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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Chapter Chapter 3 3 NEF NEF ENGINE ENGINE

ChapterChapter 33 NEFNEF ENGINEENGINE TIERTIER 33

SR2 Series” TIER 3 NEF Engine Chapter Chapter 3 3 NEF NEF ENGINE ENGINE TIER TIER
SR2 Series” TIER 3 NEF Engine Chapter Chapter 3 3 NEF NEF ENGINE ENGINE TIER TIER

Monthyon, november 2007

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine 9 5 7 6 8 3 4 1
9 5 7 6 8 3 4 1 2
9
5
7
6
8
3
4
1
2

1

2

3

;

4

5

6

7

8

9

– Engine controller;

– Crankshaft sensor;

– High pressure pump

– Fuel filter;

– Injection pressure sensor;

– PTO;

– Preheating grid;

– Water pump;

– Turbocharged;

– Injection pressure sensor; – PTO; – Preheating grid; – Water pump; – Turbocharged; Monthyon, november

Monthyon, november 2007

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

3.1. Identification plate

TIER 3 NEF Engine

SR2 Series” 3.1. Identification plate TIER 3 NEF Engine 1 3 2 4 6 5 8
1 3 2 4 6 5 8 7
1
3
2
4
6
5
8
7
plate TIER 3 NEF Engine 1 3 2 4 6 5 8 7 1: Engine code

1: Engine code

F4

=

Engine familiy (NEF)

H

=

Non structural engine block - 4 valves on each cylinder

E

=

Engine

0

=

Engine configuration (4 strokes, vertical)

4

=

Number of cylinders

8

=

Injection and intake (Turbocharged, Diesel, ID, Intercooler)

4

=

Application (Tractors and construction machinery)

E

=

Homologation power

J

=

Emission level (Tier 3)

2: Date of manufacturing (month - year) 3: Gross power given in in Hp 4: Displacement given in cubic inches: 272 cu. in. = 4490 cc. 5: Max fuel quantity delivered by each pump piston in one cycle, given in mg/stroke 6: Engine minimum idle speed 7: Injection advanced mode data (not used) 8: Intake valve backlash (inches) 9: Exhaust valve backlash (inches)

mode data (not used) 8: Intake valve backlash (inches) 9: Exhaust valve backlash (inches) Monthyon, november

Monthyon, november 2007

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

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

TIER 3 NEF Engine

 

Engine

 

Maker - Model ………………………………………… Bore x stroke ……………………………………………

 

NEF - FHHE9484 C J 101 XXXX (Tier 3) 104mm x 132mm

Displacemen…………………………………………………4.5 Litres Rated speed ………………………………………………. 2200 rpm

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

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

Firing order ………………………………………………

1

3 – 4 – 2

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

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

 
  Monthyon, november 2007   4
 

Monthyon, november 2007

 

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Nomenclature of engine - Turbo side 5 4

Nomenclature of engine - Turbo side

5 4 6 3 1 7 2
5
4
6
3
1
7
2

COMPONENTS

1. High pressure pump;

2. Fuel filter;

3. Engine controller;

4. Common Rail with high pressure relief valve

5. Intake air (from aftercooler)

6. Engine oil filling

7. Low pressure pump

relief valve 5. Intake air (from aftercooler) 6. Engine oil filling 7. Low pressure pump Monthyon,

Monthyon, november 2007

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Nomenclature of engine - Turbo side 3 5

Nomenclature of engine - Turbo side

3 5 1 4 2
3
5
1
4
2

COMPONENTS

1. Turbocharged with wastegate

2. Engine oil filter

CONNECTIONS

3. To muffler

4. Air intake to aftercooler

5. Air intake (from filter)

oil filter CONNECTIONS 3. To muffler 4. Air intake to aftercooler 5. Air intake (from filter)

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Nomenclature of engine - Front 2 3 1

Nomenclature of engine - Front

2 3 1 4
2
3
1
4
TIER 3 NEF Engine Nomenclature of engine - Front 2 3 1 4 COMPONENTS 1. Engine
TIER 3 NEF Engine Nomenclature of engine - Front 2 3 1 4 COMPONENTS 1. Engine

COMPONENTS

1. Engine controller

2. Common rail

3. Turbocharged

4. Water pump

Front 2 3 1 4 COMPONENTS 1. Engine controller 2. Common rail 3. Turbocharged 4. Water

Monthyon, november 2007

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Nomenclature of engine - Actuators and sensors 1

Nomenclature of engine - Actuators and sensors

1 2 3 4
1
2
3
4

COMPONENTS

1. Common rail relief valve

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

3. Fuel discharge from electric- injector

4. Fuel discharge from common rail

3 . Fuel discharge from electric- injector 4 . Fuel discharge from common rail Monthyon, november

Monthyon, november 2007

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Nomenclature of engine - Actuators and sensors 1

Nomenclature of engine - Actuators and sensors

1 2 1 – Common Rail; 2 – Injection pressure sensor;
1
2
1 – Common Rail;
2 – Injection pressure sensor;
of engine - Actuators and sensors 1 2 1 – Common Rail; 2 – Injection pressure

Monthyon, november 2007

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine E.G.R. – Exaust Gas Recirculation Note: in the

E.G.R. – Exaust Gas Recirculation

TIER 3 NEF Engine E.G.R. – Exaust Gas Recirculation Note: in the picture there is a

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

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

EGR stand for Exaust Gas Recirculation.

