Iveco N60 ENT M37 Technical And Repair Manual
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Iveco N60 ENT M37 Technical And Repair Manual

Iveco N60 ENT M37 Technical And Repair Manual

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NEF E
NGINE
N60 ENT M37
T
R
ECHNICAL AND
EPAIR
M
ANUAL

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Summary of Contents for Iveco N60 ENT M37

  • Page 1 NEF E NGINE N60 ENT M37 ECHNICAL AND EPAIR ANUAL...
  • Page 2 The indications contained in this document pertain to the N60 ENT M37 marine engine and complement the IVECO MOTORS publication “of Marine Diesel Engines Installation Handbook”, the reader should refer to for anything that is not explained herein.
  • Page 3 APRIL 2004 N60 ENT M37 SECTION CONTENTS Section Page 1. OVERVIEW 2. TECHNICAL DATA 3. ELECTRICAL EQUIPMENT 4. DIAGNOSTICS 5. MAINTENANCE 6. SERVICING OPERATIONS ON INSTALLED ENGINE 7. TOOLS 8. OVERHAUL 9. SAFETY PRESCRIPTIONS Indications for consultation Sections 1-2-3 are intended for sales personnel, to provide them with exact knowledge of the product’s characteristics...
  • Page 4 N60 ENT M37 APRIL 2004...

  • Page 5: Table Of Contents

    APRIL 2004 OVERVIEW N60 ENT M37 SECTION 1 OVERVIEW Page IDENTIFYING DATA COMMERCIAL CODE PRODUCT MODEL NUMBER ENGINE PARTS AND COMPONENTS ENGINE ARCHITECTURE Crankcase Crankshaft Connecting Rods Pistons Timing system driving gear Cylinder head Valves and valve seatings Ancillary machine members drive...
  • Page 6 N60 ENT M37 OVERVIEW APRIL 2004 Page Page Fuel Pre-filter Selfdiagnosis Fuel filter EDC indicator light Pump assembly Fuel Heating Low pressure feed pump Linearization of the acceleration gradient Pressure control solenoid valve Balance of the cylinder torque delivery Low pressure limiter valve...

  • Page 7: Identifying Data

    APRIL 2004 OVERVIEW N60 ENT M37 IDENTIFYING DATA (to december 2003) Figure 1 04_004_N IDENTIFYING DATA (from january 2004) Figure 2 S. p. A. Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY ENGINE TYPE ENGINE FAMILY ENGINE DWG...

  • Page 8: Commercial Code

    N60 ENT M37 OVERVIEW APRIL 2004 COMMERCIAL CODE The purpose of the commercial code is to make it easier to understand the characteristics of the product, categorizing the engines according to their family, origins and intended application.The commercial code, therefore, cannot be used for technical purposes to recognize the engine’s components, this purpose is served by the “ENGINE S/N”.

  • Page 9: Product Model Number

    APRIL 2004 OVERVIEW N60 ENT M37 PRODUCT MODEL NUMBER The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to charac- terize its application and power output level. It is stamped on a side of crank-case.

  • Page 10: Engine Parts And Components

    1.10 N60 ENT M37 OVERVIEW APRIL 2004 ENGINE PARTS AND COMPONENTS Figure 4 04_006_N 1. Engine coolant discharge cap - 2. Electric starter motor - 3.Tube bundle engine coolant/sea water heat exchanger - 4. Location of sacrificial anode - 5. Cooled exhaust manifold - 6. Exhaust gas and sea water discharge pipeline - 7.
  • Page 11 1.11 APRIL 2004 OVERVIEW N60 ENT M37 ENGINE PARTS AND COMPONENTS Figure 5 04_007_N 1. Combustion air filter - 2. Common rail high pressure injection pump -3. Fuel filter - 4. Sea water pump - 5. Sea water inlet - 6.Throttle potentiometer - 7.

  • Page 12: Engine Architecture

    NEF engines are the highest expression of design and engi- The new criteria chosen in defining the parameters setting neering efficiency that IVECO MOTORS makes available on the combustion conditions, metering and injection, optimized the market place. Engines highly innovative designed to be...

  • Page 13: Crankshaft

    1.13 APRIL 2004 OVERVIEW N60 ENT M37 Crankshaft Figure 7 04_012_N 1.Timing system driving gear - 2. Flywheel connecting hub - 3. Oil pump driving gear. The crankshaft is made in steel hardened by induction and Connecting Rods rests on seven mountings; inside the hollow shaft are the ducts for the lubrication oil circulation.

  • Page 14: Pistons

    1.14 N60 ENT M37 OVERVIEW APRIL 2004 Pistons Timing system driving gear Figure 9 Figure 10 04_015_N Timing system driving gear machine members are push rods and rockers type, with a camshaft that is located in the crankcase and set into rotation directly by the crankshaft.
  • Page 15 1.15 APRIL 2004 OVERVIEW N60 ENT M37 Figure 12 04_016_N 1. Spindle - 2. Rocker - 3. Adjuster screw - 4. Rod - 5. Bridge - 6. Cotters - 7. Cup - 8. Spring - 9.Tappet - 10. Camshaft - 11.

  • Page 16: Cylinder Head

    1.16 N60 ENT M37 OVERVIEW APRIL 2004 Cylinder head Figure 13 04_018_N 1. Electro-injector - 2. Electro-injector electric connection terminal - 3.Thermostat valve - 4. Induction manifold - 5. Fuel filling pipe to the injector - 6. Cylinder head - 7. Chassis bracket for injectors electric outfit - 8. Electric connector - 9. Electro- injector wiring harness - 10.

  • Page 17: Valves And Valve Seatings

    1.17 APRIL 2004 OVERVIEW N60 ENT M37 Valves and valve seatings Ancillary machine members drive Figure 14 Figure 15 04_023_N 04_019_N 1. Crankshaft - 2. Engine coolant pump pulley - 3. Stationary 1. Induction valves - 2.Exhaust valves - 3. Inserted element - guide pulley - 4.

  • Page 18: Combustion Air Intake And Exhaust System

    1.18 N60 ENT M37 OVERVIEW APRIL 2004 COMBUSTION AIR INTAKE AND EXHAUST SYSTEM Figure 16 04_025_N Engine coolant Cold air inlet Exhaust gas Sea water 1. Air filter - 2.Turbocompressor - 3. Exhaust gas inlet in turbine - 4. Heat exchanger air/sea water - 5.

  • Page 19: Comburent Air Filter

    1.19 APRIL 2004 OVERVIEW N60 ENT M37 Comburent air filter Air / seawater heat exchanger Figure 17 Figure 19 04_024_N 04_027_N 1. Filter clogging sensor. 1. Sea water outlet - 2. Sacrificial anode (Zinc) - 3. Sea Turbocompressor water inlet - 4. comburent air inlet - 5. Comburent air outlet - 6.

