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STEYR F4HE9484 Engine Service Repair Manual

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STEYR F4HE9484 Engine Service Repair Manual

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  1. SERVICE MANUAL F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684 84328779 08/04/2010

  2. Contents INTRODUCTION HYDRAULIC-PNEUMATIC-ELECTRICAL-ELECTRONICSYSTEMSA ELECTRICAL POWER SYSTEM ......................................................... A.30.A ENGINE AND PTO IN....................................................................B ENGINE ................................................................................... B.10.A FUEL AND INJECTION SYSTEM......................................................... B.20.A AIR INTAKE SYSTEM..................................................................... B.30.A EXHAUST SYSTEM....................................................................... B.40.A ENGINE COOLANT SYSTEM ............................................................ B.50.A LUBRICATION SYSTEM .................................................................. B.60.A STARTING SYSTEM ...................................................................... B.80.A 84328779 08/04/2010

  3. INTRODUCTION 84328779 08/04/2010 1

  4. Contents INTRODUCTION Foreword ........................................................................................3 Safety rules .....................................................................................4 Torque ..........................................................................................6 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684 Torque ..........................................................................................9 F4CE9484, F4GE9484, F4CE9684, F4GE9684 Special tools .................................................................................. 11 F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684 Special tools .................................................................................. 18 F4CE9484, F4GE9484, F4CE9684, F4GE9684 84328779 08/04/2010 2

  5. INTRODUCTION Foreword Engine Overhaul Part of the operations illustrated within this manual can be partially executed while the engine is assembled on the vehicle, depending on the room available for access to the engine and on the equipment application as well. NOTE: With regard to the engine disassembly operations, please apply for information consulting the specific manual. The following information relates to the engine overhaul operations only for what concerns the different components customizing the engine, according to its specific duties. In section "General Overhaul", all the operations of engine block overhaul have been contemplated. Therefore the above mentioned section is to be considered as following the part hereby described. 84328779 08/04/2010 3

  6. INTRODUCTION Safety rules Standard safety prescriptions Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in charge of maintenance. Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation. Keep working areas as clean as possible, ensuring adequate aeration. • Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment. • Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on a regular basis and the personnel must be trained on interventon methods and priorities. • Organize and identify specific exit points to evacuate the areas in case of an emergency, providing for adequate indications of the emergency indications of the emergency exit lines. • Smoking in working areas subject to fire danger must be strictly prohibited. • Provide warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy com- prehension of the instructions even in case of an emergency. • Prevention of injury Do not wear unsuitable clothes for work, with fluttering ends, nor jewels such as and chains when working close to engines and equipment in motion. • Wear safety gloves and goggles when performing the following operations: • filling inhibitors or anti-frost • • lubrication oil topping or replacement • utilization of compressed air or liquids under pressure (pressure allowed < 2 bar (29 psi)). • Wear safety helmet when working close to hanging loads or equipment working at head height level. • Always wear safety shoes and clothes adhering to the body, better if provided with elastics at the ends. • Use protection cream for hands. • Change wet clothes as soon as possible. • In presence of electrical current 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 up flames close to batteries and to any fuel material. • Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers. • Do not execute any intervention if not provided with necessary instructions. • Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for. Serious injury may occur. • In case of test or calibration operations requiring engine running, ensure that the area is sufficiently ventilated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning or death. • During maintenance Never open filler cap of cooling system when the engine is hot. Operating pressure would provoke high tempera- ture with serious danger and risk of burn. Wait until the temperature decreases under 50 °C (122 °F). • Never top up an overheated engine with cooler and utilize only appropriate liquids. • Always operate when the engine is tuned off; when particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation. • Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil. • 84328779 08/04/2010 4

