SERVICE MANUAL Part number 47899763 1st edition English July 2015 NEF Four Cylinder Mechanical Tier 2 and Stage II Engine See the following page for engine model numbers
F4GE0404B*D602 F4GE0454B*D601 F4GE0454B*D651 F4GE0454E*D601
SERVICEMANUAL
4789976314/07/2015
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.101]Cylinderheads.....................................................................10.2 [10.102]Panandcovers....................................................................10.3 [10.103]Crankshaftandflywheel............................................................10.4 [10.114]Pumpdrives........................................................................10.8 [10.206]Fuelfilters..........................................................................10.9 [10.210]Liftpumpandlines...............................................................10.10 [10.218]Fuelinjectionsystem.............................................................10.11 [10.250]Turbochargerandlines...........................................................10.12 [10.304]Enginelubricationsystem........................................................10.14 [10.400]Enginecoolingsystem...........................................................10.15 [10.414]Fananddrive....................................................................10.17 Electricalsystems.......................................................................55 4789976314/07/2015
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INTRODUCTION
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Contents
Safetyrules.....................................................................................4 Torque..........................................................................................6 4789976314/07/2015 2
INTRODUCTION
INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing
4789976314/07/2015 3
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
INTRODUCTION Safetyrules Personalsafety FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: Noticeindicatesasituationwhich,ifnotavoided,couldresultinmachineorpropertydamage.Thecolor ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor Information NOTE: Noteindicatesadditionalinformationwhichclarifiessteps,procedures,orotherinformationinthismanual. 4789976314/07/2015 4
INTRODUCTION Safetyrules-Ecologyandtheenvironment Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,filters,batteries,fuels,anti-freeze, cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use, Helpfulhints • • • • etc.Donotmixdrainedbrakefluidsorfuelswithlubricants.Storealldrainedfluidssafelyuntilyoucandisposeof • Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly. • • • • Batteryrecycling Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful thisisalegalrequirement. Mandatorybatteryrecycling NOTE: Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead, CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany Pointsofsaleareobligedto: • Acceptthereturnofyourusedbatteries • Storethereturnedbatteriesinasuitablelocation • Sendthereturnedbatteriestothebatterymanufacturerforrecycling 4789976314/07/2015 5
