Nef 220 N67 Mns M22
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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
JUNE 2007 EDITION
1.
N67 MNS M22 N67 MNT M28
JUNE 2007
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 - June 2007 Edition
N67 MNS M22 N67 MNT M28
JUNE 2007
1.
SECTION CONTENTS Section
Page
1.
OVERVIEW
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 SYSTEM FOR HOMOLOGATED INSTALLATIONS
181
10. SAFETY REGULATIONS
5
197
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
JUNE 2007
PAGE LEFT INTENTIONALLY BLANK
JUNE 2007
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
JUNE 2007
N67 MNS M22 N67 MNT M28
OVERVIEW
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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.
N67 MNS M22 N67 MNT M28
OVERVIEW
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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
JUNE 2007
JUNE 2007
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 HX40L8274BN/J16S3 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
JUNE 2007
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
JUNE 2007
2.41
Dimensions Figure 1
(1.7)
(1.)
0 (1.1) 2 (.2)
7 (1.22)
(1.)
12 (.)
2, (2.1)
1 (0.)
710 (27.)
0 (2.)
70 (0.70) 04_305_N
Measurements in: millimeters (inches).
2.42
N67 MNS M22 N67 MNT M28
TECHNICAL DATA
PAGE LEFT INTENTIONALLY BLANK
JUNE 2007
JUNE 2007
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 - N67 MNT M28.10
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
JUNE 2007
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
200 400 600 800
1000
1200
CHARACTERISTIC CURVES
1400
1600
I (A)
N67 MNS M22 N67 MNT M28
3.48
ELECTRICAL EQUIPMENT
JUNE 2007
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.
JUNE 2007
ELECTRICAL EQUIPMENT
N67 MNS M22 N67 MNT M28
N67 MNS M22.10 N67 MNT M28.10 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
JUNE 2007
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007 N67 MNS M22 N67 MNT M28
M22.10 - M28.10 WIRE HARNESS
3.53
3.54
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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)
JUNE 2007
ELECTRICAL EQUIPMENT
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N67 MNS M22 N67 MNT M28
3.57
N67 MNS M22 N67 MNT M28
3.58
ELECTRICAL EQUIPMENT
JUNE 2007
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
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
6
SSV
3.60 ELECTRICAL EQUIPMENT JUNE 2007
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
JUNE 2007 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 JUNE 2007
M22.10 - M28.10
JUNE 2007
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
JUNE 2007
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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)
JUNE 2007 N67 MNS M22 N67 MNT M28
3.67
M22.11 WIRE HARNESS
N67 MNS M22 N67 MNT M28
3.68
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
CG
RL
30
Component code
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
1
1
EC
1
1
87
RL1
6
6
86
GG 2 GG 2
+BATT (MM)
V
K
AN L
1
1
I
1 K
T
1
1
4
4
3
3
2
2
1
1
JSV
J16F
1
1 1
16
70
3 3
1 V
W
1
85
G
MP
EC 3 2 1
30
N
MM 30
AC
50
J1 2
M
+B D+
70
GG
W
–B
31
-
+BATT (GG)
16
+
–BATT (MM)
Quadro princ N 220 AFAM
Minimum cable cross section in mm2
Component code or connector code
Cable colour
S
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
EC
engine stop solenoid valve
SSV
runaway engine
J1
alternator excitation
K
air filter clogging sensor (for alarm)
Gauges CG revolution-counter
MA
alarms management module
MO
engine oil pressure
MM QP
electric starter motor main analog instrument panel
TA
engine temperature
V
voltmeter
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
QP
70
70
RL1
31
M
10
0
8 7 6 5 4 3 2 1
0 0 0 1
X100
3
50
MM
2
–BATT (MM)
30
R
4
J1 2
5
6
GG 2 GG 2
GG
+B
W
+BATT (GG)
8
3 3
1 1
1
1
W
4 3 2 1
J16F
2 1
JSV
1
I
3
V
1
4
1
1
40
CG
1
1
T
C
1
1
MO
K
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
–B
D+
7
50
30
9 10 11 12 13 14 15 16 JB
85
20
1
JB
+BATT (MM)
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
+
85
30
1
1
EC 3 2 1
8A
FS
15
CA
6
16
30
6
N67 MNS M22 N67 MNT M28
16
3.72 JUNE 2007
M22.11
Quadro princ N 220 AFAM
SBLA SSV
SIFA
SATA
SS
SBPO
QP
70
86
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
GG 2 GG 2
W
3 3
1 1
1
W
1
V 1
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
50
30
BZ GR VB S BN H M 9 10 11 12 13 14 15 16 JC
85
87
86
I 1
1
40
CG
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
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 220 AFAM SBPO
JUNE 2007 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 JUNE 2007
Supplementary services battery recharge M22.11
JUNE 2007
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
JUNE 2007
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007 N67 MNS M22 N67 MNT M28
3.79
M28.11 WIRE HARNESS
N67 MNS M22 N67 MNT M28
3.80
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
RL1
31
M
10
0
8 7 6 5 4 3 2 1
0 0 0 1
X100
3
50
MM
2
–BATT (MM)
30
R
4
J1 2
5
6
GG1 2 GG 2
GG 2 GG 2
GG
+B W
+BATT (GG)
8
3 3
3 3
1 1
1 1
1
1
W
3 4 5
T
4 5
RT
P
2
3
1
2
3
1
J16F
JSV 1
2
1
2
3
2
1
4
1
I
3
V
1
4
1
1
40
CG
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
–B
D+
7
50
30
9 10 11 12 13 14 15 16 JB
85
20
1
JB
+BATT (MM)
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 JUNE 2007
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
JUNE 2007 N67 MNS M22 N67 MNT M28
3.85
M28.11
SSV
SS
n
Two-engines installation
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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
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N67 MNS M22 N67 MNT M28
Sk Accum_Servizi NEF280 S3
3.86 ELECTRICAL EQUIPMENT JUNE 2007
Supplementary services battery recharge M28.11
JUNE 2007
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
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JUNE 2007
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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 JUNE 2007
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
JUNE 2007 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 JUNE 2007
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
JUNE 2007 N67 MNS M22 N67 MNT M28
4.95
4.96
N67 MNS M22 N67 MNT M28
DIAGNOSTICS
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JUNE 2007
JUNE 2007
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
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JUNE 2007
N67 MNS M22 N67 MNT M28
MAINTENANCE
JUNE 2007
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.
JUNE 2007
JUNE 2007
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
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JUNE 2007
JUNE 2007
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
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JUNE 2007
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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.
