

al

pe

rf

or

man

ce

The

p

res

su

re

reg

u

la

to

r

d

oes

n

ot

work

pr

ope

rl

y

C

h

eck

act

iv

e

d

ia

gn

os

is

,

check

th

at

th

e

connect

or

is

p

rop

erly

connect

ed

to

th

e

pr

e

ssu

re

re

gu

la

tor

an

d

an

y

se

n

sor

rep

la

cement

If

repla

cement

d

oes

n

ot

resolv

e

the

trouble,

wi

th

a

m

ul

ti

meter

chec

k

that

ca

bl

in

g

w

or

ks

pr

ope

rl

y

The

e

ng

ine

su

dde

n

ly

stops

(without

p

rev

ious

The

fuel

filt

er

is

clog

ge

d

C

h

eck

d

ia

gn

os

is

an

d

then

fuel

filt

er

rep

la

cement

C

h

eck

w

hy

clog

gi

ng

occurs

(

p

hesi

tati

ons)

and

d

o

es

not

res

ta

rt

Rup

ture

o

r

m

al

function

of

the

ra

il

p

res

su

re

sensor

or

of

the

o

verp

res

su

re

val

ve

C

h

eck

act

iv

e

d

ia

gn

os

is

an

d

any

se

ns

or

rep

la

cement

If

repla

cement

d

oes

n

ot

resolv

e

the

trouble,

wi

th

a

m

ul

ti

meter

chec

k

that

ca

bl

in

g

w

or

ks

pr

ope

rl

y

se

n

so

r

o

r

o

f

th

e

o

ve

rp

re

ss

u

re

va

lv

e

Ch

e

ck

an

d

/o

r

re

p

la

ce

th

e

o

ve

rp

re

ssu

re

val

ve

Coola

n

t

h

ig

h

temper

atur

e

de

te

ct

e

d

by

th

e

eng

ine

se

ns

or

None

In

su

fficient

e

ng

ine

w

at

er

lev

e

l

Req

u

es

t

ta

n

k

lev

el

res

e

t

SECTION 3 - INDUSTRIAL APPLICATION

79

VECTOR 8 ENGINES

Print P2D32V001E

Base - April 2006

VECTOR 8 DRAGON FVAE2884A*B200 MAINTENANCE PLAN

Hourly intervals

h

Time intervals

First level service

500

1 year

Second level service

2500

5 years

General overhaul

5000

10 years

Engine replacement

25000

25 years

DAILY CHECKS

Check fumes

Check for faults during start-up

Check for clogged air/oil/diesel filter warning light activation

Check for abnormal noises

WEEKLY CHECKS

Check oil level manually - top up if necessary

Check coolant level - top up if necessary

Check for fluid leaks

Inspect the engine for lost or missing bolts/damaged parts

Inspect belt wear

Remove any dirt built up on the engine (leaves, dust, etc)

Take note of oil/diesel consumption per service hours/km and report and unexplained increases.

Check coolant overheating or excessive heating time

FIRST LEVEL MAINTENANCE

Carry out every 500 hours or at least once per year

Change oil filters

Change fuel filters

Change fuel prefilter

Change engine oil

Adjust valve clearance

Change alternator belt

Change blow-by filter

SECOND LEVEL MAINTENANCE

Carry out every 2500 hours or at least once every 5 years

Operations from the previous level

Change water pump

Change injectors

Change starter motor

Change alternator

 

 

 

 

 

 

 

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