Download Case New Holland Kobelco Iveco F4BE0484E, F4BE0684D, F4BE0684B Tier 2 Diesel Engine Shop Ma

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REPAIR MANUAL FOR ENGINES F4BE0484E F4BE0684D F4BE0684B

F4BE0484E

F4BE0684D -- F4BE0684B Every information, illustration and specification contained in the present manual is based on the most recent information available at the time of printing.

CNH France S.A. reserves the right, to modify the text at any time without prior communication.

Edition – June 2003

2

Copyright ©

WE

MOTORI

2

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Copyright Š IN--1

INTRODUCTION

TO THE READER - This manual was written for a skilled technician and contains all the technical information needed to repair this vehicle.

- Read this manual carefully for the information concerning repairing operations.

FURTHER REFERENCES PAGE NUMBER - Every page carries a number on the top right corner. Every page contains the following information:

Example:: T 1 -- 2 -- 3

Progressive page number for each group Group number (if any) Section number S:

Safety rules

T:

Technical section

W:

Instruction section for excavator repairing

EW:

Instruction section for engine repairing

Operation principle Performance tests Fault diagnosis

SYMBOLS This manual contains safety warning symbols and indications referring to possible injuries or vehicle damages.

!

This symbol regards safety.

Use great care when you see this symbol because possible injuries to the personnel may occur.

Strictly observe the precautions marked with this symbol.

The safety warning symbol is used also to draw attention on the weight of a component or an element.

Make sure you are always using the right equipment and lifting techniques when handling heavy loads, in order to prevent injuries or damages.

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IN--2

INTRODUCTION

UNIT OF MEASURE This manual adopts the units of measure based on the International System.

The MKSA system units of measure are indicated within brackets after the units of measure of the International System.

Example: 24.5 Mpa (250 kgf/cm2).

The following table converts the International System units of measure in some of the main units belonging to other systems.

Quantity Length Volume Mass Force Torque

To convert from (IS) mm mm L L m3 kg N N N.m N.m

in (Others) in ft US gal US qt yd3 lb kgf lbf kgf.m lbf.ft

Multiply by 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 0.10197 0.7375

Quantity Pressure Power Temperature Speed Capacity

To convert from (IS) MPa MPa kW kW °C km/h min --1 L/min mL/rev

in (Others) kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

Multiply by 10.197 145.0 1.360 1.341 °C x 1.8 + 32 0.6214 1.0 0.2642 1.0

Copyright ©

REPAIR MANUAL

ENGINES

INDEX OF SECTIONS

Section 1 -- Diagnostics

EW--1--1

Section 2 -- Engine F4BE0484E overhaul

EW--2--1

Section 3 -- Overhaul of F4BE0684B -- F4BE0684D engines

EW--3--1

Section 4 -- Recharging and start--up

EW--4--1

4

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WE

MOTORI

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SECTION 1

DIAGNOSTICS

INDEX Diagnostics . . . . . . . . . . . . . . . . . . . . . . .

EW--1--3

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INDICE

Copyright © EW--1--3

DIAGNOSTICS Main engine operating anomalies: 1 2 3 4 5

------

1

6 -7 -8 -9 -10 -11 -12 --

Engine won’t start; Engine overheats; Engine lacks power and works erratically; Engine exhaust smoke black or dark grey; Engine exhaust smoke grey (verging on white);

Engine exhaust smoke light blue; Engine knocks irregularly; Engine stops; Engine exceeds max. revs number; Excessive or insufficient oil pressure; Excessive fuel consumption; Engine won’t stop.

ENGINE WON’T START

Connections to battery terminals are in working order

NO

Clean, check, tighten or replace clamp nuts.

YES

Batteries in working order NO

Carry out the checks described in the “Electric system” repair manual.

NO

Carry out the checks described in the “Electric system” repair manual.

YES

Starter motor in working order

YES

Thermal starter in working order

Replace.

NO

YES

Injection pump timed NO

Verify correct timing as described in the relevant chapter.

(to be continued)

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EW--1--4

DIAGNOSTICS

Injectors in working order

Check operation and adjust.

NO

YES

The feeding circuit or injection pump does not show air penetration

Check and blow off.

NO

YES

The feeding circuit or pump does not show traces of water

NO

Check and clean the feeding circuit (including the tank).

YES

Prescribed compression ratio NO

Overhaul the engine or make repairs only on concerned parts (valves, piston rings, etc.).

YES

Fuel filters in working order

Replace.

NO

YES

Automatic advance variator and electric STOP device both in working order

Check and replace the concerned parts.

NO

YES

Fuel pump fed correctly

Check and replace (if necessary) the fuel pump.

NO

YES

Fuel tank supplied correctly

Refuel.

NO

Copyright Š EW--1--5

DIAGNOSTICS

2

ENGINE OVERHEATS

Check for leaks and restore the level.

Coolant level correct NO

YES

Fan and water pump drive belts in working order

Check for leaks and restore the level.

NO

YES

Water pump in working order

Overhaul or replace the unit.

NO

YES

Thermostat in working order

Replace.

NO

YES

Radiator in working order NO

Wash down thoroughly, check for fluid leaks, replace (if necessary) the part.

YES

Air filter and circuit piping both in working order

Clean or replace faulty parts.

NO

YES

Openings for coolant flow to the head in working order

Wash down thoroughly.

NO

Copyright ©

EW--1--6

DIAGNOSTICS

Valve timing correct

NO

Check and perform correct timing.

YES

Injection pump timed

NO

Check correct timing as described in the relevant paragraph.

YES

Cylinder head gasket in working order

Replace.

NO

YES

Fan in working order

Replace.

NO

3

ENGINE LACKS POWER AND WORKS ERRATICALLY

Air filter in working order NO

Clean the unit and replace (if necessary) the filter element.

