USE AND MAINTENANCE

USO E MANUTENZIONE
EMPLOI ET ENTRETIEN
BETRIEBSANLEITUNG
USO Y MANUTENCIÓN

E N G I N E S
NEF
A U T O M O T I V E
S ERIES

Iveco SpA
PowerTrain
Publication edited by
Marketing - Adv. & Promotion
Print L31012004 - 01/02
NEF AUTOMOTIVE Liability
Allow us to congratulate you on your purchase, and thank you for The information published in this booklet is correct as of the date of
choosing Iveco Motors. publication.
Please take the time to read these instructions for the use and main- The manufacturer reserves the right to modify this information at any
tenance of your new engine carefully. time without prior notification for technical or commercial reasons
If you follow the instructions, you can be sure the engine will run per- or in order to comply with the laws in effect in various nations. The
fectly for a long time to come. manufacturer shall not be held liable for errors or omissions.
Iveco Motors will be happy to help you should you need us; where-
ver you are located, you'll find an Iveco Service Centre nearby.

Warranty
Please follow the instructions provided in this booklet carefully to
make sure that your engine will run perfectly and that you will be co-
vered by the warranty.
Failure to follow these instructions may invalidate the warranty.

Spare parts
It is important to use only Original Iveco Motors Spare Parts to make
sure that your engine continues to run well.
When ordering spare parts, please provide:
- the technical code and serial number of the engine
- the spare part code, as shown in the spare part catalogue.

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SAFETY REQUIREMENTS - Wear a safety helmet when working in the presence of suspen-
ded loads or equipment located at head level.
- Always wear safety shoes and overalls.
Basic safety
- Protect your hands with cream.
The following basic safety instructions are intended to reduce danger
to persons or objects when an engine is running or idle. - If your overalls get wet, change them immediately.
- Engines must not be used for any purpose other than that speci- - When working on parts that may be under voltage, make sure
fied by the manufacturer. Before an engine may safely be used your hands and feet are dry. If necessary, use an insulated foot-
for any other purpose, a specific agreement shall be drawn up board. If you are not experienced in this type of maintenance
with the manufacturer. work, always have it done by specialised personnel.
- Tampering with the engine, making alterations or using parts - Do not attempt to carry out repairs with which you have no
other than Original Iveco Motors \Spare Parts may compromise experience. Always follow the instructions, and, if in doubt, con-
safe operation. tact the manufacturer or specialised personnel.
- These instructions shall be applied in accordance with the provi- - Keep the engine clean at all times, removing any oil, diesel oil, or
sions of other Regulations in effect in the specific Country of use. coolants that may be spilled.
- Store greasy cloths in flameproof containers.
- Do not leave cloths on the engine.
During maintenance operations
- Obtain suitable safe containers for used motor oil.
- Never wear loose clothing, rings or chain jewellery when
working with engines or moving parts. - When starting up an engine after repair work, make sure that
you will be able to stop air intake in the event of a runaway upon
- Wear protective gloves and safety goggles:
startup.
- when filling batteries with acid
-when topping up inhibitors or antifreeze
-when changing or topping up lubricant oil (hot engine oil may
scald when drained; let oil cool to below 60°)
-when working with compressed air (compressed air used for
cleaning must be under 2 Atm (30 psi / 2 kg/cm2).

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Engine cooling circuit - Remove water and sediments from the tank regularly.
- Never add coolant to an overheated engine until it has cooled - Replace the fuel filter regularly, whenever the pressure drops or
down. the performance of the engine decreases.
- Check the coolant level regularly and top it up whenever neces- - Do not smoke or light any flame while filling the fuel tank.
sary, using the appropriate fluid only. Water used in the engine's
cooling circuit must always be clean and as free as possible of
minerals which could form deposits and of corrosive chemical
products. Artificially softened water should never be used; rust
and corrosion may be prevented by treating water with anticor-
rosive agents approved by the manufacturer.
- In winter measure the specific density of antifreeze regularly to
make sure that the engine is adequately protected from cold.
Remove the radiator cap gradually; cooling circuits are normally
under pressure and hot liquid could be sprayed out if the pres-
sure is reduced too quickly.
- Check belt tension and wear regularly.

Lubrication circuit
Check the oil level in the oil pan regularly and top it up if necessary.
- Change lubricant oil regularly with the recommended frequency,
making sure that the oil you use has the characteristics and visco-
sity specified in these Instructions.

Fuel circuit
- Try to keep the fuel tank full most of the time in order to pre-
vent condensation.

