Iveco VECTOR 8 Technical And Repair Manual Download Page 193

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SECTION 5 - TOOLS

VECTOR 8 ENGINES

Print P2D32V001E

Base - April 2006

TOOLS

TOOL NO.

DESCRIPTION

99305019

Case with full set of valve seating regrinding tools

99305047

Spring loading control apparatus

99322230

Rotary telescopic stand (capapity 2000 daN, torque 375 daNm)

99342145

Puller to remove injector holder

99360091

Tool for dismantling fuel filter

99360184

Calipers for disassembling and reassembling engine piston rings
(105 — 160 mm)

Summary of Contents for VECTOR 8

Page 1: ...VECTOR SERIES Industrial application VECTOR 8 Technical and Repair manual ...

Page 2: ...that all accident prevention equipment is available and efficient All protections specified by safety regulations i e goggles helmet gloves boot etc must be checked and worn All machining lifting and conveying equipment should be in spected before use The data contained in this publication was correct at the time of going to press but due to possible modifications made by the Manufacturer for reas...

Page 3: ...s 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 PRELIMINARY REMARKS 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 se...

Page 4: ... 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 supporting stands and that the manual automatic safety devices have been actuated in the event that the assembly is to be lifted by means of a hoist When you have to operate on as...

Page 5: ...es before welding Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials flow which may catch fire easily on welding Should the vehicle be subjected to temperatures exceeding 80 C dryer ovens disassemble drive electronic central units The disposal of all liquids and fluids must be performed with full observance of specific rules in force...

Page 6: ...his 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 battery terminals Do not cause sparks to be generated in checking if the circuit is energised Do not...

Page 7: ...hain 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 ...

Page 8: ...wiring harnesses in particular the data interconnection line between central units CAN line is to be considered inviolable CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES Power 1 kW 1 36 metric HP 1 kW 1 34 HP 1 metric HP 0 736 kW 1 metric HP 0 986 HP 1 HP 0 746 kW 1 HP 1 014 metric HP Torque 1 Nm 0 1019 kgm 1 kgm 9 81 Nm Revolutions p...

Page 9: ...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 instruction...

Page 10: ...2 VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 11: ...eing dealt with see next page instead of giving descriptions of some operations or procedures Example Ø 1 housing for connecting rod small end bush Ø 2 housing for connecting rod bearings α Tighten to torque Tighten to torque angular value 1 2 3 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 SPECIAL REMARKS ...

Page 12: ... caulk Rotation Regulation Adjustment Angle Angular value Visual inspection Fitting position check Preload Measurement Value to find Check Number of revolutions Equipment Temperature Surface for machining Machine finish bar Pressure Interference Strained assembly Oversized Higher than Maximum peak Thickness Clearance Undersized Less than Minimum Lubrication Damp Grease Selection Classes Oversizing...

Page 13: ...5 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 UPDATING Section Description Page Date of revision ...

Page 14: ...6 VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 15: ...HNICAL CODE AND COMMERCIAL CODE 3 LUBRICATION 5 OPERATING PRINCIPLE 5 Oil vapour recirculation blow by filter 7 ENGINE COOLING 8 COOLING SYSTEM ASSEMBLY 9 VARIANT FOR APPLICATIONS WITH BRAKE AIR COMPRESSOR 10 AIR AIR INTERCOOLER SYSTEM DRAGON G DRIVE AND GRIFFON APPLICATIONS 11 AIR WATER INTERCOOLER SYSTEM SPRINKLER APPLICATIONS 12 SUPERCHARGING 13 ...

Page 16: ...2 SECTION 1 GENERAL SPECIFICATIONS VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 17: ...CHNICAL CODE AND COMMERCIAL CODE SECTION 1 GENERAL SPECIFICATIONS 3 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 Technical Code Open Commercial Code FVAE2885X F100 VECTOR 8 TE2 FVAE2884A B201 FVAE2884A B200 FVKE2887A A200 ...

Page 18: ...4 SECTION 1 GENERAL SPECIFICATIONS VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 19: ...ducts positioned lengthwise in the crankcase to lubricate the crankshaft bearings and the camshaft and to cool the piston through calibrated jets Other ducts direct the oil to each of the heads to lubricate the timing components The oil flow rate is managed by two pressure relief valves 4 one per bank which close when the oil pressure reaches minimum values engine idling in order to protect the be...

Page 20: ...ater oil heat exchange 3 Oil filter support 4 Relief pressure valve piston cooler 5 Relief pressure valve Engine oil pressure system 103278 6 SECTION 1 GENERAL SPECIFICATIONS VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 21: ...he pipe 2 whilst the remaining vapours are recirculated in the intake 1 Blow by filter 2 Sump drainage pipe 3 Oil vapour inlet 4 Gas outlet Figure 4 Figure 5 1 Blow by filter casing 2 Filter 3 Gasket 4 Cover 5 Cover fixing bolts The blow by comprises two filtering layers 2 a casing 1 and two gaskets 3 which ensure the seal between the casing and the two covers 4 103275 81366 SECTION 1 GENERAL SPEC...

Page 22: ...cation oil is cooled From here the coolant reaches the engine block and after having cooled the cylinders is sent to the thermostat casing Depending on the temperature the coolant is either recirculated by the water pump 1 or sent to the radiator Figure 6 103273 1 Circulation pump 2 Engine lubrication water oil heat exchanger 3 Thermostat casing 8 SECTION 1 GENERAL SPECIFICATIONS VECTOR 8 ENGINES ...

Page 23: ...erature 70 C sent to the circulation pump Coolant coming from the engine block passing through the thermostat casing thermostat valve opening temperature around 70 C complete travel 85 C to the cooling radiator 112492 1 Thermostat casing 2 Radiator 3 Coolant circulation pump 4 Cooling fan A B C SECTION 1 GENERAL SPECIFICATIONS 9 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 24: ...COMPRESSOR Figure 8 103509 10 SECTION 1 GENERAL SPECIFICATIONS VECTOR 8 ENGINES Base April 2006 Print P2D32V001E Rif Description 1 Circulation pump 2 Engine lubrication water oil heat exchanger 3 Air system compressor for DRAGON applications ...

Page 25: ...a consequent increase in temperature and after having been collected in a single pipe it is sent to the intercooler This heat exchanger which the flow of air produced by the fan fastened axially and driven by the crankshaft comes into contact with cools the compressed air and sends it via the pipe to the main manifold and from there to the two intake manifolds located on each bank On versions for ...

Page 26: ...LER APPLICATIONS Figure 10 112488 1 Heat exchanger air water intercooler 2 Turbochargers Intake air and hot compressed air Cold compressed air Exhaust 12 SECTION 1 GENERAL SPECIFICATIONS VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 27: ...quent increase in temperature The hot compressed air is directed to the inside of the heat exchanger air air intercooler in which it is cooled and sent to the intake manifolds and to the inlet valves Figure 11 103512 FROM THE AIR AIR HEAT EXCHANGER TO THE AIR AIR HEAT EXCHANGER SECTION 1 GENERAL SPECIFICATIONS 13 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 28: ...14 SECTION 1 GENERAL SPECIFICATIONS VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 29: ... mechanical components of the fuel system 9 Fuel pre filter for G DRIVE and SPRINKLER applications 9 Fuel pre filter for DRAGON and GRIFFON applications 10 Fuel filter for G DRIVE and SPRINKLER applications 11 Fuel filters for DRAGON and GRIFFON applications 12 Low pressure pump for G DRIVE and SPRINKLER applications 13 Low pressure pump for DRAGON applications 14 High pressure pump 15 High pressu...

Page 30: ...2 SECTION 2 FUEL VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 31: ...stem and the fuel system Electrical system The control unit governs the engine via the sensors on the engine 1 Engine coolant temperature sensor 2 Engine oil temperature sensor 3 Oil filter clogging sensor 4 ADEM III engine control module 5 Atmospheric pressure sensor 6 Fuel temperature sensor 7 Electro injectors 8 Engine speed timing sensor on crankshaft 9 Engine speed timing sensor on camshaft 1...

Page 32: ...n the camshaft reference 9 Figure 1 It produces signals obtained by means of the magnetic flow lines which close through the ports in the gear fitted on the camshaft The signal produced and sent to the electronic control unit allows the latter to calculate the moment of injection The sensor should be fitted by tightening it to a torque of 28 7 Nm Engine rpm sensors This is an inductive type sensor...

Page 33: ...fuel in low temperature conditions There is also a mechanical pump on the pre filter that is used to prime the circuit On reaching the low pressure pump the fuel is sent for filtering to the filter or filters depending on the applications 8 The pump pressure is maintained at 5 bar The high pressure system is a common rail system consisting of a high pressure pump and 8 injectors which is electrica...

Page 34: ...l suction pipe from the tank to the pre filter equipped with a priming pump fuel pre heating element and clogging sensor pipes supplying the mechanical low pressure fuel pump pipe from the low pressure pump to the fuel filter filters pipes which supply the high pressure pump from the filter filters The fuel system is completed by the fuel return circuit from the common rail injectors and high pres...

