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NEF Engine N67 MNS M22 N67 MNT M28 Technical and Repair Manual T E C H N O L O G I C A L E X C E L L E N C E NOVEMBER 2006 EDITION 1. N67 MNS M22 N67 MNT M28 NOVEMBER 2006 FOREWORD We strongly recommend that you carefully read the indications contained in this document: compliance with them protects the engine against irregular operation and assures its reliability, safeguarding sea-going and maintenance personnel against accident hazards. The indications contained in this document pertain to the N67 MNS M22.10 or N67 MNS M22.11, N67 MNT M28.10 or N67 MNT M28.11 marine engine and complement the IVECO MOTORS-FPT publication of “Marine Diesel Engines Installation Handbook” that the reader should refer to for anything that is not explained herein. Technical engineers and fitters are required to comply with safety regulations on work. They have to implement and adopt the device required for individual personal safeguard while carrying out maintenance or checks. Safety rules are reported in Section 9 of this publication. Regulations on handling engine are reported at the end of Section 6 of this publication. In order to start the engine, strictly follow the procedure stated at the end of Section 5 of this publication. To get the best possible performance out of the engine, it is mandatory to conform with its intended mission profile. The engine must not be used for purposes other than those stated by the manufacturer. IVECO MOTORS-FPT is available beforehand to examine requirements for special installations, if any. In particular o Use of unsuitable fuels and oils may compromise the engine’s regular operation, reducing its performance, reliability and working life; o Exclusive use of IVECO Original Parts is a necessary condition to maintain the engine in its original integrity; o Any tampering, modifications, or use of non-original parts may jeopardize the safety of service personnel and boat users. To obtain spare parts, you must indicate: - - Commercial code, serial number and indications shown on the engine tag; Part number of the spare as per spare part catalog. The information provided below refer to engine characteristics that are current as of the publication date. IVECO MOTORS-FPT reserves the right to make modifications at any time and without advance notice, to meet technical or commercial requirements or to comply with local legal and regulatory requirements. We refuse all liability for any errors and omissions. The reader is reminded that the IVECO MOTORS-FPT Technical Assistance Network is always at the Customer’s side with its competence and professionalism. Publication IVECO MOTORS-FPT edited by: IVECO PowerTrain Advertising & Promotion Pregnana Milanese (MI) www.ivecomotors.com Printed P3D32N002 E - November 2006 Edition N67 MNS M22 N67 MNT M28 NOVEMBER 2006 1. SECTION CONTENTS Section Page 1. OVERVIEW 5 2. TECHNICAL DATA 37 3. ELECTRICAL EQUIPMENT 43 4. DIAGNOSTICS 87 5. MAINTENANCE 97 6. SERVICING OPERATIONS ON INSTALLED ENGINE 103 7. TOOLS 115 8. OVERHAUL 123 9. SAFETY REGULATIONS 181 Indications for consultation Sections 1-2-3 are intended for sales personnel, to provide them with exact knowledge of the product’s characteristics and enable them to meet the Customer’s demands with precision. The remaining sections are meant for personnel in charge of carrying out ordinary and extraordinary maintenance; with an attentive consultation of the chapter devoted to diagnosing, they will also be able to provide an effective technical assistance service. 1. N67 MNS M22 N67 MNT M28 NOVEMBER 2006 PAGE LEFT INTENTIONALLY BLANK NOVEMBER 2006 N67 MNS M22 N67 MNT M28 OVERVIEW 1. SECTION 1 OVERVIEW Page IDENTIFYING DATA 7 COMMERCIAL CODE 8 PRODUCT MODEL NUMBER 9 ENGINE PARTS AND COMPONENTS N67 MNS M22 10 ENGINE PARTS AND COMPONENTS N67 MNT M28 12 ENGINE ARCHITECTURE 14 Crankcase 14 Crankshaft 15 Connecting Rods 15 Pistons 16 Timing system driving gear 16 Cylinder head 18 Valves and valve seats 19 Ancillary machine parts drive 19 COMBUSTION AIR INTAKE AND EXHAUST SYSTEM 20 Comburent air filter 21 Turbocompressor 21 Air / sea-water heat exchanger 21 COOLING FRESH WATER CLOSED-LOOP 22 Exhaust manifold cooling 23 Thermostatic valve 24 Water pump 24 Additional expansion tank 24 SEA-WATER OPEN COOLING LOOP 25 Sea-water pump 26 Sea-water / coolant heat exchanger 26 (continues on next page) 1. N67 MNS M22 N67 MNT M28 OVERVIEW Page ENGINE OIL LUBRICATION LOOP 27 Gear pump 28 Filter bracket 28 Oil vapour recirculation 28 FUEL LINE N67 MNS M22 29 Fuel supply system scheme 30 FUEL LINE N67 MNT M28.10 31 Fuel supply system scheme 32 Fuel pre-filter 33 Fuel filter 33 FUEL LINE N67 MNT M28.11 34 Fuel supply system scheme 35 Fuel pre-filter 36 Fuel filter 36 NOVEMBER 2006 N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 1. IDENTIFYING DATA Figure 1 04_306_N The engine identification data are stenciled on a tag positioned aside the coolant tank. Figure 2 S. p. A. Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY ENGINE TYPE ENGINE FAMILY ENGINE DWG POWER (KW) AND SPEED (RPM) POWER SET CODE ENGINE S/N YEAR OF BUILD HOMOLOGATION No COMMERC. TYPE / VERSION 06_013_N The last two figures of the commercial code refer to the engine model (detail A or B in figure n. 2). Until the beginning of the year 2006 the engines produced had the code N67 MNT M28.10 or N67 MNS M22.10 (detail A in figure n. 2). During the year 2006 relevant modifications have been made to the electric system and to the fuel supply circuit and N67 MNT M28 ! .10 .XX .11 " a new model identified with the code N67 MNT M28.11 or N67 MNS M22.11 was created (detail B in figure 2). This document concerns both the models. The relating contents are developed in different chapters which can be identified thanks to the presence in each title of the extension M22.10 - M28.10 or M22.11 - M28.11. N67 MNS M22 N67 MNT M28 1. OVERVIEW NOVEMBER 2006 COMMERCIAL CODE The purpose of the commercial code is to make the characteristics of the product easier to understand, categorizing the engines according to their family, origins and intended application. The commercial code, therefore, cannot be used for the technical purpose of recognizing the engine’s components, which is served by the “ENGINE S/N”. N 67 M N T M 28 . 1 0 VERSION VERSION: TURBOCHARGED: 1 = COOLED 2 = NOT COOLED MAXIMUM PERFORMANCE LEVEL ACHIEVABLE 28 = 280 HP APPLICATION: M = MARINE AIR INTAKE: T = INTERCOOLED SUPERCHARGED BASE: N = NON STRUCTURAL FUEL SUPPLY: M = MECHANICAL INJECTION PUMP DISPLACEMENT: 67 = 6700 cc NOMINAL ENGINE FAMILY IDENTIFIER: N = NEF N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 1. PRODUCT MODEL NUMBER The model number is assigned by the manufacturer; it is used to identify the main characteristics of the engine, and to characterize its application and power output level. It is stamped on a side of crank-case, close to oil filter. F 4 G E 0 6 8 6 A * E 6 0 1 VARIANTS TO BASIC ENGINE E = EMISSION FOR MARINE APPLICATION POWER RANGE: A = MAXIMUM POWER 280 HP INTENDED USE (6 = MARINE) FUEL + INJECTION (8 = DIESEL, TCA, DIRECT INJECTION) NO. OF CYLINDERS NO. OF STROKES AND CYLINDER DISPOSITION (0 = 4 STROKES, VERTICAL) ENGINE DESIGN ITERATION ENGINE FAMILY IDENTIFIER N67 MNS M22 N67 MNT M28 1.10 OVERVIEW NOVEMBER 2006 ENGINE PARTS AND COMPONENTS N67 MNS M22 Figure 3A 7 8 9 6 10 11 12 5 4 13 14 15 3 2 1 06_054_N 19 18 17 16 1. Engine coolant discharge cap - 2. Electric starter motor - 3. Tube bundle engine coolant/sea water heat exchanger 4. Location of sacrificial anode - 5. Cooled exhaust manifold - 6. Exhaust gas and sea water discharge pipeline 7. Lifting eyebolt - 8. Rocker arm covers - 9. Oil refill cap - 10. Location of thermostatic valve 11. Cap for engine coolant outlet to sanitary water heating system - 12. Coolant refill cap - 13. Fuel filter 14. Screw cap to drain water - 15. Engine coolant tank - 16. Auxiliary belt automatic tensioner - 17. Alternator 18. Cap for engine coolant discharge and recirculation from sanitary water heating system - 19. Oil filter. N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 1.11 Figure 3B 10 11 12 13 9 14 15 8 7 6 16 5 4 05_021_N 3 2 1 1. Combustion air filter - 2. Sea water inlet - 3. Sea water pump - 4. Throttle lever lever on injection pump - 5. Rubber holder junction for fuel outflow to the tank - 6. Wiring connectors N67 MNS M22.10 - 7. Low pressure mechanical feed pump 8. Fuel intake fitting - 9. Manual lubricating oil extraction pump - 10. Connector for instrument panel connection wire harness N67MNS M22.11 - 12. Lifting eyebolt - 13. Oil vapor separator - 14. Air filter clogging sensor - 15. Cooled turbocharger 16. Sea water junction pipe from pump to engine coolant/sea water heat exchanger (Oil gear box heat exchanger, on request). N67 MNS M22 N67 MNT M28 1.12 OVERVIEW NOVEMBER 2006 ENGINE PARTS AND COMPONENTS N67 MNT M28 Figure 4A 7 8 9 6 10 11 12 13 5 4 14 15 3 2 1 04_303_N 19 18 17 16 1. Engine coolant discharge cap - 2. Electric starter motor - 3. Tube bundle engine coolant / sea-water heat exchanger - 4. Location of sacrificial anode - 5. Cooled exhaust manifold - 6. Exhaust gas and sea-water discharge pipeline - 7. Lifting eyebolt - 8. Rocker arm covers - 9. Oil refill cap - 10. Location of thermostatic valve - 11. Cap for engine coolant outlet to sanitary water heating system 12. Coolant refill cap - 13. Fuel intake fitting - 14. Fuel filter - 15. Engine coolant tank - 16. Auxiliary belt automatic tensioner 17. Alternator - 18. Cap for engine coolant discharge and recirculation from sanitary water heating system - 19. Oil filter. N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 1.13 Figure 4B 17 11 12 13 10 14 15 9 8 7 6 16 5 4 05_021_N 3 2 1 1. Combustion air filter - 2. Sea water inlet - 3. Sea water pump - 4. Throttle lever lever on injection pump 5. Rubber holder junction for fuel outflow to the tank - 6. Sacrificial anode - 7. Wiring connectors N67MNT M28.10 8. Combustion air-sea water heat exchanger - 9. Location of sea water discharge cap - 10. Manual lubricating oil extraction pump 11. Oil dipstick - 12. Lifting eyebolt - 13. Oil vapor separator - 14. Air filter clogging sensor - 15. Cooled turbocharger 16. Sea water junction pipe from after-cooler to engine coolant/sea water heat exchanger (Oil gear box heat exchanger, on request) 17. Connector for instrument panel connection wire harness N67MNT M28.11. N67 MNS M22 N67 MNT M28 1.14 OVERVIEW NOVEMBER 2006 ENGINE ARCHITECTURE NEF engines are the highest expression of design and engineering efficiency that IVECO MOTORS-FPT makes available on the market place. They are highly innovative engines designed to be able to comply now with the regulations on fumes and acoustic emissions that will be enforced in the near future. Designed with innovative techniques and manufactured with advanced working processes, they are the result of hundreds of years of design and engineering tradition as well as of an important international cooperation. The excellent performance of NEF engines originates from induction and exhaust ducts of new design where, by improving the gas exchange phases, the intaken air turbolence is improved, thus enabling the complete exploitation of the new injection system capacity. The new criteria chosen in defining the parameters setting the combustion conditions, metering and injection, enable to obtain new balance between high performance and consumption reduction. NEF engines can be fitted with a mechanical pump or a total electronic controlled “Common Rail” fuel supply system. Every technical solution has been accurately devised so as to assure qualitative product perfection. The configuration of the engine itself has been designed in such a way as to facilitate access to each individual part thus reducing maintenance time. Cylinder head fitted with two valves per cylinder, rear timing control, new design connecting rods and aluminum-nickel pistons are components of an engine fitted with 40% less elements than an engine of equivalent performance. Crankcase Figure 5 8 1 2 7 3 4 5 6 04_011_N 1. Reconditionable integral cylinder barrels - 2. Water pump seat - 3. Camshaft bushing seat - 4. Oil pump seat - 5. Main bearings 6. Crankcase backing plate - 7. Oil cooler (water/oil) seat - 8. Product model number location. Moreover, within the cast iron crankcase, coolant circulation grooves, ducts for lubrication loops for the various machine parts and the seat for push rod bushings have been grooved in. The backing plate (6) applied to the lower part makes the crankcase tougher and improves resistance to stress. NOVEMBER 2006 N67 MNS M22 N67 MNT M28 OVERVIEW 1.15 Crankshaft Figure 6 1 3 2 04_012_N 1. Timing system driving gear - 2. Flywheel connecting hub - 3. Oil pump driving gear. The crankshaft is made in steel hardened by induction and rests on seven mountings; inside the hollow shaft are the ducts for the lubrication oil circulation. On the front tang, the oil pump driving gear, the phonic wheel, the flywheel connecting hub and the driving pulley of the ancillary components are keyed on. On the rear tang the camshaft driving gear and the coupling flange to the engine flywheel are keyed on. The bench half bearings are in cast babbitt lining steel and the 6th is fitted with a shoulder ring to contain the end play of the driving shaft. Details 1 and 2 in the figure, assembled by negative allowance on the rear tang, are not replaceable. The front and rear retaining rings are of the slide type with radial seal and require special fixtures to be assembled and disassembled. Connecting Rods Figure 7 04_013_N They are made in steel, manufactured by pressing, with small end oblique edged and cap separation obtained by fracture splitting technique. The connecting rod half bearings are cast babbitt lining steel. Every connecting rod is marked on the body and on the cap by a number that identifies their coupling and the cylinder into which it is to be assembled; moreover, a letter is impressed on the body stating its weight class. In case a replacement were necessary, only one type of connecting rod is available as spare part of an intermediate class weight that can be used to replace any other. Therefore, connecting rods that are still efficient, do not need to be replaced even if they are of a different class weight. 1.16 N67 MNS M22 N67 MNT M28 OVERVIEW Pistons NOVEMBER 2006 Timing system driving gear Figure 8 Figure 9 1 04_015_N 04_014_N The timing system driving gear machine is a push rods and rockers type, with a camshaft (1) that is located in the crankcase and set into rotation directly by the crankshaft. Figure 10 The pistons integrate the high swirl combustion chamber; the annular chambers inside the junk ring enable an effective heat elimination obtained by circulating the lubrication oil delivered by the spray nozzles mounted on the crankcase. On the piston skirt the are three seats for the retaining rings; the first one of these is obtained by a special trapezoidal section cast iron insert. The piston rings have different functions and different geometry. - - - The 1st piston ring has a trapezoidal section and ceramic chrome plating; The 2nd piston ring has a a torsional conical rectangular seal; The 3rd piston ring has a double oil scraper with internal spring. 1 3 04_317_N 2 1. Positioning reference - 2. Crankshaft - 3. Camshaft. The figure illustrates the position that the toothed wheel has to have to set the correct timing strokes. NOVEMBER 2006 N67 MNS M22 N67 MNT M28 OVERVIEW 1.17 Figure 11 1 2 5 3 6 7 4 8 9 04_316_N 1. Rocker - 2. Rocker support - 3. Adjuster screw - 4. Rod - 5. Cotters - 6. Cup - 7. Spring - 8. Tappet - 9. Camshaft. The timing camshaft rests on seven mountings; the mounting points at front and rear end, are fitted with cast babbitt lining steel bushings, assembled by negative allowance. The timing camshaft is set into rotation by the crankshaft with direct coupling to a straight toothed wheel. 1.18 N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 Cylinder head Figure 12 9 8 7 6 5 04_318_N 1 2 3 4 1. Engine coolant outlet to sea-water heat exchanger - 2. Lifting eyebolt - 3. Thermostat valve - 4. Cylinder head - 5. Combustion air inlet - 6. Exhaust valve - 7. Induction valve - 8. Exhaust gas outlet - 9. Injector. The cylinder head is monolithic and is made in cast iron; it houses the slots for the following parts: - Valves, with seats and elements inserted; - Thermostatic valve; - Injectors. To the cylinder head are coupled: - Exhaust manifold; - Induction manifold. N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 Valves and valve seats 1.19 Ancillary machine parts drive Figure 13 Figure 14 04_327_N 3 2 4 5 1 6 04_303_N 1 3 2 1. Induction valve - 2. Exhaust valve - 3. Inserted elements. Valves seat, obtained in the cylinder head, have elements inserted with 45° taper ratio for the exhaust valve and 60° taper ratio for the induction valves. 1. Crankshaft - 2. Engine coolant pump pulley - 3. Stationary guide pulley - 4. Alternator pulley - 5. Tightener spring 6. Stationary guide pulley. Motion to ancillary machine parts is transmitted by a Poly-V belt put under tension by a gauged spring (5). Stationary guide pulley (3) is located between the alternator pulley and the engine coolant pump pulley in order to provide an adequate contact surface on the latter. N67 MNS M22 N67 MNT M28 1.20 OVERVIEW NOVEMBER 2006 COMBUSTION AIR INTAKE AND EXHAUST SYSTEM Figure 15 4 1 2 3 5 6 04_320_N Engine coolant Cold air inlet Exhaust gas Sea-water 1. Air filter - 2. Turbocompressor - 3. Exhaust gas inlet in turbine - 4. Heat exchanger air / sea-water (not present on the N67 MNS M22 engine) - 5. Sea-water outlet pipe from the exchangers - 6. Exhaust terminal (riser). Before reaching the cylinders, supercharging feeding air, intaken through the filter, runs through the heat / sea-water exchanger, thus reducing its temperature, in order to favour a higher engine volumetric efficiency. The turbocompressor casing and exhaust manifold are cooled down by engine coolant. The exhaust gas flows into the exhaust terminal and, where applicable (riser), mixed with sea-water to be expelled. N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 Comburent air filter 1.21 Air / sea-water heat exchanger Figure 16 Figure 18 5 4 3 1 2 04_321_N 1 1. Filter clogging sensor. 04_027_N 6 1. Sea-water outlet - 2. Sacrificial anode (Zinc) - 3. Sea-water inlet - 4. comburent air inlet - 5. Comburent air outlet 6. Condensate drainage hole. Turbocompressor Figure 17 The flow of water coming from the sea-water pump goes through the tube bundle (3) and, by going through it, absorbs some of the heat of the overheated air of the turbosupercharge, passing through the exchanger coming from the turbocompressor (4). The outlet water (1) is conveyed towards the fresh water / sea-water heat exchanger, while the turbosupercharged air, cooled down, reaches the induction manifold (5) and from there reaches the cylinders. Through hole (6) air humidity condensated in water is expelled. 1 04_026_N 1. Coolant inlet. The engine is turbosupercharged by a fixed geometry turbine with no waste-gate control. The turbine is cooled by the coolant circulation from the crankcase. The compressor-turbine spindle rotates on brass bearings lubricated by pressure lubrication, directly from the oil filter. 1.22 N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 COOLING FRESH WATER CLOSED-LOOP Figure 19 5 6 7 2 4 3 1 04_326_N Hot engine coolant Cold engine coolant Sea-water 1. Coolant pump - 2. Thermostatic valve - 3. Pump intake flow - 4. Oil / coolant heat exchanger - 5. Coolant / sea-water heat exchanger - 6. To exhaust manifold cooling - 7. Turbocompressor. The centrifugal pump (1) set into rotation by the crankshaft by means of the poli-V belt, intakes the coolant and sends it to the crankcase to touch the areas of the thermic exchange of the cylinders and afterwards to the engine head put of which it comes through the thermostatic valve (2). The liquid is made to return to the pump until it reaches the setting temperature of the valve; once this temperature has been reached it is deviated proportionally to the temperature reached, towards the coolant / sea-water heat exchanger (5). A part of it goes back to the pump, another reaches the heat exchanger where it heats the sea-water up to re-enter then into the inlet of the pump. The coolant, before going through the crankcase, cools down the engine oil that goes through its own heat exchanger (4). Some of this oil comes out from the rear branchpipe to touch the turbocompressor and cools down the case (7) and goes through the exhaust manifold cavity, in order to reduce its temperature as it is prescribed by nautical regulations; this part of the liquid flows then into the branch pipe intake of the centrifugal pump. NOVEMBER 2006 N67 MNS M22 N67 MNT M28 OVERVIEW 1.23 Exhaust manifold cooling Figure 20 3 4 5 6 2 1 7 8 04_328_N Engine coolant going through exhaust manifold Hot engine coolant going through coolant exchanger Sea-water 1. Sea-water/coolant exchanger - 2. Turbocompressor - 3. Exhaust manifold - 4. Degassing piping 5. Thermostatic valve water / water exchanger connector - 6. Plug with pressure valve - 7. Thermostatic valve 8. Water pump manifold inlet. 