Hyundai F4GE9484F*J608 Technical And Repair Manual
  1. Manuals
  2. Brands
  3. Hyundai Manuals
  4. Engine
  5. F4GE9484F*J608
  6. Technical and repair manual
Hyundai F4GE9484F*J608 Technical And Repair Manual

Hyundai F4GE9484F*J608 Technical And Repair Manual

N series f4g tier 3
Hide thumbs
Table of Contents

Advertisement

Quick Links

N SERIES
F4G TIER 3
Agricultural applications (Hyundai)
F4GE9484F*J608
F4GE9454J*J604
Technical and Repair manual

Advertisement

Table of Contents
loading

Related Manuals for Hyundai F4GE9484F*J608

Summary of Contents for Hyundai F4GE9484F*J608

  • Page 1 N SERIES F4G TIER 3 Agricultural applications (Hyundai) F4GE9484F*J608 F4GE9454J*J604 Technical and Repair manual...
  • Page 2 This publication contains data, features, instructions and methods for performing repair interventions on the assembly and its components. This publication is addressed to qualified, specialised person- nel. Check that you have the publication related to the assembly on which you are about to work available before you start. Make sure that you have all the necessary safety apparatuses, such as, for example, protective eyewear, helmet, gloves, foot- wear, etc.
  • Page 3 F4GE N SERIES F4GE N SERIES Part 1 F4GE N Series Print P2D32N010 E Base - Febraury 2009...
  • Page 4 F4GE N SERIES Base - Febraury 2009 Print P2D32N010 E...

  • Page 5: Table Of Contents

    F4GE N SERIES INTRODUCTION Introduction Page PREFACE TO USER’S GUIDELINE MANUAL ..SYMBOLS ....... - Warnings .

  • Page 6: Introduction

    INTRODUCTION F4GE N SERIES Base - Febraury 2009 Print P2D32N010 E...

  • Page 7: Preface To User's Guideline Manual

    F4GE N SERIES INTRODUCTION PREFACE TO USER’S GUIDELINE MANUAL Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents. The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
  • Page 8 INTRODUCTION F4GE N SERIES Removal Intake Disconnection Refitting Exhaust Connection Removal Operation Disassembly Fitting in place ρ Compression ratio Assembly Tolerance Tighten to torque Weight difference Tighten to torque + angle value Rolling torque α Press or caulk Rotation Regulation Angle Adjustment Angular value...

  • Page 9: General Warnings

    F4GE N SERIES INTRODUCTION GENERAL WARNINGS Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks.
  • Page 10 INTRODUCTION F4GE N SERIES Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc. Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside. Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health;...

  • Page 11: General Warnings On The Electric System

    F4GE N SERIES INTRODUCTION GENERAL WARNINGS ON THE ELECTRIC SYSTEM If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated.

  • Page 12: Bonding And Screening

    INTRODUCTION F4GE N SERIES Bonding and screening Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M). Further, following warnings are to be compulsorily observed for electronic components: Electronic central units must be connected to system bonding when they are provided with a metallic shell.

  • Page 13: Conversions Between The Main Units Of Measurement Of The International System And Most Used Derived Quantities

    F4GE N SERIES INTRODUCTION CONVERSIONS BETWEEN MAIN UNITS MEASUREMENT INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES Power 1 kW 1.36 metric HP 1 kW 1.34 HP 1 metric HP = 0.736 kW 1 metric HP = 0.986 HP 1 HP 0.746 kW 1 HP 1.014 metric HP...

  • Page 14: Key Of Lecture Of The Headings And Footnotes

    INTRODUCTION F4GE N SERIES KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES Type of Section Page vehicle title number When month - year update Basic edition referred to Printout Language is present (revi) to the month - year editorial number Publication basic edition phase closing...
  • Page 15 F4GE N SERIES Part 1 F4GE N SERIES Section General specifications Fuel Agricultural applications Overhaul and technical specifications Tools Appendix Safety prescriptions Print P2D32N010 E Base - February 2009...
  • Page 16 F4GE N SERIES Base - February 2009 Print P2D32N010 E...
  • Page 17 F4GE N SERIES UPDATING Section Description Page Date of revision Print P2D32N010 E Base - February 2009...
  • Page 18 F4GE N SERIES Base - February 2009 Print P2D32N010 E...
  • Page 19 F4GE N SERIES SECTION 1 - GENERAL SPECIFICATIONS SECTION 1 General Specifications Page LUBRICATION ......OIL VAPOUR RECIRCULATING SYSTEM .
  • Page 20 SECTION 1 - GENERAL SPECIFICATIONS F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 21: Part

    F4GE N SERIES SECTION 1 - GENERAL SPECIFICATIONS LUBRICATION Lubrication involves the heat exchanger and the turboblower. All these components may often vary according to the specific Lubrication by forced circulation is achieved through oil rotary duty. expansion pump, placed in the front part of the basement, driven by the straight-tooth gear splined to the shaft’s bar hold.

