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Make/Model Information:

  • Brand:   Iveco
  • Models included:
    • Iveco GE NEF 45M
    • Iveco GE NEF 60M
    • Iveco GE NEF 75M
    • Iveco GE NEF 85M
    • Iveco GE NEF 100M
    • Iveco GS NEF 45M
    • Iveco GS NEF 60M
    • Iveco S NEF 75M
    • Iveco GS NEF 85M
    • Iveco GS NEF 100M
    • Iveco GE NEF 200E
    • Iveco GS NEF 200E
    • Iveco GE NEF 125M
    • Iveco GE NEF 130M
    • Iveco GE NEF 160M
    • Iveco GS NEF 125M
    • Iveco GS NEF 130M
    • Iveco GS NEF 160M

File Information:

  • Type:   Factory Service Manual (FSM)
  • Language:   English (EN)
  • Number of pages:   381
  • File size:  ∼ 20.70 MB
  • File Format:   PDF only
  • SME Watermarks:   None
  • Password lock:   No
  • Edit/copy/modify:   Yes
  • SKU:   ENIV-0037

NOTE:  This list was created by program script and may not accurately represent the text from the source pages.   For full preview please click on 'Download sample':

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NEF TIER 2 SERIES
Power generation application
NEF 45 GE NEF 45M, GE NEF 60M, GE NEF 75M, GE NEF 85M
,GE NEF 100M, GS NEF 45M, GS NEF 60M
,GS NEF 75M, GS NEF 85M, GS NEF 100M
NEF 60 GE NEF 200E GS NEF 200E
NEF 67 GE NEF 125M, GE NEF 130M, GE NEF 160M
,GS NEF 125M, GS NEF 130M, GS NEF 160M
NEF TIER 2 SERIES
Power generation application
NEF 45
GE NEF 45M
GE NEF 60M
GE NEF 75M
GE NEF 85M
GE NEF
100MGS NEF 45M
GS NEF 60M
GS NEF 75M
GS NEF 85M
GS NEF 100M
NEF 60
GE NEF 200E
GS NEF 200E
NEF 67
GE NEF 125M
GE NEF 130M
GE NEF 160M
GS NEF 125M
GS NEF 130M
GS NEF 160M
Technical and Repair manual
F4GE NEF engines Part 1
F4AE NEF engines Part 2
Main electrical power and Troubleshooting Part 3
NEF POWER GENERATION
ENGINES
NEF POWER GENERATION ENGINES 1
Print P4D32N001 E Base - April 2007
Section
General specifications 1
Fuel 2
Power Generation application 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the NEF engine illustrating its features
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty andis dividedin four sepa-
rate parts:
1. Mechanical part, related to the engine overhaul,
limited to those components with different characteristics
based on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
based on the relating specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who,
being entitled to provide technical assistance, shall have simple
and direct instructions to identify the cause of the major incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
F4GE NEF ENGINES
1 F4GE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 1 - GENERAL SPECIFICATIONS 1 F4GE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 1
General specifications
ELECTRICAL SPECIFICATIONS
OF THE GENERATING SETS 3
CORRESPONDENCE BETWEEN TECHNICAL
CODE AND COMMERCIAL CODE 4
LUBRICATION 5
OIL VAPOUR RECIRCULATING SYSTEM 6
COOLING SYSTEM 7
AIR INDUCTION BOOST DIAGRAM 8
- Description 8
SECTION 2 - FUEL 1 F4GE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 2
INJECTION FEED SYSTEM BY MECHANICAL
ROTARY PUMP 3
- General information 3
- Description of working principles 3
FEED PUMP 4
- STANADYNE DB4 pump 4
- Description of operation 4
PRIMING PUMP 5
FUEL FILTER 6
SECTION 3 - POWER GENERATION APPLICATION 1 F4GE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 3
Power Generation application
GENERAL INFORMATION 3
- Clearance data - 4 cyl. 4
- Clearance data - 6 cyl. 7
PART ONE - MECHANICAL COMPONENTS 9
REMOVING AND REFITTING
THE SOUND-PROOFING UNIT 11
- Removal 11
- Refitting 12
REMOVING AND REFITTING THE ENGINE/
GENERATOR 13
- Removal 13
- Refitting 13
SEPARATING THE GENERATOR FROM
THE ENGINE 14
DETACHING THE TANK FROM THE BASE 15 ..