JUNE 2007
JUNE 2007
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
JUNE 2007
JUNE 2007
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
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
JUNE 2007
JUNE 2007
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
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
JUNE 2007
JUNE 2007
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
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
JUNE 2007
JUNE 2007
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
JUNE 2007
OVERHAUL
JUNE 2007
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
JUNE 2007
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
JUNE 2007
CLEARANCE DATA Type 6 Cylinders 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
JUNE 2007
Type 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
JUNE 2007
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
JUNE 2007
Type 6 Cylinders Cylinder head - timing system
Valve guide seats on cylinder head
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
JUNE 2007
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
JUNE 2007
Type 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
JUNE 2007
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
JUNE 2007
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
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JUNE 2007
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
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JUNE 2007
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
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JUNE 2007
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
JUNE 2007
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
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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
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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
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JUNE 2007
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
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Checks and measurements
JUNE 2007
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
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JUNE 2007
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
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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
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JUNE 2007
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
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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
JUNE 2007
OVERHAUL
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
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JUNE 2007
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
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Measuring piston diameter
JUNE 2007
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
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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
JUNE 2007
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 2000 366 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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
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JUNE 2007
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
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Checking cylinder head wet seal
JUNE 2007
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
JUNE 2007
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
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Valve guide
JUNE 2007
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
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JUNE 2007
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
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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
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JUNE 2007
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
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JUNE 2007
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
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JUNE 2007
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
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Figure 124
JUNE 2007
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.
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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.
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Figure 133
JUNE 2007
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
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JUNE 2007
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.
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Refitting the cylinder head
JUNE 2007
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
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JUNE 2007
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.
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Figure 147
JUNE 2007
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
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JUNE 2007
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
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Figure 156
JUNE 2007
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.
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JUNE 2007
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
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JUNE 2007
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
JUNE 2007
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
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JUNE 2007
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
JUNE 2007
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
N67 MNS M22 N67 MNT M28
9.181
SECTION 9
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
Page
SAFETY SYSTEM FOR APPROVED INSTALLATIONS 182 Installation Assembly Drawing
182
Engine equipment characteristics
183
JC Connector
183
Synoptic panel
184
Harnessing
185
Location of standard equipment sensors
186
Location of safety system sensors
187
Insulated pole power network (upon request)
188
Electric starter motor
188
Alternator
189
Exhaust Gas Temperature Sensor (O)
190
Engine oil temperature sensors (SAA)
190
Coolant temperature sensor (TA)
190
Engine oil low pressure sensor (WA)
191
Input air pressure sensor (H)
192
Component providing a reostatic signal for fluid pressure analogic indication.
192
Engine oil pressure sensor located upstream of the filter (VAP)
192
Engine oil pressure sensor located upstream of the filter (VAD)
192
Fuel pressure sensor (VCA)
192
Component providing a reostatic signal for fluid pressure analogic indication.
192
Oil low pressure sensor (WAA)
193
Fuel leakage sensor (WPC)
193
SAFETY SYSTEM ELECTRIC DIAGRAMS Harness assembly drawing
194 195
9.182
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
SAFETY SYSTEM FOR APPROVED INSTALLATIONS Installation Assembly Drawing Figure 1 GG2
GG3
O
WA
IAA
K
K
VCA
VAP
EC1 EC2
SAA
VAD
H
JC
TA
WAA
WPC
07_006_N
H. Combustion air pressure sensor - IAA. Coolant high temperature sensor - JC. Display panel connector - K. Air filter clogging sensor - O. Exhaust gas temperature sensor - SAA. Oil temperature sensor - TA. Coolant temperature sensor - VAD. Oil pressure sensor after the filter - VAP. Oil pressure sensor before the filter - VAP. Fuel pressure sensor - WA. Oil very low pressure sensor WAA. Oil low pressure sensor - WPC. Fuel leakage sensor. Connectors: EC1, EC2, K, GG2, GG3 to be connected to the standard equipment harness.
It is known that engines subjected to the release of a conformity declaration by Certification Bodies must incorporate, besides the standard equipment, a series of components designed to detect and monitor the engine operating parameters. The system that is created and that we will define as “Safety System” is required to control acoustic and optical alarms in case the engine operating conditions are such to jeopardize the safety of on-board components or engine efficiency.
The safety system supply standard of this engine does not foresee an alarm assembly and management unit, leaving in such way to the Workshop or the Installer the responsibility to complete the system in compliance with the instructions provided by the different approval norms.
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Engine equipment characteristics The engine is supplied with all the standard equipment components, to which the safety system components must be added. It is the Workshop or the Installer responsibility to connect two different electric cables to the relevant components and provide for the construction and layout of the monitoring unit. To connect the components of the safety system to the alarm monitoring and management unit a connector is provided, identified by the acronym JC, located at the end of the relevant cable. It is the Workshop or the Installer responsibility to perform the electric connection between the JC connector and the monitoring unit.
JC Connector Figure 2
30 29 28
18 17 16 27
31 19 7 6 15 26
8
20 9
2 1 5 14
3 4 13 25
21 10 11 12
22 23
24
07_007_N
JC CONNECTOR OF THE SAFETY SYSTEM HARNESS SEEN FROM THE COUPLING SIDE
As for the identification of the functions performed by each line, please refer to the electric diagrams attached at the end of the document. Pin
Component and detected Acronym parameter 1-2/3-4 Oil very low pressure pressure WA switch 5 Fuel leakage level switch WPC 6
Combustion air pressure sensor
H
7
-
8
Common terminal (please refer to the electric diagram) Engine coolant temperature sensor
9
Fuel pressure sensor
VCA
10
Oil pressure sensor after the filter
VAD
11
Oil temperature sensor
SAA
12
Oil low pressure pressure switch
WAA
TA
N67 MNS M22 N67 MNT M28
9.183
13/14
Exhaust gas temperature sensor
O
15
Coolant high temperature switch
IAA
16
(W)
17
Engine rpm signal from the alternator Engine stoppage solenoid valve
18
Air filter clogging pressure switch
19
Oil pressure sensor before the filter
EC K VAP
High safety level requested by all approval norms, it is obtained by making some signals redundant; as a result, the engine equipment includes suitable components designed to detect the same physical quantity, but dedicated to different monitoring systems. In compliance with the instructions provided by Certification Bodies, it must be possible to verify the efficiency of some components; for explanatory purposes, we mention the presence of an oil flow on-off valve towards the oil very low pressure pressure switch which will be closed to certify the efficiency of the sensor.