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

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

Since the production of oxide of nitrogen (pollution) is directly proportional to

combustion temperature,

reduce the combustion temperature, we reduce pollution.

IVECO NEF got the EGR just mdifying the cams shaft.

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

it means that if we

gas is going outside of cylinder, part re-enter in the same cylinders. it means that if

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LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine E.G.R. – Exaust Gas Recirculation On
LOADER-BACKHOE CASE “580-590-695 SR2 Series”
TIER 3 NEF Engine
E.G.R. – Exaust Gas Recirculation
On NEF engines an extra lobe on the cam shaft let
to get the exhaust gas recirculation during the intake
cycle by keeping the exhaust valve open for a short
time.
B
A
11
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LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine E.G.R. – Exaust Gas Recirculation 12
LOADER-BACKHOE CASE “580-590-695 SR2 Series”
TIER 3 NEF Engine
E.G.R. – Exaust Gas Recirculation
12
Monthyon, november 2007
LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Nomenclature of engine - Actuators and
LOADER-BACKHOE CASE “580-590-695 SR2 Series”
TIER 3 NEF Engine
Nomenclature of engine - Actuators and sensors
4
COMPONENTS
1. Proportional valve
3
2. Low pressure pump
3 - High pressure pump
4. Fuel filter;
5. Fuel temperature sensor;
2
4
1
13
Monthyon, november 2007

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine 2 1 3 Nomenclature of engine - Actuators
2 1
2
1
3
3

Nomenclature of engine - Actuators and sensors

COMPONENTS

1. Engine oil filter;

2. Engine oil pressure temperature sensore;

3. Coolant temperature sensor;

Engine oil filter; 2. Engine oil pressure temperature sensore; 3. Coolant temperature sensor; Monthyon, november 2007

Monthyon, november 2007

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LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Nomenclature of engine - Actuators and
LOADER-BACKHOE CASE “580-590-695 SR2 Series”
TIER 3 NEF Engine
Nomenclature of engine - Actuators and sensors
1
COMPONENTS
1. Timing gear sensor (camshaft);
2. Cranshaft sensor;
2
15
Monthyon, november 2007
LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Nomenclature of engine - Actuators and
LOADER-BACKHOE CASE “580-590-695 SR2 Series”
TIER 3 NEF Engine
Nomenclature of engine - Actuators and sensors
COMPONENTS
3
1 – Fuel pre-filter;
2
2 – Breather screw;
3 – Fuel lifting pump;
4 – Water in fuel sensor;
1
4
16
Monthyon, november 2007
LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Nomenclature of engine - Actuators and
LOADER-BACKHOE CASE “580-590-695 SR2 Series”
TIER 3 NEF Engine
Nomenclature of engine - Actuators and sensors
2
3
1
1. Fuel filter
2. To high pressure pump
To fuel tank
17
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LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Injection pump 4 5 3 1
LOADER-BACKHOE CASE “580-590-695 SR2 Series”
TIER 3 NEF Engine
Injection pump
4
5
3
1
2
1 – From engine controller
2 – To fuel filter
3 – From fuel filter to high pressure pump
4 – Return fuel to filter
5 – To Common Rail
18
Monthyon, november 2007
LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine “Common rail” injection system High pressure
LOADER-BACKHOE CASE “580-590-695 SR2 Series”
TIER 3 NEF Engine
“Common rail” injection system
High
pressure
pump
Fuel
filter
Fuel
prefilter
Fuel
radiator
Low pressure
pump
Fuel tank
19
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LOADER-BACKHOE CASE “580-590-695 SR2 Series”

TIER 3 NEF Engine

3.7. “Common Rail” injection system

TIER 3 NEF Engine 3.7. “Common Rail” injection system High pressure pump A. Fuel return port

High pressure pump

3.7. “Common Rail” injection system High pressure pump A. Fuel return port - B. Fuel inlet
3.7. “Common Rail” injection system High pressure pump A. Fuel return port - B. Fuel inlet

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

controlled by PWM signal from EDC7 electronic control unit). 1. Cylinder - 2. Three lobes cam
controlled by PWM signal from EDC7 electronic control unit). 1. Cylinder - 2. Three lobes cam

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

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

is required. With fuel supply gear pump installed on the back of the high pressure pump.

Monthyon, november 2007

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine 3.7. “Common Rail” injection system Electric injector -
CASE “580-590-695 SR2 Series” TIER 3 NEF Engine 3.7. “Common Rail” injection system Electric injector -

3.7. “Common Rail” injection system

Electric injector - rest condition

1. Pressure rod

2. Needle

3. Nozzle

4. Coil

5. Pilot valve

6. Ball shutter

7. Control area

8. Pressure chamber

9. Control volume

10. Supply-contro line

11. Control fuel outlet

12. Electrical connector

13. Spring.

10. Supply-contro line 11. Control fuel outlet 12. Electrical connector 13. Spring. Monthyon, november 2007 21

Monthyon, november 2007

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

LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine From Rail To reservoir 3.7. “Common Rail”

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine From Rail To reservoir 3.7. “Common Rail” injection
From Rail To reservoir
From Rail
To reservoir

3.7. “Common Rail” injection system

Injection starting

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

At the same time, the fuel pressure in the pressure chamber (8) pushes the needle (2)upward, allowing the fuel spraying into the cylinder combustion chamber.