  7. INTRODUCTION Keep the engine clean from oil spills, diesel fuel and or chemical solvents. • Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas venti- lated. Whenever necessary wear safety mask. • Do not leave rags impregnated with flammable substances close to the engine. • Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of a runaway speed rate. • Do not utilize fast screw tightening tools. • Never disconnect batteries when the engine is running. • Disconnect batteries before any intervention on the electrical system. • Disconnect batteries from system before applying a load to them with the battery loader. • After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation. • Do not disconnect and connect electrical connections in presence of electrical feed. • Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these precautions may cause serious injury and poisoning. • Avoid incorrect tightening or out of sequence. Danger: incorrect tightening may seriously damage engine’s com- ponents, 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 lengths shall not be changed. • Do not connect to the engine electrical equipment unless specifically approved by Iveco. • Do not modify fuel systems or hydraulic system unless Iveco specific approval has been released. Any unautho- rized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. • For engines equipped with electronic controller: Do not execute electric arc welding without having previously removed electronic controller. • Remove electronic controller in case of any intervention requiring heating over 80 °C (176 °F) temperature. • Do not paint the components and the electronic connections. • Do not vary or alter any data filed in the electronic controller driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration. • Respect of the Environment Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel’s safety and health shall be adopted. • Be informed and inform personnel as well of the laws in force regulating use and exhaust of liquids and engine drain oil. Provide for adequate board indications and organic specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventative safety measures. • Collect drain oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be ventilated far from heat sources and not exposed to fire danger, • Handle the batteries with care, storing them in ventilated environment and within anti-acid containers. Warning: Battery exhalation represent serious danger of intoxication and environment contamination. • 84328779 08/04/2010 5

  8. SERVICE MANUAL HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS F4CE9484 , F4CE9684 , F4DE9484 , F4DE9684 , F4DE9687 , F4GE9484 , F4GE9684 , F4HE9484 , F4HE9684 84328779 08/04/2010 A

  9. HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM Alternator - Overview F4CE9484, F4GE9484, F4CE9684, F4GE9684 1 ALTERNATORCG2 The alternator is placed on the front right hand side of the engine and is driven by a Poly V-belt. Specifications: Working voltage: • 12 V • Current delivered: • 90 A @ 6000 RPM • Absorption in stand-by: • Less than or equal to 1 mA • Sense of rotation: • Clockwise • 84328779 08/04/2010 A.30.A / 3

  10. HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM Alternator - Remove F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684 Prior operation: Fan and drive Belt - Remove (B.50.A) 1. Remove the cables from the back of the alternator (1). 2. Remove the retaining bolts (2) securing the alterna- tor (1) to the support. 3. Remove the alternator (1). 1 ALTERNATOR Next operation: Alternator - Install (A.30.A) 84328779 08/04/2010 A.30.A / 4

  11. HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM Alternator - Install F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684 Prior operation: Alternator - Remove (A.30.A) 1. Install the alternator (1) and tighten the bolts (2) to the specified torque. 2. Connect the positive and negative cables onto the back of the alternator. 1 ALTERNATOR Next operation: Fan and drive Belt - Install (B.50.A) 84328779 08/04/2010 A.30.A / 5

  12. HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM Alternator - Remove F4GE9484, F4GE9684 Prior operation: Fan and drive Belt - Remove (B.50.A) 1. Properly hold the alternator (1) separating it from its support by loosening the screw (2). 2. Remove the screw, nut and washer. 3. Remove the alternator (1). 1 ALTERNATORG Next operation: Alternator - Install (A.30.A) 84328779 08/04/2010 A.30.A / 6

  13. HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM Alternator - Remove F4CE9484, F4CE9684 Prior operation: Fan and drive Belt - Remove (B.50.A) 1. Properly hold the alternator (2) and loosen the screw (3) to remove the alternator from its support. 2. Remove it from its bracket by loosening the screw (1). 3. Recover the nuts and washers. 1 ALTERNATORC Next operation: Alternator - Install (A.30.A) 84328779 08/04/2010 A.30.A / 7

  14. HYDRAULIC - PNEUMATIC - ELECTRICAL - ELECTRONIC SYSTEMS - ELECTRICAL POWER SYSTEM Alternator - Install F4CE9484, F4GE9484, F4CE9684, F4GE9684 Prior operation: Alternator - Remove (A.30.A) 1. Connect the alternator (1) to the support. 2. Tighten the screw (2) without locking it. 1 ALTERNATORG 3. Fit the alternator (2) bracket (1) to the engine block. 4. Tighten the screws (3) fastening the alternator to the support. 2 ALTERNATORCG Next operation: Fan and drive Belt - Install (B.50.A) 84328779 08/04/2010 A.30.A / 8

  15. ENGINE AND PTO IN - ENGINE ENGINE - General specification F4HE9484, F4HE9684 1 F4HECOMPLETE The NEF F4HE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves per cylinder. They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the working process in accordance to the operation, limiting pollution emissions and consumption as much as possible. NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for which the engine has been designed. 84328779 08/04/2010 B.10.A / 9