Page 35: ...NS SECTION 2 FUEL 7 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 Rif Description 1 Injector 2 Common rail pressure relief valve 3 Pressure sensor 4 Common rail 5 Diesel pre filter 6 High pressure pump 7 Low pressure pump 8 Fuel filters depending on the application ...

Page 36: ... M Promp high pressure regulator receives a constant flow of fuel in order to work properly The M Promp valve located upstream from the high pressure pump governs the necessary flow to the high pressure pump allowing only the fuel necessary to maintain the pressure in the rail improving energy efficiency and limiting system heating The high pressure pump 1 takes the fuel up to a pressure of 1600 b...

Page 37: ...aration type has the water sensor 4 at the base of the cartridge 3 to indicate if there is water in the fuel The manual priming pump 2 is located on the filter mounting 1 1 Filter support 2 Manual priming pump and system bleed 3 Fuel pre filter cartridge 4 Water sensor 103268 SECTION 2 FUEL 9 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 38: ... on the filter mounting 1 There is a heater 3 on the mounting for heating the diesel an intake with a rapid connector 6 for the return pipe from the tank and a temperature sensor 8 1 Filter mounting 2 Manual priming pump and system bleed 3 Heater 4 Fuel pre filter cartridge 5 Water in fuel presence sensor 6 Attachment with rapid pipe connector 7 System breather jet 8 Temperature sensor 89669 10 SE...

Page 39: ...el pressure sensor 3 and the diesel temperature sensor 4 are located on the mounting 1 Fuel filter 2 System bleed screw 3 Diesel pressure sensor 4 Diesel temperature sensor 5 Filter diesel inlet 6 Diesel outlet from the filter to the high pressure pump 103477 Fuel filter for G DRIVE and SPRINKLER applications SECTION 2 FUEL 11 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 40: ...e pump and the high pressure pump The bleed screws and the filter blockage sensor 2 are located on the mounting 1 Filter cartridges 2 Filter blockage sensor 83422 Fuel filters for DRAGON and GRIFFON applications 12 SECTION 2 FUEL VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 41: ...el at low pressure to the high pressure pump 1 Mechanical low pressure pump 2 Pump control coupling LPP 3 Flange 4 Safety valve 5 By pass valve Components 4 and 5 are housed inside the pump Main specifications Safety valve 4 Valve opening pressure 9 5 bar Maximum pressure 12 bar By pass valve 5 Valve opening pressure 1 5 bar 103266 SECTION 2 FUEL 13 VECTOR 8 ENGINES Print P2D32V001E Base April 200...

Page 42: ...ressure to the high pressure pump 1 Mechanical low pressure pump 2 Braking system air compressor 3 Safety valve 4 By pass valve Components 3 and 4 are housed inside the pump Main specifications Safety valve 4 Valve opening pressure 9 5 bar Maximum pressure 12 bar By pass valve 5 Valve opening pressure 1 5 bar 89701 14 SECTION 2 FUEL VECTOR 8 ENGINES Base April 2006 Print P2D32V001E Low pressure pu...

Page 43: ...ere is an outlet 8 for draining off excess fuel to go to thelow pressure pumpto bere circulated tothe high pressure pump The pump s gear 5 is attached onto the pump s shaft directly and secured by the nut 6 350 torque 300 Nm with the screwdriver with final take off at 350 Nm with dynamometric wrench 1 High pressure pump 2 Fixing screws 3 Fuel inlet 4 and 9 Outlet to Common Rail 5 Pump gear 6 Fixin...

Page 44: ...mping supply duct 6 Pressure regulator supply duct 7 Pressure regulator M promp 8 Lubrication oil inlet 9 Fuel return to the low pressure pump 10 Relief valve regulated to 5 bar 103245 103246 16 SECTION 2 FUEL VECTOR 8 ENGINES Base April 2006 Print P2D32V001E High pressure pump operating principle ...

Page 45: ...cides the amount of fuel with which to supply the pumping elements any excess fuel flows out through the duct 9 The pressure relief valve 10 has the function of keeping a constant inlet pressure at 5 bar for the pressure regulator High pressure regulator Located at the high pressure pump inlet on the low pressure system it controls the flow of fuel to the high pressure pump according to the comman...

Page 46: ...re at the inlet of the regulator exceeds 5 bar the relief cylinder 8 Figure 16 will begin to open in order to lead the additional fuel to the outlet Depending on the fuel flow required with the pressure regulator partially closed the cylinder moves into a dynamically balanced position such as to ensure a constant pressure of 5 bar at the regulator inlet 18 SECTION 2 FUEL VECTOR 8 ENGINES Base Apri...

Page 47: ...rest position due to the pre loading spring 3 The shutter 4 is in the position of maximum delivery and the HPP will provide the rail with max pressure The clearance between the internal parts in the high pressure pump permits fuel leakage which is used to lubricate the pump This excess fuel is sent towards the pressure relief valve The cylinder 8 in the pressure relief valve will then move into a ...

Page 48: ...PWM is in regulation mode the coil 1 is energised between 0 1600mA depending on the pressure required by the ECM and the core 2 is moving the shutter 4 towards the closing position in order to limit the fuel flow to the HPP and thereby reducing the fuel pressure in the rail The cylinder 8 in the pressure relief valve will move into a balance position and there it will maintain the pressure in the ...

Page 49: ...uel inlet from the high pressure pump one for each common rail 4 Pressure sensor 5 Pressure relief valve one on the right hand rail 112490 81388 RAIL FOR G DRIVE DRAGON SPRINKLER APPLICATIONS RAIL FOR GRIFFON APPLICATION SECTION 2 FUEL 21 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 50: ...ut off the fuel to the cylinder in question To reset the flow limiter it is necessary to stop the engine in order to zero the rail pressure However if the cause of it switching on is not removed the same fault will occur the next time the engine is started If the leakage is considerable it will be impossible to restart the engine due to the lack of pressure in the rail Figure 19 Single stage press...

Page 51: ...d by the spring in the opening position If there is a substantial loss in pressure downstream of the limiter the inlet pressure becomes predominant and moves the piston to the opposite side obstructing the outlet of the fuel Limiter with piston in outlet closed position 89672 1 Body 2 Piston 3 Fuel inlet 4 Spring 5 Part bolted onto the common rail A B C SECTION 2 FUEL 23 VECTOR 8 ENGINES Print P2D...

Page 52: ...ectro injectors At the electro injector inlet there is therefore always fuel available at the injection pressure calculated by the engine s electronic control unit ADEM III When the solenoid valve of an electro injector is energized by the electronic control unit fuel taken directly from the rail is injected into the relevant cylinder 1 Nozzle 2 Electro injector 3 Seals 103478 24 SECTION 2 FUEL VE...

Page 53: ...seal 23 ENGINE FLYWHEEL 23 Fitting the engine flywheel 23 Fitting the gearbox 25 RODS 27 ROCKER ARM ASSEMBLY 27 ROCKER ARMS 27 JUMPERS 27 ROCKER ARM SUPPORT ROCKERS 27 Adjusting operating clearance between valves and rockers 28 Fitting the cylinder head tappet covers 30 Fitting the injectors 30 LUBRICATION 31 Oil pump 32 COMPLETING THE ENGINE 33 COMMON RAIL ASSEMBLY PROCEDURE 38 Preparing for asse...

Page 54: ... 60 ENGINE PARAMETER READING 63 READING PARAMETER FOR SAVE CODE 64 EVENTS TABLE 65 FAULTS TABLE 67 ILC SIMULATOR 99368543 TOOL 70 FOURTH PART PLANNED MAINTENANCE 77 VECTOR 8 DRAGON FVAE2884A B200 MAINTENANCE PLAN 79 VECTOR 8 GENSET FVAE2885X A100 MAINTENANCE PLAN 81 DESCRIPTION OF PREVENTIVE AND ROUTINE MAINTENANCE WORK 83 CHECKING REFILLING ENGINE OIL FILTERS 84 CHANGING ENGINE OIL FILTERS 84 CHA...

Page 55: ...Figure 1 GENERAL SPECIFICATIONS G DRIVE application 103260 SECTION 3 INDUSTRIAL APPLICATION 3 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 56: ...103503 DRAGON application Figure 2 4 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 57: ...Figure 3 SPRINKLER application 112503 SECTION 3 INDUSTRIAL APPLICATION 5 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 58: ...the engine including cylinder heads gearbox of the timing system and of the front part cover Electrical section describing the connections to the different components of the engine control module and of the sensors assembled to the engine Diagnosis section Section of preventive maintenance operations providing instructions for the execution of the main operations Data features and performances are...

