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FPT F Series Use And Maintenance

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Publication edited by
Marketing - Adv. & Promotion
Print L31900466 - 04/2019
USE AND MAINTENANCE
USO E MANUTENZIONE
F
SERIES
G-DRIVE ENGINES

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  • Page 1 USE AND MAINTENANCE USO E MANUTENZIONE SERIES G-DRIVE ENGINES Publication edited by Marketing - Adv. & Promotion Print L31900466 - 04/2019...
  • Page 2 F34TE1W F34TE1W F34TE1W USE AND AND MAINTENANCE MAINTENANCE MAINTENANCE...

  • Page 3: Table Of Contents

    Check of water presence in pre-filter or in fuel filter (component not supplied by FPT) ......
  • Page 4 Replace fuel filter ..................44 Change air filter .

  • Page 6: General Information

    • The engines must only be used for the purposes declared by the Man- ufacturer. For the engine to perform at its best and to be covered by the FPT war- • Tampering, modifications and the use of non-original spare parts could ranty, pay close attention to the instructions provided in this manual;...

  • Page 7: Safety Warnings Symbols

    Safety warnings warnings symbols symbols Safety Safety warnings symbols You will find these symbols on the following pages; follow the instructions to which they refer, for your own safety and that of your engine. Risk Risk of of of injury: Risk injury: injury:...

  • Page 8: Engine Technical Data

    Engine technical technical data data Engine Engine technical data Perfor- Perfor- Perfor- mance mance mance F34TE1W F34TE1W F34TE1W The technical code and the serial number are indicated on a data plate [gross] [gross] (*) (*) [gross] located in different parts of the engine depending on the model: flywheel Continuous 39.4 39.4...
  • Page 9 No type of overload is permitted for this. General prescriptions It is severely prohibited, under penalty of cancellation of the war- ranty and of the responsibilities of FPT, to change the character- istics indicated above. Failure to comply completely or partially with these requirements...

  • Page 10: External View

    External view view External External view F34 (F5HFL464D*F019) (F5HFL464D*F019) (F5HFL464D*F019) Air filter Lifting eyelet Engine wiring DOC+PM Cat Oil filter Fuel filter Oil dipstick Oil sump Oil filling cap Injection pump Radiator Engine controller Lifting eyelet NOTE: The lifting eyelets are sized to move the engine only. It is not NOTE: NOTE: that make up the genset, for example single-phase / three-phase electric...
  • Page 11 F34 (F5HFL464D*F019) (F5HFL464D*F019) (F5HFL464D*F019) Throttle body Turbocharger air outlet Alternator Oil sump Starter motor Interface control unit Turbocharger Exhaust manifold EGR valve EGR heat exchanger...
  • Page 12 F34 (F5HFL464D*F019) (F5HFL464D*F019) (F5HFL464D*F019) Lifting eyelet Radiator inlet pipe Blow-by filter Auxiliary member belt Crankshaft pulley Water pump Radiator outlet pipe Interface control unit Alternator NOTE: The lifting eyelets are sized to move the engine only. It is not NOTE: NOTE: that make up the genset, for example single-phase / three-phase electric permitted to use these eyelets to lift the engine together with other parts...
  • Page 13 F34 (F5HFL464D*F019) (F5HFL464D*F019) (F5HFL464D*F019) Air filter Flow valve DOC+PM Cat Turbocharger Interface control unit Flywheel Fuel filter Oil filling cap Oil filter Lifting eyelet NOTE: NOTE: NOTE: The lifting eyelets are sized to move the engine only. It is not that make up the genset, for example single-phase / three-phase electric permitted to use these eyelets to lift the engine together with other parts machines, lower crankcase, etc.

  • Page 14: Identification Plate

    Identification plate plate Identification Identification plate FPT code FPT code and bar code Client Code with engine registration number Client Code with date of manufacture (mm/yy) Space for bar code Engine serial number Month and year of manufacture Engine theoretical code...
  • Page 15 • Box "A": Model • Box "B": Engine serial number...

  • Page 16: Signs

    Signs Signs Signs NOTE: NOTE: NOTE: Labels containing an exclamation mark highlight a potential dan- ger. Some warning labels (below the description) are affixed to the engine. Risk of of of burns: burns: Risk Risk burns: Lifting Lifting Lifting point point point (only (only...

  • Page 17: Use

    2 2 2 - - - USE Preliminary Preliminary checks Preliminary checks checks Before staring the engine each time: • Check and top up the level of the technical fluids, if necessary (fuel, engine Oil and coolant). • Make sure that the batteries are efficient and that the terminals are correctly connected.

