N SERIESEU/2002/88/CE

G-DRIVE application

N45NEF45 AM1

NEF45 SM1- NEF45 SM2 - NEF45 TM1NEF45 TM2

N67NEF67 TE2 - NEF67 TM2 - NEF67 TM3

Technical and Repair manual

F4GE N Series Part 1

F4HE N Series Part 2

N SERIES G-Drive EU/2002/88/CE

1G-Drive EU/2002/88/CE N SERIES

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INTRODUCTION 1G-Drive EU/2002/88/CE N SERIES

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Introduction

Page

PREFACE TO USER’S GUIDELINE MANUAL 3. . . .

SYMBOLS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

- Service operations 3. . . . . . . . . . . . . . . . . . . . . .

GENERAL WARNINGS 5. . . . . . . . . . . . . . . . . . . . .

GENERAL WARNINGSON THE ELECTRIC SYSTEM 7. . . . . . . . . . . . . . .

- Bonding and screening 8. . . . . . . . . . . . . . . . . . .

CONVERSIONS BETWEEN THE MAIN UNITSOF MEASUREMENT OF THE INTERNATIONALSYSTEM AND MOST USED DERIVEDQUANTITIES 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

KEY OF LECTURE OF THE HEADINGSAND FOOTNOTES 10. . . . . . . . . . . . . . . . . . . . .

Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sectionsare indicated in the general table of contents.The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assemblydetaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’selectronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for thecontrol units peculiar to the electric system.Section 1 describes the engine illustrating its features and working in general.Section 2 describes the type of fuel feed.Section 3 relates to the specific duty and is divided in four separate parts:1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on therelating specific duty.2. Electrical part, concerningwiring harness, electrical and electronic equipment with different characteristics basedon the relatingspecific duty.3. Maintenance planning and specific overhaul.4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple anddirect instructions to identify the cause of the major inconveniences.Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to executesuch operations.The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers inorder to prevent serious accidents taking place.Themanual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,there have been defined a set of symbols to classify warnings and a set for assistance operations.

General danger

It includes the dangers of above described signals.

Danger of serious damage for the assembly

Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and maysometimes cause the warranty to become null and void.

Environment protection

Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such away so as to protectthe environment as much as possible.

Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.

SYMBOLS - Warnings

It indicates an additional explanation for a piece of information.

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PREFACETOUSER’SGUIDELINE MANUAL

Service operations

Example

Ø 1 = housing for connecting rod small end bush

Ø 2 = housing for connecting rod bearings

NOTE

α

Tighten to torqueTighten to torque + angular value

1∅

∅ 2

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RemovalDisconnection

Intake

RefittingConnection

Exhaust

RemovalDisassembly

Operation

Fitting in placeAssembly ρ Compression ratio

Tighten to torqueToleranceWeight difference

αTighten to torque + angle value Rolling torque

Press or caulk Rotation

RegulationAdjustment

AngleAngular value

!WarningNote

Preload

Visual inspectionFitting position check

Number of revolutions

MeasurementValue to findCheck

Temperature

Equipmentbar

Pressure

Surface for machiningMachine finish

OversizedHigher than….Maximum, peak

InterferenceStrained assembly

UndersizedLess than….Minimum

ThicknessClearance

SelectionClassesOversizing

LubricationDampGrease

Temperature < 0 °CColdWinter

SealantAdhesive

Temperature > 0 °CHotSummer

Air bleeding

GENERALWARNINGS

Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested tocontact 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 andmaintenance 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 andon 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 usedmust contain clear indications on maximum carrying capacity acceptable. The use of saidmeansis 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 fromaccidentally striking workshop personnel.

Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could bedangerous 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. Strictlyfollow 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 supportingstands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be liftedby 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 pressureout.

Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained onharmful 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 pollutingfluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers tostore harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammablesubstances 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 oilspots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.

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INTRODUCTION 5G-Drive EU/2002/88/CE N SERIES

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Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembledparts 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; FPT commercial and assistance network isavailable 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 chassisbonding) 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 othermaterials flow which may catch fire easily on welding.

Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic centralunits.

The disposal of all liquids and fluids must be performed with full observance of specific rules in force.

Put on, where required by the intervention, garments and protections provided in accident prevention rules; contactwith 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 fromheating or frompaint welding because they can cause damages to health; operateoutdoors 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 seriousburns. 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.

