Professional Documents
Culture Documents
CNH
F5C - F5A
Structural and
Non Structural Version
ENGINES
CNH
F5C - F5A
Repair
Manual
4 Cylinders, Mechanical
Repair
Manual
Tier III
Copyright ©
All the information, illustrations and data provided by this manual are based upon the most recent information available
at the time of its publication.
CNH ITALIA S.p.A. reserves the right to implement modifications, at any time, without communications.
FOREWORD
TO THE READER
- This Manual is written for an expert technician to - For any question or comment, or in case any
provide the technical information required to per- error regarding the content of this manual is
form repair operations on this machine. found, you are asked to please contact:
- Please read carefully this manual for the correct CNH ITALIA S.p.A.
information regarding the repair procedures. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PARTS & SERVICE
Fax ++39 011 0077357
SYMBOLS
This manual includes safety warning symbols and indications to recall the attention on possible personal
injuries or damages to the machine.
FOREWORD
UNITS OF MEASURE
In this manual, the units of measure of the IS (International System) are used.
The units of measure of the MKSA system are listed in parenthesis after the units of the International system.
Example: 24.5 Mpa (250 kgf/cm2).
Here below, a conversion table of the units of the IS and some units of measure of other systems is listed. as
a reference.
To convert To convert
into Multiply into Multiply
Quantity from Quantity from
(Others) by (Others) by
(SI) (SI)
mm in 0.03937 MPa kgf/cm2 10.197
Length Pressure
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 kW PS 1.360
Power
Volume L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C x 1.8 + 32
Mass kg lb 2.205 km/h mph 0.6214
Velocity
N kgf 0.10197 min --1 rpm 1.0
Force
N lbf 0.2248 L/min US gpm 0.2642
Flow
N.m kgf.m 0.10197 mL/rev cc/rev 1.0
Torque
N.m lbf.ft 0.7375
Copyright ©
F5 ENGINES 3
SPECIAL REMARKS
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
UPDATING
Introduction
Page
SYMBOLS ............................... 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM . . . . . . . . . . . . . . . 7
SYMBOLS - Warnings
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.
Example
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Regulation Angle
Adjustment Angular value
Warning
! Preload
Note
Visual inspection
Number of revolutions
Fitting position check
Measurement
Value to find Temperature
Check
Equipment Pressure
bar
Oversized
Surface for machining
Higher than….
Machine finish
Maximum, peak
Undersized
Interference
Less than….
Strained assembly
Minimum
Selection
Thickness
Classes
Clearance
Oversizing
Lubrication Temperature < 0 °C
Damp Cold
Grease Winter
Temperature > 0 °C
Sealant
Hot
Adhesive
Summer
Air bleeding
Copyright ©
F5 ENGINES INTRODUCTION 5
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.
Copyright ©
6 INTRODUCTION F5 ENGINES
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; CNH 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 chas-
sis 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.
Copyright ©
F5 ENGINES INTRODUCTION 7
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 CNH 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.
Copyright ©
8 INTRODUCTION F5 ENGINES
- 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
Figure 2
88039
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
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10 INTRODUCTION F5 ENGINES
Copyright ©
F5 ENGINES 1
F5 ENGINES
Section
Section
General information 1
Supply 2
Industrial appliance 3
Tools 5
SECTION 1
General specifications
Page
TECHNICAL CODING . . . . . . . . . . . . . . . . . . . . . 3
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 7
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Working system . . . . . . . . . . . . . . . . . . . . . . . 12
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . 13
E.G.R. SYSTEM
(EXHAUST GAS RECIRCULATION) . . . . . . . . 14
INTERNAL EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EXTERNAL EGR . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BOOSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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2 SECTION 1 - GENERAL SPECIFICATIONS F5CE ENGINES
Copyright ©
F5CE ENGINES SECTION 1 - GENERAL SPECIFICATIONS 3
TECHNICAL CODING
Technical Code
F5CE5454B
F5CE9484E
F5CE9484C
F5CE9454E
F5CE9454C
F5CE9454G
TECHNICAL DESIGNATION
F 5 C E 9 4 8 4 B * A 0 0 1 -
Number of cylinders
5 - External EGR
9 - Internal EGR
Engine (invariable) B 61 kW / 2500 rpm
C 65 kW / 2300 rpm
Engine family evolution (also irrespective of the displacement)
E 55 kW / 2500 rpm
ENGINE VIEWS
Figure 1
118979
Figure 2
118977
Figure 3
118978
Figure 4
118980
Figure 5
118981
LUBRICATION SYSTEM The lubrication system also comprises the heat exchanger, he
centrifugal blower for the versions with turbosupercharger
Forced circulation lubrication is controlled by the rotor oil and eventually the compressor if the compressed air system
pump housed in the front part of the engine basement and is also fitted.
driven by the toothed gear splined on the shank of the engine
drive shaft. All the above mentioned components vary depending on their
use and therefore will be illustrated in the specific section.
From the oil pan, the lubrication oil is distributed to the engine
drive shaft, the camshaft and the valve control.
Figure 6
Pressurized oil
Dropping oil
118982
Oil pump
Figure 7
119405
PUMP SPECIFICATIONS
Rotating speed 750 rpm - 4200 rpm
Feed pressure 2 Bar - 4 Bar
Rated flow 12.2 l/min - 75.9 l/min
Oil type SAE 20/30
Max. oil temperature 80 °C
1. Main gear - 2. Secondary gear - 3. Pump unit - 4. Drive shaft - 5. Secondary shaft
6. Cover - 7. Internal rotor - 8. External rotor - 9. Bush.
Copyright ©
F5CE ENGINES SECTION 1 - GENERAL SPECIFICATIONS 9
119406
Figure 9
119407
ENGINE COOLING SYSTEM - heat exchanger cooling the lubricant oil. This component
may vary depending on the specific engine fitting;
The closed circuit forced circulation engine cooling system is
composed of the following parts: - centrifugal water pump positioned in the front part of the
engine basement;
- expansion tank: position, form and dimensions may vary
depending on the engine fitting; - thermostat controlling cooling liquid circulation.
- radiator dissipating the heat absorbed by the engine
cooling liquid. This component’s position and dimensions
may vary depending on the outfit;
- fan increasing the radiator’s cooling power. This
component may vary depending on the specific engine
fitting;
Figure 10
Closed thermostat
Open thermostat
Water inflow
118983
WATER PUMP
Figure 11
120047
THERMOSTAT
Figure 12
119412
THERMOSTAT DIAGRAM
Working system
When the engine is cool, water output from the front part of the cylinder head flows into an inlet containing the thermostat, which
cuts out water circulation to the radiator. This way, water circulation will only be possible in the pump-engine circuit, insofar allowing
engine heat-up quickly. The thermostat valve starts opening at nearly 80 ˚C, allowing water circulation into the radiator and also
obstructing direct return towards the engine. Check the thermostat efficiency and replace it in case of doubtful functioning.
1. Stroke starts at 79˚ ± 2 ˚C
2. 7 mm stroke at 94˚±2˚C
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F5CE ENGINES SECTION 1 - GENERAL SPECIFICATIONS 13
HEAT EXCHANGER
Figure 13
SECTION A-A
SECTION B-B
119408
The heat exchanger within the engine cooling system has the duty to control the engine oil temperature, reducing it by absorbing
heat throughout the engine cooling liquid.
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14 SECTION 1 - GENERAL SPECIFICATIONS F5CE ENGINES
114026
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F5CE ENGINES SECTION 1 - GENERAL SPECIFICATIONS 15
Figure 15
119409
1. Valve unit - 2. Heat exchanger - 3. Water pipe - 4. Exhaust gas pipe - 5. Intake manifold
6. Exhaust manifold - 7. Engine head.
Working system
The external EGR system is a device fitted between the exhaust manifold and the intake manifold. Allows partial exhaust gas
recovery into the engine cylinders after having been cooled throughout a heat exchanger. This way the combustion temperature
maximum values, responsible of the formation of Nitrogen oxides (NOx) can be reduced. Hence, reducing the aforesaid
temperatures by decreasing the concentration of oxygen in the combustion chamber, the EGR system efficiently controls NOx
emissions.
The exhaust gases through the conduit (4) and only after receiving the consent by the electronic control unit EGR, cross the valve
(1) and reach the heat exchanger (2) where, thanks to the engine coolant recycle, are cooled to be then entered into the aspiration
manifold (5).
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16 SECTION 1 - GENERAL SPECIFICATIONS F5CE ENGINES
BOOSTING
The boosting system is composed of the following parts:
- Air filter;
- Turbosupercharger.
Figure 16
119413
Copyright ©
F5CE ENGINES SECTION 2 - SUPPLY 1
SECTION 2
Supply
Page
SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PIPE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SUPPLY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Supply Phase . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Delivery Phase . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Engine Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Working System . . . . . . . . . . . . . . . . . . . . . . . 9
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SUPPLY
The engine supply system consists of the following components:
- Fuel tank (aboard the vehicle)
- Fuel delivery and return pipes
- Fuel pre-filter (if fitted, it is placed nearby the engine on the vehicle’s chassis)
- Priming pump, fitted on the engine and driver by the engine camshaft
- Fuel filter (its position on the engine may vary depending on the outfit and use)
- Supply rotary pump
- Injector feed pipe (from the fuel supply pump to the fuel injectors)
- Injectors
Figure 1
119420
PIPE LAYOUT
Figure 2
118976
1. Injector feed pipe - 2. Fuel exhaust pipe from injectors - 3. Supply rotary pump - 4. Union for pressure gauge pipe within
LDA intake manifold - 5. KSB thermal bulb - 6. Solenoid valve - 7. Injector.
