Professional Documents
Culture Documents
TECH-COM 2004-3
NEF Engine
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
NEF ENGINE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DEALER-CERTIFIED TECHNICIAN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1
IMPORTANT INSTRUCTIONS FOR USING THE TECH-COM DVD
The Tech-Com DVD is organized just like the Reference Manual. If you are using a television and a
DVD player:
1. Put the disc in your DVD player and press “Play” on the DVD remote.
2. You will see the program opening, which ends with a Main Menu. From this menu, you can choose
a topic. Please complete the topics in order, beginning with number 1, if you have not completed the
program before. Once you have completed the program, you can easily choose a topic that you want
to review from the Main Menu.
3. Use the arrow buttons and the Enter button on the DVD remote to select a menu item, and to select
the “Back,” “Repeat,” and “Forward” buttons at the bottom of the screen. These are called the
navigation buttons.
4. Video clips move on to the next screen in the program automatically. If you select the Back button
and press Enter, you will go to the last screen with navigation buttons where you can select “Forward”
to see the video again.
5. The Menu button on the DVD remote will always take you back to the Main Menu.
6. When you get to the end of a topic, you will see a summary of what was covered. When you select
the Forward button, you will return to the Main Menu to make another choice.
7. To quit the program, press “Stop” on the DVD remote.
8. As long as you don’t eject the disc, the DVD player remembers where you stopped the last time you
played the disc. This is where it will pick up when you start the program again. To start over at the
beginning, you must eject the disc and put it back in again.
1. Use the DVD software, not Windows Media Player, if playing the DVD on a computer.
2. You can use the mouse to select topics and the navigation buttons at the bottom of the screen. There
is also a DVD control window at the bottom of the screen that you can use to move through the
program.
All other functions are the same as those listed for the DVD player/television above.
2
INTRODUCTION
WHAT IS THE NEF ENGINE? When you complete this Tech-Com, you should be
NEF stands for New Engine Family. The NEF engine familiar with:
was designed to: • How the engines in the NEF product line are
• Meet the ever-changing levels of emissions identified.
legislation. • The NEF engine features, including the cylinder
• Increase power and torque rise. block, cylinder head, mechanical fuel supply, and
electronic fuel supply.
• Decrease sound levels.
• NEF engine diagnostics and troubleshooting.
• Improve starting ability.
You’ll find an introduction to the NEF engine in
The NEF engine is a joint venture with Iveco, Tech-Com 2004-1 “Tier 2 Engines.” Also refer to the
Cummins, and New Holland. You’ll find this engine product-specific Repair Manuals for individual
on many New Holland products. specifications for each NEF engine.
3
ENGINE IDENTIFICATION
NEF engines are available in a number of
configurations:
4
ENGINE IDENTIFICATION
F 4 A E 0 6 8 4 F D + 1
Y Y Y Y Y Y
2
In the next section of this Tech-Com, we’ll take a
closer look at the engine features. To review before
going on, answer questions 1 -- 2 in the
Dealer-Certified Technician Test.
5
ENGINE FEATURES
ENGINE DESIGN
Block Design
The block configurations are similar, but not
interchangeable, between the electronic and me-
chanically fueled engines.
The NEF engine block features:
20044782
6
ENGINE FEATURES
• Cylinder block is cast and machined for the
integral oil cooler, as well as the water pump’s
spiral impeller, Figure 4.
A = To the radiator
B = From the radiator
80734
7
ENGINE FEATURES
Structural Crankcase
Some New Holland products contain NEF engines
with a structural crankcase, which means the engine
is required to support another key member, such as
an axle.
50044758
8
ENGINE FEATURES
Non-Structural Crankcase
Some New Holland products contain NEF engines 2
with a non-structural crankcase, which is not 1
required to support another key member of the
vehicle.
20041038
6
The non-structural pans have one drain plug in the oil
pan sump, 1, Figure 7.
20032538
7
Crankshaft
The crankshaft, Figure 8, is forged and fully 2
counterweighted. The 6-cylinder crankshaft is sup-
ported in the cylinder block by seven main bearings.
Main bearing assembly number six incorporates the 1
thrust bearing to control crankshaft end play.