  • Page 20: Cooling Fresh Water Closed-Loop

    1.20 N60 ENT M37 OVERVIEW APRIL 2004 COOLING FRESH WATER CLOSED-LOOP Figure 20 04_028_N Hot engine coolant Cold engine coolant Sea water 1. Coolant pump - 2.Thermostatic valve - 3. Pump intake flow - 4. Oil / coolant heat exchanger - 5. Coolant / sea water heat exchanger - 6.To exhaust manifold cooling - 7.Turbocompressor.

  • Page 21: Exhaust Manifold Cooling

    1.21 APRIL 2004 OVERVIEW N60 ENT M37 Exhaust manifold cooling Figure 21 04_029_N Engine coolant through exhaust manifold Hot engine coolant through coolant exchanger Sea water 1. Sea water/coolant exchanger - 2.Turbocompressor - 3. Exhaust manifold - 4.Thermostatic valve-exchanger water/water...

  • Page 22: Thermostatic Valve

    1.22 N60 ENT M37 OVERVIEW APRIL 2004 Thermostatic valve Water pump Figure 22 Figure 24 04_031_N Low temperature operation When the temperature of the coolant is lower than the set values, the coolant coming from inside the engine (1) ricir- culate directly towards the centrifugal pump (2).

  • Page 23: Sea Water Open Cooling Loop

    1.23 APRIL 2004 OVERVIEW N60 ENT M37 SEA WATER OPEN COOLING LOOP Figure 25 04_033_N Engine coolant Cold air Sea water 1. Sea water / coolant exchanger - 2. Outlet (riser) - 3. Sea water outlet piping from exchanger - 4. Sea water / oil gear exchanger (optional) - 5.

  • Page 24: Sea Water Pump

    1.24 N60 ENT M37 OVERVIEW APRIL 2004 Sea water Pump Sea water/coolant heat exchanger Figure 26 Figure 27 04_034_N 1. Inlet - 2. Outlet.. Sea water pump, with a neoprene rotor, is geared up by crankshaft. 04_035_N 1. Sea water inlet - 2. Sea water outlet - 3. Engine coolant inlet - 4.

  • Page 25: Engine Oil Lubrication Loop

    1.25 APRIL 2004 OVERVIEW N60 ENT M37 ENGINE OIL LUBRICATION LOOP Figure 28 04_036_N Oil delivery Return into sump 1. Oil sump - 2. Crankshaft - 3. Oil pump - 4. Oil filter bracket with engine coolant / oil heat exchanger - 5. Oil filter - 6.

  • Page 26: Gear Pump

    1.26 N60 ENT M37 OVERVIEW APRIL 2004 Gear Pump Oil vapour recirculation Figure 29 Figure 31 04_037_N 1. Gear oil pump - 2. Crankshaft with driving gear oil pump. Filter bracket Figure 30 04_038_N Oil vapours Oil condensate 1. Condensate oil to the sump. - 2.Vapours coming from the timing gear box - 3.

  • Page 27: Fuel Line

    1.27 APRIL 2004 OVERVIEW N60 ENT M37 FUEL LINE Figure 32 04_072_N High pressure Low pressure 1. Fuel filter - 2. Common rail - 3. Electro-injector - 4. Electro-injector return loop pressurization valve - 5. Rail overpressure valve - 6. High and low pressure pump - 7. Priming pump - 8. Settling pre-filter.

  • Page 28: Fuel Supply System Scheme

    1.28 N60 ENT M37 OVERVIEW APRIL 2004 Fuel supply system scheme Figure 33 04_040_N 1. High pressure radial pump - 2. Fuel temperature sensor - 3. Fuel filter - 4. Electro-injector - 5. Pressure sensor - 6. Common rail - 7. Common rail overpressure valve - 8. Electro-injector return loop pressurization valve, 1.3 to 2 bar - 9. Fuel tank - 10.

  • Page 29: Fuel Pre-Filter

    1.29 APRIL 2004 OVERVIEW N60 ENT M37 give cause to an hydraulic overpressure, that acting on the Fuel Pre-filter spear valve, lifts it up and opens the nozzles. The span of time, the moment, and the optimal pressure for the injection...

  • Page 30: Fuel Filter

    1.30 N60 ENT M37 OVERVIEW APRIL 2004 Fuel filter It preserves the efficiency of high pressure line withholding particles above 5 µm. It has a high filtering capacity as well as a good separation of Figure 35 water from fuel.

  • Page 31: Pump Assembly

    1.31 APRIL 2004 OVERVIEW N60 ENT M37 Pump assembly Figure 36 04_046_N 1. Connector fuel outlet to rail - 2. High pressure pump - 3. Pressure control solenoid - 4. Fuel inlet connector from filter - 5. Fuel outlet connector to recirculation manifold - 6. Fuel inlet from tank - 7. Fuel outlet connector from low pressure pump to filter - 8.

  • Page 32: Low Pressure Feed Pump

    1.32 N60 ENT M37 OVERVIEW APRIL 2004 Low pressure feed pump Figure 37 04_043_N A. Fuel inlet from tank - B. Fuel outlet to filter - 1. Recirculation valve - 2. By-pass valve. The gear wheel pump is assembled on the rear part of the It is set into rotation by the high pressure pump shaft.
  • Page 33 1.33 APRIL 2004 OVERVIEW N60 ENT M37 Figure 39 04_045_N A. Fuel inlet from tank - B. Fuel oulet to filter - 1. Recirculation valve - 2. By-pass valve. In figure 39, is represented the section of the pump during the stage of filling up the line, as an example by means of the manual pump located on the pre-filter.

  • Page 34: Pressure Control Solenoid Valve

    1.34 N60 ENT M37 OVERVIEW APRIL 2004 Pressure control solenoid valve Low pressure limiter valve Figure 40 Figure 41 04_052_N 04_051_N 1. Electric Connector - 2. Fuel outlet - 3. Fuel inlet. Positioned at the inlet of the high pressure pump, enables to...

  • Page 35: Pressure Control With Engine At Maximum Rating

    1.35 APRIL 2004 OVERVIEW N60 ENT M37 Pressure control with engine at maximum rating Figure 42 04_017_N 1. Coil - 2. Nucleus - 3. Preloading spring - 4. Spear valve - 5. High pressure pump feed - 6. Fuel inlet (from filter) - 7.

  • Page 36: Pressure Control With Engine At Minimum Rating

    1.36 N60 ENT M37 OVERVIEW APRIL 2004 Pressure control with engine at minimum rating Figure 43 04_020_N 1. Coil - 2. Nucleus - 3. Preloading spring - 4. Spear valve - 5. High pressure pump feed - 6. Fuel inlet (from filter) - 7.

  • Page 37: High Pressure Pump

    1.37 APRIL 2004 OVERVIEW N60 ENT M37 High pressure pump During the induction stroke,the pumping, driven by the cam located on the pump shaft, is fed through pumping feeding duct.The amount of fuel to send to the pumping is set by the...
  • Page 38 1.38 N60 ENT M37 OVERVIEW APRIL 2004 Figure 47 sez. A-A 04_050_N 1, 2. Fuel outlet ducts - 3. Fuel outlet from the pump with connector for high pressure piping for common rail In the section of figure 47 the fuel flow through the pump-...