Page 59: ...0 FVKE2887 A A200 ρ Compression ratio 16 1 Max output kW HP rpm 560 760 2100 745 1000 2200 680 920 2100 Max torque Nm kgm rpm 3200 320 1400 1700 3960 396 1400 1700 3200 320 1500 Loadless engine idling rpm 800 600 25 Loadless engine peak rpm 2300 2350 25 Bore x stroke Displacement cm3 145 x 152 20080 TURBOCHARGING with intercooler Turbocharger type HOLSET HX55 KKK K31 HOLSET HX55 bar LUBRICATION Oi...

Page 60: ...8 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 61: ...PART ONE MECHANICAL COMPONENTS SECTION 3 INDUSTRIAL APPLICATION 9 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 62: ...10 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 63: ...row waste on the ground on tips or in water courses Obtain information on the appropriate ways of recycling or disposing of waste from the local authorities or collection centres 103226 82196 Handle all components very carefully Do not put your fingers between different components Always wear recommended protective clothing such as goggles gloves safety shoes and protective headgear The following ...

Page 64: ...g undoing the bolts for the flexible mountings 3 Remove the atmospheric pressure sensor 4 from the support If present on the application remove the flexible belt 16 and the air conditioning compressor 17 Completely undo the screw 5 and release the belt 6 Remove the alternator complete with bracket Remove the control unit support complete with diesel filter mounting 112865 The oil filter blockage s...

Page 65: ...Figure 7 Loosen the rail check u bolt 4 fixing screws Disassemble the assembly of the delivery pipes 1 from the high pressure pump 2 and the ones on the electro injectors unscrew the washers 3 with a 99368506 wrench Remove the rail assembly Disassemble the diesel fuel exhaust pipes from the overpressure valve rail 5 Plug all the pipes in order to prevent possible contamination Unscrew the fittings...

Page 66: ...connectors on the pump NOTE Inspect the hydraulic pump and especially the state of wear of the teeth of the driving gear 1 both those receiving motion from the gearbox and the front teeth transmitting motion to the pump of the primary cooling circuit Replace if there is excessive gear wear lock gear 1 rotation properly and loosen screw 2 Disassemble the gear and set the screw aside Figure 11 The g...

Page 67: ...g the compressor on the spacer NOTE Take the compressor to the workbench and separate the low pressure pump if not previously removed Recover the universal joint 1 checking its state of wear After firmly securing the compressor in a vice remove the gear 2 by unscrewing the nut 3 andusing aspecific extractor In addition remove the fittings 4 and 5 Unscrew the screw 13 that fixing the LPP 8 to air c...

Page 68: ...e the air pipe 6 between the turbo blower and the waste gate valve 7 Lastly unscrew the nuts fixing the turbo blower to the exhaust manifold Then remove the cooling pipes of the waste gate valve 7 and detach it from the exhaust manifold Then repeat this procedure for the second turbo blower Figure 20 Disassemble the junction plate 3 of the cooling pipes 1 and the three way fitting on the exchanger...

Page 69: ...e blocks by means of gaiters 10 Undo the screws 5 fixing the couplings 4 on the main bearings and at the top unscrew the screws 6 fixing the three way coupling 7 on the oil water cooler 8 ofthe engine oil Figure 22 Unscrew the 10 screws 1 fastening the intercooler to the air intake manifolds 114242 82212 SECTION 3 INDUSTRIAL APPLICATION 17 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 70: ...has been removed together with the ADEM III control unit support Remove the diesel recovery piping Remove the intake manifolds 3 remove the gaskets and remove the high pressure pump 4 from the flywheel casing complete with gear Figure 25 Unscrew the screws 1 and remove the exhaust manifolds 2 on both sides comprehensive of seals 103190 82214 NOTE Separate the screws appropriately marking their pla...

Page 71: ...ms 2 from the support 1 taking out the circlips and seals on both sides of the support Extract the rods 3 from their seat on the heads and the jumpers 4 Unscrew the fixing screws 7 and remove the head 6 Remove the cases 5 protecting the valves Always change the O ring in the assembly phase Lubricate the O rings with vaseline before installating 82216 82220 82218 82217 82219 NOTE If necessary repla...

Page 72: ...emoved the gear casing undo the bolt 9 and remove the spacers 8 and 13 complete with O rings Fit tool 99368502 1 and place the fixed spanner 2 as shown in the diagram to prevent the rotation of the flywheel during the dismantling of the pulley and the damper flywheel on one side and the actual flywheel on the other Figure 31 Figure 32 Figure 33 At the front undo the 8 botls 1 and remove the pulley...

Page 73: ...w the flywheel fixing screws Remove washer and engine flywheel assembly Fit the tool 99368513 1 and extract the rear oil seal 2 Unscrew the screws 1 2 and 3 after suitably slinging the flywheel cover casing 4 Detach the flywheel cover casing from the crankcase 103194 103219 82228 103195 NOTE Mark the position of the screws 1 2 Screws 1 M12x35 mm 6 bolts tot Screws 2 M14x90 mm 12 bolts tot SECTION ...

Page 74: ...joint shall be assembled immediately 10 20 minutes 103197 Figure 40 DIAGRAM SHOWING TIGHTENING ORDER FOR BOLTS FIXING FLYWHEEL COVER CASING ON G DRIVE APPLICATION 103198 NOTE Make sure you put the screws in the seats from where they were taken There are screws of different lengths as well as different sizes Figure 41 DIAGRAM SHOWING TIGHTENING ORDER FOR BOLTS FIXING FLYWHEEL CASING COVER FOR GRIFF...

Page 75: ... P 20 the bevel on the inner diameter of the ring gear should be facing the engine flywheel Figure 44 Screw the pins 99367019 3 onto the crankshaft and fit the flywheel 2 with tool 99368533 1 and a suitable lift Fitting the engine flywheel 83436 Figure 45 Stop engine shaft rotation with tool 99368502 the fixed wrench 5 keeps the flywheel in position preventing its rotation Assemble tool 99368546 1...

Page 76: ...Nm Angle 120 Torque 910 to 1600 Nm 82246 NOTE If the screws turn out to have been removed previously check the stated diameter if the diameter d turns out to be 23 5 mm 24 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 77: ...10x1 5x25 mm cheese headed screws 45 to 50 Nm Lubricate the screws with UTDM oil or alternatively with engine oil Figure 48 82248 Figure 49 82250 In addition check the state of wear of both the bearings and the gears If there is noisiness or clear seizure of the gears replace them Check the state of wear of the teeth of the gears and the contact surface between the inside of the bearing and the sh...

Page 78: ...ts M12x1 75x80 mm 73 P 80 Nm Before tightening lubricate the bolt with UTDM oil or alternatively with engine oil Fit the seal 1 in its seat on the gearbox with the aid of tool 99368512 82251 On the opposite side fit the shaft illustrated in the diagram The idler gear should not be present Take the new flat gasket out of the package and put it in its seat on the gearbox cover Fit the cover together...

Page 79: ...zure Riscontrando anomalie sostituire i particolari interessati Check that the plug is assembled on the end of each rocker arm holding shaft RODS Install rods 1 rocker arm supports 2 with rocker arms and bridges 3 Figure 56 Make sure that the bevelled side of the fall plate is turned towards the inside of the engine Figure 55 Make sure that cylinder 1 is in the firing order and that cylinder 6 is ...

Page 80: ...e side of the starting motor Insert tool 99368502 in order to turn the engine flywheel and fix it with the nuts of the cover that has been removed Turn the engine clockwise for 360 then assemble rocker arm units 3 7 e 8 Check that the contact between the register and the plate is centred and that the rods can turn freely Figure 59 Apply the 20 120 Nm torque wrench with the 1 2 square connection to...

Page 81: ...lowing balancing adjustments it is recommended to trace some marks on the flywheel 1 placed at 90 one from the other see picture After obtaining this condition of balancing we move on to adjust the valves in the following order To make the adjustment proceed as illustrated here BALANCING ADJUST FIRST STEP BALANCING ADJUST SECOND STEP Apply the 10 60 Nm torque wrench with the 3 8 square connection ...

Page 82: ...OTE NOTE NOTE The cover fixing screws have different lengths M8x1 25x40 front screws three per cover M8x1 25x25 rear screws two per cover Always change the seal Always change the O ring in the assembly phase Lubricate the O rings with vaseline before fitting Clean the injector seat 1 thoroughly and fit the injector complete with mounting bracket 2 in its seat pressing it until it clicks and is cor...

Page 83: ...ering parts 4 and the gaskets 5 Carefully clean the blow by filter body 6 and the covers The oil vapours that form inside the engine during operation are directed into a condenser blow by filter where some of them are condensed and recirculated again and some of them are directed via two pipes to the intake The oil vapour condenser needs a periodical overhaul engine oil is a pollutant Protect your...

Page 84: ...embly also includes the bushing in which the gear spindle 8 turns Fit the gear 8 on the cover assembly 4 and check its rotation Fit the cover together with the gears on the pump casing 5 Fit the suction strainer on the pump with a new seal M8x1 25 screws tightening torque 22 27 Nm Fit the pump together with the suction strainer to the crankcase The oil pump is secured with three M10x25mm hexagonal...