Copyright ©
F5CE ENGINES SECTION 2 - SUPPLY 5
Figure 3
119961
Working system description Then, the fuel reaches the valve controlling fuel pressure within
The fuel (5) is primed from the fuel tank from the priming the supply pump.
pump (6). The latter is fitted on the engine basement and is The distributor piston further increases such pressure and
driven by the engine camshaft. delivers the fuel to the injectors (1) throughout the delivery
Throughout the filter (4), fuel is conveyed to the transfer pipe fitting.
pump, which is placed inside the supply rotary pump (2), The fuel leak (3) from the injectors is recovered and sent back
which is a turbine blade pump type. The supply rotary pump to the fuel tank.
duty is to increase the fuel pressure based on the increase of
engine revolutions’ number.
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6 SECTION 2 - SUPPLY F5CE ENGINES
SUPPLY PUMP
The rotary type supply pump is driven by a gear which is coupled to the engine camshaft gear.
Figure 4
1
15
2
14
3
5
13
12
7
8
9
11
10
30454
119415
1. Fuel supply pipe - 2. Solenoid valve - 3. Axial groove - 4. Compression chamber - 5. Fuel delivery pipe from pump to
injectors - 6. Distributor piston - 7. End of delivery port - 8. Cursor - 9. Injector.
The distributor piston (6) is at B.D.C. and the cursor (8) closes the delivery port (7). The fuel is delivered to the compression
chamber (4) through the feed pipe (1) which is kept open by the solenoid valve (2).
Delivery phase
Figure 6
119416
The distributor piston (5) driven by the cam disk, goes up to the T.D.C. and simultaneously rotates on its own axle. The combination
of the two motions determines the closure of the fuel feed pipe (1) as well as the fuel compression within the chamber (2). The
distributor piston inner pipe (5) is connected to the feed pipe (4) thus enabling fuel delivery to the injectors (6).
Copyright ©
8 SECTION 2 - SUPPLY F5CE ENGINES
119417
1. Fuel feed pipe - 2. Compression chamber - 3. Fuel delivery pipe - 4. End of delivery pipe -
5. Cursor - 6. Distributor piston.
The distributor piston (6) moving towards the T.D.C. connects the high pressure inner chamber to the pipe (1), thereby establishing
pressure balance between the distributor piston inner chamber, the injectors’ delivery pipe and the pump interior.
Since such pressure is lower than the one required to start the injector, end of delivery will be determined.
Engine stop
Figure 8
119418
1. Fuel feed pipe - 2. Mobile cap - 3. Spring - 4. Solenoid valve - 5. Compression chamber.
119419
Working system
The duty of the L.D.A. device is to adjust the fuel delivery depending on the air pressure within the intake manifold.
Air pressure acts on the membrane (1), which is tied up to the setting pin (4). In the lower part of the setting pin (4) there is a
conical housing (5) in which the feeling pin runs (6).
The setting pin (4) axial motion drives the feeling pin (6) shift and the latter acts on the stop lever (7). The stop lever rotates on
its own axle (8) and acts on the control plate in order to adjust the fuel delivery depending on the air quantity within the cylinders.
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10 SECTION 2 - SUPPLY F5CE ENGINES
PRIMING PUMP
The priming pump duty is to prime the fuel from the tank and convey it to the fuel supply pump. It is fitted on the engine basement
and driven by the engine camshaft.
Figure 10
88209
FUEL FILTER
The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water from the
fuel in which it is contained.
At the bottom of the filtering cartridge there may be a water drainage device; depending on the appliance (use in cold climate
conditions), the fuel filter support may be equipped with a heater and a temperature sensor. Some versions are also equipped
with a water detecting sensor at the bottom of the cartridge filter.
Figure 11
119411
1. Fuel filter support - 2. Cartridge filter- 3. Water drainage device (not available on all versions).
Copyright ©
12 SECTION 2 - SUPPLY F5CE ENGINES
Copyright ©
F5CE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 1
SECTION 3
Industrial application
Page
MAIN SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 3
PART ONE
MECHANICAL COMPONENTS . . . . . . . . . . . 3
- Timing gearcase . . . . . . . . . . . . . . . . . . . . . . . 12
- Flywheel assembly . . . . . . . . . . . . . . . . . . . . . 14
- Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
PART TWO
ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . 23
- Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2 SECTION 3 - INDUSTRIAL APPLICATION F5CE ENGINES
Page Page
PART THREE - DIAGNOSIS ................ 32
DIAGNOSIS BY FAILURE . . . . . . . . . . . . . . . . . . . 32
PART FOUR
SCHEDULED MAINTENANCE . . . . . . . . . . . . 45
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . 47
- Servicing plan . . . . . . . . . . . . . . . . . . . . . . . . . 47
MAIN SPECIFICATIONS
N. of cylinders 4 on-line
∅
Diameter mm 99
Stroke mm 104
Max. power KW 40 48 55
(HP) (54) (65) (75)
Loadless engine
idling rpm
1150 ± 50
Loadless engine
peak rpm
2750 ± 50
Copyright ©
4 SECTION 3 - INDUSTRIAL APPLICATION F5CE ENGINES
N. of cylinders 4 on-line
∅
Diameter mm 99
Stroke mm 104
Max. power KW 57 61 65
(HP) (77) (83) (88)
Loadless engine
idling rpm
1150 ± 50
Loadless engine
peak rpm
2750 ± 50
Copyright ©
F5CE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 5
DIAGNOSI
540110 ENGINE DISASSEMBLY ON - Remove the water delivery pipe (1) from the exchanger.
BENCH - Loose the clip and disconnect the pipe (2); remove oil
delivery pipe connected to the turbocharger (3) and t
the oil return pipe (4).
NOTE Engine disassembly operations to remove the - Remove the turbocharger unit (5)
engine from the vehicle are described in the specific
section. Engine disassembly operations, as well as
engine overhaul, must be executed by qualified
engineers only, duly provided with the specific Figure 2
tools required.
Figure 1
119105
119106
118976
1. Fuel delivery pipes - 2. Fuel recovery pipes - 3. Mechanical pump - 4. LDA - 5. Wax KSB - 6. Injectors.
Copyright ©
10 SECTION 3 - INDUSTRIAL APPLICATION F5CE ENGINES
Figure 7 Figure 9
1
6 4
3
119108
119107
- Place a container under the diesel fuel filter and unscrew - Loosen the screw (1) and the relevant screw nut on the
the condense drainage faucet under said filter; belt tensioning bracket (3).
completely drain the diesel fuel container therein. - Loosen the screw (2, Figure 10) in order to withdraw the
- Disassemble the diesel fuel filter (1), the filter support belt (2).
(2), the priming pump (3), the oil filter (4), the oil filter - Remove the belt tensioning bracket (3).
support (5), and the KSB water sensor (6).
- Disassemble the pulleys and the guide rollers.
Figure 10
Warning! The oil filter contains a certain quantity of 1 2
engine oil.
Collect the engine oil and dispose it complying with
the applicable laws and regulations in force.
Figure 8
75686
122435
Figure 12 Figure 14
119110
119112
- Remove the electromagnetic joint support (1) and the - Fit tool (1) 380002385 to the flywheel box and, using a
water pump (2). wrench, lock the flywheel rotation.
- Loosen the screw (4) and remove the pulley (3). - Loosen the screws fastening the flywheel to the engine
drive shaft.
Figure 13
Figure 15
119113
119111
Timing gearcase
Figure 16
119114
- Remove the rear part (1), of the timing gearcase cover. Figure 17
119115
Figure 18 Figure 20
119130
119117
Figure 19
119118
Figure 22
119116
119119
122431
- Fit the specific tool 99346259 (5) to the rear shank (6)
SCHEME FOR THE APPLIANCE OF LOCTITE 5699 of the engine drive shaft, fix it with the screws (4) and
SEALER ON THE TIMING GEARCASE spline the new grommet (3) thereon.
- Accurately clean the timing gearcase and the engine - Position part (1) on part (5), tighten the screw nut (2)
basement. until the grommet has been fitted (3) into the flywheel
casing (7).
119113
Figure 26 Figure 28
119463 119127
119117
Timing Figure 30
Figure 29
119126
- Seize the 45˚ bevel tooth (1) of the engine drive shaft
gear with the timing gear tooth marked with two Figure 31
notches (2), as shown in the figure.
- Rotate the camshaft keeping the timing gear fix until the
camshaft’s pin fits into the relevant housing within the
timing gear.
- Screw the screws of the transmission gear without fully
tightening them.
- With magnetic base comparator, check the clearance
among the engine shaft gear and the cam shaft gear: it
must be 0.068 ÷ 0.168 mm.
- Screw the fastening screws (1) of the transmission gear.
119461
- Fit the inner part of tool to the front shank of the engine
drive shaft. Make sure that the engine drive shaft pin is
correctly fitted into the tool spline in order to avoid
damaging it. Fix it with the screw (1) and spline the new
grommet thereon.
- Place the outer section of the tool on the previously
fitted one, tighten the screw nut (2) until completely
fitting the grommet (3) into the casing.
Copyright ©
F5CE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 17
Figure 32 Figure 34
70221
119573
Figure 35
119462
Figure 36 Figure 38
122432
- Fit the discharge manifold (3) provided with new seal (2)
and tighten the nuts (1) with studs applying the required
- Reassemble the electromagnetic joint support (1). torque..
- Reassemble the pulley (2). Figure 39
- Reassemble the pulley (3), tighten the fastening screw
(4) to the prescribed torque setting.