1.24 N67 MNS M22 N67 MNT M28 OVERVIEW Thermostatic valve NOVEMBER 2006 Water pump Figure 21 Figure 23 3 1 04_331_N 2 Low temperature operation When the temperature of the coolant is lower than the set values, the coolant coming from inside the engine (1) recirculate directly towards the centrifugal pump (2). Figure 22 04_030_N 3 1 The water pump has its own seat within the crankcase and is set into rotation by the poli-V belt. Additional expansion tank 04_332_N 2 High temperature operation When the temperature of the coolant is above the set values, the thermostatic valve partially or totally shuts in the recirculation towards the pump and opens the path towards the coolant / sea-water heat exchange (3). In some cases an additional tank may be fitted with the purpose of increasing the available expansion volume; the connection to the main tank will be made through a pipe fitted on the hose holder of the union pipe “overflow”. The plug of this tank has to be equipped with a pressure relief valve to enable liquid downflow while the engine is cooling. This second tank, usually made in transparent material and not pressurized, can be installed in order to have a better access to check its level, that anyway has to be periodically checked also in the main tank. N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 1.25 SEA-WATER OPEN COOLING LOOP Figure 24 1 2 3 4 5 6 7 04_333_N Engine coolant Cold air Sea-water 1. Sea-water / coolant exchanger - 2. Outlet (riser) - 3. Sea-water outlet piping from exchanger - 4. Sea-water / oil gear exchanger (optional) - 5. Sea-water pump - 6. Sea-water inlet - 7. Air / sea-water exchanger (intercooler) (not present on the N67 MNS M22 engine). Sea-water drawn from under the bottom of the boat is the means by which the engine heat that has not been transformed into mechanical work is eliminated. The water, intaken by the pump set into rotation by the cranckshaft by means of a toothed wheel transmission, is directly sent to the supercharging heat exchanger (aftercooler), where the water temperature is reduced to improve engine volumetric efficiency and thus its performance; the water from the after-cooler, going through the gearbox oil heat exchanger (if fitted), reaches the “sea-water / fresh water” heat exchanger removing the heat yielded by the engine and conveyed by the coolant; temperature control is carried out by the thermostatic valve. The water, before being let into the sea drainage duct, touches and cools down the “riser” - the exhaust gas outlet - leaving the boat with the latter. N67 MNS M22 N67 MNT M28 1.26 OVERVIEW Sea-water pump NOVEMBER 2006 Sea-water / coolant heat exchanger Figure 25 Figure 26 2 3 1 2 1 1 3 04_034_N 1. Inlet - 2. Outlet. 5 2 The sea-water pump, with a neoprene rotor, is geared up by crankshaft. 04_035_N 4 1. Sea-water inlet - 2. Sea-water outlet - 3. Engine coolant inlet 4. Engine coolant outlet - 5. Sacrificial anode. The engine coolant, coming from thermostatic valve, goes into the exchanger (3) and touches the tube bundle that is run through the sea-water flow coming from the supercharging air heat exchanger (1); the cooled down engine coolant, goes through the manifold leading to the induction of the centrifugal pump (4). The sea-water coming out of the exchanger (2) is sent to the outlet. OVERVIEW NOVEMBER 2006 N67 MNS M22 N67 MNT M28 1.27 ENGINE OIL LUBRICATION LOOP Figure 27 7 8 9 6 5 4 10 3 2 1 04_330_N Oil delivery Return to sump 1. Oil sump - 2. Crankshaft - 3. Oil pump - 4. Oil filter bracket with engine coolant / oil heat exchanger - 5. Oil filter 6. Oil filler cap - 7. Oil vapours vent - 8. Oil delivery to turbocompressor - 9. Oil return from turbocompressor 10. Timing camshaft. Lubrication of the engine machine parts is oil forced circulation obtained by a gear pump located in the crankcase. The pump is set into rotation by the crankshaft by means of a toothed wheel and an intermediate gear. The oil pressurized by the pump, is sent to a filter and then to the engine ducts after going through the heat exchanger located on the flange coupling onto the crankcase also integrating the oil filter bracket; the exchanger is inserted on a seat in the engine crankcase and is touched by the engine coolant. A duct is specifically assigned to supply the nozzles that deliver the coolant to the pistons, the other one is assigned to the lubrication of the machine internal parts: bench bear- ings, connecting rods and timing, push rods and rockers; the lubrication of spindles and toothed wheels to actuate ancillary machine parts is obtained by dedicated ducts. The flows afterwards converge by gravity into the oil sump. The oil for the lubrication of the spindle of the turbocompressor rotors is drawn immediately after the oil filter, and reaches there by means of a piping external to the crankcase coupled to the rest by a special fitting. Oil vapours flow out from the vent to reach its own filter. 1.28 N67 MNS M22 N67 MNT M28 OVERVIEW Gear pump NOVEMBER 2006 Oil vapour recirculation Figure 28 Figure 30 5 1 2 4 3 2 04_037_N 1. Gear oil pump - 2. Crankshaft with driving gear oil pump. 1 Filter bracket Figure 29 04_329_N 7 6 Oil vapours Oil condensate 1. Condensate oil to the sump - 2. Flow limiter valve 3. Residual vapours to engine intake - 4. Oil vapour filter unit 5. Centrifugal separator. 5 4 3 2 8 1 04_190_N 1. Heat exchanger with engine coolant - 2. Oil delivery to internal engine machine parts - 3. Flow recirculated by pressure regulator valve. - 4. Delivery to nozzles piston cooling - 5. Flow inlet from the pump. - 6. Flange coupling onto crankcase - 7. Oil filter - 8. Oil for turbocompressor lubrication connector outlet. Seats for the pressure and the by-pass valve are fitted on the support. The ducts fitted inside enable to divert the oil inside the engine crankcase to the different lubrication functions. The filter, single cartridge, is two-stage with 5 µm parallel filtering. The oil vapours which generate inside the engine, flow out from the vent located on the 5th and 6th cylinder rocker arm lid, going through the centrifugal gas separator, where some of them condensate and return to the oil sump through the dedicated ducts. Residual vapours, due to inside pressure, are pushed to the filter unit. In the unit there are two filtering cartridges operating in parallel condensating a further vapour part that returns in liquid form to the oil sump. The part which is not condensated is sent to the engine intake by a gauged hole after the air filter. The vapour maximum load intaken by the engine is adjusted by the action of a membrane valve located in the filter unit. OVERVIEW NOVEMBER 2006 N67 MNS M22 N67 MNT M28 1.29 FUEL LINE N67 MNS M22 Figure 31 4 3 2 5 1 06_046_N 1. Settling prefilter - 2. Low pressure mechanical feed pump - 3. Fuel filter - 4. Injector - 5. Injection pump. Injection system is made up of mechanical rotary pump. Main components are set on board of the engine except the prefilter. 1.30 N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 N67 MNS M22 Fuel supply system scheme Figure 32 2 4 5 1 3 8 7 6 04_406_N 1. Fuel filter - 2. Engine stop solenoid valve - 3. Low pressure mechanical feed pump - 4. Injection pump - 5. Injector 6. Fuel tank - 7. Manual priming pump - 8. Pre-filter. During engine rotation, the low pressure pump (3) draws fuel from the tank (6) through the prefilter (8), the main filter (1) and the solenoid valve (2) to supply the injection pump (4). The injection pump supply injectors (5) with adequate timing and pressure parameters to obtain the performance and, at the same time, complying with anti-pollution regulations. Fuel not injected by the pump flows with the injectors leakage to recirculate to the tank. Manual priming pump (7) allows to fill up the fuel system. The solenoid valve (2) cut off the fuel to the injection pump inlet to obtain the engine stop. The standard set-up includes a normally open solenoid valve; it requires electric supply to stop the engine (excitation engine stop). On request, it is possible to insert a normally closed solenoid valve, viceversa requesting electric supply to keep the engine running (non-excitation engine stop). OVERVIEW NOVEMBER 2006 N67 MNS M22 N67 MNT M28 1.31 FUEL LINE N67 MNT M28.10 Figure 33 3 2 4 1 04_307_N 1. Settling prefilter - 2. Fuel filter - 3. Injector - 4. Injection pump. Injection system is made up of mechanical rotary pump. Main components are set on board of the engine except the prefilter. 1.32 N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 N67 MNT M28.10 Fuel supply system scheme Figure 34 1 2 8 3 4 7 5 6 04_308_N 1. Fuel filter - 2. Engine stop solenoid valve - 3. Low pressure mechanical feed pump - 4. Injection pump - 5. Injector 6. Fuel tank - 7. Manual priming pump - 8. Pre-filter. During engine rotation, the low pressure pump (3) draws fuel from the tank (6) through the prefilter (8), the main filter (1) and the solenoid valve (2) to supply the injection pump (4). The injection pump supply injectors (5) with adequate timing and pressure parameters to obtain the performance and, at the same time, complying with anti-pollution regulations. Fuel not injected by the pump flows with the injectors leakage to recirculate to the tank. Manual priming pump (7) allows to fill up the fuel system. The solenoid valve (2) cut off the fuel to the injection pump inlet to obtain the engine stop. The standard set-up includes a normally open solenoid valve; it requires electric supply to stop the engine (excitation engine stop). On request, it is possible to insert a normally closed solenoid valve, viceversa requesting electric supply to keep the engine running (non-excitation engine stop). N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 1.33 N67 MNT M28.10 Fuel pre-filter Fuel filter Figure 35 1 Figure 36 5 2 2 3 1 3 04_322_N 4 1. Inlet pipe from prefilter - 2. Injection pump supply pipe 3. Screw cap to drain water. 04_041_N 1. Fastener bracket - 2. System bleeding screw 3. Cartridge - 4. Sensor for detecting the presence of water in the fuel - 5. Manual priming pump. In the fuel circuit, it is placed before the fuel filter to protect it. Holds impurity larger than 36,5 µm and assures an high separation from water which may be present in fuel. On request can be equipped with the sensor for detecting the presence of water in fuel (4). - - - Filtering rating: 36,5 µm; Operating max pressure: 3 bar; Operating temperature: from -40 to +70 °C. In the lower part there is a screw cap (3) to drain the water which may be present in fuel. 1.34 N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 FUEL LINE N67 MNT M28.11 Figure 37 3 2 4 1 05_024_N 1. Settling prefilter - 2. Fuel filter - 3. Injector - 4. Injection pump. Injection system is made up of mechanical rotary pump. Main components are set on board of the engine except the prefilter. N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 1.35 N67 MNT M28.11 Fuel supply system scheme Figure 38 2 3 4 5 1 - 06_014_N 8 7 6 1. Fuel filter - 2. Engine stop solenoid valve - 3. Low pressure mechanical feed pump - 4. Injection pump 5. Injector - 6. Fuel tank - 7. Prefilter - 8. Electric pump. During engine rotation, the low pressure pump (3) draws fuel from the tank (6) through the prefilter (7), the main filter (1) and the solenoid valve (2) to supply the injection pump (4). The injection pump supply injectors (5) with adequate timing and pressure parameters to obtain the performance and, at the same time, complying with anti-pollution regulations. Fuel not injected by the pump flows with the injectors leakage to recirculate to the tank. Manual priming pump (7) allows to fill up the fuel system. The solenoid valve (2) cut off the fuel to the injection pump inlet to obtain the engine stop. The standard set-up includes a normally open solenoid valve; it requires electric supply to stop the engine (excitation engine stop). On request, it is possible to insert a normally closed solenoid valve, viceversa requesting electric supply to keep the engine running (non-excitation engine stop). 1.36 N67 MNS M22 N67 MNT M28 OVERVIEW NOVEMBER 2006 N67 MNT M28.11 Fuel pre-filter Fuel filter In the fuel circuit, it is placed before the fuel filter to protect it. Holds impurity larger than 30 µm and assures an high separation from water which may be present in fuel. On request can be equipped with the sensor for detecting the presence of water in fuel (4). Figure 41 For the 12 V electric pump filter Figura 39 2 4 3 1 2 5 3 1 04_322_N 6 06_060_N 7 1. System bleeding screw - 2.Fuel exit connection 3. Pump electric connector - 4. Electric pump 5. Fuel entry connection - 6. Pre-filter 7. Sensor for the presence of water in the fuel. For the 24 V electric pump filter Figura 40 4 06_061_N 3 2 5 6 7 1 8 1. Pump electric connection - 2. Resistor for adapting to the 24 V current - 3 Fuel exit connection - 4. Electric pump 5. Fuel entry connection - 6. System bleeding screw 7. Pre-filter - 8. Sensor for the presence of water in the fuel. 1. Inlet pipe from prefilter - 2. Injection pump supply pipe 3. Screw cap to drain water. In the lower part there is a screw cap (3) to drain the water which may be present in fuel. NOVEMBER 2006 TECHNICAL DATA N67 MNS M22 N67 MNT M28 2.37 SECTION 2 TECHNICAL DATA Page GENERAL SPECIFICATIONS Dimensions 39 41 2.38 N67 MNS M22 N67 MNT M28 TECHNICAL DATA PAGE LEFT INTENTIONALLY BLANK NOVEMBER 2006 NOVEMBER 2006 N67 MNS M22 N67 MNT M28 TECHNICAL DATA 2.39 GENERAL SPECIFICATIONS N67 MNS M22 Cycle 4 Stroke Diesel Air supply Supercharged and intercooled Injection Number of cylinders Bore Stroke Total displacement Compression ratio Direction of rotation, brake side Minimum idling rpm Maximum engine rpm, no load N67 MNT M28 Direct mm mm cm3 rpm rpm rpm 6 in line 104 132 6700 17,5 ± 0,8 : 1 counterclockwise 650 ± 25 3150 ± 25 Allowed engine inclination angles Maximum longitudinal in continuous operation (static + dynamic) Maximum transverse in continuous operation (static + dynamic) Longitudinal for oil level check with standard dipstick degrees/360 degrees/360 degrees/360 +18 ±23 0 ÷ +6 Supercharge Turbo-charger with water-cooled body Maximum pressure HOLSET HX40 bar 1,6 type SAE 15 W40/E 3 Lubrication Oil Oil compliant with specifications ACEA E3/API CF4/MIL L2104E/F Total oil capacity on first filling liters (kg) 16,5 (15) Total oil capacity with sump at minimum level liters (kg) 9 (8,2) Total oil capacity with sump at top level liters (kg) 14,5 (13) Oil pressure, warm engine, minimum idling rpm bar ≥ 1,2 Oil pressure, warm engine, maximum rpm bar ≥ 3,8 Maximum allowed temperature °C 120 Oil dipstick valid for static inclination degrees/360 0 to +6 Fuel Supply Fuel oil compliant with standard Low pressure transfer pump Flow rate at maximum rpm Fuel return flow rate to tank Filtering: pre-filter filter liters/h liters/h µm µm EN 590 inside injection pump 36,5 4 Injection System Type mechanical rotary pump 2.40 N67 MNS M22 N67 MNT M28 TECHNICAL DATA NOVEMBER 2006 N67 MNS M22 N67 MNT M28 Low Temperature Starting Allowed, without external aids, down to °C -15 Cooling Cooling fresh water closed loop Total coolant quantity 50% mixture of water/antifreeze Compliant with SAE J 1034 specification liters Expansion tank 22,5 standard Forced circulation centrifugal pump Flow rate at maximum rpm Temperature regulation 21 initial opening maximum opening liters/h °C °C with thermostatic valve 72° ± 2 82° ± 2 Sea-water line forced circulation Water pump self-priming with neoprene impeller Sea-water pump height above sea level m Max. pump capacity liters/h ≤2 12000 Exhaust gas expulsion Optional mixed with sea water Electrical system Nominal voltage Self-regulated alternator: Voltage Maximum current intensity Electrical starter motor: Nominal voltage Absorbed electrical power Recommended battery capacity Current discharge at -18 °C (SAE J 537) V dc 12 V dc A 14 90 V dc W Ah 12 4000 ≥ 120 A ≥ 900 Drive train coupling Flywheel diameter mm (inches) - (11,5) Flywheel case type SAE 3 Weights Without liquids and without marine gear kg 605 N67 MNS M22 N67 MNT M28 TECHNICAL DATA NOVEMBER 2006 2.41 Dimensions Figure 1 (1.) (1.) 0 (1.1) 26 (.2) (1.22) (1.) 126 (.66) 2, (2.61) 1 (0.) 10 (2.) 60 (2.6) 0 (0.0) 04_305_N Measurements in: millimeters (inches). 2.42 N67 MNS M22 N67 MNT M28 TECHNICAL DATA PAGE LEFT INTENTIONALLY BLANK NOVEMBER 2006 NOVEMBER 2006 ELECTRICAL EQUIPMENT N67 MNS M22 N67 MNT M28 3.43 SECTION 3 ELECTRICAL EQUIPMENT Page FOREWORD 45 ALTERNATOR 46 ELECTRICAL STARTER MOTOR 47 EQUIPOTENTIAL CONNECTIONS TO ENGINE GROUND 48 N67 MNS M22.10 49 M22.10 - M28.10 OVERALL 51 M22.10 - M28.10 SYNOPTIC 52 M22.10 - M28.10 WIRE HARNESS 53 M22.10 - M28.10 LOCATION OF ELECTRICAL COMPONENTS IN THE ENGINE 54 M22.10 - M28.10 POWER SUPPLY LINE 55 M22.10 - M28.10 RELAY BOX 56 Internal components position 56 M22.10 - M28.10 ELECTRICAL DIAGRAMS 58 Wiring diagram key 58 Electrical equipment component code 59 Main analog instrument panel 60 Secondary analog instrument panel 61 Supplementary services battery recharge 62 N67 MNS M22.11 63 M28.11 OVERALL 65 M22.11 SYNOPTIC 66 M22.11 WIRE HARNESS 67 M22.11 LOCATION OF ELECTRICAL COMPONENTS IN THE ENGINE 68 M22.11 POWER SUPPLY LINE 69 (continues on next page) 3.44 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT Page M22.11 WIRING DIAGRAMS 70 Wiring diagram key 70 Electrical equipment component code 71 Main analog instrument panel 72 Secondary analog instrument panel 73 Supplementary services battery recharge 74 N67 MNT M28.11 75 M28.11 OVERALL 77 M28.11 SYNOPTIC 78 M28.11 WIRE HARNESS 79 M28.11 LOCATION OF ELECTRICAL COMPONENTS IN THE ENGINE 80 M28.11 POWER SUPPLY LINE 81 M28.11 WIRING DIAGRAMS 82 Wiring diagram key 82 Electrical equipment component code 83 Main analog instrument panel 84 Secondary analog instrument panel 85 Supplementary services battery recharge 86 NOVEMBER 2006 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 3.45 FOREWORD Figure 1 04_306_N The engine identification data are stenciled on a tag positioned aside the coolant tank. Figure 2 S. p. A. Viale dell'Industria, 15/17 - 20010 Pregnana Mil.se MI - ITALY ENGINE TYPE ENGINE FAMILY ENGINE DWG POWER (KW) AND SPEED (RPM) POWER SET CODE ENGINE S/N YEAR OF BUILD HOMOLOGATION No COMMERC. TYPE / VERSION 06_013_N The last two figures of the commercial code refer to the engine model (detail A or B in figure n. 2). Until the beginning of the year 2006 the engines produced had the code N67 MNT M28.10 or N67 MNS M22.10 (detail A in figure n. 2). During the year 2006 relevant modifications have been made to the electric system and to the fuel supply circuit and N67 MNT M28 ! .10 .XX .11 " a new model identified with the code N67 MNT M28.11 or N67 MNS M22.11 was created (detail B in figure 2). This document concerns both the models. The relating contents are developed in different chapters which can be identified thanks to the presence in each title of the extension M22.10 - M28.10 or M22.11 - M28.11. 3.46 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 ALTERNATOR Figure 3 +B D+ 04_223_N “Bosch” Model 14 V - 90 A Figure 4 +B. (12 V) Power supply output terminal D+. (Lamp) Power supply voltage of recharge/alarm indicator light located on the panel. 100 Tightening torque for wire terminal nut B+ from 12 to 15 Nm. 80 Ambient temp. 25 °C 90 Specifications Nominal voltage 14 V Nominal current max 90 A Rpm max 6000 rpm Current max at 1800 rpm 50 A Polarity Negative ground Rotation Clockwise viewed from pulley Belt Poli-V Poles 12 Weight 5.7 kg Output current (A) 70 Ambient temp. 90 °C 60 50 40 30 20 10 0 04_224_N 0 1 2 3 4 5 6 Alternator speed (rpm x 1000) CHARACTERISTIC CURVES 7 8 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 3.47 ELECTRICAL STARTER MOTOR Figure 5 +B +50 Starter control 04_225_N Engine electrical ground connection point “Bosch” Model - Specifications Nominal power 4.3 kW Nominal voltage 12 V Polarity Negative ground Engagement circuit Positive command Rotation Clockwise viewed from pinion end Operating voltage 13 V max (20 °C) Water resistance Water spray test based on JIS D0203 SI Figure 6 RPM kW Nm V 2600 65 130 13 2400 60 120 12 2200 55 110 11 2000 50 100 10 1800 45 90 9 1600 40 80 8 1400 35 70 7 1200 30 60 6 1000 25 50 5 800 20 40 4 600 15 30 3 400 10 20 2 200 5 10 1 0 0 0 0 V kW RPM Nm 04_226_N 200400 600800 1000 1200 CHARACTERISTIC CURVES 1400 1600 I (A) N67 MNS M22 N67 MNT M28 3.48 ELECTRICAL EQUIPMENT NOVEMBER 2006 EQUIPOTENTIAL CONNECTIONS TO ENGINE GROUND Figure 7 3 04_334_N 2 1 To prevent electrochemical corrosion phenomena, some elements included in the cooling circuits were electrically grounded with copper braids with eyelet terminations. Elements connected to the engine ground with metallic braid conductors: 1. Junction of the fresh water outlet pipe from the water/ water heat exchanger; 2. Fresh water supply pipe to water/water exchanger; 3. Sea-water supply pipe to water/water exchanger. CAUTION To enhance connection efficiency, the screw threads and the surfaces in contact with the electrical terminals must be clean and not oxidized, so thoroughly inspect and remove any impurities before each reinstallation procedure. NOVEMBER 2006 ELECTRICAL EQUIPMENT N67 MNS M22 N67 MNT M28 N67 MNS M22.10 MODEL PRODUCED UNTIL THE BEGINNING OF THE YEAR 2006 3.49 3.50 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT PAGE LEFT INTENTIONALLY BLANK NOVEMBER 2006 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 3.51 M22.10 - M28.10 OVERALL Figure 8 1 2 3 4 11 10 9 8 7 6 5 04_319_N 1. Indicator and control panel - 2. Provided wire harness - 3. Relay box - 4. JF Connection - 5. Power supply and interface wire harness - 6. JA and JB connectors - 7. Wiring harness to be manufactured by the shipyard - 8. Sensor for the presence of water in fuel - 9. Sedimenting pre-filter - 10. M Connector - 11. Power line for electric starter motor and alternator. The electric equipment of the system carries out the main connections by means of the wiring provided with the engine, to which the power supply, the electronic components assembled on the engine, the electronic central unit of the injection system, relay box and the instrument and control panel are connected. The entire product is apt for the needs of an adequate installation and complies with electromagnetic compatibility limits legislation on electric installations (EMC). Wiring cannot be modified in any way and any possibility of using its wiring lines for different components is absolutely excluded. Wiring harness for power supply has to be manufactured by the shipyard following the indications contained in the “N67 MNS M22 Installation Directive” or “N67 MNT M28 Installation Directive” document. CAUTION Never use the wiring of the engine equipment to supply any other electrical appliance for the boat. Information related to analogue and digital instrument and control panel and the related sensors are present in the “N67 MNS M22 Installation Directive” or “N67 MNT M28 Installation Directive” document. 