9
ENGINE FEATURES
Dynamic Balancer
A gear driven and counterweighted dynamic balancer,
1, Figure 9, is used to smooth the firing impulses of
the 4-cylinder engine. The balancer is bolted to the
bottom of the cylinder block and is driven by the gear
at the rear of the crankshaft. The balancer must be
properly timed with a locking pin for installation into the
engine with the #1 cylinder at TDC.
80371
9
Connecting Rod
The connecting rod, Figure 10, is forged and has
one unique characteristic. At the crankshaft end, or
“big end,” of the connecting rod, the rod cap is parted
from the upper rod half by an innovative fracturing
process rather than machining. This improves
strength and provides better fit up. Rod and cap are
etched with matching numbers for identification. The
wrist pin end, or small end, of the rod is tapered to
allow more material to be added to the piston in the
area of the wrist pin to carry higher loads.
00880t
10
Piston
NEF engines feature a single piece, aluminum,
three-ring piston, Figure 11, with a Ni-resist insert
top ring groove. The piston is molybedum coated to
aid in break in. An arrow on top of the piston indicates
the direction of installation. If removed, the piston
must be properly installed relative to the notch in the
piston skirt, which provides clearance for the piston
oil cooling nozzle.
The piston oil cooling nozzle directs oil flow into the
underside of the piston crown for heat removal.
10
ENGINE FEATURES
Camshaft
The camshaft and injection pump drive are located at
the rear of engine. The camshaft, Figure 12, is
supported by seven bearing journals in the 6-cylinder
engine. The front and rear camshaft bearing journals
ride in bushings. The remaining camshaft journals
ride in the bearing surfaces machined into the block
casting. The camshaft is retained in position at the
rear of the engine using a bolt in thrust plate.
50044759
12
11
ENGINE FEATURES
The camshaft features a bolt-on cam gear,
Figure 13. Cam gears are normally press fit to the
camshaft. Cam gears are slotted at the rear face,
allowing rotation to be monitored by the camshaft
position sensor when using electronic fuel control.
12
ENGINE FEATURES
COOLING AND LUBRICATION
Structural Engine Gerotor-Type Oil Pump The oil pump housing has a built-in regulating valve,
NEF structural engines have a georotor-type oil 4, and a separate relief valve, 5.
pump, 1, Figure 14, and housing, 2, bolted to the
front of the engine. The center georotor gear is driven
by the crankshaft, 3.
4
5
Pressurized oil
Oil under gravity
80370
14
13
ENGINE FEATURES
Structural Gerotor Pump Oil Filter Mount
The NEF gerotor pump’s oil filter mount, 1,
Figure 15, is upside down for better clearance.
However, the filter is equipped with a check valve so
any oil remaining in the filter won’t spill during filter
change. The mount is designed to keep oil in the filter
so it doesn’t drain back when the engine is off.
80311
15
Non-Structural Engine Gerotor-Type Oil Pump
Engines with non-structural crankcases have a
gerotor-type oil pump, 1, Figure 16, located in the
front housing of the engine block, under the cover.
75811
16
Non-Structural Gerotor Pump Oil Filter Mount
The gear pump’s oil filter, 1, Figure 17, is right-side
up. The oil pressure relief on NEF engines with gear
pumps is located in the filter mount.
10037084
17
14
ENGINE FEATURES
Water Pump
The water pump, Figure 18, is integral to the block.
The water pump assembly includes a shaft seal and
impeller mounted to the engine with a two-bolt
flange. The remainder of the water pump assembly
is machined to the block.
18
Oil Cooler
The multiple plate-type oil cooler, 1, Figure 19,
provides critical heat removal from the engine. The 1
cooler assembly is bolted into the engine block,
sandwiched between the block and the oil filter
mounting base.
15
CYLINDER HEAD
NEF engines can be configured with two or four
valves per cylinder, depending upon whether the fuel
system is mechanical or electronic. Figure 20 is the
cylinder head on a 4-valve per cylinder common rail
engine. The valve seats are inserts and can be
replaced as needed.