- Reassemble the heat exchanger reminding to replace the
old gasket with a new one; tighten the fastening screws
to the prescribed torque setting.
Figure 37
32655
Before reassembly, check that the rocker arm rods must not
be deformed; there must be no trace of wear or seizure on
the spherical housings of the rocker arm adjusting screws as
well as on the tappets (pointers); otherwise these parts must
be replaced. The suction valve rods are identical and
therefore interchangeable.
- Fit the control rods in their housing.
Figure 40
119108
119119
- Fit the rocker arm positioning the equalizer couples: the
suction equalizer first (short rod) and then the exhaust
equalizer (long rod) (2).
- Tighten the fastening screw (1).
Copyright ©
F5CE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 19
Figure 41 Figure 43
119128
- Make the holes (1) for fuel exhaust all face the same
direction.
Figure 44
1
119111
6 4
- Replace the gaskets (3), reassemble the rocker arm 3
holding case (2) and tighten the fastening screws to the
prescribed torque setting. 119107
- After having completed the assembly, check that the - Reassemble the KSB water temperature sensor (6), the
rocker arms are correctly positioned on the valves and oil filter support (5), the priming pump (3), the diesel fuel
the tappet control rods. filter support (2), the fuel filter (1) and the oil filter (4).
Figure 42 Figure 45
119122
119905
- Reassemble the injectors (2) replacing the grommets.
Tighten the fastening screws(1) to the prescribed torque - Fit the head covers (1) replacing the gaskets (2).
setting.
Copyright ©
20 SECTION 3 - INDUSTRIAL APPLICATION F5CE ENGINES
Figure 46 Figure 48
119716
119105
- Reassemble the fuel exhaust pipes (1).
- Reassemble the pipe from the pump to the injector and
tighten the brackets’ fastening screws (3).
- Reassemble the pipe from the pump to the fuel filter (2)
and from the fuel filter to the priming pump (1).
Figure 47 - Reassemble the L.D.A. pipe
Figure 49
119116
119124 Figure 50
119123
Figure 51 Figure 53
119130
- Assemble the oil pan (1) and fit the plate thereon (3).
Tighten the fastening screws (2) to the prescribed
torque setting. 119904
NOTE Before assembly, check that the port threads and - Reassemble the turbocharger (5) unit.
the gaskets show no trace of wear or dirt. - Reassemble the pipe (2) and fit the clip in the correct
housing.
- Reassemble the oil delivery pipe (3) and the return pipe
(4).
Figure 52
Figure 54
122434
Figure 1
CABLE FOR ENGINES WITH EXTERNAL EGR SYSTEM
Copyright ©
SECTION 3 - INDUSTRIAL APPLICATION
88313
1. Water temperature sensor - 2. Air temperature pressure sensor - 3. EGR Valve - 4. Engine drive shaft evolutions sensor - 5. Sectioning
25
26
Figure 2
SECTION 3 - INDUSTRIAL APPLICATION
20000. Starter battery - 25201. Remote control for pre-heating switch - 48035. Engine rev. no. sensor - 52502. Key commutator for services with start - 61121.
Resistor for engine pre-heating - 58101. Pre-heating (on) warning light - 58105- Engine high water temperature warning light - 58484. Diagnosis warning light -
47034. Engine water temperature sensor for EGR - 78029. EGR solenoid valve - 86020. EGR E.C.U. - 85156. Air pressure temperature sensor.
F5CE ENGINES
119452
Copyright ©
Copyright ©
F5CE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 27
EGR E.C.U.
Figure 3
119453
Technical specifications.
Manufacturer Bitron
Rated Voltage 13.5 V
Actual Voltage 10 ÷ 16 V
Working temperature -30 ÷ 100 ˚C
Maximum current input <5 A
EGR valve control signal PWM 140 ± 7 Hz
Copyright ©
28 SECTION 3 - INDUSTRIAL APPLICATION F5CE ENGINES
120035
Figure 2
119454
Characteristics
Working temperature range
- Connector’s side -40 ˚C ÷ 130 ˚C; 150 ˚C for periods < 10 min.
- Bulb’s side on engine -40 ˚C ÷ 140 ˚C
Voltage 6 ÷ 28 V
Copyright ©
F5CE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 31
75722
Characteristics
Voltage: 12 ÷ 24 V
Contact closure
with decreasing pressure: 0.2 bar
Contact opening
with increasing pressure: 0.9 bar
Copyright ©
32 SECTION 3 - INDUSTRIAL APPLICATION F5CE ENGINES
ELECTRICAL LAYOUT
119455
Characteristics.
Contact closing temperature 65 ÷ 5 ˚C
Maximum load on contacts Max 15A
Copyright ©
F5CE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 33
Figure 5
Mass
NTC
+5 V
Output signal (pressure)
119455
Copyright ©
34 SECTION 3 - INDUSTRIAL APPLICATION F5CE ENGINES
Pin 25 E.C.U.
Pin 23 E.C.U.
Pin 24 E.C.U.
119457
Torque setting 10 ± 2 Nm
Copyright ©
F5CE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 35
119458
Figure 8
119459
Starter Figure 9
Manufacturer BOSCH
Electrical system 12 V
Rated output 3 kW
119464
Figure 10
119460
Copyright ©
F5CE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 37
NOTE
The engine does not start Discharged of damaged battery Check the battery and recharge it.
F5CE ENGINES
Deposits or water presence in the fuel Disconnect the pipes and clean them Always bleed the supply sys-
tank with compressed air jet. Disassemble the tem.
ignition pump and clean it. Eliminate any
presence of water in the fuel tank and
refuel.
Insufficient fuel reserve Refuel
No supply Overhaul or replace the supply or
transfer pumps
Air bubbles in the fuel pumps or in the Check the pipes to ascertain the cause of
ignition pump air presence and the supply pump. Elimin-
ate any air from the ignition pump interior
loosing the specially provided cap and
manually operating the supply pump.
Defective starter Repair or replace the starter
In case of EGR system failure, its operation is disabled and the related EGR failure indicator lamp flashes (if
Copyright ©
Incorrect adjustment of the tie rods con- Adjust the tie rods in order to be able to
necting the accelerator pedal and the take the control lever to maximum deliv-
regulator’s lever. ery position.
Anomalous engine strokes Defective injectors. Replace the injectors.
Obstructed fuel pipes. Disassemble the pipes, clean them and
replace those that are seriously dented.
Ignition pump incorrect setting. Correct the pump setting so that ignition Apply to CNH Technical Service
may be carried out according to the pre-
scribed spark lead angle.
F5CE ENGINES
Copyright ©
POSSIBLE ROOT CAUSE RECOMMENDED TESTS
FAILURE NOTES
(*) = if applicable to the appliance OR REMEDY
Anomalous engine strokes Engine strokes cause excessive slack of Grind the engine drive shaft pins and fit
F5CE ENGINES
one or more crankshaft bearings or big undersize bearings. Replace the thrust
end bearings or excessive shoulder slack. bearing half rings.
Unbalanced engine drive shaft. Check the engine drive shaft alignment.
Loose flywheel fastening screws. Replace the loose screws and tighten
them to the prescribed torque setting.
Connecting rod misalignment. Replace the connecting rod.
Noisy piston pins for excessive slack of Replace the piston pin and/or the piston
piston hubs and connecting rod bush. and the connecting rod bush.
Loose bushes in their housing on the con-
necting rod.
Noisy timing Adjust the slack between camshaft and
tappet and check there are no broken
springs. Furthermore, check that the slack
between valve stems and valve guides as
well as tappets an relevant seat.
Anomalous engine fumes. Black or dark Excessive pump maximum delivery. Disconnect the pump and adjust its deliv- Apply to CNH Technical Service
grey fumes. ery referring to the calibration table of the
screw nuts.
Defective or incorrectly adjusted K.S.B. Adjust the ignition pump or replace it. Apply to CNH Technical Service
device.
The ignition pump is excessively delayed Correct setting, check the spark lead
(or spark lead changing device is defec- changing device.
tive).
Copyright ©
SCHEDULED MAINTENANCE
Servicing Plan
Engine lubrication frequency has been calculated presuming the use of fuel with content of Sulphur < 0.5%.
! WARNING! In case of use of fuel containing a percentage of Sulphur e > 0.5 %, the engine oil replacement interval must
be halved.
