Iveco VECTOR Series Technical And Repair Manual
  1. Manuals
  2. Brands
  3. Iveco Manuals
  4. Engine
  5. VECTOR Series
  6. Technical and repair manual

Iveco VECTOR Series Technical And Repair Manual

Industrial application
Hide thumbs
Table of Contents

Advertisement

Quick Links

VECTOR SERIES
Industrial application
VECTOR 8
Technical and Repair manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the VECTOR Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Iveco VECTOR Series

Summary of Contents for Iveco VECTOR Series

  • Page 1 VECTOR SERIES Industrial application VECTOR 8 Technical and Repair manual...
  • Page 2 Produced by: Publication edited by Iveco Motors Iveco SpA PowerTrain Mkt. Advertising & Promotion B.U. TECHNICAL PUBLISHING Viale dell’Industria, 15/17 20010 Pregnana Milanese Iveco Technical Publications Milano (Italy) Lungo Stura Lazio, 15/19 Print P2D32V001E - Ed. 04.2006 10156 Turin - Italy...
  • Page 3 VECTOR ENGINES PRELIMINARY REMARKS 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 4: Vector Engines

    Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable containers. Worn out, damaged or consumable parts must be replaced by IVECO Motors original spares. During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.

  • Page 5: General Warnings

    Before washing under pressure mechanical parts, protect electric connectors, and central units, if present. Tightening screws and nuts must always be according to prescriptions; IVECO Motors commercial and assistance network is available to give all clarifications necessary to perform repair interventions not provided in this document.
  • Page 6 Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses. Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding, bonding, etc.) comply with IVECO Motors system and are carefully recovered after repair or maintenance interventions.
  • Page 7 VECTOR ENGINES 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 8 Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling directives issued by IVECO Motors. It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in order to simplify and normalise the electrical intervention that is care of preparation personnel.
  • Page 9 VECTOR 8 ENGINES VECTOR 8 ENGINES Section General specifications Fuel Industrial application Overhaul and technical specifications Tools Appendix Safety prescriptions PREFACE TO USER’S GUIDELINE MANUAL Section 1 describes the VECTOR engine illustrating its featu- res and working in general. Section 2 describes the type of fuel feed. Section 3 relates to the specific duty and is divided in four sepa- rate parts: 1.
  • Page 10 VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...
  • Page 11 VECTOR 8 ENGINES SPECIAL REMARKS Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see next page) instead of giving descriptions of some operations or procedures. Example ∅ Ø...
  • Page 12 VECTOR 8 ENGINES SYMBOLS - ASSISTANCE OPERATIONS 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...
  • Page 13 VECTOR 8 ENGINES UPDATING Section Description Page Date of revision Print P2D32V001E Base - April 2006...
  • Page 14 VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 15: Table Of Contents

    VECTOR 8 ENGINES SECTION 1 - GENERAL SPECIFICATIONS SECTION 1 General specifications Page CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE ..LUBRICATION ......OPERATING PRINCIPLE .

  • Page 16: Section 1 - General Specifications

    SECTION 1 - GENERAL SPECIFICATIONS VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 17: Correspondence Between Technical Code And Commercial Code

    VECTOR 8 ENGINES SECTION 1 - GENERAL SPECIFICATIONS CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE Open Technical Code Commercial Code FVAE2885X*F100 VECTOR 8 TE2 FVAE2884A*B201 FVAE2884A*B200 FVKE2887A*A200 Print P2D32V001E Base - April 2006...
  • Page 18 SECTION 1 - GENERAL SPECIFICATIONS VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 19: Lubrication

    VECTOR 8 ENGINES SECTION 1 - GENERAL SPECIFICATIONS LUBRICATION The forced feed lubrication is produced by the following components: - oil pump with rotors, housed in the rear part of the crankcase inside the sump. It is driven by a helical toothed gear fitted on the crankshaft.The pump casing contains an oil pressure regulation valve. - water/oil heat exchanger.
  • Page 20 SECTION 1 - GENERAL SPECIFICATIONS VECTOR 8 ENGINES Figure 3 103278 1. Oil pump - 2. Water/oil heat exchange - 3. Oil filter support - 4. Relief pressure valve (piston cooler) - 5. Relief pressure valve (Engine oil pressure system). Base - April 2006 Print P2D32V001E...

  • Page 21: Oil Vapour Recirculation - Blow-By Filter

    VECTOR 8 ENGINES SECTION 1 - GENERAL SPECIFICATIONS Oil vapour recirculation - blow-by filter The oil vapours produced by the lubrication of the moving parts are directed via the pipe (3) and then are collected and filtered in the blow - by (1). In the blow-by, some of the vapours condense and return to the oil sump via the pipe (2), whilst the remaining vapours are recirculated in the intake.

  • Page 22: Engine Cooling

    SECTION 1 - GENERAL SPECIFICATIONS VECTOR 8 ENGINES ENGINE COOLING The cooling system is reponsible for cooling the engine casing and the engine lubrication oil inside the heat exchanger (2). From the circulation pump (1), the coolant is sent to the heat exchanger (2) where the engine lubrication oil is cooled. From here the coolant reaches the engine block and, after having cooled the cylinders, is sent to the thermostat casing.

  • Page 23: Cooling System Assembly

    VECTOR 8 ENGINES SECTION 1 - GENERAL SPECIFICATIONS COOLING SYSTEM ASSEMBLY Figure 7 112492 1. Thermostat casing - 2. Radiator - 3. Coolant circulation pump - 4. Cooling fan. Coolant coming from the cooling radiator being drawn into the pump. Coolant coming from the engine block passing through the thermostat casing (temperature <...

  • Page 24: Variant For Applications With Brake Air Compressor

    SECTION 1 - GENERAL SPECIFICATIONS VECTOR 8 ENGINES VARIANT FOR APPLICATIONS WITH BRAKE AIR COMPRESSOR Figure 8 103509 Rif. Description Circulation pump Engine lubrication water/oil heat exchanger Air system compressor (for DRAGON applications) Base - April 2006 Print P2D32V001E...

  • Page 25: Air/Air Intercooler System

    VECTOR 8 ENGINES SECTION 1 - GENERAL SPECIFICATIONS AIR/AIR INTERCOOLER SYSTEM (DRAGON, G-DRIVE AND GRIFFON APPLICATIONS) Figure 9 112484 1. Air filter - 2. Turbochargers - 3. Heat exchanger (air/air intercooler) Air drawn in by the filters and sent to the turbochargers. Air drawn in from the heat exchanger (air/air intercooler) to the main intake manifold and from there to the bank intake manifolds.

  • Page 26: Air / Water Intercooler System

    SECTION 1 - GENERAL SPECIFICATIONS VECTOR 8 ENGINES AIR / WATER INTERCOOLER SYSTEM (SPRINKLER APPLICATIONS) Figure 10 112488 Intake air and hot compressed air Cold compressed air Exhaust 1. Heat exchanger (air/water intercooler) - 2. Turbochargers Base - April 2006 Print P2D32V001E...