Injection end

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

balance suitable to keep closed the injector needle ( 2 ) and shut off t he

Monthyon, november 2007

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine “Common Rail” injection system Engine controller input

“Common Rail” injection system

Engine controller input /output signals

Coolant temperature sensor Intake manifold combined pressure/temp. sensor Fuel temperature sensor Ambient pressure
Coolant temperature
sensor
Intake manifold combined
pressure/temp. sensor
Fuel temperature
sensor
Ambient pressure
sensor
Common rail fuel pressure
sensor
Engine oil combined pressure/temp sensor Timing gear sensor Crankshaft speed sensor Throttle potentiommeter signal
Engine oil combined
pressure/temp sensor
Timing gear
sensor
Crankshaft speed
sensor
Throttle potentiommeter
signal
Crankshaft speed sensor Throttle potentiommeter signal Proportional solenoid valve installed on high pressure
Proportional solenoid valve installed on high pressure pump
Proportional solenoid valve
installed on high pressure
pump
solenoid valve installed on high pressure pump Diagnostic connector Injector solenoids Preheating grid
Diagnostic connector
Diagnostic connector
Injector solenoids
Injector solenoids
Preheating grid relay
Preheating grid relay
on high pressure pump Diagnostic connector Injector solenoids Preheating grid relay Monthyon, november 2007 23

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

TIER 3 NEF Engine

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LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Monthyon, november 2007 24
LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Monthyon, november 2007 24
LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Monthyon, november 2007 24

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

TIER 3 NEF Engine

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

TIER 3 NEF Engine

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TIER 3 NEF Engine

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1 2
1
2
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TIER 3 NEF Engine

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1
2
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TIER 3 NEF Engine

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1
2
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TIER 3 NEF Engine

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LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Monthyon, november 2007 30

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TIER 3 NEF Engine

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1
2
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TIER 3 NEF Engine

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1
2
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TIER 3 NEF Engine

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TIER 3 NEF Engine

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1 2
1
2
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TIER 3 NEF Engine

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1 2
1
2
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TIER 3 NEF Engine

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1 2
1
2
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TIER 3 NEF Engine

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LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Monthyon, november 2007 37

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine 1 2 In case of Cluster replacement Monthyon,
1 2 In case of Cluster replacement
1
2
In case of Cluster
replacement
CASE “580-590-695 SR2 Series” TIER 3 NEF Engine 1 2 In case of Cluster replacement Monthyon,

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

TIER 3 NEF Engine

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

TIER 3 NEF Engine

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

TIER 3 NEF Engine

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine View information or download Monthyon, november 2007 42
View information or download
View information or download
CASE “580-590-695 SR2 Series” TIER 3 NEF Engine View information or download Monthyon, november 2007 42

Monthyon, november 2007

42

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

TIER 3 NEF Engine

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1 2
1
2
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TIER 3 NEF Engine

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1
1
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TIER 3 NEF Engine

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

TIER 3 NEF Engine

CASE “580-590-695 SR2 Series” TIER 3 NEF Engine After cluster replacement is necessary to enter in
After cluster replacement is necessary to enter in this screen and set properly the following
After cluster replacement
is necessary to enter in this screen
and set properly the following
parameters :
Air conditioning;
Preheating grid;
Pilot control,
than send the values to the controler
2
1
conditioning; Preheating grid; Pilot control, than send the values to the controler 2 1 Monthyon, november

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

TIER 3 NEF Engine

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1 2
1
2
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LOADER-BACKHOE CASE “580-590-695 SR2 Series”

TIER 3 NEF Engine

LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Select Language Monthyon, november 2007 48
Select Language
Select
Language
LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Select Language Monthyon, november 2007 48
LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Select Language Monthyon, november 2007 48

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TIER 3 NEF Engine

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INJECTORS CUT OFF
INJECTORS CUT OFF
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PRESENTATION

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CASE “580-590-695 SR2 Series” TIER 3 NEF Engine Programming This ECU software download procedu re is

Programming

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

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

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

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

a different machine that is loaded with inappropriate software for the selected machine. Monthyon, november 2007

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Blank Controller Download

 

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

• One process to initialize the controller.

 

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

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

 
 
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1 Chose here the right program 2 64 Monthyon, november 2007
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Chose here the right program
2
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LOADER-BACKHOE CASE “580-590-695 SR2 Series” TIER 3 NEF Engine ******** * ****** * Monthyon, november 2007
******** * ****** *
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FAULT CODE LIST

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CASE “580-590-695 SR2 Series” TIER 3 NEF Engine How to record engine parameter with the E.S.T

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

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