3 8
003199t
20
1. Exhaust manifold 6. Cold start seat
2. Electro-injectors 7. Electro-injector wiring housing
3. Electro injector relative wiring 8. Cylinder head
4. Thermostat 9. Fuel inlet connector
5. Intake manifold
16
CYLINDER HEAD
Intake, 1, Figure 21, and exhaust valves, 2, are
ground to the same angles as the seats, and are 2
recessed into the cylinder head for piston clearance.
The valve guides are cast into cylinder head. Valve
stem oil seals are used on both the intake and 1
exhaust valves.
INJECTORS
80623
22
17
CYLINDER HEAD
Electronic Common Rail Fuel System
The electronically controlled injection nozzles, 1,
Figure 23, are mounted under the rocker cover and
are centrally located between the intake and exhaust
valve assemblies on each cylinder. The nozzle tip is
sealed with a copper washer, 3. The upper nozzle
body employs an O-ring, 2, to keep nozzle return fuel
from leaking into the engine oil. Return fuel is ported
from the nozzle body to a common drilling in the
cylinder head. This fuel exits the cylinder head at the
rear.
18
CYLINDER HEAD
COLD STARTING AID
A cold starting aid, 2, Figure 24, is optional on some
engines. If equipped, the mechanical NEF engines
have a grid heater installed at the intake manifold, 1,
for improved startability.
80385
24
In the next section of this Tech-Com, we’ll look at the
fuel supply features for both the Bosch VE
mechanical and Bosch Electronic Common Rail fuel
systems. Try answering questions 9 - 10 in the
Dealer-Certified Technican Test to review before
going on.
19
FUEL SUPPLY
MECHANICAL ENGINE
Two-valve per cylinder engines are equipped with
either a rotary, 1, Figure 25, or in-line fuel injection
pump, mounted at the left rear of engine.
20
FUEL SUPPLY
Other fuel supply features include:
BSF4471A
27
1. Common Rail
2. Fuel Inlet from High Pressure Pump
3. Pressure Sensor
4. Relief Valve
21
FUEL SUPPLY
• Solenoid valve-controlled injectors in the cylin- In a common rail fuel system, the injection pressure
der head, 6, Figure 28 is generated independent of engine speed and
• Electronic Control Unit (ECU), 11 injected fuel quantity. Fuel is stored under pressure
in the high pressure accumulator, or common rail,
• Crankshaft speed sensor, 5
ready for injection. Individual high pressure lines
• Camshaft speed sensor, 8 come off the common rail to each cylinder, and are
• Fuel pressure sensor, 3 (cable shown) connected to the cross-feed tube that connects to
• Coolant temperature sensor, 2 each injector nozzle. Fuel quantity and timing are
electronically controlled from the valve assembly
• Engine oil pressure and temperature sensor, 4
mounted on top of the injection nozzle. The degree
• Electro-injector, 6, (Electro-injector connection is of acceleration determines the injected fuel quantity,
shown at 1) while the ECU determines the start of injection and
• Air pressure-temperature (boost) sensor, 7 injection pressure.
• Fuel heater and temp sensor, 9
The fuel system consists of a low pressure stage for
Figure 28 also shows the pressure regulator wiring, the low pressure delivery of fuel, and a high pressure
10. stage for high pressure delivery.
80375
28
1. Connection for electro-injectors 7. Air pressure temperature sensor
2. Engine coolant temperature sensor 8. Timing system phase sensor
3. Fuel pressure sensor cable 9. Fuel temperature sensor
4. Engine oil pressure and temperature sensor 10. Pressure regulator wiring
5. Crankshaft sensor 11. EDC7C control unit
6. Electro-injector
22
FUEL SUPPLY
9
7
10
5 3 2
1
4
29
Low Pressure Delivery • Pilot injection. In this phase, a small amount of
The common rail low pressure fuel system consists fuel is injected into the cylinder to precondition
of the fuel tank with primary fuel filter, supply pump, the combustion chamber. This reduces combus-
secondary fuel filter, and low pressure fuel lines. tion pressure rise and peaks, which reduces
combustion noise and fuel consumption. Pilot
The supply pump, Figure 29, draws fuel from the fuel injection can also reduce exhaust gas emissions.
tank, 1, through the primary fuel filter, 2, to the inlet
• Main injection. The main injection phase is
of the supply pump, 3. Fuel from the supply pump
responsible for the engine’s torque development.
then enters the secondary filter, 4, under pressure to
feed the high pressure pump, 5. • Secondary injection. This phase is timed to take
place during the exhaust cycle. Secondary
Figure 30 also shows fuel supply components. injection introduces a precisely metered quantity
of fuel to the exhaust gas, which can reduce
nitrous oxide (NOx) combustion, a gas that is
High Pressure Delivery harmful to people and the environment.