  • Page 18: For Proper Use Of The Engine

    If the air filter is clogged, ensure it is cleaned: Risk of damage (4) after having released the two quick-clos- • Remove the air filter cover (4) Do not use detergents or diesel to clean the air filter. Never ing hooks (3) (3).
  • Page 19 General prescriptions If using in extremely dusty environments and on the basis of the final configuration of the current generator, soundproofed or without sound-proof cas- ing, suitable protections are required for most sensitive com- ponents. Failure to comply completely or partially with these require- ments may result in the risk of serious damage to the engine and may even, on occasion, invalidate the warranty...

  • Page 20: Interconnection Control Unit

    Interconnection control control unit unit Interconnection Interconnection control unit Some information is provided below concerning its components and func- tions that are controlled by programming switches. To permit the correct electric operation of the control unit, a connection unit has been installed in the engine. The connection unit controls the engine's electronic control system and the power unit system.
  • Page 21 (K2) (K2) (K2) After run B maintenance (JP1) (JP1) (Engine (JP1) (Engine (Engine speed speed speed selection) selection) selection) (K3) (K3) (K3) Main after run 1500 RPM RPM 50 50 Hz 1500 1500 (K4)Starter motor (K4) (K4) (K5) (K5) (K5)SCR heating (K6) (K6) (K6)Fuel filter heating...
  • Page 22 IDLE There is the possibility of using an external three-position switch to select an engine speed of 1500 1500 1500 RPM RPM, 1800 1800 1800 RPM RPM or idle. In this case, after having positioned the micro switches as indicated below, connect the switch at pins 3, 4 and 5 of the JX connector.
  • Page 23 Select Select Select the the diagnostics diagnostics function diagnostics function function (JP4) (JP4)Cold (JP4) Cold Cold Start Start Start Lamp Lamp Lamp Diagnostic position Connected Operating position (prearranged) Not connected (predefined) (JP3) (JP3) (JP3) Setting Setting of of of cold Setting cold cold start...

  • Page 24: Special Warnings

    Special warnings warnings Special Special warnings Contamination, fire When refuelling, always make sure that no solid or liquid High High High coolant coolant coolant temperature temperature temperature pollutants enter the fuel tank; remember that it is prohibited to smoke or use naked flames when refuelling. In the event of an excessive temperature or the signalling of the alarm, Failure to comply with these prescriptions can result in the disengage the load and stop the engine in order to check the condition of...

  • Page 25: Running In

    Risk of burns Risk of skin irritation or allergic reactions Visually check that the exhaust circuit is not clogged or dam- The batteries contain an acid solution that will burn the skin aged, to prevent hazardous or toxic emissions inside the and corrode clothing;...

  • Page 26: Maintenance Personnel

    Authorised Service Centres who have detailed technical information and specific equipment. The most qualified Service Centres are those included in the FPT Tech- • Mask with respirator and filter, compliant with current regulations, on nical Service Network.

  • Page 27: Refilling

    (4) Fuel tank not supplied by FPT. Refer to the data supplied by the sup- plier/manufacturer of the genset. Only use fuel which meets the require- ments of international standards ASTM D975 or EN 590. The Manufac-...
  • Page 28 turer of the genset is responsible for any information regarding fuel tank The quantities indicated refer to the total capacity of the G-Drive including capacity as it is subject to variations based on the configuration of the gen the capacity of the engine, radiator and pipes. set itself.

  • Page 29: Main Characteristics Of Oil

    Main characteristics characteristics of of of oil oil oil Main Main characteristics International International International Sulphur Sulphur Sulphur Quantity of of of Quantity Quantity SAE grade grade grade Base Base Base stock stock stock specifica- specifica- specifica- content content in in in content oil oil oil International...

  • Page 30: Coolant Fluid Filling

    Coolant fluid fluid filling filling Coolant Coolant fluid filling To start the engine and if the coolant circuit needs to be filled with a significant amount of coolant, proceed as indicated below: Unscrew the plug (1) (1) on the exchanger. •...

  • Page 31: Refuelling

    Refuelling Refuelling Refuelling Winter Winter diesel Winter diesel diesel Only use diesel that complies with the ASTM D975 or EN 590 standard The degree of fluidity of the diesel oil can may be reduced at low tem- and which is generally commercially available. Fuel additives are not rec- peratures due to the separation of the paraffin.

  • Page 32: Programmed Maintenance

    Clean heat exchanger (radiator) 600 h h h blow-by filter must be halved or suitably modified; please refer to the FPT Service Network for support. Air filter replacement 1200 1200...

  • Page 33: Requirements

    • Electrically disconnect the battery/batteries before performing any elec- operations are carried out by qualified personnel belonging trical work. to the FPT Service Network. • Contact the Manufacturer before installing any electronic equipment. Failure to comply completely or partially with these require-...