SECTION 4
Mechanical overhaul
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . 10
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 15
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Page Page
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
GENERAL SPECIFICATIONS
Type 4 CYLINDERS
Number of cylinders 4
∅
Bore mm 99
Stroke mm 104
TIMING
Checking timing
mm 0.25 ± 0.05
X
mm 0.50 ± 0.05
X
Checking operation
mm 0.20 to 0.40
X
mm 0.45 to 0.65
FUEL FEED
Injection
Type: Bosch VE 4/12F
Type 4 CYLINDERS
∅1 0.4
Spare pistons
∅1 type:
X Size X 10
2 Outside diameter ∅1 98.908 to 98.918
∅ Pin housing ∅2 36.003 to 36.009
Piston — cylinder barrels 0.082 to 0.112
X
Piston protrusion X -0.22 ÷ +0.07
Type 4 CYLINDERS
∅1 Crankshaft bearing
bush seat ∅1 39.460 to 39.49
Big end bearing seat
X 67.833 to 67.841
∅ 2 0 67.842 to 67.848
Type 4 CYLINDERS
Maximum error on
parallelism of
connecting rod axles 0.09
∅1 ∅2
Crankshaft bearing pins
No. 1-2-3-4 ∅1 76.182 to 76.208
No. 5 ∅1 83.182 to 83.208
Big end bearing pins ∅2 64.015 to 64.038
S 1 S 2
Crankshaft half bearings S 1 2.165 to 2.174
Big end half
bearings S2 1.876 to 1.883
Crankshaft supports
∅ 3 No. 1-2-3-4 ∅3 80.588 to 80.614
No. 5 ∅3 87.588 to 87.614
X 1
X 2
X 3
Shoulder half-rings X3 2.51 to 2.56
Type 4 CYLINDERS
∅ 2
∅2 0.023 to 8.038
Valve guides
∅3 12.950 to 12.985
∅ 3
∅ 4 Valves:
∅4 7.985 to 8.000
α 60˚ 30’ ± 0˚ 10’
∅4 7.985 to 8.000
α α 60˚ 30’ ± 0˚ 10’
Valve stem and guide 0.040 to 0.053
Valve seat on cylinder
head
∅1 39.987 to 40.013
∅ 1 ∅1 43.787 to 43.813
∅2 40.863 to 43.88
α
α 60˚ ± 1˚
X 0.3 to 0.7
0.050 to 0.101
Between valve seat
and head 0.050 to 0.101
Valve seats -
Copyright ©
8 SECTION 4 - MECHANICAL OVERHAUL F5CE ENGINES
Type 4 CYLINDERS
Bush inside
∅ diameter ∅5 54.083 to 54.147
H H 5.5105
H 6.213
Copyright ©
F5CE ENGINES SECTION 4 - MECHANICAL OVERHAUL 9
Type 4 CYLINDERS
∅2
∅ 3 Tappet cap outside
diameter: ∅2 15.924 to 15.954
∅3 15.960 to 15.975
∅2
Between tappets and housings 0.03 to 0.068
Tappets -
∅ 1
Rocker shaft ∅1 18.979 to 19.000
∅ 2
Between rockers and shaft 0.020 to 0.054
Copyright ©
10 SECTION 4 - MECHANICAL OVERHAUL F5CE ENGINES
119546
Figure 1 The third (central) main bearing cap (1) and associated
support have a bearing-half (2) equipped with thrust.
Figure 4
70158
119547
Figure 5
119545 120173
Disassemble the crankshaft half bearings (1).
Loosen the screws (1) and disassemble the crankshaft bearing Loosen the fastening screws (2) and disassemble the oil
caps (2). nozzles (3).
Copyright ©
F5CE ENGINES SECTION 4 - MECHANICAL OVERHAUL 11
zs
Figure 6 REPAIRS
CYLINDER UNIT
Checks and measurements
Figure 9
119548
NOTE Note down the plate assembly position (2). Once completed the engine disassembly, carefully clean the
cylinder-crankcase units.
Use suitable eyebolts to handle the cylinder unit. Carefully
check the crankcase has for cracks. Check the conditions of
the processing caps: replace them if oxidized or in case their
Figure 7 tight is doubtful. Check the surface of the cylinder barrels:
there must be no trace of meshing, scratches, oval or conical
shaping and excessive wear.
Cylinder barrel inner diameter check to detect any oval or
conical shaping or wear shall be executed throughout the
bore meter (1) equipped with comparator, which must be
previously be reset on the ring calliper (2) of the cylinder
barrel diameter.
119549
Figure 10
Carefully withdraw the camshaft (1) from the engine bock.
Figure 8
70167
The measurements must be made for each cylinder, at three
different heights from the barrel and on two perpendicular
planes: one parallel to the engine longitudinal axle (A) and the
other perpendicularly (B). Generally, maximum wear is
detected on the perpendicular plane (B) and with the first
measurement.
If oval or conical shaping or wear is detected, proceed boring
and grinding the cylinder barrels. Cylinder barrel grinding
70165
must be executed based on the spare pistons’ diameter plus
0,4 mm of the rated value and at the prescribed assembly
Withdraw the tappets (1) from the engine bock. slack.
Copyright ©
12 SECTION 4 - MECHANICAL OVERHAUL F5CE ENGINES
119550
TIMING SYSTEM
Camshaft
Figure 12
119551
Figure 13
70172
70171
Figure 15
119552
70176
70174
Lubricate the tappets (1) and fit them into the relevant seats
Use the beater 380000667 (2) and handgrip 380000999 (3) on within the crankcase.
to disassemble and replace the bush (1).
Figure 19
119549
119554
119553 Position the camshaft (3) holding plate (1) with the slot
towards the upper side of the crankcase and the marking
TAPPET AND RELEVANT SEAT ON CRANKCASE towards the operator; tighten the fastening screws (2) to the
MAIN DATA prescribed torque setting.
Copyright ©
16 SECTION 4 - MECHANICAL OVERHAUL F5CE ENGINES
119555
70180
Fit the nozzles (2) and tighten the fastening screws (1) to the NOTE The main journals and crankshaft bearing pins must
prescribed torque setting. always be grinded to the same undersize classes in
order not to alter the shaft’s balance.
Figure 24
119556
Figure 25
119558
ENGINE DRIVE SHAFT MAIN TOLERANCES
119574
Copyright ©
18 SECTION 4 - MECHANICAL OVERHAUL F5CE ENGINES
Figure 26 Figure 27
70185 119547
NOTE If it is not necessary to replace the crankshaft Assemble the engine drive shaft (2).
bearings, these shall be reassembled in the same
order and position they were before disassembly. Check the slack between the engine drive shaft main journals
and the respective crankshaft bearings proceeding as follows:
Figure 28
The spare crankshaft bearings (1) have undersize internal
diameter of 0.254 - 0.508 mm.
119962
Figure 32
70187
119559
- 3rd phase using tool 380000304 (1) fitted as shown in
the figure and further tighten the screws (2) by 90º ± 5º
angle. CONNECTING ROD — PISTON ASSEMBLY
Figure 31
Figure 33
119560 70191
- Remove the caps from their support.
The slack between the crankshaft bearings and the relevant CONNECTING ROD-PISTON UNIT COMPONENTS
pins should be detected comparing the width measured by
the gauge wire (2) in the point of maximum flattening with 1. Grommets. - 2. Pin. - 3. Piston. - 4. Snap rings. - 5.
the scale graduation reported on the shield (1) of the gauge Screws - 6. Half bearings. - 7. Connecting rod. - 8. Bush.
wire.
The numbers reported on the scale indicate the coupling
slack in millimetres.
If the slack detected differs from the prescribed value, replace NOTE The spare pistons are supplied with standard
the half bearings and repeat the measurement; once
achieving the slack prescribed, lubricate the crankshaft dimensions or oversize by 0.4 mm.
bearings and finally assemble the supports tightening the
fastening screws as described previously.
Copyright ©
20 SECTION 4 - MECHANICAL OVERHAUL F5CE ENGINES
Figure 34 Pistons
Piston diameter measurement
Figure 37
32613
32615
Using pincers 380000221 (3), remove the snap rings (1) from Using the micrometer (2), measure the piston diameter (1)
the piston (2). to determine the assembly slack.
Figure 38
32614
Remove the piston pin (1) grommet using the nail (3).
70192
119561
18857 32620
Measurement of the piston pin diameter (1) throughout a Check the slack between the grommets (3) of the 2nd and
micrometer (2). 3rd slots and relevant housing on the piston (2) using calliper
Conditions for the correct coupling of pins and and gauges (1).
pistons
Figure 40 Figure 43
32619
41104
Lubricate the pin (1) and its seat on piston hubs with engine SCHEME FOR THE MEASUREMENT OF SLACK
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 GROMMET
SCHEME FOR THE MEASUREMENT OF SLACK
BETWEEN THE FIRST PISTON SLOT AND THE
Split rings TRAPEZOIDAL GROMMET
Figure 41 Due to the particular for of the first grommet, having
trapezoidal section, the slack between said grommet and the
slot must be measured as follows: the piston (1) must be
projected from the crankcase so that nearly half of the
grommet (2) in question comes out of the cylinder barrel (3).
In this position, using a gauge calliper, measure the slack (X)
between grommet and slot: the slack must comply with the
prescribed value.
16552
Figure 44 Figure 46
70194
Connecting rods
Figure 45 119563
119562
Bushes Figure 49
Check that the connecting rod shoe bush is not loose and
that there is no trace of meshing or scratches otherwise
replace it.
Disassembly and reassembly must be executed using a
suitable beater.
When fixing it, make sure that the ports for oil passage on the
bush and on the connecting rod coincide. Throughout a
boring machine, bore the bush in order to obtain the
prescribed diameter.
119564
Use the pincers 380000221 (3) to fit the snap fasteners (1)
to the piston (2).
Figure 48 The snap rings must be fitted with ”TOP” marking upwards.
Furthermore, ring opening must be misaligned by 120º.
119565
Figure 51 Figure 53
119566
NOTE if it is not necessary to replace the big end bearings, - all the connecting rod/piston units must have the same
weight;
reassemble the existing ones in the same order and
position they were before disassembly. - the engine drive shaft sign (1) printed on the piston
Do not adapt the half bearings. crown must be turned towards the flywheel while the
notch on the piston shield must match the oil nozzles’
position.
Figure 54
Figure 52
70203
Figure 55 In case the slack measured differs from the prescribed value,
replace the half bearings and measure the slack again.
α
NOTE See page 17 of Section 3.
70204
Figure 56
70205
Figure 57
70206
Figure 58
119567
The intake valves (1) and exhaust valves (2) have different Repeat the operation in correspondence of each valve.
head diameter. Turn the cylinder head upside down and withdraw the valves
(5).