  • Page 22: Example

    SECTION 1 - GENERAL SPECIFICATIONS F4GE N SERIES OIL VAPOUR RECIRCULATING SYSTEM Figure 2 3240t 1. Valve - 2. Breather pipe - 3. Tappet Cap On the tappet cap (3) there is a valve (1) whose duty is to condense oil vapour inducing these to fall down because of gravity, to the Tappet cap underneath.

  • Page 23: Cooling System

    F4GE N SERIES SECTION 1 - GENERAL SPECIFICATIONS - Heat exchanger to cool the lubrication oil: even this COOLING SYSTEM component is part of the engine’s specific equipment. The engine cooling system, closed circuit forced circulation type, generally incorporates the following components: - Centrifugal water pump, placed in the front part of the engine block.

  • Page 24: Air Induction Boost Diagram

    SECTION 1 - GENERAL SPECIFICATIONS F4GE N SERIES AIR INDUCTION BOOST DIAGRAM Boosting version engines Figure 4 TURBOCHARGER AIR FILTER EXHAUST 88208 Description The turbocharger is equipped with a transforming valve to regulate the pressure , that is located on the exhaust collector The turbocharger is composed by the following main parts: before the turbine and connected by piping to the induction one turbine, one transforming valve to regulate the boost...

  • Page 25: Inter-Cooled Engine Version

    F4GE N SERIES SECTION 1 - GENERAL SPECIFICATIONS Inter-cooled engine version Figure 5 TURBOCHARGER AIR FILTER EXHAUST RADIATOR 74195 4 cylinders version Description The turbocharger is composed by the following main parts: The turbocharger is equipped with a transforming valve to one turbine, one transforming valve to regulate the boost regulate the pressure , that is located on the exhaust collector feeding pressure , one main body and one compressor.

  • Page 26: Exhaust Gas Re-Circulation System (Egr)

    SECTION 1 - GENERAL SPECIFICATIONS F4GE N SERIES The internal EGR system is not equipped with any EXHAUST GAS RE-CIRCULATION SYSTEM (EGR) electronically controlled elements: the system is always active. Its configuration does not need additional elements In the TIER 3 version, the profile of the exhaust cam has been i.e.checking valves, piping or heat exchangers.

  • Page 27: Fuel

    F4GE N SERIES SECTION 2 - FUEL SECTION 2 Fuel Page 4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTARY MECHANICAL PUMP ... . - General information ..... - Description of working principles .
  • Page 28 SECTION 2 - FUEL F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 29: General Information

    F4GE N SERIES SECTION 2 - FUEL 4-CYLINDER ENGINES WITH BOSCH VE 4/12 F ROTARY MECHANICAL PUMP General information Fuel feed system is composed by: - Fuel tank (placed on the machine) - Fuel delivery and back-flow to tank - Fuel pre-filter (if available, it is usually placed close to the engine on the machine frame) - Priming pump, assembled to the engine and driven by the camshaft - Fuel filter (assembled to the engine in different positions according to equipment application and duty) - Fuel feed rotary pump...

  • Page 30: Description Of Working Principles

    SECTION 2 - FUEL F4GE N SERIES Figure 2 75807 1. Fuel filter - 2. Feed pipeline from filter to fuel pump - 3. Feed pipeline from priming pump to filter - 4. Priming pump. Description of working principles Fuel is sucked from the fuel tank by the priming pump. This The fuel arrives therefore to the valve gauging the pressure last one is placed on the engine basement and is driven by inside feed pump.

  • Page 31: Feed Pump

    F4GE N SERIES SECTION 2 - FUEL FEED PUMP The rotary type pump is driven by a gear mating the camshaft’s one. Example of identification = Distribution rotary plunger = Pump dimensions = 4 cylinders engine 12 = Distribution plunger in mm. 1150 N°.