9.184
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Synoptic panel Figure 3 SENSORS FOR APPROVED EQUIPMENT SENSORS FOR INSTRUMENTS AND ALARMS
JC
ENGINE STOPPAGE SOLENOID VALVE
ELECTRIC FUEL PUMP TIMER
( )
*
ELECTRIC FUEL PUMP ( )
*
ALTERNATOR
ELECTRIC STARTER MOTOR
N67 MNS M 22.11 N67 MNT M 28.11 JB
RL1
BATTERY 07_020_N
4
1
2
3
( ) Not available on the engine model N67 MNS M22 * 1.Instrument panel connecting cable connector - 2. Cabling of standard components installed on the engine 3. Power network - 4. Connector designed for cabling the safety system components installed on the engine.
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
9.185
Harnessing Figure 4 RT ( )
*
( )
* T
J1
+BAT (GG)
P
( )
*
+BAT (GG)
4
*
4
GG GG ( )
*
JB RL1
1
87 85 86 30
5
4
4
8
15
JSV
T
( ) GG1
*
( )
*
GG
GG3
GG2
W V
J16F
1
4
50
4
−BAT (GG)
1
4
7
50
I
1
−BAT (GG)
W
( )
+BAT (MM)
−BAT (MM) MM
K
EC
EC1
4 16
K
K
EC2
K
WA
VCA VA
VCA TA
07_021_N
VA1
JC
O
IAA
WPC
TA
WAA WAA
H H
VA
SAA
VA1
SAA
STANDARD EQUIPMENT CONNECTORS I. Engine coolant high temperature sensor (per alarm) - K. Air filter clogging sensor (per alarm) - P. Electric fuel pump (*) T. Electric fuel pump actuation timer (*) - T. Sensor engine coolant temperature (per indicating instrument) - V. Oil pressure sensor (for indicating instrument) - W. Oil low pressure sensor (per alarm) - EC. Engine stoppage solenoid valve - GG. Alternator JB. Connectorpre-set for instrument panel cabling - MM. Electric starter motor - JSV. Module connector for overspeed control RL1. Engine start relay. SAFETY SYSTEM CONNECTORS H. Combustion air pressure sensor - IAA. Engine coolant high temperature switch - JC. Connectors pre-set to cable the alarm monitoring and management unit - K. Air filter clogging pressure switch - O. Exhaust gas temperature sensor SAA. Oil temperature sensor - TA. Engine coolant temperature sensor - VAD. Oil pressure sensor after the filter VAP. Oil pressure sensor before the filter - VCA. Fuel pressure sensor - WA. Oil very low pressure pressure switch WAA. Oil low pressure pressure switch - WPC. Fuel leakage level switch. Connectors: EC1, EC2, K, GG2, GG3 will have to be connected to as many connectors of the standard harness. ( ) Not available on the engine model N67 MNS M22 *
9.186
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Location of standard equipment sensors Figure 5
P
GG
I
T
RL1
MM
K
EC
JB
06_015_N
JSV
T
W
V
I. Engine coolant high temperature sensor (per alarm) - K. Air filter clogging sensor (per alarm) - P. Electric fuel pump (*) T. Electric fuel pump actuation timer (*) - T. Sensor engine coolant temperature (per indicating instrument) - V. Oil pressure sensor (for indicating instrument) - W. Oil low pressure sensor (per alarm) - EC. Engine stoppage solenoid valve - GG. Alternator JB. Connector pre-arrange for instrument panel cabling - MM. Electric starter motor - JSV. Module connector for overspeed control RL1. Engine start relay. ( ) Not available on the engine model N67 MNS M22 *
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
9.187
Location of safety system sensors Figure 6 WA
GG2
O
GG3
K K
( )
*
IAA
WPC
VCA EC1 EC2
VAP
SAA
VAD
H
JC
TA
WAA
Standard equipment harness Safety system harness
07_022_N
H. Combustion air pressure sensor - IAA. Engine coolant high temperature switch - JC. Connectors pre-arranged to cable the alarm monitoring and management unit - K. Air filter clogging pressure switch - O. Exhaust gas temperature sensor - SAA. Oil temperature sensor - TA. Engine coolant temperature sensor - VAD. Oil pressure sensor after the filter - VAP. Oil pressure sensor before the filter - VCA. Fuel pressure sensor – WA. Oil very low pressure pressure switch - WAA. Oil low pressure pressure switch WPC. Fuel leakage level switch. Connectors: EC1, EC2, K, GG2, GG3 will have to be connected to as many connectors of the standard harness. ( ) Not available on the engine model N67 MNS M22 *
9.188
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SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
Insulated pole power network (upon request)
JUNE 2007
Electric starter motor Figure 8
Figure 7
2
System power supply 1
30
50
+B
D+
3
W
M 31
–B
07_009_N
2 1
The power network can be built in order to avoid using the engine and the hull structure with the conductor function, if made out of metal. To this purpose, the electric starter motor and the alternator required by this equipment are featured by a 24V tension and by the presence of both terminals for electric connections attached to the positive and negative poles of the battery.
3
07_008_N
1. Excitation coil control (50) - 2. Power positive pole (+B) 3. Negative power supply pole (-BATT).
Technical characteristics: -
Power supply rated voltage: 24 V
-
Absorbed power: 4 kW
-
“50” terminal: bar connector (fast-on)
-
“+B” terminal: threaded element M10 tightening torque 12-18 Nm
-
“-B” terminal: threaded element M10 tightening torque 12-18 Nm
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Alternator Figure 9
+B D+ W -B
+B D+ W -B 07_007_N
Technical characteristics: -
Output voltage: 28 V
-
Maximum current intensity 70 A
-
“+B” terminal: threaded element M8 tightening torque 11 Nm ± 20%
-
“D+” terminal: threaded element M4 tightening torque 2,0 Nm ± 20%
-
“W” terminal: bar connector (fast-on)
-
“-B” terminal: threaded element M6 tightening torque 5.0 Nm ± 20%
+B. (24 V)
Power supply output terminal;
D+.
Power voltage of the recharge/alarm warning light located on the control panel;
W.
Output terminal of the rpm counter control signal;
−B. (0 V)
Power supply output terminal.
N67 MNS M22 N67 MNT M28
9.189
9.190
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Coolant high temperature sensor (IAA)
Exhaust Gas Temperature Sensor (O)
Figure 11
Figure 10
04_260_N
NiCr-Ni insulated pole thermocouple sensor provides the signal for the analogic indication of the exhaust gas.
04_313_N
Thermometric switch providing information for the engine high temperature alarm.