Figure 60
NOTE Number the valves before removing them from the
cylinder head in order to be able to reassemble
them in the same order in case replacement is not
necessary.
A = intake side
119568
Figure 61
119569
119591
INTAKE AND EXHAUST VALVE MAIN DATA
18625
Figure 64
18882
INTAKE EXHAUST
119570
VALVE SEATS
Figure 66
122433
If the valve seat are damaged replace them with the spare Heat cylinder head up to 80º ÷ 100ºC and with the beater
ones included in the supply. With the tools and being careful assemble the new valve seats previously cooled in them.
not to indent the cylinder heads, remove as much material
as possible form the valve seats until removal from cylinder
head is possible by means of a punch.
Copyright ©
F5CE ENGINES SECTION 4 - MECHANICAL OVERHAUL 29
50676
Figure 69
119567
Place the spring (4) and the upper plate (3) on the cylinder
head. Using tool 380000302 (1), compress the spring (4) and
constrain the parts to the valve (5) throughout the half cones
(2).
Copyright ©
30 SECTION 4 - MECHANICAL OVERHAUL F5CE ENGINES
119573
TORQUE SETTING
TORQUE
DESCRIPTION
Nm kgm
Crankshaft caps
- pre-tightening 50 ± 5 5 ± 0.5
- tightening 80 ± 5 8 ± 0.6
ockk
TORQUE
DESCRIPTION
Nm kgm
Intake manifold fastening (M8x1 .25 6g x 60) 25 ± 5 2.5 ± 0.5
maanifoldld
Inntakee
35 ± 5
Exhaaust
- pre-tightening 50 ± 5 5 ± 0.5
ect
- tightening 30 ± 5 3 ± 0.5
Pipe fixing on manifold side 20 ± 5 2 ± 0.5
LDA
DA
TORQUE
DESCRIPTION
Nm
Water pipe fixing to the heat exchanger 25 ± 5 2.5 ± 0.5
oolinng
pipee
Water pipe fixing to the support 25 ± 5 2.5 ± 0.5
p
Co
- tightening 90 ± 5 9 ± 0.5
Fuel pump fixing (screw nuts) 25 ± 5 2.5 ± 0.5
Copyright ©
34 SECTION 4 - MECHANICAL OVERHAUL F5CE ENGINES
Copyright ©
F5CE ENGINES SECTION 5 - TOOLS 1
SECTION 5
Tools
Pagina
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Copyright ©
2 SECTION 5 - TOOLS F5CE ENGINES
Copyright ©
F5CE ENGINES SECTION 5 - TOOLS 3
TOOLS
TOOL No. DEFINITION
380000220 Ring for plunger introduction into the cylinder barrel (60 ÷ 125 mm)
Pair of measuring devices for angular tightening with 1/2“ and 3/4”
380000304 square coupling
Rotary stand for overhauling units (capacity 1000 daN, torque 120
380000978 daNm)
380100072 Puller for the gear coupling the injection pump to the engine
Copyright ©
6 SECTION 5 - TOOLS F5CE ENGINES
380100075 Shrink fitter for the assembly of the drive shaft front gasket
380100076 Shrink fitter for the assembly of the drive shaft rear gasket
Copyright ©
F5CE ENGINES APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . . . 3
Copyright ©
2 APPENDIX F5CE ENGINES
Copyright ©
F5CE ENGINES APPENDIX 3
Section
General information 1
Supply 2
Industrial appliance 3
Tools 5
SECTION 1
General
Page
TECHNICAL CODING . . . . . . . . . . . . . . . . . . . . . 3
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Working system . . . . . . . . . . . . . . . . . . . . . . . 13
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . 14
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . . . 15
TECHNICAL CODING
Technical Code
F5AE9484A
F5AE9484B
F5AE9484G
F5AE9454A
F5AE9454G
TECHNICAL DESIGNATION
F 5 A E 9 4 8 4 A * A 0 0 1 -
Number of cylinders
5 - External EGR
9 - Internal EGR
Engine (invariable) A 48 kW / 2300 rpm
B 57 kW / 2300 rpm
Engine family evolution (also irrespective of the displacement)
G 65 kW / 2300 rpm
ENGINE VIEWS
Figure 1
120013
Figure 2
120014
Figure 3
120015
Figure 4
120016
Figure 5
120017
LUBRICATION The lubrication system also comprises the heat exchanger, the
centrifugal blower for the versions with turbosupercharger
Forced circulation lubrication is controlled by the rotor oil and eventually the compressor if the compressed air system
pump housed in the front part of the engine basement and is also fitted.
driven by the toothed gear splined on the shank of the engine
drive shaft. All the above mentioned components vary depending on their
use and therefore will be illustrated in the specific section.
From the oil pan, the lubrication oil is distributed to the engine
drive shaft, the camshaft and the valve control.
Figure 6
Pressurized oil
Dropping oil
120007
Oil pump
Figure 7
119405
PUMP SPECIFICATIONS
Rotating speed 750 rpm - 4200 rpm
Feed pressure 2 Bar - 4 Bar
Rated flow 12.2 l/min - 75.9 l/min
Oil type SAE 20/30
Max oil temperature 80 °C
1. Main gear - 2. Secondary gear - 3. Pump unit - 4. Drive shaft - 5. Secondary shaft
6. Cover - 7. Internal rotor - 8. External rotor - 9. Bush
Copyright ©
F5AE ENGINES SECTION 1 - GENERAL SPECIFICATIONS 9
119717
1. Reference notches for alignment and timing - 2. Balancing masses -3. Bushes - 4. Shouldering fifth wheels - 5. Shaft - 6. Box.
Copyright ©
10 SECTION 1 - GENERAL SPECIFICATIONS F5AE ENGINES
119406
Figure 10
119407
COOLING SYSTEM - heat exchanger cooling the lubricant oil. This component
may vary depending on the specific engine fitting.
The closed circuit forced circulation engine cooling system is
composed of the following parts: - centrifugal water pump positioned in the front part of the
engine basement;
- expansion tank: position, form and dimensions may vary
depending on the engine fitting. - thermostat controlling cooling liquid circulation.
- radiator dissipating the heat absorbed by the engine
cooling liquid. This component’s position and dimensions
may vary depending on the outfit.
- fan increasing the radiator’s cooling power. This
component may vary depending on the specific engine
fitting.
Figure 11
Closed thermostat
Open thermostat
Water inflow
120018
WATER PUMP
Figure 12
120047
THERMOSTAT
Figure 13
119412
THERMOSTAT DIAGRAM
Working system
When the engine is cool, water output from the front part of the cylinder head flows into an inlet containing the thermostat, which
cuts out water circulation to the radiator. This way, water circulation will only be possible in the pump-engine circuit, insofar allowing
engine heat-up quickly. The thermostat valve starts opening at nearly 80 ˚C, allowing water circulation into the radiator and also
obstructing direct return towards the engine. Check the thermostat efficiency and replace it in case of doubtful functioning.
1. Stroke starts at 79˚ ± 2 ˚C
2. 7 mm stroke at 94˚±2˚C
Copyright ©
14 SECTION 1 - GENERAL SPECIFICATIONS F5AE ENGINES
HEAT EXCHANGER
Figure 14
SECTION A-A
SECTION B-B
119408
The heat exchanger within the engine cooling system has the duty to control the engine oil temperature, reducing it by absorbing
heat throughout the engine cooling liquid.
Copyright ©
F5AE ENGINES SECTION 1 - GENERAL SPECIFICATIONS 15
TURBOCHARGING
The turbocharging system is composed of the following parts:
- air filter;
- turbosupercharger.
Figure 15
Sucked air
INTERNAL EGR
The specific design of suction cams of the internal EGR system allows part of exhaust gas to be recycled to engine cylinders.
This type of EGR, called internal EGR, is not equipped with any electronic control, the system is always active. Its configuration
requires no additional parts such as control valves, pipelines or heat exchangers therefore engine profile remains unchanged.
Besides main lobe, suction cam has an additional lobe as to configuration without EGR. During concerned cylinder exhaust phase,
this lobe allows a shaft advanced opening of intake valve. In this way, part of the exhaust gas is trapped in the suction duct and later,
during cylinder suction phase, this gas is recycled to cylinder inlet for combustion phase.
114026
Copyright ©
F5AE ENGINES SECTION 2 - SUPPLY 1
SECTION 2
Supply
Page
SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PIPE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SUPPLY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Supply phase . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Delivery phase . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Working system . . . . . . . . . . . . . . . . . . . . . . . 9
PRIMING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SUPPLY
The engine supply system consists of the following components:
- Fuel tank (aboard the vehicle)
- Fuel delivery and return pipes
- Fuel pre-filter (if fitted, it is placed nearby the engine on the vehicle’s chassis)
Priming pump, fitted on the engine and driver by the engine camshaft
- Fuel filter (its position on the engine may vary depending on the outfit and use)
- Supply rotary pump
- Injector feed pipe (from the fuel supply pump to the fuel injectors)
- Injectors
Figure 1
119420
PIPE LAYOUT
Figure 2
118976
1. Injector feed pipe - 2. Fuel exhaust pipe from injectors - 3. Supply rotary pump - 4. Union for pressure gauge pipe within
LDA intake manifold - 5. KSB thermal bulb - 6. Solenoid valve - 7. Injector
Copyright ©
F5AE ENGINES SECTION 2 - SUPPLY 5
Figure 3
119961
The fuel (5) is primed from the fuel tank from the priming Then, the fuel reaches the valve controlling fuel pressure within
pump (6). The latter is fitted on the engine basement and is the supply pump.
driven by the engine camshaft.