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GENERALWARNINGS ON THE ELECTRIC SYSTEM

To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries orspecial 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 tighteningtorque.

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/bodystructure.

Once the intervention on the electric systemhas been completed, recover connectors andwiring harnesses accordingto original arrangement.

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 batteryterminals.

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 screeningbraiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions.

Measurements in drive electronic central units, plugged connections and electric connections to components can onlybemade 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.

Connectors present must be seen from cable side. Connectors views contained in the manual are representative ofcable side.

!

NOTE

INTRODUCTION 7G-Drive EU/2002/88/CE N SERIES

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8 INTRODUCTION G-Drive EU/2002/88/CE N SERIES

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Bonding and screening

Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other,trying then to have their centering tidily and properly made (Figure 1, re. M).

Further, following warnings are to be compulsorily observed for electronic components:

- 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 openingbonding (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.

1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTORd. DISTANCE! 0

88039

Figure 1

Figure 2

INTRODUCTION 9G-Drive EU/2002/88/CE N SERIES

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CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THEINTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES

Power

1 kW = 1.36 metric HP1 kW = 1.34 HP1 metric HP = 0.736 kW1 metric HP = 0.986 HP1 HP = 0.746 kW1 HP = 1.014 metric HP

Torque

1 Nm = 0.1019 kgm1 kgm = 9.81 Nm

Revolutions per time unit

1 rad/s = 1 rpm x 0.10461 rpm = 1 rad/s x 9.5602

Pressure

1 bar = 1.02 kg/cm2

1 kg/cm2 = 0.981 bar1 bar = 105 Pa

Where accuracy is not particularly needed:

- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1

1 kgm = 10 Nm;

- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1

1 kg/cm2 = 1 bar.

Temperature

0° C = 32° F1° C = (1 x 1.8 + 32) ° F

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KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Basic edition referred tomonth - year editorial

phase closing

When month - yearupdate is present (revi) to

the basic edition

Type ofvehicle

Sectiontitle

Pagenumber

Printoutnumber

LanguagePublication

Section

General specifications 1

Fuel 2

G-DRIVE applications 3

Overhaul and technical specifications 4

Tools 5

Safety prescriptions Appendix

Part 1F4GE N SERIES

1G-Drive EU/2002/88/CE N SERIES

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SECTION 1 - GENERAL SPECIFICATIONS 1G-Drive EU/2002/88/CE N SERIES

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SECTION 1

General Specifications

Page

CORRESPONDENCE BETWEEN TECHNICAL CODEAND COMMERCIAL CODE 3. . . . . . . . . . . . . . .

LUBRICATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL VAPOUR RECIRCULATING SYSTEM 7. . . . . . .

COOLING SYSTEM 8. . . . . . . . . . . . . . . . . . . . . . . .

- Version with turbocharger (4 cylinders) 8. . . . . .

- Version with turbocharger (6 cylinders) 9. . . . . .

- Version without turbocharger 10. . . . . . . . . . . . .

AIR INDUCTION BOOST DIAGRAM 11. . . . . . . . . .

- Boosting version engines 11. . . . . . . . . . . . . . . . .

- Description 11. . . . . . . . . . . . . . . . . . . . . . . . . . .

- Inter-cooled engine version 12. . . . . . . . . . . . . . .

- Description 12. . . . . . . . . . . . . . . . . . . . . . . . . . .

CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE

SECTION 1 - GENERAL SPECIFICATIONS 3G-Drive EU/2002/88/CE N SERIES

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Technical Code Commercial Code

F4GE0405A*F650 NEF45 AM1S

F4GE04055C*F650 NEF45 SM1A

F4GE04055A*F650 NEF45 SM2A

F4GE0485A*F650 NEF45 TM2A

F4GE0485C*F650 NEF45 TM1A

F4GE0685D*F650 NEF67 TM2A

F4GE0685B*F650 NEF67 TM3A

Figure 1

LUBRICATION

Lubrication by forced circulation is achieved through oil rotaryexpansion pump, placed in the front part of the basement,driven by the straight-tooth gear splined to the shaft’s bar hold.

From the pan, the lubrication oil flows to the driving shaft, tothe camshaft and to the valve drive.

Lubrication involves the heat exchanger (2,3), theturboblower for turbocompressed versions, and for anycompressed air system.