  • Page 32: Priming Pump

    SECTION 2 - FUEL F4GE N SERIES PRIMING PUMP This pump has the specific duty to prime the fuel available in the tank and convey it to the feed pump inlet. It is assembled to the engine basement and driven by the camshaft. Figure 4 88209 1.

  • Page 33: Fuel Filter

    F4GE N SERIES SECTION 2 - FUEL FUEL FILTER The filter is assembled close to the feed and priming pump and has the specific duty to provide barrier to the impurities and separation of water from fuel. On the filter cartridge base there is a water dump screw, throughout which it is possible to provide regular drainage; on the bearing for those equipment applications requiring it (cold climate areas), there can be a heater assembled to and a temperature sensor.
  • Page 34 SECTION 2 - FUEL F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 35: Agricultural Applications

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION SECTION 3 Agricultural application Page GENERAL INFORMATION ....CLEARANCE DATA ..... . . PART ONE - MECHANICAL COMPONENTS .
  • Page 36 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Page PART THREE - TROUBLESHOOTING ..PART FOUR - MAINTENANCE PLANNING ... . . MAINTENANCE SCHEDULE .

  • Page 37: Specific Duty

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION GENERAL INFORMATION Figure 1 132103 NEF engines have been designed and developed by FPT NOTE Data, technical specifications and performances specifically for transportation by land and farming equipment granted shall be valid only if the Setter will follow and in general.
  • Page 38 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES CLEARANCE DATA Type F4GE9454J*604 ρ Compression ratio 17.5:1 Max. output (90) (HP) 2200 Max. torque (kgm) (40.0) 1250 Loadless engine idling Loadless engine peak rpm 2430 Bore x stroke 104 X 132 Displacement 4485 SUPERCHARGING...
  • Page 39 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Type F4GE9484F*J608 ρ Compression ratio 17.5:1 Max. output (HP) (101) 2200 Max. torque (kgm) (43.0) 1250 Loadless engine idling Loadless engine peak rpm 2430 Bore x stroke 104 X 132 Displacement 4485...
  • Page 40 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...
  • Page 41 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION PART ONE - MECHANICAL COMPONENTS Print P2D32N010 E Base - February 2009...
  • Page 42 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 43: Overhaul Of The Engine

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION OVERHAUL OF THE ENGINE Figure 3 Preface Part of the operations illustrated within this section 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.
  • Page 44 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 5 Figure 6 75673 75674 - Assemble the second bracket 99361037 throughout the On the left hand side: screw-threaded ports (1). - Disassemble oil filter (1) and bracket as well (for versions - Lift the engine using the rocker arm 99360595 and put with engine oil filter not directly assembled on to the it on the turning stand 99322205.

  • Page 45: Disassembly Of Application Components

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Disassembly of application components - Place a container under the fuel filter and screw out the condense drain faucet underneath said filter. Carry out Figure 7 complete drainage of the fuel contained therein. - Screw out completely the faucet and, using equipment 99360076 disassemble oil filter (1).
  • Page 46 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES BOSCH VE 4/12 F Pump Figure 11 Figure 10 75679 75677 - Disconnect the pipelines (1) and (2) that provide feed and fuel recovery between pump and injectors; screw - Disconnect the LDA pipe (1) from the head and from out the nuts fixing the pipes to the pumping elements;...
  • Page 47 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Figure 13 Figure 15 87409 88102 - Disassemble suction and exhaust manifolds: loosen the - Loosen the two fixing screws (2) and disassemble 8 screws (1) fixing the suction manifold plate to the priming pump (1).
  • Page 48 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 17 Figure 19 123023 - Disassemble thermostat unit; loosen the three fixing 75686 screws (1) and disassemble the thermostat unit (2) - Properly hold the alternator (1) separating it from its together with the bracket (5);...
  • Page 49 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Figure 21 Figure 23 107275 - Loosen the screws (5) and disassemble the oil filter/heat 88140 (2) exchanger bearing (4), interlayer plate (3) and Fit tool 99360330 (2) in the starter motor housing to be able relating gaskets (1).
  • Page 50 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 28 Figure 26 116242 - Loosen the screws (1 and 3) and remove the front cover (2). 78256 NOTE Take note of the screw (1 and 3) assembly position, since the screws have different length. - Remove the engine drive shaft fixing ring from the front cover.
  • Page 51 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION (Demonstrative) Figure 31 Figure 33 84077 75690 - Screw up two medium length screws in the ports (4) to - Loosen the screws (2) and remove the flywheel cover sling the flywheel with a hoist. box (1).
  • Page 52 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 36 Figure 35 99222 - Loosen the screws (1) and disassemble the oil suction 87655 rose pipe (3). - Remove the gear (1) transmitting motion to the ignition - Loosen the screws (2) and remove the stiffening pump and the relevant support.