OVERHAULING THE 6-CYLINDER ENGINE 16 ..
- Introduction 16
- Operations of preparing the engine for assembly
on the rotary stand 16
- Installation of rear components 25
- Flywheel installation 28
- Installation of front components 28
- Completing the engine 37
- Rotary feed pump disassembly and assembly
procedure 39
- Disassembly 40
- Rotary feed pump setting check 41
- Assembly 41
2 SECTION 3 - POWER GENERATION APPLICATION F4GE NEF ENGINES
Base - April 2007 Print P4D32N001 E
ASSEMBLY PROCEDURE OF THE ”ADC100” ELEC-
TRONIC ACTIVATOR ON STANADYNE SERIES ”D”
INJECTION PUMPS 43
- Assembly of the actuator 44
PASSAGE FROM 50 HZ TO 60 HZ FOR NEF MOTORS
WITH STANADYNE PUMP 45
- Passage from 50 Hz to 60 Hz 45
- Passage from 60 Hz to 50 Hz 47
- Stabilization of the rotation regime 47
- Identification tag 47
REPLACEMENT OF THE ELECTRO-VALVE AND THE
SOLENOID VALVE THROTTLE ON STANADYNE
PUMPS 48
- Electro-valve replacement 49
- Replacement of the solenoid valve throttle 51
- Checks and controls 52
PART FOUR -
MAINTENANCE PLANNING 53
MAINTENANCE PLANNING 55
- Recovery 55
- Planning of controls and periodical intervention 55
- Checks not included in maintenance
planning-daily checks 56
MAINTENANCE PROCEDURES 56
- Checks and controls 56
- Engine oil level check. 56
- Check of fuel system 57
- Cooling system check 57
- Lubricating system check 57
- Check for any water in the fuel filter 57
- Check of drive belt tensioning 58
- Check of belt’s tear and wear status 58
- Check and setting of tappet clearance 58
- Oil motor and filter replacement 59
- Changing the coolant 59
- Fuel filter replacement 60
- Alternator belt replacement 60
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1 F4GE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 4
Overhaul and technical specifications
GENERAL SPECIFICATIONS 3
CLEARANCE DATA 4
ENGINE OVERHAUL 10
ENGINE REMOVAL AT THE BENCH 10
REPAIR OPERATIONS 11
CYLINDER UNIT 11
- Checks and measurements 11
- Checking head supporting surface
on cylinder unit 12
TIMING SYSTEM 13
- Camshaft 13
- Checking cam lift and pin alignment 14
BUSHES 14
- Bush replacement 16
- Tappets 16
- Fitting tappets camshaft 16
OUTPUT SHAFT 17
- Measuring journals and crankpins 17
- Replacing oil pump control gear 21
- Fitting main bearings 21
- Finding journal clearance 21
- Checking output shaft shoulder clearance 22
CONNECTING ROD PISTON ASSEMBLY 22 ..
- Pistons 23
- Measuring piston diameter 23
- Piston pins 24
2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE NEF ENGINES
Base - April 2007 Print P4D32N001 E
- Conditions for proper pin-piston coupling 24
- Split rings 24
- Connecting rods 25
- Bushes 26
- Checking connecting rods 26
- Checking torsion 26
- Checking bending 27
- Fitting connecting rod-piston assembly 27
- Connecting rod-piston coupling 27
- Fitting split rings 28
- Fitting connecting rod-piston assembly
into cylinder barrels 28
- Finding crankpin clearance 29
- Checking piston protrusion 30
CYLINDER HEAD 31
- Removing the valves 31
- Checking cylinder head wet seal 32
- Checking cylinder head supporting surface 32
VALVES 33
- Removing carbon deposits, checking
and grinding valves 33
- Checking clearance between valve stem
and valve guide and valve centering 33
VALVE GUIDE 34
VALVE SEATS 34
- Regrinding replacing the valve seats 34
VALVE SPRINGS 35
FITTING CYLINDER HEAD 35
- Refitting the cylinder head 36
TIGHTENING TORQUE 37
SECTION 5 - TOOLS 1 F4GE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 5
TOOLS 3
APPENDIX 1 F4GE NEF ENGINES
Print P4D32N001 E Base - April 2007
Appendix
SAFETY PRESCRIPTIONS 3
Sezione
General specifications 1
Fuel 2
Power Generation application 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the NEF engine illustrating its features
and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty andis dividedin four sepa-
rate parts:
1. Mechanical part, related to the engine overhaul,
limited to those components with different characteristics
based on the relating specific duty.