The distributor piston further increases such pressure and
Throughout the filter (4), fuel is conveyed to the transfer delivers the fuel to the injectors (1) throughout the delivery
pump, which is placed inside the supply rotary pump (2), pipe fitting.
which is a turbine blade pump type. The supply rotary pump
The fuel leak (3) from the injectors is recovered and sent back
duty is to increase the fuel pressure based on the increase of
to the fuel tank.
engine revolutions’ number.
Copyright ©
6 SECTION 2 - SUPPLY F5AE ENGINES
SUPPLY PUMP
The rotary type supply pump is driven by a gear which is coupled to the engine camshaft gear.
Figure 4
1
15
2
14
3
5
13
12
7
8
9
11
10
30454
119415
1. Fuel supply pipe - 2. Solenoid valve - 3. Axial groove - 4. Compression chamber - 5. Fuel delivery pipe from pump to
injectors - 6. Distributor piston - 7. End of delivery port - 8. Cursor - 9. Injector.
The distributor piston (6) is at B.D.C. and the cursor (8) closes the delivery port (7). The fuel is delivered to the compression
chamber (4) through the feed pipe (1) which is kept open by the solenoid valve (2).
Delivery phase
Figure 6
119416
The distributor piston (5) driven by the cam disk, goes up to the T.D.C. and simultaneously rotates on its own axle. The combination
of the two motions determines the closure of the fuel feed pipe (1) as well as the fuel compression within the chamber (2). The
distributor piston inner pipe (5) is connected to the feed pipe (4) thus enabling fuel delivery to the injectors (6).
Copyright ©
8 SECTION 2 - SUPPLY F5AE ENGINES
119417
1. Fuel feed pipe - 2. Compression chamber - 3. Fuel delivery pipe - 4. End of delivery pipe -
5. Cursor - 6. Distributor piston.
The distributor piston (6) moving towards the T.D.C. connects the high pressure inner chamber to the pipe (1), thereby establishing
pressure balance between the distributor piston inner chamber, the injectors’ delivery pipe and the pump interior.
Since such pressure is lower than the one required to start the injector, end of delivery will be determined.
Engine stop
Figure 8
119418
1. Fuel feed pipe - 2. Mobile cap - 3. Spring - 4. Solenoid valve - 5. Compression chamber.
119419
Working system
The duty of the L.D.A. device is to adjust the fuel delivery depending on the air pressure within the intake manifold.
Air pressure acts on the membrane (1), which is tied up to the setting pin (4). In the lower part of the setting pin (4) there is a
conical housing (5) in which the feeling pin runs (6).
The setting pin (4) axial motion drives the feeling pin (6) shift and the latter acts on the stop lever (7). The stop lever rotates on
its own axle (8) and acts on the control plate in order to adjust the fuel delivery depending on the air quantity within the cylinders.
Copyright ©
10 SECTION 2 - SUPPLY F5AE ENGINES
PRIMING PUMP
The priming pump duty is to prime the fuel from the tank and convey it to the fuel supply pump. It is fitted on the engine basement
and driven by the engine camshaft.
Figure 10
88209
FUEL FILTER
The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water from the
fuel in which it is contained.
At the bottom of the filtering cartridge there may be a water drainage device; depending on the appliance (use in cold climate
conditions), the fuel filter support may be equipped with a heater and a temperature sensor. Some versions are also equipped
with a water detecting sensor at the bottom of the cartridge filter.
Figure 11
119411
1. Fuel filter support - 2. Cartridge filter- 3. Water drainage device (not available on all versions).
Copyright ©
12 SECTION 2 - SUPPLY F5AE ENGINES
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 1
SECTION 3
Industrial appliance
Page
MAIN SPECIFICATIONS . . . . . . . . . . . . . . . . . . 3
PART ONE -
MECHANICAL COMPONENTS . . . . . . . . . 5
- Timing gearcase . . . . . . . . . . . . . . . . . . . . . . . 11
- Flywheel assembly . . . . . . . . . . . . . . . . . . . . . 13
- Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS BY FAILURE . . . . . . . . . . . . . . . . . 33
SCHEDULED MAINTENANCE . . . . . . . . . . . . . 41
- Servicing plan . . . . . . . . . . . . . . . . . . . . . . . . . 41
MAIN SPECIFICATIONS
N. of cylinders 4 on-line
∅
Diameter mm 99
Stroke mm 104
Max. power KW 44 48 55
(HP) (60) (65) (75)
Loadless engine
idling rpm
1150 ± 50
Loadless engine
peak rpm
2750 ± 50
Copyright ©
4 SECTION 3 - INDUSTRIAL APPLICATION F5AE ENGINES
N. of cylinders 4 on-line
∅
Diameter mm 99
Stroke mm 104
Max. power KW 57 65
(HP) (77) (88)
Loadless engine
idling rpm
1150 ± 50
Loadless engine
peak rpm
2750 ± 50
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 5
DIAGNOSI
119720
NOTE Before fitting the engine on the rotary stand
380000978, disassemble the parts which may - Remove the L.D.A. pipe. Remove the fast clutch fuel
interfere with the bracket assembly. Depending on pipes from the priming pump to the filter (1) and from
the appliance, it may be necessary to remove the the filter to the ignition pump (2), then fit the specially
starter and the oil filter. provided caps to the pipes, the pumps and the filter.
Unscrew the screws (3), fastening the fuel ignition pipes
- Drain the engine oil from the oil pan collecting it in a and remove them.
suitable container.
Figure 3
Warning! Avoid skin contact with the engine oil: in
case of contact wash your skin with running water.
Figure 1
119106
NOTE Before removing the pump verify if, for the model
used, a shaft block system exists. In that case, block
the engine by means of the specific tool in the
corresponding position, to the TDC of cylinder 1,
119718 (at compression end, as shown in the procedure at
- Remove oil delivery pipe connected to the turbocharger page 19). Now block with the specific system the
(3) and t the oil return pipe (1). pump shaft; this way the pump should be timed, so
that when refitting (if no maintenance intervention
- Remove the turbocharger unit (2). is required on it) no adjustment is necessary.
- Duly hold the starter (5), unscrew the fastening screws
and remove the starter.
- Remove the water hose (4).
Copyright ©
8 SECTION 3 - INDUSTRIAL APPLICATION F5AE ENGINES
zl
118976
1. Fuel delivery pipes - 2. Fuel recovery pipes - 3. Mechanical pump - 4. LDA - 5. Wax KSB - 6. Injectors.
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 9
Figure 5 Figure 7
120021
119721
- Place a container under the diesel fuel filter and unscrew - Loosen the screw (1) and the relevant screw nut on the
the condense drainage faucet under said filter; belt tensioning bracket (3).
completely drain the diesel fuel container therein. - Loosen the screw (2, Figure 8) in order to withdraw the
belt (2).
- Disassemble the diesel fuel filter (1), the filter support
(2), the priming pump (3), the oil filter (4), the oil filter - Remove the belt tensioning bracket (3).
support (5), and the KSB water sensor (6). - Disassemble the pulleys and the guide rollers.
Figure 8
Figure 6
119722
120020
Figure 10 Figure 12
119112
119723
Figure 11
Figure 13
119724
119111
Timing gearcase
Figure 14
119725
119115
Figure 16 Figure 18
119726
119117
Figure 17
1
119118
120148
119119
119729
119731
Figure 24 Figure 26
119732 119733
119117
- Assemble the oil pump (2).
- Screw the fastening screws (1) without fully locking
them.
- With magnetic base comparator, check the clearance
among the engine shaft gear and the oil pump gear: it
must be 0.068 ÷ 0.168 mm.
- Fully tighten the fastening screws (1).
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 15
Timing Figure 28
Figure 27
119735
119734
Figure 29
- Seize the 45˚ bevel tooth (1) of the engine drive shaft
gear with the timing gear tooth marked with two
notches (2), as shown in the figure.
- Rotate the camshaft keeping the timing gear fix until the
camshaft’s pin fits into the relevant housing within the
timing gear.
- Screw the screws of the transmission gear without fully
tightening them.
- With magnetic base comparator, check the clearance
among the engine shaft gear and the cam shaft gear: it
must be 0.068 ÷ 0.168 mm.
- Screw the fastening screws (1) of the transmission gear.
119736
Figure 30 Figure 32
70221
Figure 33
119462
119115
Piston projection Engine gasket thickness
from basement B A
(
(mm)) NOTE Always use new screws for assembly.
Thickness (mm)
From 0.07 to -0.07 0.80
- Place the head (3) on the block taking the centring pins
From -0.08 to -0.22 0.70 as a reference.
- Measure the piston projection and refer to the table - Lubricate the head fastening screws (2) and tighten them
above to select the appropriate thickness of the gasket. to the prescribed torque wrench.
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 17
Figure 34 Figure 36
122432
Figure 35
32655
Before reassembly, check that the rocker arm rods must not
be deformed; there must be no trace of wear or seizure on
the spherical housings of the rocker arm adjusting screws as
well as on the tappets (pointers); otherwise these parts must
be replaced. The suction valve rods are identical and
therefore interchangeable.
- Fit the control rods in their housing.
Figure 38
119108
119119
- Fit the rocker arm positioning the equalizer couples: the
suction equalizer first (short rod) and then the exhaust
equalizer (long rod) (2).
- Screw the fastening screws.
Copyright ©
18 SECTION 3 - INDUSTRIAL APPLICATION F5AE ENGINES
Figure 39 Figure 41
119128
- Make the holes (1) for fuel exhaust all face the same
direction.