  • Page 53: Installation Of Rear Components

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Installation of rear components Figure 38 Figure 39 70157 - Loosen the screws (2) and disassemble the timing gearbox (1). 70210 NOTE Take note of the screw (2) assembly position, since DIAGRAM SHOWING SCREW TIGHTENING TO FIX REAR GEARBOX the screws have different length.
  • Page 54 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 42 Figure 40 87653 - Place the dial gauge (1) on the timing gear (2) and check 70211 that the slack between the gears (2) and (3) is included in the range between 0,076 ÷ 0,280 mm. - Use a felt pen to mark the driving gear (1) tooth fitted on the output shaft (2) having the mark (→) for timing on the side surface.
  • Page 55 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Figure 46 Figure 45 122588 84077 DIAGRAM SHOWING SEALING LOCTITE 5205 - Re-assemble the box (1) to the engine basement. APPLICATION - Tighten the fastening screws (2) to the same position detected before disassembly. NOTE It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal.

  • Page 56: Flywheel Installation

    SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Flywheel installation Figure 50 Figure 48 (Demonstration) 75690 - Screw up two hooks or trail rings in the flywheel (1) 84071 threaded ports (4) for handling . - Using a hoist, handle the flywheel to place it in its housing Turn the flywheel until, when pushing the pin 99360616 (1), inside the flywheel cover box.

  • Page 57: Installation Of Front Components

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Installation of front components Figure 55 Figure 52 106549 - Remove the fixing ring (2) from the front cover (1), accurately clean the plug surface. 70220 - Assemble oil pump (1). - Tighten fixing screws (2) and lock them to the prescribed couple.
  • Page 58 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 59 Figure 57 99222 106550 - Assemble the front cover (2) to the block and tighten - Assemble the plate (4), the rose pipe (3), tighten the the screws (1) fixing them to the prescribed couple. fixing screws (1, 2 and 4) and fix them to the prescribed couple.
  • Page 59 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Figure 60 Figure 62 119123 Set the gasket (1) on the oil sump (2). NOTE The shape and the size of the sump vary according to the usage of the engine. 75697 - Assemble the pulley (1) to the engine drive shaft , and the distance ring (3).
  • Page 60 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 64 Figure 66 75686 - Connect the alternator (1) to the support. 122589 - Tighten the screw without locking it (2). - Lubricate the fixing ring (4) using engine oil and place it on the oil filter (2).
  • Page 61 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Figure 68 Figure 70 75705 75688 - Place the head (3) over the block and insert screws (1) - Carry out the assembly of the rocker arms after previous and (2). check of the components. ROCKER ARM UNIT COMPONENTS: 1.
  • Page 62 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 73 Figure 76 122587 Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in 75806 contact with the Rocker Arm adjustment screw and with the tappet (arrows) shall not present evidence of seizure or wear: in case of detection proceed replacing them.
  • Page 63 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Figure 77 Figure 79 75707 - Assemble injectors after having replaced the sealing 123025 gasket (1). - Assemble exhaust manifold (1) providing new gaskets (2). NOTE During assembly of injectors, verify that the injector sphere is correctly positioned on the head housing.
  • Page 64 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 81 Figure 82 75701 - Apply on the surface joining the suction manifold plate 86571 (1) a sufficient coat of Loctite 5999 and provide. fixing the screws to the prescribed couple. - Assemble the pulley fan bearing (8) tightening the screws to the prescribed couple.
  • Page 65 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Figure 83 Figure 84 88102 - Assemble priming pump (1) providing new gasket and tighten the screws (2) to the prescribed couple. - Also assemble feed pump (see specific procedure) and the power take-off underneath. NOTE Pump mounting requires specific procedure contained in this section.

  • Page 66: Operations

    SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 86 Figure 88 75679 123024 - Assemble the fuel filter bearing (4) to the bracket fixed - Assemble the pipes (1) and (2) providing fuel feed and to the engine head. recovery between pump and injectors;...

  • Page 67: Completion Of Engine

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Completion of engine Figure 90 Figure 91 75675 116386 On the right hand side: Proceed assembling the turbocharger: - reassemble the pipes (1) from the union (2) to the - Hold the turbocharger and place it on the exhaust lubrication oil filter (placed on the opposite side): tighten manifold after having interposed the gasket.

