6 - Nef Engine Tier 3

LOADER-BACKHOE CASE 580-590-695 SR2 Series
TIER 3 NEF Engine
Chapter 3 NEF ENGINE TIER 3
Monthyon, november 2007

TIER 3 NEF Engine 9 1 Engine controller; 2 Crankshaft sensor; 5 7 3 High pressure pump ; 4 Fuel filter; 5 Injection pressure sensor; 6 PTO; 7 Preheating grid; 8 Water pump; 6 9 Turbocharged;
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4 1 2 Monthyon, november 2007 2
3.1. Identification plate

TIER 3 NEF Engine
3 6
5 7 8
1: Engine code F4 = Engine familiy (NEF) H = Non structural engine block - 4 valves on each cylinder E = Engine 0 = Engine configuration (4 strokes, vertical) 4 = Number of cylinders 8 = Injection and intake (Turbocharged, Diesel, ID, Intercooler) 4 = Application (Tractors and construction machinery) E = Homologation power J = Emission level (Tier 3) 2: Date of manufacturing (month - year) 3: Gross power given in in Hp 4: Displacement given in cubic inches: 272 cu. in. = 4490 cc. 5: Max fuel quantity delivered by each pump piston in one cycle, given in mg/stroke 6: Engine minimum idle speed 7: Injection advanced mode data (not used) 8: Intake valve backlash (inches) 9: Exhaust valve backlash (inches)

TIER 3 NEF Engine
Engine
Maker - Model ..
NEF - FHHE9484 C J 101 XXXX (Tier 3)
Bore x stroke ... 104mm x 132mm Displacemen4.5 Litres Rated speed . 2200 rpm Gross power per SAE J1995 @ 2000 RPM 82 Kw @ 2000 rpm Firing order ...1 3 4 2 Intake ..Turbo aftercooler Maximum operating slope)....35%

TIER 3 NEF Engine
Nomenclature of engine - Turbo side

5 4 COMPONENTS 1. High pressure pump; 6 2. Fuel filter; 3. Engine controller; 4. Common Rail with high pressure relief valve 5. Intake air (from aftercooler) 3 1 2 7 6. Engine oil filling 7. Low pressure pump

TIER 3 NEF Engine
Nomenclature of engine - Turbo side

5 1 3 COMPONENTS 1. Turbocharged with wastegate 2. Engine oil filter 4 CONNECTIONS 3. To muffler 4. Air intake to aftercooler 5. Air intake (from filter) 2

TIER 3 NEF Engine
Nomenclature of engine - Front

3 2 COMPONENTS
1. Engine controller 2. Common rail 3. Turbocharged 4. Water pump

TIER 3 NEF Engine
Nomenclature of engine - Actuators and sensors
COMPONENTS
1. Common rail relief valve 2. Engine air pressure-temperature

combined sensor ( turbocharging)
2 4 3
3. Fuel discharge from electricinjector
4. Fuel discharge from common rail

TIER 3 NEF Engine
1 Common Rail; 2 Injection pressure sensor; Monthyon, november 2007 9

TIER 3 NEF Engine
E.G.R. Exaust Gas Recirculation

In general on tier 3 engines has been developped a new system called E.G.R in order to reduce the pollution. EGR stand for Exaust Gas Recirculation. Practically part of exhaust gas is introduced in the cylinders in order to reduce the combustion temperature. In fact, the exhaust gas doesnt contain oxygen, practically are neutral and are as obstacle to heat propagation. Since the production of oxide of nitrogen (pollution) is directly proportional to combustion temperature, it means that if we reduce the combustion temperature, we reduce pollution. IVECO NEF got the EGR just mdifying the cams shaft. So when the gas is going outside of cylinder, part re-enter in the same cylinders. Note: in the picture there is a solution adopted by isuzu.
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TIER 3 NEF Engine
On NEF engines an extra lobe on the cam shaft let to get the exhaust gas recirculation during the intake cycle by keeping the exhaust valve open for a short time.
B A
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TIER 3 NEF Engine
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TIER 3 NEF Engine
4 3
COMPONENTS 1. Proportional valve 2. Low pressure pump 3 - High pressure pump 4. Fuel filter;
2 4 1
5. Fuel temperature sensor;
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TIER 3 NEF Engine

2 COMPONENTS 1 1. Engine oil filter; 2. Engine oil pressure temperature sensore; 3. Coolant temperature sensor; 3
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TIER 3 NEF Engine

1 COMPONENTS 1. Timing gear sensor (camshaft); 2. Cranshaft sensor;
2
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TIER 3 NEF Engine
COMPONENTS 1 Fuel pre-filter;
2 Breather screw; 3 Fuel lifting pump; 4 Water in fuel sensor;
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TIER 3 NEF Engine
3 1
1. Fuel filter 2. To high pressure pump To fuel tank

Monthyon, november 2007 17

TIER 3 NEF Engine
Injection pump
4 5 3 2 1
1 From engine controller 2 To fuel filter 3 From fuel filter to high pressure pump 4 Return fuel to filter 5 To Common Rail
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TIER 3 NEF Engine
Common rail injection system
High pressure pump
Fuel filter Fuel prefilter Fuel radiator
Low pressure pump
Fuel tank
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TIER 3 NEF Engine
3.7. Common Rail injection system
High pressure pump
A. Fuel return port - B. Fuel inlet port from EDC heat exchanger - C. Fuel inlet port from fuel filter - D. Fuel outlet port from low pressure pump to fuel filter - E. Fuel outlet port from high pressure pump to the rail. 1. High pressure pump - 2. Fuel supply pump -3. Fuel pressure regulator (N.O. proportional solenoid valve controlled by PWM signal from EDC7 electronic control unit).
1. Cylinder - 2. Three lobes cam - 3. Suction valve - 4. Delivery valve - 5. Piston - 6. Pump shaft - 7. Low pressure fuel inlet - 8. Piston fuel supply channels.
Pump with three radial piston driven by the timing gear. No timing adjustment is required. With fuel supply gear pump installed on the back of the high pressure pump. 20