The high pressure system includes a high pressure
pump, 6, Figure 29, with pressure control valve, high The excess fuel needed to open the injector nozzles
pressure fuel lines, 7, the common rail, 8, as the high flows back to the tank through a collector line. The
pressure accumulator, injectors, 9, and fuel return return fuel from the pressure control valve and the
lines, 10. low pressure stage also flows through this line with
the fuel used to lubricate the high pressure pump.
The high pressure pump pressurizes the fuel, then
feeds it by a single high pressure line to the common The fuel lines are made from steel tubing because
rail. The injector nozzles open when the solenoid they must be able to withstand the maximum system
valve is triggered and inject fuel directly into the pressure, as well as high frequency pressure
engine’s combustion chamber. Fuel pressure inside fluctuations.
the rail remains practically constant, even after an
These electronic NEF engines also feature dual
injector has taken fuel from the rail for injection.
filtration with an integral hand primer.
With a common rail fuel system, injection actually
The next section of this Tech-Com is NEF engine
takes place in three phases:
diagnostics. Questions 11 - 15 review this section on
the fuel system.
23
FUEL SUPPLY
80719
30
1. Fuel outlet fitting to rail 6. Fuel outlet fitting to filter mounting
2. High pressure pump 7. Fuel inlet fitting from the cooler of the pack
3. Pressure regulator 8. Fuel outlet fitting from the mechanical pump to the filter
4. Drive gear 9. Mechanical supply pump
5. Fuel filter inlet fitting from filter
24
NEF ENGINE DIAGNOSTICS
When diagnosing NEF engine concerns, you must • Electrical harness and/or connector is bad or
determine whether the problem is related to the defective.
mechanical, fuel delivery, or electrical/electronic
system. Most engine concerns are identified by an • Electronic module (controller/processor) is bad
indicator light and/or audible alarm from the vehicle or defective.
operating system, by the operator noticing a change
When an operating condition exists outside the
in engine performance, or a change in the sound of
parameters identified for the switch or sensor
the engine.
reporting the condition, use direct reading devices
(such as pressure gauge, temperature gun, or
NOTE: When diagnosing standard mechanical or thermocouple) to verify the condition exists. For
common rail engines, remember the term FACT is example:
applicable.
25
NEF ENGINE DIAGNOSTICS
Standard troubleshooting practices apply when
performing diagnostics on the fuel system for
mechanical engines.
MEASURING BOOST
Typical boost pressures are identified in Table 1.
ENGINE FAMILY
Characteristics @ RPM Unit NEF 4V - CR NEF 4V - CR NEF 2V - CR (60 NEF 2V - CR (74 NEF 2V - CR
(101 kW) (173 kW) kW) kW) (138 kW)
Boost pressure 1000 kPa 34.10 40.10 N/A 43.8 36.1
1600 112.80 162.20 N/A 72.9 100.9
2000 120.70 158.70 N/A 85.1 117.8
31
The faults tab displays a fault count that includes all
faults currently stored in the ECU memory. The faults
stored in the ECU memory are separated into two
groups, Figure 32:
26
NEF ENGINE DIAGNOSTICS
Operating Parameters
Figure 33 shows the operating parameters screen.
With the electronic engine, the right-hand side will be
completed with the appropriate sensor/sender value.
33
Mechanical engine parameters can be viewed on the
vehicle information screen, Figure 34, for units
compatible with EST.
34
Identification Screen
The identification screen, Figure 35, gives controller
information. When connected to the vehicle, the
individual information for the engine controller
installed will be displayed in the right-hand column.
35
27
NEF ENGINE DIAGNOSTICS
FINDING TOP DEAD CENTER (TDC)
Mechanical Engines
To find TDC on a mechanical engine:
1. Remove the valve cover on the number 1
cylinder, Figure 36.