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CONTENTS

Page
Engine identification.................................................................................................5
Engine technical data N40 ENT C ..........................................................................5
Engine technical data N60 ENT C ..........................................................................5
Starting and running .................................................................................................7
On the spot maintenance .....................................................................................13
Protecting the engine from cold ...........................................................................17
Checking the engine .............................................................................................18
Scheduled maintenance ........................................................................................20
Unscheduled maintenance.....................................................................................21
Lubricants, coolants and fuels ................................................................................22

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ENGINE IDENTIFICATION
The engine code is stamped on rear engine block. Engine technical data N60 ENT C
Number of cylinders 6, in line
Engine technical data N40 ENT C Bore 102 mm
Number of cylinders 4, in line Stroke 120 mm
Bore 102 mm Displacement 5.9 l
Stroke 120 mm Type: Diesel 4 stroke Common Rail
Displacement 3.9 l
Type: Diesel 4 stroke Common Rail

Maximum rating
202 kW 275 CV @ 2500 rpm
Maximum rating
125 kW 170 CV @ 2700 rpm

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ELECTRICAL SYSTEM
Batteries : 2 x 12 V - 70/88/110/143/170 Ah (depending
on version).
Alternator: 70A/90A
Sensors and connectors for fault diagnosis system operable from the
ground.

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STARTING AND RUNNIG
Engine starting with an external temperature over 10°C

Key switch position

0. = Key in and out, engine stopping, steering lock.
1. = Enginepre-starting, various auxiliary functions, pre-heating.
2. = Engine starting.

• Turn on battery isolator switch on chassis (whwre fitted).

• Insert the key in the ignition switch and turn clockwise to position 1 (MAR).
• All standard warning lamps plus the EDC warning lamp light up.
• Turn the key to position 2 (AVV) and release it as soon as the engine starts
Do not depress the accelerator pedal while the engine is started.
• The control unit performs a general check of about 1 or 2 seconds on all sen-
sors before starting fuel injection.

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If the lamp does not light up carry out the following tests:
• Press blink code button 3 in order to test EDC telltale 1 and warning lamp 2.
• If these lamps do not light up check fuse.
You don’t need to wait for the lamp to go out in order to turn the engine on.
If the lamp remains on or blinks, a defect has been detected; in this case, refer to
the fault diagnosis paragraph.
• Wait for air pressure to reach the specified value in reservoirs.
• If the engine does not start immediately, do not run the starter motor for more
than 30 seconds. After starting the engine proceed slowly and keep engine at an
average speed until normal operating temperature is reached.
By this method it is possible to obtain the following results:
• Constant and regular oil flow throughout the lubrication circuit.
• Exhaust emissions within the specified limits.
• Reduced fuel consumption.

Warning! Do not run the engine at idling speed, either cold or warm, for a
long time to reduce the quantity of noxious emissions.

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Engine starting with an external temperature below 10°C
• The vehicle is equipped with an electric device that pre-heats the intake air for
starting the engine in low temperatures.
• Insert the key inthe ignition switch and turn clockwise to position 1 (MAR).
• Warning lamp 3 lights up for 2 seconds in Auto-test mode.
It stays on if cold-starting is required (and throughout the duration of the latter,
otherwise it goes out)..
• All standard warning lamps plus the EDC warning lamp light up.
• Turn the key to position 2 (AVV) and release it as soon as the engine starts.
Note: If engine starting does not occur within a few seconds from the moment the
lamp starts to blink, the lamp is turned off and the pre-heating system is also
switched off to avoid discharging the batteries.
The pre-heating operation must therefore be repeated.

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Before driving away
Ensure the brake low air pressure (brake failure) warning lamp is extinguished, and that
the braking system air pressure gauge shows a minimum pressure of 6.5 bar for both
front and rear axles. If the warning light illuminates, or the gauge indicates less than 6.5
bar; there is a fault in the braking system. Refer to an Authorised Dealer immediately.
If the vehicle must be moved, extreme care should be taken s full braking efficiency will
not be available.

Engine stopping
To stop the engine turn the key to position 0 (STOP).
As the EDC control unit remains connected to the batteries immediately after the en-
gine has been turned off, it is of the utmost importance that you wait at least three se-
conds before disconnecting the batteries through the isolator switch.

Warning!
Serious damage to electronics on-board the vehicle can result from either of the fol-
lowing incorrect operations:
• Use of the isolator switch while attempting to stop the vehicle (use in the event of
an emergency only).
• Connection/disconnection of the EDC control unit connectors with the engine
running and the control unit energized.

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Checking faults using the EDC warning light (Fault diagnosis)
The EDC warning light informs the driver on possible injection system faults.
If the warning lamp comes on during normal operation of the vehicle, a fault has
been detected.

Off
light Standard operation

Serious defect 1. Continue your trip carefully. Turn to an

Continuous The system operates Authorised Dealer as soon as you can.
light irregularly.

Very serious 1. Park the vehicle on the road side.

defect 2. Contact the Dealer.
Blinking The system operates 3. Turn the vehicle to the nearest
light irregularly. Authorised dealer.
Failure of one or more
of the safety functions.
Possible engine STOP.