3.52 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.10 - M28.10 SYNOPTIC Figure 9 INDICATIONS AND ALARMS SENSORS ENGINE STOP SOLENOID VALVE EMERGENCY STOP BUTTON (OPT) ENGINE SPEED ADDITIONAL SENSORS (OPT) ALTERNATOR ELECTRIC STARTER MOTOR NEF MNS M 22.10 NEF MNT M 28.10 JB JA JF BATTERY RELAY BOX 06_059_N 1 2 3 4 1. Connector for instrument panel connection wire harness - 2. Engine wire harness 3. Interface wire harness - 4. Power line. The wire harnesses provided with the engine include the connectors for all optional components which may ordered and their connections to the JB connector for the indicator and control panel. 04_309_N Engine wire harness MM GG A I JA B W W T T JB M V V O EC C K K ELECTRICAL EQUIPMENT Figure 10 Interface wire harness A. Camshaft sensor (on request) - B. Drive shaft sensor (on request) - C. Emergency shut-down push-button (on request, installer’s responsibility) - I. High coolant temperature sensor (for alarm) - K. Air filter clogging sensor (for alarm) - M. Sensor for detecting the presence of water in the fuel pre-filter (for alarm) - O. Exhaust gas temperature sensor (on request) - T. Coolant temperature sensor (for gauge) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - EC. Engine stop solenoid valve GG. Alternator - JB. Instrument panel connection wire harness - JF. Relay box - MM. Electric starter motor. JF – BATT + BATT NOVEMBER 2006 N67 MNS M22 N67 MNT M28 M22.10 - M28.10 WIRE HARNESS 3.53 3.54 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.10 - M28.10 LOCATION OF ELECTRICAL COMPONENTS IN THE ENGINE Figure 11 GG I MM K EC B M JA-JB T W V A 04_323_N A. Drive shaft sensor (on request) - B. Drive shaft sensor (on request) - I. High coolant temperature sensor (for alarm) - K. Air filter clogging sensor (for alarm) - M. Sensor for detecting the presence of water in the fuel pre-filter (for alarm) - T. Coolant temperature sensor (for gauge) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - EC. Engine stop solenoid valve GG. Alternator - JA. Interface connection wire harness - JB. Instrument panel connection wire harness - MM. Electric starter motor. ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.10 - M28.10 POWER SUPPLY LINE Figure 12 4 2 Equipment power supply 30 50 +B W D+ M 04_302_N 1 3 1.Alternator - 2. Electric starter motor - 3. Battery 4. Engine wire harness. The power supply line, to be implemented by the shipyard, comprises: o A. A connection between the negative pole of the battery and engine ground with a conductor having a cross section of at least 70 mm2; o B. A connection between the positive pole of the battery and the terminal “30” of the electrical starter motor, with a conductor having a cross section of at least 70 mm2; o C. A connection between the +B terminal of the alternator to the positive +30 terminal of the electric starter motor, to complete the recharge circuit, is reached with a conductor having a cross section of at least 10 mm2.. The connection of the electric equipment of the engine to the battery has to be carried out by the two-eyed terminals, +B and -B present on the wiring harness. CAUTION In presence of equipments with excitation engine stop, if magneto-thermal protecting breakers or battery-switch are installed on system electrical supply lines, eventual interruption of electrical supply will not allow to stop the engine. N67 MNS M22 N67 MNT M28 3.55 N67 MNS M22 N67 MNT M28 3.56 ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.10 - M28.10 RELAY BOX Figure 13 Figure 15 1 04_310_N 1. JF connection. It is the main point of interconnection and carries out many interfacing functions among the various components of the system. Inside the box, are present the power management relays of some components and two fuses that protect the electrical lines against short circuits or excessive current absorption. Connect it to wiring using the 16 pole JF connector. This is to be installed and anchored in such a way as to dampen the vibrations and stresses occurring when underway, and will be accessible during servicing operations and when underway. 1 3 6 13 16 5 9 10 2 4 7 8 12 15 11 14 04_324_N Internal components position Figure 14 R1 FS3 R3 FS2 R2 RS JF 04_325_N R1. Power supply to terminal 50 of the electric starter motor R2. Emergency engine shut-down provision - R3. Key switch electric discharge - FS 2. Fuse on solenoid valve supply line for engine stop - FS 3. Fuse on main supply line - RS. Alternator pre-excitation resistor - JF. Interface connector wire harness. JF CONNECTOR (view of the wire harness terminal, coupling side) NOVEMBER 2006 ELECTRICAL EQUIPMENT PAGE LEFT INTENTIONALLY BLANK N67 MNS M22 N67 MNT M28 3.57 N67 MNS M22 N67 MNT M28 3.58 ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.10 - M28.10 ELECTRICAL DIAGRAMS Wiring diagram key General conditions for the preparation and interpretation of wiring diagrams o Key switch open; o Engine not running; o Liquids at efficient levels and pressures. Figure 16 Connection JC: connector 8: terminal Component terminal Fuse code Component code MS CG 20 CA 30 QP 30 TA MO C C V X100 10 15 50 4 JE 4 JH 0 JH 10 JE 50 0 0 0 1 L L- L+ 3 AS 10 40 1 JD 9 1 SA P1 AQ 1 2 JF FS2 FS3 JC 1 2 8 4 7 6 9 40 36 39 14 15 16 13 5 10 11 JC 33 34 32 44 27 41 26 25 21 42 22 43 23 45 JB 1 2 8 4 7 6 9 40 36 39 14 15 16 13 5 10 11 JB 33 34 32 44 27 41 26 25 21 42 22 43 23 45 15 A 15 A JA 10 17 14 16 6 9 A JF JA 10 5 O B D1 RS JF 11 7 JA 6 R3 11 + + R2 JF 15 BATT JA 1 70 30 R1 GG 3 1 2 EC 1 2 3 JA 20 10 50 M A B C AC M BATT W GG 1 70 1 2 Minimum cable cross section in mm2 T EC 31 1 1 1 V 1 JA Component code or connector code 3 1 2 1 J1 4 JF 6 - J Terminal connections M C 2 B NOVEMBER 2006 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT 3.59 Electrical equipment component code A drive shaft sensor (on request) AC battery AQ engine shut-off push-button on main panel AS engine shut-off push-button on secondary panel Indicator lights B drive shaft sensor (on request) EDC EDC malfunction C emergency shut-down push-button (optional, installer’s responsibility) SAC presence of water in fuel pre-filter CA key switch SATA coolant high temperature CS engine start push-button on secondary panel SBLA low coolant level EC engine stop solenoid valve SBPO low oil pressure GG alternator SCP pre-post heating I high coolant temperature sensor (for alarm) SIFA clogged air filter K air filter clogging sensor (for alarm) SIFB clogged oil vapor filter L instrument panel light switch SIFC clogged fuel filter M sensor for detecting the presence of water in the fuel pre-filter (for alarm) SIFO clogged oil filter SP pre-lubrication MM electric starter motor SS alternator fault MS IVECO MOTORS-FPT indications and alarms module SSV engine overspeed O exhaust gas temperature sensor (on request) Gauges P1 sound alarm inhibition push-button CG revolution-counter QP main analog instrument panel MO engine oil pressure QS secondary analog instrument panel TA engine temperature SA buzzer V voltmeter T coolant temperature sensor (for gauge) V oil pressure sensor (for gauge) W low oil pressure sensor (for alarm) Connectors JA JB JC connection between engine wiring and interface wire harness on engine wire harness set for connection to the main analog instrument panel on main analog instrument panel set for connection to the engine wire harness JD JE JF IVECO MOTORS-FPT indications and alarms module on main analog instrument panel set for connection to the secondary analog instrument panel relay box JH on secondary analog instrument panel set for connection to the main analog instrument panel Relays contained in the relay box R1 power supply to terminal 50 of the electric starter motor R2 emergency engine shut-down provision R3 key switch electric discharge Fuses contained in the relay box FS 2 on solenoid valve supply line for engine stop FS 3 on main supply line BATT - AC + BATT FS3 70 70 M 31 15 A 15 A FS2 30 2 JB 1 JA 1 JF 15 50 8 4 JF R1 7 4 6 7 0 0 0 1 2 JA R3 9 RS D1 W 2 GG GG 3 5 10 R2 JA JF 40 36 39 14 15 16 13 9 6 16 40 36 39 14 15 16 13 L- L+ 3 0 X100 9 P1 10 20 6 AQ L CA 10 50 4 JE 10 8 JH 10 JA 10 17 14 2 JC 1 JH 4 AS JE 4 15 30 2 11 J1 1 5 5 11 1 50 30 7 1 3 EC 1 2 10 11 10 11 EC 1 JA SA JF 40 T 34 JB 33 1 1 34 JC 33 C TA 1 V 1 32 32 C MO JD 9 1 7 8 3 1 2 M A B C B O A M 2 1 JA 20 C B B 1 2 JA 12 13 44 27 41 26 25 21 42 22 43 23 45 46 47 44 27 41 26 25 21 42 22 43 23 45 46 47 V MS SCP SBLA SIFB SS SIFA 1 1 K 1 1 I 1 1 W A A 1 2 JA 18 19 3 JB 3 17 20 24 28 29 37 20 19 18 30 38 12 35 31 16 12 11 14 6 SIFO JC 5 SIFC 3 17 20 24 28 29 37 17 18 4 SP 19 18 30 38 12 35 31 3 EDC SATA SBPO SAC 10 19 15 13 2 JD panel - + JF 1 QP CG Main analog instrument 6 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT 6 SSV 3.60 NOVEMBER 2006 M22.10 - M28.10 1 BATT - AC + BATT JF FS3 70 70 M 31 15 A 15 A FS2 30 QP 2 JB 1 JA 1 JF 15 50 8 8 4 7 4 JF 6 7 0 0 0 1 2 JA R3 9 RS D1 R2 5 10 W 2 GG GG 3 JA JF 40 36 39 14 15 16 13 9 6 16 40 36 39 14 15 16 13 L- L+ 3 0 X100 9 P1 10 20 6 AQ L CA 10 50 4 R1 JA 10 17 14 2 JC 1 15 30 CG J1 1 1 2 5 5 50 30 JB JC EC 1 34 34 40 1 3 EC 1 2 1 2 3 * C TA 4 5 6 7 8 9 10 11 12 * C MO JE V AS JD 9 MS 1 7 SS SIFA 0 0 0 1 2 X100 L- L+ 3 0 20 CG SCP 17 18 4 5 SBLA 12 11 10 9 40 JH 1 50 30 SA 3 EDC SATA SBPO 10 19 15 13 2 SAC CS 10 8 SP SIFC SIFO SIFB 8 7 6 JD 5 9 MS 16 12 11 14 4 1 7 24 3 P2 SSV 6 2 1 8 10 19 15 13 2 JD SA 3 17 18 4 QS 5 16 12 11 14 6 23 ELECTRICAL EQUIPMENT Secondary analog instrument panel * See main instrument panel wiring diagram - + 6 6 NOVEMBER 2006 N67 MNS M22 N67 MNT M28 3.61 M22.10 - M28.10 * – + Two-engines installation AC2 – IE1 M 30 10 50 JA 11 10 J1 GG2 B+ B+ GG J1 50 MM 30 M 87 85 30 86 70 6 6 – BAT 70 70 10 AC1 MM RL 10 BAT + 6 + 11 JA BAT – 70 – AC2 + – + * AC1 + BAT – BAT M 30 50 MM GG1 J1 B+ 11 Key: - AC1: Main Battery - AC2: Battery for auxiliary services - IE1: Engine 1 electrical system - IE2: Engine 2 electrical system - RL: Relay 50A max. - * : Electrical power supply for services 6 Single engine installation 10 10 70 + BAT JA IE2 Supplementary services battery recharge 6 70 N67 MNS M22 N67 MNT M28 6 10 3.62 ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.10 - M28.10 NOVEMBER 2006 ELECTRICAL EQUIPMENT N67 MNS M22.11 MODEL PRODUCED FROM THE YEAR 2006 N67 MNS M22 N67 MNT M28 3.63 3.64 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT PAGE LEFT INTENTIONALLY BLANK NOVEMBER 2006 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 3.65 M28.11 OVERALL Figure 17 1 2 6 5 3 4 06_051_N 1. Indicator and control panel - 2. Provided wire harness - 3. JB Connection - 4. Power line for electric starter motor and alternator - 5. Sensor for the presence of water in the fuel - 6. Sedimenting pre-filter. The electric equipment of the system carries out the main connections by means of the wiring provided with the engine, to which the power supply, the electronic components assembled on the engine, the electronic central unit of the injection system, relay box and the instrument and control panel are connected. The entire product is apt for the needs of an adequate installation and complies with electromagnetic compatibility limits legislation on electric installations (EMC). Wiring cannot be modified in any way and any possibility of using its wiring lines for different components is absolutely excluded. Wiring harness for power supply has to be manufactured by the shipyard following the indications contained in the “N67 MNS M22 Installation Directive” document. CAUTION Never use the wiring of the engine equipment to supply any other electrical appliance for the boat. Information related to analogue and digital instrument and control panel and the related sensors are present in the “N67 MNS M22 Installation Directive” document. 3.66 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.11 SYNOPTIC Figure 18 INDICATIONS AND ALARMS SENSORS ENGINE STOP SOLENOID VALVE EMERGENCY STOP BUTTON (OPT) ALTERNATOR ELECTRIC STARTER MOTOR N67 MNS M22.11 JB RL1 BATTERY 06_052_N 1 2 3 1. Connector for instrument panel connection wire harness - 2. Engine wire harness - 3. Power line. Together with the wiring supplied with the engine there are also the connectors for all the system components and the relating connections to the JB connector for the signalling and command board. 06_053_N I RL1 87 85 86 30 4 50 7 4 8 5 4 T V W 4 16 J16F EC GG K GG +BAT (MM) 4 J1 MM 50 JSV 1 4 15 1 −BAT (GG) 4 W 1 −BAT (MM) Figure 19 J1. Alternator excitation - JSV. Over speed module - J16F. Engine rotation over speed control module (on request) - RL1. Starter relay motor - MM. Electric starter motor. ELECTRICAL EQUIPMENT I. High coolant temperature sensor (for alarm) - K. Air filter clogging sensor (for alarm) - T. Coolant temperature sensor (for gauge) - V. Oil pressure sensor (for gauge) W. Low oil pressure sensor (for alarm) - W. Signal for revolution counter - EC. Engine stop solenoid valve - GG. Alternator - JB. Instrument panel connection wire harness - JB +BAT (GG) NOVEMBER 2006 N67 MNS M22 N67 MNT M28 3.67 M22.11 WIRE HARNESS N67 MNS M22 N67 MNT M28 3.68 ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.11 LOCATION OF ELECTRICAL COMPONENTS IN THE ENGINE Figure 20 GG I RL1 MM K EC JB 06_055_N JSV T W V I. High coolant temperature sensor (for alarm) - K. Air filter clogging sensor (for alarm) - T. Coolant temperature sensor (for gauge) V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - EC. Engine stop solenoid valve - GG. Alternator JB. Instrument panel connection wire harness - MM. Electric starter motor - JSV. Over speed module - RL1. Starter relay motor. ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.11 POWER SUPPLY LINE Figure 21 4 5 6 Equipment power supply 30 50 +B W D+ M 06_004_N 3 2 1 1.Alternator - 2. Electric starter motor - 3. Battery 4. Engine wire harness - 5. This conductor is present on the engine wiring - 6. This conductor must be parallel connected to the existing one. The connection of the +B terminal of the alternator to the positive +30 terminal of the electric starter motor must be achieved with a conductor having a cross section of at least 20 mm2. On the engine wiring there is a 6 mm2 section conductor: a 16 mm2 section or – or higher – conductor must be connected to it. The connection of the positive +30 terminal of the electric starter motor to the positive pole of the battery, achieved with a conductor having a cross section of at least 70 mm2, allows to obtain, as shown in the figure, the simultaneous connection of the alternator to the battery. On the same +30 terminal of the start-up electric engine it is necessary to connect the eye battery lead connection marked with “+ BAT (MM)”. The connection between the engine ground and the negative pole of the battery must be achieved according to the guidelines provided in the Engine electrical ground paragraph. CAUTION Do not use any magneto-thermal activation protection items to stop engine. Using off-the-shelf equipment, you stop the engine energizing the proper solenoid valve. In lack of power supply you could not stop the engine. N67 MNS M22 N67 MNT M28 3.69 N67 MNS M22 N67 MNT M28 3.70 ELECTRICAL EQUIPMENT NOVEMBER 2006 M22.11 WIRING DIAGRAMS Wiring diagram key General conditions for the preparation and interpretation of wiring diagrams: o Key switch open o Engine not running o Liquids at efficient levels and pressures Figure 22 30 Connection JC: connector 16: terminal Component terminal Fuse code CA RL 30 Component code CG 86 20 MO 30 QP TA D V X100 10 MA 40 50 SA SSV 0 0 0 1 SIFA 0 FS C SCP C SBLA 85 SATA 87 SBPO 87a 50 SS 15 1 8 4 AQ 8A 3 1 4 2 8 7 6 5 4 3 2 1 12 10 11 2 5 6 D1 9 3 7 R JC 1 R JB 1 A AN N V G L VN K BZ GR VB S BN H M 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 JC A AN N V G L VN K B Z SN S BN H M 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 JB VB 3 1 V K AN L 1 1 1 1 2 V W KSB I1 30 J1 1 87 86 6 85 6 I1 1 G MP 1 EC 2 N 2 2 RL1 3 3 1 GG 1 GG 1 I K T 1 1 4 4 3 3 2 2 1 1 JSV J16F 1 +BATT (MM) 16 70 MM 30 AC 50 J1 2 M 70 +BATT (GG) +B D+ GG W –B 31 - 16 + –BATT (MM) Minimum cable cross section in mm2 Quadro princ N 100-150 AFAM Component code or connector code Cable colour S NOVEMBER 2006 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT 3.71 Electrical equipment component code AC battery Indicator lights AQ engine shut-off push-button on main panel SAC AS engine shut-off push-button on secondary panel CA key switch SATA Presence of an alarm on the personalized board (if the IVECO MOTORS-FPT alarm and signalling module is not present) coolant high temperature CS engine start push-button on secondary panel SBLA low coolant level D 6 diodes block SBPO low oil pressure D1 Protection diode (on the main board) SCP pre-post heating GG alternator SIFA clogged air filter I high coolant temperature sensor (for alarm) SS alternator fault I1 KSB refrigerating liquid temperature sensor SSV runaway engine J1 engine stop solenoid valve J1 alternator excitation Gauges CG revolution-counter K air filter clogging sensor (for alarm) MO engine oil pressure KSB cold injection advance adjustment device TA engine temperature MA alarms management module V voltmeter MM QP electric starter motor main analog instrument panel QS secondary analog instrument panel SA buzzer T coolant temperature sensor (for gauge) V oil pressure sensor (for gauge) W low oil pressure sensor (for alarm) J16F Engine rotation over speed control module (on request) Connectors JA IVECO MOTORS-FPT indications and alarms module JB ON ENGINE WIRE HARNESS set for connection to the main analog instrument panel JC ON MAIN ANALOG INSTRUMENT PANEL set for connection to the engine wire harness JSV Over speed module connector MF ON SECONDARY ANALOG INSTRUMENT PANEL pre-set clamp for connection to the main analog instrument panel MP ON MAIN ANALOG INSTRUMENT PANEL pre-set clamp for connection to the secondar y analog instrument panel Relays RL1 RL power supply to terminal 50 of the electric starter motor For engine stop from alarm module Fuse FS on “15” supply line Board electric cables colour index K orange A sky blue B white L blue G yellow H grey M brown N black S pink R red V green Z purple 70 RL1 2 87 J1 1 EC 31 M 10 0 8 7 6 5 4 3 2 1 0 0 0 1 3 50 MM 2 –BATT (MM) 30 R 4 J1 2 5 6 2 2 +BATT (GG) 8 +B D+ GG W –B 7 3 3 1 GG 1 GG 1 1 W 9 10 11 12 13 14 15 16 JB 85 X100 3 2 1 J16F 2 1 JSV I 4 1 1 3 V 40 CG 4 1 1 50 30 1 JB +BATT (MM) 86 I1 2 2 4 D1 1 3 87 20 A AN N V G L VN K BZ GR VB S BN H M 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 JC A AN N V G L VN K B Z SN S BN H M R AQ 87a 86 JC 1 50 RL 1 1 T C 1 1 MO K C TA V MP SCP VB N G V K AN L D S SA 8 1 7 3 9 6 5 2 11 10 12 4 MA Main analog instrument panel - 70 85 30 I1 1 3 8A FS 15 30 ELECTRICAL EQUIPMENT AC + KSB QP CA 6 16 30 6 N67 MNS M22 N67 MNT M28 16 3.72 NOVEMBER 2006 M22.11 Quadro princ N 100-150 AFAM SBLA SSV SIFA SATA SS SBPO 70 2 3 J1 1 EC 31 M G 6 AN N V 4 3 A 2 50 MM 6 5 4 3 2 2 J1 5 G AN N V A –BATT (MM) 30 +BATT (MM) I1 2 JB 1 R 2 4 D1 1 3 +B 0 8 7 6 5 4 3 2 1 0 0 0 1 X100 Z SN S BN H M GG 2 GG 2 W 3 3 1 1 1 W 1 3 2 1 J16F 2 1 JSV 1 3 I 1 40 CG 4 1 50 30 4 V 1 9 10 11 12 13 14 15 16 JB B +BATT (GG) 1 2 3 4 JSV GG –B D+ VN K L 8 8 7 7 VN K L 10 20 BZ GR VB S BN H M 9 10 11 12 13 14 15 16 JC 85 87 86 T 1 1 K 1 1 C MO C TA V MF MP SCP VB N G V K RN VN AN L S VB N G SBPO CS K SATA V AS AN L D 10 S SA 0 X100 8 7 6 5 4 3 2 1 20 50 30 QS 7 3 9 6 5 2 11 10 12 4 8 1 40 CG MA Secondary analog instrument panel - AC 70 RL1 86 87 I1 1 R JC 1 AQ 87a RL ELECTRICAL EQUIPMENT + 85 30 KSB QP 8A FS 50 6 15 30 16 CA SIFA SATA 30 6 16 SBLA SS Quadro fly N 100-150 AFAM SBPO NOVEMBER 2006 N67 MNS M22 N67 MNT M28 3.73 M22.11 SSV SS n Two-engines installation !# n !# )% - n"!44¬-- -- n"!44¬-- ¬ * $ " " '' $ " '' " -- "!44¬'' * ¬ 2, - "!44¬-- "!44¬-- '' ¬ n !# n !