Page 85: ... M10x1 5 fixing screws to a torque of 49 60 Nm Before tightening the screws see order in Figure 71 lubricate them with graphitized oil Always fit new gaskets Before tightening lubricate the screws with UTDM oil or alternatively with engine oil Fit the intake manifolds together with new gaskets on the heads Tighten the M10x1 25 screws to a torque of 38 45 Nm Fit the diesel supply pipe to the high p...

Page 86: ...ave already been fitted together with the air intake manifolds Tighten all the screws to a torque of 22 27 Nm To facilitate assembly here we describe how to use the water pipe fixing screws correctly 6 M8x1 25x75 mm 7 M8x65 mm 8 M8x1 25x60 mm 9 M8x20 mm 10 M8x30 mm 103472 NOTE NOTE 34 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 87: ...lter on the manifold and the inlet and outlet pipes from the filter Always change the gaskets with new spare parts Do not reuse gaskets even if they look sound 114242 103474 NOTE For G DRIVE GRIFFON and DRAGON applications For SRINKLER applications Figure 76 83499 Fit the turbo blower 2 on the exhaust manifold tightening the M12x1 75mm nuts in two successive phases Torque 85 95 Nm Then fit the was...

Page 88: ...acer tighten M12x1 75 screws securing it to gears box at 42 51 Nm tightening torque Put compressor into its seat by tightening M12x1 75 at 74 90 Nm Nm torque Secure bracket 13 Figure 77 to engine block During assembly check that the coupling drive 9 and the teeth on the front of the secondary circuit cooling pump gear show no signs of wear or cracks Change any damaged parts Fit support bracket 13 ...

Page 89: ...necessary to prevent the gear 1 from turning in an appropriate manner without damaging the parts Before tightening lubricate the screws with UTDM oil or alternatively with engine oil The gear has a left hand locking screw At the front of the gearbox fit the secondary system cooling circuit pump together with the gears Supporting the pump place it in its seat Tighten the M10x1 5 nuts securing the w...

Page 90: ...igh pressure pump HPP and the injector s are mounted firmly in average position of bolt clearance with the defined tightening torque All the pipes are fitted by only tightening the areas connected to the HPP the rails and the injectors manually J1 1 J8 2 V1 1 V3 2 see Figure Figure 84 Fit the centre support plate 1 closing the fastenings for the pipes from the HPP to the rails from the rails to th...

Page 91: ...que of 25 Nm Any leaks are checked when the engine is switched on Test procedure for checking for diesel leaks from the Common Rail system The following procedure is carried out on the engine to check that there are no diesel leaks from the Common Rail system after repair operations The aim of this test is to let the rail pressure reach maximum values with the engine running in no load idling cond...

Page 92: ... present on the application fit the air conditioning compressor 17 Figure 3 and the flexible belt 16 Figure 3 Fit the alternator complete with mounting bracket and tension the bolt 6 tightening the bolt 5 Fit the ADEM III control unit 2 on the support with the flexible mounts 3 M8x1 25 screws to tighten to a torque of 22 27 Nm Fit the engine electric cable connecting the control unit to the variou...

Page 93: ...en the different pipes in the lubricating circuit that there are no fuel leaks from the fuel pipes that there are no air leaks from pneumatic pipes if fitted Carefully check and bleed the engine cooling equipment by repeated draining operations Checks and inspections Start the engine and leave it running just above the idling speed wait until the coolant reaches the temperature necessary to open t...

Page 94: ...42 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 95: ...SECOND PART ELECTRICAL EQUIPMENT SECTION 3 INDUSTRIAL APPLICATION 43 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 96: ...44 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 97: ...crankshaft 9 Engine speed timing sensor on camshaft 10 Common rail fuel pressure sensor 11 Common rail high pressure control solenoid valve also called pulse wide modulation PWM or M Promp valve 12 Intake air temperature sensor after intercooler 13 Intake air pressure sensor 14 Engine oil pressure sensor 15 Alternator 103265 LOCATION OF COMPONENTS ON THE ENGINE SECTION 3 INDUSTRIAL APPLICATION 45 ...

Page 98: ...nsor on crankshaft 9 Engine speed timing sensor on camshaft 10 Common rail fuel pressure sensor 11 Common rail high pressure control solenoid valve also called pulse wide modulation PWM or M Promp valve 12 Intake air temperature sensor after intercooler 13 Intake air pressure sensor 14 Engine oil pressure sensor Circuit diagram of engine cable 89782 14 46 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ...

Page 99: ...solut voltage 5 0 25 Vdc energy absorption 20 mA Max Tightening torque 10 2 Nm Atmosferic pressure sensor max pressure 116 kPa assoluta voltage 5 0 25 Vdc energy absorption 20 mA Max Tightening torque 10 2 Nm Figure 3 Figure 4 Engine components Temperature sensors These are NTC type sensors and are used to indicate the operating temperatures of the engine coolant reference 1 Figure 1 engine oil re...

Page 100: ... 5 Figure 6 Engine speed timing sensor on camshaft This is an inductive type sensor and is positioned on the distribution shaft reference 9 Figure 1 It generates signals that are obtained by means of the magnetic flow lines that close up through the holes on the gears that are keyed on the distribution shaft The signal that is generated and sent to the electronic unit that can calculate the inject...

Page 101: ...eatures max pressure 5 28 Vdc resistance 130 mA a 28 Vdc Max work temperature 40 C 125 C Tightening torque 10 2 Nm A Electrical contact in open position B Electrical contact in close position low level in the oil sump SECTION 3 INDUSTRIAL APPLICATION 49 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 102: ... on engine side It is fitted directly on the engine using flexible plugs that dampen the vibration transmitted by the engine Connector on engine side ADEM III engine control unit 81391 89788 50 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 103: ...26 Not used 27 Not used 28 Cylinder 6 injector pin 2 0921 29 Cylinder 8 injector pin 2 1013 30 Not used 31 Not used 32 Indicator signal of engine oil temperature 0911 33 Indicator signal of engine coolant temperature 1002 34 Indicator signal of fuel temperature 1003 35 Indicator signal of turbo blower air temperature 0912 36 Common to pins 1 of cylinder 1 and 2 injectors 0913 37 Common to pins 1 o...

Page 104: ...ot used 55 Not used 56 Not used 57 Not used 58 Positive of the timing system speed sensor 1007 59 Negative of the timing system speed sensor 1008 60 Not used 61 To the rail pressure control valve pin 1 1014 62 To the rail pressure control valve pin 2 1015 63 Not used 64 Not used 65 Not used 66 Not used 67 Not used 68 Not used 69 Not used 70 Not used ...

Page 105: ...the control unit governs the regulator to have the optimum pressure at all times PILOT AND MAIN INJECTION ADVANCE CONTROL Depending on the signals from the various sensors the control unit determines the optimal injection point according to internal mapping PEAK SPEED LIMITATION Appropriate engine speed thresholds are stored in the control unit according to the application When the engine speed ex...

Page 106: ...54 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 107: ...THIRD PART DIAGNOSTICS SECTION 3 INDUSTRIAL APPLICATION 55 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 108: ...56 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 109: ...fic instructions to remedy the main faults The connection of the two tools is different so that they cannot be mixed up The tags of tool 99368550 tool have DIAGNOSE written on them and the ones for of tool 99368543 have LOCAL CONTROL written on them Troubleshooting carried out with the 99368550 equipment can be performed by using simulation tool ILC 99368543 with which it is possible to pilot the ...

Page 110: ...allation CD The CD must be installed on a personal computer not included in the kit having following minimum characteristics Processor Intel Centrino I IULV 512 MB Ram 40 GByte HD Internal modem 56 kbps V90 Card LAN 100 BASE TX 10 BASE T 88 character keyboard Standard PC external interfaces Operating system Windows 2000 Professional Program installation must be performed following the procedures t...

Page 111: ...entral area referred to as Operative Area which makes it possible to display the available lists and functions thus allowing you to access the various operations Main screen with function selecting options Description of buttons STOP It allows you to exit the VECTOR application at any time TOOLS This button is selected to access the Select language function If you do not wish to use the function s...

Page 112: ...it Stored fault code reading Some of the stored and listed faults might be intermittent More precisely some of them might when being diagnosed not be present yet previously memorized by the control unit itself intermittent faults This screen also allows you to clear the faults found in the memory after the repair work has been carried out Reading the FAULT CODES present and intermittent Event code...

Page 113: ...rs include all the parameters available in the control unit It is important that work parameters are read when the system is active engine running The ON OFF button allows you to have according to the choice made the parameters updated button set to ON or frozen upon selection button set to OFF Work parameter reading Diagnostic Test The Utilities screen allows you display the Engine Test options a...