  • Page 68: Operations

    SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Figure 93 Figure 94 75673 On the left hand side: - Assemble oil filter (1) together with bracket (for the 87712 versions with engine oil filter not directly assembled to the exchanger); tighten the screws (3) assembling the bracket (4) including filter bearing (5).

  • Page 69: Rotary Feed Pump Disassembly And Assembly Procedure

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Find the top dead centre with the tool (99395097) - False Rotary feed pump disassembly and assembly injector procedure Figure 96 NOTE This procedure prescribes that: - the fuel pipes (from the pumping elements to the injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump) have all been removed;...
  • Page 70 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES BOSCH VE 4/12 F Pump Figure 100 Figure 98 75694 75721 - Unscrew the side screw that locks the pump shaft - From the pump side, loosen the fixing nuts (1) without partially (1) and remove spacer (2).
  • Page 71 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Figure 101 Figure 103 75721 - Loosen screw (1) that prevents pump shaft rotation and 75694 insert spacer (2). Tighten screw (1)so that it locks spacer (2): in this way the supply pump shaft will be able to rotate freely.

  • Page 72: Power Take-Off Disassembly And Assembly Procedure

    SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Feed system bleed procedure Power take-off disassembly and assembly procedure (Demonstration) Figure 105 Figure 106 76211 75720 In case any operation has been executed on the components of the feed circuit, it is necessary to execute bleeding of air within the system.

  • Page 73: Checks And Inspections

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Checks and inspections NOTE The following tests shall be made after engine assembly to the vehicle. Preventively check that the liquid levels have been correctly restored. Start the engine, let it run at revolution regimen slightly higher than idling and wait that the cooling liquid temperature reaches the value enabling thermostat opening, then check that:...
  • Page 74 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 75: Part Two

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION PART TWO - ELECTRICAL EQUIPMENT Print P2D32N010 E Base - February 2009...
  • Page 76 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 77: Electrical Component Layout

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION ELECTRICAL COMPONENT LAYOUT Figure 107 132105 Below there are listed the electric components which are present on F4GE94--- engines. 1. Cooling liquid temperature sensor; 2. Alternator; 3. Starter; 4. (A) Engine STOP solenoid, (B) KSB electromagnet;...

  • Page 78: Cooling Liquid Temperature Sensor

    SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Cooling liquid temperature sensor Starter Figure 108 Figure 109 88314 Starter is usually driven by starting unit placed on the vehicle dashboard and provides positive tension to the tele-switch as- sembled to the starter itself. Specifications: BOSCH 3 kW - 12V KSB Water temperature sensor...

  • Page 79: Electromagnets Assembled To Feed Pump

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Electromagnets assembled to feed pump Alternator Figure 111 Figure 113 75725 It is place front view on the right hand side of the engine, and is driven by tooth belt. Specifications: 75724a Working tension: 12 V Current delivered:...
  • Page 80 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 81: Part Three - Troubleshooting

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION PART THREE - TROUBLESHOOTING Print P2D32N010 E Base - February 2009...
  • Page 82 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...
  • Page 83 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Print P2D32N010 E Base - February 2009...
  • Page 84 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...
  • Page 85 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Print P2D32N010 E Base - February 2009...
  • Page 86 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...
  • Page 87 F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Print P2D32N010 E Base - February 2009...
  • Page 88 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 89: Part Four - Maintenance Planning

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION PART FOUR - MAINTENANCE PLANNING Print P2D32N010 E Base - February 2009...
  • Page 90 SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 91: Maintenance Schedule

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION MAINTENANCE SCHEDULE On purpose to guarantee the right engine use please follow the below indicated maintenance schedule. 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.

  • Page 92: Checks Not Included In Maintenance Planning-Daily Checks

    SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Checks not included in maintenance planning-daily 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. - Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits.

  • Page 93: Check Of Fuel System

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Check of fuel system Lubricating system check The check must be executed both when the engine The check must be executed both when the engine disconnected and when it is running. disconnected and when it is running. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the Verify the presence of any oil leakage or blow-by from the...

  • Page 94: Check Of Drive Belt Tensioning

    SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Check of drive belt tensioning Adjust the slack between rocker arms and valves using socket There is an automatic tensioner which corrects the belt wrench (1), point wrench (3) and feeler gauge (2). tension.