  • Page 27: Supercharging

    VECTOR 8 ENGINES SECTION 1 - GENERAL SPECIFICATIONS SUPERCHARGING The exhaust fumes are directed to the turbocharger (1) which rotates the section which draws in the air from the filters and compresses it (with a consequent increase in temperature). The hot compressed air is directed to the inside of the heat exchanger (air/air intercooler) in which it is cooled and sent to the intake manifolds and to the inlet valves.
  • Page 28 SECTION 1 - GENERAL SPECIFICATIONS VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...
  • Page 29 VECTOR 8 ENGINES SECTION 2 - FUEL SECTION 2 Fuel Page HIGH—PRESSURE ELECTRONIC INJECTION FUEL SYSTEM (COMMON RAIL) ..- General Information ....- Description of the system .
  • Page 30 SECTION 2 - FUEL VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 31: High-Pressure Electronic Injection

    VECTOR 8 ENGINES SECTION 2 - FUEL HIGH—PRESSURE ELECTRONIC INJECTION FUEL SYSTEM (COMMON RAIL) General Information Reducing emissions and fuel consumption requires a high level of precision and high injection pressures. The common rail system makes it possible to inject fuel at pressures of up to 1600 bar, while the injection precision, obtained with an electronic control module (ECM), (also called electronic control unit, ECU) optimises the operation of the engine, limiting emissions and consumption.
  • Page 32 SECTION 2 - FUEL VECTOR 8 ENGINES Pressure sensors The pressure sensors are used to notify the electronic control unit of the oil pressure values (reference 3, Figure 1), the atmospheric pressure (reference 5, Figure 1) and the turbo outlet air pressure (reference 13, Figure 1). Temperature sensors These are NTC type sensors and are used to notify the electronic control unit of the operating temperatures of the engine coolant (reference 1, Figure 1), the engine oil (reference 2, Figure 1), the fuel (reference 6, Figure 1) and the heat exchanger outlet air...

  • Page 33: Operation

    VECTOR 8 ENGINES SECTION 2 - FUEL OPERATION The fuel system consists of a low pressure part and a high pressure part. The low pressure pump (LPP) (no.7) is located on the left side of the engine and it sucks the fuel from the fuel tank. The fuel drawn in by the low pressure pump enters the pre-filter (5) where the water and the larger particles of impurities, that may be present, are separated out.
  • Page 34 SECTION 2 - FUEL VECTOR 8 ENGINES The fuel system is composed of a low—pressure circuit and a high—pressure circuit. The high—pressure circuit is composed of the following pipes: - pipe connecting the high—pressure pump outlet to the common rail; - pipes connecting the electro—injectors to the common rail.
  • Page 35 VECTOR 8 ENGINES SECTION 2 - FUEL Figure 4 103513 DIAGRAM SHOWING PIPES FOR DRAGON / GRIFFON APPLICATIONS Rif. Description Injector Common rail pressure relief valve Pressure sensor Common rail Diesel pre-filter High pressure pump Low pressure pump Fuel filters (depending on the application) Print P2D32V001E Base - April 2006...

  • Page 36: Fuel System Diagram

    SECTION 2 - FUEL VECTOR 8 ENGINES Fuel system diagram Figure 5 103269 1. High—pressure pump — 2. Rail pressure valve — 3. Pressure sensor — 4. Common rail — 5. Clogging sensor on fine fuel filters — 6. Fuel filter/s (*) — 7. Low—pressure pump — 8. Pre—filter with pre—heating element and priming pump — 9.

  • Page 37: Main Mechanical Components Of The Fuel System

    VECTOR 8 ENGINES SECTION 2 - FUEL Main mechanical components of the fuel system Fuel pre-filter for G-DRIVE and SPRINKLER applications The fuel pre—filter, a water separation type, has the water sensor (4) at the base of the cartridge (3) to indicate if there is water in the fuel.

  • Page 38: Fuel Pre-Filter For Dragon And Griffon Applications

    SECTION 2 - FUEL VECTOR 8 ENGINES Fuel pre-filter for DRAGON and GRIFFON applications The high water separation type fuel pre-filter has a sensor (5) at the base of the cartridge (4) that signals the presence of water to be drained. There is a manual priming pump (2) and an air breather jet (7) on the filter mounting (1).

  • Page 39: Fuel Filter For G-Drive And Sprinkler Applications

    VECTOR 8 ENGINES SECTION 2 - FUEL Fuel filter for G-DRIVE and SPRINKLER applications The fuel filter (1) is fitted in the circuit between the high pressure pump and the low pressure pump behind the engine management control unit. The bleed screw (2), the diesel pressure sensor (3) and the diesel temperature sensor (4) are located on the mounting. Figure 8 103477 1.

  • Page 40: Fuel Filters For Dragon And Griffon Applications

    SECTION 2 - FUEL VECTOR 8 ENGINES Fuel filters for DRAGON and GRIFFON applications The fuel filters (1) are located in the circuit between the low pressure pump and the high pressure pump. The bleed screws and the filter blockage sensor (2) are located on the mounting. Figure 9 83422 1.

  • Page 41: Low Pressure Pump For G-Drive, And Sprinkler Applications

    VECTOR 8 ENGINES SECTION 2 - FUEL Low pressure pump for G-DRIVE, and SPRINKLER applications The low pressure pump (1) (LPP) is fitted on the rear of the gear casing through the flange (3). It receives power through the coupling (2) which meshes with the front teeth of the pump gear for the engine cooling circuit. It has the task of pumping the fuel at low pressure to the high pressure pump.

  • Page 42: Low Pressure Pump For Dragon Applications

    SECTION 2 - FUEL VECTOR 8 ENGINES Low pressure pump for DRAGON applications The mechanical low pressure pump (1) is fitted axially behind the braking system air compressor (2), if fitted. Otherwise, it is fitted directly on the rear part of the gear casing. It has the task of pumping fuel at low pressure to the high pressure pump.

  • Page 43: High-Pressure Pump

    VECTOR 8 ENGINES SECTION 2 - FUEL High—pressure pump The high—pressure pump (1) is located in the centre of the V—block and is secured to the rear gear housing of the engine. Drive is provided by gears directly from the camshaft. It receives the supply to the inlet (3) and, after compressing it, delivers it to the rails via outlets (4) and (9).

  • Page 44: High Pressure Pump Operating Principle

    SECTION 2 - FUEL VECTOR 8 ENGINES High pressure pump operating principle Figure 13 103246 103245 1. Outlet for supply to the rail — 2. Rail supply valve — 3. Pumping element — 4. Pump shaft — 5. Pumping supply duct — 6.
  • Page 45 VECTOR 8 ENGINES SECTION 2 - FUEL The pumping element (5) is oriented on the cam on the pump shaft. In the suction phase, the pumping element is fed through the supply line (3). The amount of fuel to send to the pumping element is decided by the pressure regulator (7).
  • Page 46 SECTION 2 - FUEL VECTOR 8 ENGINES Pressure relief valve 5 bar Mounted in parallel with the pressure regulator, its function is to keep the pressure at the regulator inlet constant, which is necessary for the system to work properly. When the pressure at the inlet of the regulator exceeds 5 bar, the relief cylinder (8, Figure 16), will begin to open in order to lead the additional fuel to the outlet.
  • Page 47 VECTOR 8 ENGINES SECTION 2 - FUEL Pressure regulator and 5 bar pressure relief valve at max. fuel delivery Figure 16 81386 1. Coil — 2. Core — 3. Pre—loading spring — 4. Shutter — 5. High—pressure pump supply — 6. Fuel inlet (from the filter) — 7. Fuel return from the high—pressure pump —...
  • Page 48 SECTION 2 - FUEL VECTOR 8 ENGINES Pressure regulator and 5 bar pressure relief valve in regulation mode Figure 17 81387 1. Coil — 2. Core — 3. Pre—loading spring — 4. Shutter — 5. High—pressure pump supply — 6. Fuel inlet (from the filter) — 7. Fuel return from the high—pressure pump —...