  • Page 34: Check Of Water Presence In Pre-Filter Or In Fuel Filter (Component Not Supplied By Fpt)

    - - filter filter or or or in in in fuel fuel filter filter (component (component not not supplied supplied by by by FPT) FPT) Check Check water presence filter fuel filter...

  • Page 35: Check Engine Lubricant Oil Level

    Check engine engine lubricant lubricant oil oil oil level level Check Check engine lubricant level Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning.
  • Page 36 If the level is low, top-up with the specified oil as indicated on the • page3 3 3 - - - 26 Unscrew the plug (1) (1) and introduce oil through the filler (2) (2). • Use the dipstick (3) (3) to check that the oil does not exceed the "MAX"...

  • Page 37: Check Engine Coolant Level

    Check engine engine coolant coolant level level Check Check engine coolant level Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury General prescriptions Clean the oil cap before performing the operation so as to minimize the risk of contaminating the system.

  • Page 38: Check Tension And Condition Of Ancillary Belt

    Check tension tension and and condition condition of of of ancillary ancillary belt belt Check Check tension condition ancillary belt Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Only proceed when the engine is not turning and is at low temperature so as not to run the risk of burns.
  • Page 39 Use the designated tool to check the tension of the auxiliary unit drive • belt. The correct static tension of the auxiliary unit drive belt (4) (4) must fall within the range indicated below: Static voltage (Value measured (N/rib/spam) / Control frequency (Hz) •...

  • Page 40: Change Engine Lubricant Oil

    Change engine engine lubricant lubricant oil oil oil Change Change engine lubricant Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Only proceed when the engine is not running and is at low temperature in order to avoid the risk of burns.
  • Page 41 General risk, general prescriptions Eliminate the consumables and any materials in contact with them (for example, filters) in accordance with current regulations.The FPT Technical Service Network workshops are equipped for this purpose. Correct behavior will ensure that vehicle is used as environmen-...

  • Page 42: Change Engine Lubricant Oil Filter

    Change engine engine lubricant lubricant oil oil oil filter filter Change Change engine lubricant filter Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury The filter must be replaced when the lubricant oil is changed.
  • Page 43 Use the specific tool to unscrew and remove the oil filter (1) (1) from the • filter mount (3) (3) and recover the gasket (2) (2). (1) and the gasket (2) (2). Replace the oil filter (1) • Carefully clean the surfaces of the support that are in contact with •...