Temperature
Voltage
°C
mV
100
4.10
Operating voltage
from 6 V to 24 V
200
8.13
Room temperature condition
normally open
300
12.21
Closing temperature
100 ± 3 °C
400
16.40
Poles
isolated
500
20.65
600
24.91
700
29.14
800
33.30
900
37.36
Engine oil temperature sensors (SAA) Coolant temperature sensor (TA) Figure 12
05_114_C
Negative temperature coefficient resistance providing the signal for temperature analogic indication. Operating voltage
from 6 V to 24 V
Calibration field
from 0°C to 120 °C
Resistance value at 90°
51.2 ± 4.3 Ω
Poles
isolated
JUNE 2007
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
Engine oil low pressure sensor (WA)
N67 MNS M22 N67 MNT M28
9.191
Figure 14
Figure 13
1 WA 05_055_C
Switch actuated by the fluid pressure, providing the information to the engine lubricating oil low pressure alarm. Operating voltage
from 6 V to 24V
Room pressure condition Switchover pressure Poles
normally closed 0.4 bar isolated
Electric diagram: 05_054_C
1 1 2 3 4
2
4
07_011_N
WA. Engine oil low pressure sensor 1. Valve to certify the operation of the WA sensor.
An oil flow on-off valve is located along the lubrication circuit pressure switch connection duct(1), used to certify sensor efficiency. By closing the valve before engine start, as soon as the engine is re-started again, you will be able to test the efficiency of the monitoring and alarm system and the possible emergency stoppage due to circuit missed pressurization. Following the opening of the valve, you will be able to re-start the engine.
9.192
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
Input air pressure sensor (H)
JUNE 2007
Engine oil pressure sensor located upstream of the filter (VAP) Engine oil pressure sensor located upstream of the filter (VAD) Fuel pressure sensor (VCA)
Figure 15
Figure 16
04_237_N
Component providing a reostatic signal for fluid pressure analogic indication. 04_237_N
Operating voltage
from 6 V to 24 V
Calibration field from
0 bar to 2 bar
Resistance value at 0.5 bar
56 ± 7 Ω
Resistance value at 1 bar
100 ± 6 Ω
Resistance value at 1.5 bar
145 ± 8 Ω
Operating temperature
from - 25°C to +100°C
Poles
isolated
Component providing a reostatic signal for fluid pressure analogic indication. Operating voltage
from 6 V to 24 V
Calibration field from
0 bar to 10 bar
Resistance value at 0 bar
10 Ω +3/-5 Ω
Resistance value at 2 bar
52 ± 4 Ω
Resistance value at 4 bar
88 ± 4 Ω
Resistance value at 6 bar
124 ± 5 Ω
Maximum resistance value
184 Ω
Operating temperature
from - 25°C to +100°C
Poles
isolated
JUNE 2007
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
N67 MNS M22 N67 MNT M28
9.193
Fuel leakage sensor (WPC)
Oil low pressure sensor (WAA)
Figure 18
Figure 17
2
04_314_N
Pressure switch providing the signal to turn the illuminated indicator on in case of insufficient pressure in the lubricating oil circuit. 1
Operating voltage
from 6 V to 24 V
Room pressure condition
normally closed
Calibration field
from 0.5 bar to 0.8 bar
Closing pressure
0.5 bar
Opening pressure
0.8 bar
Switch capacity
15 A non inductive
Poles
isolated
07_010_N
Switch actuated by the presence of fuel in the leakage collection container (1). The injector feeding pipe double liner 2) is connected to the manifold conveying any leakage towards the container where the sensor is located. Operating voltage
from 6 V to 24 V
No leakage condition
normally open
Switch capacity
0.1 A non inductive
Poles
isolated
9.194
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
SAFETY SYSTEM ELECTRIC DIAGRAMS Standard equipment component codes
Safety system component code
AC
Battery
H
Combustion air pressure sensor
EC
Engine stoppage solenoid valve
GG
Alternator
IAA JC
I
Coolant high temperature sensor (per alarm)
O
Coolant high temperature switch Connector set up to allow cabling of the alarm monitoring and management unit Exhaust Gas Temperature Sensor
K
Air filter clogging sensor (per alarm)
SAA
Oil temperature sensor
MM
Electric starter motor
TA
Coolant temperature sensor
P (*)
Electric fuel pump
VAD
Oil pressure sensor after the filter
Coolant temperature sensor (per indicating instrument) Electric fuel pump timer
VAP
Oil pressure sensor before the filter
VCA
Fuel pressure sensor
Engine oil pressure sensor (per indicating instrument) Engine oil low pressure sensor (per alarm)
WA
Oil very low pressure pressure switch
WAA
Oil low pressure pressure switch
WPC
Fuel leakage sensor
T
T (*) V
W J16F
Engine rotation overspeed control module (upon request)
Connectors JB ON THE ENGINE HARNESS Pre-arranged to allow the connection to the main analogic panel JC ON THE MAIN ANALOGIC INSTRUMENT PANEL Pre-arranged to allow the connection to the engine harness JSV Overspeed module Elettromagnetic switch RL1 Electric starter motor 50 terminal power supply ( ) Not available on the engine model N67 MNS M22 *
Connectors: EC1, EC2, K, GG2, GG3 to be connected to the standard equipment harness.
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
9.195
Harness assembly drawing Figure 19
JB
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 JB
JC
19 18 17 16 15 14 13 12 11 10 9
8
7
6
5
4
3
2
1 JC
4
3
2
1 WA
31
EC 3 2 1 EC2 3 2 1
EC1 3 2 1 EC 3 2 1
P
1
EC 1
K K 1 1
K 1
1 V
W 1
30
1
87
RL1
6
6
86
85
GG 2 (*) GG 2
3 3
1 1
1
1
1
I 1
O
4
A
3
3
IAA
2
2
1
1
J16F
1
1
2
2
3
3
4
4
5
5
RT (*)
T (*)
VCA
H
1
4
JSV
SAA
K
T
1
VAP
B
1
VAD
TA
WAA
1
WPC
1
2
1
(*) GG1 2 GG3 2
3 3
1 1
3
P
2
P (*)
+BATT (MM)
GG2 2 GG 2
16
70
3 3
1 1
MM 30
AC
Safety system harness
50
J1 2
M
+B D+
70
GG
W
–B
31
-
+BATT (GG)
16
+
–BATT (MM)
( ) Not available on the engine model N67 MNS M22 *
Sk el RINA NEF 220-280
9.196
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SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
PAGE LEFT INTENTIONALLY BLANK
JUNE 2007
JUNE 2007
SAFETY REGULATIONS
N67 MNS M22 N67 MNT M28
10.197
SECTION 10
SAFETY REGULATIONS
Page
SAFETY REGULATIONS
199
Standard safety regulations
199
Accident prevention
199
During maintenance
199
Respecting the Environment
200
10.198
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SAFETY REGULATIONS
Page left intentionally blank
JUNE 2007
JUNE 2007
SAFETY REGULATIONS
N67 MNS M22 N67 MNT M28
10.199
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;
10.200
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.