Page 114: ... rail operation pressure rise up to 160 000 kPa Let the engine run in these conditions for 5 minutes and see if there is any leakage from the rail and from the pipes Then press STEP DOWN in order to bring the pressure back to the initial level Press STOP to finish the test During the injector operation inspection the VARIATION OF THE FUEL DELIVERY is to be observed while a cylinder is excluded the...

Page 115: ...kPa Fuel Temperature Deg C Engine Load Factor Diagnostic Clock hours Engine Oil Pressure abs kPa Turbo Outlet Pressure abs kPa Battery Voltage Volt Hydraulic Oil Temperature Deg C Injection Actuation Pressure kPa Fuel Consumption Rate 1 h Engine Oil Temperature Deg C Inlet Air Temperature Deg C Fan Pump Pressure kPa Injector Actuation Current Number of Engine Cylinders Active Diagnostic Codes Pres...

Page 116: ...arameter Units of measurement Desired Engine speed rpm Boost pressure kPa Engine Oil Pressure kPa Engine Coolant Temperature Deg C Fuel Position Atmospheric Pressure kPa Fuel Temperature Deg C Engine Oil Temperature Deg C Inlet Air Temperature Deg C Desired Fuel Rail Pressure absolute kPa Fuel Rail Pressure absolute kPa ...

Page 117: ...ilter Restriction Warning 99 1 Engine Overspeed Derate 3 2 Engine Overspeed Shutdown 4 3 Engine Overspeed Warning 190 1 Fuel Filter Restriction Derate 5 1 Fuel Filter Restriction Shutdown 6 3 Fuel Filter Restriction Warning 95 1 Fuel Repair Pressure Leak Derate 499 2 Fuel Repair Pressure Leak Shutdown 499 3 Fuel Repair Pressure Leak Warning 499 1 High Boost Pressure Derate 162 2 High Boost Pressur...

Page 118: ...igh Hydraulic Oil Temperature Shutdown 24 3 High Hydraulic Oil Temperature Warning 600 1 High Inlet Air Temperature Derate 25 2 High Inlet Air Temperature Shutdown 26 3 High Inlet Air Temperature Warning 27 1 Low Boost Pressure Derate 93 2 Low Boost Pressure Shutdown 93 3 Low Boost Pressure Warning 93 1 Low Coolant Level Derate 57 2 Low Coolant Level Shutdown 58 3 Low Coolant Level Warning 59 1 Lo...

Page 119: ...ure Sensor Open Short To Battery 110 3 Engine Coolant Temperature Sensor Short to Ground 110 4 Engine Coolant Fan Pump Pressure Sensor Short to Ground 290 4 Engine Oil Pressure Sensor Open Short To Battery 100 3 Engine Oil Pressure Sensor Short to Ground 100 4 Engine Oil Refill Relay Open Circuit 1000 5 Engine Oil Refill Relay Short Circuit 1000 6 Engine Oil Temperature Sensor Open Short To Batter...

Page 120: ... Circuit 3 6 Injector Cylinder 4 Open Circuit 4 5 Injector Cylinder 4 Short Circuit 4 6 Injector Cylinder 5 Open Circuit 5 5 Injector Cylinder 5 Short Circuit 5 6 Injector Cylinder 6 Open Circuit 6 5 Injector Cylinder 6 Short Circuit 6 6 Injector Cylinder 7 Open Circuit 7 5 Injector Cylinder 7 Short Circuit 7 6 Injector Cylinder 8 Open Circuit 8 5 Injector Cylinder 8 Short Circuit 8 6 Inlet Air He...

Page 121: ...l 190 8 Remote Operator s Lamp Open Circuit 823 5 Remote Operator s Lamp Short Circuit 823 6 Remote Throttle Position Sensor 1923 8 Secondary Engine Speed Signal abnormal 342 8 Secondary Engine Speed Signal Machanical Failure 342 11 TGC Relay Open Circuit 477 5 TGC Relay Short Circuit 477 6 Turbo Outlet Pressure Sensor 1 Open Short To Battery 273 3 Turbo Outlet Pressure Sensor 1 Short To Ground 27...

Page 122: ...be able to monitor operation via the diagnostic equipment ILC simulator tool use Connect connector 3 to the electrical shunt box on which the unit is inserted Press switch 1 15 Press START 5 If required use potentiometer 4 in order to increase engine rpm Pushbutton 2 used to fill up the sump with oil is not used in this Vector version Figure 3 The connection 3 varies depending on the application N...

Page 123: ...t No sign of starting Trouble in the ADEM III electronic control unit Short circuit Check unit cabling integrity before replacing it No enabled diagnosis is available the unit is damaged Crankshaft sensor no signal or signal not plausible Check the sensor is clean and correctly secured Check the phonic wheel is clean and integral Check the integrity of the sensor R 920 Ω If the sensor is integral ...

Page 124: ...ed on the ordinary maintenance manual or during sensor inspection Therefore first check the sensor connection and replace the sensor if trouble is due to it The engine will not start Indicators on Filters clogged After checking the conditions of cartridge clogging replace them or check the sensor Afterwards check the connection and if the trouble is due to the sensor replace it Fuel leaking from t...

Page 125: ... lt b Heater never turns on Possible filter clogging due to fuel paraffining with very low outside temperatures 15 C Remote control for the fuel filter heater is defective Check vehicle cable and or replace the filter The clogged filter indicator turns on Starting difficult a The pre post heating elements are not powered cold starting may be diffic lt and g y difficult and smokiness on starting b ...

Page 126: ...rts may cause severe injuries Normally with these symptoms it is natural to abandon the attempt of starting the engine Because insisting the engine starts with one cylinder less and slowly the smoke diminishes and disappears exhaust fuel smell Check that the relevant engine injector cable cylinder number match Check cable positioning and if required connect the engine cable properly Difficult star...

Page 127: ...formances Possible smoke and rocking Fuel leaks from fittings or pipes after the low pressure pump Check the conditions of the pipes and relevant seals Abnormal performance rocking Diesel fuel filter clogged Check the presence of errors detectable data with the diagnosis instrument then replace the filters Air blow by before the low pressure pump Check the conditions of the pipes and relevant seal...

Page 128: ... multimeter check that cabling works properly Abnormal performance The pressure regulator does not work properly Check active diagnosis check that the connector is properly connected to the pressure regulator and any sensor replacement If replacement does not resolve the trouble with a multimeter check that cabling works properly The engine suddenly stops without previous The fuel filter is clogge...

Page 129: ...FOURTH PART PLANNED MAINTENANCE SECTION 3 INDUSTRIAL APPLICATION 77 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 130: ...78 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 131: ... up if necessary Check for fluid leaks Inspect the engine for lost or missing bolts damaged parts Inspect belt wear Remove any dirt built up on the engine leaves dust etc Take note of oil diesel consumption per service hours km and report and unexplained increases Check coolant overheating or excessive heating time FIRST LEVEL MAINTENANCE Carry out every 500 hours or at least once per year Change ...

Page 132: ...aft High pressure fuel pump Low pressure fuel pump Wiring Turbochargers Turbocharger oil delivery return pipes Starter motor Seals and gaskets Oil pump Oil pressure regulation valve Gears Oil exchanger Oil level sensor Oiljet pressure regulation valves Air oil water heaters Taper roller bearings on front casing Crankshaft and camshaft bearings Rockers and mounts Roller tappets Rocker shafts Connec...

Page 133: ... the Iveco Motors sales organization SECTION 3 INDUSTRIAL APPLICATION 81 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 Continuous Prime Stand By Periodic Checks 100 h 1 month Hourly intervals h Time intervals Hourly intervals h Time intervals First level service 1000 1 year 500 1 year Second level service 5000 2 years 1000 2 years General overhaul 25000 10 years 2000 10 years For special appli...

Page 134: ...ef valves adjustment Clean oil heat exchanger Gear inspection Oil pressure relief valve replacements Valve control rods replacement Connecting rod replacement Oil pump replacement Gasket replacement Starter motor replacement Oil return hoses replacement Oil intake hoses replacement Turbine replacement Engine lead assembly replacement Low pressure pump replacement High pressure pump replacement Con...

Page 135: ...at the scheduled times Regular maintenance is the best guarantee for safe operation and keeping running costs at optimal levels These operations are to be carried out at the set mileages User recommendations The frequency of engine lubrication is in relation to a percentage of sulphur in the diesel of less than 0 5 If using diesel with a percentage of sulphur higher than 0 5 the mileage must be ha...

Page 136: ... or fingers between pieces Wear the required safety clothing such as goggles gloves safety shoes and helmet Before touching the filters make sure the engine temperature is not such as to cause burns Engine lubricating oil is harmful avoid contact with skin and eyes In the event of contact wash with plenty of running water To change the engine oil filters proceed as illustrated here Before removing...

Page 137: ...erages that can lead people to drink from them Never throw waste on the ground on tips or in water courses Obtain information on the appropriate ways of recycling or disposing of waste from the local authorities or collection centres Use only genuine products capable of extending the efficiency and life of the engine After fitting the filters check the sump oil level and turn the engine for a litt...