80593
36
2. Remove the starter motor and install special tool
380000988-01, 1, Figure 37. 3
3. Using a 1/2 inch drive ratchet, rotate the engine
using special tool number 380000732, 2, in the
direction of engine rotation (usually clockwise) 1
until the intake valve on the number 1 cylinder
closes. Continue rotating until the timing pin –
special tool number 380000988-02, 3, - engages
in the timing hole in the flywheel.
50044790
37
28
NEF ENGINE DIAGNOSTICS
4. Verify the correct position by unscrewing the
retaining bolts, 2, Figure 38, and removing the
priming pump, 1, from the crankcase. Check
through the seat of the priming pump to be sure
the camshaft, 1, Figure 39, is at TDC, using the
reference marks, 2, on the shaft.
80684
38
5. If you cannot see the marks, 2, withdraw the pin
from the flywheel, and rotate the engine 360
degrees until the reference marks are visible,
then re-insert the pin to lock.
80685
39
29
NEF ENGINE DIAGNOSTICS
On NEF mechanical engines equipped with the
factory-installed timing pin, you need only rotate the
engine until the pin drops into the corresponding hold
in the cam gear. The pin will only move about 1/4
inch. There is no concern about being 360 degrees
off since you are directly pinning the cam gear.
Removing this pin from the engine is NOT
recommended.
ELECTRONIC ENGINES
On the electronic NEF engine, the camshaft speed
and timing sensor is a segment sensor and works
together with the crankshaft increment sensor. The
camshaft speed and timing sensor is used for engine
synchronization and TDC reference with regard to
camshaft position. This sensor is installed into the
rear engine cover plate at the rear left-hand side of
engine, Figure 40.
50044760
40
30
NEF ENGINE DIAGNOSTICS
To find TDC on an electronic engine:
80615
41
3. Line up the gears, 1 and 2, Figure 42, so the
timing marks, 3, on the camshaft gear teeth are
on either side of the notched tooth on the
crankshaft gear.
80341
42
The final section of this Tech-Com covers
troubleshooting. Try answering questions 16 - 22 to
review this section before going on.
31
TROUBLESHOOTING
Engine concerns can usually be classified as one of
the following:
• Engine overheats.
32
TROUBLESHOOTING
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE REMEDY
The engine does not start Battery dead or faulty. Check and recharge battery. Replace
battery if necessary.
Connections to battery terminals Clean, examine and tighten the nuts
corroded or loose. on the battery terminals. Replace the
cable terminals and the nuts if
excessively corroded.
Incorrect timing of injection pump. Check and correctly time the injection
pump. See pump manufacturer or
authorized timing center.
Deposits or water in the fuel tank. Disconnect the hoses and clean them
using a jet of compressed air.
Dismantle and clean the injection
pump. Remove water from tank and
refuel. Drain fuel system.
No fuel in tank. Refuel.
No power supply. Overhaul or replace the fuel pump.
Air bubbles in the fuel lines or Check the hoses to ensure that air is
injection pump. in fact present and also check the fuel
pump. Eliminate the air from the
injection pump by unscrewing the cap
and working the fuel pump by hand.
Faulty starter motor. Repair or replace the starter motor.
Poor engine ground. Check engine controller ground
--electronic engines.
The engine does not start at low Fuel system clogged with paraffin Replace the fuel with fuel suitable
temperatures crystals forming due to the use of for use at low temperatures.
unsuitable fuel. Replace the fuel filters.
The engine cuts out Idle rpm too low. Adjust with adjustment screw.
Irregular flow of injection pump. Adjust flow. See pump manufacturer
or authorized timing center.
Impurities or water in the fuel lines. Disconnect the hoses and clean
them using a jet of compressed air.
Dismantle and clean the injection
pump. Remove water from fuel tank
and refuel. Drain fuel system.
Clogged fuel filter. Dismantle and replace if necessary.
Presence of air in the fuel and Check that the hoses are not
injection system. cracked or the unions loose. Replace
worn parts, remove the air from the
hoses and deaerate the injection
pump and fuel filter by unscrewing
the caps and working the primer
pump by hand.