JUNE 2007
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
T E C H N O L O G I C A L
E X C E L L E N C E
JUNE 2007 EDITION
1.
N67 MNS M22 N67 MNT M28
JUNE 2007
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 - June 2007 Edition
N67 MNS M22 N67 MNT M28
JUNE 2007
1.
SECTION CONTENTS Section
Page
1.
OVERVIEW
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 SYSTEM FOR HOMOLOGATED INSTALLATIONS
181
10. SAFETY REGULATIONS
5
197
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
JUNE 2007
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JUNE 2007
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
JUNE 2007
N67 MNS M22 N67 MNT M28
OVERVIEW
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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.
N67 MNS M22 N67 MNT M28
OVERVIEW
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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
JUNE 2007
JUNE 2007
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 HX40L8274BN/J16S3 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
JUNE 2007
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
JUNE 2007
2.41
Dimensions Figure 1
(1.7)
(1.)
0 (1.1) 2 (.2)
7 (1.22)
(1.)
12 (.)
2, (2.1)
1 (0.)
710 (27.)
0 (2.)
70 (0.70) 04_305_N
Measurements in: millimeters (inches).
2.42
N67 MNS M22 N67 MNT M28
TECHNICAL DATA
PAGE LEFT INTENTIONALLY BLANK
JUNE 2007
JUNE 2007
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 - N67 MNT M28.10
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
JUNE 2007
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
200 400 600 800
1000
1200
CHARACTERISTIC CURVES
1400
1600
I (A)
N67 MNS M22 N67 MNT M28
3.48
ELECTRICAL EQUIPMENT
JUNE 2007
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.
JUNE 2007
ELECTRICAL EQUIPMENT
N67 MNS M22 N67 MNT M28
N67 MNS M22.10 N67 MNT M28.10 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
JUNE 2007
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007 N67 MNS M22 N67 MNT M28
M22.10 - M28.10 WIRE HARNESS
3.53
3.54
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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)
JUNE 2007
ELECTRICAL EQUIPMENT
PAGE LEFT INTENTIONALLY BLANK
N67 MNS M22 N67 MNT M28
3.57
N67 MNS M22 N67 MNT M28
3.58
ELECTRICAL EQUIPMENT
JUNE 2007
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
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
6
SSV
3.60 ELECTRICAL EQUIPMENT JUNE 2007
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
JUNE 2007 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 JUNE 2007
M22.10 - M28.10
JUNE 2007
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
JUNE 2007
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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)
JUNE 2007 N67 MNS M22 N67 MNT M28
3.67
M22.11 WIRE HARNESS
N67 MNS M22 N67 MNT M28
3.68
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
CG
RL
30
Component code
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
1
1
EC
1
1
87
RL1
6
6
86
GG 2 GG 2
+BATT (MM)
V
K
AN L
1
1
I
1 K
T
1
1
4
4
3
3
2
2
1
1
JSV
J16F
1
1 1
16
70
3 3
1 V
W
1
85
G
MP
EC 3 2 1
30
N
MM 30
AC
50
J1 2
M
+B D+
70
GG
W
–B
31
-
+BATT (GG)
16
+
–BATT (MM)
Quadro princ N 220 AFAM
Minimum cable cross section in mm2
Component code or connector code
Cable colour
S
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
EC
engine stop solenoid valve
SSV
runaway engine
J1
alternator excitation
K
air filter clogging sensor (for alarm)
Gauges CG revolution-counter
MA
alarms management module
MO
engine oil pressure
MM QP
electric starter motor main analog instrument panel
TA
engine temperature
V
voltmeter
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
QP
70
70
RL1
31
M
10
0
8 7 6 5 4 3 2 1
0 0 0 1
X100
3
50
MM
2
–BATT (MM)
30
R
4
J1 2
5
6
GG 2 GG 2
GG
+B
W
+BATT (GG)
8
3 3
1 1
1
1
W
4 3 2 1
J16F
2 1
JSV
1
I
3
V
1
4
1
1
40
CG
1
1
T
C
1
1
MO
K
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
–B
D+
7
50
30
9 10 11 12 13 14 15 16 JB
85
20
1
JB
+BATT (MM)
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
+
85
30
1
1
EC 3 2 1
8A
FS
15
CA
6
16
30
6
N67 MNS M22 N67 MNT M28
16
3.72 JUNE 2007
M22.11
Quadro princ N 220 AFAM
SBLA SSV
SIFA
SATA
SS
SBPO
QP
70
86
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
GG 2 GG 2
W
3 3
1 1
1
W
1
V 1
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
50
30
BZ GR VB S BN H M 9 10 11 12 13 14 15 16 JC
85
87
86
I 1
1
40
CG
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
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 220 AFAM SBPO
JUNE 2007 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 JUNE 2007
Supplementary services battery recharge M22.11
JUNE 2007
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
JUNE 2007
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007 N67 MNS M22 N67 MNT M28
3.79
M28.11 WIRE HARNESS
N67 MNS M22 N67 MNT M28
3.80
ELECTRICAL EQUIPMENT
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
N67 MNS M22 N67 MNT M28
ELECTRICAL EQUIPMENT
JUNE 2007
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
RL1
31
M
10
0
8 7 6 5 4 3 2 1
0 0 0 1
X100
3
50
MM
2
–BATT (MM)
30
R
4
J1 2
5
6
GG1 2 GG 2
GG 2 GG 2
GG
+B W
+BATT (GG)
8
3 3
3 3
1 1
1 1
1
1
W
3 4 5
T
4 5
RT
P
2
3
1
2
3
1
J16F
JSV 1
2
1
2
3
2
1
4
1
I
3
V
1
4
1
1
40
CG
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
–B
D+
7
50
30
9 10 11 12 13 14 15 16 JB
85
20
1
JB
+BATT (MM)
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 JUNE 2007
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
JUNE 2007 N67 MNS M22 N67 MNT M28
3.85
M28.11
SSV
SS
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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
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N67 MNS M22 N67 MNT M28
Sk Accum_Servizi NEF280 S3
3.86 ELECTRICAL EQUIPMENT JUNE 2007
Supplementary services battery recharge M28.11
JUNE 2007
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
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JUNE 2007
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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 JUNE 2007
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
JUNE 2007 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 JUNE 2007
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
JUNE 2007 N67 MNS M22 N67 MNT M28
4.95
4.96
N67 MNS M22 N67 MNT M28
DIAGNOSTICS
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JUNE 2007
JUNE 2007
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
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JUNE 2007
N67 MNS M22 N67 MNT M28
MAINTENANCE
JUNE 2007
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.