2. Electrical part, concerning wiring harness, electrical
and electronic equipment with different characteristics
based on the relating specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who,
being entitled to provide technical assistance, shall have simple
and direct instructions to identify the cause of the major incon-
veniences.
Sections 4 and 5 illustrate the overhaul operations of the engi-
ne overhaul on stand and the necessary equipment to execute
such operations.
F4AE NEF ENGINES
1 F4AE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 1 - GENERAL SPECIFICATIONS 1 F4AE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 1
General specifications
ELECTRICAL SPECIFICATIONS
OF THE GENERATING SETS 3
CORRESPONDENCE BETWEEN TECHNICAL
CODE AND COMMERCIAL CODE 4
LUBRICATION 5
OIL VAPOUR RECYCLING 6
COOLING SYSTEM 7
AIR INDUCTION - BOOST DIAGRAM 8
- Description 8
SECTION 2 - FUEL 1 F4AE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 2
COMMON RAIL 3
- General specifications 3
- Electric system description 3
WORKING PROCESS 5
FUEL SYSTEM LAYOUT 6
MECHANICAL FEEDING PUMP 7
CP3.3 HIGH PRESSURE PUMP 8
RAIL 12
PRESSURE LIMITER FOR FUEL RETURN 12
BOOST GAUGE VALVE 13
ELECTRO-INJECTOR 14
SECTION 3 - POWER GENERATION APPLICATION 1 F4AE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 3
Power Generation application
GENERAL SPECIFICATIONS 3
- Clearance data - 6 cyl. 4
PART ONE - MECHANICAL COMPONENTS 5
REMOVING AND REFITTING
THE SOUND-PROOFING UNIT 7
- Removal 7
- Refitting 8
REMOVING AND REFITTING THE RADIATOR
ASSEMBLY AND ENGINE AIR CLEANER 9 ..
- Removal 9
- Refitting 9
REMOVING AND REFITTING THE ENGINE/
GENERATOR 10
- Removal 10
- Refitting 10
SEPARATING THE GENERATOR FROM THE ENGINE 11
DETACHING THE TANK FROM THE BASE 12 ..
ENGINE OVERHAUL 13
- Preface 13
- Engine setting operations for the assembly
on turning stand 13
- Disassembly of application components 14
- Assembly of application components 21
- Completion of the engine 32
- Checks and inspections 34
PART TWO -
MAINTENANCE PLANNING 35
MAINTENANCE PLANNING 37
SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 1 F4AE NEF ENGINES
Print P4D32N001 E Base - April 2007
SECTION 4
Overhaul and technical specifications
GENERAL SPECIFICATIONS 3
CLEARANCE DATA 4
ENGINE OVERHAUL 11
ENGINE REMOVAL AT THE BENCH 11
REPAIR OPERATIONS 12
CYLINDER UNIT 12
- Checks and measurement 12
- Checking head supporting surface
on cylinder unit 13
TIMING SYSTEM 14
- Camshaft 14
- Checking cam lift and pin alignment 14
BUSHES 14
- Bush replacement 15
- Tappets 15
- Fitting tappets camshaft 16
OUTPUT SHAFT 17
- Measuring journals and crankpins 17
- Replacing oil pump control gear 19
- Fitting main bearings 19
- Finding journal clearance 19
- Checking crankshaft shoulder clearance 20
CONNECTING ROD PISTON ASSEMBLY 20 ..