Page 138: ...for the environment Potentially hazardous waste used on IVECO vehicles includes lubricants fuels coolants filters and batteries Use watertight containers when draining off fluids Never use containers for foodstuffs or beverages that can lead people to drink from them Never throw waste on the ground on tips or in water courses Obtain information on the appropriate ways of recycling or disposing of ...

Page 139: ...pieces Wear the required safety clothing such as goggles gloves safety shoes and helmet To change the fuel pre filter and water separator filter proceed as illustrated here Before disassembling place under the filter a basin of suitable capacity Improper waste disposal is a threat for the environment Potentially hazardous waste used on IVECO vehicles includes lubricants fuels coolants filters and ...

Page 140: ...it is also possible to removethe tappet cover Fitting the 24 mm ratchet wrench on the back of tool 99368502 see preceding page turn the engine flywheel until we obtain the required cylinder balancing the 4 valves are at the same height To obtain cylinder no 1 or no 6 in T D C conditions it is necessary to position the damping flywheel as indicated in the picture For the following balancing adjustm...

Page 141: ...oceed as illustrated here Figure 12 Figure 13 With kit wrench 99368503 screw or unscrew the adjuster screw 2 Check that the tappet feeler gauge 3 can slide with a slight amount of friction Keeping the adjuster screw 2 still use wrench 99368503 to lock the check nut of the adjuster screw 1 81606 82184 82183 82185 SECTION 3 INDUSTRIAL APPLICATION 89 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 142: ...he flywheel cover Tightening torque 7 10 Nm Figure 15 1 Adjuster screw lock nut 2 Adjuster screw Apply the 10 60 Nm torque wrench with the 3 8 square connection 99389831 4 to the wrench 99368503 to lock the lock nut to a torque of 40 Nm 0 5 mm 0 5 mm 82186 81611 90 SECTION 3 INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 143: ...d helmet Improper waste disposal is a threat for the environment Potentially hazardous waste used on IVECO vehicles includes lubricants fuels coolants filters and batteries Use watertight containers when draining off fluids Never use containers for foodstuffs or beverages that can lead people to drink from them Never throw waste on the ground on tips or in water courses Obtain information on the a...

Page 144: ...ially hazardous waste used on IVECO vehicles includes lubricants fuels coolants filters and batteries Use watertight containers when draining off fluids Never use containers for foodstuffs or beverages that can lead people to drink from them Never throw waste on the ground on tips or in water courses Obtain information on the appropriate ways of recycling or disposing of waste from the local autho...

Page 145: ...e operations fit the injector 7 back on together with the fixing bracket 6 Handle all parts extremely carefully Never get your hands or fingers between pieces Wear the required safety clothing such as goggles gloves safety shoes and helmet CHANGING AN INJECTOR To change an injector proceed as illustrated here Disassemble the pipes 2 on the injector side and on the flow limiting device side by mean...

Page 146: ...ack on to a tightening torque of 32 36 Nm Always change the O ring in the assembly phase Lubricate the O ring before installation use vaseline Check the sealing surface of the leaking pipe and the surface on the injector and flow limiter Cleaning the surfaces and remove dirt if necessary In case the sealing surface are damaged replace the part Lubricate with clean engine oil the fitting and the se...

Page 147: ... filters and batteries Use watertight containers when draining off fluids Never use containers for foodstuffs or beverages that can lead people to drink from them Never throw waste on the ground on tips or in water courses Obtain information on the appropriate ways of recycling or disposing of waste from the local authorities or collection centres Support the blow by filter to prevent sudden disco...

Page 148: ...sening the clamp 1 remove the pipe 2 feeding the tank s pump Undo the screws fixing the pipe 3 returning to the pump from the radiator Figure 28 On the top side undo the screws 1 to free the pipe 2 from the flange 3 fitted on the pump Unscrew the nuts 4 securing the pump to the cover of the gearbox Use a crowbar to separate the pump from the gearbox cover Figure 29 Support the pump to prevent sudd...

Page 149: ...ure 30 complete with seal 1 Fitting At the assembly stage after changing the damaged parts assemble all the parts on the bench to complete the pump Change the seal on the cover If the pump is not changed wash to remove any incrustation Figure 34 Fitting the complete pump on the gearbox must include engaging the teeth 1 on the gear 2 on the drive disc then screw the nuts onto the stud bolts on the ...

Page 150: ...ctrical connections of cables 2 3 4 5 and 6 Remove the starter motor by unscrewing the nuts 1 Fitting Change the motor with a new one and position it in its seat after changing the gasket between the flywheel housing and the motor Tighten the fixing nut M12 x 1 75 to a torque of 105 86 Nm Before proceeding to work on an electric or electronic component make sure the system is not powered It is rec...

Page 151: ...r Liners 12 TIMING SYSTEM 14 Camshaft 14 Checking cam lift and pin alignment 14 Replacing the camshaft idle gear 14 Changing the bushings 16 Changing the tappets 16 Fitting tappets and camshaft 16 OUTPUT SHAFT 16 Measuring journals and crankpins 16 Checking main journal alignment 18 Crankshaft balancing instructions 19 Replacing water pump drive gear 19 Changing the oil pump and timing system gear...

Page 152: ...the rod piston assemblies into the cylinder liners 32 Measuring the mounting clearance of big end pins 33 Fitting the connecting rod caps 33 Check of piston protrusion 33 CYLINDER HEAD 34 Hydraulic leak test 34 Dismantling valves 34 Checking the cylinder head support surface 34 VALVE 34 Removing carbon deposits and checking the valves 34 Refacing the valves 35 Checking valve centering 35 Checking ...

Page 153: ... Bore mm 145 Stroke mm 152 Total displacement cm3 20 080 TIMING start before T D C A end after B D C B 16º 25º start before B D C D end after T D C C 66º 15º X Checking timing mm X mm Checking operation mm X mm 0 5 0 5 FUEL FEED Injection Type Bosch high pressure common rail Control unit ADEM III Nozzle type Injectors Injection sequence 1 3 7 2 6 5 4 8 bar Injection pressure bar Variable up to 160...

Page 154: ...ength L 164 003 164 028 266 5 267 5 2 Cylinder sleeve crankcase seats interference 0 028 0 022 Outside diameter 2 Cylinder liners 3 X Cylinder liner position X on crankcase X 0 025 0 095 inside diameter 3 145 00 145 03 1 Pistons 1 X measuring dimension X 25 2 outside diameter 1 144 825 144 870 outside diameter 2 62 000 62 008 Piston cylinder liners 0 261 0 309 Piston diameter 1 _ X Pistons positio...

Page 155: ...rings S2 S3 2 975 2 990 5 975 5 990 measured on of 140 mm 1 0 110 0 174 Piston rings slots 2 0 070 0 105 3 0 040 0 075 Piston rings _ X1 2 X Piston ring end opening in cylinder liners 3 2 X X X1 0 50 0 65 3 X X2 0 90 1 15 X3 0 40 0 70 1 Small end bushing seat 1 67 994 67 963 2 Big end bearing seat 2 110 000 110 022 4 Small end bushing diameter 3 outside 4 68 080 68 120 inside 3 62 015 62 030 S Big...

Page 156: ...5 000 104 980 Crankpins 2 105 000 104 980 Main bearing shells S1 2 958 2 970 S 1 S 2 Big end bearing shells S2 supplied as spares 2 466 2 478 3 Main bearing housings 128 000 130 025 Bearing shells main journals no 1 5 no 2 3 4 0 065 0 134 0 065 0 134 Bearing shells crankpins 0 044 0 110 Main bearing shells Big end bearing shells X1 Main journal for shoulder X1 56 00 56 40 X2 Main bearing housing f...

Page 157: ...alve guides and seats on the head 0 015 0 035 Valve guide 17 212 17 225 4 Valves 4 Valves 4 α 9 960 9 975 60 30 7 30 α 4 α 9 960 9 975 45 30 7 30 Valve stem and its guide 0 052 0 092 Valve seat in h d head 52 985 53 020 1 1 1 50 985 51 020 Outside diameter of valve seat angle of valve seat 2 seat angle of valve seat in cylinder head 53 000 52 500 2 α 60 α α 2 51 000 50 500 α α 45 X Recessing of va...

Page 158: ...ng height free height H 74 H H 1 2 under a load of H 1 H2 N 450 25 H1 57 5 N 800 40 H2 46 5 X Injector protrusion X not adjustable Seats for camshaft bushing no 1 5 Camshaft seats no 2 3 4 86 000 86 030 1 2 3 Camshaft supporting pins 1 5 Ø 79 950 79 968 Outer diameter of camshaft bushings 86 133 86 163 Inner diameter of camshaft bushings 80 018 80 087 Bushings and housings in the cylinder head 0 1...