  • Page 95: Fuel Filter Replacement

    F4GE N SERIES SECTION 3 - AGRICULTURAL APPLICATION Fuel filter replacement - After the complete drainage, screw the plug and carry out the clean oil filling. During this operation don’t smoke and don’t use free flames. Use only the recommended oil or oil having the re- Avoid to breathe the vapors coming from filter.

  • Page 96: Alternator Belt Replacement

    SECTION 3 - AGRICULTURAL APPLICATION F4GE N SERIES Alternator belt replacement Warning: with switched off motor (but still hot) the belt can operate without advance notice. Wait for the motor temperature lowering to avoid very serious accidents. Figure 118 88544 - By means of a square wrench of proper size act on point A, indicated on the figure, of the automatic belt tightener (1) and release the pressure.

  • Page 97: Operations

    F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS SECTION 4 Overhaul and technical specifications Page GENERAL SPECIFICATIONS ....CLEARANCE DATA ..... . . TABLE OF PRE-DELIVERY VALUES FOR BOSCH INJECTION PUMPS VE 4/12 F .
  • Page 98 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Page Page CYLINDER HEAD ......- Piston pins .

  • Page 99: General Specifications

    F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS GENERAL SPECIFICATIONS Type 4 CYLINDERS Cycle Four-stroke diesel engine Power See properties described in Section 3 Injection Direct Number of cylinders ∅ Bore Stroke +.. = Total displacement 4485 TIMING start before T.D.C.
  • Page 100 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES CLEARANCE DATA Type 4 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS ∅ 1 104.000 to 104.024 ∅1 Cylinder barrels Spare pistons ∅ 1 type: Size 55.9 ∅ 1 Outside diameter 103.714 to 103.732 ∅...
  • Page 101 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Type 4 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS 2.705 to 2.735 Split ring slots 2.440 to 2.460 4.030 to 4.050 * measured on a ∅ of 99.00 mm 2.560 to 2.605 Split rings 2.350 to 2.380 3.970 to 3.990...
  • Page 102 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Type 4 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS 82.990 ÷ 83.010 ∅ 1 Journals 68.987 ÷ 69.013 ∅ 2 Crankpins ∅ ∅ Main half bearings 2.456 to 2.464 Big end half bearings 1.955 to 1.968 Main bearings ∅...
  • Page 103 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Type 4 CYLINDERS CYLINDER HEAD — TIMING SYSTEM ∅ 1 Valve guide seats on ∅ 1 cylinder head 8.019 to 8.039 ∅ Valves: ∅ 4 7.960 to 7.980 α 60º ∅...
  • Page 104 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Type 4 CYLINDERS CYLINDER HEAD — TIMING SYSTEM Valve spring height: free spring 63.50 / 65.69* under a load equal to: 329 N 49.02 641 N 38.20 Injector protrusion Camshaft bush housings No.
  • Page 105 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Type 4 CYLINDERS CYLINDER HEAD — TIMING SYSTEM ∅ 1 Tappet cap housing ∅ 1 on block 16.000 to 16.030 ∅ 2 Tappet cap outside ∅ ∅ 2 diameter: 15.929 to 15.959 ∅...

  • Page 106: Table Of Pre-Delivery Values For Bosch Injection Pumps Ve 4/12 F

    F4GE9454F*J604 4-CYLINDER ENGINES 4-CYLINDER ENGINES 0.8 ± 0.05 F4GE9484F*J608 NOTE INJECTION PUMP CALIBRATION Overhaul and calibration interventions are up to BOSCH assistance network. The contract technical specification containing the data to calibrate the pump at the bench is identified by the code shown on injection pump body and is available at BOSCH technical assistance network.
  • Page 107 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS ENGINE OVERHAUL Figure 3 ENGINE REMOVAL AT THE BENCH The following instructions are prescribed on the understanding that the engine has previously been placed on the rotating bench and that removal of all specific components of the equipment have been already removed as well.

  • Page 108: Repair Operations

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES REPAIR OPERATIONS Figure 6 CYLINDER UNIT Checks and measurements Figure 9 70163 Remove the screws (1) and disconnect camshaft (3) retaining plate (2). 70166 NOTE Take note of plate (2) assembling position. Once engine is disassembled, clean accurately the cylinder-block assembly.

  • Page 109: Checking Head Supporting Surface On Cylinder Unit

    F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS 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 α...