Broken injection pump controls. Replace the faulty parts.
Abnormal clearance between cam- Adjust clearance by replacing shims.
shaft cams and tappets.
Burned, corroded or chalky valves. Replace the valves, rectify or replace
the cylinder head seatings.
Poor engine ground. Check engine controller ground
--electronic engines.
33
TROUBLESHOOTING
The engine overheats Faulty water pump. Check the unit and replace if
necessary. Replace the gasket.
Water pump drive belt slack. Check and adjust the tightness of
the belt. On applications provided
with automatic tensioner, check
correct setting.
Engine operation is irregular and Incorrect timing of injection pump. Check timing and correctly set
lacks power pump.
Impurities or water in the fuel and Carefully clean the system and
injection system. refuel. If necessary drain fuel
system.
34
TROUBLESHOOTING
Engine running with abnormal Faulty operation of injectors. Replace all injectors.
knocking
Fuel lines blocked. Dismantle the hoses, clean them
and replace those that are seriously
dented.
Noise from piston journals due to Replace the piston journal and/ or
excessive play of piston hubs and in the piston and rod bushing.
the rod bushing.
35
TROUBLESHOOTING
The engine smokes abnormally. Excessive maximum pump output. Disconnect the pump and adjust
Black or dark grey smoke. delivery in accordance with the
data given in the calibration table.
See pump manufacturer or
authorized timing center.
The holes in the injectors (or some Replace the injectors with a series
of them) are partially or entirely of new injectors or clean and rectify
blocked. the original ones using suitable
equipment.
Blue, grey--blue, grey smoke tend- Excessive delay in injection pump. Correct the set--up of the pump.
ing to white See pump manufacturer or
authorized timing center.
36
DEALER-CERTIFIED TECHNICIAN TEST
Technicians enrolled in the Tech-Com program must use the test answer sheet included in this package.
1. The first two digits in the NEF engine identification number indicate the ___________.
A. power rating
B. type of fuel injection system
C. engine family
D. cylinder orientation
2. The last (11th) digit in the NEF engine identification is a 6. This tells you the engine has a __________.
A. common rail 4 valve fuel injection system
B. common rail 2 valve fuel injection system
C. in-line 2 valve fuel injection system
D. rotary 2 valve fuel injection system
4. The exterior MFD shaft runs through the center of the oil pan on_____________ crankcases, so there are
two oil drain plugs.
A. structural
B. non-structural
6. What is the purpose of the dynamic balancer bolted to the bottom of the cylinder block?
A. It reinforces the structural crankcase.
B. It smoothes the firing impulses of the 4-cylinder engine.
C. It reduces torsional vibration and noise.
D. All of the above.
8. The ________engine oil filter mount is upside down for better clearance.
A. structural
B. non-structural
37
DEALER-CERTIFIED TECHNICIAN TEST
9. NEF engines with a mechanical fuel system have the injector nozzles mounted ____________.
A. under the rocker cover, between the intake and exhaust valve assemblies on each cylinder
B. out board of the rocker cover on the exhaust manifold side of the engine
10. The grid heater for cold starting is built into the intake manifold on all NEF engines. True or false?
A. True
B. False
11. An authorized Bosch dealer should carry out internal pump timing procedures. True or false?
A. True
B. False
12. If you are hand priming a mechanical NEF engine, the supply pump arm should be on the _________ side
of the cam lobe.
A. high
B. low
13. Electronic engines store fuel under pressure in the ___________ until it is ready for injection.
A. aneroid assembly on top of the injection pump
B. sump
C. cross-feed tube
D. common rail
14. The __________ determines the start of injection by the camshaft speed sensor, common rail pressure
sensor, and engine cranking speed on electronic engines.
A. ADIC
B. ECU
C. transmission controller
D. injection pump
15. On an electronic engine, the ________ injection phase introduces a precisely metered quantity of fuel to the
exhaust gas, which can reduce nitrous oxide (NOx) combustion.
A. pilot
B. main
C. secondary
D. primary
16. You are diagnosing an NEF engine concern indicated by a fault code. Which of the following would be your
first line of troubleshooting the potential cause?