JUNE 2007
JUNE 2007
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
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JUNE 2007
JUNE 2007
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
JUNE 2007
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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
JUNE 2007
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.
JUNE 2007
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.
JUNE 2007
JUNE 2007
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
JUNE 2007
JUNE 2007
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
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
JUNE 2007
JUNE 2007
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
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
JUNE 2007
JUNE 2007
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
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
JUNE 2007
JUNE 2007
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
JUNE 2007
OVERHAUL
JUNE 2007
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
JUNE 2007
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
JUNE 2007
CLEARANCE DATA Type 6 Cylinders 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
JUNE 2007
Type 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
JUNE 2007
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
JUNE 2007
Type 6 Cylinders Cylinder head - timing system
Valve guide seats on cylinder head
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
JUNE 2007
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
JUNE 2007
Type 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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
OVERHAUL
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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 2000 366 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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
JUNE 2007
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
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JUNE 2007
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
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JUNE 2007
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
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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
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Figure 124
JUNE 2007
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.
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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
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Figure 133
JUNE 2007
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.
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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
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Refitting the cylinder head
JUNE 2007
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.
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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.
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Figure 147
JUNE 2007
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.
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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.
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Figure 156
JUNE 2007
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.
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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.
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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
JUNE 2007
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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
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JUNE 2007
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
JUNE 2007
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
N67 MNS M22 N67 MNT M28
9.181
SECTION 9
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
Page
SAFETY SYSTEM FOR APPROVED INSTALLATIONS 182 Installation Assembly Drawing
182
Engine equipment characteristics
183
JC Connector
183
Synoptic panel
184
Harnessing
185
Location of standard equipment sensors
186
Location of safety system sensors
187
Insulated pole power network (upon request)
188
Electric starter motor
188
Alternator
189
Exhaust Gas Temperature Sensor (O)
190
Engine oil temperature sensors (SAA)
190
Coolant temperature sensor (TA)
190
Engine oil low pressure sensor (WA)
191
Input air pressure sensor (H)
192
Component providing a reostatic signal for fluid pressure analogic indication.
192
Engine oil pressure sensor located upstream of the filter (VAP)
192
Engine oil pressure sensor located upstream of the filter (VAD)
192
Fuel pressure sensor (VCA)
192
Component providing a reostatic signal for fluid pressure analogic indication.
192
Oil low pressure sensor (WAA)
193
Fuel leakage sensor (WPC)
193
SAFETY SYSTEM ELECTRIC DIAGRAMS Harness assembly drawing
194 195
9.182
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
SAFETY SYSTEM FOR APPROVED INSTALLATIONS Installation Assembly Drawing Figure 1 GG2
GG3
O
WA
IAA
K
K
VCA
VAP
EC1 EC2
SAA
VAD
H
JC
TA
WAA
WPC
07_006_N
H. Combustion air pressure sensor - IAA. Coolant high temperature sensor - JC. Display panel connector - K. Air filter clogging sensor - O. Exhaust gas temperature sensor - SAA. Oil temperature sensor - TA. Coolant temperature sensor - VAD. Oil pressure sensor after the filter - VAP. Oil pressure sensor before the filter - VAP. Fuel pressure sensor - WA. Oil very low pressure sensor WAA. Oil low pressure sensor - WPC. Fuel leakage sensor. Connectors: EC1, EC2, K, GG2, GG3 to be connected to the standard equipment harness.
It is known that engines subjected to the release of a conformity declaration by Certification Bodies must incorporate, besides the standard equipment, a series of components designed to detect and monitor the engine operating parameters. The system that is created and that we will define as “Safety System” is required to control acoustic and optical alarms in case the engine operating conditions are such to jeopardize the safety of on-board components or engine efficiency.
The safety system supply standard of this engine does not foresee an alarm assembly and management unit, leaving in such way to the Workshop or the Installer the responsibility to complete the system in compliance with the instructions provided by the different approval norms.
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Engine equipment characteristics The engine is supplied with all the standard equipment components, to which the safety system components must be added. It is the Workshop or the Installer responsibility to connect two different electric cables to the relevant components and provide for the construction and layout of the monitoring unit. To connect the components of the safety system to the alarm monitoring and management unit a connector is provided, identified by the acronym JC, located at the end of the relevant cable. It is the Workshop or the Installer responsibility to perform the electric connection between the JC connector and the monitoring unit.
JC Connector Figure 2
30 29 28
18 17 16 27
31 19 7 6 15 26
8
20 9
2 1 5 14
3 4 13 25
21 10 11 12
22 23
24
07_007_N
JC CONNECTOR OF THE SAFETY SYSTEM HARNESS SEEN FROM THE COUPLING SIDE
As for the identification of the functions performed by each line, please refer to the electric diagrams attached at the end of the document. Pin
Component and detected Acronym parameter 1-2/3-4 Oil very low pressure pressure WA switch 5 Fuel leakage level switch WPC 6
Combustion air pressure sensor
H
7
-
8
Common terminal (please refer to the electric diagram) Engine coolant temperature sensor
9
Fuel pressure sensor
VCA
10
Oil pressure sensor after the filter
VAD
11
Oil temperature sensor
SAA
12
Oil low pressure pressure switch
WAA
TA
N67 MNS M22 N67 MNT M28
9.183
13/14
Exhaust gas temperature sensor
O
15
Coolant high temperature switch
IAA
16
(W)
17
Engine rpm signal from the alternator Engine stoppage solenoid valve
18
Air filter clogging pressure switch
19
Oil pressure sensor before the filter
EC K VAP
High safety level requested by all approval norms, it is obtained by making some signals redundant; as a result, the engine equipment includes suitable components designed to detect the same physical quantity, but dedicated to different monitoring systems. In compliance with the instructions provided by Certification Bodies, it must be possible to verify the efficiency of some components; for explanatory purposes, we mention the presence of an oil flow on-off valve towards the oil very low pressure pressure switch which will be closed to certify the efficiency of the sensor.
9.184
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Synoptic panel Figure 3 SENSORS FOR APPROVED EQUIPMENT SENSORS FOR INSTRUMENTS AND ALARMS
JC
ENGINE STOPPAGE SOLENOID VALVE
ELECTRIC FUEL PUMP TIMER
( )
*
ELECTRIC FUEL PUMP ( )
*
ALTERNATOR
ELECTRIC STARTER MOTOR
N67 MNS M 22.11 N67 MNT M 28.11 JB
RL1
BATTERY 07_020_N
4
1
2
3
( ) Not available on the engine model N67 MNS M22 * 1.Instrument panel connecting cable connector - 2. Cabling of standard components installed on the engine 3. Power network - 4. Connector designed for cabling the safety system components installed on the engine.