INTRODUCTION
Specification
Torque Component Size
CylinderHeadandComponents
LubricationSystemandComponents 4789976314/07/2015 6
RockerAssembly 20-28Nm ( ) CylinderHead M12x70 Phase1 50Nm ( ) Phase2 90° CylinderHead M12x140 Phase1 40Nm ( ) Phase2 180° CylinderHead M12x180 Phase1 70Nm ( 51.6lbft ) Phase2 180° ValveCover 20-28Nm ( ) Intakemanifold M8x1.25 ( ) Airintakeelbow 20-28Nm ( ) Exhaustmanifold 37-49Nm ( ) Rearliftingbracket ( ) Turbocharger M10 ( ) FrontCase Frontcoverassembly 20-28Nm ( ) ( ) RearCase GearCase 20-28Nm ( ) 20-28Nm ( ) M10x1.5 ( ) Flywheelhousing M12x120 75-95Nm ( ) M12x80 75-95Nm ( ) M10x80 44-54Nm ( ) M10x40 ( ) Engineflywheel Phase1 26-34Nm ( ) Phase2 CylinderBlockandCrankshaftComponents Mainbearingcap Phase1 ( ) Phase2 74-86Nm ( ) Phase3 Connectingrod Phase1 ( ) Phase2 TimingPin 4-6Nm ( ) Crankshaftpulley 105-115Nm ( ) Camshaftretainingplate 20-28Nm ( ) Camshaftgear ( )
INTRODUCTION Component Size Specification PistonCoolingNozzles 12-18Nm ( ) Oilpump
) StiffeningPlate
) Oilplug M10x1
)
) OilPickuptube
) OilPan ( )
( ) OilBypassValve
( ) TurboLubricationLines Turboend M12x1.5 ( ) Filterbaseend 20-28Nm ( ) Drain 20-28Nm ( ) ElectricalComponents Alternator 20-28Nm ( ) ( ) M10 44-54Nm ( ) 37-49Nm ( ) Alternatorwiring 8-11Nm ( ) Starter M10 ( ) FuelSystemandComponents Fuelpump M8screw 20-28Nm ( ) M6screw ( ) M6nut 9-11Nm ( ) FuelPumpDriveGear Phase1 15-20Nm
) Phase2 ( ) TimingPinCap
) Fuelinjectors
) Fuelliftpump
) CoolingSystemandComponents WaterPump
( ) Wateroutletconnection ( )
( ) Fansupport
( ) Fanpulley M6
( ) M10 ( ) 4789976314/07/2015 7
7-9Nm (
38-48Nm (
(
9-13Nm (
20-28Nm (
M18x1.50 51-69Nm
72-88Nm
(
30-35Nm (
55-65Nm (
20-28Nm (
20-28Nm
M8x1.25x70
28-38Nm
8-12Nm
2.2N·m ( 19lb ) 2.9N·m ( 26lb ) 3.2N·m ( 28lb ) 4.2N·m ( 37lb ) 2N·m ( 18lbin ) 2.9N·m ( 26lb ) 4.5N·m ( 40lb ) 5.9N·m ( 52lb ) 6.4N·m ( 57lb ) 8.5N·m ( 75lb ) 4N·m ( 36lbin ) 5.8N·m ( 51lb ) 7.5N·m ( 66lb ) 10N·m ( 89lb ) 11N·m ( 96lb ) 15N·m ( 128lb ) 6.8N·m ( 60lb ) 10N·m ( 89lb ) 18N·m ( 163lb ) 25N·m ( 217lb ) 26N·m ( 234lb ) 35N·m ( 311lb ) 17N·m ( 151lb ) 24N·m ( 212lb )
M10 ( 27lbft ) 49N·m ( 36lb ) ( 38lbft ) 70N·m ( 51lb ) 33N·m ( 25lb ) 48N·m ( 35lb )
M12 ( 47lbft ) 85N·m ( 63lb ) ( 67lbft ) 121N·m ( 90lb ) 58N·m ( 43lb ) 83N·m ( 61lb )
M16 ( 116lb ) ( 155lbft ) ( 166lb ) ( 222lb ) ( 106lb ) ( 151lb ) M20 ( 235lb ) ( 313lbft ) ( 325lb ) ( 433lb ) ( 214lb ) ( 295lb )