# - "!44¬-- -- " '' $ " "!44¬'' Key: - AC1: Main Battery - AC2: Battery for auxiliary services - IE1: Engine 1 electrical system - IE2: Engine 2 electrical system - RL: Relay 50A max. - *: Electrical power supply for services Single engine installation * ¬ n"!44¬-- )% N67 MNS M22 N67 MNT M28 Sk Accum_Servizi NEF280 S3 3.74 ELECTRICAL EQUIPMENT NOVEMBER 2006 Supplementary services battery recharge M22.11 NOVEMBER 2006 ELECTRICAL EQUIPMENT N67 MNT M28.11 MODEL PRODUCED FROM THE YEAR 2006 N67 MNS M22 N67 MNT M28 3.75 3.76 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT PAGE LEFT INTENTIONALLY BLANK NOVEMBER 2006 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 3.77 M28.11 OVERALL Figure 23 1 2 8 7 3 4 5 06_062_N 1. Indicator and control panel - 2. Provided wire harness - 3. JB Connection - 4. Fuel electric pump timer - 5. Power line for electric starter motor and alternator - 6. Sedimenting pre-filter - 7. Sensor for the presence of water in the fuel - 8. Fuel electric pump. The electric equipment of the system carries out the main connections by means of the wiring provided with the engine, to which the power supply, the electronic components assembled on the engine, the electronic central unit of the injection system, relay box and the instrument and control panel are connected. The entire product is apt for the needs of an adequate installation and complies with electromagnetic compatibility limits legislation on electric installations (EMC). Wiring cannot be modified in any way and any possibility of using its wiring lines for different components is absolutely excluded. Wiring harness for power supply has to be manufactured by the shipyard following the indications contained in the “N67‑MNT M28 Installation Directive” document. CAUTION Never use the wiring of the engine equipment to supply any other electrical appliance for the boat. Information related to analogue and digital instrument and control panel and the related sensors are present in the “ N67 MNT M28 Installation Directive” document. 3.78 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT NOVEMBER 2006 M28.11 SYNOPTIC Figure 24 INDICATIONS AND ALARMS SENSORS ENGINE STOP SOLENOID VALVE FUEL ELECTRIC PUMP TIMER FUEL ELECTRIC PUMP ALTERNATOR ELECTRIC STARTER MOTOR ¬.¬-.4¬-¬ *" RL1 BATTERY 05_007_N 1 2 3 1. Connector for instrument panel connection wire harness - 2. Engine wire harness 3. Interface wire harness - 4. Power line. Together with the wiring supplied with the engine there are also the connectors for all the system components and the relating connections to the JB connector for the signalling and command board. ) 2, ¬¬¬¬¬¬ 4 6 7 '' '' *& %# + "!4¬-- '' '' "!4¬'' "!4¬'' -- *36 "!4¬'' "!4¬'' * "!4¬-- 7 ELECTRICAL EQUIPMENT Figure 25 I. High coolant temperature sensor (for alarm) - K. Air filter clogging sensor (for alarm) - P. Fuel electric pump - T. Coolant temperature sensor (for gauge) - T. Fuel electric pump timer - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) - W. Signal for revolution counter - EC. Engine stop solenoid valve - GG. Alternator JB. Instrument panel connection wire harness - J1. Alternator excitation - JSV. Over speed module - J16F. Engine rotation over speed control module (on request) - RL1. Starter relay motor - MM. Electric starter motor. *" 05_006_N 0 4 24 NOVEMBER 2006 N67 MNS M22 N67 MNT M28 3.79 M28.11 WIRE HARNESS N67 MNS M22 N67 MNT M28 3.80 ELECTRICAL EQUIPMENT NOVEMBER 2006 M28.11 LOCATION OF ELECTRICAL COMPONENTS IN THE ENGINE Figure 26 P GG I RL1 T MM K EC JB 06_015_N JSV T W V I. High coolant temperature sensor (for alarm) - K. Air filter clogging sensor (for alarm) - P. fuel electric pump - T. Fuel electric pump timer - T. Coolant temperature sensor (for gauge) - V. Oil pressure sensor (for gauge) - W. Low oil pressure sensor (for alarm) EC. Engine stop solenoid valve - GG. Alternator - JB. Instrument panel connection wire harness - MM. Electric starter motor JSV. Over speed module - RL1. Starter relay motor. ELECTRICAL EQUIPMENT NOVEMBER 2006 M28.11 POWER SUPPLY LINE Figure 27 4 5 6 Equipment power supply 30 50 +B W D+ M 06_004_N 3 2 1 1.Alternator - 2. Electric starter motor - 3. Battery 4. Engine wire harness - 5. This conductor is present on the engine wiring - 6. This conductor must be parallel connected to the existing one. The connection of the +B terminal of the alternator to the positive +30 terminal of the electric starter motor must be achieved with a conductor having a cross section of at least 20 mm2. On the engine wiring there is a 6 mm2 section conductor: a 16 mm2 section or – or higher – conductor must be connected to it. The connection of the positive +30 terminal of the electric starter motor to the positive pole of the battery, achieved with a conductor having a cross section of at least 70 mm2, allows to obtain, as shown in the figure, the simultaneous connection of the alternator to the battery. On the same +30 terminal of the start-up electric engine it is necessary to connect the eye battery lead connection marked with “+ BAT (MM)”. The connection between the engine ground and the negative pole of the battery must be achieved according to the guidelines provided in the Engine electrical ground paragraph. CAUTION Do not use any magneto-thermal activation protection items to stop engine. Using off-the-shelf equipment, you stop the engine energizing the proper solenoid valve. In lack of power supply you could not stop the engine. N67 MNS M22 N67 MNT M28 3.81 N67 MNS M22 N67 MNT M28 3.82 ELECTRICAL EQUIPMENT NOVEMBER 2006 M28.11 WIRING DIAGRAMS Wiring diagram key General conditions for the preparation and interpretation of wiring diagrams: o Key switch open o Engine not running o Liquids at efficient levels and pressures Figure 28 30 Connection JC: connector 16: terminal Component terminal Fuse code CA CG RL 30 Component code 86 20 MO 30 QP TA D V X100 10 MA 40 SA SSV 50 0 0 0 1 SIFA 0 FS C SCP C SBLA 85 SATA 87 SBPO 87a 50 SS 15 1 8 4 AQ 8A 3 1 4 2 8 7 6 5 4 3 2 1 12 10 11 2 5 6 D1 9 3 7 R JC 1 R JB 1 A AN N V G L VN K BZ GR VB S BN H M 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 JC A AN N V G L VN K B Z SN S BN H M 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 JB VB 1 1 EC 6 6 86 3 3 1 1 +BATT (MM) GG1 2 GG 2 16 70 MM 30 AC 50 J1 2 M +BATT (GG) 16 + +B D+ GG –B 31 70 1 87 GG 2 GG 2 3 3 1 1 1 V 1 RL1 - 1 W 1 85 G V K AN L MP EC 3 2 1 30 N 1 I 1 K T 1 1 4 4 3 3 2 2 1 1 JSV J16F 1 1 2 2 3 3 4 4 5 5 RT T 1 1 W 3 P 2 P –BATT (MM) Quadro princ N 280 AFAM Minimum cable cross section in mm2 Component code or connector code Cable colour S NOVEMBER 2006 N67 MNS M22 N67 MNT M28 ELECTRICAL EQUIPMENT 3.83 Electrical equipment component code AC battery Indicator lights AQ engine shut-off push-button on main panel SAC AS engine shut-off push-button on secondary panel CA key switch SATA Presence of an alarm on the personalized board (if the IVECO MOTORS-FPT alarm and signalling module is not present) coolant high temperature CS engine start push-button on secondary panel SBLA low coolant level D 6 diodes block SBPO low oil pressure D1 Protection diode (on the main board) SCP pre-post heating EC engine stop solenoid valve SIFA clogged air filter GG alternator SS alternator fault I high coolant temperature sensor (for alarm) SSV runaway engine K air filter clogging sensor (for alarm) MA Alarms management module MM P QP electric starter motor fuel electric pump main analog instrument panel QS secondary analog instrument panel SA buzzer T coolant temperature sensor (for gauge) T fuel electric pump timer V oil pressure sensor (for gauge) W low oil pressure sensor (for alarm) J16F Engine rotation over speed control module (on request) Connectors JA IVECO MOTORS-FPT indications and alarms module JB ON ENGINE WIRE HARNESS set for connection to the main analog instrument panel JC ON MAIN ANALOG INSTRUMENT PANEL set for connection to the engine wire harness JSV Over speed module MF ON SECONDARY ANALOG INSTRUMENT PANEL pre-set clamp for connection to the main analog instrument panel MP ON MAIN ANALOG INSTRUMENT PANEL pre-set clamp for connection to the secondar y analog instrument panel Gauges CG revolution-counter MO engine oil pressure TA engine temperature V voltmeter Relays RL1 RL power supply to terminal 50 of the electric starter motor For engine stop from alarm module Fusibles FS on “15” supply line Board electric cables colour index K orange A sky blue B white L blue G yellow H grey M brown N black S pink R red V green Z purple QP 70 JB 31 R 3 50 MM 2 –BATT (MM) 30 +BATT (MM) M 0 8 7 6 5 4 3 2 1 0 0 0 1 4 J1 2 5 6 8 GG1 2 GG 2 GG 2 GG 2 +B W +BATT (GG) GG –B D+ 7 3 3 3 3 1 1 1 1 1 1 W 3 4 5 T 5 RT P 2 3 1 2 4 1 J16F JSV 3 2 1 1 3 2 2 4 1 I 3 V 1 4 1 1 50 40 CG 1 9 10 11 12 13 14 15 16 JB 10 X100 30 1 85 20 1 1 T C K P 1 1 MO C TA V MP SCP VB N G V K AN L D S SA 7 3 9 6 5 2 11 10 12 4 8 1 MA Main analog instrument panel - RL1 86 87 EC 2 4 D1 1 3 87 86 A AN N V G L VN K BZ GR VB S BN H M 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 JC A AN N V G L VN K B Z SN S BN H M R AQ 87a RL JC 1 50 30 ELECTRICAL EQUIPMENT AC + 70 85 30 1 1 EC 3 2 1 8A FS 15 CA 6 16 30 6 N67 MNS M22 N67 MNT M28 16 3.84 NOVEMBER 2006 M28.11 Quadro princ N 280 AFAM SBLA SSV SIFA SATA SS SBPO QP 70 JB 1 31 G 6 AN N V 4 3 A 2 50 MM 6 5 4 3 2 2 J1 5 G AN N V A –BATT (MM) 30 +BATT (MM) M R 2 4 D1 1 3 +B 0 8 7 6 5 4 3 2 1 0 0 0 1 X100 Z SN S BN H M 2 3 3 GG1 2 GG 3 3 GG 2 GG 2 W 1 1 1 1 1 W 1 4 5 T 4 5 RT P 2 3 1 3 3 1 2 1 T 1 1 I 1 40 CG 2 1 50 30 1 V 1 9 10 11 12 13 14 15 16 JB B +BATT (GG) 1 2 3 4 JSV GG –B D+ VN K L 8 8 7 7 VN K L 10 20 BZ GR VB S BN H M 9 10 11 12 13 14 15 16 JC 85 87 86 K 1 1 C P MO C TA V MF MP SCP VB N G V K RN VN AN L S VB N G SBPO CS K SATA V AS AN L D 10 S SA 0 X100 8 7 6 5 4 3 2 1 20 50 30 QS 7 3 9 6 5 2 11 10 12 4 8 1 40 CG MA Secondary analog instrument panel - AC 70 RL1 86 87 EC R JC 1 AQ 87a RL ELECTRICAL EQUIPMENT + 85 30 1 1 EC 3 2 1 8A FS 50 6 15 30 16 CA SIFA SATA 30 6 16 SBLA SS Quadro fly N 280 AFAM SBPO NOVEMBER 2006 N67 MNS M22 N67 MNT M28 3.85 M28.11 SSV SS n Two-engines installation !# n !# )% - n"!44¬-- -- n"!44¬-- ¬ * $ " " '' $ " '' " -- "!44¬'' * ¬ 2, - "!44¬-- "!44¬-- '' ¬ n !# n !# - "!44¬-- -- " '' $ " "!44¬'' Key: - AC1: Main Battery - AC2: Battery for auxiliary services - IE1: Engine 1 electrical system - IE2: Engine 2 electrical system - RL: Relay 50A max. - *: Electrical power supply for services Single engine installation * ¬ n"!44¬-- )% N67 MNS M22 N67 MNT M28 Sk Accum_Servizi NEF280 S3 3.86 ELECTRICAL EQUIPMENT NOVEMBER 2006 Supplementary services battery recharge M28.11 NOVEMBER 2006 N67 MNS M22 N67 MNT M28 DIAGNOSTICS 4.87 DIAGNOSTICS Page FOREWORD 89 MAJOR DIAGNOSTIC ACTIONS 90 Checking pressure in fuel supply line 90 Checking component resistance value 90 Checking line insulation 90 REFERENCE VALUES 91 For non hardwired sensors 91 For inductive sensors 91 Sensors wired with shielded wires 91 GUIDE TO SYMPTOM DIAGNOSING 92 4.88 N67 MNS M22 N67 MNT M28 DIAGNOSTICS Page left intentionally blank NOVEMBER 2006 NOVEMBER 2006 DIAGNOSTICS FOREWORD A proper diagnosis is reached through the competence acquired with years of experience and attending training courses. When the user complains of poor performance or operating anomalies, due consideration must be given to his/her indications, in order to derive useful information that will orient our actions. After ascertaining the existence of the anomaly, we recommend starting troubleshooting operations with tests and measurements, to obtain a picture of the overall operating conditions and identify the real fault causes. If adopted diagnostic modes provide no indications, proceed to check ratings and technical data provided in the “N67 MNS M22 Installation Directive” or “N67 MNT M28 Installation Directive” document. We have provided, in the following pages, a TROUBLESHOOTING GUIDE organized by symptoms, describing the possible anomalies not recognized by the electronic unit, frequently mechanical or hydraulic in nature. For operation and maintenance instructions, see the indications provided in Section 5. N67 MNS M22 N67 MNT M28 4.89 4.90 N67 MNS M22 N67 MNT M28 DIAGNOSTICS NOVEMBER 2006 MAJOR DIAGNOSTIC ACTIONS Checking pressure in fuel supply line Figure 1 Checking component resistance value Figure 2 A 04_086_N Ensure that the system is not powered. The measurement must be taken on each individual component, isolated from its wiring or connected only to the instrument, set as ohmmeter on the appropriate end of scale value (see REFERENCE VALUE table in the pages that follow). At the end, restore the correct connection. B Checking line insulation Figure 3 04_307_N Gauges will be interposed in A and B by “T” unions. Measurements have to be carried out at various engine speeds from minimum to maximum at intervals of 200 RPM. 04_087_N Acceptable limit ratings Point Minimum Maximum A - 15 kPa 0 kPa B 0 kPa 30 kPa Figure 4 04_088_N Ensure that the system is not powered. The measurement must be taken on each individual conductor, isolated from all the components to which it is normally connected.The measurement must be taken with the instrument set as ohmmeter on end of scale value ≥ 200 KΩ, and it must be taken both towards the positive potential and the negative battery potential. At the end, restore the correct connection. N67 MNS M22 N67 MNT M28 DIAGNOSTICS NOVEMBER 2006 4.91 REFERENCE VALUES For non hardwired sensors Component Test conditions Minimum Ω value Maximum Ω value Coolant temperature sensor 90 °C 51.2 ± 4.3 Lubrication oil pressure sensor 0 bar 2 bar 4 bar 6 bar maximum 10 52 88 124 - +3/-5 ±4 ±4 ±5 184 Drive shaft sensor 20 °C 800 1000 Camshaft sensor 20 °C 800 1000 Engine stop solenoid valve (12V) 20 °C 4 6 Engine stop solenoid valve (24V) 20 °C 16 24 CAUTION Measurements refer only to the reference component. Measurements closest to reality are taken including the relevant wiring. Always check the continuity of the SHIELD conductor from the sensor to the electronic unit and the latter’s good insulation from the other signal conductors. For inductive sensors Sensors wired with shielded wires Component Test conditions Value Drive shaft sensor Engine running 650 rpm > 0.8 Vac Camshaft sensor Engine running 650 rpm > 0.8 Vac Figure 5 1 1, 2. Sensor terminals - 3. Shield electrically insulated from sensor. 2 3 04_063_N Possible cause - Low charge - Faulty terminal connections - Malfunction - Faulty terminal connections - Incorrect timing - Wear or defective - Malfunction - Faulty terminal connections - Incorrect priming - Incorrect filling (air in fuel circuit) - Presence of water - Clogged Part Battery Electrical starter motor Injection pump "15" control from key switch Fuel feed pump Fuel circuit Fuel circuit Fuel filter and pre-filter Symptom Engine does not start Engine does not start Engine does not start Engine does not start Engine does not start Engine does not start Engine does not start Engine does not start GUIDE TO SYMPTOM DIAGNOSING - Bleed - Check tank - Replace - Drain water from fuel filter and prefilter. Clean fuel tank and piping. Remove and clean injection pump. Restore fuel loop, fill the tank and vent the air. - Check seal and air with a clear tube, arranged as an inverted U, inserted before the inlet junction. N67 MNS M22 N67 MNT M28 - Check seal or air intake on induction side - Check wiring, key switch and relay R1 contained in relay box - Check, restore correct timing - Injection pump overhaul - Check efficiency - Check connections to positive (+ 30) and engine ground - Recharge (disconnecting battery from system wiring) - Clean, check insulation, tighten terminals Recommended tests or action 4.92 DIAGNOSTICS NOVEMBER 2006 Part Coolant level Water pump drive belt Water pump Thermostatic valve Coolant / sea-water heat exchanger Air filter Cylinder head gaskets Injection pump Symptom Engine frequently overheats Engine frequently overheats Engine frequently overheats Engine frequently overheats Engine frequently overheats Engine frequently overheats Engine frequently overheats Engine frequently overheats GUIDE TO SYMPTOM DIAGNOSING - Incorrect timing - Incorrect calibration - Compression leaking from cylinder head gaskets - Clogged - Clogged - Locked, closed or only partially open - Malfunction - Poor tension - Wear - Below MIN level Possible cause - Check, restore correct timing - Injection pump calibration/overhaul - Check cooling water circuit pressure - Replace head gaskets - Clean or replace - Check filter clogging sensor - Clean or replace - Replace - Check for impurities in coolant - Replace - Check belt tension - Check for liquid leakage on drive belt - Check tension - Replace - Check for liquid leakage on drive belt - Check for leaks - Top up correct level Recommended tests or action NOVEMBER 2006 DIAGNOSTICS N67 MNS M22 N67 MNT M28 4.93 Part Fuel circuit Injectors Engine air feed Gas exhaust system Gas exhaust system Turbocompressor Camshaft Engine valves Injection pump Automatic injection advance device Symptom Poor performance Poor performance Poor performance Poor performance Poor performance Poor performance Poor performance Poor performance Poor performance Poor performance GUIDE TO SYMPTOM DIAGNOSING - Injection pump calibration/overhaul - Check, restore correct timing - Injection pump overhaul - Check, restore correct clearance - Check - Replace - Check, restore correct timing - Check - Check parts and lubrication circuit - Replace - Check exhaust back-pressure DIAGNOSTICS - Malfunction - Incorrect timing - Incorrect calibration - Excessive or nil clearance - Wear - Incorrect timing - Inefficient - Inefficient bearings - Clogged - Check and remove cause of leak - Check filter clogged sensor - Clean or replace filter - Loosening the connector on the pipe connecting the injector, it excludes the injection, enabling to locate the cylinder where the anomaly is present. Proceed with caution in order to avoid dangerous fuel sprays and dispersions in the environment. - Clean or replace clogged filters - Check intake seals - Check pressure relief valve on the fuel gear pump - Check the integrity of the fuel gear pump Recommended tests or action N67 MNS M22 N67 MNT M28 - Leakage along the cooled manifold before the turbine. - Air filter clogged - Malfunction - Locked, closed - Locked, open - Tank net filter clogged - Fuel prefilter clogged - Fuel filter clogged - Air in fuel circuit - Fuel pressure too low - Heavy fuel leakage Possible cause 4.94 NOVEMBER 2006 Speed regulator on injection pump Tie rods between command lever and regulation lever on injection pump Cylinders, pistons Water in cylinders Oil in cylinders Poor performance Poor performance Poor performance The engine emits grey-white smoke The engine smoke Fuel tank Net filter Prefilter Fuel filter Fuel circuit Engine stop solenoid valve power supply only (on versions with de-energizing engine stop) Engine stops Engine stops Engine stops Engine stops blue L.D.A. device on injection pump Poor performance emits Part Symptom GUIDE TO SYMPTOM DIAGNOSING - Connections - Wiring - Key switch - Relay R1 - Check +B and –B electrical connections - Check wiring, key switch and relay R1 - See “Poor performance” - Replace - Check efficiency of fuel filter clogging sensor - Refill and bleed fuel circuit - Modify float or tank tilt - Check lubrication oil consumption - Overhaul - Check coolant level - Check fresh water circuit pressurization - Check heat exchanger - Check efficiency of sensor to detect the presence of water in fuel - Engine overhaul - Check, adjust the tie-rods so that command lever can be moved to the full delivery position. - Injection pump calibration/overhaul - Injection pump calibration/overhaul - Check and remove cause of leak Recommended tests or action DIAGNOSTICS - See “Poor performance” - Clogged - Not enough fuel in tank - Float in incorrect position - Oil leaking in turbocompressor - Oil leaking from valve guides - Leakages from cylinder gasket - Water in intake system from air / sea-water heat exchanger - Water in fuel - Excessive wear - Incorrectly adjusted - Malfunction - Malfunction - Losses along the intake manifold Possible cause NOVEMBER 2006 N67 MNS M22 N67 MNT M28 4.95 4.96 N67 MNS M22 N67 MNT M28 DIAGNOSTICS Page left intentionally blank NOVEMBER 2006 NOVEMBER 2006 MAINTENANCE N67 MNS M22 N67 MNT M28 5.97 SECTION 5 MAINTENANCE PERIODICITY OF CHECKS AND MAINTENANCE OPERATIONS Page 99 PREPARING THE ENGINE FOR LONG IDLE PERIODS 101 ENGINE’S FIRST START / RESTORING NORMAL OPERATING CONDITIONS 101 5.98 N67 MNS M22 N67 MNT M28 MAINTENANCE Page left intentionally blank NOVEMBER 2006 N67 MNS M22 N67 MNT M28 MAINTENANCE NOVEMBER 2006 5.99 PERIODICITY OF CHECKS AND MAINTENANCE OPERATIONS Execution of the operations indicated below requires competence and compliance with the safety regulations enforced in each Country. Checks can be performed by the user of the vessel and/or by the workshop personnel. Periodic maintenance operations must be performed by qualified personnel and require the use of tools, work instruments, and suitable protection means. Extraordinary maintenance operations is to be performed by IVECO MOTORS-FPT authorized workshop personnel with adequate training and sufficient technical information. Checks Periodicity Every 150 300 600 900 1200 Annual start hours hours hours hours hours (2) Check engine lubricating oil level n Check engine coolant level n Check oil level in the gearbox n Inspect