All these components may often vary according to the specificduty.

LUBRICATION SYSTEM LAYOUT (4 cylinder engine)

1. Heat exchanger body - 2. Lubrication oil pipe to supercharger - 3. Oil filter - 4. Heat exchanger -5. Oil rotary expansion pump.

116396

Routing of oil underpressureRouting of oil returnby gravity to sump

Introduction of oil

4 SECTION 1 - GENERAL SPECIFICATIONS G-Drive EU/2002/88/CE N SERIES

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Figure 2

LUBRICATION SYSTEM LAYOUT (6 cylinder engines)

1. Lubrication oil pipe to supercharger - 2. Heat exchanger body - 3. Heat exchanger -4. Oil rotary expansion pump - 5. Oil filter.

112886

SECTION 1 - GENERAL SPECIFICATIONS 5G-Drive EU/2002/88/CE N SERIES

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Figure 3

LUBRICATION SYSTEM LAYOUT

1. Heat exchanger body - 2. Heat exchanger - 3. Oil rotary expansion pump - 4. Oil filter.

129123

Version without turbocharger

6 SECTION 1 - GENERAL SPECIFICATIONS G-Drive EU/2002/88/CE N SERIES

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3240t

Figure 4

OIL VAPOUR RECIRCULATING SYSTEM

1. Valve - 2. Breather pipe - 3. Tappet Cap

On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity,to the Tappet cap underneath.

The remaining non-condensed vapours shall be properly conveyed through the breather pipe (2), by suction as an example (con-nection towards these vapours shall be designed by the Engineer).

1

2

3

SECTION 1 - GENERAL SPECIFICATIONS 7G-Drive EU/2002/88/CE N SERIES

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Figure 5

129304

DIAGRAM OF THE COOLING SYSTEM

COOLING SYSTEMThe engine cooling system, closed circuit forced circulationtype, generally incorporates the following components:

- Expansion tank; placement, shape and dimensions aresubject to change according to the engine’s equipment.

- Radiator, which has the duty to dissipate the heatsubtracted to the engine by the cooling liquid. Also thiscomponent will have specific peculiarities based on theequipment developed, both for what concerns theplacement and the dimensions.

- Viscous pusher fan, having the duty to increase the heatdissipating power of the radiator. This component as wellwill be specifically equipped based on the engine’sdevelopment.

- Heat exchanger to cool the lubrication oil: even thiscomponent is part of the engine’s specific equipment.

- Centrifugal water pump, placed in the front part of theengine block.

- Thermostat regulating the circulation of the cooling liquid.

- The circuit may eventually be extended to thecompressor, if this is included in the equipment.

Version with turbocharger (4 cylinders)

8 SECTION 1 - GENERAL SPECIFICATIONS G-Drive EU/2002/88/CE N SERIES

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Figure 6

106532

COOLING SYSTEM LAYOUT

Version with turbocharger (6 cylinders)

SECTION 1 - GENERAL SPECIFICATIONS 9G-Drive EU/2002/88/CE N SERIES

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Figure 7

130199

COOLING SYSTEM LAYOUT

Version without turbocharger

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Figure 8

Description

AIR FILTER TURBOCHARGER

EXHAUST

4 cylinders version

88208

AIR INDUCTION BOOST DIAGRAMBoosting version engines

The turbocharger is composed by the following main parts:one turbine, one transforming valve to regulate the boostfeeding pressure , one main body and one compressor.

During engine working process, the exhaust emission flowthrough the body of the turbine, provoking the turbine diskwheel’s rotation.

The compressor rotor, being connected by shaft to theturbine disk wheel, rotates as long as this last one rotates,compressing the sucked air through the air filter.

The air coming out of the compressor is sent via the intakemanifold directly to the pistons.

The turbocharger is equipped with a transforming valve toregulate the pressure , that is located on the exhaust collectorbefore the turbine and connected by piping to the inductioncollector.

It’s duty is to choke the exhaust of the emissions , releasing partof them directly to the exhaust tube when the boost feedingpressure, over the compressor, reaches the prescribed barvalue.

The cooling process and the lubrication of the turbochargerand of the bearings is made by the oil of the engine.

SECTION 1 - GENERAL SPECIFICATIONS 11G-Drive EU/2002/88/CE N SERIES

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