  16. ENGINE AND PTO IN - ENGINE General Specifications Engine Type Cycle Power Injection Number of cylinders Bore Stroke Total Displacement Timing Start before T.D.C. End after B.D.C. Start before B.D.C. End after T.D.C. Valve Clearance Intake Exhaust Fuel Feed Injection Type Control Injector Nozzle Type Injection Sequence Injection pressure Aspiration Turbocharging Turbocharger Type Lubrication Oil Pressure @ Low Idle Oil Pressure @ Fast Idle Oil Pan Capacity Oil Filter Capacity Cooling Water Pump Thermostat 4 Cylinders 6 Cylinders Four-Stroke diesel engine Turbocharged with intercooler Direct 4 6 104 mm (4 in) 132 mm (5 in) 4485 cm³ 6728 cm³ 18.5 ° 29.5 ° 67 ° 35 ° 0.20 - 0.30 mm (0.008 - 0.012 in) 0.45 - 0.55 mm (0.018 - 0.022 in) Bosch high pressure common rail EDC7 ECU CRIU 2 DSLA and DLLA 1-3-4-2 250 - 1600 bar (3625 - 23200 psi) 1-5-3-6-2-4 Intercooled Holset HX35 0.7 bar (10 psi) 3.5 bar (51 psi) 15 l (15.85 US qt) 1 l (1.06 US qt) Belt Driven 79 - 83 °C (174 - 181 °F) 84328779 08/04/2010 B.10.A / 10

  17. ENGINE AND PTO IN - ENGINE Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize 104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) 103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 - 4.086 in) (*) 55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*) 38.010 - 38.016 mm (1.496 - 1.497 in) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) 37.994 - 38.000 mm (1.496 - 1.496 in) 0.01 - 0.022 mm (0.0004 - 0.001 in) Pistons Skirt Height Pin housing Piston (oversize) Protrusion Pin Piston Pin - Pin Housing Piston ring landings Combustion Intermediate Oil Control Piston Rings Combustion Intermediate Oil Control Piston Ring and Ring Landing Clearance Combustion Intermediate Oil Control Piston Ring End Gap Combustion Intermediate Oil Control Connecting Rod Small end housing Big end housing Small end bushing Inside Diameter Big end bearing shell thickness Piston Pin and Bushing Clearance Oversize Big end bearing Shells Crankshaft Main Journals Crankpins MainBearingShellThickness Big end Bearing Shell Thickness Main Bearing Bore No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin Clearance (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A 2.705 - 2.735 mm (0.106 - 0.108 in) 2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 - 0.096 in) (*) 4.030 - 4.050 mm (0.159 - 0.159 in) 2.560 - 2.605 mm (0.101 - 0.103 in) 2.350 - 2.380 mm (0.093 - 0.094 in) 3.970 - 3.990 mm (0.156 - 0.157 in) 0.100 - 0.175 mm (0.004 - 0.007 in) 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*) 0.040 - 0.080 mm (0.002 - 0.003 in) 0.30 - 0.40 mm (0.012 - 0.016 in) 0.60 - 0.80 mm (0.024 - 0.031 in) 0.30 - 0.55 mm (0.012 - 0.022 in) 40.987 - 41.013 mm (1.614 - 1.615 in) 72.987 - 73.013 mm (2.874 - 2.875 in) 38.019 - 38.033 mm (1.497 - 1.497 in) 1.955 - 1.968 mm (0.077 - 0.077 in) 0.019 - 0.039 mm (0.001 - 0.002 in) 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) 82.99 - 83.01 mm (3.267 - 3.268 in) 68.987 - 69.013 mm (2.716 - 2.717 in) 2.456 - 2.464 mm (0.097 - 0.098 in) 1.955 - 1.968 mm (0.077 - 0.078 in) 87.982 - 88.008 mm (3.464 - 3.465 in) 87.977 - 88.013 mm (3.464 - 3.465 in) 0.041 - 0.119 mm (0.002 - 0.005 in) 0.041 - 0.103 mm (0.002 - 0.004 in) 0.033 - 0.041 mm (0.001 - 0.002 in) 84328779 08/04/2010 B.10.A / 11