Page 159: ...mm Cam lift H 6 9360 7 4066 1 Tappet cap seat in the crankcase 1 34 025 34 000 Tappet cap outside diameter 2 Measurement from axis tappet at end of fixing pin X 33 600 33 800 18 80 19 00 1 Rocker arm shaft 1 31 984 32 000 Rocker arms 1 32 025 32 050 Rocker arms 1 32 025 32 050 1 Between rocker arms and shaft 0 025 0 066 ...

Page 160: ...onnecting would interfere with the cylinder liner Remove the connecting rod cap 2 and extract the piston from the cylinder liner Set the crankcase horizontally Remove the top 4 and side 3 bolts fixing the main bearing caps to the crankcase and ex tract them On the central main bearing housings 5 and on the cap there are the thrust half rings for adjusting the crankshaft end float 82230 ENGINE OVER...

Page 161: ... REPAIR OPERATIONS CYLINDER UNIT Checks and measurements Should the ring gauge be not available use a micrometer for zero setting Measurements shall be performed on each cylinder at three different heights in the barrel and on two planes perpendicular with each other one parallel to the longitudinal axis of the engine A and the other perpendicular B Maximum wearis usuallyfound onplane B in corresp...

Page 162: ...f the cylinder head mating surface with a calibrated rule and feeler gauge After finding the areas of deformation level off the supporting surface after taking out the centring pins 2 with tool 1 and the cylinder liners 3 according to the procedures given under the heading REPLACING CYLINDER LINERS Remove the cylinder liners 2 from the cylinder assembly with tool 99360799 1 fitted as illustrated i...

Page 163: ... hand main oilway The bushing 3 is removedfrom thecylinder assembly with a percussion extractor 1 and a suitable part 2 Use an appropriate drift to fit the bushing Change the seals 5 of the bushing 3 for the right hand main oilway The bushing 3 is removed from the cylinder assembly with a percussion extractor 99340205 1 and a suitable part 2 Use an appropriate drift to fit the bushing If changing ...

Page 164: ...ck the useful cam lift that must be the same for both the inlet and exhaust if it is not change the camshaft Using a feeler gauge 1 check that the clearance between the plate 3 retaining the camshaft 2 to the cylinder assembly and the driving gear 4 is from 0 070 to 0 175 mm Check that the teeth of the driving gear 4 are neither broken nor excessively worn The driving gear 4 of the camshaft is rem...

Page 165: ...n of seizure or wear SEAT Ø 86 000 86 030 PIN Ø 79 950 79 968 Thickness variation max 0 025 mm Heigth to be obteined after driving the bushes Heigth to be obteined after driving the bushes Thickness variation max 0 025 mm SEAT Ø 86 000 86 030 PIN Ø 79 950 79 968 82233 Figure 18 SECTION 4 OVERHAUL AND TECHNICAL SPECIFICATIONS 15 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 166: ... insert the found values in the proper table During assembly the bushings must be facing so that the lubrication holes match those in the seats On completing assembly bore the bushings to the diameter shown in Figure 18 Changing the tappets The surface of the tappets in contact with the cams of the camshaft must be perfectly smooth with no dents Slight dents can be removed with an extremely fine a...

Page 167: ...and its grinding is not foreseen 105 000 104 980 121 995 121 975 CRANKSHAFT JOURNAL DATA Check the state of the main journals and crankpins of the crankshaft They must show no sign of scoring ovality or excessive wear The data given refer to the nominal pin diameter 8821 37710 NOTE SECTION 4 OVERHAUL AND TECHNICAL SPECIFICATIONS 17 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 168: ...t main journal Checking main journal alignment LIMIT POSITION LIMIT POSITION NORMAL POSITION MAIN JOURNAL CRANKPIN Diagram for checking the flywheel mating surface is orthogonal and coaxial with the axis of rotation and main journals Turn the shaft with the dial gauge at B no change greater than 0 04 mm must be measured on the dial gauge with the dial gauge at A no change greater than 0 03 mm must...

Page 169: ... 90 check window 110 170 Nm when the counterweights are parallel to the main bearing housings Crankshaft balancing instructions The crankshaft must be dynamically balanced Maximum permissible unbalance for each of the two planes of balancing 1000 g mm Check that the toothing of the gear 2 is neither damaged nor worn if it is then extract it with an appropriate extractor The gear 2 must be mounted ...

Page 170: ... with the housing of the split pin on the crankshaft Using the right drift bring the gear flush onto the crankshaft and screw down the M8x1 25x80 mm screw tightening it to a torque of 22 to 27 Nm Fitting the main bearings The crankshaft must be dynamically balanced Arrange the main bearing shells with the lubrication hole in their respective seats and fit the crankshaft 3 with the tool 99360500 2 ...

Page 171: ... assembly Lubricate under the bottom side of the heads of screws 2 and 3 that fix the bench caps with engine oil and tighten to the fixing torque prescribed When tightening to an angle use tool 99395216 Figure 35 Tightening sequence Figure 36 M20x1 5 bolts Type of tightening pre torque angle Pre torque 160Nm Angle 240 Guard torque 600 1000 Nm M16x1 5 bolts Type of tightening pre torque angle Pre t...

Page 172: ...rrange the thrust rings 2 on the central main bearing housing 1 with the grooves facing the crankshaft shim adjustment Fit the caps 1 Figure 34 back on and tighten the screws 2 Figure 34 to the prescribed tightening torque 1 2 When tightening to an angle use tool 99395216 Remove caps from supports The backlash between the main bearings and the pins is found by comparing the width of the calibrated...

Page 173: ...t which the dial gauge pointer stops Figure 39 Figure 40 Figure 41 Figure 42 Trace two marks one on the crankshaft key 1 and one reference one on the cylinder block crankcase Rotate the crankshaft until a movement of the pointer is detected on the dial gauge and then make a second mark on the crankshaft 2 Measure the halfway point between the two reference marks and make a third reference mark 3 o...

Page 174: ...s not achieved the camshaft should be adjusted using the openings in the toothed wheel See timing diagrams overleaf 82243 82244 Figure 45 113063 Fit the flywheel 2 taking care to ensure that the reference markt 1 is aligned with the position of the camshaft rpm sensor see timing diagrams on the pages that follow Tighten the bolts 3 to the recommended torque 24 SECTION 4 OVERHAUL AND TECHNICAL SPEC...

Page 175: ...ATIONS G DRIVE GRIFFON SPRINKLER 1 Camshaft 2 Camshaft rpm sensor 3 Camshaft flywheel 4 Engine flywheel 5 Crankshaft rpm sensor fitted on the flywheel casing SECTION 4 OVERHAUL AND TECHNICAL SPECIFICATIONS 25 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 ...

Page 176: ...ING APPLICATIONS DRAGON 1 Camshaft 2 Camshaft rpm sensor 3 Camshaft flywheel 4 Engine flywheel 5 Crankshaft rpm sensor fitted on the flywheel casing 26 SECTION 4 OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Base April 2006 Print P2D32V001E ...

Page 177: ...8 fitted fit the two timing gears 6 and the spacer 5 and secure the assembly using the bolts 4 Fit the tool 1 99368508 on the front casing as shown in the diagram Fit the flywheel 2 so that the tool 99368508 is inserted via the seat for the timing sensor on the tooth on the flywheel see arrow Proceed with tightening the bolts 3 113064 113065 Method 2 using equipment Flywheel timing SECTION 4 OVERH...

Page 178: ... rod 3 by removing the ring 2 and extracting the gudgeon pin 4 Measure through the micrometer 1 the piston diameter 2 to determine the assembly play The diameter shall be measured at 21 mm from the piston skirt The clearance between the piston 1 and cylinder liner can be checked using a feeler 2 as shown in the above figure Measure the diameter of the gudgeon pin 1 using a micrometer 2 Gudgeon pin...

Page 179: ...ravity Conditions for correct mating of gudgeon pin and piston PRINCIPAL PISTON GUDGEON PIN AND PISTON RING DATA Piston rings Figure 58 Check thickness of piston rings 2 by a micrometer 1 Figure 59 Check the clearance between the piston rings 2 and their seats on the piston 1 using a feeler gauge 3 113006 36131 36133 16522 SECTION 4 OVERHAUL AND TECHNICAL SPECIFICATIONS 29 VECTOR 8 ENGINES Print P...

Page 180: ...rods CONROD BUSHING ROD HALF LOWER AND UPPER Figure 63 Figure 64 The ring 2 of the first slot has a V shape The clearance X between a ring and its seat is measured by placing the piston 1 with its ring in the cylinder liner 3 so that the ring comes half way out of the cylinder liner The upper bushing of the connecting rod cannot be replaced 3613 83434 16826 83420 82267 NOTE 30 SECTION 4 OVERHAUL A...

Page 181: ...linder where the rod should be installed may be stamped on it Therefore when replacing the rod it is necessary to mark the new rod with the same number as the rod whitch is being replaced Fitting the piston rings 1 Check of connecting rod alignment Fitting the connecting rod piston assembly Connecting rod piston mating The connecting rod piston coupling must be made taking account that on fittingt...