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The EDC warning lamp provides information on the faults it has detected by means of
a code consisting of long or short blinks (blink code).
The fault check process is enabled by means of the diagnosis key located under the fuse
door.
This key also controls another EDC warning lamp connected in parallel to the one on
the dashboard.

Fault check and identification process

• Stop the vehicle and switch the engine off.
• Turn the ignition key to MAR (control panel on engine off).
• Press the fault diagnosis key and ensure the EDC lamp blinks once.
No faults stored.
• If after being off for some time, the lamp starts blinking (long flashes first and short
ones afterwards), a fault is present.

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ON THE SPOT MAINTENANCE

Precautionary measures for electronic units installed on the vehicle

In order to avoid improper operations which can result in permanent damage to the control units installed on the vehicle, it is advisable
to observe the following instructions :
• Proceed as follows to carry out electric arc welding on the chassis; disconnect battery positive terminal and connect it to chassis
earth; disconnect connector from control units.
• When welding close to an electric control unit, remove the latter from the chassis; use d.c. to carry out the welding operation;
ensure the welding machine is carthed as close to the welding point as possible; ensure battery cables are not parallel to the vehi-
cle’s electrical cables.
• Never disconnect and/or connect connectors from control units with engine running or with control unit energized.
• After any servicing operation requiring battery disconnection make sure that, on reconnection, terminals are well secured to the
poles.
• Do not disconnect the battery with engine running.
• Do not use a battery charger to start the engine.
• Disconnect the battery from on-board mains when charging it.
• Remove the electronic control units if special operations require temperatures higher than 80°C.

Precautions to be strictly observed

• Before carrying out any servicing operation on the electrical system control unit and in particular before replacing the engine star-
ting relay, it is absolutely necessary to take the following precautions to avoid the risks of short circuits.
• Before removing the relay from the control ubit, it is of the utmost importance that you switch off the main switch or disconnect
the battery terminals.
• A new relay is to be installed where the plastic casing has come off during relay removal or if the relay has been opened for any
reason.
• Do not generate temperatures over 100°C (sparks, welding operations, etc...) in proximity of pretightening or airbag devices.

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Batteries
The used type of batteries require few maintenance operations, therefore, under nor-
mal operating conditions, it is not necessary to top up the electrolyte.
However, periodical checks are required to verify that the electrolyte level is compri-
sed between the MIN and MAX references shown on the battery.
Safety precautions to be adhered to when handling batteries
1. Smoking fires or free flames are strictly forbidden. Avoid generating sparks while
connecting components or measurement instruments to batteries. Before discon-
necting the batteries always disconnect permanently energized components
(tachograph, interior lighting device, etc.) by removing the relevant fuse from the
control unit.
Avoid reversing connecting wires and mishandling fixed wrenches; shortcircuit
risk.
Avoid removing terminals caps if no absolutely necessary. When performing wire
connections install the earth wire last.
2. Wear protection goggles or mask!
3 Keep batteries and acids at a safe distance from children!
4. The battery contains acids. Wear gloves and protective clothes.
Do not tilt or overturn the battery as acid may issue from its holes.
5. Strictly adhere to directions provvided by the manufacturer.
6. Risk of explosions! Take particular care after the battery has been recharged or at
the end of long journey. During the charging phase explosive gas (hydrogen and
oxygen mixture) is developed inside the battery! Air carefully.

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Battery recharge
Warning: The battery recharging procedure is described for information only. When this operation
must be carried out you should call the Iveco Service Organization.
It is recommended that the battery is recharged slowly and at low amperage for approximately 24
hours. A longer or more violent recharge may damage the battery.
Recharge the battery following the procedure below:
• If the vehicle is fitted with an alarm system, switch it off.
• Disconnect the electrical system terminals from the battery poles.
• Connect the recharging unit cables to the battery poles.
• Switch on the recharging unit.
• Once the recharging operation is completed, switch the unit off before disconnecting it from
the battery.
Reconnect the terminals to the battery poles observing their polarity.

Practical hints
To prevent the battery from running down and to preserve its operation, you should follow
these recommendations:
• The battery terminals must be well tightened.
• The users (car radio, lights, etc.) should not be kept On for a long time when the engine
is not running.
• When the engine is stopped and the vehicle has been correctly parked, before leaving it
make sure that no interior or exterior lights are still ON.
• Before carrying out any operation on the electrical system, disconnect the battery nega-
tive terminal.

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Air bleeding from the fuel feeding system
Bleed air from the feeding system as follows:
• Loosen screw1 and connect the specific tube for draining bleed residues into a
suitable container.
• Operate the manual primer pump control2 until fuel without air is let out from
bleeder screw 1.
• Close screw 1.
• Continue to operate the manual control until the primer pump 2 starts running
idle.
• Start the engine and let it run of a few minutes to eliminate any residual air.