A. Bad or defective electronic module.
B. Bad or defective switch/sensor/part.
C. Operating condition outside the parameters identified for the switch or sensor reporting the condition.
D. All of the above.
38
DEALER-CERTIFIED TECHNICIAN TEST
17. NEF mechanical concerns are _________.
A. sometimes indicated by a warning light, gauge, and/or audible alarm
B. related to major engine components such as the block, pistons, or controllers
C. typically identified by a unique sound or problem with engine performance
D. all of the above
18. When diagnosing NEF electronic engine concerns with Atlas and the EST, the _________ screen shows the
sensor/sender values.
A. Operating Parameters
B. Faults
C. Identification
D. Additional Tools
19. If you are working on an NEF mechanical engine equipped with a factory-installed timing pin, you should not
remove the pin from the engine. True or false?
A. True
B. False
20. You have removed the injection pump from a mechanical NEF engine when the engine wasn’t at TDC. The
engine has been rotated. What can you do?
A. Reset the pump and lock it.
B. Put the pump back on the engine and find TDC.
C. Take the pump to an authorized Bosch dealer.
D. Any of the above options is acceptable.
23. You are troubleshooting an NEF engine that doesn’t start when the outside temperature is low. Which of the
following is a likely cause?
A. New fuel pump is needed.
B. There is air in the fuel and injection system.
C. Fuel system is clogged with paraffin crystals that form when the fuel used is unsuitable for low
temperatures.
D. Thermostat is blocked.
39
DEALER-CERTIFIED TECHNICIAN TEST
24. Dismantling the fuel lines, cleaning them, and replacing any that are extremely dented can correct an
__________ concern.
A. engine does not start
B. engine running with abnormal knocking
C. engine overheats
D. engine smokes
40
RELEASES TO DATE
1990 1992
9001 Diesel Engine Low Power Diagnosis 9201 Discbine® Mower-Conditioner
and Troubleshooting Operation, Preventive Maintenance,
9002 Automatic Head Height and Terrain and Failure Analysis
Tracert Systems 9202 Separating the C-Series Tractor
9003 Understanding and Troubleshooting Loader Backhoe
the Skid-Steer Loader Operator 9203 Square Baler Knotter: Operation,
Restraint System Adjustment, and Troubleshooting
9004 The Bidirectionalt Tractor Hydrostatic 9204 Introduction to the PowerStart 40
Transmission System Series Tractors
9005 The Ultra-Commandt Powershift 9205 The PowerStart 40 Series Tractor
Transmission Engine
9006 The 30 Series 3-Cylinder 8 x 8 and 16 9206 Introduction to Forage Harvesters and
x 8 Synchromesh Transmissions Cutterhead Maintenance
9007 Rotary Feed and Flow Action Square 9207 PowerStart 16 x 16 Transmission
Balers 9208 Troubleshooting Large 4WD Electrical
9008 Hydrostatic Power Steering for 3230 Circuits
Through 4830 Series Tractors
9009 224 and 274 Self-Propelled
Commercial Mowers 1993
9301 Introduction to the Models 2450/2550
Self-Propelled Windrowers
1991
9302 The PowerStart 40 Series Hydraulics
9101 Metalert® II Electronic Metal Detector 9303 Bale Commandt Electrical Operation
System and Troubleshooting
9102 Tractor Air Conditioning 9304 The Lucas CAV Model DPS Rotary
9103 C Series Transmission: Electrical Fuel Injection Pump
Control Circuitry 9305 Skid-Steer Loader Final Drive
9104 15 Speed, 3 x 5, and 15 x 5 Large Troubleshooting and Repair
4WD Transmissions 9306 Model 2450/2550 Windrower
9105 Hydraulic and Hydrostatic Component Hydraulic/Hydrostatic System
Failure Analysis 9307 D-Series Tractor Loader Backhoe
9106 Model 5 and Model 10 Electronic Hydraulic System Troubleshooting
Scales 9308 Model 2120 Electronic Hydraulic