  • Page 49: Rail

    VECTOR 8 ENGINES SECTION 2 - FUEL Rail (pressure accumulator) Figure 18 81388 RAIL FOR G-DRIVE / DRAGON / SPRINKLER APPLICATIONS 112490 RAIL FOR GRIFFON APPLICATION 1. Common rail (one for each row) — 2. Flow limiters — 3. Fuel inlet from the high—pressure pump (one for each common rail) —...
  • Page 50 SECTION 2 - FUEL VECTOR 8 ENGINES Single—stage pressure relief valve (item 5, Figure 18) Fitted at one end of the rail, its function is to protect the system’s components if any malfunctioning of the rail pressure sensor or of the pump pressure regulator causes an excessive increase in the pressure of the high—pressure system. The valve is a mechanical type and when the pressure in the high—pressure system reaches 1850 bar the valve opens to run fuel off into the outlet line and accordingly reduce the pressure to acceptable values.
  • Page 51 VECTOR 8 ENGINES SECTION 2 - FUEL Figure 20 89672 1. Body - 2. Piston - 3. Fuel inlet - 4. Spring - 5. Part bolted onto the common rail The flow of fuel from the common rail to the injectors takes place via the ports in the small diameter of the piston. In normal conditions, the pressure of the fuel is exerted on both sides of the piston, maintained by the spring in the opening position If there is a substantial loss in pressure downstream of the limiter, the inlet pressure becomes predominant and...

  • Page 52: Electro-Injector

    SECTION 2 - FUEL VECTOR 8 ENGINES Electro—injector The high—pressure pump keeps the delivery fuel pressure constantly high, irrespective of the phase and the cylinder that must receive the injection and it accumulates the fuel in the common rail and piping to all the electro—injectors. At the electro—injector inlet there is therefore always fuel available at the injection pressure calculated by the engine’s electronic control unit (ADEM III).
  • Page 53 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION SECTION 3 Industrial application Page GENERAL SPECIFICATIONS ....- Clearance data - 8 cyl....PART ONE - MECHANICAL COMPONENTS .
  • Page 54 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Page Page SECOND PART - ELECTRICAL EQUIPMENT ....CHANGING AN INJECTOR ....LOCATION OF COMPONENTS ON THE ENGINE CHANGING BLOW-BY FILTER .

  • Page 55: General Specifications

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION GENERAL SPECIFICATIONS Figure 1 103260 G-DRIVE application Print P2D32V001E Base - April 2006...
  • Page 56 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Figure 2 103503 DRAGON application Base - April 2006 Print P2D32V001E...
  • Page 57 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 3 112503 SPRINKLER application Print P2D32V001E Base - April 2006...
  • Page 58 - Diagnosis section; prescriptions provided by Iveco Motors. - Section of preventive maintenance operations, providing Furthermore, the users assembled by the setter instructions for the execution of the main operations.

  • Page 59: Clearance Data - 8 Cyl

    Data, features and performances are valid only if the technician fully complies with all the installation requirements provided by Iveco Motors. Furthermore, the use of the unit after overhaul showd conform to the original specified power and engine rev/min for which the engine has been designed.
  • Page 60 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 61: Part One

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION PART ONE - MECHANICAL COMPONENTS Print P2D32V001E Base - April 2006...
  • Page 62 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 63: Engine Overhaul

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION ENGINE OVERHAUL Figure 1 103226 Preface Figure 2 NOTE All operations of Engine disassembly operations as well as overhaul operations must be executed by qualified technicians provided with the specific tooling and equipment required. The following information relates to the engine overhaul operations only for what concerns the different components customising the engine, according to its specific duties.
  • Page 64 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Figure 3 112865 Figure 4 - Remove the engine wiring: disconnect the wiring from coolant temperature sensor (1), sensors (2 and 14), XJ2 connector from ADEM III (4), atmospheric pressure 103227 sensor (5), fuel temperature sensor (6), electro injector - Remove the diesel filter (1) using tool 99360091.
  • Page 65 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 7 Figure 5 103479 89790 - Loosen the rail check u-bolt (4) fixing screws. - Remove the pipes (1) to the blow-by filter (2) from the - Disassemble the assembly of the delivery pipes (1) from flywheel side.
  • Page 66 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Figure 11 Figure 9 103229 - Remove the pipe (1) which connects the pump to the water/oil heat exchanger fitted between the two banks 89792 and remove the hose (2) between the thermostat body - Inspect the hydraulic pump and especially the state of and the elbow connector on the pump.
  • Page 67 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION For G-DRIVE, GRIFFON and SPRINKLER applications NOTE Recover the universal joint (1), checking its state of Figure 12 wear. - After firmly securing the compressor in a vice, remove the gear (2) by unscrewing the nut (3) and using a specific extractor.
  • Page 68 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES For G-DRIVE, DRAGON and GRIFFON applications For SPRINKLER applications Figure 19 Figure 18 83499 - Remove the manifold (1) between the turbo—blower (2) and the intercooler (3), loosening the clamp (4) on the manifold and on the turbo—blower .
  • Page 69 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 21 114242 - Proceed as follows: Figure 22 Undo the screws of the collars (1) securing the pipes (2) to the intake ducts. Undo bolts (3) securing fastening collars (9) that join pipes (2) to fittings (4) on the engine blocks by means of gaiters (10).
  • Page 70 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Figure 23 103190 - Unscrew the fixing screws and remove the water outlet Figure 24 pipes (1) from the heads. - Remove the thermostat casing (5). NOTE Separate the screws appropriately, marking their placement to facilitate assembly.
  • Page 71 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 26 Always change the O—ring in the assembly phase. NOTE Lubricate the O-rings with vaseline before installating Figure 29 82216 - From the front side disassemble the engine oil filter supports (1) including the oil temperature transmitters (2), the pressure sensor (5), the seal (4) and the filter clog sensor (3).
  • Page 72 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Figure 31 - At the front, undo the 8 botls (1) and remove the pulley (2), the damper flywheel (3) and the counter-weight (4). Figure 34 103191 - Fit tool 99368502 (1) and place the fixed spanner (2) as shown in the diagram to prevent the rotation of the flywheel during the dismantling of the pulley and the damper flywheel on one side and the actual flywheel on...
  • Page 73 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 35 Figure 37 103194 82228 - From the inside of the flywheel box prevent flywheel - Fit the tool 99368513 (1) and extract the rear oil seal (2). rotation by using rotation tool 99368502 (1) and fixed wrench (2).

  • Page 74: Installation Of Components For The Application

    DIAGRAM SHOWING TIGHTENING ORDER FOR BOLTS FIXING FLYWHEEL COVER CASING ON G-DRIVE APPLICATION Figure 41 103197 - Form a bead of IVECO 2992692 sealant as shown in the figure. 83507 DIAGRAM SHOWING TIGHTENING ORDER FOR A perfect seal is only obtained by carefully cleaning BOLTS FIXING FLYWHEEL CASING COVER FOR the surface to seal.

  • Page 75: Fitting The Rear Oil Seal

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Fitting the rear oil seal Fitting the engine flywheel Figure 42 Figure 44 00901t - Apply tool 99368511 part (6) to the rear output shaft tang (5), secure it with screws (4) and fit the new sealing 83436 ring (3).
  • Page 76 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Figure 46 82246 NOTE If the screws turn out to have been removed previously, check the stated diameter: if the diameter ”d” turns out to be < 23.5 mm. Tightening: pre—torque + angle Pre—torque = 350 Nm Angle 120°...