exhaust duct(s) n Drain water from fuel pre-filter(s) (1) n Check battery terminal tightening and cleanliness n n Check electrolyte level in batteries n n (1) Check condition of oil vapor filter Periodic maintenance operations n Periodicity Clean air filter(s) Every 150 300 600 900 1200 Annual start hours hours hours hours hours (2) (1) n n Check belt tension and conditions n n Check zinc anode corrosion condition (4) n n Restore battery electrolyte level n n Drain/draw water and condensations from tank(s) n n (1) Replace engine lubricating oil (after first 50 hours) n n Replace fuel pre-filter(s) (1) (3) Max n Replace fuel filter(s) (1) (3) Max n Replace oil filter(s) (after first 50 hours) n n Replace gearbox(es) oil (see data provided by the manufacturer) n n Inspect sea-water intake (1) n n Check wear of sea-water pump impeller n n Adjust valve-rocker arm clearance every 3000 hours Extraordinary maintenance operations (5) Periodicity Every 150 300 600 900 1200 Every 3 start hours hours hours hours hours years (7) Clean turbocompressor n n Clean heat exchangers n n (6) Replace water pump and alternator drive belt n Inspect damper in drive shaft front pulley n n 5.100 N67 MNS M22 N67 MNT M28 MAINTENANCE (1) The periodicity of these operations may vary depending on engine use and environmental conditions of operation. (2) These operations must be carried out annually even if the specified number of operating hours is not reached. (3) Maximum time interval for high quality fuel; it may be reduced depending on their contamination. The filter is provided with clogging sensor; if a clogging indication is provided, replace the filter. The pre-filter is provided with a water presence detector; if the presence of water is detected, drain the water from the appropriate drain and if the light stays lighted, replace the filter. (4) If zinc corrosion exceeds 50% of its volume, replace it. (5) Instructions provided in Section 8. (6) Combustion air/sea-water exchanger: clean air side and water side - Engine coolant/sea-water exchanger: clean the sea-water side - Gearbox oil/sea-water heat exchanger (if‑provided): clean sea-water side. (7) These operations must be performed every three years even if the specified operating hours are not reached. NOVEMBER 2006 NOVEMBER 2006 MAINTENANCE PREPARING THE ENGINE FOR LONG IDLE PERIODS To prevent oxidation to the internal parts of the engine and to some components of the injection system, if idle periods exceeding two months are expected, the engine needs to be prepared with six-months periodicity, proceeding as follows: 1. Drain the lubricating oil from the sump, after heating the engine; 2. Pour 30/M type protective oil (alternatively, oil conforming with MIL 2160B Type 2 specifications) into the engine to the “minimum” level marked on the dipstick. Start the engine and let it run for about 5 minutes; 3. Drain the fuel from the injection line and from the filter, taking care to avoid letting the fuel come in contact with the auxiliaries belt; 4. Connect the fuel line to a tank containing CFB protective liquid (ISO 4113) and assist the inflow of the liquid by pressurizing the line and turning the engine over for about 2 minutes, after excluding the operation of the injection system. The required operation may be carried out by directly polarizing the terminal 50 of the electric starter motor with positive voltage 12 V, using a conductor prepared for the occasion; 5. Nebulize 30/M type protective oil at the rate of about 70 g (10 g per liter of displacement) into the turbocompressor intake, while the engine is turning over as described above; 6. Close with suitable stoppers or seal with adhesive tape all engine intake, exhaust, aeration and venting ports; 7. Drain the residual 30/M type protective oil from the sump; it may be re-used for 2 more engine preparation operations; 8. Apply tags with the inscription “ENGINE WITHOUT OIL” on the engine and onboard panel; 9. Drain the coolant, if it has not been mixed with antifreeze and corrosion inhibiting agents, affixing tags to indicate that the operation has been carried out. If external parts of the engine are to be protected, spray protective liquid OVER 19 AR onto unpainted metal parts, such as flywheel, pulleys and others; avoid spraying belts, connector cables and electrical equipment. N67 MNS M22 N67 MNT M28 5.101 ENGINE’S FIRST START / RESTORING NORMAL OPERATING CONDITIONS 1. Drain the residual protective oil type 30/M from the sump; 2. Pour lubricating oil into the engine, as provided by the specifications and in the quantities set out in the Table of Refills; 3. Drain the CFB protective liquid from the fuel line, completing the operations set out in item 3 of “PREPARING THE ENGINE FOR LONG IDLE PERIODS”; 4. Remove the caps and/or the seals from the engine’s intake, exhaust, aeration and vent ports, restoring normal operating conditions. Connect the turbocompressor intake to the air filter; 5. Attach the fuel lines to the vessel’s fuel tank, completing the operations set out in item 4 of “PREPARING THE ENGINE FOR LONG IDLE PERIODS”. During the filling operations, attach the fuel tank return pipe to a collecting container to prevent residues of CFB protective liquid from flowing into the vessel’s fuel tank; 6. Verifiy the quantity of cooling liquid and refill as provided by the specifications; 7. Start the engine and keep it running until idling speed has completely stabilized; 8. Shut the engine down; 9. Remove the tags with the inscription “ENGINE WITHOUT OIL” from the engine and from the panel. 5.102 N67 MNS M22 N67 MNT M28 MAINTENANCE Page left intentionally blank NOVEMBER 2006 NOVEMBER 2006 SERVICING OPERATIONS ON INSTALLED ENGINE N67 MNS M22 N67 MNT M28 6.103 SECTION 6 SERVICING OPERATIONS ON INSTALLED ENGINE Page FOREWORD 105 PRESCRIPTIONS FOR WORK ON THE INJECTION SYSTEM 106 VALVES CLEARANCE ADJUSTMENT 106 VENTING THE AIR FROM THE FUEL FEED LOOP M22 - M28.10 107 VENTING THE AIR FROM THE FUEL FEED LOOP M28.11 107 CLEANING THE ENGINE COOLANT / SEA-WATER HEAT EXCHANGER 108 CLEANING THE AIR / SEA-WATER HEAT EXCHANGER 109 ADJUSTING INJECTION PUMP TIMING 110 Injection pump timing data 111 VERIFY INJECTION PUMP TIMING 111 CALIBRATING THE INJECTION PUMP 111 MARINE PARTS DECOUPLING 112 INSTRUCTIONS FOR DISEMBARKING THE ENGINE 114 Handling 114 6.104 N67 MNS M22 N67 MNT M28 SERVICING OPERATIONS ON INSTALLED ENGINE Page left intentionally blank NOVEMBER 2006 NOVEMBER 2006 SERVICING OPERATIONS ON INSTALLED ENGINE FOREWORD Many of the procedures for carrying out the instructions that follow depend on the configuration of the housing on the vessel and on the disposition of the installation components. Prescriptions and cautions for use, handling and technical assistance are provided in Section 9. Technicians and maintenance personnel are reminded of the need to comply with safety rules. The checks necessary at the completion of an installation or re-embarkation are described in the “N67 MNT M28 Installation Directive” document. Spare parts will be supplied only if the following data are provided: - - Engine technical code and serial number; Part number as per spare parts catalog. The information provided below refer to engine characteristics which were current as of the publishing date. The manufacturer reserves the right to make changes at any time and without advance notice, to comply with technical or commercial requirements or to adapt to legal requirements in different Countries. The manufacturer shall not be liable for any errors and omissions. The IVECO MOTORS-FPT Technical Assistance Network is always at the Customer’s side with its competence and professionalism. N67 MNS M22 N67 MNT M28 6.105 6.106 N67 MNS M22 N67 MNT M28 SERVICING OPERATIONS ON INSTALLED ENGINE PRESCRIPTIONS FOR WORK ON THE INJECTION SYSTEM NOVEMBER 2006 VALVES CLEARANCE ADJUSTMENT The successful outcome of repair work is assured by the operator’s experience and ability and by compliance with the following instructions. Figure 1 o Keep parts and components clean, making sure that during handling and assembly (starting with the simple replacement of filter and pre-filter) no sludge or foreign matter is allowed to enter the lines, with particular attention to the fuel supply line in the segment downstream of the filter; 2 1 3 o Maintain the proper polarization of all electrical connections; o Tighten the threaded connections to the prescribed torque; o Make sure that the flywheel and camshaft sensors are positioned so they abut, ensuring they are as close to perpendicular (with respect to the bearing surface) as possible. CAUTION q Do not disconnect electrical connections without removing power from the circuits first; q Do not proceed with operating simulations with unsuitable tools and instruments; q Do not force measuring probes or mechanical tools into the electrical connections; q Do not proceed with arc welding without first disconnecting electronic system units. To proceed with the overhaul of the engine or its parts, you must disconnect the electrical connections of the system’s components and of the sensors providing indications on the control panel. To proceed as indicated, we provide below the procedure to avoid the risk to damage the electrical components. o Set the key switch to the STOP position and shut the engine down; o Wait 10 sec. and disconnect the battery terminals; o Disconnect the connectors releasing the restrain system, than split the parts avoiding sudden motions; o Remove, if necessary, the entire wiring harness from the engine. 04_335_N Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Working clearance shall be as follows: - - Intake valves 0.25 ± 0.05 mm; Exhaust valves 0.50 ± 0.05 mm. CAUTION In order to adjust faster the operating clearance for rocker arms - valves, proceed as follows: Rotate the drive shaft, balance cylinder 1 valves and adjust the valves marked by the n symbol as shown in the table: Cylinder n. 1 2 3 4 5 6 intake - - n - n n exhaust - n - n - n Rotate the drive shaft, balance cylinder 6 valves and adjust the valves marked by the n symbol as shown in the table: Cylinder n. 1 2 3 4 5 6 intake n n - n - - exhaust n - n - n - N67 MNS M22 N67 MNT M28 SERVICING OPERATIONS ON INSTALLED ENGINE NOVEMBER 2006 VENTING THE AIR FROM THE FUEL FEED LOOP M22 - M28.10 6.107 VENTING THE AIR FROM THE FUEL FEED LOOP M28.11 Figure 2A Figure 2B 3 4 3 2 2 5 1 6 1 05_022 _V 1. System bleeding screw - 2.Fuel exit connection - 3. Pump electric connector - 4. Electric pump 5. Fuel entry connection - 6. Pre-filter. 04_041_N 1. Fuel prefilter - 2. System bleeding screw 3. Manual priming pump. To exhaust air from fuel system, operate the pre-filter (1) manual pump (3) or use a specific electric pump. Loosen the vent fitting (2) on the pre-filter and operate the pump until only fuel without air flows out. Tighten the vent fitting and continue pumping during the initial startup phases. Make sure that the fuel that flows out of the fitting is not dispersed in the environment. CAUTION Never attempt to vent the high pressure system, as this is useless and extremely dangerous. If the key commuter is rotated into the “ON” position, the timer supplies the electric pump in order to set the fuel supply circuit at low pressure. Loosen the vent fitting on the pre-filter and operate the pump until only fuel without air flows out. Tighten the vent fitting. CAUTION Do not supply the electric pump for long period in the absence of fuel. Under these circumstances the electric engine is not cooled down. CAUTION Never attempt to vent the high pressure system, as this is useless and extremely dangerous. 6.108 N67 MNS M22 N67 MNT M28 SERVICING OPERATIONS ON INSTALLED ENGINE NOVEMBER 2006 CLEANING THE ENGINE COOLANT / SEA-WATER HEAT EXCHANGER Figure 3 1 2 3 5 1 4 04_271_N 4 1. Cover - 2. Spacer - 3. Tube bundle - 4. Sealing rings - 5. Zinc sacrificial anode. In order to guarantee a perfect operation of the heat exchanger, regularly clean the tube bundle. If the surfaces of the heat exchanger come into contact with salted water, they may be subjected to biological fouling and to hydrocarbon deposit which may be present in harbors’ waters. o Remove the tube bundle (3) from the exchanger body and immerse it for a few minutes in a solution prepared with water and a degreasing scale-remover detergent, observing the detergent manufacturer’s directions for use. The cleansing solution should not damage copper, brass, aluminum and tin; o Complete tube cleaning by rinsing thoroughly with fresh water, until detergent residues are entirely removed; o Reassemble the tube bundle (3) by correctly positioning spacer (2), sealing rings (4), and covers (1); o Check the zinc anode corrosion level (5); replace the anode if corrosion exceeds 50% of the volume. N67 MNS M22 N67 MNT M28 SERVICING OPERATIONS ON INSTALLED ENGINE NOVEMBER 2006 6.109 CLEANING THE AIR / SEA-WATER HEAT EXCHANGER (NOT PRESENT ON THE N67 MNS M22 ENGINE) Figure 4 3 1 1 2 4 7 04_272_N 4 6 5 6 5 1. Cover - 2. Spacer - 3. Tube bundle - 4. Sealing rings - 5. Plug - 6. Tube bundle fixing screw - 7. Zinc sacrificial anode. In order to guarantee a perfect operation of the heat exchanger, regularly clean the tube bundle. If the surfaces of the heat exchanger come into contact with salted water, they may be subjected to biological fouling and to hydrocarbon deposit which may be present in harbors’ waters; surfaces coming into contact with comburent air are subject to oil deposits resulting from the fumes exhausted at the base and from sucked downstream the air filter. o Remove tube bundle fixing plugs (5) and screws (6); o Remove the tube bundle (3) from the exchanger body and immerse it for a few minutes in a solution prepared with water and a degreasing scale-remover detergent, observing the detergent manufacturer’s directions for use. The cleansing solution should not damage copper, brass, aluminum and tin; o Complete tube cleaning by rinsing thoroughly with fresh water, until detergent residues are entirely removed; o Reassemble the tube bundle (3) by correctly positioning spacers (2), sealing rings (4) and covers (1); o Reassemble screws (6) in order to suitably secure the tube bundle and relevant plugs (5); o Check the zinc anode corrosion level (7); replace the anode if corrosion exceeds 50% of the volume. 6.110 N67 MNS M22 N67 MNT M28 SERVICING OPERATIONS ON INSTALLED ENGINE NOVEMBER 2006 ADJUSTING INJECTION PUMP TIMING It requires to ensure the exact pumper position of injection pump compared to an exact angular position of crankshaft. Figure 6 Figure 5 88141 1 1 2 2 4 3 5 6 04_346_N o Remove the screw (3) and screw the tool 99395100 (2), inclusive of centesimal dial gauge (1), ensuring that the shaft is making contact with the pumper; Bring the cylinder 1 piston to T.D.C., compression end, proceeding as follows: o Rotate crankshaft in a position where both intake and exhaust valves are closed; o Swap the cylinder 1 injector with tool 99395097 (1) inclusive of centesimal dial gauge, and preload the dial gauge; o Rotate the crankshaft in the opposite direction to normal rotation, until reaching the lesser value on the dial gauge; o Carefully rotate the crankshaft in the normal direction of rotation, until reaching the maximum value on the dial gauge (corresponding to cylinder 1 piston T.D.C. position); o Verify that both intake and exhaust valves are closed, then set the dial gauge to zero. o Preload the dial gauge by 3 mm; o Rotate the crankshaft in the opposite direction to normal rotation, until the pumper reaches its own B.D.C., as shown by the dial gauge; o Set the dial gauge to zero; o Rotate the crankshaft of about 30° in the opposite direction to normal rotation; o Carefully rotate the crankshaft in the normal direction of rotation, until reading the 0.00 mm value on the dial gauge (1) of tool 99395097 (Fig. 5), corresponding to cylinder 1 piston T.D.C. position; o Partially loosen the lateral screw (5) locking the pump shaft, without removing the slip washer; o Loosen the pump fixing nuts (4) without remove them, so as to allow the pump body rotation; o Carefully rotate the pump body until reading the prescribed pumper stroke value on the dial gauge (1) of tool 99395100 (Fig. 6) (see following table); o Tighten the pump fixing nuts (4) and the lateral screw (5) to prescribed torque values; proceed with timing verification. NOVEMBER 2006 N67 MNS M22 N67 MNT M28 SERVICING OPERATIONS ON INSTALLED ENGINE 6.111 Injection pump timing data With reference to the engine code and that applied to the injection pump (point 6 of Figure 6). Engine N67 MNS M22 (162 kW @ 2800 rpm) Injection pump Bosch VE6/12F 1400 L 1012 (STD) Pumper stroke with cylinder 1 piston at T.D.C. 1,4 ± 0,05 mm N67 MNS M22 (147 kW @ 2800 rpm) not available - N67 MNS M22 (132 kW @ 2800 rpm) not available - N67 MNS M22 (132 kW @ 2300 rpm) Bosch VE6/12F 1400 L 1012 (/4) 1,4 ± 0,05 mm N67 MNS M22 (110 kW @ 2800 rpm) Bosch VE6/12F 1400 L 1012 (/3) 1,4 ± 0,05 mm N67 MNT M28 (206 kW @ 2800 rpm) Bosch VE6/12F 1400 L 1012 1,4 ± 0,05 mm N67 MNT M28 (191 kW @ 2800 rpm) Bosch VE6/12F 1400 L 1012 A 1,4 ± 0,05 mm N67 MNT M28 (170 kW @ 2800 rpm) Bosch VE6/12F 1400 L 1012 B 1,3 ± 0,05 mm N67 MNT M28 (132 kW @ 2500 rpm) Bosch VE6/12F 1400 L 1012 C 1,3 ± 0,05 mm VERIFY INJECTION PUMP TIMING CALIBRATING THE INJECTION PUMP Arrange in advance the tools on the engine, as shown in procedures described in Figures 5 and 6. The BOSCH servicing network must carry out the revision and calibration operations. o Carefully rotate the crankshaft in the normal direction of rotation, until reading the 0.00 mm value on the dial gauge (1) of tool 99395097 (Fig. 5), corresponding to cylinder 1 piston T.D.C. position; The paper containing the data for calibrating the pump on the bench is identified by the code applied to the body of the injection pump (point 6 of Figure 6) and is available from the BOSCH servicing network. o Read the pumper stroke value on the dial gauge (1) of tool 99395100 (Fig. 6); Otherwise contact the IVECO MOTORS-FPT Technical Service Centre. o If the measured value is not within the prescribed tolerance, follow operations described in chapter “ADJUSTING INJECTION PUMP TIMING” in the previous page. 6.112 N67 MNS M22 N67 MNT M28 SERVICING OPERATIONS ON INSTALLED ENGINE NOVEMBER 2006 MARINE PARTS DECOUPLING Some periodical maintenance and overhaul interventions require full access to engine parts and removal of marine parts. The following sequence is suggested to simplify the necessary operations. Figure 9 Figure 7 04_273_N o Remove the support and the oil filter from their housing located on engine base. o Decouple the air filter and the turbocompressor exhaust riser. Figure 10 04_336_N o Remove cooling circuit exhaust pipes, located on engine head. Figure 8 04_338_N o Remove the booster air pipe, joining the turbocompressor to the air / water exchanger (aftercooler) (not present on the N67 MNS M22 engine). Figure 11 04_337_N o Remove coolant inlet pipe which joints the engine to the water / water heat exchanger. 04_277_N o Prepare turbocompressor removal by disassembling coolant and lubricant inlet pipes. NOVEMBER 2006 SERVICING OPERATIONS ON INSTALLED ENGINE Figure 12 N67 MNS M22 N67 MNT M28 6.113 Figure 15 04_278_N o Decouple the turbocompressor from the exhaust manifold and remove it; please note that, when reassembling it, it will be necessary to observe the assembling direction of the gasket placed between the two components and marked with the caption “TURBO SIDE”. 04_281_N Remove the exhaust manifold to complete engine preparation for overhauling. Figure 16 Figure 13 04_279_N o Remove the tube bundle heat exchanger and the circulating pump outlet/inlet coolant pipe after having loosened the threaded collar of the coolant outlet pipe. Figure 14 04_280_N The alternator and the belt tensioner are simultaneously anchored to the exchanger support. Remove them if necessary. 04_341_N Marine parts include the open cooling circuit sea-water pump which may be removed from its housing if necessary. 