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
9.185
Harnessing Figure 4 RT ( )
*
( )
* T
J1
+BAT (GG)
P
( )
*
+BAT (GG)
4
*
4
GG GG ( )
*
JB RL1
1
87 85 86 30
5
4
4
8
15
JSV
T
( ) GG1
*
( )
*
GG
GG3
GG2
W V
J16F
1
4
50
4
−BAT (GG)
1
4
7
50
I
1
−BAT (GG)
W
( )
+BAT (MM)
−BAT (MM) MM
K
EC
EC1
4 16
K
K
EC2
K
WA
VCA VA
VCA TA
07_021_N
VA1
JC
O
IAA
WPC
TA
WAA WAA
H H
VA
SAA
VA1
SAA
STANDARD EQUIPMENT CONNECTORS I. Engine coolant high temperature sensor (per alarm) - K. Air filter clogging sensor (per alarm) - P. Electric fuel pump (*) T. Electric fuel pump actuation timer (*) - T. Sensor engine coolant temperature (per indicating instrument) - V. Oil pressure sensor (for indicating instrument) - W. Oil low pressure sensor (per alarm) - EC. Engine stoppage solenoid valve - GG. Alternator JB. Connectorpre-set for instrument panel cabling - MM. Electric starter motor - JSV. Module connector for overspeed control RL1. Engine start relay. SAFETY SYSTEM CONNECTORS H. Combustion air pressure sensor - IAA. Engine coolant high temperature switch - JC. Connectors pre-set to cable the alarm monitoring and management unit - K. Air filter clogging pressure switch - O. Exhaust gas temperature sensor SAA. Oil temperature sensor - TA. Engine coolant temperature sensor - VAD. Oil pressure sensor after the filter VAP. Oil pressure sensor before the filter - VCA. Fuel pressure sensor - WA. Oil very low pressure pressure switch WAA. Oil low pressure pressure switch - WPC. Fuel leakage level switch. Connectors: EC1, EC2, K, GG2, GG3 will have to be connected to as many connectors of the standard harness. ( ) Not available on the engine model N67 MNS M22 *
9.186
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Location of standard equipment sensors Figure 5
P
GG
I
T
RL1
MM
K
EC
JB
06_015_N
JSV
T
W
V
I. Engine coolant high temperature sensor (per alarm) - K. Air filter clogging sensor (per alarm) - P. Electric fuel pump (*) T. Electric fuel pump actuation timer (*) - T. Sensor engine coolant temperature (per indicating instrument) - V. Oil pressure sensor (for indicating instrument) - W. Oil low pressure sensor (per alarm) - EC. Engine stoppage solenoid valve - GG. Alternator JB. Connector pre-arrange for instrument panel cabling - MM. Electric starter motor - JSV. Module connector for overspeed control RL1. Engine start relay. ( ) Not available on the engine model N67 MNS M22 *
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
9.187
Location of safety system sensors Figure 6 WA
GG2
O
GG3
K K
( )
*
IAA
WPC
VCA EC1 EC2
VAP
SAA
VAD
H
JC
TA
WAA
Standard equipment harness Safety system harness
07_022_N
H. Combustion air pressure sensor - IAA. Engine coolant high temperature switch - JC. Connectors pre-arranged to cable the alarm monitoring and management unit - K. Air filter clogging pressure switch - O. Exhaust gas temperature sensor - SAA. Oil temperature sensor - TA. Engine coolant temperature sensor - VAD. Oil pressure sensor after the filter - VAP. Oil pressure sensor before the filter - VCA. Fuel pressure sensor – WA. Oil very low pressure pressure switch - WAA. Oil low pressure pressure switch WPC. Fuel leakage level switch. Connectors: EC1, EC2, K, GG2, GG3 will have to be connected to as many connectors of the standard harness. ( ) Not available on the engine model N67 MNS M22 *
9.188
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SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
Insulated pole power network (upon request)
JUNE 2007
Electric starter motor Figure 8
Figure 7
2
System power supply 1
30
50
+B
D+
3
W
M 31
–B
07_009_N
2 1
The power network can be built in order to avoid using the engine and the hull structure with the conductor function, if made out of metal. To this purpose, the electric starter motor and the alternator required by this equipment are featured by a 24V tension and by the presence of both terminals for electric connections attached to the positive and negative poles of the battery.
3
07_008_N
1. Excitation coil control (50) - 2. Power positive pole (+B) 3. Negative power supply pole (-BATT).
Technical characteristics: -
Power supply rated voltage: 24 V
-
Absorbed power: 4 kW
-
“50” terminal: bar connector (fast-on)
-
“+B” terminal: threaded element M10 tightening torque 12-18 Nm
-
“-B” terminal: threaded element M10 tightening torque 12-18 Nm
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Alternator Figure 9
+B D+ W -B
+B D+ W -B 07_007_N
Technical characteristics: -
Output voltage: 28 V
-
Maximum current intensity 70 A
-
“+B” terminal: threaded element M8 tightening torque 11 Nm ± 20%
-
“D+” terminal: threaded element M4 tightening torque 2,0 Nm ± 20%
-
“W” terminal: bar connector (fast-on)
-
“-B” terminal: threaded element M6 tightening torque 5.0 Nm ± 20%
+B. (24 V)
Power supply output terminal;
D+.
Power voltage of the recharge/alarm warning light located on the control panel;
W.
Output terminal of the rpm counter control signal;
−B. (0 V)
Power supply output terminal.
N67 MNS M22 N67 MNT M28
9.189
9.190
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SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
Coolant high temperature sensor (IAA)
Exhaust Gas Temperature Sensor (O)
Figure 11
Figure 10
04_260_N
NiCr-Ni insulated pole thermocouple sensor provides the signal for the analogic indication of the exhaust gas.
04_313_N
Thermometric switch providing information for the engine high temperature alarm.