  • Page 77: Fitting The Gearbox

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Fitting the gearbox Figure 47 103193 - Check the dimensions of the parts removed, examining Figure 49 their state of wear. NOTE Replace all the seals and O-rings. Figure 48 82250 - In addition, check the state of wear of both the bearings and the gears.
  • Page 78 - Check the state of the contact surface of the shaft and its dimensions. Blow compressed air into the bearing lubrication passage to remove any debris. - After applying a bead of IVECO 45500318 sealant onto the contact surface of the crankcase with the gearbox, position the box.

  • Page 79: Rods

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION RODS Figure 56 Figure 53 82261 82721 The valve pushrods must be free from distortion; the cup - Install rods (1), rocker arm supports (2) with rocker arms seatings for the adjustment screws and the ball ends locating and bridges (3).

  • Page 80: Adjusting Operating Clearance Between Valves And Rockers

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Adjusting operating clearance between valves Figure 57 and rockers Figure 59 89827 81603 - Unscrew the three fixing nuts of the cover of the box - Undo the three nuts fixing the flywheel cover casing that covers the flywheel (on the opposite side of the cover (side opposite the starter motor).
  • Page 81 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 60 Figure 63 82722 83505 - Using the wrench 99368503 (4), loosen the check nut - To obtain cylinder no.1 or no.6 in T.D.C. conditions it is (1) of the adjuster screw (2). necessary to position the damping flywheel as indicated - Insert the tappet feeler gauge (0,50 mm) 99368545 (3).

  • Page 82: Fitting The Cylinder Head Tappet Covers

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Fitting the cylinder head tappet covers Fitting the injectors Figure 65 Figure 66 82256 82219 - Clean the injector seat (1) thoroughly and fit the injector - Position a new gasket. complete with mounting bracket (2) in its seat pressing it until it clicks and is correctly inserted.

  • Page 83: Lubrication

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION LUBRICATION The oil vapours that form inside the engine during operation The engine is lubricated by a gear pump driven by the are directed into a condenser (blow-by filter) where some crankshaft. of them are condensed and recirculated again and some of There is a safety valve located on the oil filter mounting which them are directed via two pipes to the intake.

  • Page 84: Oil Pump

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Oil pump Figure 68 82254 - Check the pump casing and the external gears. If there - Fit the gear (8) on the cover assembly (4) and check its are any visible signs of deterioration (cracks in the casing rotation.

  • Page 85: Completing The Engine

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION COMPLETING THE ENGINE NOTE Before tightening the screws (see order in Figure 69 Figure 71), lubricate them with graphitized oil. Always fit new gaskets. NOTE Figure 72 82216 - From the front, fit the engine oil filter support (1) together with the temperature transmitter (2), pressure sensor (5), the gasket (4) and the filter clog sensor (3).
  • Page 86 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Figure 73 103472 - Fit the head water outlet pipes (1). - Fit the seals (2), fit the elbow (3), the connecting pipes (4) and O-rings and the thermostat casing (5). NOTE The new head—side gaskets have already been fitted together with the air intake manifolds.
  • Page 87 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 74 114242 - Fit the three—way coupling (7) on the water/oil cooler For SRINKLER applications (8) with the gasket. Figure 76 - Tighten the M8x40mm and M8x100 mm screws (6) to a torque of 22—27 Nm.
  • Page 88 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES For DRAGON applications Figure 78 Figure 77 89698 89697 Should compressor have been dismounted jointly NOTE with spacer, tighten (M12x1.75) screws securing it - On the bench, fit the previously removed fittings onto to gears box at 42 ÷...
  • Page 89 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION For G-DRIVE / SPRINKLER and GRIFFON applications For all applications Figure 79 Figure 81 89792 - Fit the cooling pump. - If the same pump is used replace seal (3). - If necessary, replace the pump gear (1) tightening the 103475 bolt (2) to the recommended torque.

  • Page 90: Common Rail Assembly Procedure

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES COMMON RAIL ASSEMBLY PROCEDURE - lubricate all the connectors with clean oil. Preparing for assembly Figure 83 - This procedure allows to have the best assembling, reducing the stress on the CR components due to tolerances and misalignments and will avoid the risk to have dangerous fuel leakage under pressure, during all typical condition of the Vector engines operative duty.

  • Page 91: Test Procedure For Checking For Diesel Leaks From The Common Rail System

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 84 103480 - Tighten the connectors for the pipes from the HPP to Test procedure for checking for diesel leaks the rails (V1.1 and V2.1) to the interface with the HPP from the Common Rail system.
  • Page 92 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Figure 85 Figure 86 103227 - Fit the control unit support (3) on the engine (M8x1.25 bolts to be tightened to a torque of 22-27Nm) complete with atmospheric pressure sensor (5) and diesel filter mounting.

  • Page 93: Checks And Inspections

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Checks and inspections NOTE The following checking inspections must be carried out after the engine assembly on the vehicle . Start the engine and leave it running just above the idling speed, wait until the coolant reaches the temperature necessary to open the thermostat and then check: - that there are no water leaks from the connecting...
  • Page 94 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 95: Second Part

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION SECOND PART - ELECTRICAL EQUIPMENT Print P2D32V001E Base - April 2006...
  • Page 96 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 97: Location Of Components On The Engine

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION LOCATION OF COMPONENTS ON THE ENGINE Figure 1 103265 1. Engine coolant temperature sensor — 2. Engine oil temperature sensor — 3. Oil filter clogging sensor — 4. ADEM III engine control module — 5. Atmospheric pressure sensor — 6. Fuel temperature sensor — 7. Electro—injectors — 8. Engine speed/timing sensor on crankshaft —...

  • Page 98: Circuit Diagram Of Engine Cable

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Circuit diagram of engine cable Figure 2 89782 1. Engine coolant temperature sensor — 2. Engine oil temperature sensor — 3. Oil filter clogging sensor — 4. ADEM III engine control module — 5. Atmospheric pressure sensor — 6. Fuel temperature sensor — 7. Electro—injectors — 8. Engine speed/timing sensor on crankshaft —...

  • Page 99: Engine Components

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Engine components Temperature sensors These are NTC type sensors and are used to indicate the operating temperatures of the engine coolant (reference 1, Figure 1), engine oil (reference 2, Figure 1), fuel (reference 6, Figure 1) and exchanger outlet air (reference 12, Figure 1) to the electronic unit Figure 3 89783...
  • Page 100 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Engine speed/timing sensor on camshaft This is an inductive type sensor and is positioned on the distribution shaft (reference 9, Figure 1). It generates signals that are obtained by means of the magnetic flow lines that close up through the holes on the gears that are keyed on the distribution shaft..
  • Page 101 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Engine oil level sensor This sensor is used to indicate that the sump oil level is too low. Features: - max pressure ..5 - 28 Vdc - resistance .

  • Page 102: Adem Iii Engine Control Unit

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES ADEM III engine control unit Figure 8 81391 A: Ground wire XJ1: connector on utilities XJ2: connector on engine side. It is fitted directly on the engine using flexible plugs that dampen the vibration transmitted by the engine. Figure 9 89788 Connector on engine side.
  • Page 103 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Pinout of engine side connector XJ2 Function Cable code Potential +5V supplying atmospheric pressure sensor 0905 Potential +5V supplying rail fuel pressure sensor 1004 Reference potential 0V for the rail fuel pressure sensor 1005 Not used —...
  • Page 104 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Function Cable code Not used — Not used — Not used — Not used — Not used — Not used — Not used — Positive of the timing system speed sensor 1007 Negative of the timing system speed sensor 1008 Not used...