TIER 3 NEF Engine
Electric injector - rest condition
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Pressure rod Needle Nozzle Coil Pilot valve Ball shutter Control area Pressure chamber Control volume Supply-contro line Control fuel outlet Electrical connector Spring.
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TIER 3 NEF Engine

Injection starting When the coil (4) is energized, the ball shutter (6)is moved upward. The fuel in the control chamber (9) flows out through the return line (11) causing a pressure drop in the control chamber (9).
From Rail
At the same time, the fuel pressure in the pressure chamber (8) pushes the needle (2)upward, allowing the fuel spraying into the cylinder combustion chamber.
To reservoir
Injection end When the coil (4) is de-energized, the ball shutter (6) takes back its closed position, in order to restore a force balance suitable to keep closed the injector needle (2) and shut off the fuel injection.
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TIER 3 NEF Engine
Common Rail injection system Engine controller input /output signals

Coolant temperature sensor Intake manifold combined pressure/temp. sensor Engine oil combined pressure/temp sensor Timing gear sensor
Fuel temperature sensor
Crankshaft speed sensor
Ambient pressure sensor
Throttle potentiommeter signal
Common rail fuel pressure sensor
Proportional solenoid valve installed on high pressure pump Injector solenoids Preheating grid relay
Diagnostic connector
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TIER 3 NEF Engine
TECHNICAL TECHNICALDATAS DATAS STALLS STALLS
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TIER 3 NEF Engine
2
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TIER 3 NEF Engine
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TIER 3 NEF Engine
1 2
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TIER 3 NEF Engine
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TIER 3 NEF Engine
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TIER 3 NEF Engine
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TIER 3 NEF Engine
1 2
In case of Cluster replacement
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TIER 3 NEF Engine
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TIER 3 NEF Engine
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TIER 3 NEF Engine
View information or download
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TIER 3 NEF Engine
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TIER 3 NEF Engine
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TIER 3 NEF Engine
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TIER 3 NEF Engine
After cluster replacement is necessary to enter in this screen and set properly the following parameters : Air conditioning; Preheating grid; Pilot control, than send the values to the controler
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TIER 3 NEF Engine
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TIER 3 NEF Engine
Select Language
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TIER 3 NEF Engine
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TIER 3 NEF Engine
INJECTORS CUT OFF
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TIER 3 NEF Engine
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PRESENTATION
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TIER 3 NEF Engine
Programming
This ECU software download procedure is required if any one of the following conditions exist:
Blank ECU from Service Parts - Programming an engine controller from
service parts that has no software pre-loaded (normal service part). Black ECU from an interrupted Download - Programming an engine controller that has lost its information due to an interrupted download process for a normal update. Wrong ECU - Programming an engine controller from service parts or from a different machine that is loaded with inappropriate software for the selected machine.

TIER 3 NEF Engine
Blank Controller Download Downloading to a blank controller requires a two part download process:
One process to initialize the controller. A second process to download the software file to the ECU. The progress bar will be displayed two times. The time required for this type of download will be about 60% longer than for the Normal Machine Update download.
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TIER 3 NEF Engine
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TIER 3 NEF Engine
Chose here the right program
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TIER 3 NEF Engine
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TIER 3 NEF Engine
** ** ********** **
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TIER 3 NEF Engine
FAULT CODE LIST
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TIER 3 NEF Engine
How to record engine parameter with the E.S.T
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6 - Nef Engine Tier 3

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6 - Nef Engine Tier 3

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LOADER-BACKHOE CASE 580-590-695 SR2 Series

TIER 3 NEF Engine

Chapter 3 NEF ENGINE TIER 3

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

4 1 2 Monthyon, november 2007 2

LOADER-BACKHOE CASE 580-590-695 SR2 Series

3.1. Identification plate

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

NEF - FHHE9484 C J 101 XXXX (Tier 3)

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Turbo side

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Turbo side

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Front

1. Engine controller 2. Common rail 3. Turbocharged 4. Water pump

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Actuators and sensors

1. Common rail relief valve 2. Engine air pressure-temperature

3. Fuel discharge from electricinjector

4. Fuel discharge from common rail

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Actuators and sensors

1 Common Rail; 2 Injection pressure sensor; Monthyon, november 2007 9

LOADER-BACKHOE CASE 580-590-695 SR2 Series

E.G.R. Exaust Gas Recirculation

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

E.G.R. Exaust Gas Recirculation

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

E.G.R. Exaust Gas Recirculation

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Actuators and sensors

5. Fuel temperature sensor;

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Actuators and sensors

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Actuators and sensors

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Actuators and sensors

COMPONENTS 1 Fuel pre-filter;

2 Breather screw; 3 Fuel lifting pump; 4 Water in fuel sensor;

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Nomenclature of engine - Actuators and sensors

1. Fuel filter 2. To high pressure pump To fuel tank

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Monthyon, november 2007

LOADER-BACKHOE CASE 580-590-695 SR2 Series

Common rail injection system

High pressure pump

Fuel filter Fuel prefilter Fuel radiator