6 - Nef Engine Tier 3

1Monthyon, november 2007

LOADER-BACKHOE CASE “580-590-695 SR2 Series”

TIER 3 NEF Engine

ChapterChapter 33

NEF NEF ENGINEENGINE

TIER 3TIER 3



TIER 3 NEF Engine

1 – Engine controller;

12

2 – Crankshaft sensor;

3

3 – High pressure pump

;

5

5 – Injection pressure sensor;

6

6 – PTO;

7

7 – Preheating grid;

8

8 – Water pump;

9

9 – Turbocharged;

4 – Fuel filter;

4



TIER 3 NEF Engine

5

87

2413

6

3.1. Identification plate

1: Engine codeF4 = Engine familiy (NEF)H = Non structural engine block - 4 valves on each cylinderE = Engine0 = Engine configuration (4 strokes, vertical)4 = Number of cylinders8 = Injection and intake (Turbocharged, Diesel, ID, Intercooler)4 = Application (Tractors and construction machinery)E = Homologation powerJ = Emission level (Tier 3)

2: Date of manufacturing (month - year)3: Gross power given in in Hp4: Displacement given in cubic inches: 272 cu. in. = 4490 cc.5: Max fuel quantity delivered by each pump piston in one cycle, given in mg/stroke6: Engine minimum idle speed7: Injection advanced mode data (not used)8: Intake valve backlash (inches)9: Exhaust valve backlash (inches)



TIER 3 NEF Engine

Engine

Maker - Model ………………………………………….. NEF - FHHE9484 C J 101 XXXX (Tier 3)

Bore x stroke ……………………………………………... 104mm x 132mm

Displacemen…………………………………………………4.5 Litres

Rated speed ………………………………………………. 2200 rpm

Gross power per SAE J1995 @ 2000 RPM …… 82 Kw @ 2000 rpm

Firing order ………………………………………………...1 – 3 – 4 – 2

Intake ………………………………………………….…….Turbo aftercooler

Maximum operating slope)……………………..……..35%



TIER 3 NEF Engine

COMPONENTS

1

1. High pressure pump;

2

2. Fuel filter;

3

3. Engine controller;

4

4. Common Rail with high pressure relief valve

5

5. Intake air (from aftercooler)

6

6. Engine oil filling

7

7. Low pressure pump

Nomenclature of engine - Turbo side



TIER 3 NEF Engine

COMPONENTS

1. Turbocharged with wastegate

2. Engine oil filter

4

3. To muffler

3

4. Air intake to aftercooler

5

2

5. Air intake (from filter)

1

Nomenclature of engine - Turbo side

CONNECTIONS



TIER 3 NEF Engine

COMPONENTS

1

1. Engine controller

2

2. Common rail

4

3. Turbocharged

4. Water pump

3

Nomenclature of engine - Front



TIER 3 NEF Engine

COMPONENTS

1

1. Common rail relief valve

2

2. Engine air pressure-temperature combined sensor ( turbocharging)

3

3. Fuel discharge from electric-injector

44. Fuel discharge from common rail

Nomenclature of engine - Actuators and sensors



TIER 3 NEF Engine

1 – Common Rail;

2 – Injection pressure sensor;

1

2




TIER 3 NEF Engine

E.G.R. – Exaust Gas Recirculation

In general on tier 3 engines has been developped a new system called E.G.R in order to reduce the pollution.

EGR stand for Exaust Gas Recirculation.

Practically part of exhaust gas is introduced in the cylinders in order to reduce the combustion temperature.

In fact, the exhaust gas doesn’t contain oxygen, practically are neutral and are as obstacle to heat propagation.

Since the production of oxide of nitrogen(pollution) is directly proportional tocombustion temperature, it means that if wereduce the combustion temperature, we reduce pollution.

IVECO NEF got the EGR just mdifying the cams shaft.

So when the gas is going outside of cylinder, part re-enter in the same cylinders.

Note: in the picture there is a solution adopted by isuzu.



TIER 3 NEF Engine

On NEF engines an extra lobe on the cam shaft let to get the exhaust gas recirculation during the intake cycle by keeping the exhaust valve open for a short time.

AB




TIER 3 NEF Engine




TIER 3 NEF Engine

1. Proportional valve

1

2

COMPONENTS

2. Low pressure pump

4

4. Fuel filter;

5. Fuel temperature sensor;

4


3 - High pressure pump

3



TIER 3 NEF Engine

1. Engine oil filter;

COMPONENTS

1

2. Engine oil pressure temperature sensore;

2

3

3. Coolant temperature sensor;




TIER 3 NEF Engine

1

1. Timing gear sensor (camshaft);

2

2. Cranshaft sensor;

COMPONENTS




TIER 3 NEF Engine

COMPONENTS

2

4

1

3

1 – Fuel pre-filter;

2 – Breather screw;

3 – Fuel lifting pump;

4 – Water in fuel sensor;