  • Page 105: Electronic Control Of The Engine Control Unit

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Electronic control of the engine control unit ENGINE PRE—HEATING ELEMENT CONTROL Pre/post—heating is turned on even if just one of the water, air or fuel temperature sensors signals a temperature ≤ 5 °C. PHASE RECOGNITION The cylinder in which fuel must be injected is identified upon starting via the signals of the sensor on the camshaft and/or on the crankshaft.
  • Page 106 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 107: Third Part - Diagnostics

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION THIRD PART - DIAGNOSTICS Print P2D32V001E Base - April 2006...
  • Page 108 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 109: Troubleshooting

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION TROUBLESHOOTING General information Troubleshooting carried out with the 99368550 equipment can be performed by using simulation tool ILC 99368543 with This Troubleshooting guide has been written for first level which it is possible to pilot the power pack that is to be service engineers.

  • Page 110: Troubleshooting With Tool 99368550

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES TROUBLESHOOTING WITH The CD must be installed on a personal computer (not TOOL 99368550 included in the kit) having following minimum characteristics: Figure 1 Processor Intel Centrino I.IULV 512 MB Ram 40 GByte HD Internal modem 56 kbps V90 Card LAN 100 BASE-TX/10-BASE-T 88 character keyboard...

  • Page 111: Diagnosis Procedures For Vector 8V Engines

    SECTION 3 - INDUSTRIAL APPLICATION Description of buttons Diagnosis procedures for Vector 8V engines SW IVECO MOTORS user interface for VECTOR diagnosis. The graphic interface of the Vector diagnosis software has been designed to ensure easier utilization of the equipment...

  • Page 112: Diagnosis Environment

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Diagnosis Environment Stored fault code reading ECM electronic control unit identification code Some of the stored and listed faults might be intermittent. More precisely, some of them might, when being diagnosed, The diagnosis instrument consults a storage area of the not be present, yet previously memorized by the control unit electronic control unit, where the identification data are listed.
  • Page 113 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Fault parameter registration Work parameter reading The ”Stored SnapShot” screen provides a picture of the Work parameters include all the parameters available in the conditions at the time when a fault or event occurred. The control unit.
  • Page 114 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES - Electric test of injector solenoid valves with engine OFF. - High pressure system efficiency test with engine started (rail pressure step test). - Injector efficiency test with engine started (cut-out test). The initial conditions are: Engine on idle Initial pressure in kPa...

  • Page 115: Engine Parameter Reading

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION ENGINE PARAMETER READING Parameter Units of measurement Engine speed Desired Engine speed Throttle Position Boost pressure Engine Oil Pressure Engine Coolant Temperature Deg C Fuel Position Rated Fuel Limit FRC Fuel Limit Atmospheric Pressure Fuel Temperature Deg C...

  • Page 116: Reading Parameter For Save Code

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES READING PARAMETER FOR SAVE CODE Parameter Units of measurement Desired Engine speed Boost pressure Engine Oil Pressure Engine Coolant Temperature Deg C Fuel Position Atmospheric Pressure Fuel Temperature Deg C Engine Oil Temperature Deg C Inlet Air Temperature Deg C...
  • Page 117 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION EVENTS TABLE Low Engine Oil temperature Warning 492-1 Low Fuel Rail Pressure - Pressure Derate 398-2 Low Fuel Rail Pressure - Pressure Shutdown 398-3 Low Fuel Rail Pressure - Pressure Warning 398-1 Low Oil Level 171-1 Very Low Oil Level...
  • Page 118 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES EVENTS TABLE High Fuel Rail Pressure - Pressure Derate 396-2 High Fuel Rail Pressure - Pressure Shutdown 396-3 High Fuel Rail Pressure - Pressure Warning 396-1 High Fuel Temperature Derate 54-2 High Fuel Temperature Shutdown 55-3 High Fuel Temperature Warning 56-1...
  • Page 119 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION FAULTS TABLE 5 Volt Supply Above Normal 262-3 5 Volt Supply Below Normal 262-4 8 Volt Supply Above Normal 41-3 8 Volt Supply Below Normal 41-4 Alternator Disable Relay Open Circuit 1002-5 Alternator Disable Relay Short Circuit 1002-6 Alternator Pump Pressure Sensor Open / Short To Battery +...
  • Page 120 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES FAULTS TABLE Fuel Rail Pressure Sensor # 1 Short To Ground 1797-4 Fuel Temperature Sensor Open / Short To Battery + 174-3 Fuel Temperature Sensor Short To Ground 174-4 Hydraulic Oil Temperature Sensor Open / Short To Battery + 600-3 Hydraulic Oil Temperature Sensor Short To Ground 600-4...
  • Page 121 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION FAULTS TABLE Loss of Secondary Engine Speed Signal 342-2 Engine flywheel speed irregular signal 605-8 Personality Module Interlock Mismatch 253-2 Primary Engine Speed Signal Abnormal 190-8 Remote Operator’s Lamp Open Circuit 823-5 Remote Operator’s Lamp Short Circuit 823-6 Remote Throttle Position Sensor...

  • Page 122: Ilc Simulator 99368543 Tool

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES The ILC simulation tool is used to start the power unit ILC SIMULATOR 99368543 TOOL remotely and in order to be able to monitor operation via the diagnostic equipment. Figure 3 ILC simulator tool use: - Connect connector (3) to the electrical shunt box on which the unit is inserted.
  • Page 123 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Print P2D32V001E Base - April 2006...
  • Page 124 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...
  • Page 125 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Print P2D32V001E Base - April 2006...
  • Page 126 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...
  • Page 127 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Print P2D32V001E Base - April 2006...
  • Page 128 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 129: Fourth Part

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION FOURTH PART - PLANNED MAINTENANCE Print P2D32V001E Base - April 2006...
  • Page 130 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Base - April 2006 Print P2D32V001E...

  • Page 131: Vector 8 Dragon Fvae2884A*B200 Maintenance Plan

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 DRAGON FVAE2884A*B200 MAINTENANCE PLAN Hourly intervals Time intervals First level service 1 year Second level service 2500 5 years General overhaul 5000 10 years Engine replacement 25000 25 years DAILY CHECKS Check fumes Check for faults during start-up Check for clogged air/oil/diesel filter warning light activation...
  • Page 132 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES GENERAL OVERHAUL Carry out every 5000 hours or at least once every 10 years In addition to the operations at the previous level, change the following: Cylinder liners Cylinder heads Damper Pistons Camshaft High pressure fuel pump Low pressure fuel pump...

  • Page 133: Vector 8 Genset Fvae2885X*A100 Maintenance Plan

    This is the maximum power available for a period of 500 hours/year with an average load factor of 90% of the stand-by power. No type of overload is permitted for this usage. CONTINUOUS POWER Contact the Iveco Motors sales organization. Continuous / Prime Stand-By...
  • Page 134 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES FIRST LEVEL SERVICE Oil filter replacement Fuel filter replacement Fuel pre-filter replacement Blow-by filter replacement Engine oil change Check density and pH of coolant Valve clearance adjustment Check on cooling assembly cleanliness Replace supercharging hoses 1) only at the end of the service interval expressed in hours of operation SECOND LEVEL SERVICE...

  • Page 135: Description Of Preventive And Routine Maintenance Work

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION DESCRIPTION OF PREVENTIVE AND ROUTINE MAINTENANCE WORK Philosophy of Preventive and Routine Maintenance Work To make sure the working conditions are always perfect, the following pages specify the controls, checks and adjustments that must be carried out on the various parts of the engine at the scheduled times.