  • Page 39: Rail And High Pressure Piping

    1.39 APRIL 2004 OVERVIEW N60 ENT M37 Rail and high pressure piping Figure 48 04_053_N 1. Pressure sensor - 2. Fuel inlet from the high pressure pump - 3. Common Rail - 4. Overpressure valve. The internal volume of the rail is sized in such a way as to...

  • Page 40: Electro-Injectors

    1.40 N60 ENT M37 OVERVIEW APRIL 2004 Electro-injectors Figure 50 04_055_N 1. Pressure rod - 2. Metering rod - 3. Nozzle - 4. Coil - 5. Pilot Valve - 6. Ball valve - 7. Control area - 8. Pressure chamber - 9.
  • Page 41 1.41 APRIL 2004 OVERVIEW N60 ENT M37 Figure 51 04_056_N 1. Pressure rod - 2. Metering rod - 3. Nozzle - 4. Coil - 5. Pilot Valve - 6. Ball valve - 7. Control area - 8. Pressure chamber - 9.

  • Page 42: Pressurization Valve Of The Electro-Injector Backflow

    1.42 N60 ENT M37 OVERVIEW APRIL 2004 The ratio between the pilot system time and the amount of Pressurization valve of the electro-injector fuel delivered is a non linear characteristic and with narrow backflow limit of tolerance typical of every family of electro-injectors;...

  • Page 43: Edc 7 System Electronic And Electric Main Components

    1.43 APRIL 2004 OVERVIEW N60 ENT M37 EDC 7 SYSTEM ELECTRONIC AND ELECTRIC MAIN COMPONENTS Figure 53 04_058_N 1. Coolant temperature sensor - 2. Electro-injector - 3. Fuel pressure sensor on rail - 4. Combustion air pressure / temperature sensor - 5.Timing sensor - 6. Pressure control solenoid valve - 7. Fuel filter with temperature sensor and electric...

  • Page 44: Edc 7 Electronic Central Unit

    1.44 N60 ENT M37 OVERVIEW APRIL 2004 EDC 7 Electronic Central Unit Air pressure / temperature sensor Figure 54 Figure 55 04_061_N It integrates a temperature sensor and a pressure one. Positioned at the entrance of the intake manifod produces a signal that is proportional to the absolute pressure value of the intaken air and supercharged.

  • Page 45: Oil Pressure / Temperature Sensor

    1.45 APRIL 2004 OVERVIEW N60 ENT M37 Oil pressure / temperature sensor Crankshaft sensor Figure 56 Figure 57 04_062_N The body of the sensor is similar to that one of the air pres- sure/temperature sensor and the functions carried out are analogous.

  • Page 46: Camshaft Sensor

    1.46 N60 ENT M37 OVERVIEW APRIL 2004 Camshaft sensor Coolant temperature sensor Figure 58 Figure 59 04_065_N It is a resistor with negative temperature coefficient and is positioned on the cylinder head at a short distance from the thermostatic valve. It provides the indication of the metering...

  • Page 47: Fuel Temperature Sensor

    1.47 APRIL 2004 OVERVIEW N60 ENT M37 Fuel temperature sensor Fuel pressure sensor Figure 60 Figure 61 04_067_N 04_066_N It is assembled on one end of the rail and provides the fuel 1. Fuel temperature sensor - instantaneous pressure value necessary to assess the injec- 2.

  • Page 48: Pressure Control Solenoid

    1.48 N60 ENT M37 OVERVIEW APRIL 2004 Pressure control solenoid Figure 62 04_068_N A. Solenoid connector. The amount of fuel that feeds the high pressure pump is It provides the primary indication for the reckoning of the metered by the solenoid valve connected to the low pressure fuel amount to be injected.

  • Page 49: System Functions

    1.49 APRIL 2004 OVERVIEW N60 ENT M37 SYSTEM FUNCTIONS By means of the computer electronic management it is pos- Metering and fuel injection sible to actuate in fast sequence both primary functions such It is carried out by the span of time of the injectors electric...

  • Page 50: Pre-Injection

    1.50 N60 ENT M37 OVERVIEW APRIL 2004 Pre-injection Fuel Heating By this term it is stated the delivery of a limited amount of fuel It assures a correct density of the fuel even at low tempera- that is obtained in the short interval of opening and closing of tures, improving atomization in order to obtain a better gra- the spray-nozzle metering rod, before the main injection.

  • Page 51: Recovery

    1.51 APRIL 2004 OVERVIEW N60 ENT M37 Recovery It is a special way of control and management characterised by the adoption of a number of strategies which enable the system to operate even in the case selfdiagnosis has recog- nized the presence of anomalies. In the majority of cases sea- faring can be continued regularly or with reduced perfor- mance.
  • Page 52 1.52 N60 ENT M37 OVERVIEW APRIL 2004...

  • Page 53: Technical Data

    2.53 APRIL 2004 TECHNICAL DATA N60 ENT M37 SECTION 2 TECHNICAL DATA Page PERFORMANCE GENERAL SPECIFICATIONS Dimensions...
  • Page 54 2.54 N60 ENT M37 TECHNICAL DATA APRIL 2004...
  • Page 55 2.55 APRIL 2004 TECHNICAL DATA N60 ENT M37 PERFORMANCE Brake horsepower values in accordance with ISO 3046-1, attainable after about 50 hours of operation under reference envi- ronmental conditions characterized by 750 mmHg, 25°C, 30% relative humidity.Values fall within a tolerance of 5%.
  • Page 56 2.56 N60 ENT M37 TECHNICAL DATA APRIL 2004 Gas Emissions Compliance with Standard IMO MARPOL 73/78 ADDENDUM DIR. 94/25/EC Sound Emissions Maximum value of average level for engines in basic configuration dBA (measurement standard) 94 (ISO 3744) Power Takeoffs (Optional)
  • Page 57 2.57 APRIL 2004 TECHNICAL DATA N60 ENT M37 GENERAL SPECIFICATIONS Cycle 4-Stroke Diesel Charge Supercharged and intercooled Injection Direct Number of cylinders 6 in line Bore Stroke Total displacement 5900 Compression ratio 17 ± 0.8 : 1 Direction of rotation, brake side...
  • Page 58 2.58 N60 ENT M37 TECHNICAL DATA APRIL 2004 Low Temperature Starting Allowed, without external aids, down to °C - 15 Cooling Closed coolant loop with sea water heat exchanger 50% mixture of water/Paraflu II or equiv. Compliant with SAE J 1034 specification...
  • Page 59 2.59 APRIL 2004 TECHNICAL DATA N60 ENT M37 Dimensions Figure 5 (6.96) 840 (33.07) 610 (24.01) 1350 (53.15) 850 (33.46) 04_070_N Measurements in: millimeters (inches).
  • Page 60 2.60 N60 ENT M37 TECHNICAL DATA APRIL 2004...
  • Page 61 3.61 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 SECTION 3 ELECTRICAL EQUIPMENT Page OVERALL SYNOPTIC WIRE HARNESS LOCATION OF ELECTRICAL COMPONENTS ON ENGINE POWER SUPPLY LINE ALTERNATOR ELECTRICAL STARTER MOTOR RELAY BOX Relays contained in the relay box RPM control...