  • Page 110: Timing System

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES TIMING SYSTEM Camshaft Figure 12 70169 CAMSHAFT MAIN DATA Specified data refer to pin standard diameter Camshaft pin and cam surfaces shall be absolutely smooth; BUSHES if they show any traces of seizing or scoring replace the camshaft and the bushes.
  • Page 111 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 15 Sec. A-A 107399 CAMSHAFT BUSH AND HOUSING MAIN DATA * Value to be obtained after driving the bushes. Print P2D32N010 E Base - February 2009...

  • Page 112: Fitting Tappets - Camshaft

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Bush replacement Fitting tappets — camshaft Figure 18 Figure 16 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 using the beater 99360362 (2) and the handgrip 99370006 Figure 19 (3).

  • Page 113: Output Shaft

    F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS OUTPUT SHAFT Figure 21 Measuring journals and crankpins Figure 23 70179 Check camshaft end float (1). It shall be 0.23 ± 0.13 mm. 70182 Grind journals and crankpins if seizing, scoring or excessive Figure 22 ovalisation are found.
  • Page 114 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Figure 25 measured on > 45.5 mm radius between adjacent journals 70183 OUTPUT SHAFT MAIN TOLERANCES TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL Roundness ○ SHAPE SHAPE Cilindricity /○/ Parallelism Verticality DIRECTION Straightness POSITION Concentricity or coaxiality...

  • Page 115: Replacing Oil Pump Control Gear

    F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Finding journal clearance Replacing oil pump control gear Figure 28 Figure 26 70161 Refit the output shaft (2). 70184 Check the backlash between output shaft main journals and Check that gear toothing (1) is not damaged or worn, the relevant bearings as follows: otherwise remove it using the proper puller (3).

  • Page 116: Checking Output Shaft Shoulder Clearance

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Checking output shaft shoulder clearance Figure 30 Figure 32 70187 Tighten the pre-lubricated screws (1) in the following three successive stages: 70190 stage, with dynamometric wrench to 50 ± 6 Nm. This check is performed by setting a magnetic-base dial gauge stage, with dynamometric wrench to 80 ±...
  • Page 117 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 34 Figure 35 126311 126312 The circlips (2) retaining the gudgeon pin are removed using Remove split rings (2) from piston using pliers 99360183 (1). round-nose pliers (1). Figure 36 87730 MAIN DATA CONCERNING KS.
  • Page 118 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Piston pins Figure 40 Figure 37 18857 128140 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 119: Connecting Rods

    F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 42 Figure 44 70194 Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3). Connecting rods Figure 43 80339 NOTE Every connecting rod is marked as follows:...
  • Page 120 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Bushes Figure 47 Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen. Otherwise replace. Removal and refitting shall be performed using the proper beater.
  • Page 121 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 49 Figure 51 70202 DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL - Split ring openings shall be displaced with each other by 70200 120°; - connecting rod-piston assemblies shall have the same Fit half bearings (1) on connecting rod and cap.
  • Page 122 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Figure 53 Figure 55 α 70204 70207 - Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the dynamometric If a different clearance value is found, replace the half bearings wrench (2).
  • Page 123 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS CYLINDER HEAD Figure 58 Removing the valves Figure 57 75751 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 75750 cap (3) and the springs (4).
  • Page 124 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Checking cylinder head wet seal Figure 61 Figure 60 0,4 C 0,025 / ¯ 25,4 0,4 TOTAL 0,01 / ¯ 50 75756 75753 The rated thickness A for the cylinder head is 95 ± 0.25 mm, This check shall be performed using the proper tools.
  • Page 125 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VALVES Figure 64 Figure 62 EXHAUST INTAKE VALVE VALVE 18882 Check the valve stem (1) using a micrometer (2), it shall be 7.943 to 7.963. 116395 INTAKE AND EXHAUST VALVE MAIN DATA Removing carbon deposits, checking and grinding valves Checking clearance between valve stem and...

  • Page 126: Valve Guide

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES VALVE GUIDE VALVE SEATS Regrinding — replacing the valve seats Figure 66 Figure 67 75754 Check the valve seats (2). If slight scoring or burnout is found, INTAKE EXHAUST 70328 regrind seats using adequate tool (1) according to the angle values shown in Figure 68.
  • Page 127 F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS FITTING CYLINDER HEAD Figure 69 Figure 71 75758 After regrinding, check that valve (3) sinking value is the 75759 specified one by using the base 99370415 (2) and the dial gauge 99395603 (1).
  • Page 128 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES Refitting the cylinder head NOTE Before using the fixing screws again, measure them Figure 73 twice as indicated in the picture, checking D1 and D2 diameters: if D1 - D2 < 0,1 mm the screw can be utilised again; if D1 - D2 >...