  • Page 136: Checking/Refilling Engine Oil Filters

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES CHECKING/REFILLING ENGINE OIL CHANGING ENGINE OIL FILTERS FILTERS Handle all parts extremely carefully. Handle all parts extremely carefully. Never get your hands or fingers between pieces. Never get your hands or fingers between pieces. Wear the required safety clothing such as goggles, Wear the required safety clothing such as goggles, gloves, safety shoes and helmet.
  • Page 137 SECTION 3 - INDUSTRIAL APPLICATION Figure 2 Improper waste disposal is a threat for the environment. Potentially hazardous waste used on IVECO vehicles includes lubricants, fuels, coolants, filters and batteries. — Use watertight containers when draining off fluids. Never use containers for foodstuffs or beverages that can lead people to drink from them.

  • Page 138: Changing The Engine Oil

    Before touching the sump plug, check that the environment. Potentially hazardous waste used on temperature of the oil in the engine is not such as IVECO vehicles includes lubricants, fuels, coolants, to cause burns. filters and batteries. Engine lubricating oil is harmful: avoid contact with —...

  • Page 139: Changing Fuel Prefilter And Water Separator Filter

    (1) with the aid of a 27 mm wrench (2). Improper waste disposal is a threat for the environment. Potentially hazardous waste used on IVECO vehicles includes lubricants, fuels, coolants, filters and batteries. — Use watertight containers when draining off fluids.

  • Page 140: Adjusting Rocker Arm Assembly

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES ADJUSTING ROCKER ARM ASSEMBLY - Fitting the 24 mm ratchet wrench on the back of tool 99368502 (see preceding page), turn the engine flywheel until we obtain the required cylinder balancing (the 4 Handle all parts extremely carefully.
  • Page 141 VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 10 Figure 12 SECOND STEP BALANCING ADJUST 81606 - To make the adjustment, proceed as illustrated here: 82184 - Insert the tappet feeler gauge (0.50) 99368545 (3). Figure 11 Figure 13 82183 82185 - Using the wrench kit 99368503, loosen the lock nut (1)
  • Page 142 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES - Adjust the other valves in the order shown on previous Figure 14 page. - Now close all 16 covers, extract the tool for turning the flywheel and close the flywheel cover. Tightening torque 7 ÷...

  • Page 143: Changing Fuel Filters

    Tighten the air jets nozzle when the fuel go out. Improper waste disposal is a threat for the environment. Potentially hazardous waste used on IVECO vehicles includes lubricants, fuels, coolants, filters and batteries. — Use watertight containers when draining off fluids.
  • Page 144 For applications DRAGON and GRIFFON Improper waste disposal is a threat for the environment. Potentially hazardous waste used on IVECO vehicles includes lubricants, fuels, coolants, Handle all parts extremely carefully. Never get your filters and batteries. hands or fingers between pieces. Wear the required safety clothing such as goggles, gloves, safety shoes —...

  • Page 145: Changing An Injector

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 21 CHANGING AN INJECTOR To change an injector, proceed as illustrated here: Handle all parts extremely carefully. Never get your hands or fingers between pieces. Wear the required safety clothing such as goggles, gloves, safety shoes and helmet Figure 19 - Unscrew the cheese-headed screw M10x70 (3)
  • Page 146 SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES Figure 25 Always change the O—ring in the assembly phase. Lubricate the O—ring before installation (use vaseline). Figure 24 - Using the specific wrench, screw the cheese—headed screw M10x70 back on to a tightening torque of 32 ÷ 36 - Check the sealing surface of the leaking pipe and the surface on the injector and flow limiter.

  • Page 147: Changing Blow-By Filter

    The blow-by filters can only be replaced by taking the unit apart completely and disassembling the same at the bench. Improper waste disposal is a threat for the environment. Potentially hazardous waste used on IVECO vehicles includes lubricants, fuels, coolants, filters and batteries. — Use watertight containers when draining off fluids.

  • Page 148: Changing Primary System Pump

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES CHANGING PRIMARY SYSTEM PUMP Removal The centrifugal pump of the primary cooling system can be changed as follows: Figure 28 - Place a big enough container to collect the motor’s Figure 29 coolant contained in the sections of piping that have to be removed and in the pump itself.

  • Page 149: Fitting

    VECTOR 8 ENGINES SECTION 3 - INDUSTRIAL APPLICATION Figure 30 Figure 33 - Turn the pump and undo the three screws (7, Figure 30) fixing the cover (6, Figure 30), complete with seal (1). - After removing the pump, separate the components from (1) to (7).

  • Page 150: Removing/Refitting Starter Motor

    SECTION 3 - INDUSTRIAL APPLICATION VECTOR 8 ENGINES REMOVING/REFITTING STARTER MOTOR Figure 36 Removal Before proceeding to work on an electric or electronic component, make sure the system is not powered. The starter motor is located on the left-hand side of the flywheel housing in an area fairly easy to access from the bottom.
  • Page 151 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS SECTION 4 Overhaul and technical specifications Page GENERAL SPECIFICATIONS ....ASSEMBLY CLEARANCE DATA ... . ENGINE OVERHAUL .
  • Page 152 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Page Page PISTON ROD ASSEMBLY ....REPLACING THE INJECTOR—HOLDER CASES - Pistons ....... - Fitting the valves .

  • Page 153: General Specifications

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS GENERAL SPECIFICATIONS Type VECTOR 8 Cycle Four-stroke diesel engine Power Supercharged with intercooler Injection Direct Number of cylinders 8 in two banks at 90˚ ∅ Bore Stroke +.. = Total displacement 20.080 TIMING start before T.D.C.

  • Page 154: Assembly Clearance Data

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES ASSEMBLY CLEARANCE DATA Type VECTOR 8 CYLINDER BLOCK AND CRANK MECHANISM COMPONENTS ∅ 1 ∅ 1 ∅ 1 164 000 ÷ 164 025 164.000 ÷ 164.025 Cylinder liners Cylinder liners Cylinder liners: ∅...
  • Page 155 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 VECTOR 8 Type Type 3.440 ÷ 3.470 Type of piston 3.060 ÷ 3.080 Piston ring slots 6.030 ÷ 6.050 *measured on ∅ of 140 mm 3 330 ÷ 3 296 3.330 ÷...
  • Page 156 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES VECTOR 8 Type Type Measuring dimension X Max. error on alignment of connecting rod axes 0.08 ∅1 ∅1 121 995 ÷ 121 975 121.995 ÷ 121.975 Main journals Main journals ∅...
  • Page 157 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Type VECTOR 8 CYLINDER HEAD — VALVE TRAIN ∅ 1 Valve guide seats in cylinder head ∅1 16.980 ÷ 16.997 ∅ ∅2 Valve guide 10.015 ÷ 10.030 ∅3 17.012 ÷ 17.015 ∅...
  • Page 158 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES VECTOR 8 Type Type 0.050 ÷ 0.100 Between valve Between valve seat and head 0.050 ÷ 0.100 Valve seat 54.270 ÷ 54.285 51.270 ÷ 51.285 Valve spring height: free height under a load of: H 2 N 450 ±25 57.5...
  • Page 159 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 Type Type Cam lift: 6.9360 7.4066 ∅ 1 Tappet cap seat ∅1 34.025 ÷ 34.000 in the crankcase: Tappet cap outside ∅2 diameter: 33.600 ÷ 33.800 Measurement from axis tappet at end of fixing 18.80 ÷...