9107 Batteries Shuttle Shift Transmission
9108 Bale Commandt System for Model
650 and 660 Round Balers
9109 20 Series Compact Tractor System 1994
and Auxiliary Hydraulics 9401 Basic Hydraulics
9402 The New Generation Skid-Steer
Loaders
9403 LS Series Yard Tractors
9404 Introduction to the GENESISt 70
Series
9405 70 Series Electrical System and the
PDT
9406 Understanding the Metric System
41
RELEASES TO DATE
1995 1998
9501 Optimizing Tractor Performance 9801 Intermediate Hydraulics
Through Ballasting and Tire Selection 9802 Customer Relations
9502 Pumps and Actuators 9803 Introduction to the TV140
9503 GENESISt 70 Series Hydraulics Bidirectionalt Tractor
9504 Air Conditioning R-134a 9804 Introduction to the TS Tractors
9505 Basic Electrical Diagnostics 9805 Troubleshooting
9506 Skid Steer Loader Steering, Neutral & 9806 60 Series Electrical
Final Drive 9807 Skid-Steer Loader Advanced
9507 600 Series Disc Mowers and 1411 Disc Warning System
Mower-Conditioners 9808 Introduction to the HW300 Series
Windrowers
1996 1999
9601 Haybine® Operation and Adjustment
9901 New Holland Worldwide Dealer
9602 Intermediate Electrical Diagnostics Standards: Customer Satisfaction
9603 Introduction to the GEMINIt 60 Series 9902 New Holland FWD Axles
9604 Bale Command Plust Operation and 9903 TV140 Electrical System
Calibration
9904 Introduction to the TN Family of
9605 Introduction to the 35 Series Tractors
9606 9030 Hydraulic and Electro-Hydraulic 9905 Crop Processing
Three-Point Hitch Systems 9906 Introduction to the TN Standard
9607 Metalert® III Tractors
9608 Skid-Steer Loader Electrical 9907 Connecting Hydraulic Applications to
CCLS Hydraulics
9908 Loadstar Attachments
1997
9701 Diesel Engine Theory and Timing
2000
9702 Introduction to “Boomert”: The 25
and 30 Series Class II Compact 2000-1 Understanding the Global Coding
Tractors System
9703 Understanding Disc Cutting 2000-2 Introduction to the FP230/240 Forage
9704 E-Series Backhoe Loader Hydraulics Harvesters
9705 60 Series Transmissions 2000-3 Introduction to the TC Class III
Compact Tractors
9706 Boomert 25 and 30 Series Compact
Tractor Electrical 2000-4 Introduction to the Model 1441/1442
Disc Cutters
9707 E-Series Transmission
2000-5 Introduction to the TM Tractors
9708 35 Series Hydraulics
2000-6 LS Skid Steer Neutral Adjustment
Procedures
2000-7 TM Tractors Power Command
Transmission
2000-8 The 21st Century Bidirectional TV140
42
RELEASES TO DATE
2001
2001-1 The Product Automated Library (PAL) 2003
2001-2 Introduction to the MC Commercial 2003-1 Introduction to the TM II Tractors
Mowers 2003-2 Introduction to the BR Balers
2001-3 2300 Series Auger Headers Wobble 2003-3 Introduction to the HS Series Headers
Drive
2003-4 Introduction to the Cummins
2001-4 TN Series Electrical Power Shuttle Accumulator Pump System (CAPS)
Transmissions
2003-5 Flexi-Coil 40 Series and New Holland
2001-5 Introduction to the B27P and B37P SC Series Air Carts
Round Balers
2003-6 Introduction to the TG Series Tractors
2001-6 TS Tractors with Electroshift Left-Hand
Power Shuttle 2003-7 Introduction to the TS-A Series
2001-7 The 70A Series Tractors
2001-8 Timing Procedures for the Delphi
DP200 Series Fuel Injection Pump
2004
2004-1 Tier 2 Engines
2002 2004-2 Class IV Compact Tractors and EHSS
2002-1 Using the ASIST Knowledge Search 2004-3 NEF Engine
Feature
2002-2 TN Tractor Hydraulics
2002-3 Using the Portable Data Assistant
(PDA)
2002-4 TC Tractor Hydrostatic Transmission
2002-5 Introduction to the Cursor Engines
2002-6 70A Tractor Electro-Hydraulic Remote
Valves
2002-7 Introduction to the Electronic Service
Tool (EST)
2002-8 CV Joints
43
RELEASES TO DATE
44