  18. ENGINE AND PTO IN - ENGINE Clearance Data 37.475 - 37.545 mm (1.475 - 1.478 in) 32.180 - 32.280 mm (1.267 - 1.271 in) 37.28 - 37.38 mm (1.468 - 1.472 in) 0.095 - 0.265 mm (0.004 - 0.010 in) Thrust Journal Thrust Bearing Bore Thrust Bearing Crankshaft End Play Cylinder Head and Components 7.042 - 7.062 mm (0.277 - 0.278 in) Valve Guide Bore Intake Valves Stem diameter Face angle Exhaust Valves Stem diameter Face angle Valve Stem and Guide Clearance Valve Seat Bore Intake Exhaust Valve seat Outside Diameter: Intake Exhaust Valve Seat Angle Intake Exhaust Valve Sink Intake Exhaust Interference Between Valve Seat and Cylinder Head Intake Exhaust Valve Spring Height Free Under a load equal to: 330.8 - 348.8 N (74.4 - 78.4 lb) Under a load equal to: 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft Journals 1-5 / 1-7 Bushing inside diameter Bushing and Journal Clearance Cam Lift Intake Exhaust Tappet Bore Tappet outside diameter Top Middle Bottom Tappets and Bore Clearance (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A 6.970 - 6.990 mm (0.274 - 0.275 in) 59.75 - 60.25 ° 6.970 - 6.990 mm (0.274 - 0.275 in) 44.75 - 44.25 ° 0.052 - 0.092 mm (0.002 - 0.004 in) 34.837 - 34.863 mm (1.372 - 1.373 in) 34.837 - 34.863 mm (1.372 - 1.373 in) 34.917 - 34.931 mm (1.375 - 1.375 in) 34.917 - 34.931 mm (1.375 - 1.375 in) 60 ° 45 ° 0.59 - 1.11 mm (0.023 - 0.044 in) 0.96 - 1.48 mm (0.038 - 0.058 in) 0.054 - 0.094 mm (0.002 - 0.004 in) 0.054 - 0.094 mm (0.002 - 0.004 in) 47.75 mm (1.880 in) 35.33 mm (1.391 in) 25.2 mm (0.992 in) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) 53.995 - 54.045 mm (2.126 - 2.128 in) 54.083 - 54.147 mm (2.129 - 2.132 in) 0.038 - 0.162 mm (0.001 - 0.006 in) 7.582 mm (0.299 in) 6.045 mm (0.238 in) 16.000 - 16.030 mm (0.630 - 0.631 in) 15.924 - 15.954 mm (0.627 - 0.628 in) 15.960 - 15.975 mm (0.628 - 0.629 in) 15.924 - 15.954 mm (0.627 - 0.628 in) 0.025 - 0.070 mm (0.001 - 0.003 in) 84328779 08/04/2010 B.10.A / 12

  19. ENGINE AND PTO IN - ENGINE Clearance Data 21.965 - 21.977 mm (0.865 - 0.865 in) 22.001 - 22.027 mm (0.866 - 0.867 in) 0.024 - 0.162 mm (0.001 - 0.006 in) Rocker shaft Rockers Rockers and Shaft Clearance (*) Valid for engines: F4HE9684P, F4HE9684A, F4HE9687P, F4HE9687A 84328779 08/04/2010 B.10.A / 13

  20. ENGINE AND PTO IN - ENGINE ENGINE - General specification F4DE9484, F4DE9684, F4DE9687 1 F4DECOMPLETE The NEF F4DE engines are characterized by four stroke diesel cycles turbocharged with 4 or 6 cylinders and 4 valves per cylinder. They have high pressure injection fueling (common rail) and are entirely electronically driven in order to optimize the working process in accordance to the operation, limiting pollution emissions and consumption as much as possible. NOTE: Data, features and performance are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the use of the unit after overhaul should conform to the original specified power and engine RPM for which the engine has been designed. 84328779 08/04/2010 B.10.A / 14