  • Page 160: Engine Overhaul

    Dismantling the engine at the bench The instructions below assume that the engine has been fitted on an overhaul stand and all the specific components for Iveco Motors application components have been removed (see Section 3 of this manual).The section therefore includes all the most important overhaul procedures for the engine block.

  • Page 161: Repair Operations

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS REPAIR OPERATIONS Figure 3 CYLINDER UNIT Checks and measurements Figure 4 16788 - Using a hoist (1) and tool 99360500 (2), appropriately fitted on the crankpins, extract the crankshaft (3) from the 16792 cylinder assembly.

  • Page 162: Replacing Cylinder Liners

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Figure 8 Figure 6 16796 - Check the flatness of the cylinder head mating surface with a calibrated rule and feeler gauge. After finding the areas of deformation, level off the supporting surface, after taking out the centring pins (2), with tool (1), and the cylinder liners (3) according to the procedures given under the heading REPLACING...
  • Page 163 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 10 Figure 13 16804 - Change the seals (5) of the bushing (3) for the right—hand 82720 main oilway. The bushing (3) is removed from the cylinder - Always change the coolant seals (3, 4 and 5). assembly with a percussion extractor 99340205 (1) and a Fit the top brass ring (2) onto the cylinder liner (1).

  • Page 164: Timing System

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES TIMING SYSTEM Camshaft Figure 15 89794 MAIN DATA ABOUT CAMSHAFT PINS Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the camshaft and the bushes.
  • Page 165 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 18 Heigth to be obteined after driving the bushes Thickness variation max 0.025 mm SEAT Ø 86.000 ÷ 86.030 PIN Ø 79.950 ÷ 79.968 Heigth to be obteined after driving the bushes Thickness variation max 0.025 mm...

  • Page 166: Changing The Bushings

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Changing the bushings Fitting tappets and camshaft Figure 19 Lubricate the tappets and fit them in their seats. NOTE We recommend to lubricate the tappets carefully by keeping them immersed for 30’. Lubricate the camshaft bushings and fit the shaft, taking care not to damage the supporting bushings.
  • Page 167 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 21 121.995 121.975 105.000 104.980 8821 CRANKSHAFT JOURNAL DATA Check the state of the main journals and crankpins of the crankshaft. They must show no sign of scoring, ovality or excessive wear.

  • Page 168: Checking Main Journal Alignment

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Checking main journal alignment Figure 23 Figure 27 0.025 LIMIT POSITION LIMIT POSITION 0.025 NORMAL POSITION 83496 Detail of couplings of central main journal. MAIN JOURNAL CRANKPIN Figure 24 8296 The tolerances allowed on the engine shaft pins are: - ovality = 0.007 mm - taper 0.012 mm...

  • Page 169: Crankshaft Balancing Instructions

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 29 82236 Check that with a pressure of 15 bar (15 kg/cm2) there is no leakage from the plugs (1). The counterweights (2) must be fitted with the crankshaft fitted in the cylinder assembly. The numbering marked on the counter- weights must correspond to that marked on the cranks of the crankshaft.

  • Page 170: Changing The Oil Pump And Timing System Gear

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Fitting the main bearings Changing the oil pump and timing system gear Figure 31 NOTE The crankshaft must be dynamically balanced. Figure 32 Arrange the main bearing shells with the lubrication hole in 82270 their respective seats and fit the crankshaft (3) with the tool 99360500 (2) and suitable hoist (1).

  • Page 171: Finding Journal Clearance

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Finding journal clearance Tightening sequence Figure 35 Figure 33 16813 Check the clearance between the crankshaft main journals and 89797 their respective bearings as follows: M20x1.5 bolts - thoroughly clean the pins; Type of tightening: pre-torque + angle - apply a calibrated wire (2) on the main journals (1);...

  • Page 172: Checking Crankshaft Thrust Clearance

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES - Remove caps from supports. Checking crankshaft thrust clearance The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the Figure 37 narrowest point with the scale on the envelope (1) containing the calibrated wire.

  • Page 173: Camshaft Timing

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Camshaft timing Figure 41 Method 1 (without equipment) Figure 39 82240 Check that TDC coincides with the mark made: 113060 - Rotate the crankshaft backwards. Determine top dead centre (TDC) for cylinder 1 proceeding - Rotate the crankshaft again, forwards, until the dial gauge as follows: changes direction.
  • Page 174 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Figure 43 Figure 45 82243 - Rotate the crankshaft fowards until a lifting height of 5.48 mm is reached. - The camshaft is timed if the reference mark made previously on the crankshaft is aligned with the reference on the cylinder block/crankcase.
  • Page 175 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 46 112863 TIMING DIAGRAMS FOR THE FOLLOWING APPLICATIONS:G DRIVE - GRIFFON - SPRINKLER 1. Camshaft - 2. Camshaft rpm sensor - 3. Camshaft flywheel - 4. Engine flywheel - 5.
  • Page 176 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Figure 47 112864 TIMING DIAGRAMS FOR THE FOLLOWING APPLICATIONS: DRAGON 1. Camshaft - 2. Camshaft rpm sensor - 3. Camshaft flywheel - 4. Engine flywheel - 5. Crankshaft rpm sensor fitted on the flywheel casing Base - April 2006 Print P2D32V001E...
  • Page 177 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Method 2 (using equipment) Figure 48 113064 Position cylinders 1 and 6 at TDC. Fit tool 99368509 (3) on the front casing.Secure it using the bolts (2, 5). At TDC the pins (2) and (3) for the tool engage in the dowels for the crankshaft and the camshaft respectively guaranteeing the timing.

  • Page 178: Piston Rod Assembly

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES PISTON ROD ASSEMBLY Pistons Measuring the piston diameter Figure 50 Figure 53 82253 16821 PISTON—GUDGEON PIN ASSEMBLY - Measure through the micrometer (1) the piston diameter 1. Piston — 2. Trapezoidal grommet — 3. Washer — 4. Oil (2) to determine the assembly play.

  • Page 179: Conditions For Correct Mating Of Gudgeon Pin And Piston

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Figure 56 113006 PRINCIPAL PISTON, GUDGEON PIN AND PISTON RING DATA Conditions for correct mating of gudgeon pin Piston rings and piston Figure 58 Figure 57 16522 36131 - Check thickness of piston rings (2) by a micrometer (1). - Lubricate the gudgeon pin (1) and its seating on the piston with engine oil;...

  • Page 180: Connecting Rods

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Figure 63 Figure 60 3613 The ring (2) of the first slot has a V—shape. The clearance ”X” between a ring and its seat is measured by placing the piston (1), with its ring, in the cylinder liner (3) so that the ring comes half—way out of the cylinder liner.

  • Page 181: Check Of Connecting Rod Alignment

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Check of connecting rod alignment Fitting the connecting rod—piston assembly Connecting rod—piston mating Figure 65 Figure 66 37715 The connecting rod — piston coupling must be made 16557 taking account that, on fitting the assembly in the cylin- Use apparatus 99395363 (1) to check parallelism of the rod der block, the wording ”TAPPET SIDE”...

  • Page 182: Check Of Rod/Piston Alignment

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Fitting the rod—piston assemblies into the Check of rod/piston alignment cylinder liners Figure 68 Figure 70 81350 DIAGRAM FOR INSERTING THE CONNECTING ROD-PISTON ASSEMBLY IN CYLINDER 1. Tappet side — 2. Camshaft 37716 After assembling the rod—piston group (1) check the squaring Figure 71...