Page 182: ...ve not been replaced in the same position found at removal Do not try to adapt the half bearings Figure 68 After assembling the rod piston group 1 check the squaring using apparatus 99395363 3 and feeler gauge 2 Squaring must be exact otherwise the cause should be found and faulty part replaced DIAGRAM FOR INSERTING THE CONNECTING ROD PISTON ASSEMBLY IN CYLINDER 1 Tappet side 2 Camshaft Fitting th...

Page 183: ...ual to the prescribed value replace the bearing halves and repeat the check When the rod piston group have been assembled check for piston protrusion at T D C from the upper engine block level The protrusion should be from 0 21 to 0 59 mm α Upon final reassembly the big end cap fastening screws must always be replaced Manually check that the connecting rods can be moved sideways on the drive shaft...

Page 184: ...and at a pressure of 4 5 bar into the cylinder head Under these conditions no leaks should be found if they are replace the cylinder head Dismantling valves Figure 76 Figure 77 Check the flatness of the support surface using a rule and a feeler gauge Remove carbon deposits from valve using a steel brush Check that valves do not show signs of binding or cracking Use a micrometer to check that the v...

Page 185: ... Figure 82 Refacing the valves MAIN DATA OF THE VALVE SEATS AND VALVE GUIDE SEATS ON THE CYLINDER HEADS A INLET S EXHAUST A Intake valve on the engines with serial numbers starting up to 484 B Intake valve on the engines with serial numbers starting from 485 Check with a micrometer that the diameter of the valve stems is as indicated if necessary rebore the seats on the valves with the grinding ma...

Page 186: ...llar drill adjust the stop device 3 on the milling cutter 2 operate the milling cutter and remove the valve seat thoroughly clean the cylinder head cool the new valve seats to 180 C in liquid nitrogen drive the valve seats 3 into the cylinder head with a drift 1 and suitable part 2 Assembly interference inlet 0 015 to 0 035 mm exhaust 0 015 to 0 035 mm Regrind the valve seats 2 with tool 99305019 ...

Page 187: ...of the new spring indicated in the following diagrams REPLACING THE INJECTOR HOLDER CASES Imperfect coupling between the injector and case forced into the cylinder head or between the case and the seat on the cylinder head causes a loss of compression or water leakage In the first case the trouble is eliminated by regrinding the seat of the case 2 with the milling cutter 99394011 3 and the bushing...

Page 188: ...4 5 mm 4 7 8 1 3 5 6 2 3 5 6 2 4 7 8 1 α Fit new cylinder head gaskets Mount the cylinder heads 1 Lubricate the fixing bolts with UTDM oil Align the cylinder heads with the tool applied in the holes to fasten the exhaust manifolds Tighten the cylinder head bolts following the order shown in the following figure as follows first phase pre torque 70 Nm DIAGRAM OF TIGHTENING SEQUENCE FOR CYLINDER HEA...

Page 189: ...casing to crankcase M14x2 135 165 13 5 16 5 Bolt fixing gear pin centring M10x1 5 45 50 4 5 5 0 Bolt fixing centring pin M12x1 75 100 110 10 0 11 0 Bolt fixing cylinder head cover M8x1 25 20 24 2 0 2 4 Bolt fixing clearance adjustment cover M6x1 7 10 0 7 1 0 Bolt fixing left and right intake manifold to cylinder head M10x1 5 38 45 3 8 4 5 Bolt fixing exhaust manifold M10x1 5 N 12 bolts from front ...

Page 190: ... 25 22 27 2 2 2 7 Bolt fixing spacer to front casing M12x1 75 74 90 7 4 9 0 Bolt fixing air compressor spacer 74 90 7 4 9 0 Bolt fixing high pressure pump HPP to crankcase M10x1 5 49 60 4 9 6 0 High pressure gear pump fixing nut HPP 350 35 High pressure gear pump fixing nut HPP 160 180 35 Bolt fixing ECU to support M8x1 25 22 27 2 2 2 7 Nut fixing compressor drive gear 160 180 16 18 Bolt fixing lo...

Page 191: ...SECTION 5 TOOLS 1 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 SECTION 5 Tools Page TOOLS 3 ...

Page 192: ...2 SECTION 5 TOOLS F4AE NEF ENGINES Base April 2006 Print P2D32V001E ...

Page 193: ...ll set of valve seating regrinding tools 99305047 Spring loading control apparatus 99322230 Rotary telescopic stand capapity 2000 daN torque 375 daNm 99342145 Puller to remove injector holder 99360091 Tool for dismantling fuel filter 99360184 Calipers for disassembling and reassembling engine piston rings 105 160 mm ...

Page 194: ...asket on valve guides 99360500 Tool for lifting the output shaft 99360603 Band for inserting piston into cylinder barrel 90 175 99360785 Ring 145 mm use with 99360799 99360799 Tool for disassembling and reassembling cylinder liners use with special rings 99361011 Brackets securing engine to rotating overhaul stand 99322230 ...

Page 195: ...ading electro injector seat 99367016 Sleeve key 27 mm for flywheel fixing bolts 99367019 Guides set 2 M24x2 to mount engine flywheel 99368501 Tool for rotating the engine flywheel 99368502 Tool for rotating engine flywheel to be used with 99368547 99368503 Key for adjusting tappet clearance screw use with 99389831 ...

Page 196: ...ller for dismantling injectors 99368506 Key 27 mm for dismantling fuel injector pipes use with 99389813 99368508 Tool for positioning fonic wheel during timing ignition 99368509 Tool for timing camshaft 99368511 Tool for fiitting output shaft rear gasket 99368512 Tool for fiitting output shaft front gasket ...

Page 197: ...tput shaft rear gasket 99368514 Tool to remove output shaft front gasket 99368515 Stud set use with 99360799 99368516 Puller to remove the control gear of hight pressure pump use with 99368517 99368517 Retainer tool control gear of hight pressure pump 99368533 Support for disassembling and assembling the engine flywheel ...

Page 198: ... Tool for drain engine oil 99368539 Installer oil filter engine 99368540 Ring wrench with 14X18 insert 18mm for turbine bolts 99368542 Set of 8 insert box wrenches 14X18 13 17 18 19 21 22 24 27 30 mm 99368543 ILC simulator for Vector Engine 99368544 Tool for disassembling and reassembling engine valves ...

Page 199: ...eaction for teeghtening fly wheel bolts use with 99367016 99389816 99389818 99368547 Dial gauge base to adjust transmission shaft bearings use with 99395603 99368548 Dial gauge base to adjust transmission shaft bearings use with 99395603 99368550 Diagnostic interface for Vector engine 99368551 Dial gauge base to adjust transmission shaft bearings use with 99395603 ...

Page 200: ...smission shaft bearings use with 99395603 99389813 Torque wrench 20 120 Nm with 1 2 square attachment 99389816 Torque overgear x 4 with 3 4 square attachment 99389817 Torque wrench 60 320 Nm with 1 2 square attachment 99389818 Torque wrench 150 800Nm with 3 4 square attachment 99389831 Torque wrench 10 60 Nm with 3 8 square attachment ...

Page 201: ... Nm 99389833 Torque wrench with 14X18 attachment 20 120 Nm 99390425 Tap for to thread injector seat disassembly M12x1 75 99394004 End mill for to work the rocker side of injector seat 99394017 Reamer for to work the bottom side fo the injector seat use with 99394019 99394018 End mill for to work the rocker side of injector seat use with 99394019 ...

Page 202: ...D32V001E TOOLS TOOL NO DESCRIPTION 99394019 Driver bushing 99395216 Pair of measuring devices for angular tightening with 1 2 and 3 4 square attachments 99395363 Complete square for checking rod squaring 99395603 Dial gauge 0 10 mm 99395687 Bore gauge 50 178 mm ...

Page 203: ...APPENDIX 1 VECTOR 8 ENGINES Print P2D32V001E Base April 2006 Appendix Page SAFETY PRESCRIPTIONS 3 Standard safety prescriptions 3 Prevention of injury 3 During maintenance 3 Respect of the Environment 4 ...

Page 204: ...2 APPENDIX F4AE NEF ENGINES Base April 2006 Print P2D32V001E ...

Page 205: ...dy better if provided with elastics at the ends Use protection cream for hands Change wet cloths as soon as possible In presence of current tension exceeding 48 60 V verify efficiency of earth and mass electrical connections Ensure that hands and feet are dry and execute working operations utilizing isolating foot boards Do not carry out working operations if not trained for Do not smoke nor light...

Page 206: ...htening may seriously damage engine s components affecting engine s duration Avoid priming from fuel tanks made out of copper alloys and or with ducts not being provided with filters Do not modify cable wires their length shall not be changed Do not connect any user to the engine electrical equipment unless specifically approved by Iveco Motors Do not modify fuel systems or hydraulic system unless...

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