Figure 42
119111
Figure 43
120020
Figure 44 Figure 46
119716
Figure 45
112012
Figure 47
120034
119727
Figure 48 Figure 50
119105
112011
Figure 51
Figure 49
119726 119718
NOTE Before mounting, verify that the threads of the - Reassemble the oil delivery pipe (3) and the return pipe
holes and the screws are not worn or dirty. (1).
- Refit the starter (5).
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 21
87720
PART TWO -
ELECTRICAL EQUIPMENT
Copyright ©
24 SECTION 3 - INDUSTRIAL APPLICATION F5AE ENGINES
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 25
120035
Figure 2
119454
Characteristics
Working temperature range
- Connector’s side -40 ˚C ÷ 130 ˚C; 150 ˚C for periods < 10 min.
- Bulb’s side on engine -40 ˚C ÷ 140 ˚C
Voltage 6 ÷ 28 V
Tightening torque 20 ÷ 30 Nm
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 27
120036
Characteristics
Voltage 12 ÷ 24 V
Calibration 0.6 ÷ 0.9 bar
Tightening torque 35 Nm
Copyright ©
28 SECTION 3 - INDUSTRIAL APPLICATION F5AE ENGINES
119455
Characteristics
Operating tension 12 - 24 V
Contact opening with raising temperature 63 ± 3 ˚C
Contact closing with decreasing temperature 53 ± 3 ˚C
Tightening torque 30 Nm MAX
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 29
Figure 5
119457
Torque setting 8 ± 2 Nm
Copyright ©
30 SECTION 3 - INDUSTRIAL APPLICATION F5AE ENGINES
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 31
Defective L.D.A. device. Check that the membrane is not perfor- Apply to CNH Technical Service.
ated and that the counter spring is
appropriate and correctly loaded (test on
bench).
Check the pressure within the intake
manifold is correct in relation to the
engine speed at full load.
Incorrect adjustment of the tie rods con- Adjust the tie rods in order to be able to
necting the accelerator pedal and the take the control lever to maximum deliv-
regulator’s lever. ery position.
Defective injectors. Replace the injectors.
Obstructed fuel pipes. Disassemble the pipes, clean them and
replace those that are seriously dented.
Ignition pump incorrect setting. Correct the pump setting so that ignition Apply to CNH Technical Service.
may be carried out according to the pre-
scribed spark lead angle.
F5AE ENGINES
Copyright ©
POSSIBLE ROOT CAUSE RECOMMENDED TESTS
FAILURE NOTES
(*) = if applicable to the appliance OR REMEDY
Anomalous engine strokes. Engine strokes cause excessive slack of Grind the engine drive shaft pins and fit
F5AE ENGINES
one or more crankshaft bearings or big undersize bearings. Replace the thrust
end bearings or excessive shoulder slack. bearing half rings.
Unbalanced engine drive shaft. Check the engine drive shaft alignment.
Loose flywheel fastening screws. Replace the loose screws and tighten
them to the prescribed torque setting.
Connecting rod misalignment. Replace the connecting rod.
Noisy piston pins for excessive slack of Replace the piston pin and/or the piston
piston hubs and connecting rod bush. and the connecting rod bush.
Loose bushes in their housing on the con-
necting rod.
Noisy timing. Adjust the slack between camshaft and
tappet and check there are no broken
springs. Furthermore, check that the slack
between valve stems and valve guides as
well as tappets an relevant seat.
Anomalous engine fumes. Black or dark Excessive pump maximum delivery. Disconnect the pump and adjust its deliv- Apply to CNH Technical Service.
grey fumes. ery referring to the calibration table of the
screw nuts.
Defective or incorrectly adjusted K.S.B. Adjust the ignition pump or replace it. Apply to CNH Technical Service.
device.
The ignition pump is excessively delayed Correct setting, check the spark lead
(or spark lead changing device is defec- changing device.
tive).
Copyright ©
PART FOUR
SCHEDULED MAINTENANCE
Copyright ©
40 SECTION 3 - INDUSTRIAL APPLICATION F5AE ENGINES
Copyright ©
F5AE ENGINES SECTION 3 - INDUSTRIAL APPLICATION 41
SCHEDULED MAINTENANCE
Servicing Plan
Engine lubrication frequency has been calculated presuming the use of fuel with content of Sulphur < 0.5%.
! WARNING! In case of use of fuel containing a percentage of Sulphur e > 0.5 %, the engine oil replacement interval must
be halved.
SECTION 4
Mechanical overhaul
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . 3
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . 10
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 11
TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Bush replacement . . . . . . . . . . . . . . . . . . . . . . 15
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Page Page
- Valve disassembly . . . . . . . . . . . . . . . . . . . . . . . 25
- Snap rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Cylinder head base surface check . . . . . . . . . . 26
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . 22
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Valve scaling, checking and grinding . . . . . . . . 26
- Connecting rod-piston unit assembly . . . . . . . . 23
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Snap ring assembly . . . . . . . . . . . . . . . . . . . . . . 23
- Valve guide replacement . . . . . . . . . . . . . . . . . 27
- Snap ring fixing . . . . . . . . . . . . . . . . . . . . . . . . . 23
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Connecting rod-piston unit fixing into
cylinder barrel . . . . . . . . . . . . . . . . . . . . . . . . . 24 VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 28
GENERAL SPECIFICATIONS
Type 4 CYLINDERS
Number of cylinders 4
∅
Bore mm 99
Stroke mm 104
TIMING
Checking timing
mm
X 0.20 to 0.30
mm
X 0.45 to 0.55
Checking operation
mm
X 0.20 to 0.40
mm
0.45 to 0.65
FUEL FEED
Injection
Type: Bosch VE 4/12F
Type 4 CYLINDERS
∅1 0.4
Spare pistons
∅1 type:
X Size X 10
2 Outside diameter ∅ 1 98.908 ÷ 98.918
∅ Pin housing ∅2 36.003 ÷ 36.009
Piston — cylinder barrels 0.082 ÷ 0.112
X
Piston protrusion X -0.22 ÷ +0.07
Type 4 CYLINDERS
Type 4 CYLINDERS
Main bearings
∅ 3 No. 1-2-3-4 ∅3 80.588 ÷ 80.614
No. 5 ∅3 87.588 ÷ 87.614
X 1
X 2
X 3
Shoulder half-ringser X3 2.51 ÷ 2.56
Type 4 CYLINDERS
∅ 2
∅2 8.023 ÷ 8.038
Valve guides
∅3 12.950 ÷ 12.985
∅ 3
∅ 4 Valves:
∅4 7.985 ÷ 8.000
α 60˚ 30’ ± 0˚ 10’
∅4 7.985 ÷ 8.000
α α 60˚ 30’ ± 0˚ 10’
Valve stem and guide 0.040 ÷ 0.053
Housing on head for
valve seat:
∅1 39.987 ÷ 40.013
∅ 1 ∅1 43.787 ÷ 43.813
∅2 40.863 ÷ 43.88
α
α 60˚ ± 1˚
X 0.3 ÷ 0.7
0.050 ÷ 0.101
Between valve seat
and head 0.050 ÷ 0.101
Valve seats -
Copyright ©
8 SECTION 4 - MECHANICAL OVERHAUL F5AE ENGINES
Type 4 CYLINDERS
Camshaft seats
∅ ∅ ∅ No. 2-3-4 50.069 ÷ 50.119
1 23 4 5 No. 1 40.069 ÷ 40.119
∅ 2
Camshaft supporting pins
1 39.975 ÷ 40.025
2⇒4 ∅ 49.975 ÷ 50.025
∅ 1 ∅ 3 5 53.995 ÷ 54.045
Bush inside
∅5 diameter ∅5 54.083 to 54.147
H H 5.5105
H 6.213
Copyright ©
F5AE ENGINES SECTION 4 - MECHANICAL OVERHAUL 9
Type 4 CYLINDERS
∅2
∅ 3 Tappet cap outside
diameter: ∅2 14.776 ÷14.780
∅3 14.950 ÷ 14.970
∅2
Between tappets and housings -
Tappets -
∅ 1
Rocker shaft ∅1 18.979 ÷ 19.000
∅ 2
Between rockers and shaft 0.020 ÷ 0.054
Copyright ©
10 SECTION 4 - MECHANICAL OVERHAUL F5AE ENGINES
119546
Figure 1
The third main bearing cap (1), the central one, and its support,
have the half bearing (2) provided with shoulder.
Figure 4
70158
120037
120173
119545
Loosen the screws (1) and disassemble the crankshaft bearing Disassemble the crankshaft half bearings (1).
caps (2). Loosen the fastening screws (2) and disassemble the oil
nozzles (3).
Copyright ©
F5AE ENGINES SECTION 4 - MECHANICAL OVERHAUL 11
zs
Figure 6 REPAIRS
CYLINDER UNIT
Checks and measurements
Figure 9
119548
NOTE Note down the plate assembly position (2). Once completed the engine disassembly, carefully clean the
cylinder-crankcase units.
Use suitable eyebolts to handle the cylinder unit. Carefully
check the crankcase has for cracks. Check the conditions of
the processing caps: replace them if oxidized or in case their
Figure 7 tight is doubtful. Check the surface of the cylinder barrels:
there must be no trace of meshing, scratches, oval or conical
shaping and excessive wear.
Cylinder barrel inner diameter check to detect any oval or
conical shaping or wear shall be executed throughout the
bore meter (1) equipped with comparator, which must be
previously be reset on the ring calliper (2) of the cylinder
barrel diameter.