  • Page 62: Electrical Equipment

    3.62 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004...

  • Page 63: Overall

    Wiring harness for power supply has to be manufactured by “N60 ENT M37 Installation Directive” document. the yard following the indications contained in the “N60 ENT M37 Installation Directive” document.

  • Page 64: Synoptic

    3.64 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 SYNOPTIC Figure 2 GEAR BOX INDICATIONS AND ALARMS SENSORS THROTTLE POSITION SENSOR INDICATIONS AND ALARMS SENSORS ELECTRO-INJECTORS EDC COMPONENTS ALTERNATOR ELECTRIC STARTER MOTOR RELAY NEF ENT M37 BATTERY 04_235_N 1. Connector for instrument panel connection wire harness - 2. Engine wire harness - 3. Interface wire harness - 4. Power line.

  • Page 65: Wire Harness

    3.65 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 WIRE HARNESS Figure 3 04_221_N Engine wire harness Interface wire harness...

  • Page 66: Location Of Electrical Components On Engine

    3.66 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 LOCATION OF ELECTRICAL COMPONENTS ON ENGINE Figure 4 04_220_N A. Fuel temperature sensor for EDC - B. Drive shaft sensor - C. Camshaft sensor - F. Engine coolant temperature sensor for EDC - H. Combustion air pressure/temperature sensor for EDC - K. Air filter clogging sensor (for alarm) - T. Coolant temperature sensor (for gauge) - V.

  • Page 67: Power Supply Line

    3.67 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 POWER SUPPLY LINE Figure 5 EDC power supply 04_076_N 1.Alternator - 2. Electric starter motor - 3. Battery - 4. Engine wire harness. The power supply line, to be built by the yard, comprises: ❏...

  • Page 68: Alternator

    3.68 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 ALTERNATOR Figure 6 04_223_N Model “Bosch” 14 V - 90 A Specification Nominal voltage 14 V +B. (12 V) Power supply output terminal Nominal current max 90 A D+. (Lamp) Power supply voltage of recharge/alarm indi- cator light located on the panel.

  • Page 69: Electrical Starter Motor

    3.69 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 ELECTRICAL STARTER MOTOR Figure 8 Starter control 04_225_N Engine electrical ground connection point Model “Bosch” - Specification Nominal power 4.3 kW Nominal voltage 12 V Polarity Negative ground Engagement circuit Positive command...

  • Page 70: Relay Box

    On the relay box is located the multipolar connector, protected by a screw-on lid (5), for connection with the computerized diagnostic tools prescribed by IVECO MOTORS (see Section 4). This shall be installed and anchored in such a way as to...

  • Page 71: Relay Box Connectors

    3.71 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 Relay box connectors version to 10/2003) version from 11/2003) Figure 12 Figure 15 04_214_N 04_215_N Figure 13 Figure 16 PIN 25 PIN 36 04_216_N JF1 CONNECTOR (view of the wire harness terminal, coupling side)

  • Page 72: Identification Of Terminal Function

    3.72 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 CONNECTIONS OF THE CENTRAL ELECTRONIC UNIT (ECU) EDC 7 Identification of terminal function Figure 18 EDC A Connector Figure 19 04_227_N 04_060_N A. 36 poles connector - A1. 16 poles connector - ECU FUNCTION A2.
  • Page 73 3.73 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 Identification of terminal function ECU FUNCTION EDC A1 Connector Ground supply rail pressure sensor Figure 20 Ground combustion air pressure/temperature sensor Not used Camshaft sensor Drive shaft sensor Drive shaft sensor Not used...
  • Page 74 3.74 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 Identification of terminal function EDC A2 Connector Figure 27 04_229_N ECU FUNCTION ECU FUNCTION Positive supply (+B) Not used Ground for K1 e K2 relays Not used Negative supply (-B) Not used...
  • Page 75 3.75 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 ECU FUNCTION ECU FUNCTION Control from SW 1 to enable engine controls Not used from ENGINE ROOM Not used Not used Not used Engine start control from SW 2 Not used (located on relay box)

  • Page 76: Electro-Injectors Connectors

    3.76 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 Electro-injectors connectors Figure 28 04_230_N Figure 29 04_231_N 1. Electro-injectors cylinders 1 and 2 connector - 2. Electro-injectors cylinders 3 and 4 connector - 3. Electro-injectors cylinders 5 and 6 connector. The wiring connecting the electro-injectors to ECU is made...
  • Page 77 3.77 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 EQUIPOTENTIAL CONNECTIONS TO ENGINE GROUND Figure 30 04_232_N To prevent electrochemical corrosion phenomena, some ele- CAUTION ments included in the cooling circuits were electrically grounded with copper braids with eyelet terminations. To enhance connection efficiency, the screw threads and...

  • Page 78: Electrical Diagrams

    3.78 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 ELECTRICAL DIAGRAMS Wiring diagram key General conditions for the preparation and interpretation of wiring diagrams ❏ Key switch open ❏ Engine not running ❏ Liquids at efficient levels and pressures Figure 45...

  • Page 79: Electrical Equipment Component Code

    EDC converter module for digital panel drive shaft sensor electric starter motor camshaft sensor IVECO MOTORS indications and alarms module engine coolant temperature sensor for EDC throttle position sensor combustion air pressure/temperature sensor for emergency shut-down push-button (optional, installer’s responsibility)
  • Page 80 Gauges ON MAIN ANALOG INSTRUMENT PANEL set for connection to the engine wire harness revolution-counter IVECO MOTORS indications and alarms module gear box oil pressure gauge ON INTERFACE WIRE HARNESS FOR CONVERTER MODULE engine oil pressure gauge external throttle control...

  • Page 81: Equipment Versions Until 10/2003

    3.81 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 EDC connector A2 VERSION TO 10/2003...
  • Page 82 3.82 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 EDC connectors A - A1 VERSION TO 10/2003...
  • Page 83 3.83 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 Main analog instrument panel VERSION TO 10/2003...
  • Page 84 3.84 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 Secondary analog instrument panel VERSION TO 10/2003...

  • Page 85: Equipment Versions Since 11/2003

    3.85 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 EDC connector A2 VERSION FROM 11/2003...
  • Page 86 3.86 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 EDC connectors A - A1 VERSION FROM 11/2003...
  • Page 87 3.87 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 Main analog instrument panel VERSION FROM 11/2003...
  • Page 88 3.88 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 Secondary analog instrument panel VERSION FROM 11/2003...

  • Page 89: Can - Bus Converter Module Interface Wiring

    3.89 APRIL 2004 ELECTRICAL EQUIPMENT N60 ENT M37 CAN - BUS converter module interface wiring...

  • Page 90: Supplementary Services Battery Recharge

    3.90 N60 ENT M37 ELECTRICAL EQUIPMENT APRIL 2004 Supplementary services battery recharge...
  • Page 91 4.91 APRIL 2004 DIAGNOSTICS N60 ENT M37 SECTION 4 DIAGNOSTICS Page FOREWORD ECU BEHAVIOUR Anomalies indicator light Blink code Error deletion procedure Recovery BLINK CODE TABLE DIAGNOSING WITH PT-01 INSTRUMENT Functions of the Instrument Identifier Fault Memory Parameter reading Active diagnostics...
  • Page 92 4.92 N60 ENT M37 DIAGNOSTICS APRIL 2004...