M24 ( 410lb ) 735N·m ( 500lbft ) ( 560lb ) 1016N·m ( 750lbft ) ( 370lb ) ( 510lb )
NOTE:
INTRODUCTION Torque-Minimumtighteningtorquesfornormalassembly METRICNON-FLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT
UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr
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INTRODUCTION METRICFLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr (
(
(
IDENTIFICATION MetricHexheadandcarriagebolts,classes5.6andup 20083680 1 1.Manufacturer'sIdentification MetricHexnutsandlocknuts,classes05andup 20083681 2 4789976314/07/2015 9
21lb )
28lb ) ( 31lb ) ( 41lb ) ( 19lb ) ( 27lb )
43lb ) ( 58lb ) ( 62lb ) ( 83lb ) ( 39lb ) ( 57lb ) 8.3N·m ( 73lb ) ( 96lb ) ( 105lb ) ( 141lb ) 7.5N·m ( 66lb ) ( 96lb ) ( 179lb ) ( 240lb ) ( 257lb ) ( 343lb ) ( 163lb ) ( 240lb ) M10 40N·m ( 30lbft ) 54N·m ( 40lb ) 57N·m ( 42lbft ) 77N·m ( 56lb ) 37N·m ( 27lbft ) 53N·m ( 39lbft ) M12 70N·m ( 52lbft ) 93N·m ( 69lb ) 100N·m ( 74lb ) 134N·m ( 98lb ) 63N·m ( 47lbft ) 91N·m ( 67lbft ) M16 174N·m ( 128lb ) 231N·m ( 171lb ) 248N·m ( 183lb ) 331N·m ( 244lb ) 158N·m ( 116lb ) 226N·m ( 167lb ) M20 350N·m ( 259lb ) 467N·m ( 345lb ) 484N·m ( 357lb ) 645N·m ( 476lb ) 318N·m ( 235lb ) 440N·m ( 325lb ) M24 607N·m ( 447lb ) 809N·m ( 597lb ) 838N·m ( 618lb ) 1118N·m ( 824lbft ) 552N·m ( 407lb )
1/4 8N·m ( 71lb ) 11N·m ( 97lb ) ( 106lbin ) ( 142lbin ) 8.5N·m ( 75lbin ) ( 109lb ) 5/16 ( 150lbin ) ( 204lbin ) ( 212lbin ) ( 283lbin ) 17.5N·m ( 155lb ) ( 220lb ) 3/8 ( 22lb ) ( 30lbft ) ( 31lb ) ( 42lb ) 31N·m ( 23lbft ) 44N·m ( 33lbft ) 7/16 48N·m ( 36lb ) 65N·m ( 48lbft ) 68N·m ( 50lb ) 91N·m ( 67lb ) 50N·m ( 37lbft ) 71N·m ( 53lbft ) 1/2 74N·m ( 54lb ) 98N·m ( 73lbft ) 104N·m ( 77lbft ) 139N·m ( 103lbft ) 76N·m ( 56lbft ) 108N·m ( 80lb ) 9/16 107N·m ( 79lbft ) 142N·m ( 105lbft ) 150N·m ( 111lbft ) 201N·m ( 148lbft ) 111N·m ( 82lbft ) 156N·m ( 115lb ) 5/8 147N·m ( 108lbft ) 196N·m ( 145lbft ) 208N·m ( 153lbft ) 277N·m ( 204lbft ) 153N·m ( 113lb ) 215N·m ( 159lb ) 3/4 261N·m ( 193lbft ) 348N·m ( 257lbft ) 369N·m ( 272lbft ) 491N·m ( 362lbft ) 271N·m ( 200lb ) 383N·m ( 282lb ) 7/8 ( 310lbft ) ( 413lbft ) ( 438lbft ) ( 584lbft ) 437N·m ( 323lb ) 617N·m ( 455lb ) 1 ( 465lbft ) ( 620lbft ) ( 656lbft ) ( 875lbft ) ( 483lb ) ( 681lb )
INTRODUCTION 1.Manufacturer'sIdentification 3.ClockMarkingofPropertyClassandManufacturer'sIdentification(Optional),i.e.marks 60° apartindicateClass 120° INCHNON-FLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLT andNUT SAEGRADE8BOLT andNUT LOCKNUT GrBW/Gr5 BOLT LOCKNUT GrCW/Gr8 BOLT UNPLATED PLATED SILVER PLATED W/ZnCr GOLD UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD
NOTE: 1/4in and 5/16in hardwaretorquespecificationsareshowninpound-inches.