119549
Figure 10
Carefully withdraw the camshaft (1) from the engine bock.
Figure 8
70167
The measurements must be made for each cylinder, at three
different heights from the barrel and on two perpendicular
planes: one parallel to the engine longitudinal axle (A) and the
other perpendicularly (B). Generally, maximum wear is
detected on the perpendicular plane (B) and with the first
measurement.
If oval or conical shaping or wear is detected, proceed boring
and grinding the cylinder barrels. Cylinder barrel grinding
70165
must be executed based on the spare pistons’ diameter plus
0,4 mm of the rated value and at the prescribed assembly
Withdraw the tappets (1) from the engine bock. slack.
Copyright ©
12 SECTION 4 - MECHANICAL OVERHAUL F5AE ENGINES
119550
TIMING SYSTEM
Camshaft
Figure 12
119551
Figure 13
70172
70171
Figure 15
119552
70176
70174
Lubricate the tappets (1) and fit them into the relevant seats
Use the beater 380000667 (2) and handgrip 380000999 (3) on within the crankcase.
to disassemble and replace the bush (1).
Figure 19
119549
119554
119553 Position the camshaft (3) holding plate (1) with the slot
towards the upper side of the crankcase and the marking
TAPPET AND RELEVANT SEAT ON CRANKCASE towards the operator; tighten the fastening screws (2) to the
MAIN DATA prescribed torque setting.
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16 SECTION 4 - MECHANICAL OVERHAUL F5AE ENGINES
119555
70180
Fit the nozzles (2) and tighten the fastening screws (1) to the NOTE The main journals and crankshaft bearing pins must
prescribed torque setting. always be grinded to the same undersize classes in
order not to alter the shaft’s balance.
Figure 24
120038
Figure 25
120039
ENGINE DRIVE SHAFT MAIN TOLERANCES
119574
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18 SECTION 4 - MECHANICAL OVERHAUL F5AE ENGINES
Figure 26 Figure 27
120037
120173
Assemble the engine drive shaft (2).
NOTE If it is not necessary to replace the crankshaft Check the slack between the engine drive shaft main journals
bearings, these shall be reassembled in the same and the respective crankshaft bearings proceeding as follows:
order and position they were before disassembly.
Figure 28
Figure 32
70187
119559
- 3rd phase using tool 380000304 (1) fitted as shown in
the figure and further tighten the screws (2) by 90º ± 5º
angle. CONNECTING ROD — PISTON ASSEMBLY
Figure 31
Figure 33
119560 70191
- Remove the caps from their support.
The slack between the crankshaft bearings and the relevant CONNECTING ROD-PISTON UNIT COMPONENTS
pins should be detected comparing the width measured by
the gauge wire (2) in the point of maximum flattening with 1. Grommets. - 2. Pin. - 3. Piston. - 4. Snap rings. -
the scale graduation reported on the shield (1) of the gauge 5. Screws - 6. Half bearings. - 7. Connecting rod. - 8. Bush.
wire. The numbers reported on the scale indicate the
coupling slack in millimetres.
If the slack detected differs from the prescribed value, replace
the half bearings and repeat the measurement; once NOTE The spare pistons are supplied with standard
achieving the slack prescribed, lubricate the crankshaft dimensions or oversize by 0.4 mm.
bearings and finally assemble the supports tightening the
fastening screws as described previously.
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20 SECTION 4 - MECHANICAL OVERHAUL F5AE ENGINES
Figure 34 Pistons
Piston diameter measurement
Figure 37
32613
32615
Using pincers 380000221 (3), remove the snap rings (1) from Using the micrometer (2), measure the piston diameter (1)
the piston (2). to determine the assembly slack.
Figure 38
32614
Remove the piston pin (1) grommet using the nail (3).
70192
119561
18857 32620
Measurement of the piston pin diameter (1) throughout a Check the slack between the grommets (3) of the 2nd and
micrometer (2). 3rd slots and relevant housing on the piston (2) using calliper
Conditions for the correct coupling of pins and and gauges (1).
pistons
Figure 40 Figure 43
32619
41104
Lubricate the pin (1) with engine oil and the relevant seat on SCHEME FOR THE MEASUREMENT OF SLACK
the piston hubs; the pin must fit into the piston applying a BETWEEN THE FIRST PISTON SLOT AND THE
slight pressure with fingers and must not slip out for gravity. TRAPEZOIDAL GROMMET
Due to the particular for of the first grommet, having
trapezoidal section, the slack between said grommet and the
Snap rings slot must be measured as follows: the piston (1) must be
Figure 41 projected from the crankcase so that nearly half of the
grommet (2) in question comes out of the cylinder barrel (3).
In this position, using a gauge calliper, measure the slack (X)
between grommet and slot: the slack must comply with the
prescribed value.
16552
Figure 44 Figure 46
70194
Connecting rods
Figure 45 119563
119562
Bushes Figure 49
Check that the connecting rod shoe bush is not loose and
that there is no trace of meshing or scratches otherwise
replace it.
Disassembly and reassembly must be executed using a
suitable beater.
When fixing it, make sure that the ports for oil passage on the
bush and on the connecting rod coincide. Throughout a
boring machine, bore the bush in order to obtain the
prescribed diameter.
119564
Use the pincers 380000221 (3) to fit the snap fasteners (1)
to the piston (2).
Figure 48 The snap rings must be fitted with ”TOP” marking upwards.
Furthermore, ring opening must be misaligned by 120º.
119565
Figure 51 Figure 53
119566
Figure 52
70203
Figure 55 In case the slack measured differs from the prescribed value,
replace the half bearings and measure the slack again.
α
NOTE See page 16 of Section 3.
70204
- Lubricate the fastening screws (1) with engine oil and CYLINDER HEAD
tighten them to the prescribed torque setting (50 ± 5
Nm) using a torque wrench.
Valve disassembly
Figure 58
Figure 56
1
α
2
75750
70205
The intake valves (1) and exhaust valves (2) have different
- Fit the tool 380000304 (1) to the socket wrench and head diameter.
then further tighten the screws (2) by 70º ± 5º.
Figure 57
NOTE Number the valves before removing them from the
cylinder head in order to be able to reassemble
them in the same order in case replacement is not
necessary.
A = intake side
70206
Figure 59 VALVES
Figure 62
EXHAUST INTAKE
VALVE VALVE
119567
18625
119568
Remove the grommets (1 and 2) from their valve guides. Eliminate carbon deposits from the valves using the specially
provided metal brush.
Check the valves for meshing, cracks or burns.
Cylinder head base surface check If necessary, grind the valve seats removing as less material as
possible.
Any deformation detected on the whole length of the
cylinder head must not exceed 0.20 mm. Figure 64
In case higher value is detected, grind the cylinder head in
order to obtain the prescribed value. Refer to the main
specifications reported here following and follow the
instructions accompanying the figures below.
Figure 61
18882
119591
Using a micrometer (2) measure the valve stem (1): the
A rated thickness of the cylinder head is 90 ± 0,1 mm. prescribed value is 7,985 ÷ 8,000 mm.
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F5AE ENGINES SECTION 4 - MECHANICAL OVERHAUL 27
INTAKE EXHAUST
119570
VALVE SEATS
Figure 66
122433
119567
50676
Place the spring (4) and the upper plate (3) on the cylinder
head. Using tool 380000302 (1), compress the spring (4) and
MAIN SPECIFICATIONS FOR INTAKE AND EXHAUST
constrain the parts to the valve (5) throughout the half cones
VALVE SPRING TEST
(2).
Before assembly, test the valve spring flexibility using specific
tool. Compare the load and elastic strain test results with the
technical specifications of the new springs, reported in the
table below.
119573
119572
Lubricate the valve stems (1) and fit them in the relevant
valve guides in the same position they were before
disassembly.
Fit the grommets (2 and 3) to the valve guide using tool
380000134.
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F5AE ENGINES SECTION 4 - MECHANICAL OVERHAUL 29
TORQUE SETTING
TORQUE
DESCRIPTION
Nm kgm
Side cap M6 40 ± 5 4 ± 0.5
Oill Pann Unitit
TORQUE
DESCRIPTION
Nm kgm
- pre-tightening 50 ± 5 5 ± 0.5
ting
Co
TORQUE
DESCRIPTION
Nm kgm
Water pipe fixing to the heat exchanger 25 ± 5 2.5 ± 0.5
oolinng
pipee
Water pipe fixing to the support 25 ± 5 2.5 ± 0.5
p
Co
25 ± 5
Fan
50 ± 5
oup
18 ± 2
mp
- tightening 90 ± 5 9 ± 0.5
Inje
p
SECTION 5
Tools
Pagina
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2 SECTION 5 - TOOLS F5AE ENGINES
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F5AE ENGINES SECTION 5 - TOOLS 3
TOOLS
- Puller for the gear coupling the injection pump to the engine
- Shrink fitter for the assembly of the drive shaft rear gasket
- Shrink fitter for the assembly of the drive shaft front gasket
380000220 Ring for plunger introduction into the cylinder barrel (60 ÷ 125 mm)
380000221 Pliers for plunger snap ring disassembly and reassembly (65 - 110 mm)
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F5AE ENGINES SECTION 5 - TOOLS 5
Pair of measuring devices for angular tightening with 1/2” and 3/4”
380000304 square coupling
Rotary stand for overhauling units (capacity 1000 daN, torque 120
380000978 daNm)
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . . 3
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2 APPENDIX F5AE ENGINES
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F5AE ENGINES APPENDIX 3