  • Page 93: Foreword

    Technicians and maintenance personnel are recommended, in these cases, to check ratings and technical data foreseen in the “N60 ENT M37 Installation Directive” document. In order partly to overcome service personnel’s lack of experience on this new system, we have provided, in the pages that follow, a TROUBLESHOOTING GUIDE.

  • Page 94: Ecu Behaviour

    4.94 N60 ENT M37 DIAGNOSTICS APRIL 2004 ECU BEHAVIOUR Anomalies indicator light Error deletion procedure The ECU continuously monitors, with complex self-testing routines, its own operating conditions as well as those of the Figure 1 components connected to it and of the engine.

  • Page 95: Blink Code Table

    4.95 APRIL 2004 DIAGNOSTICS N60 ENT M37 BLINK CODE TABLE (software version 4.1_2 V5.3) Blinking EDC indicator Indicated fault Max power Code light reduction Control area (on) not significant in marine applications (on) not significant in marine applications throttle position sensor...
  • Page 96 4.96 N60 ENT M37 DIAGNOSTICS APRIL 2004 Blinking EDC indicator Indicated fault Max power Code light reduction Engine RPM sensor flywheel sensor timing system sensor engine speed signal plausibility blinking runaway engine coil relay electric starter motor revolution counter signal...

  • Page 97: Diagnosing With Pt-01 Instrument

    DIAGNOSTICS N60 ENT M37 DIAGNOSING WITH PT -01 INSTRUMENT Engine diagnosing must be done with the IVECO MOTORS The instrument is powered directly from the diagnosing out- PT-01 instrument. let. In case of prolonged use with the engine off, the instru- ment can be powered externally through the connector (4) of Fig.2.

  • Page 98: Fault Memory

    4.98 N60 ENT M37 DIAGNOSTICS APRIL 2004 Engine serial number Relays Main Alphanumeric code Fuel filter heater Fault Memory Power supply voltage This option allows to display the faults that occurred during operation.They are grouped in two categories: Indicator lights...

  • Page 99: Major Diagnostic Actions

    4.99 APRIL 2004 DIAGNOSTICS N60 ENT M37 MAJOR DIAGNOSTIC ACTIONS The following is a description of the procedures to carry out Checking component resistance value the major instrumental measurements mentioned in the diagnostics guide. Figure 5 Checking pressure in fuel supply line...

  • Page 100: Reference Values

    4.100 N60 ENT M37 DIAGNOSTICS APRIL 2004 REFERENCE VALUES For non hardwired sensors Component Test conditions Minimum Maximum Ω value Ω value Intake air temperature sensor -10° C 8100 10800 0 °C 5200 6750 Coolant temperature sensor 20 °C 2300...

  • Page 101: For Wired Sensors Powered By The Ecu

    4.101 APRIL 2004 DIAGNOSTICS N60 ENT M37 REFERENCE VALUES For wired sensors powered by the ECU Component Test Minimum - maximum connection conditions value Combustion air temperature sensor signal A21 A29 Panel key ON 0,5 ÷ 4,5 Vcc Coolant temperature sensor signal...

  • Page 102: Guide To Blink Code Diagnosing

    4.102 N60 ENT M37 DIAGNOSTICS APRIL 2004...
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  • Page 112: Guide To Symptom Diagnosing

    4.112 N60 ENT M37 DIAGNOSTICS APRIL 2004...
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  • Page 117 5.117 APRIL 2004 MAINTENANCE N60 ENT M37 SECTION 5 MAINTENANCE Page PERIODICITY OF CHECKS AND MAINTENANCE OPERATIONS PREPARING THE ENGINE FOR LONG IDLE PERIODS ENGINE’S FIRST START / RESTORING NORMAL OPERATING CONDITIONS...
  • Page 118 5.118 N60 ENT M37 MAINTENANCE APRIL 2004...
  • Page 119 Periodic maintenance operations must be performed by qualified personnel and require the use of tools, work instruments, and suitable protection means. Extraordinary maintenance operations shall be performed by IVECO MOTORS authorized workshop personnel with adequate training and sufficient technical information.
  • Page 120 5.120 N60 ENT M37 MAINTENANCE APRIL 2004 (1) The periodicity of these operations may vary depending on engine use and environmental conditions of operation. (2) These operations must be conducted annually even if the specified number of operating hours is not reached.
  • Page 121 5.121 APRIL 2004 MAINTENANCE N60 ENT M37 PREPARING THE ENGINE ENGINE’S FIRST START / RESTORING FOR LONG IDLE PERIODS NORMAL OPERATING CONDITIONS To prevent oxidation to the internal parts of the engine and 1. Drain the residual protective oil type 30/M from the to some components of the injection system, if idle periods sump.
  • Page 122 5.122 N60 ENT M37 MAINTENANCE APRIL 2004...
  • Page 123 6.123 APRIL 2004 SERVICING OPERATIONS ON INSTALLED ENGINE N60 ENT M37 SECTION 6 SERVICING OPERATIONS ON INSTALLED ENGINE Page FOREWORD PRESCRIPTIONS FOR WORK ON THE INJECTION SYSTEM AND ITS COMPONENTS REPLACING THE ELECTRO-INJECTORS Removal Fitting FUEL SYSTEM PIPING VENTING THE AIR FROM THE FUEL FEED LOOP...
  • Page 124 6.124 N60 ENT M37 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2004...

  • Page 125: Servicing Operations On Installed Engine

    Technicians and maintenance personnel are reminded of the need to comply with safety rules. The checks necessary at the completion of an installation or re-embarkation are described in the “N60 ENT M37 Instal- lation Directive” document. Spare parts shall be supplied only if the following data are provided: engine technical code and serial number;...

  • Page 126: Prescriptions For Work On The Injection System And Its Components

    IVECO MOTORS after specific agreements with the Technical Assistance Service. ❏ The electro-injectors cannot be overhaul; their replace- ment must be authorized by IVECO MOTORS with the specific agreement of the Technical Assistance Service; for disassembly, follow the indications provided in the specific paragraph of this Section.

  • Page 127: Replacing The Electro-Injectors

    6.127 APRIL 2004 SERVICING OPERATIONS ON INSTALLED ENGINE N60 ENT M37 REPLACING THE ELECTRO-INJECTORS Removal Figure 2 Make conditions safe (they may differ depending on the application). ❏ Disconnect the battery cables; ❏ Disconnect the oil vapour pipes from the tappet cover, then remove this cover;...