NO

Replace by following the instructions given in the “Owner Handbook”.

NO

Check and make (if necessary) the required repairs.

YES

Fuel filters in working order

YES

Feeding circuit in working order

(to be continued)

Copyright Š EW--1--7

DIAGNOSTICS

The feeling circuit does not show impurities and/ or traces of water

NO

Take off the pipes and injection pump, clean them thoroughly, then clean (if necessary) and dry the fuel tank.

YES

Thermostat in working order

Replace.

NO

YES

Fuel pump in working order

Replace.

NO

YES

Injectors in working order

Check operation and adjust them.

NO

YES

Injection pump timed NO

Check correct timing as described in the relevant paragraph.

YES

Automatic advance variator (in injection pump) in working order

Check and bench--adjust the injection pump.

NO

YES

Distributing plunger (in injection pump) in working order

Check and bench--adjust the injection pump.

NO

(to be continued)

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EW--1--8

DIAGNOSTICS

Injection pump rate correct

Check and bench--adjust the injection pump.

NO

YES

Speed governor (in injection pump) in working order at all speeds

Check and bench--adjust the injection pump.

NO

YES

Circuit and L.D.A. device both in working order

NO

Check.

YES

Injection pump with peak adjusting--screw fine-tuned

Fine--tune the peak adjusting--screw.

NO

YES

Correct play between the valves and rocker arms NO

Adjust the play between the valves and rocker arms.

YES

Prescribed compression ratio

Check and bench--adjust the injection pump.

NO

YES

Turbocharger in working order

Repair or replace the unit.

NO

YES

Correct tie rod length between the accelerator and injection pump

Adjust the tie rod length.

NO

Copyright Š EW--1--9

DIAGNOSTICS

4

ENGINE EXHAUST SMOKE BLACK OR DARK GREY

Air filter in working order

NO

Replace.

YES

Thermal starter in working order

Replace.

NO

YES

Automatic addition device comes into operation

Check and replace (if necessary).

NO

YES

Injectors in working order

Check operation and adjust them as described.

NO

YES

Injection pump timed NO

Check correct timing as described in the relevant paragraph.

YES

L.D.A. device in working order

Ad just the L.D.A. device.

NO

YES

Injection pump adjusted as prescribed

Check and bench--adjust the injection pump.

NO

(to be continued)

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EW--1--10

DIAGNOSTICS

Injection pipes intact

NO

Check the condition of pipes and replace them (if necessary).

NO

Check by means of a Motometer 75301430 tool and carry out the necessary operations.

YES

Prescribed compression ratio

YES

High--quality diesel fuel

Clean the tank and replace the diesel oil filter.

NO

5

ENGINE EXHAUST SMOKE GREY (VERGING ON WHITE)

The thermostat comes into operation correctly

Replace.

NO

YES

Injectors in working order NO

Check operation and adjust as described in S.I. 1094.

NO

Check correct timing as described in the relevant paragraph.

YES

Injection pump timed

YES

Coolant level correct NO

Possible flow of coolant into the combustion chamber; replace the cylinder head gasket or overhaul the engine.

(to be continued)

Copyright Š EW--1--11

DIAGNOSTICS

High--quality diesel oil

Clean the tank and replace the diesel oil filters.

NO

6

ENGINE EXHAUST SMOKE LIGHT BLUE

Excessive oil consumption

7

YES

Check the oil vapour vent and cylinder compression. Overhaul, if necessary, the cylinder head or engine.

ENGINE KNOCKS IRREGULARLY

Knock detected in the injection pump YES

Perform correct timing of injection pump on the engine.

NO

Knock detected in the drive shaft YES

Check the following items: journal play and out-of--roundness; screw fastening for bed caps and engine flywheel; oil pressure. Replace the parts or overhaul the engine.

NO

Knock detected in the connecting rods YES

Check the following items: crankpin play and out--of--roundness; screw fastening for connecting rod caps; connecting rod squaring. Replace the parts or overhaul the engine.

YES

Check the following items: play between the pistons and the cylinder liners; integrity of piston rings; play between the pins and the piston hubs.

Replace the parts or overhaul the engine.

NO

Knock detected in pistons

(to be continued)

Copyright Š

EW--1--12

DIAGNOSTICS

Knock detected in the cylinder head YES

Check the following items: operation play between the rocker arms and the valves; injection pump timing; valve timing. Adjust.

YES

Check and replace (if necessary) the gears; moreover, check for broken springs, for excessive play between the stems and guides, the tappets and seats. Adjust the play between the valves and rocker arms.

NO

Knock detected in the valve gear

NO

Knock detected in injectors YES

Check and adjust as described in S.I. 1094, then replace.

YES

Replace loose screws and tighten all screws to the specified torque and angles.

NO

Knock detected in the engine flywheel

NO

Knock detected in the fuel piping YES

8

Clean the pipes and replace the pipes that show evident dents; clean (if necessary) the injection pump.

ENGINE STOPS

Fuel tank filled

Refuel and drain (if necessary).

NO

YES

Fuel filters in working order

Replace.

NO

(to be continued)

Copyright Š EW--1--13

DIAGNOSTICS

Feeling circuit in working order

Check the circuit and drain.

NO

YES

Regular idle speed

Adjust.

NO

YES

Regular injection pump rates

Bench--check the flow rates.

NO

YES

Injection pump controls in working order

Replace worn parts and adjust.

NO

YES

Correct play between the valves and rocker arms NO

Ad just the play between the valves and rocker arms.

YES

Intact valves

Replace the valves.

NO

9

ENGINE EXCEEDS MAX. REVS NUMBER

Speed governor in working order

NO

Check and replace (if necessary) the worn parts.

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