- Pistons 21
- Measuring piston diameter 21
- Piston pins 22
2 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4AE NEF ENGINES
Base - April 2007 Print P4D32N001 E
- Conditions for proper pin-piston coupling 22
- Piston rings 22
- Connecting rods 23
- Bushes 23
- Checking connecting rods 24
- Checking torsion 24
- Checking bending 24
- Fitting connecting rod-piston assembly 24
- Connecting rod-piston coupling 24
- Fitting split rings 25
- Fitting connecting rod-piston assembly
into cylinder barrels 25
- Finding crankpin clearance 26
- Checking piston protrusion 27
CYLINDER HEAD 28
- Removing the valves 28
- Checking cylinder head supporting surface 29
- Checking cylinder head wet seal 29
VALVES 30
- Removing carbon deposits, checking
and grinding valves 30
- Checking clearance between valve stem
and valve guide and valve centering 30
VALVE GUIDE 31
VALVE SEATS 31
- Regrinding replacing the valve seats 31
CYLINDER HEAD VALVE SEATS 31
VALVE SPRINGS 33
FITTING CYLINDER HEAD 33
- Refitting the cylinder head 34
TIGHTENING TORQUE 35
Section
Main electrical power on the machine 1
Troubleshooting 2
MAIN ELECTRICAL POWER ON THE
MACHINE AND TROUBLESHOOTING
PREFACE TO USER’S GUIDELINE MANUAL
Section 1 describes the electrical equipment as regards its
characteristics and its general operation in relation to the
engines described in the preceding parts.
Section 2 describes the fault diagnosis of the engines described
in the preceding parts, dedicated to technical support providers
who need straightforward guidelines in order to verify the
causes of the main failures.
1 NEF POWER GENERATION ENGINES
Print P4D32N001GB Base - April 2007
SECTION 1 - MAIN ELECTRICAL POWER ON THE MACHINE 1 NEF POWER GENERATION ENGINES
Print P4D32N001GB Base - April 2007
SECTION 1
Main electrical power on the machine
GENERATOR SET COMPONENTS LAYOUT 5 .
- GENEF - MECHANIC PUMP 5
- GENEF - COMMON RAIL 6
LOCATION OF COMPONENTS ON ENGINE 7
- GENEF - MECHANIC PUMP 7
- GENEF - COMMON RAIL 8
POWER NETWORK 9
- GENEF - MECHANIC PUMP 9
- GENEF - COMMON RAIL 10
ASSEMBLY DRAWING OF INJECTION SYSTEM AND
CONTROL PANEL INTERFACE GENEF -
COMMON RAIL. 11
- Key 12
- Electric wiring GENEF - COMMON RAIL 13
- Connectors GENEF - COMMON RAIL 14
GENERATOR SET WIRING DIAGRAMS 15
- Generator set with manual column panel PGM1
for 230Vac applications
GENEF - MECHANIC PUMP 15
- Generator set with PG804 automatic panel
GENEF - MECHANIC PUMP 16
- Generator set with Compact Mage manual panel
GENEF - MECHANIC PUMP 17
- Generator set with Compact Mage automatic panel
GENEF - MECHANIC PUMP 18
- Key to components on engine side 19
- Key to control panel components 19
- Wiring diagram for 12Vdc applications
GENEF - COMMON RAIL 20
SECTION 2 - TROUBLESHOOTING 1 NEF POWER GENERATION ENGINES
Print P4D32N001GB Base - April 2007
SECTION 2
Troubleshooting
PREFACE 3
METHODS OF DIAGNOSIS 4
- Blink code 4
- PT-01 4
DIAGNOSIS WITH BLINK CODE 5
- Indicator light off 5
- Indicator light on steady 5
- Indicator light blinking 5
- BLINK CODE activation / reading 5
EDC BLINK-CODE 6
- Procedure for failure memory clear by
Blink Code key 7
TROUBLESHOOTING
Software release 4.1_2 9
TROUBLESHOOTING WITH PT-01
PORTABLE TESTER 27
PT-01 PORTABLE TESTER 29
- Main functions 29
- Test parameters 29
FAILURE CODES
(SOFTWARE VERSION 3.3_1) 30
FAILURE CODES
(SOFTWARE VERSION 4.1_2) 32
TROUBLESHOOTING 35
- F4GE engines 37
- F4AE engines 45


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