  • Page 128: Fitting

    6.128 N60 ENT M37 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2004 Fitting Figure 6 Figure 4 04_198_N Fit a new sealing ring (2) lubricated with petroleum jelly and a new sealing washer (3) on injector (1). 04_200_N Figure 5 Fit a new sealing ring (3) lubricated with petroleum jelly on...

  • Page 129: Fuel System Piping

    6.129 APRIL 2004 SERVICING OPERATIONS ON INSTALLED ENGINE N60 ENT M37 FUEL SYSTEM PIPING Figure 8 Figure 9 04_244_N 04_072_N A.To rail supply - B. Return flow from rail 1. Piping for electro-injectors - 2. Common rail - 1. Rubber holder junction for fuel inflow from pre-filter - 3.

  • Page 130: Valves Clearance Adjustment

    6.130 N60 ENT M37 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2004 VALVES CLEARANCE ADJUSTMENT Figure 10 04_203_N Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Working clearance shall be as follows: intake valves 0.25 ±...

  • Page 131: Cleaning The Engine Coolant / Sea Water Heat Exchanger

    6.131 APRIL 2004 SERVICING OPERATIONS ON INSTALLED ENGINE N60 ENT M37 CLEANING THE ENGINE COOLANT / SEA WATER HEAT EXCHANGER Figure 11 04_271_N 1. Cover - 2. Spacer - 3.Tube bundle - 4. Sealing rings - 5. Zinc sacrificial anode.

  • Page 132: Cleaning The Air / Sea Water Heat Exchanger

    6.132 N60 ENT M37 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2004 CLEANING THE AIR / SEA WATER HEAT EXCHANGER Figure 12 04_272_N 1. Cover - 2. Spacer - 3.Tube bundle - 4. Sealing rings - 5. Plug - 6.Tube bundle fixing screw - 7. Zinc sacrificial anode.

  • Page 133: Remove The Ring Sealing The Engine's Driving Shaft From The Front Cover

    6.133 APRIL 2004 SERVICING OPERATIONS ON INSTALLED ENGINE N60 ENT M37 REMOVE THE RING SEALING THE ENGINE’S DRIVING SHAFT FROM THE FRONT COVER Figure 13 Figure 15 04_206_N 04_204_N Use the tool 99340055 (4) to operate on the front bar hold Apply tool 99346252 part (4) to the front output shaft tang of the driving shaft.

  • Page 134: Remove The Holding Ring Of The Flywheel Cover Box

    6.134 N60 ENT M37 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2004 REMOVE THE HOLDING RING OF THE FLYWHEEL COVER BOX Figure 16 Figure 17 04_207_N 04_208_N Using the tool 99340056 (3) to operate on the driving shaft’s back bar hold (5).

  • Page 135: Fitting Flywheel Housing Box

    6.135 APRIL 2004 SERVICING OPERATIONS ON INSTALLED ENGINE N60 ENT M37 FITTING FLYWHEEL HOUSING BOX FITTING REAR GEARBOX To apply loctite 5205 sealant To apply loctite 5999 sealant. Flywheel housing box weight 23 kg Figure 18 Figure 20 04_209_N 04_211_N...

  • Page 136: Decoupling Sea Water Components

    6.136 N60 ENT M37 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2004 DECOUPLING SEA WATER COMPONENTS Some periodical maintenance and overhaul interventions Figure 24 require full access to engine parts and removal of sea water components.The following sequence is suggested to simplify the necessary operations.
  • Page 137 6.137 APRIL 2004 SERVICING OPERATIONS ON INSTALLED ENGINE N60 ENT M37 Figure 27 Figure 30 04_278_N 04_281_N Decouple the turbocharger from the exhaust manifold and Remove the exhaust manifold to complete engine prepara- remove it; please note that we reassembling its is necessary tion for overhauling.

  • Page 138: Instructions For Disembarking The Engine

    6.138 N60 ENT M37 SERVICING OPERATIONS ON INSTALLED ENGINE APRIL 2004 INSTRUCTIONS FOR DISEMBARKING THE ENGINE The following is a description of the recommended sequence of the operations to be completed before extract- ing the engine from the vessel. After the key switch has been in the OFF position for at least 10 seconds, disconnect the battery terminals and disconnect the connectors from the relay box.
  • Page 139 7.139 APRIL 2004 TOOLS N60 ENT M37 SECTION 7 TOOLS Page TOOLS...
  • Page 140 7.140 N60 ENT M37 TOOLS APRIL 2004...
  • Page 141 7.141 APRIL 2004 TOOLS N60 ENT M37 TOOLS TOOL No. DEFINITION 99305018 Kit for valve seat regrinding 99305047 Spring load tester 99317915 Set of 3 pin wrenches (14 - 17 - 19 mm) Revolving stand for overhauling units (700 daN/m capacity, 120...
  • Page 142 7.142 N60 ENT M37 TOOLS APRIL 2004 TOOLS TOOL No. DEFINITION 99341001 Double acting puller 99341009 Pair of brackets 99341015 Press 99342101 Tool to remove injectors 99346252 Tool for fitting output shaft rear gasket 99346253 Tool for fitting output shaft rear gasket...
  • Page 143 7.143 APRIL 2004 TOOLS N60 ENT M37 TOOLS TOOL No. DEFINITION 99360076 Tool to remove oil filter (engine) 99360183 Pliers for removing/refitting piston rings (65 — 110 mm) 99360268 Tool for removing/refitting engine valves 99360339 Tool for rotating/stopping the engine flywheel...
  • Page 144 7.144 N60 ENT M37 TOOLS APRIL 2004 TOOLS TOOL No. DEFINITION 99360595 Lifting rig for engine removal/refitting 99360605 Band for fitting piston into cylinder barrel (60 — 125 mm) 99361037 Brackets for fastening engine to revolving stand 99322205 99363204 Tool to remove gaskets...
  • Page 145 7.145 APRIL 2004 TOOLS N60 ENT M37 TOOLS TOOL No. DEFINITION Torque screwdriver for injector solenoid valve connector stop nut 99389834 setting Pair of gauges with ½” and ¾” square head for angle tightening 99395216 99395363 Complete bush testing square 99395603 Dial gauge (0 —...
  • Page 146 7.146 N60 ENT M37 TOOLS APRIL 2004...
  • Page 147 8.147 APRIL 2004 OVERHAUL N60 ENT M37 SECTION 8 OVERHAUL Page GENERAL SPECIFICATIONS CLEARANCE DATA ENGINE OVERHAUL - ENGINE REMOVAL AT THE BENCH REPAIR OPERATIONS CYLINDER UNIT Checks and measurements Checking head supporting surface on cylinder unit TIMING SYSTEM Camshaft...
  • Page 148 8.148 N60 ENT M37 OVERHAUL APRIL 2004 Page Fitting connecting rod-piston assembly Connecting rod-piston coupling Fitting split rings Fitting connecting rod-piston assembly into cylinder barrels Finding crankpin clearance Checking piston protrusion CYLINDER HEAD Removing the valves Checking cylinder head wet seal...