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  22. ENGINE AND PTO IN - ENGINE General Specifications Engine Type Cycle Power Injection Number of cylinders Bore Stroke Total Displacement Timing Start before T.D.C. End after B.D.C. Start before B.D.C. End after T.D.C. Valve Clearance Intake Exhaust Fuel Feed Injection Type Control Injector Nozzle Type Injection Sequence Injection pressure Aspiration Turbocharging Turbocharger Type Lubrication Oil Pressure @ Low Idle Oil Pressure @ Fast Idle Oil Pan Capacity Oil Filter Capacity Cooling Water Pump Thermostat 4 Cylinders 6 Cylinders Four-Stroke diesel engine Turbocharged with intercooler Direct 4 6 104 mm (4 in) 132 mm (5 in) 4485 cm³ 6728 cm³ 18.5 ° 29.5 ° 67 ° 35 ° 0.20 - 0.30 mm (0.008 - 0.012 in) 0.45 - 0.55 mm (0.018 - 0.022 in) Bosch high pressure common rail EDC7 ECU CRIU 2 DSLA and DLLA 1-3-4-2 250 - 1600 bar (3625 - 23200 psi) 1-5-3-6-2-4 Intercooled Holset HX35 0.7 bar (10 psi) 3.5 bar (51 psi) 15 l (15.85 US qt) 1 l (1.06 US qt) Belt Driven 79 - 83 °C (174 - 181 °F) 84328779 08/04/2010 B.10.A / 15

  23. ENGINE AND PTO IN - ENGINE Clearance Data Cylinder Block and Crankshaft Components Cylinder Barrels Oversize 104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) 103.714 - 103.732 mm (4.083 - 4.084 in) / 103.759 - 103.777 mm (4.085 - 4.086 in) (*) 55.9 mm (2.201 in) / 49.5 mm (1.949 in) (*) 38.010 - 38.016 mm (1.496 - 1.497 in) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) 37.994 - 38.000 mm (1.496 - 1.496 in) 0.01 - 0.022 mm (0.0004 - 0.001 in) Pistons Skirt Height Pin housing Piston (oversize) Protrusion Pin Piston Pin - Pin Housing Piston ring landings Combustion Intermediate Oil Control Piston Rings Combustion Intermediate Oil Control Piston Ring and Ring Landing Clearance Combustion Intermediate Oil Control Piston Ring End Gap Combustion Intermediate Oil Control Connecting Rod Small end housing Big end housing Small end bushing Inside Diameter Big end bearing shell thickness Piston Pin and Bushing Clearance Oversize Big end bearing Shells Crankshaft Main Journals Crankpins MainBearingShellThickness Big end Bearing Shell Thickness Main Bearing Bore No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Journal Clearance No. 1,5 / 1,7 No. 2,3,4 / 2,3,4,5,6 Bearing Shell and Crankpin Clearance (*) Valid for engines: F4DE9684A. 2.705 - 2.735 mm (0.106 - 0.108 in) 2.440 - 2.460 mm (0.096 - 0.097 in) / 2.420 - 2.440 mm (0.095 - 0.096 in) (*) 4.030 - 4.050 mm (0.159 - 0.159 in) 2.560 - 2.605 mm (0.101 - 0.103 in) 2.350 - 2.380 mm (0.093 - 0.094 in) 3.970 - 3.990 mm (0.156 - 0.157 in) 0.100 - 0.175 mm (0.004 - 0.007 in) 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*) 0.040 - 0.080 mm (0.002 - 0.003 in) 0.30 - 0.40 mm (0.012 - 0.016 in) 0.60 - 0.80 mm (0.024 - 0.031 in) 0.30 - 0.55 mm (0.012 - 0.022 in) 40.987 - 41.013 mm (1.614 - 1.615 in) 72.987 - 73.013 mm (2.874 - 2.875 in) 38.019 - 38.033 mm (1.497 - 1.497 in) 1.955 - 1.968 mm (0.077 - 0.077 in) 0.019 - 0.039 mm (0.001 - 0.002 in) 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) 82.99 - 83.01 mm (3.267 - 3.268 in) 68.987 - 69.013 mm (2.716 - 2.717 in) 2.456 - 2.464 mm (0.097 - 0.098 in) 1.955 - 1.968 mm (0.077 - 0.078 in) 87.982 - 88.008 mm (3.464 - 3.465 in) 87.977 - 88.013 mm (3.464 - 3.465 in) 0.041 - 0.119 mm (0.002 - 0.005 in) 0.041 - 0.103 mm (0.002 - 0.004 in) 0.033 - 0.041 mm (0.001 - 0.002 in) 84328779 08/04/2010 B.10.A / 16