Fire risk: take extreme care when closing the bleed screw to avoid dangerous fuel le-
akages.

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PROTECTING
THE ENGINE FROM COLD
Cooling circuit
Check the percentage of PARAFLU 11 in the coolant every year.
It should be at least 50% at all times throughout the year; if necessary, top up with wa-
ter and PARAFLU 11 to provide adequate protection from rust.

Fuel supply
Use the winter fuels provided by oil companies.
Keep the fuel tank as full as possible at all times.

Electrical system
Cold creates additional stress on batteries; their capacity decreases as the temperature
drops.
Check the batteries frequently; a flat battery will be damaged by frost.

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CHECKING THE ENGINE
Before each journey
Place the vehicle on level ground, stop the engine and leave it so for at least 30 minutes.
Then use the gauge on the upper panel to check the engine level.

Topping up engine oil level

Topping up is required when the gauge in the cab is positioned within the MIN.
Refill with new oil through filler 2. Then check the oil level by means of dipstick 1.

Risk of fire: Always remember to close filler 2 when topping up is completed to avoid
dangerous oil losses while the vehicle is travelling.

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With engine cold:
check engine coolant level. It should be between MAX and MIN reference marks.
Top up through filler 3, if necessary.
Note:
Plug 4 is sealed off and should not be tampered with.

Warning: turn off the engine and wait until it cools down before removing the plug
or you could be hit by the hot fluid ejected from the tank.

Weekly
Slacken tap 1 to drain water which may have accumulated in the fuel prefilter.

Check the battery electrolyte level;

if necessar, top up using distiller water with batteries at rest and cold through filler
caps 1.
(Not applicable to maintenance free batteries).
Note: when the vehicle is not used for more than one week, disconnect the main
switch (where fitted) and remove the steady ground connection from the minus-
pole of the battery.

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SCHEDULED MAINTENANCE
To make sure that your engine continues to run at its best, you Maintenance schedule
should check, inspect and adjust it according to the instructions pro- • Change engine oil 40,000 km or 800 hours
vided on the following pages, at the intervals specified. (or 1 year)
Regular maintenance is your best guarantee of safe operation and • Change oil filter 40,000 km or 800 hours
low operating costs. • Check auxiliary belts
Please contact your nearest Iveco Service Centre to arrange to have condition 40,000 km or 800 hours
the maintenance work done after the specified number of kilome- • Change fuel
tres. filter 80,000 km or 1600 hours
• Change fuel
Note to the user prefilter 80,000 km or 1600 hours
The engine should be lubricated after the specified number of kilo- • Replace auxiliary
metres where diesel contains less than 0.5% sulphur. belts 160,000 km or 3200 hours

NOTE: Where diesel fuel contains more than 0.5% sulphur, the en-
gine should be lubricated after half the specified number of kilome-
tres.

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UNSCHEDULED MAINTENANCE

Maintenance
• Clean radiator inlet Every 6 months

• Ceck coolant liquid Yearly

density (before the winter season)

• Replace engine coolant

liquid Every 2 years

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LUBRICANTS, COOLANTS AND FUELS Refueling
Use standard type diesel oil only (EN 590 standard).
Fuel additives are not recommended. The use of fuel additives could
Iveco-approved lubricants l kg restrict the warranty conditions provided for by the vehicle’s manu-
facturer.
Engine sump* 4 cyl.- Max level 8.3 7.5 Refueling from barrels or cans can lead to fuel pollution resulting in
Min level 5.3 4.8 irregular operation of the fuel feed system. If so, either filter the fuel
6 cyl. - Max level 10.8 9.7 by means of the suitable equipment or let possible impurities settle,
Min level 8 7.2
Urania LD5 (1)
as required.
Urania Turbo (2)
Oil filter 1 0.9
Low temperature fuel:
To low temperatures the fuel’s fluidity rate can be lower than speci-
Cooling system Liquid (3) - -
fied owing to the separation of the paraffin wax. This process may re-
sult in filter restriction.
Fuel tank Diesel (4) - -
The EN 590 standard provides for several fuel classes to be adhered
to at low ambient temperatures.
* Oil must be changed at least once a year even if the number of ki- Complying with the regulations in force depending on climate condi-
lometres specified in the maintenance schedule has not been rea- tions (yearly seasons and different countries’ geographical position) is
ched. the oil companies’ full responsibility.

1) According to standard ACEA E3 and/or ACEA E5.

2) According to standard ACEA E2.
3) Use a mixture of 50% water and 50% Paraflu 11 (SAEJ1034) protective
antifreeze. This mixture has a freezing point of - 35 °C.
4)When filling the fuel tank, use a funnel with a very fine metal screen
to prevent impurities in the fuel from blocking up the filters.

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