TIER 3 NEF Engine


2. To high pressure pump

To fuel tank

1. Fuel filter

13

2



TIER 3 NEF Engine

1 – From engine controller 2 – To fuel filter3 – From fuel filter to high pressure pump4 – Return fuel to filter5 – To Common Rail

21

3

4

5

Injection pump



TIER 3 NEF Engine

Fuel tank

Fuelprefilter

High pressure

pump

Fuelfilter

Low pressurepump

Fuelradiator

“Common rail” injection system



TIER 3 NEF Engine 3.7. “Common Rail” injection system High pressure pump

A. Fuel return port - B. Fuel inlet port from EDC heatexchanger - C. Fuel inlet port from fuel filter - D. Fueloutlet port from low pressure pump to fuel filter - E. Fuel outlet port from high pressure pump to the rail. -1. High pressure pump - 2. Fuel supply pump -3. Fuelpressure regulator (N.O. proportional solenoid valve controlled by PWM signal from EDC7 electroniccontrol unit).

1. Cylinder - 2. Three lobes cam - 3. Suction valve - 4. Delivery valve - 5. Piston - 6. Pump shaft - 7. Lowpressure fuel inlet - 8. Piston fuel supply channels.

Pump with three radial piston driven by the timing gear. No timing adjustment is required. With fuel supply gear pump installed on the back of the high pressure pump.



TIER 3 NEF Engine

1. Pressure rod

2. Needle

3. Nozzle

4. Coil

5. Pilot valve

6. Ball shutter

7. Control area

8. Pressure chamber

9. Control volume

10. Supply-contro line

11. Control fuel outlet

12. Electrical connector

13. Spring.

3.7. “Common Rail” injection system

Electric injector - rest condition



TIER 3 NEF Engine

When the coil (4) is energized, the ball shutter (6)ismoved upward. The fuel in the control chamber (9) flows out through the return line (11) causing a pressure drop in the control chamber (9).

At the same time, the fuel pressure in the pressurechamber (8) pushes the needle (2)upward, allowingthe fuel spraying into the cylinder combustionchamber.

Injection starting

When the coil (4) is de-energized, the ball shutter (6) takes back its closed position, in order to restore a force balance suitable to keep closed the injectorneedle (2) and shut off the fuel injection.

Injection end

From Rail

To reservoir

3.7. “Common Rail” injection system



TIER 3 NEF Engine

“Common Rail” injection system

Engine controller input /output signals

Coolant temperaturesensor

Fuel temperaturesensor

Common rail fuel pressuresensor

Intake manifold combinedpressure/temp. sensor

Engine oil combinedpressure/temp sensor

Timing gearsensor

Crankshaft speedsensor

Throttle potentiommetersignal

Ambient pressuresensor

Injector solenoids Preheating grid relay

Proportional solenoid valve installed on high pressurepump

Diagnostic connector



TIER 3 NEF Engine

TECHNICAL DATASTECHNICAL DATAS

STALLSSTALLS



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine

2

1



TIER 3 NEF Engine

2

1



TIER 3 NEF Engine

2

1



TIER 3 NEF Engine



TIER 3 NEF Engine

2

1



TIER 3 NEF Engine

12



TIER 3 NEF Engine



TIER 3 NEF Engine

12



TIER 3 NEF Engine

1

2



TIER 3 NEF Engine

1

2



TIER 3 NEF Engine



TIER 3 NEF Engine

In case of Clusterreplacement

21



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine

View information or download



TIER 3 NEF Engine

2

1



TIER 3 NEF Engine

1



TIER 3 NEF Engine



TIER 3 NEF Engine

1

2

After cluster replacement is necessary to enter in this screen

and set properly the following parameters :

Air conditioning;Preheating grid;Pilot control,

than send the values to the controler



TIER 3 NEF Engine

2

1



TIER 3 NEF Engine

SelectLanguage



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine

INJECTORS CUT OFF



TIER 3 NEF Engine


LOADER-BACKHOE CASE “580-590-695 SR2 Series”PRESENTATION



TIER 3 NEF Engine

Programming

This ECU software download procedure is required if any one of the following conditions exist:

• Blank ECU from Service Parts - Programming an engine controller from service parts that has no software pre-loaded (normal service part).

• Black ECU from an interrupted Download - Programming an engine controller that has lost its information due to an interrupted download process for a normal update.

•Wrong ECU - Programming an engine controller from service parts or from a different machine that is loaded with inappropriate software for the selected machine.



TIER 3 NEF Engine

Blank Controller Download

Downloading to a blank controller requires a two part download process:

• One process to initialize the controller.

• A second process to download the software file to the ECU.

The progress bar will be displayed two times. The time required for this type of download will be about 60% longer than for the Normal Machine Update download.



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine

2

1

Chose here the right program



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine

* * * * ** *** *** ****



TIER 3 NEF Engine

FAULT CODE LIST



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine



TIER 3 NEF Engine

How to record engine parameter with the E.S.T

Documents

6 - Nef Engine Tier 3