  • Page 149: General Specifications

    8.149 APRIL 2004 OVERHAUL N60 ENT M37 GENERAL SPECIFICATIONS Type 6 CYLINDERS Cycle Four-stroke diesel engine Power Turbocharged with intercooler Injection Direct Number of cylinders 6 in-line ∅ Bore Stroke +.. = Total displacement 5880 TIMING start before T.D.C. 8.5º...

  • Page 150: Clearance Data

    8.150 N60 ENT M37 OVERHAUL APRIL 2004 CLEARANCE DATA Type 6 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅ 1 102.01 to 102.03 ∅1 Cylinder barrels ∅ Cylinder barrels: ∅ 2 outside diameter length Cylinder barrels — housings on engine block (interference) ∅...
  • Page 151 8.151 APRIL 2004 OVERHAUL N60 ENT M37 Type 6 CYLINDER CYLINDER UNIT AND CRANKSHAFT COMPONENTS 2.705 to 2.735 Split ring slots 2.420 to 2.440 4.020 to 4.040 S 1* 2.560 to 2.605 Split rings 2.350 to 2.380 3.975 to 4.000 * measured on 98 mm ∅...
  • Page 152 8.152 N60 ENT M37 OVERHAUL APRIL 2004 Type 6 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS Size Max. tolerance on connecting rod axis alignment ∅ ∅ ∅ 1 Journals 82.99 to 83.01 ∅ 2 Crankpins 68.987 to 69.013 Main half bearings 2.456 to 2.464...
  • Page 153 8.153 APRIL 2004 OVERHAUL N60 ENT M37 Type 6 CYLINDERS CYLINDER HEAD — TIMING SYSTEM ∅ 1 7.042 to 7.062 Valve guide seats on ∅ 1 cylinder head 7.042 to 7.062 ∅ ∅ 2 Valve guides ∅ 3 ∅ 3...
  • Page 154 8.154 N60 ENT M37 OVERHAUL APRIL 2004 Type 6 CYLINDERS CYLINDER HEAD — TIMING SYSTEM Valve spring height: free spring 47.75 under a load equal to: 339.8 ± 9 N 35.33 741 ± 39 N 25.2 Injector protrusion Camshaft bush 59.222 to 59.248...
  • Page 155 8.155 APRIL 2004 OVERHAUL N60 ENT M37 Type 6 CYLINDERS CYLINDER HEAD — TIMING SYSTEM ∅ 1 Tappet cap housing ∅ 1 on block 16.000 to 16.030 ∅2 Tappet cap outside ∅ ∅ 2 diameter: 15.924 to 15.954 ∅ 3 15.960 to 15.975...
  • Page 156 8.156 N60 ENT M37 OVERHAUL APRIL 2004...

  • Page 157: Engine Overhaul Engine Removal At The Bench

    8.157 APRIL 2004 OVERHAUL N60 ENT M37 ENGINE OVERHAUL ENGINE REMOVAL AT THE BENCH The following instructions assume that the engine has Figure 3 previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well.

  • Page 158: Repair Operations

    8.158 N60 ENT M37 OVERHAUL APRIL 2004 REPAIR OPERATIONS CYLINDER UNIT Figure 6 Checks and measurements Figure 9 70163 Remove the screws (1) and disconnect camshaft (3) retaining plate (2). 70166 Once engine is disassembled, clean accurately the cylinder-block assembly.

  • Page 159: Checking Head Supporting Surface On Cylinder Unit

    8.159 APRIL 2004 OVERHAUL N60 ENT M37 Check main bearing housings as follows: Figure 11 - fit the main bearings caps on the supports without bearings; ± - tighten the fastening screws to the specified torque; - use the proper internal gauge to check whether the housing diameter is falling within the specified value.

  • Page 160: Timing System

    8.160 N60 ENT M37 OVERHAUL APRIL 2004 Figure 13 70512 MAIN DATA ABOUT CAMSHAFT PINS (6 CYL.) Camshaft pin and cam surfaces shall be absolutely smooth; camshaft and the bushes. if they show any traces of seizing or scoring replace the...
  • Page 161 8.161 APRIL 2004 OVERHAUL N60 ENT M37 Figure 16 Sec. A-A 70173 CAMSHAFT BUSH AND HOUSING MAIN DATA * Value to be obtained after driving the bushes.

  • Page 162: Bush Replacement

    8.162 N60 ENT M37 OVERHAUL APRIL 2004 Bush replacement Fitting tappets — camshaft Figure 20 Figure 18 70176 70174 Lubricate the tappets (1) and fit them into the relevant housings on the engine block. To replace front and rear bushes (1), remove and refit them...

  • Page 163: Output Shaft

    8.163 APRIL 2004 OVERHAUL N60 ENT M37 OUTPUT SHAFT Measuring journals and crankpins Figure 23 Figure 25 70179 70182 Grind journals and crankpins if seizing, scoring or excessive Check camshaft end float (1). ovalisation are found. Before grinding the pins (2) measure It shall be 0.23 ±...
  • Page 164 8.164 N60 ENT M37 OVERHAUL APRIL 2004...
  • Page 165 8.165 APRIL 2004 OVERHAUL N60 ENT M37 Measuring journals and crankpins Figure 28 70514 FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES *Rated value Figure 29 Measured on a radius greater than 45.5 mm ↗ 0.500 70577...
  • Page 166 8.166 N60 ENT M37 OVERHAUL APRIL 2004 Figure 30 INTERMEDIATE MAIN MAIN BEARING ON TIMING FIRST MAIN BEARING ON BEARINGS SYSTEM CONTROL SIDE FRONT SIDE 70237 TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL Roundness ○ SHAPE SHAPE Cilindricity /○/ Parallelism Verticality DIRECTION...

  • Page 167: Replacing Oil Pump Control Gear

    8.167 APRIL 2004 OVERHAUL N60 ENT M37 Finding journal clearance Replacing oil pump control gear Figure 33 Figure 31 70161 Refit the crankshaft (2). Check the backlash between crankshaf main journals and the 70184 relevant bearings as follows: Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3).

  • Page 168: Checking Crankshaft Shoulder Clearance

    8.168 N60 ENT M37 OVERHAUL APRIL 2004 Checking crankshaft shoulder clearance Figure 36 Figure 38 70188 stage, with tool 99395216 (1) set as shown in the 70190 figure, tighten the screws (2) with 90° ± 5° angle. This check is performed by setting a magnetic-base dial gauge (2) on the crankshaft (3) as shown in the figure, standard value is 0.068 to 0.41.

  • Page 169: Pistons - Measuring Piston Diameter

    8.169 APRIL 2004 OVERHAUL N60 ENT M37 Pistons Measuring piston diameter Figure 40 Figure 43 32615 32613 Remove split rings (1) from piston (2) using pliers 99360183 Using a micrometer (2), measure the diameter of the piston (3). (1) to determine the assembly clearance.

  • Page 170: Piston Pins

    8.170 N60 ENT M37 OVERHAUL APRIL 2004 Piston pins Figure 48 Figure 45 18857 32620 To measure the piston pin (1) diameter use the micrometer Check the clearance between the sealing rings (3) of the 2 (2). and 3 slot and the relevant housings on the piston (2), using a feeler gauge (1).