  • Page 44: Change Fuel Pre-Filter

    General risk, general prescriptions Eliminate the consumables and any materials in contact with them (for example, filters) in accordance with current regulations.The FPT Technical Service Network workshops are equipped for this purpose. Correct behavior will ensure that vehicle is used as environmen-...
  • Page 45 Replace fuel fuel filter filter Replace Replace fuel filter Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Only proceed when the engine is not running and is at low temperature in order to avoid the risk of burns.
  • Page 46 General risk, general prescriptions Eliminate the consumables and any materials in contact with them (for example, filters) in accordance with current regulations.The FPT Technical Service Network workshops are equipped for this purpose. Correct behavior will ensure that vehicle is used as environmen-...
  • Page 47 Change air air filter filter Change Change filter Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Only proceed when the engine is not running. (4) after having released the two quick- Remove the air filter cover (4) •...
  • Page 48 Clean the the heat heat exchanger exchanger (radiator) (radiator) Clean Clean heat exchanger (radiator) Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury The surfaces of the heat exchanger (radiator) come into contact with the outside air and can be subject to deposits and impurities.
  • Page 49 Replacing the the blow blow- - - by by by filter filter Replacing Replacing blow filter Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury The blow-by filter was devised and designed for collecting, filtering and condensing lubricant oil vapours.
  • Page 50 (2). Loosen the nut (2) • (1) (4) Disconnect the fittings (1) • (3). Remove the vapour recirculation pipe (3) •...
  • Page 51 Unscrew the nuts (6) (6) and remove the cover (5) (5) of the blow-by filter, • together with the diaphragm valve and breather pipe. (4) and remove the blow-by (1) (1) filter from Release the safety circlip (4) • the threaded bush (3) (3) and spindle (2) (2).
  • Page 52 Change the the ancillary ancillary belt belt Change Change ancillary belt Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Only proceed with the operation when the engine is not in operation and is at a low temperature.
  • Page 53 Loosen the bolt (5) (5) anchoring the alternator to its lower mount and • the screw (3) (3) fastening the tensioning bracket to the crankcase. (1) and unscrew the screw (7) (7) adjusting the Loosen the locking nut (1) • tensioning bracket (2) (2) to loosen and remove the auxiliary drive belt (4).
  • Page 54 Fully rotate the crankshaft twice to ensure that the ancillary drive belt • (4) has settled. Tighten the screw (3) (3) fastening the tensioning bracket (2) (2) to the • 50 N·m N·m ± 5. crankcase to a torque of 50 N·m (5) anchoring the alternator to its lower mount to a Tighten the bolt (5)
  • Page 55 Visually inspect inspect turbocharger turbocharger Visually Visually inspect turbocharger Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Only proceed when the engine is not running. Check for any cracks on the turbocharger.
  • Page 56 Visual inspection inspection of of of the the alternator alternator Visual Visual inspection alternator Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Only proceed when the engine is off.
  • Page 57 Clean/ / / replace replace radiator radiator pressure pressure cap Clean Clean replace radiator pressure Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Risk of injury: When the engine is hot, the pressure inside the cooling circuit can...
  • Page 58 Change engine engine coolant coolant Change Change engine coolant Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury Only proceed when the engine is not running and is at low temperature in order to avoid the risk of burns.
  • Page 59 Move the the engine engine Move Move engine The operations necessary to disconnect and subsequently reconnect the engine must be carried out only by technicians from authorised Service Centres. Use the lifting eyelets (1) (1) indicated in the figure when moving the engine. Using a suitable hoist, which conforms to standards and the weight ca- pacity of the engine with radiator, connect it to the lifting eyelets on the engine.
  • Page 60 Disposal of of of waste waste Disposal Disposal waste • Used lubricants. • Mixtures of water and antifreeze. The engine is composed of parts and elements that, if discarded, could case environmental damage. • Filters. • Additional cleaning materials (e.g. greasy or fuel-soaked cloths). The materials listed below must be handed over to specialised Collection Centres: The laws in force in the various countries provide for severe penalties for...
  • Page 61 4 4 4 - - - LONG LONG PERIOD LONG PERIOD PERIOD OF OF INACTIVITY INACTIVITY INACTIVITY Preparing Preparing the Preparing the engine engine engine for for a a a long long long period period period of of of inactivity inactivity inactivity PREPARING...
  • Page 62 Drain the coolant if it was not mixed if necessary with antifreeze and corrosion inhibitors, positioning signs that this operation was performed. In the case of prolonged inactivity, repeat these operations every 6 months, according to the following procedure: drain the 30/M protective oil from the sump; repeat the operations from point 2 to point 7.
  • Page 63 Engine start start- - - up up after after a a a long long period period of of of inactivity inactivity Engine Engine start after long period inactivity refilling operations, connect the fuel return pipe to a container to prevent any residual CFB protective liquid from flowing into the tank. Drain residual protective oil from the sump.
  • Page 64 5 5 5 - - - ENGINE ENGINE MALFUNCTIONS ENGINE MALFUNCTIONS MALFUNCTIONS Engine Engine Engine fault fault fault The electronic control unit which oversees the control and management of all engine operations is able to recognise a fault and adopt strategies which allow the vehicle still to be driven safely.
  • Page 65 In In In the the event event of of of a a a fault: fault: event fault: General risk, general prescriptions If these conditions occur, only continue driving if absolutely Malfunction Malfunction Malfunction in in in the the recharging recharging system recharging system system...
  • Page 66 6 6 6 - - - BEHAVIOUR BEHAVIOUR BEHAVIOUR IN IN IN EMERGENCY EMERGENCY EMERGENCY For personal personal personal safety safety safety Carbon Carbon Carbon monoxide monoxide monoxide (CO) (CO) (CO) poisoning poisoning poisoning The user of the machine, manufactured according to safety regulations, The carbon monoxide contained in the exhaust gas of the engine is dan- following the instructions given in this manual and assisted by the indica- gerous not only because it causes poisoning but also because it forms an...
  • Page 67 • If there is a possibility of fractures, do not move the affected part and • Remove the clothing saturated with the caustic substance. transfer the injured person very carefully and only if absolutely neces- • Wash thoroughly with running water, without spraying uninvolved parts. sary.
  • Page 68 SAE classification classification of of of oils oils in in in relation relation to to to the the ambient ambient classification oils relation ambient temperatures of of of use use of of of the the engine engine/ / / vehicle vehicle temperatures temperatures...
  • Page 70 Check engine lubricant oil level ..........34 Check of water presence in pre-filter or in fuel filter (component not supplied by FPT) ....33 Check tension and condition of ancillary belt .
  • Page 71 Guarantee ........... . . Identification plate .
  • Page 72 Special warnings ..........23 Visual inspection of the alternator .

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