  • Page 129: Tightening Torque

    F4GE N SERIES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS TIGHTENING TORQUE TORQUE COMPONENT COMPONENT 15 ± 3 1.5 ± 0.3 Cooling Nozzles (M8x1.25x10) 50 ± 6 5.0 ± 0.6 Main bearing cap 1st stage 80 ± 6 8.0 ± 0.6 2nd stage 90º...
  • Page 130 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS F4GE N SERIES TORQUE COMPONENT COMPONENT 77 ± 12 7.7 ± 1.2 Rear lifting bracket (M12x1.75x30) 110 ± 5 11.0 ± 0.5 Crankshaft pulley (M12x1.75x10.9) Flywheel housing 85 ± 10 8.5 ± 1.0 (M12x120) 85 ±...
  • Page 131 F4GE N SERIES SECTION 5 - TOOLS SECTION 5 Tools Page TOOLS ........Print P2D32N010 E Base - February 2009...
  • Page 132 SECTION 5 - TOOLS F4GE N SERIES Base - February 2009 Print P2D32N010 E...
  • Page 133 F4GE N SERIES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION Revolving stand for overhauling units (1000 daN capacity, 120 daN/m 99322205 torque) 99340035 Injection pump gear extractor 99340055 Tool to remove output shaft front gasket 99340056 Tool to remove output shaft rear gasket 99340205 Injector pull-our tool 99346252...
  • Page 134 SECTION 5 - TOOLS F4GE N SERIES TOOL NO. DESCRIPTION 99346253 Tool for fitting output shaft rear gasket 99360076 Tool to remove oil filter (engine) 99360183 Pliers for removing/refitting piston rings (65 — 110 mm) 99360268 Tool for removing/refitting engine valves 99360330 Flywheel crank handle 99360344...

  • Page 135: Base - February

    F4GE N SERIES SECTION 5 - TOOLS TOOL NO. DESCRIPTION 99360351 Tool for stopping the engine flywheel Beater for removing/refitting camshaft bushes (to be used with 99360362 99370006) 99360500 Tool for lifting the output shaft 99360595 Lifting rig for engine removal/refitting 99360605 Band for fitting piston into cylinder barrel (60 —...
  • Page 136 SECTION 5 - TOOLS F4GE N SERIES TOOL NO. DESCRIPTION 99361037 Brackets for fastening engine to revolving stand 99322205 99363204 Tool to remove gaskets 99370006 Interchangeable willow handgrip 99370415 Gauge base for different measurements (to be used with 99395603) 99395097 Tool to check top dead centre (use with 99395604) Dial gauge holder for rotary injection pump timing (use with 99395100...
  • Page 137 F4GE N SERIES SECTION 5 - TOOLS TOOL NO. DESCRIPTION Pair of gauges with ½” and ¾” square head for angle tightening 99395216 99395603 Dial gauge (0 — 5 mm) 99395604 Dial gauge (0 — 10 mm) 99395682 Diesel fuel engine cylinder compression control device Print P2D32N010 E Base - February 2009...
  • Page 138 SECTION 5 - TOOLS F4GE N SERIES Base - February 2009 Print P2D32N010 E...
  • Page 139 F4GE N SERIES APPENDIX Appendix Page SAFETY PRESCRIPTIONS ....Print P2D32N010 E Base - February 2009...
  • Page 140 APPENDIX F4GE N SERIES Base - February 2009 Print P2D32N010 E...

  • Page 141: Operations

    F4GE N SERIES APPENDIX - Do not execute any intervention if not provided with SAFETY PRESCRIPTIONS necessary instructions. Standard safety prescriptions Particular attention shall be drawn on some precautions that - Do not use any tool or equipment for any different must be followed absolutely in a standard working area and operation from the ones they’ve been designed and whose non fulfillment will make any other measure useless...
  • Page 142 APPENDIX F4GE N SERIES - Avoid incorrect tightening or out of couple. Danger: Respect of the Environment incorrect tightening may seriously damage engine’s - Respect of the Environment shall be of primary components, affecting engine’s duration. importance: all necessary precautions to ensure - Avoid priming from fuel tanks made out of copper alloys personnel’s safety and health shall be adopted.

This manual is also suitable for:

F4ge9454j*j604

Table of Contents