Temperature
Voltage
°C
mV
100
4.10
Operating voltage
from 6 V to 24 V
200
8.13
Room temperature condition
normally open
300
12.21
Closing temperature
100 ± 3 °C
400
16.40
Poles
isolated
500
20.65
600
24.91
700
29.14
800
33.30
900
37.36
Engine oil temperature sensors (SAA) Coolant temperature sensor (TA) Figure 12
05_114_C
Negative temperature coefficient resistance providing the signal for temperature analogic indication. Operating voltage
from 6 V to 24 V
Calibration field
from 0°C to 120 °C
Resistance value at 90°
51.2 ± 4.3 Ω
Poles
isolated
JUNE 2007
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
Engine oil low pressure sensor (WA)
N67 MNS M22 N67 MNT M28
9.191
Figure 14
Figure 13
1 WA 05_055_C
Switch actuated by the fluid pressure, providing the information to the engine lubricating oil low pressure alarm. Operating voltage
from 6 V to 24V
Room pressure condition Switchover pressure Poles
normally closed 0.4 bar isolated
Electric diagram: 05_054_C
1 1 2 3 4
2
4
07_011_N
WA. Engine oil low pressure sensor 1. Valve to certify the operation of the WA sensor.
An oil flow on-off valve is located along the lubrication circuit pressure switch connection duct(1), used to certify sensor efficiency. By closing the valve before engine start, as soon as the engine is re-started again, you will be able to test the efficiency of the monitoring and alarm system and the possible emergency stoppage due to circuit missed pressurization. Following the opening of the valve, you will be able to re-start the engine.
9.192
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SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
Input air pressure sensor (H)
JUNE 2007
Engine oil pressure sensor located upstream of the filter (VAP) Engine oil pressure sensor located upstream of the filter (VAD) Fuel pressure sensor (VCA)
Figure 15
Figure 16
04_237_N
Component providing a reostatic signal for fluid pressure analogic indication. 04_237_N
Operating voltage
from 6 V to 24 V
Calibration field from
0 bar to 2 bar
Resistance value at 0.5 bar
56 ± 7 Ω
Resistance value at 1 bar
100 ± 6 Ω
Resistance value at 1.5 bar
145 ± 8 Ω
Operating temperature
from - 25°C to +100°C
Poles
isolated
Component providing a reostatic signal for fluid pressure analogic indication. Operating voltage
from 6 V to 24 V
Calibration field from
0 bar to 10 bar
Resistance value at 0 bar
10 Ω +3/-5 Ω
Resistance value at 2 bar
52 ± 4 Ω
Resistance value at 4 bar
88 ± 4 Ω
Resistance value at 6 bar
124 ± 5 Ω
Maximum resistance value
184 Ω
Operating temperature
from - 25°C to +100°C
Poles
isolated
JUNE 2007
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
N67 MNS M22 N67 MNT M28
9.193
Fuel leakage sensor (WPC)
Oil low pressure sensor (WAA)
Figure 18
Figure 17
2
04_314_N
Pressure switch providing the signal to turn the illuminated indicator on in case of insufficient pressure in the lubricating oil circuit. 1
Operating voltage
from 6 V to 24 V
Room pressure condition
normally closed
Calibration field
from 0.5 bar to 0.8 bar
Closing pressure
0.5 bar
Opening pressure
0.8 bar
Switch capacity
15 A non inductive
Poles
isolated
07_010_N
Switch actuated by the presence of fuel in the leakage collection container (1). The injector feeding pipe double liner 2) is connected to the manifold conveying any leakage towards the container where the sensor is located. Operating voltage
from 6 V to 24 V
No leakage condition
normally open
Switch capacity
0.1 A non inductive
Poles
isolated
9.194
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SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
SAFETY SYSTEM ELECTRIC DIAGRAMS Standard equipment component codes
Safety system component code
AC
Battery
H
Combustion air pressure sensor
EC
Engine stoppage solenoid valve
GG
Alternator
IAA JC
I
Coolant high temperature sensor (per alarm)
O
Coolant high temperature switch Connector set up to allow cabling of the alarm monitoring and management unit Exhaust Gas Temperature Sensor
K
Air filter clogging sensor (per alarm)
SAA
Oil temperature sensor
MM
Electric starter motor
TA
Coolant temperature sensor
P (*)
Electric fuel pump
VAD
Oil pressure sensor after the filter
Coolant temperature sensor (per indicating instrument) Electric fuel pump timer
VAP
Oil pressure sensor before the filter
VCA
Fuel pressure sensor
Engine oil pressure sensor (per indicating instrument) Engine oil low pressure sensor (per alarm)
WA
Oil very low pressure pressure switch
WAA
Oil low pressure pressure switch
WPC
Fuel leakage sensor
T
T (*) V
W J16F
Engine rotation overspeed control module (upon request)
Connectors JB ON THE ENGINE HARNESS Pre-arranged to allow the connection to the main analogic panel JC ON THE MAIN ANALOGIC INSTRUMENT PANEL Pre-arranged to allow the connection to the engine harness JSV Overspeed module Elettromagnetic switch RL1 Electric starter motor 50 terminal power supply ( ) Not available on the engine model N67 MNS M22 *
Connectors: EC1, EC2, K, GG2, GG3 to be connected to the standard equipment harness.
N67 MNS M22 N67 MNT M28
SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
JUNE 2007
9.195
Harness assembly drawing Figure 19
JB
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 JB
JC
19 18 17 16 15 14 13 12 11 10 9
8
7
6
5
4
3
2
1 JC
4
3
2
1 WA
31
EC 3 2 1 EC2 3 2 1
EC1 3 2 1 EC 3 2 1
P
1
EC 1
K K 1 1
K 1
1 V
W 1
30
1
87
RL1
6
6
86
85
GG 2 (*) GG 2
3 3
1 1
1
1
1
I 1
O
4
A
3
3
IAA
2
2
1
1
J16F
1
1
2
2
3
3
4
4
5
5
RT (*)
T (*)
VCA
H
1
4
JSV
SAA
K
T
1
VAP
B
1
VAD
TA
WAA
1
WPC
1
2
1
(*) GG1 2 GG3 2
3 3
1 1
3
P
2
P (*)
+BATT (MM)
GG2 2 GG 2
16
70
3 3
1 1
MM 30
AC
Safety system harness
50
J1 2
M
+B D+
70
GG
W
–B
31
-
+BATT (GG)
16
+
–BATT (MM)
( ) Not available on the engine model N67 MNS M22 *
Sk el RINA NEF 220-280
9.196
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SAFETY SYSTEM FOR HOMOLOGATED INSTALLATIONS
PAGE LEFT INTENTIONALLY BLANK
JUNE 2007
JUNE 2007
SAFETY REGULATIONS
N67 MNS M22 N67 MNT M28
10.197
SECTION 10
SAFETY REGULATIONS
Page
SAFETY REGULATIONS
199
Standard safety regulations
199
Accident prevention
199
During maintenance
199
Respecting the Environment
200
10.198
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SAFETY REGULATIONS
Page left intentionally blank
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JUNE 2007
SAFETY REGULATIONS
N67 MNS M22 N67 MNT M28
10.199
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;
10.200
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.
JUNE 2007
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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