6.114 N67 MNS M22 N67 MNT M28 SERVICING OPERATIONS ON INSTALLED ENGINE INSTRUCTIONS FOR DISEMBARKING THE ENGINE The following is a description of the recommended sequence of the operations to be completed before extracting the engine from the vessel. - After the key switch has been in the OFF position for at least 10 seconds, disconnect the battery terminals and disconnect the connectors from the relay box; - Disconnect from the engine the power wiring harness terminals (battery positive and negative); - Loosen and remove the fuel pipelines and the pipes of the gearbox heat exchanger, if provided; - Loosen and remove the sea-water inlet pipes, engine exhaust pipes, and, if separate, the sea-water loop discharge; - Remove the pipeline from the additional engine coolant expansion tank (if provided); - Loosen and remove engine anchor bolts; - Uncouple the gearbox; - Observe the following instructions when hooking the engine. Handling The engine must be handled by experienced personnel, using the prescribed tool or a rocker arm that keeps the lifting lines parallel and with adequate equipment in terms of capacity and size. The two eyebolts provided for lifting the engine alone must always be used simultaneously. NOVEMBER 2006 NOVEMBER 2006 N67 MNS M22 N67 MNT M28 TOOLS 7.115 SECTION 7 TOOLS Page TOOLS 117 7.116 N67 MNS M22 N67 MNT M28 TOOLS Page left intentionally blank NOVEMBER 2006 NOVEMBER 2006 TOOLS TOOLS TOOL NO. DEFINITION 99305019 Kit for valve seat regrinding 99305047 Spring load tester 99322205 Revolving stand for overhauling units (700 daN/m capacity, 120 daN/m torque) 99340035 Injection pump gear extractor 99340055 Tool to remove output shaft front gasket 99340056 Tool to remove output shaft rear gasket N67 MNS M22 N67 MNT M28 7.117 7.118 N67 MNS M22 N67 MNT M28 TOOLS NOVEMBER 2006 TOOLS TOOL NO. DEFINITION 99340205 Tool to remove injectors 99346252 Tool for fitting output shaft rear gasket 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 NOVEMBER 2006 TOOLS N67 MNS M22 N67 MNT M28 TOOLS TOOL NO. DEFINITION 99360330 Flywheel crank handle 99360339 Tool for stopping the engine flywheel 99360344 Adapter, cylinder compression test (use with 99395682) 99360351 Tool for flywheel holding 99360362 Beater for removing/refitting camshaft bushes (to be used with 993700069) 99360500 Tool for lifting the output shaft 7.119 7.120 N67 MNS M22 N67 MNT M28 TOOLS NOVEMBER 2006 TOOLS TOOL NO. DEFINITION 99360595 Lifting rig for engine removal/refitting 99360605 Band for fitting piston into cylinder barrel (60 - 125 mm) 99361037 Brackets for fastening engine to revolving stand 99322205 99363204 Tool to remove gaskets 99365195 Comparator holder tool for injection pump timing (to be used with 99395604) 99367121 Manual pump for pressure and de-pressure measuring NOVEMBER 2006 TOOLS N67 MNS M22 N67 MNT M28 7.121 TOOLS TOOL NO. DEFINITION 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) 99395100 Dial gauge holder for rotary injection pump timing (use with 99395603) 99395216 Pair of gauges with 1/2” and 3/4” square head for angle tightening 99395220 All-purpose goniometer/Inclinometer 7.122 N67 MNS M22 N67 MNT M28 TOOLS NOVEMBER 2006 TOOLS TOOL NO. DEFINITION 99395363 Complete bush testing square 99395603 Dial gauge (0 ÷ 5 mm) 99395604 Dial gauge (0 ÷ 10 mm) 99395682 Diesel fuel engine cylinder compression control device NOVEMBER 2006 N67 MNS M22 N67 MNT M28 OVERHAUL 8.123 SECTION 8 OVERHAUL Page Graph and symbols 125 GENERAL SPECIFICATIONS 126 CLEARANCE DATA 127 ENGINE OVERHAUL - ENGINE REMOVAL AT THE BENCH 133 Preface 133 Engine setting operations for the assembly on turning stand 133 Components removal 134 CYLINDER UNIT 140 Checks and measurements 142 Checking head supporting surface on cylinder unit 142 TIMING SYSTEM 143 Checking cam lift and pin alignment 143 Bushes 143 Bush replacement 144 Tappets 144 Fitting tappets - camshaft 145 OUTPUT SHAFT 146 Measuring journals and crankpins 146 Replacing oil pump control gear 149 Fitting main bearings 149 Finding journal clearance 149 Checking crankshaft shoulder clearance 150 CONNECTING ROD - PISTON ASSEMBLY 151 Measuring piston diameter 152 Piston pins 152 Conditions for proper pin-piston coupling 152 Split rings 152 (continues on next page) 8.124 N67 MNS M22 N67 MNT M28 OVERHAUL Page Connecting rods 153 Bushes 154 Checking connecting rods 154 Checking torsion 154 Checking bending 155 Fitting connecting rod-piston assembly Connecting rod piston coupling 155 Fitting split rings 156 Fitting connecting rod-piston assembly into cylinder barrels 156 Finding crankpin clearance 157 Checking piston protrusion 158 CYLINDER HEAD 159 Removing the valves 159 Checking cylinder head wet seal 160 Checking cylinder head supporting surface 160 VALVES 161 Removing carbon deposits, checking and grinding valves 161 Checking clearance between valve stem and valve guide and valve centering 161 Valve guide 162 Regrinding - Replacing the valve seats 162 Valve springs 163 FITTING CYLINDER HEAD 163 INSTALLATION OF COMPONENTS 164 Refitting the cylinder head 172 Adjusting valve clearance 174 Adjusting injection pump phase 177 Completion of the engine 177 TIGHTENING TORQUES 178 NOVEMBER 2006 OVERHAUL NOVEMBER 2006 Graph and symbols Surface for machining Machine finish Interference Strained assembly Thickness Clearance Intake Exhaust Operation Compression ratio Preload Oversized Higher than … Maximum, peak Undersized Less than … Minimum Selection Classes Oversizing Replacement Original spare parts N67 MNS M22 N67 MNT M28 8.125 8.126 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 GENERAL SPECIFICATIONS Type 6 Cylinders Cycle Four-stroke diesel engine Air feeding Supercharged and intercooled Injection Direct Number of cylinders 6 in-line Bore mm 104 Stroke mm 132 Total displacement cm3 6728 Timing start before T.D.C. end after B.D.C. A B 15° 35° start before B.D.C. end after T.D.C. D C 69° 21° Checking timing X Checking operation X { mm - mm - { mm 0.25 ± 0.05 mm 0.50 ± 0.05 Fuel feed Injection Type: rotary Bosch VE 6/12 F 1400 L 1012 Nozzle type Injectors DSLA 145 P Injection sequence 1-5-3-6-2-4 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 CLEARANCE DATA 6 Cylinders Type Cylinder unit and crankshaft components Cylinder barrels Spare pistons type: Size Outside diameter Pin housing Ø1 104.000 to 104.024 X Ø 1 Ø 2 55.9 103.730 to 103.748 38.010 to 38.016 Piston - cylinder barrels Piston diameter Piston protrusion Piston pin mm Ø 1 X Ø 3 Piston pin - pin housing 0.252 to 0.294 0.4; 0.8 0.28 to 0.52 37.994 to 38.000 0.010 to 0.022 8.127 8.128 N67 MNS M22 N67 MNT M28 OVERHAUL Type NOVEMBER 2006 6 Cylinders Cylinder unit and crankshaft components mm Split ring slots X 1 X 2 X 3 2.705 to 2.735 2.440 to 2.460 4.030 to 4.050 Split rings S 1 S 2 S 3 2.560 to 2.605 2.350 to 2.380 3.970 to 3.990 1 2 3 0.100 to 0.175 0.060 to 0.110 0.040 to 0.080 Split rings - slots Split rings 0.4; 0.8 Split ring end opening in cylinder barrel: X 1 X 2 X 3 0.30 to 0.40 0.60 to 0.80 0.30 to 0.55 Small end bush housing Ø 1 40.987 to 41.013 Big end bearing housing Ø 2 72.987 to 73.013 Small end bush diameter Outside Inside Ø 4 Ø 3 40.987 to 41.013 38.019 to 38.033 Spare big end half bearings S 1.955 to 1.968 Small end bush - housing 0.266 to 0.566 Piston pin - bush 0.019 to 0.039 Big end half bearings 0.250 to 0.500 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Type 6 Cylinders Cylinder unit and crankshaft components mm Size X - Max. tolerance on connecting rod axis alignment = - Journals Crankpins Main half bearings Big end half bearings Main bearings n° 1-7 n° 2-3-4-5-6 Ø 1 Ø 2 82.99 to 83.01 68.987 to 69.013 S 1 S 2 2.456 to 2.464 1.955 to 1.968 Ø 3 Ø 3 87.982 to 88.008 87.977 to 88.013 Half bearings - Journals n° 1-7 n° 2-3-4-5-6 Half bearings Crankpins 0.064 to 0.095 0.059 to 0.100 0.033 to 0.041 Main half bearings Big end half bearings + 0.250 ; + 0.500 Shoulder journal X 1 37.475 to 37.545 Shoulder main bearing X 2 31.730 to 32.280 Shoulder half-rings X 3 37.28 to 37.38 Output shaft shoulder 0.095 to 0.270 8.129 8.130 N67 MNS M22 N67 MNT M28 OVERHAUL Type 6 Cylinders Cylinder head - timing system Valve guide seats on cylinder head NOVEMBER 2006 mm Ø 1 8.019 to 8.039 Ø 4 α 7.943 to 7.963 60° Ø 4 α 7.943 to 7.963 45° Valve stem and guide 0.056 to 0.096 Valves: Housing on head for valve seat: Ø 1 46.987 to 47.013 Ø 1 43.637 to 43.663 Valve seat outside diameter; valve seat angle on cylinder head: Ø 2 α 47.063 to 47.089 60° Ø 2 α 43.713 to 43.739 45° X 0.356 to 1.102 Sinking X 0.104 to 0.840 Between valve seat and head 0.050 to 0.102 0.050 to 0.102 Valve seats - N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Type 6 Cylinders Cylinder head - timing system mm Valve spring height: free spring under a load equal to: 329 N 641 N Injector protrusion H 63.50 H 1 H 2 49.02 38.20 X non regolabile Camshaft bush housings n° 1-7 59.222 to 59.248 Camshaft housings n° 2-3-4-5-6 54.089 to 54.139 Camshaft journals: 1 ‘ 7 Ø 53.995 to 54.045 Camshaft bush outside diameter: Ø 59.222 to 59.248 Bush inside diameter Ø 54.083 to 54.147 Bushes and housings on block - Bushes and journals 0.038 to 0.162 Cam lift: H 11.02 H 10.74 8.131 8.132 N67 MNS M22 N67 MNT M28 OVERHAUL Type NOVEMBER 2006 6 Cylinders Cylinder head - timing system mm Tappet cap housing on block Ø 1 - Tappet cap outside diameter: Ø 2 Ø 3 15.929 to 15.959 15.965 to 15.980 Between tappets and housings - Tappets - Rocker shaft Ø 1 18.963 to 18.975 Rockers Ø 2 19.000 to 19.026 Between rockers and shaft 0.025 to 0.063 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 8.133 ENGINE OVERHAUL - ENGINE REMOVAL AT THE BENCH Preface Figure 2 Part of the operations illustrated within this section can be partially executed while the engine is assembled on the boat, depending on the room available for access to the engine and on the equipment application as well. CAUTION All operations of engine disassembly operations as well as overhaul operations must be executed by qualified engineers provided with the specific tooling and equipment required. Operations described below refer to the engine without the components for its marine adaptation (see Section 6). 1 76147 The following operations are relating to the 4 cylinder engine but are similar and applicable for the 6 cylinder. o Assemble the bracket bearing 99361037 using the four screw threaded ports (1). Engine setting operations for the assembly on turning stand On the left hand side: Figure 1 o Remove the hose between sea water pump and heat exchanger; o Remove the oil dipstick together with guide pipe (2); (loosen the guide pipe disassembling from the block); properly pipe the screw-threaded port to avoid inlet of foreign matters. 2 1 1 76146 76145 On the right hand side: o Disassemble the starter; properly hold the starter (1) and loosen the fixing screws (2); o Assemble the second bracket 99361037 throughout the screw-threaded ports (1); o Disassemble oil filter. o Lift the engine using the rocker arm 99360595 and put it on the turning stand 99322205; CAUTION The oil filter contains inside approx. 1 kg of engine oil. Provide tank with enough capacity to contain the liquid. Avoid contact of engine oil with the skin: in case of skin contamination rinse in running water. Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force. o Drain the oil through the cap underneath the plug. CAUTION Avoid contact of engine oil with the skin: in case of skin contamination rinse in running water. Engine oil is highly pollutant: provide for disposal in compliance with the law and regulations in force. 8.134 N67 MNS M22 N67 MNT M28 OVERHAUL Components removal NOVEMBER 2006 Figure 6 Figure 4 3 1 2 1 3 90510 B 04_339_N o Place a container under the fuel filter and screw out the condense drain faucet underneath said filter. Carry out complete drainage of the fuel contained therein; o Screw out completely the faucet and, using equipment 99360076 disassemble oil filters (1); o Disconnect fuel pipelines (2 and 3) respectively from prefilter to filter bearing and from this last one to the feed pump; 2 4 o Disconnect the supply pipe unit from the injectors (1); o Remove fuel exhaust pipe (2) from the injectors by removing screw (4) and seal (3). Figure 7 o Remove the fuel filter bearing from the bracket fixed to the engine head. 1 Figure 5 1 76148 o Loosen the screws (1) holding the fixing brackets of such pipelines. Pipe the pipeline ends. 2 88142 o Disconnect the LDA pipe (1) from the head and from the feed pump; o Cap the ends of the pipelines as well as the feed pump and the engine head; o Disassemble the pipes (2) that constitute the fuel recovery and supply between the pump and the injectors. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 8 8.135 Figure 10 1 76149 2 1 04_340_N o Remove tappet caps: Loosen the fixing screws (1) and lift the caps (2); remove the gaskets. o Disassemble rocker arm bearings; loosen the two fixing screws (1) and remove the complete rocker armbearing; withdraw tappet rods; CAUTION o Repeat the operation for all the remaining rocker arm bearings. On the tappet cap there is a blow-by valve for the lubrication oil vapours. All the gaskets shall always be replaced during assembly. Figure 11 Figure 9 1 2 1 04_285_N 2 84082 o Remove injectors (2) with tool 99340205 (1) and take out the cylinder head. o Workon the drive belt tensor (1) and extract the belt (2) from the belt pulleys, from the water pump ones and from the belt rebound pulleys; o Disassemble the belt tensor; o Unloose the screw fixing the alternator to the upper bracket. 8.136 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 12 Figure 15 1 1 2 4 5 2 3 3 75685 76152 o Disassemble thermostat unit; loosen the three fixing screws (1) and disassemble the thermostat unit (2) together with the bracket (3); remove the gasket (4) and the thermostat (5); o In order to facilitate head overhauling operations at the test bench keep bracket (3) assembled on it by fixing it with the thermostat unit screws. o Disassemble cylinder head; loosen the screws (1) and (2) fixing the cylinder head (3); o Hook the brackets with metal ropes and, throughout a hoist withdraw cylinder head from the block. Figure 16 Figure 13 2 2 1 1 3 4 75686 o Properly hold the alternator (1) separating it from its bearing by loosening the screw (2); remove screw nut and washer. Figure 14 2 75692 o Apply the suitable tool (2) on the flywheel covering box (1) in order to lock flywheel (3) rotation. (use the starting motor fixing nuts and studs); o Loosen the flywheel fixing screws (4) to engine drive shaft. Figure 17 3 74175 1 1 2 3 04_273_N o Loosen the screws (1) and disassemble the oil filter/heat exchanger bearing (2), interlayer plate (6) and relating gaskets; o Disassemble injection pump (see specific procedure). o Unloose the screws (3) and disassemble the damping flywheel (2) and the pulley (1); o The tool for flywheel holding can help removal of damping flywheel (2) mounted on the pulley (1). N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 CAUTION 8.137 Figure 20 In some versions, the phonic wheel mounted on pulley (1) may be not present and pulley (1) can be different from the pulley shown in Figure 17. Figure 18 1 2 3 4 5 6 70148 o Remove the screws (1) and disconnect the water pump (2); o Remove the screw (3) and the roller (4); o Remove the screw (5) and disconnect the engine speed sensor (6). Figure 19 04_205_N o Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring (2) from the front cover (1). Figure 21 1 04_204_N 2 70149 1 o Loosen the screws (1) and remove the front cover (2). CAUTION Take note of the screw (1) assembly position, since the screws have different length. o Remove the engine drive shaft fixing ring from the front cover. Use the tool 99340055 (4) to operate on the front tang (2) of the engine drive shaft. Throughout the tool guide ports, drill the internal holding ring (1) using Ø 3.5 mm drill for a 5 mm depth; o Fix the tool to the ring tightening the 6 screws specially provided. Proceed withdrawing the ring (1) tightening the screw (3). 8.138 N67 MNS M22 N67 MNT M28 OVERHAUL Figure 22 NOVEMBER 2006 Figure 25 1 2 75811 o Loosen the screws (1) and remove oil pump (2). Figure 23 04_207_N 1 2 o Remove the flywheel cover box fixing ring using the tool 99340056 (3) to operate on the back tang (5) of the engine drive shaft; o Throughout the tool guide ports, drill the internal holding ring using Ø 3.5 mm drill for a 5mm depth; o Fix the tool 99340056 (3) to the ring (1) tightening the 6 screws specially provided (4); 4 3 75691 o Screw out the opposite screws (1) fromthe portswhere the withdrawal pins shall be introduced (see following picture); o Loosen remaining flywheel fixing screws (3) to the engine drive shaft (4); o Proceed with drawing the ring (1) tightening the screw (2); o Using the specially provided tie rod (3) for the tool 99363204 and the lever (4), withdraw the external holding ring of the flywheel cover box. Figure 26 o Remove the flywheel block tool (2). Figure 24 1 4 2 1 2 70153 3 o Loosen the screws (2) and remove the flywheel cover box (1). 75690 o Screw down two medium length screws in the ports (4) to sling the flywheel with a hoist; o Throughout two guide pins (2) previously screwed up into the engine drive shaft ports (3) control the engine flywheel withdrawal by means of a hoist. CAUTION Take note of the screw (1) assembly position, since the screws have different length. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 27 8.139 Figure 29 04_342_N 1 2 1 2 3 o Turn the engine upside-down; o Loosen the screws (2) and remove the oil sump (1). 1 2 CAUTION The shape and dimensions of the sump and of the rose pipe may vary according to the engine application. The relating illustrations provide general guidelines of the operation to be performed. The procedures described are applicable anyway. 3 90505 Figure 28 o Loosen the screws (1) and disassemble the gear from the camshaft (2). 3 Figure 30 1 1 2 1 2 4 88074 o Loosen the screws (1) and disassemble the oil suction rose pipe (3); o Loosen the screws (2) and remove the stiffening plate (4). 70157 o Loosen the screws (2) and disassemble the timing gearbox (1). CAUTION Take note of the screw (2) assembly position, since the screws have different length. 8.140 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 CYLINDER UNIT Figure 31 Figure 33 1 1 2 2 70158 Remove the screws (1) fastening the connecting rod caps (2) and remove them. Withdraw the pistons including the connecting rods from the top of the engine block. 70160 The second last main bearing cap (1) and the relevant support are fitted with shoulder half-bearing (2). CAUTION CAUTION Keep the half-bearings into their housings since, in case of use, they shall be fitted in the same position found at removal. Take note of lower and upper half-bearing assembling positions since in case of reuse they shall be fitted in the same position found at removal. Figure 34 Figure 32 1 1 2 2 70161 70159 Remove the screws (1) and the main bearing caps (2). Use tool 99360500 (1) and hoist to remove the crankshaft (2) from the block. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 35 8.141 Figure 37 1 2 1 3 70164 70162 Remove the main half-bearings (1). Remove the screws (2) and remove the oil nozzles (3). Withdraw carefully the camshaft (1) from the engine block. Figure 38 Figure 36 1 1 3 2 70163 Remove the screws (1) and disconnect camshaft (3) retaining -plate (2). CAUTION Take note of plate (2) assembling position. 70165 Withdraw the tappets (1) from the engine block. 8.142 N67 MNS M22 N67 MNT M28 OVERHAUL Checks and measurements NOVEMBER 2006 Should ovalisation, taper or wear be found, bore and grind the cylinder barrels. Cylinder barrel regrinding shall be performed according to the spare piston diameter oversized by 0.5 mm and to the specified assembling clearance. Figure 39 Figure 41 1 1 2 2 70166 Once engine is disassembled, clean accurately the cylinderblock assembly. Use the proper rings to handle the cylinder unit. The engine block shall not show cracks. Check operating plug conditions and replace them in case of uncertain seal or if rusted. Inspect cylinder barrel surfaces; they shall be free from seizing, scores, ovalisation, taper or excessive wear. Inspection of cylinder barrel bore to check ovalisation, taper and wear shall be performed using the bore dial gauge 99395687 (1) fitted with the dial gauge previously set to zero on the ring gauge (2) of the cylinder barrel diameter. CAUTION Should the ring gauge be not available, use a micrometer for zero-setting. 70168 CAUTION Figure 40 In case of regrinding, all barrels shall have the same oversize (0.5 mm). Check main bearing housings as follows: o Fit the main bearings caps on the supports without bearings; o Tighten the fastening screws to the specified torque; o Use the proper internal gauge to check whether the housing diameter is falling within the specified value. Replace if higher value is found. 70167 Measurements shall be performed on each cylinder, at three different heights in the barrel and on two planes perpendicular with each other: one parallel to the longitudinal axis of the engine (A), and the other perpendicular (B). Maximum wear is usually found on plane (B) in correspondence with the first measurement. Checking head supporting surface on cylinder unit After checking for possible deformation zones, perform the smoothing of supporting surface using a grinder. Planarity error shall not exceed 0.075 mm. Check cylinder unit operating plug (1) conditions, replace them in case of uncertain seal or if rusted. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 8.143 TIMING SYSTEM Figure 42 04_347_N MAIN DATA ABOUT CAMSHAFT PINS (6 cylinders) Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the camshaft and the bushes. Checking cam lift and pin alignment Bushes Set the camshaft on the tailstock and using a centesimal dial gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft. Check cam lift; found values shall be: 6.045 mm for exhaust cams and 7.582 mm for intake cams, in case of different values replace the camshaft. Figure 44 1 Figure 43 3 2 1 2 70172 Camshaft bushes (2) shall be pressed into their housings. Internal surfaces must not show seizing or wear. Use bore dial gauge (3) to measure camshaft front and rear bush (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axes. 70171 Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes. 8.144 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 45 Section A-A 70513 CAMSHAFT BUSH AND HOUSING MAIN DATA * Value to be obtained after driving the bushes. Bush replacement Tappets Figure 46 Figure 47 1 84053 2 2 3 70174 To replace front and rear bushes (1), remove and refit them using the beater 99360362 (2) and the handgrip 99370006 (3). CAUTION When refitting the bushes (1), direct them to make the lubricating holes (2) coincide with the holes on the block housings. MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Fitting tappets - camshaft 8.145 Figure 50 Figure 48 3 1 2 70238 1 70176 Lubricate the tappets (1) and fit them into the relevant housings on the engine block. Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque. Figure 51 Figure 49 1 1 70179 70164 Lubricate the camshaft bushes and fit the camshaft (1) taking care not to damage the bushes or the housings. Check camshaft end float (1). It shall be 0.23 ± 0.13 mm. Figure 52 1 2 70180 Fit nozzles (2) and tighten the fastening screws (1) to the specified torque. 8.146 N67 MNS M22 N67 MNT M28 OVERHAUL OUTPUT SHAFT Measuring journals and crankpins Figure 53 70182 1 2 Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground. CAUTION It is recommended to insert the found values in the proper table. See Figure 54. Undersize classes are : 0.250 - 0.500 mm. CAUTION Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be marked on the side of the crank arm No. 1. For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB NOVEMBER 2006 OVERHAUL NOVEMBER 2006 N67 MNS M22 N67 MNT M28 8.147 Measuring journals and crankpins (6 cylinders) Figure 54 70514 FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES * Rated value. Figure 55 70577 MAIN OUTPUT SHAFT TOLERANCES * Measured on a radius greater than 45.5 mm. ** 0.500 between adjacent main journals. N67 MNS M22 N67 MNT M28 8.148 OVERHAUL NOVEMBER 2006 Figure 56 MAIN BEARING ON TIMING SYSTEM CONTROL SIDE INTERMEDIATE MAIN BEARINGS FIRST MAIN BEARING ON FRONT SIDE 70237 Tolerances Tolerance characteristic Shape Roundness Cilindricity Parallelism Direction Verticality Straightness Position Concentricity or coaxiality Circular oscillation Oscillation Total oscillation Taper Levels of importance for product characteristics Critical Important Secondary Graphic symbol Graphic symbol N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Replacing oil pump control gear 8.149 Finding journal clearance Figure 59 Figure 57 1 2 1 2 70184 70161 3 o Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3). When fitting the new gear, heat it to 180 °C for 10 minutes in an oven and then key it to the crankshaft. Fitting main bearings o Refit the crankshaft (2). o Check the backlash between crankshaft main journals and the relevant bearings as follows: Figure 60 1 Figure 58 2 3 1 4 70186 o Clean accurately the parts and remove any trace of oil; 70185 CAUTION Refit the main bearings that have not been replaced, in the same position found at removal. Main bearings (1) are supplied spare with 0.250 - 0.500 mm undersize on the internal diameter. CAUTION Do not try to adapt the bearings. o Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings.The second last main half bearing (1) is fitted with shoulder half rings. o Position a piece of calibrated wire (3) on the crankshaft pins (4) so that it is parallel to the longitudinal axis; o Fit caps (1), including the half bearings (2) on the relevant supports. 8.150 N67 MNS M22 N67 MNT M28 OVERHAUL Figure 61 NOVEMBER 2006 Figure 63 1 1 2 70187 70189 Tighten the pre-lubricated screws (1) in the following three successive stages: o 1st stage, with torque wrench to 50 ± 6 Nm; o Remove caps from supports. The backlash between the main bearings and the pins is found by comparing the width of the calibrated wire (2) at the narrowest point with the scale on the envelope (1) containing the calibrated wire. The numbers on the scale indicate the backlash in mm. Replace the half bearings and repeat the check if a different backlash value is found. Once the specified backlash is obtained, lubricate the main bearings and fit the supports by tightening the fastening screws as previously described. o 2nd stage, with torque wrench to 80 ± 6 Nm. Figure 62 2 Checking crankshaft shoulder clearance 1 Figure 64 70188 o 3rd stage, with tool 99395216 (1) set as shown in the figure, tighten the screws (2) with 90° ± 5° angle. 1 70190 2 3 This check is performed by setting a magnetic-base dial gauge (2) on the crankshaft (3) as shown in the figure, standard value is 0.068 to 0.41. If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between crankshaft pins and main half bearings. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 8.151 CONNECTING ROD - PISTON ASSEMBLY Figure 65 Figure 66 Remove split rings (1) from piston (2) 3 4 1 1 2 2 3 5 1 8 7 6 70191 CONNECTING ROD - PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Split rings - 5. Screws 6. Half bearings - 7. Connecting rod - 8. Bush. 32613 using pliers 99360183 (3). CAUTION Pistons are supplied from parts with 0.5 mm oversize. Figure 67 Piston pin (1) split rings (2) are removed 1 2 3 32614 using a scriber (3). Figure 68 87760 MAIN DATA CONCERNING KS. PISTON, PINS AND SPLIT RINGS 8.152 N67 MNS M22 N67 MNT M28 OVERHAUL Measuring piston diameter NOVEMBER 2006 Piston pins Figure 69 Figure 71 1 1 2 2 32615 o Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance. 18857 o To measure the piston pin (1) diameter use the micrometer (2). Conditions for proper pin-piston coupling Figure 72 CAUTION The diameter shall be measured at 12 mm from the piston skirt. 1 Figure 70 1 70192 32619 o Lubricate the pin (1) and its seat on piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity. o The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure. Split rings Figure 73 1 2 16552 o Use a micrometer (1) to check split ring (2) thickness. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 74 8.153 Figure 76 1 1 2 2 3 3 70194 32620 o Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1). Figure 75 o 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 77 MAIN DATA FOR CONNECTING ROD, 1 3 2 41104 DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3). In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one. 87762 BUSH, PISTON PIN AND HALF BEARINGS * Value for inside diameter to be obtained after driving in connecting rod small end and grinding. ** Value not measurable in released condition. CAUTION The surface of connecting rod and rod cap are knurled to ensure better coupling. Therefore, it is recommended not to smooth the knurls. N67 MNS M22 N67 MNT M28 8.154 OVERHAUL NOVEMBER 2006 Checking connecting rods Figure 78 Figure 79 ‘ CONNECTING ROD BODY 1234 W Connecting Weight rod No. 0001 V W 9999 X 1 2 5 3 70196 4 61696 ‘ ‘ CONNECTING ROD CAP 1234 A 123 Connecting rod No. Year Day 0001 A 1998 001 B 1999 9999 C 2000366 D 2001 CAUTION Every connecting rod is marked as follows: q On body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one; q On body with a letter showing the weight of the connecting rod assembled at production: - S V, 1820 to 1860 (yellow marking); - S W, 1861 to 1900 (green marking); - S X, 1901 to 1940 (blue marking). Spare connecting rods are of the W class with green marking (see position of * in Fig. 78). Material removal is not allowed. Check that the axis of the connecting rods (1) are parallel using tool 99395363 (5) as follows: o Fit the connecting rod (1) on tool 99395363 (5) spindle and lock it with screw (4); o Set the spindle (3) on V-blocks by resting the connecting rod (1) on the stop bar (2). Checking torsion Figure 80 1 2 3 Bushes 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. When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter. 4 5 61694 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Check connecting rod (5) torsion by comparing two points (A and B) of pin (3) on the horizontal plane of the connecting rod axis. Position the dial gauge (2) support (1) to obtain a preload of approx. 0.5 mm on the pin (3) in point A and then set the dial gauge (2) to zero. Move the spindle (4) with the connecting rod (5) and compare any deviation on the opposite side (B) of the pin (3): the difference between A and B shall not exceed 0.08 mm. Fitting connecting rod-piston assembly Connecting rod piston coupling Figure 82 1 2 Checking bending 3 Figure 81 2 C 8.155 4 1 D 3 5 4 70198 The piston crown is marked as follows: 1. Part number and design modification number; 2. Arrow showing piston assembling direction into cylinder barrel, this arrow shall face the front key of the engine block; 3. Marking showing 1st slot insert testing; 4. Manufacturing date. Figure 83 1 2 61695 Check connecting rod (5) bending by comparing two points C and D of the pin (3) on the vertical plane of the connecting rod axis. Position the vertical support (1) of the dial gauge (2) to rest the latter on pin (3), point C. Move the connecting rod forwards and backwards to find pin top position, then in this condition reset the dial gauge (2). Move the spindle with the connecting rod (5) and repeat the check of the top point on the opposite side D of the pin (3). The difference between point C and point D shall not exceed 0.08 mm. 3 4 5 70199 Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (5) are read as shown in the figure. Figure 84 1 2 72705 Insert split rings (2) for locking pin (1). 8.156 N67 MNS M22 N67 MNT M28 OVERHAUL Fitting split rings NOVEMBER 2006 Fitting connecting rod-piston assembly into cylinder barrels Figure 85 Figure 87 1 2 3 1 2 70201 32613 Use pliers 99360183 (3) to fit the split rings (1) on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120°. CAUTION Split rings are supplied spare with the following sizes: q Standard, yellow marking; q 0.5 mm oversize, yellow/green marking. o Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. Use band 99360605 (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: o The number of each connecting rod shall correspond to the cap coupling number. Figure 88 Figure 86 1 1 70202 DIAGRAM FOR CONNECTING ROD-PISTON ASSEMBLY FITTING INTO BARREL 70200 o Fit half bearings (1) on connecting rod and cap. CAUTION Refit the main bearings that have not been replaced, in the same position found at removal. Do not try to adapt the half bearings. o Split ring openings shall be displaced with each other by 120°; o Connecting rod-piston assemblies shall have the same weight; o The arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Finding crankpin clearance 8.157 Figure 91 2 Figure 89 70205 1 2 1 3 4 70203 To measure the clearance proceed as follows: o Apply tool 99395216 (1) to the socket wrench and tighten screws (2) of 60°. o Clean the parts accurately and remove any trace of oil; o Set a piece of calibrated wire (2) on the output shaft pins (1); Figure 92 2 o Fit the connecting rod caps (3) with the relevant half bearings (4). Figure 90 2 1 70206 1 70204 o Lubricate the screws (1) with engine oil and then tighten them to the specified torque using the torque wrench (2). o Remove the cap and find the existing clearance by comparing the calibrated wire width (1) with the scale on the wire envelope (2). 8.158 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Checking piston protrusion Figure 93 70207 Figure 94 1 3 70208 2 1 2 If a different clearance value is found, replace the half bearings and repeat the check. Once the specified clearance has been obtained, lubricate the main half bearings and fit them by tightening the connecting rod cap fastening screws to the specified torque. CAUTION Before the final fitting of the connecting rod cap fastening screws, check that their diameter measured at the centre of the thread length is not < 0.1 mm than the diameter measured at approx. 10 mm from screw end. Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.250 to 0.275 mm. Once connecting rod-piston assemblies refitting is over, use dial gauge 39395603 (1) fitted with base 99370415 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block. Protrusion shall be 0.28 to 0.52 mm. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 8.159 CYLINDER HEAD Removing the valves Figure 97 Figure 95 2 1 2 1 75750 Intake (1) and exhaust (2) valves have heads with different diameter. o Remove sealing rings (1 and 2) from the valve guide. CAUTION Should cylinder head valves be not replaced, number them before removing in order to refit them in the same position. Figure 96 2 1 3 4 6 75751 75752 5 o 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 cap (3) and the springs (4) and the protective cap (5). o Repeat this operation for all the valves. o Overturn the cylinder head and withdraw the valves (6). CAUTION Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green. 8.160 N67 MNS M22 N67 MNT M28 OVERHAUL Checking cylinder head wet seal NOVEMBER 2006 Figure 99 Figure 98 1 75756 75753 This check shall be performed using the proper tools. Use a pump to fill with water heated to approx. 90 °C and 2 to 3 bar pressure. Replace the cup plugs (1) if leaks are found, use the proper beater for their removal/refitting. CAUTION Before refitting, smear the plug surfaces with water-repellent sealant. Replace the cylinder head if leaks are found. Checking cylinder head supporting surface Distortion found along the whole cylinder head shall not exceed 0.20 mm. If higher values are found grind the cylinder head according to values and indications shown in the following figure. The rated thickness A for the cylinder head is 95 ± 0.25 mm, max. metal removal shall not exceed thickness B by 0.13 mm. CAUTION After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 8.161 VALVES Figure 100 Exhaust valve Figure 102 Intake valve 1 2 18882 04_348_N Check the valve stem (1) using a micrometer (2), it shall be 7.943 to 7.963. Checking clearance between valve stem and valve guide and valve centering INTAKE AND EXHAUST VALVE MAIN DATA Removing carbon deposits, checking and grinding valves Figure 101 Figure 103 1 2 75757 18625 Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. Regrind the valve seats, if required, using tool 99305018 and removing as less material as possible. Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.056 ± 0.096 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm. 8.162 N67 MNS M22 N67 MNT M28 OVERHAUL Valve guide NOVEMBER 2006 Regrinding - Replacing the valve seats Figure 104 Figure 105 04_349_N 1 2 75754 Intake Exhaust o Check the valve seats (2). If slight scoring or burnout is found, regrind seats using tool 99305014 (1) according to the angle values shown in Figure 106. Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure. Figure 106 Intake Exhaust 75755 VALVE SEAT MAIN DATA Should valve seats be not reset just by regrinding, replace them with the spare ones. o Use tool 99305019 (Figure 105) to remove as much material as possible from the valve seats (take care not to damage the cylinder head) until they can be extracted from the cylinder head using a punch. o Heat the cylinder head to 80-100 °C and using the proper beater, fit the new valve seats, previously cooled, into the cylinder head. o Use tool 99305019 to regrind the valve seats according to the values shown in Figure 106. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 8.163 FITTING CYLINDER HEAD Figure 107 Figure 109 1 3 2 1 3 75758 1 After regrinding, check that valve (3) sinking value is the specified one by using the base 99370415 (2) and the dial gauge 99395603 (1). 2 75759 o Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal. Valve springs o Fit the sealing rings (2 and 3) on the valve guide. Figure 108 50676 CAUTION Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green. Figure 110 2 MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS 1 4 Before refitting use tool 99305047 to check spring flexibility. Compare load and elastic deformation data with those of the new springs shown in the following table. Height 3 6 Under a load of H (free) 63.50 N H1 49.02 329 H2 38.20 641 75751 5 o Position on the cylinder head: the protective cap (5), the spring (4), the upper cap (3); use tool 99360268 (1) to compress the spring (4) and lock the parts to the valve (5) by the cotters (2). 8.164 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 INSTALLATION OF COMPONENTS Figure 111 Figure 112 DIAGRAM SHOWING SCREW 1 9 10 6 4 8 3 1 2 75712 1 DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION WITHIN GEARBOX AREAS 7 o Accurately clean the timing gearbox (1) and the engine block. 75711 TIGHTENING TO FIX REAR GEARBOX CAUTION It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing Loctite 5205 on the box in order to form a kerbstone of a few mm. diameter. It must be uniform (no lumps), with no air blisters, thinner or irregular zones. Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. After having completed seal application, the joints must be immediately assembled (10-20 minutes time). 5 o Reassemble to box (1) to the engine block; o Tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking torques listed here below, following the order as shown in the picture. - - - Screws M12 65 to 89 Nm; Screws M8 20 to 28 Nm; Screws M10 42 to 52 Nm. CAUTION Before every assembly, always check that threads of holes and screws have no evidence of tear and wear nor dirt. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 8.165 o Orient engine drive shaft (3) and camshaft (4) taking care that in phase of assembly of the driving gear (2) to the camshaft, the notches marked on the gears (1 and 2) shall match. Figure 113 Figure 115 1 2 1 70211 2 o With a penmarker, mark the tooth (1) of the driving gear assembled to the engine drive shaft (2) with (·) timing notch. CAUTION Screw down two pins to facilitate operation of engine drive shaft rotation. 3 90507 o Position comparator (1) on timing system gear (2) and check that the clearance between gears (2) and (3) is within 0.076 to 0.280 mm range. Figure 116 Figure 114 1 4 1 2 2 3 3 1 4 2 1 3 2 3 90506 90508 o Tighten the screws (1) fixing the gear (2) to the camshaft (3) and lock them to the prescribed torque. 8.166 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 o Reassemble the box (1) to the engine block, tighten the fixing screws in the same position as found out during disassembly and fix the screws to the locking torques listed here below, following the order as shown in the picture. Figure 117 - - Screws M12 75 to 95 Nm; Screws M10 44 to 53 Nm. CAUTION Before every assembly, always check that threads of holes and screws have no evidence of tear and wear nor dirt. 1 75708 Figure 119 DIAGRAM SHOWING SEALING LOCTITE 5205 APPLICATION CAUTION It is necessary and essential to clean the surface to be sealed in order to achieve excellent tight seal. Apply sealing Loctite 5205 on the box in order to form a kerbstone of a few mm. Diameter. It must be uniform (no lumps), with no air blisters, thinner or irregular zones. Any eventual imperfection shall be correct as soon as possible. Avoid using material in excess to seal the joint. Too much sealing material would drop out on both sides of the joint and obstruct lubricant passages. After having completed seal application, the joints must be immediately assembled (10-20 minutes time). 04_208_N o Apply to engine drive shaft rear tang (6), the detail (5) of the tool 99346252, fix it tightening the screws (4) and key the new holding ring on it (3). Figure 118 o Place detail (1) on detail (5), tighten the screw nut (2) until complete assembly of the fixing ring (3) into the flywheel cover box (7). 1 75709 DIAGRAM SHOWING SCREW TIGHTENING TO FIX FLYWHEEL COVER BOX. Figure 120 1 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 8.167 Figure 122 2 2 1 3 75696 Check the conditions of the rim tooth (2). Whether tooth break or excessive wear is detected, disassemble the rim from the engine flywheel using a common willow and replace with a new one, previously heated to 150 °C degrees for 15-20 seconds; bevelling must be made towards engine flywheel direction. 4 75692 o Tighten the screws (4) fixing the engine flywheel (3) to the engine shaft. Use tool 99360339 (2) to operate on the flywheel cover box (1) to block engine flywheel rotation. Figure 123 Figure 121 4 1 2 1 2 3 75695 75690 o Screw down two hooks or trail rings in the flywheel (1) threaded ports (4) for handling; o Using a hoist, handle the flywheel to place it in its housing inside the flywheel cover box; o Screw down to pins (2) having appropriate length, in the shaft ports (3) and using them as guide, assemble the engine flywheel (1) properly placing it inside the flywheel cover box. Tighten the engine flywheel (1) fixing screws (2) in two phases: o 1st phase; tightening by means of dynamometric wrench to torque 30 ± 4 Nm; o 2nd phase, 60° ± 5° angle dwell. CAUTION Angle dwell shall always be performed using 99395216 tool. Before every assembly, always check that threads of holes and screws have no evidence of tear and wear nor dirt. N67 MNS M22 N67 MNT M28 8.168 OVERHAUL Figure 124 NOVEMBER 2006 Figure 127 1 2 1 2 70223 70220 o Remove the fixing ring (2) from the front cover (1), accurately clean the plug surface. o Assemble oil pump (1); o Tighten fixing screws (2) and lock them to the prescribed torque. Figure 128 75710 Figure 125 2 1 70221 o Apply to the water pump (1) a new fixing ring (2). Figure 126 o Accurately clean the contact surface of engine block and apply sealing Loctite 5205 on it in order to form a uniform and continuous kerbstone with no lumps. 1 2 76112 o Assemble the water pump (1); o Tighten the screws (2) and lock them to the prescribed torque. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 129 8.169 Figure 131 3 1 2 1 1 2 4 75812 o Assemble the front cover (2) to the block and tighten the screws (1) fixing them to the prescribed torque. Figure 130 88074 o Assemble plate (4), suction rose (3) and tighten the fixing screws (2 and 1) locking them on the prescribed torque. Figure 132 1 1 04_343_N 2 3 2 3 1 7 2 4 5 6 00902T o Apply on engine drive shaft front tang (6) the detail (4) of the tool 99346252, fix it with the screws (5) and key the new holding ring on it (7); o Place the detail (2) on the detail (4), screw-up the threaded nut until carrying out the complete assembly of the holding ring (7) to the front cover. o Provide for newgasket replacement (1) of the oil sump (2). CAUTION The pictures illustrating the sump and of the rose pipe may not correspond to the ones of your model. However the procedures described are applicable anyway. Accurately clean the contact surface. Apply sealing Loctite 5999 on it, on areas around couplings between engine block and front cover, engine block and rear gearbox. After sealing application, mount the sump within 10-20 minutes. 8.170 N67 MNS M22 N67 MNT M28 OVERHAUL Figure 133 NOVEMBER 2006 Figure 135 04_342_N 1 2 2 1 3 3 70230 o Fit a new sealing ring on the speed sensor (3) (if fitted); o Assemble oil sump (1). Tighten the screws (2) and lock them to the prescribed torque. o Fit the speed sensor (3) on the front cover (1) and tighten the screw (2) to the specified torque (if fitted). Figure 136 CAUTION 1 Before every assembly, always check that threads of holes and screws have no evidence of tear and wear nor dirt. 2 3 Figure 134 4 74175 5 1 2 04_345_N 3 o Assemble the pulley (1) and the dumping flywheel (2) to the driving shaft; o Tighten the fixing screws (3) and clamp them to the torque 68 ± 7 Nm. o Assemble the following elements to the block: new gasket (1), heat exchanger (2), new gasket (3), oil filter bearing (4); o Tighten the screws (5) and lock them to the prescribed torque. CAUTION Before every assembly, always check that threads of holes and screws have no evidence of tear and wear nor dirt. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 137 8.171 Figure 139 2 04_344_N 1 3 2 1 75686 o Connect the alternator (1) to the support; o Tighten without locking the screw (2). 4 Figure 140 o Lubricate the fixing ring (2) using engine oil and place it on the oil filter (3); o Manually start the oil filter (3) on the bearing union (1) until counter-boring, further screw down the oil filter (3) by 3/4 turn; 1 o Place a new fixing ring on the block housing (4). Figure 138 2 3 1 74178 3 2 4 o Refit the automatic belt tensioner (2); o Tighten the screw (3) to the specified torque; o Turn the automatic belt tensioner (2) to fit the belt (1) on pulleys and guide rollers. CAUTION 70234 o Assemble the alternator bearing (1) ensuring that the pins (3 and 4) are against the engine block; o Tighten the screws (2) and lock them to the prescribed torque. CAUTION Before every assembly, always check that threads of holes and screws have no evidence of tear and wear nor dirt. In case the previously removed belt is assembled again, examine it carefully to check possible cuts or yielding marks. 8.172 N67 MNS M22 N67 MNT M28 OVERHAUL Refitting the cylinder head NOVEMBER 2006 Figure 142 Figure 141 1 87759 88775 o Check cleanness of cylinder head and engine block coupling surface.Take care not to foul the cylinder head gasket. There are two types of head seals, for the thickness (1.25mm Type A and 1.15 mm Type B); take the following measures: o Set the cylinder head gasket (1) with the marking “N. of component” (1) facing the head. o For each piston detect, as indicated on Figure 142, at a distance of 45 mm from the centre of the piston overhandings S1 and S2 in relation to the engine base upper plane then calculate the average: The arrow shows the point where the gasket thickness is given. Scil1 = S1 + S2 2 For 4 cylinder versions Repeat the operation for pistons 2, 3 and 4 and calculate the average value: S = Scil1 + Scil2 + Scil3 + Scil4 4 For 6 cylinder versions Repeat the operation for pistons 2, 3, 4, 5 and 6 and calculate the average value: S = Scil1 + Scil2 + Scil3 + Scil4 + Scil5 + Scil6 6 If S is > 0.40 mm use seal type A. If S is < 0.40 mm use seal type B. CAUTION Before re-utilising the fixing screws for the cylinder head, verify there is no evidence of wear or deformation and in that case replace them. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 143 8.173 Figure 145 1 2 1 4 2 3 3 2 76152 1 o Place the head (3) over the block and insert screws (1) and (2). CAUTION If the valves have been removed from the head, it is necessary to assemble them before assembling the head itself on the engine block. 3 75705 ROCKER ARM UNIT COMPONENTS: 1. Elastic ring - 2. Spacer - 3. Rocker arms - 4. Support. o Carry out the assembly of the rocker arms after previous check of the components. Figure 146 Figure 144 18 10 20 4 13 17 1 7 9 5 2 3 11 8 6 15 14 12 19 16 76214 75704 o Lubricate cylinder head bolts and install to head; o Bolts must be torqued using stitching pattern starting with the centre bolts and moving out. Bolts to be torqued in stages: all bolts torqued to snug torque, then 90 degrees rotation for all bolts. Then a further 90 degrees for the M12 x 140 and M12 x 180. - - - M12 x 70 50 Nm + 90 degrees; M12 x 140 40 Nm + 180 degrees; M12 x 180 70 Nm + 180 degrees. SHAFT AND ROCKER ARM BASIC DATA o Check the coupling surfaces of bearing and shaft: no evidence of excessive wear shall be detected or damages. Replace if necessary. 8.174 N67 MNS M22 N67 MNT M28 OVERHAUL Figure 147 NOVEMBER 2006 Figure 150 1 1 75702 ROCKER ARM ADJUSTMENT SCREW If unscrewed, check adjustment quota. Tighten the screw-threaded nut (1) to the 0.4-0.6 Nm torque. Figure 148 04_340_N o Tighten the screws (1) to the prescribed torque. Adjusting valve clearance (see Section 6). 32655 Before executing assembly, check the Rocker Arm driving rods: these shall not be deformed; the spherical ends in 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. The rods driving the suction and exhaust valves are identical and therefore interchangeable. Figure 151 75707 Figure 149 1 75703 o Insert the tappet driving rods and the Rocker Arm unit. Before using the fixing screws again, measure them 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 > 0.1 mm the screw must be replaced. o Assemble injectors after having replaced the sealing gasket (1). CAUTION During assembly of injectors, verify that the injector sphere is correctly positioned on the head housing. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Figure 152 8.175 Figure 154 76149 2 1 4 5 2 1 3 75685 o Assemble thermostat unit (2) including thermostat (5) and gasket (4); o Assemble cylinder covers (2) with the respective gaskets; o Fit the seal nods and tighten the screws (1) fixing them to the prescribed torque. CAUTION Always replace the gaskets using new ones. Check the threads of the fixing screws: there shall be no evidence of wear or dirt deposit. Seal nods shall have no visible deformation. In such case provide for replacement with new nods. o Tighten the screws to the prescribed torque. CAUTION The screws (1) have been have been utilised to fix the bracket (3). Disassemble the bracket (3) and reassemble components from 1 to 5 as shown in the picture. The gasket (4) must be new. Figure 155 Figure 153 1 6 2 3 1 76206 o Assemble exhaust manifold (1) providing new gaskets (2). 2 04_303_N CAUTION The illustration of exhaust manifold may be not matching your model. Anyhow, described procedure is applicable. 5 6 4 o Den Riemen Poli V (4), auf der Riemenscheibe der Antriebswelle (5), auf den Leitrollen (6), auf der Wasserpumpe (3) und auf dem Drehstromgenerator (1) montieren. Den Riemen spannen, indem Sie auf den automatischen Riemenspanner (2) einwirken. 8.176 N67 MNS M22 N67 MNT M28 OVERHAUL Figure 156 NOVEMBER 2006 Figure 158 1 1 1 76208 76148 o Also assemble the brackets (1) fixing the fuel pipelines to the injectors: use the same screws (2) fixing the manifold plate as shown in the picture; o Fix the pipes to the injectors throughout the brackets previously assembled. o Also assemble feed pump (see specific procedure). Figure 159 CAUTION 1 Pump mounting requires specific procedure contained in this section. Figure 157 88146 o Assemble the injection pump pipe (1). 1 Figure 160 88144 1 o Assemble the injection pump supply pipes (1); o Screw down the locking nuts fixing the pipes to the injection pump; o Tighten the screws fixing the fuel recovery manifold to the injection pump; o Tighten the locking nuts on the injectors and tighten the screws to fasten the fuel recovery manifold. 88145 o Fix the LDA pipeline (1) to the engine head and to the injection pump. N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Adjusting injection pump phase 8.177 Completion of the engine (see Section 6) Figure 162 Figure 161 3 2 1 2 1 90510 B o Assemble the fuel filter bearing (4) to the bracket fixed to the engine head; o Connect the fuel pipelines (2 and 3) respectively from priming pump to filter bearing and from this last one to feed pump; o Using 99360076 equipment assemble fuel filter (1). CAUTION The filter shall be priory filled with fuel to facilitate feed system bleed operations. To complete engine assembly it is necessary to remove it from the turning stand. o Using rocker arm 99360595 hold the engine and loosen the screws fixing the brackets to the turning stand 99322205; o Disassemble the brackets from the engine after having properly put it on a wooden bearing. 76146 o Reassemble the starter; o Properly hold the starter (1) and tighten the fixing screws (2) to the prescribed torque; o Assemble oil filter; o Assemble oil level rod together with guide pipe; o Proceed to install marine parts; o Fill the engine with oil and coolant liquid quantity required. 8.178 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 TIGHTENING TORQUES Marine parts tightening torques Part Nm Torque kgm M10 Pin turbocompressor fixing on exhaust manifold 7 ± 1 0.7 ± 0.1 M10 Nut turbocompressor fixing on exhaust manifold 43 ± 6 4.3 ± 0.6 26 ± 10 2.6 ± 0.1 M8 x 115 Screw for air-air or water-water exchanger 18 ± 2 1.8 ± 0.2 M8 x 120 Screw for air-water heat exchanger 18 ± 2 1.8 ± 0.2 M12 x 30 Screw for front engine support legs 69 ± 7 6.9 ± 0.7 M12 x 30 Screw for back engine support legs 66 ± 7 6.6 ± 0.7 8 ± 1 0.8 ± 0.1 M10 x 140 Screw fixing the pump water inlet pipe and support bracket 43 ± 6 4.3 ± 0.6 M10 x 80 Screw fixing pump water inlet pipe and support bracket 43 ± 6 4.3 ± 0.6 M12 x 30 Screw fixing the sea water pump 85 ± 8 8.5 ± 0.8 M10 x 120 Screw for lower anchoring of the exhaust manifold 53 ± 6 5.3 ± 0.6 M10 x 150 Screw for lower anchoring of the exhaust manifold 53 ± 6 5.3 ± 0.6 M10 Lock nut fixing turbocompressor on exhaust manifold M6 x 20 Screw for cooled Riser stub pipe NOVEMBER 2006 N67 MNS M22 N67 MNT M28 OVERHAUL Engine parts tightening torques Part Cooling Nozzles (M8x1.25x10) Nm Torque kgm 15 ± 3 1.5 ± 0.3 Main bearing cap 1st stage 2nd stage 3rd stage 50 ± 6 80 ± 6 5.0 ± 0.6 8.0 ± 0.6 90° ± 5° Rear gear housing assembly (M8x1.25x40) (M8x1.25x25) (M10x1.5) 24 ± 4 24 ± 4 49 ± 5 2.4 ± 0.4 2.4 ± 0.4 4.9 ± 0.5 Oil pump (M8x1.25x30) 1st stage 2nd stage 8±1 24 ± 4 0.8 ± 0.1 2.4 ± 0.4 Front cover assembly (M8x1.25x45) (M8x1.25x30) 24 ± 4 24 ± 4 2.4 ± 0.4 2.4 ± 0.4 Connecting rod bolts (M11x1.25) 1st stage 2nd stage 3rd stage 30 ± 3 60 ± 5 3.0 ± 0.3 6.0 ± 0.5 60° ± 5° Ladder frame assembly (M10x1.25x25) 43 ± 5 4.3 ± 0.5 Oil rifle plugs 6 ± 1 11 ± 2 0.6 ± 0.1 1.1 ± 0.2 24 ± 4 2.4 ± 0.4 24 ± 4 60 ± 9 2.4 ± 0.4 6.0 ± 0.9 5±1 0.5 ± 0.1 (M10x1) (M14x1.5) Assemble oil suction tube (M8x1.25x20) Oil sump assembly (M8x1.25x25) (M18x1.50) Set timing pin (Torx screw M5 T25) Fuel pump assembly M8 screw M6 screw M6 nut 24 ± 4 10 ± 1 10 ± 1 2.4 ± 0.4 1.0 ± 0.1 1.0 ± 0.1 M10x1.5 flange head nuts pre-torque 1st stage 2nd stage 10 -15 50 -55 1.0 -1.5 5.0 -5.5 Fuel pump gear (drive gear nut) snug torque final torque 15 -20 85 -90 1.5 -2.0 8.5 -9.0 Inspection cover on the gearbox 30 -35 3.0 -3.5 Rocker assys (M8) 24 ± 4 2.4 ± 0.4 50 + 90° 40 + 180° 70 + 180° 5.0 + 90° 4.0 + 180° 7.0 + 180° Assy rocker covers (M8x1.25x25) 24 ± 4 2.4 ± 0.4 Intake manifold (M8x1.25) 24 ± 4 2.4 ± 0.4 Assy air intake connection (M8x1.25) 24 ± 4 2.4 ± 0.4 Oil bypass valve into lube filter head (nut M22x1.5x10) 80 ± 8 8.0 ± 0.8 Plug (M12x1.5x12) 10 ± 1 1.0 ± 0.1 Water pump (M8x1.25x25) 24 ± 4 2.4 ± 0.4 Water inlet connection 24 ± 4 24 ± 4 2.4 ± 0.4 2.4 ± 0.4 77 ± 12 7.7 ± 1.2 Cylinder head bolts (M12x70) (M12x140) (M12x180) (M8x1.25x35) (M8x1.25x70) Rear lifting bracket (M12x1.75x30) 8.179 8.180 N67 MNS M22 N67 MNT M28 OVERHAUL NOVEMBER 2006 Engine parts tightening torques (cont) Part Torque Nm Crankshaft pulley (M12x1.75x10.9) 110 ± 5 Flywheel housing (M12x120) (M12x80) (M10x80) (M10x40) 85 ± 10 85 ± 10 49 ± 5 49 ± 5 Flywheel housing on crankshaft (M12x1.25) 1st stage 2nd stage kgm 11.0 ± 0.5 8.5 8.5 4.9 4.9 ± ± ± ± 1.0 1.0 0.5 0.5 30 ± 4 3.0 ± 0.4 60° ± 5° Aspiration pump gear cover (M8x1.25x16) 24 ± 4 2.4 ± 0.4 Fuel injectors 60 ± 5 6.0 ± 0.5 Oil feed to oil filter head 24 ± 4 2.4 ± 0.4 Oil feed to turbocompressor (M12x1.5) 35 ± 5 3.5 ± 0.5 Alternator to alternator support (M8x1.25x30) 24 ± 4 2.4 ± 0.4 Alternator to water inlet conn. assy (M8x1.25x30) 24 ± 4 2.4 ± 0.4 Lower alternator mounting (M10x1.25x25) 24 ± 4 2.4 ± 0.4 Alternator upper pivot to support (M10) 49 ± 5 4.9 ± 0.5 Alternator mounting hardware (M12x1.75x120) 43 ± 6 4.3 ± 0.6 Alternator wiring (M6x1.0 nut) 10 ± 2 1.0 ± 0.2 Starter motor to gear case (M10) 49 ± 5 4.9 ± 0.5 Screw M8 for fastening cylinder barrel lubricating nozzles 15 ± 3 1.5 ± 0.3 50 ± 6 80 ± 6 5 ± 0.6 8 ± 0.6 Screw M12 for fastening output shaft caps 1st stage 2nd stage 3rd stage 90° ± 5° Screw M8 for fastening camshaft longitudinal retaining plate 24 ± 4 2.4 ± 0.4 Screw M8 for fastening camshaft gear 36 ± 4 3.6 ± 0.4 Screw M11 for fastening connecting rod caps 1st stage 2nd stage 60 ± 5 60° ± 5° 6 ± 0.5 NOVEMBER 2006 SAFETY REGULATIONS N67 MNS M22 N67 MNT M28 9.181 SECTION 9 SAFETY REGULATIONS Page SAFETY REGULATIONS 183 Standard safety regulations 183 Accident prevention 183 During maintenance 183 Respecting the Environment 184 9.182 N67 MNS M22 N67 MNT M28 SAFETY REGULATIONS Page left intentionally blank NOVEMBER 2006 NOVEMBER 2006 SAFETY REGULATIONS N67 MNS M22 N67 MNT M28 9.183 SAFETY REGULATIONS Standard safety regulations Pay particular attention to some precautions that must be followed by all means in any working place and whose non-observance will make any other measures useless or not sufficient to ensure safety to the personnel in charge of maintenance. o Be informed and inform the personnel as well of the laws in force regulating safety, by providing information documentation available for consultation; o Keep working areas as clean as possible, and ensure adequate ventilation; o Ensure that working areas are provided with emergency kits, that must be clearly visible and always fitted with adequate sanitary equipment; o Provide for adequate fire extinguishing means, properly indicated and always easy to reach. Their efficiency must be checked on a regular basis and the personnel must be trained on intervention methods and priorities; o Provide specific exit points to evacuate the areas in case of emergency, giving adequate indications of the emergency escape paths; o Smoking in working areas subject to fire danger must be strictly prohibited; o Put rags smeared with oil, diesel fuel, or solvents in fireproof containers; o Do not carry out any intervention you have not been given all necessary instructions for; o Do not use any tool or equipment for any operation different from the ones they have been designed and provided for. Serious injury may occur; o In case of test or calibration operations requiring the engine to be in operation, ensure that the area is sufficiently ventilated or use specific aspirators to eliminate exhaust gas. Danger: poisoning and death. During maintenance o Never open the filler cap of the cooling circuit when the engine is hot. Operating pressure would provoke hot liquid to pour out with serious danger and risk of scalding. Wait until the temperature decreases below 50 °C; o Never top up an overheated engine with cooler and use only appropriate liquids; o Always operate when the engine is turned off: in case particular circumstances require maintenance intervention on the running engine, be aware of all risks involved in such operation; o Provide warnings by means of adequate boards signaling danger, prohibitions, and indications to ensure easy understanding of the instructions even in case of emergency. o Be equipped with adequate and safe containers for draining engine liquids and exhaust oil; Accident prevention o The use of solvents or detergents during maintenance may generate toxic vapors. Always keep working areas ventilated. Whenever necessary wear a safety mask; o When working close to engines and equipment in motion, do not wear unsuitable clothes, with loose ends, nor jewels such as rings and chains; o Wear safety gloves and goggles when performing the following operations: - filling inhibitors or antifreeze; - topping or replacing lubrication oil; - using compressed air or liquids under pressure (pressure allowed: ≤ 2 bar). o Wear a safety helmet when working close to hanging loads or equipment operating at head height level; o Keep the engine clean from oil, diesel fuel, and/or chemical solvents stains; o Do not leave rags impregnated with flammable substances close to the engine; o Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of overspeed; o Do not use fast screwdriver tools; o Never disconnect batteries when the engine is running; o Disconnect batteries before any intervention on the electrical system; o Always wear safety shoes and clothes adhering to the body, better if provided with elastics at the ends; o Disconnect batteries from the system to charge them with the battery charger; o Use protection cream for your hands; o After every intervention, verify that the battery clips polarity is correct and that the clips are tight and safe from accidental short circuit and oxidation; o Change wet clothes as soon as possible; o In presence of current tension exceeding 48-60 V verify the efficiency of earth and mass electrical connections. Ensure that hands and feet are dry and carry out working operations using isolating foot-boards. Do not carry out working operations you are not trained for; o Do not smoke nor light up flames close to batteries and any fuel; o Do not disconnect and connect electrical connections in presence of electrical supply; 9.184 N67 MNS M22 N67 MNT M28 SAFETY REGULATIONS o Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) check for liquid or air under pressure. Take all necessary precautions by bleeding and draining residual pressure or closing separation valves. Always wear adequate safety masks or goggles. Nonobservance of these instructions may cause serious injuries and poisoning; o Avoid incorrect or over-torque tightening. Danger: incorrect tightening may seriously damage the engine components, affecting its duration; o Avoid priming from fuel tanks made of copper alloys and/or with ducts without filters; o Do not modify cable wires: their length must not be changed; o Do not connect any other equipment to the engine electrical equipment unless specifically approved by IVECO MOTORS-FPT; o Do not modify the fuel or hydraulic systems without having received specific approval from IVECO MOTORSFPT. Any unauthorized modifications will compromise the warranty assistance and furthermore may affect the engine correct working and duration. For engines equipped with an electronic control unit: o Do not carry out any electric arc welding without having removed the electronic control unit first; o Remove the electronic control unit in case of any interventions requiring heating over 80 °C; o Do not paint the components and the electronic connections; o Do not vary or alter any data filed in the electronic control unit. Any manipulation or alteration of electronic components will totally compromise the engine warranty assistance and furthermore may affect the engine correct working and duration. NOVEMBER 2006 Respecting the Environment o Respecting the Environment is of primary importance: all necessary precautions to ensure the personnel’s safety and health are to be adopted; o Be informed and inform the personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and organize specific training courses to ensure that the personnel is fully aware of such law instructions and of basic preventive safety measures; o Collect exhaust oils in adequate containers with air-tight sealing ensuring that storage is made in specific, properly identified, areas that will be ventilated, far from heat sources, and not exposed to fire danger; o Handle batteries with care, storing them in ventilated environment and in anti-acid containers. Warning: battery exhalations represent serious danger of intoxication and environment contamination. IVECO S.p.A. PowerTrain Viale Dell’Industria, 15/17 20010 Pregnana Milanese - MI - (Italy) Tel. +39 02 93.51.01 - Fax +39 02 93.59.00.29 www.ivecomotors.com
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