  • Page 183: Measuring The Mounting Clearance Of Big End Pins

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Measuring the mounting clearance of big end pins Upon final reassembly, the big end cap fastening screws must always be replaced. Figure 72 - Manually check that the connecting rods can be moved sideways on the drive shaft pins.

  • Page 184: Cylinder Head

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES CYLINDER HEAD Figure 77 Hydraulic leak test Before dismantling the cylinder head, carry out the hydraulic leak test using the appropriate tool. Pump water heated to approx. 90˚ C and at a pressure of 4 ÷...

  • Page 185: Refacing The Valves

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS Refacing the valves Checking clearance between valve stem Figure 81 Figure 79 89832 These checks are carried out using a magnetic support dial gauge which is positoned as shown in the figure above. The mounting clearance is from 0.045 to 0.070.

  • Page 186: Replacing The Valve Guides

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Replacing the valve guides Figure 86 Figure 83 16833 - cool the new valve seats to — 180°C in liquid nitrogen; 16830 - drive the valve seats (3) into the cylinder head with a drift - Dismantle the valve guides (2) with beater 99360143 (1);...

  • Page 187: Replacing The Injector-Holder Cases

    VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS REPLACING THE INJECTOR—HOLDER Figure 92 CASES Imperfect coupling between the injector and case, forced into the cylinder head or between the case and the seat on the cylinder head, causes a loss of compression or water leakage. Figure 89 37722 - Restore the hole in the case (2) with the reamer...

  • Page 188: Fitting The Valves

    SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES Fitting the valves Figure 98 Figure 95 α 37724 Fit new cylinder head gaskets. Mount the cylinder heads (1). Lubricate the fixing bolts with ”UTDM” oil. Align the cylinder heads with the tool applied in the holes to fasten the exhaust manifolds.
  • Page 189 VECTOR 8 ENGINES SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS TIGHTENING TORQUE COMPONENT TORQUE Cylinder head fixing bolt (*) pre—torque angle 240° 240° 220 ÷ 390 22 ÷ 39 guard—torque Crankcase cap fixing bolt (*) pre—torque 240° angle 240° 600 ÷ 1000 60 ÷...
  • Page 190 SECTION 4 - OVERHAUL AND TECHNICAL SPECIFICATIONS VECTOR 8 ENGINES COMPONENT TORQUE 22 ÷ 27 2.2 ÷ 2.7 Bolt fixing air conveyor to cooler body (M8x1.25) 22 ÷ 27 2.2 ÷ 2.7 Bolt fixing air delivery elbows to conveyor (M8x1.25) 38 ÷...
  • Page 191 VECTOR 8 ENGINES SECTION 5 - TOOLS SECTION 5 Tools Page TOOLS ....... . Print P2D32V001E Base - April 2006...
  • Page 192 SECTION 5 - TOOLS F4AE NEF ENGINES Base - April 2006 Print P2D32V001E...
  • Page 193 VECTOR 8 ENGINES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION 99305019 Case with full set of valve seating regrinding tools 99305047 Spring loading control apparatus 99322230 Rotary telescopic stand (capapity 2000 daN, torque 375 daNm) 99342145 Puller to remove injector holder 99360091 Tool for dismantling fuel filter 99360184...
  • Page 194 SECTION 5 - TOOLS F4AE NEF ENGINES TOOLS TOOL NO. DESCRIPTION 99360329 Key for installing gasket on valve guides 99360500 Tool for lifting the output shaft 99360603 Band for inserting piston into cylinder barrel (90 — 175) 99360785 Ring (145 mm) (use with 99360799) 99360799 Tool for disassembling and reassembling cylinder liners (use with special rings)
  • Page 195 VECTOR 8 ENGINES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION 99365063 Tool for heading electro—injector seat 99367016 Sleeve key (27 mm) for flywheel fixing bolts 99367019 Guides set (2) M24x2 to mount engine flywheel 99368501 Tool for rotating the engine flywheel 99368502 Tool for rotating engine flywheel (to be used with 99368547) 99368503...
  • Page 196 SECTION 5 - TOOLS F4AE NEF ENGINES TOOLS TOOL NO. DESCRIPTION 99368505 Puller for dismantling injectors 99368506 Key (27 mm) for dismantling fuel injector pipes (use with 99389813) 99368508 Tool for positioning fonic wheel during timing ignition 99368509 Tool for timing camshaft 99368511 Tool for fiitting output shaft rear gasket 99368512...
  • Page 197 VECTOR 8 ENGINES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION 99368513 Tool to remove output shaft rear gasket 99368514 Tool to remove output shaft front gasket 99368515 Stud set (use with 99360799) 99368516 Puller to remove the control gear of hight pressure pump (use with 99368517) 99368517 Retainer tool control gear of hight pressure pump...
  • Page 198 SECTION 5 - TOOLS F4AE NEF ENGINES TOOLS TOOL NO. DESCRIPTION 99368537 Tool for drain engine oil 99368539 Installer oil filter (engine) 99368540 Ring wrench with 14X18 insert (18mm) for turbine bolts 99368542 Set of 8 insert box wrenches 14X18 (13 - 17 - 18 - 19 - 21- 22 - 24 - 27 - 30 mm) ILC simulator for Vector Engine 99368543...
  • Page 199 VECTOR 8 ENGINES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION 99368545 Thickness gauge (0.50 mm) for tappets Torque overgear reaction for teeghtening fly wheel bolts (use with 99367016-99389816-99389818) 99368546 99368547 Dial gauge base to adjust transmission shaft bearings (use with 99395603) 99368548 Dial gauge base to adjust transmission shaft bearings (use with...
  • Page 200 SECTION 5 - TOOLS F4AE NEF ENGINES TOOLS TOOL NO. DESCRIPTION 99370415 Dial gauge base to adjust transmission shaft bearings (use with 99395603) 99389813 Torque wrench (20 — 120 Nm) with 1/2” square attachment 99389816 Torque overgear x 4 with 3/4” square attachment 99389817 Torque wrench (60 —...
  • Page 201 VECTOR 8 ENGINES SECTION 5 - TOOLS TOOLS TOOL NO. DESCRIPTION 99389832 Torque wrench with 14X18 attachment (60-320 Nm) 99389833 Torque wrench with 14X18 attachment (20-120 Nm) 99390425 Tap for to thread injector seat (disassembly) (M12x1.75) 99394004 End mill for to work the rocker side of injector seat 99394017 Reamer for to work the bottom side fo the injector seat (use with 99394019)
  • Page 202 SECTION 5 - TOOLS F4AE NEF ENGINES TOOLS TOOL NO. DESCRIPTION 99394019 Driver bushing 99395216 Pair of measuring devices for angular tightening with 1/2” and 3/4” square attachments 99395363 Complete square for checking rod squaring 99395603 Dial gauge (0 — 10 mm) 99395687 Bore gauge (50 —...
  • Page 203 VECTOR 8 ENGINES APPENDIX Appendix Page SAFETY PRESCRIPTIONS ....- Standard safety prescriptions ....- Prevention of injury .
  • Page 204 APPENDIX F4AE NEF ENGINES Base - April 2006 Print P2D32V001E...
  • Page 205 VECTOR 8 ENGINES 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 206 - Do not connect any user to the engine electrical personnel is fully aware of such law prescriptions and of equipment unless specifically approved by Iveco Motors. basic preventive safety measures. - Do not modify fuel systems or hydraulic system unless - Collect exhaust oils in adequate specially provided Iveco specific approval has been released.

This manual is also suitable for:

Vector 8

Table of Contents

Save PDF