  24. ENGINE AND PTO IN - ENGINE Clearance Data 37.475 - 37.545 mm (1.475 - 1.478 in) 32.180 - 32.280 mm (1.267 - 1.271 in) 37.28 - 37.38 mm (1.468 - 1.472 in) 0.095 - 0.265 mm (0.004 - 0.010 in) Thrust Journal Thrust Bearing Bore Thrust Bearing Crankshaft End Play Cylinder Head and Components 7.042 - 7.062 mm (0.277 - 0.278 in) Valve Guide Bore Intake Valves Stem diameter Face angle Exhaust Valves Stem diameter Face angle Valve Stem and Guide Clearance Valve Seat Bore Intake Exhaust Valve seat Outside Diameter: Intake Exhaust Valve Seat Angle Intake Exhaust Valve Sink Intake Exhaust Interference Between Valve Seat and Cylinder Head Intake Exhaust Valve Spring Height Free Under a load equal to: 330.8 - 348.8 N (74.4 - 78.4 lb) Under a load equal to: 702 - 780 N (157.8 - 175.4 lb) Camshaft Bore No.1 (flywheel side) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft Journals 1-5 / 1-7 Bushing inside diameter Bushing and Journal Clearance Cam Lift Intake Exhaust Tappet Bore Tappet outside diameter Top Middle Bottom Tappets and Bore Clearance (*) Valid for engines: F4DE9684A. 6.970 - 6.990 mm (0.274 - 0.275 in) 59.75 - 60.25 ° 6.970 - 6.990 mm (0.274 - 0.275 in) 44.75 - 44.25 ° 0.052 - 0.092 mm (0.002 - 0.004 in) 34.837 - 34.863 mm (1.372 - 1.373 in) 34.837 - 34.863 mm (1.372 - 1.373 in) 34.917 - 34.931 mm (1.375 - 1.375 in) 34.917 - 34.931 mm (1.375 - 1.375 in) 60 ° 45 ° 0.59 - 1.11 mm (0.023 - 0.044 in) 0.96 - 1.48 mm (0.038 - 0.058 in) 0.054 - 0.094 mm (0.002 - 0.004 in) 0.054 - 0.094 mm (0.002 - 0.004 in) 47.75 mm (1.880 in) 35.33 mm (1.391 in) 25.2 mm (0.992 in) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) 53.995 - 54.045 mm (2.126 - 2.128 in) 54.083 - 54.147 mm (2.129 - 2.132 in) 0.038 - 0.162 mm (0.001 - 0.006 in) 7.582 mm (0.299 in) 6.045 mm (0.238 in) 16.000 - 16.030 mm (0.630 - 0.631 in) 15.924 - 15.954 mm (0.627 - 0.628 in) 15.960 - 15.975 mm (0.628 - 0.629 in) 15.924 - 15.954 mm (0.627 - 0.628 in) 0.025 - 0.070 mm (0.001 - 0.003 in) 84328779 08/04/2010 B.10.A / 17

  25. ENGINE AND PTO IN - ENGINE Clearance Data 21.965 - 21.977 mm (0.865 - 0.865 in) 22.001 - 22.027 mm (0.866 - 0.867 in) 0.024 - 0.162 mm (0.001 - 0.006 in) Rocker shaft Rockers Rockers and Shaft Clearance (*) Valid for engines: F4DE9684A. 84328779 08/04/2010 B.10.A / 18

  26. ENGINE AND PTO IN - ENGINE ENGINE - Service limits Maintenance Planning F4DE9484, F4HE9484, F4DE9684, F4DE9687, F4HE9684 To ensure optimized working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates. The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run. Regular maintenance and inspection planning Checks and periodical inspections Frequency (hours) Daily Daily - - 4000 When anomaly occurs 500 1000 500 500 1500 Visual check of engine Inspection presence of water in fuel filter or pre-filter Inspection blow-by filter elements Inspection of belt wear status Inspection and setting of tappet clearance EDC Replacement of engine’s oil and filter Replacement of pre-filter Replacement of fuel filter Replacement of blow-by filter Replacement of belt NOTICE: The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacement and checks. The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by Iveco Motors. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed. Daily Maintenance Checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers. Fluid levels and checks of any eventual leakage from the fuel, cooling and lubricating circuits. • Notify the maintenance if any inconvenience is detected or if any filling is necessary. • After engine start and while engine is running, proceed with the following checks and controls: check presence of any eventual leakage from the fuel, cooling and lubricating circuits. • Verify absence of noise or unusual rattle during engine working. • Verify, using vehicle devices, the prescribed pressure, temperature and other parameters. • Visual check of fumes (color of exhaust emissions) • Visual check of cooling liquid level, in the expansion tank. • 84328779 08/04/2010 B.10.A / 19

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