  • Page 171: Connecting Rods

    8.171 APRIL 2004 OVERHAUL N60 ENT M37 Figure 50 Figure 52 CONNECTING ROD BODY 1234 CONNECT- WEIGHT ING ROD No. 0001 ↓ 9999 70194 Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).

  • Page 172: Checking Connecting Rods

    8.172 N60 ENT M37 OVERHAUL APRIL 2004 Checking connecting rods Checking bending Figure 53 Figure 55 61695 Check connecting rod (5) bending by comparing two points 61696 C and D of the pin (3) on the vertical plane of the connecting Check that the axis of the connecting rods (1) are parallel rod axis.

  • Page 173: Fitting Split Rings

    8.173 APRIL 2004 OVERHAUL N60 ENT M37 Figure 57 Split rings are supplied spare with the following sizes: standard, yellow marking; 0.5 mm oversize, yellow/green marking; Figure 60 70199 Connect piston (2) to connecting rod (4) with pin (3) so that...

  • Page 174: Finding Crankpin Clearance

    8.174 N60 ENT M37 OVERHAUL APRIL 2004 Figure 62 Figure 64 70204 - Lubricate the screws (1) with engine oil and then tighten 70202 them to the specified torque using the torque wrench (2). DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL...

  • Page 175: Checking Piston Protrusion

    8.175 APRIL 2004 OVERHAUL N60 ENT M37 Figure 67 Checking piston protrusion Figure 68 70207 If a different clearance value is found, replace the half bearings 70208 and repeat the check. Once connecting rod-piston assemblies refitting is over, use Once the specified clearance has been obtained, lubricate...

  • Page 176: Cylinder Head

    8.176 N60 ENT M37 OVERHAUL APRIL 2004 Figure 70 CYLINDER HEAD Removing the valves Figure 69 70321 Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the 70319 cap (3) and the springs (4).

  • Page 177: Checking Cylinder Head Wet Seal

    8.177 APRIL 2004 OVERHAUL N60 ENT M37 Checking cylinder head wet seal Figure 73 Figure 72 70325 70323 The rated thickness A for the cylinder head is 105 ± 0.25 mm, This check shall be performed using the proper tools.

  • Page 178: Valves

    8.178 N60 ENT M37 OVERHAUL APRIL 2004 VALVES Figure 76 Figure 74 INTAKE EXHAUST VALVE VALVE 18882 Check the valve stem (1) using a micrometer (2), it shall be 6.970 ± 6.999. 70326 INTAKE AND EXHAUST VALVE MAIN DATA Removing carbon deposits, checking and...

  • Page 179: Valve Guide

    8.179 APRIL 2004 OVERHAUL N60 ENT M37 VALVE GUIDE VALVE SEATS Figure 78 Regrinding — replacing the valve seats Figure 79 INTAKE EXHAUST 70330 70328 Check the valve seats (2). If slight scoring or burnout is found, Use a bore dial gauge to measure the inside diameter of the...
  • Page 180 8.180 N60 ENT M37 OVERHAUL APRIL 2004 Figure 81 EX H AU ST I NTAK E 70332 MAIN DATA CONCERNING THE SEATS ON THE CYLINDER HEAD Should valve seats be not reset just by regrinding, replace Heat the cylinder head to 80° - 100°C and using the proper them with the spare ones.
  • Page 181 8.181 APRIL 2004 OVERHAUL N60 ENT M37...

  • Page 182: Valve Springs

    8.182 N60 ENT M37 OVERHAUL APRIL 2004 FITTING CYLINDER HEAD Figure 85 Figure 87 70333 70334 After regrinding, check that valve (3) sinking value is the specified one by using the base 99370415 (2) and the dial Lubricate the valve stems (1) and fit them into the relevant gauge 99395603 (1).
  • Page 183 8.183 APRIL 2004 OVERHAUL N60 ENT M37 Refitting the cylinder head Figure 89 Before re-utilising the fixing screws for the cylinder head, verify there is no evidence of wear or deformation and in that case replace them. 70335 Check cleanness of cylinder head and engine block coupling surface.

  • Page 184: Changing The Electro-Injectors

    8.184 N60 ENT M37 OVERHAUL APRIL 2004 CHANGING THE ELECTRO-INJECTORS (see Section 6) FUEL SYSTEM PIPING (see Section 6) VENTING THE AIR FROM THE FUEL FEED LOOP (see Section 6) VALVES CLEARANCE ADJUSTMENT (see Section 6) REMOVE THE RING SEALING THE ENGINE’S DRIVING SHAFT FROM THE FRONT COVER...
  • Page 185 8.185 APRIL 2004 OVERHAUL N60 ENT M37 Engine parts tightening torques Part Torque M8 Screw fixing cylinder barrel lubrication nozzles 15 ± 3 1,5 ± 0,3 Phase 1 50 ± 6 5 ± 0,6 M12 Screw fixing crankshaft caps Phase 2 80 ±...
  • Page 186 8.186 N60 ENT M37 OVERHAUL APRIL 2004 Engine parts tightening torques Part Torque Rocker mount fixing screw 36 ± 5 3,6 ± 0,5 Valve clearance adjustment nuts 24 ± 4 2,4 ± 0,4 M14 Nuts fixing supply pipe from high-pressure pump Common rail 20 ±...
  • Page 187 8.187 APRIL 2004 OVERHAUL N60 ENT M37 Engine parts tightening torques Part Torque M12 Screw fixing engine oil level sensor 12 ± 2 1,2 ± 0,2 M12 Adapter on turbine for lubricating oil pipes (inlet) 35 ± 5 3,5 ± 0,5 Pipe fixing on M10 adapter for turbine lubrication 35 ±...
  • Page 188 8.188 N60 ENT M37 OVERHAUL APRIL 2004...
  • Page 189 9.189 APRIL 2004 SAFETY PRESCRIPTIONS N60 ENT M37 SECTION 9 SAFETY PRESCRIPTIONS Page SAFETY PRESCRIPTIONS Standard safety prescriptions Prevention of injury During maintenance Respect of the Environment...
  • Page 190 9.190 N60 ENT M37 SAFETY PRESCRIPTIONS APRIL 2004...
  • Page 191 9.191 APRIL 2004 SAFETY PRESCRIPTIONS N60 ENT M37 SAFETY PRESCRIPTIONS ❏ Do not execute any intervention if not provided with Standard safety prescriptions necessary instructions. Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and ❏...
  • Page 192 ❏ Do not connect any user to the engine electrical equip- force regulating use and exhaust of liquids and engine ment unless specifically approved by IVECO MOTORS. exhaust oil. Provide for adequate board indications and ❏ Do not modify fuel systems or hydraulic system unless organize specific training courses to ensure that person- IVECO MOTORS specific approval has been released.
  • Page 194 IVECO S.p.A. PowerTrain Viale Dell’Industria, 15/17 20010 Pregnana Milanese - MI - (Italy) Tel. +39 02 93.51.01 - Fax +39 02 93.59.00.29 www.ivecomotors.com...

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