through 1in 4789976314/07/2015
3/8in
1/4 ( 80lbin ) 12N·m ( 106lb ) 13N·m ( 115lb ) 17N·m ( 150lb ) ( 71lbin ) 12N·m ( 106lb ) 5/16 19N·m ( 168lb ) 25N·m ( 221lb ) 26N·m ( 230lb ) 35N·m ( 310lb ) 17N·m ( 150lb ) 24N·m ( 212lb ) 3/8 ( 25lb ) ( 33lb ) ( 35lb ) ( 46lb ) ( 22lbft ) ( 32lbft ) 7/16 ( 39lb ) ( 52lb ) ( 55lb ) ( 74lb ) 48N·m ( 35lbft ) 68N·m ( 50lbft ) 1/2 81N·m ( 60lb ) 108N·m ( 80lb ) 115N·m ( 85lb ) 153N·m ( 113lbft ) 74N·m ( 55lbft ) 104N·m ( 77lb ) 9/16 117N·m ( 86lb ) 156N·m ( 115lbft ) 165N·m ( 122lbft ) 221N·m ( 163lbft ) 106N·m ( 78lbft ) 157N·m ( 116lb ) 5/8 162N·m ( 119lb ) 216N·m ( 159lbft ) 228N·m ( 168lbft ) 304N·m ( 225lbft ) 147N·m ( 108lb ) 207N·m ( 153lb ) 3/4 287N·m ( 212lb ) 383N·m ( 282lbft ) 405N·m ( 299lbft ) 541N·m ( 399lbft ) 261N·m ( 193lb ) 369N·m ( 272lb ) 7/8 462N·m ( 341lb ) 617N·m ( 455lbft ) 653N·m ( 482lbft ) 871N·m ( 642lbft ) 421N·m ( 311lb ) 594N·m ( 438lb ) 1 693N·m ( 512lb ) ( 682lbft ) ( 722lbft ) ( 963lbft ) 631N·m ( 465lb ) 890N·m ( 656lb )
INTRODUCTION INCHFLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLTand NUT SAEGRADE8BOLTand NUT LOCKNUT GrFW/Gr5 BOLT LOCKNUT GrGW/Gr8 BOLT UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD
IDENTIFICATION InchBoltsandfree-spinningnuts NHIL13ENG1271EA 3 GradeMarkingExamples SAEGradeIdentification 1 4 2 5 120° Apart 3 6 60° Apart 4789976314/07/2015 11
INTRODUCTION InchLockNuts,AllMetal(Threeoptionalmethods) 20090268 4 GradeIdentification GradeCornerMarkingMethod(1)FlatsMarkingMethod(2)ClockMarkingMethod(3) GradeA NoNotches NoMark NoMarks GradeBOneCircumferentialNotch LetterB ThreeMarks GradeCTwoCircumferentialNotchesLetterC SixMarks 4789976314/07/2015
INTRODUCTION Basicinstructions-Shopandassembly Shimming Rotatingshaftseals NOTE: andthedustlipondoublelipsealswithgrease. O-ringseals Sealingcompounds compound,preparethesurfacesasdirectedbytheproductcontainer. Spareparts OnlyuseCNHOriginalPartsorCNHIndustrialOriginalParts. partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorCNHIndustrialOriginalPartscan Whenorderingspareparts,alwaysprovidethefollowinginformation: • Machinemodel(commercialname)andProductIdentificationNumber(PIN) • 4789976314/07/2015
INTRODUCTION Protectingtheelectronicand/orelectricalsystemsduringchargingandwelding Toavoiddamagetotheelectronicand/orelectricalsystems,alwaysobservethefollowingpractices: • • • weld. NOTICE: Ifyoumustweldontheunit,youmustdisconnectthebatterygroundcablefromthemachinebattery. WARNING Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):flush withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge Failuretocomplycouldresultindeathorseriousinjury. W0111A Specialtools ThespecialtoolsthatCNHIndustrialsuggestsandillustrateinthismanualhavebeenspecificallyresearchedand • Operatinginoptimaltechnicalconditions • Obtainingthebestresults • Savingtimeandeffort • Workinginsafeconditions 4789976314/07/2015
Engine
F4GE0404B*D602 F4GE0454B*D601 F4GE0454B*D651 F4GE0454E*D601
SERVICEMANUAL
4789976314/07/2015
Contents Engine-10 [10.001]Engineandcrankcase...............................................................10.1 [10.101]Cylinderheads.......................................................................10.2 [10.105]Connectingrodsandpistons.........................................................10.5 [10.114]Pumpdrives..........................................................................10.8 [10.218] Fuelinjectionsystem...............................................................10.11 [10.304]Enginelubricationsystem..........................................................10.14 [10.414]Fananddrive......................................................................10.17 4789976314/07/2015
F4GE0404B*D602 F4GE0454B*D601 F4GE0454B*D651 F4GE0454E*D601
Engine-10 Engineandcrankcase-001
10.1[10.001]/1
4789976314/07/2015
Contents Engine-10 Engineandcrankcase-001 TECHNICALDATA Engine FUNCTIONALDATA Engine SERVICE Engine Crankcase Bore-Check..............................................................................9 DIAGNOSTIC Engine Troubleshooting...........................................................................11 4789976314/07/2015 10.1[10.001]/2
