FPT NEF Series Use And Maintenance
G-drive engines
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- Page 1 USE AND MAINTENANCE USO E MANUTENZIONE UTILISATION ET ENTRETIEN BETRIEB UND WARTUNG USO Y MANTENIMIENTO SERIES G-DRIVE ENGINES Publication edited by: FPT Industrial S.p.A Via Puglia 15, 10156 Torino, Italia www.fptindustrial.com Print L31900836 - 09/2021...
- Page 2 F4HFE615B F4HFE615B*B003, F4HFE615B*B003, F4HFE615B F4HFE615B F4HFE615B*B003, F4HFE615C F4HFE615C*B003, F4HFE615C*B003, F4HFE615C F4HFE615C F4HFE615C*B003, F4HFE615D F4HFE615D*B003, F4HFE615D*B003, F4HFE615D F4HFE615D F4HFE615D*B003, F4HFE615E F4HFE615E*B003, F4HFE615E*B003, F4HFE615E F4HFE615E F4HFE615E*B003, F4HFE615F F4HFE615F*B001, F4HFE615F*B001, F4HFE615F F4HFE615F F4HFE615F*B001, F4HFE615G F4HFE615G*B001, F4HFE615G*B001, F4HFE615G F4HFE615G F4HFE615G*B001, N67ENTZW61 N67ENTZW61.00, N67ENTZW61.00, N67ENTZW61 N67ENTZW61 N67ENTZW61.00, N67ENTZW62 N67ENTZW62.00,...
- Page 3 N67ENTZW69 N67ENTZW69.00, N67ENTZW69.00, N67ENTZW69 N67ENTZW69 N67ENTZW69.00, N67ENTZW69 N67ENTZW69.00, N67ENTZW69.00, N67ENTZW69 N67ENTZW69 N67ENTZW69.00, N67ENTZW70 N67ENTZW70.00, N67ENTZW70.00, N67ENTZW70 N67ENTZW70 N67ENTZW70.00, N67ENTZW71 N67ENTZW71.00, N67ENTZW71.00, N67ENTZW71 N67ENTZW71 N67ENTZW71.00, N67ENTZW71 N67ENTZW71.00 N67ENTZW71.00 N67ENTZW71 N67ENTZW71 N67ENTZW71.00 USE AND AND MAINTENANCE MAINTENANCE MAINTENANCE...
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Page 4: Table Of Contents
Check of air filter and cleanliness of housing (component not supplied by FPT) ...... - Page 5 Drainage or suction of impurities from fuel tank ..............32 Change engine lubricant oil .
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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- N67 ENT ENT Z Z Z W W W Perfor- Perfor- mance mance mance The technical code and serial number are indicated on a plate, which is [gross] [gross] (*) (*) [gross] located on different parts of the engine, according to the model: flywheel Continuous... - Page 9 Perfor- Perfor- Perfor- N67 ENT ENT Z Z Z W W W operating period of 24 24 h h h must not exceed 80 80% % % of the declared primary mance mance mance power between the specified maintenance intervals and under standard [gross] [gross] (*) (*) [gross]...
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Page 10: External View
External view view External External view N67 ENT ENT Z Z Z W W W Rail pressure sensor Common rail Fuel exhaust pipe Fuel high pressure pump Fuel temperature sensor Fuel filter Crankshaft rpm sensor EDC17CV41 engine control unit Engine cable Lubricant oil filler cap... - Page 11 N67 ENT ENT Z Z Z W W W Turbocharger exhaust gas outlet from motorized throttle valve (ex- haust flap) Waste-Gate valve Air pipe on turbocharger Turbocharger comburent air intake from the air filter Lifting hook Coolant temperature sensor Engine coolant outlet pipe (to the radiator) Coolant/lubricant oil heat exchanger Engine coolant inlet pipe (from the radiator) Oil filter...
- Page 12 N67 ENT ENT Z Z Z W W W Turbocharger comburent air outlet to the intercooler Engine air intake Intake manifold Fan control pulley Idler pulley Crankshaft pulley with damper Water pump Alternator Automatic belt tensioner Turbocharger...
- Page 13 N67 ENT ENT Z Z Z W W W Lifting hook Motorised throttle valve (exhaust flap) Exhaust manifold Turbocharger lubricant oil delivery pipe Turbocharger lubricant oil return pipe Engine flywheel Lubricant oil drain cap Oil sump Flywheel case Blow-by filter...
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Page 14: Exhaust Gas After-Treatment System (Ats)
EXHAUST GAS GAS AFTER AFTER- - - TREATMENT TREATMENT SYSTEM SYSTEM (ATS) (ATS) EXHAUST EXHAUST AFTER TREATMENT SYSTEM (ATS) 1. 1. 1. NOx NOx sensor sensor upstream upstream of of of DOC DOC 2. 2. 2. Engine Engine coolant coolant 3 3 3 - - - way way valve valve —... -
Page 15: Plates
Plates Plates Plates IDENTIFICATION IDENTIFICATION IDENTIFICATION PLATE PLATE PLATE • Box "A" Model • Box "B" S/N TYPE TYPE TYPE- - - APPROVAL APPROVAL APPROVAL PLATE PLATE PLATE... - Page 16 "DELEGATED "DELEGATED "DELEGATED ASSEMBLY" ASSEMBLY" PLATE ASSEMBLY" PLATE PLATE This plate highlights the fact that the engine must be installed with the corresponding ATS system by the bodybuilder. When installation has been completed, it must be removed.
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Page 17: Signs
Signs Signs Signs NOTE: Labels containing an exclamation mark highlight a potential dan- NOTE: NOTE: ger. Some warning labels (below the description) are affixed to the engine. Risk Risk Risk of of of burns: burns: burns: Lifting point point (only (only the the engine). -
Page 18: Use
2 2 2 - - - USE Preliminary Preliminary Preliminary checks checks checks • Actual power values must comply with the rated values reported in the technical-commercial documentation. Before each engine start-up: • Particular attention must be paid to engines that equip the emergency •... - Page 19 Risk of injury: Risk of burns When the engine is hot, the pressure inside the cooling cir- Never loosen the high pressure fuel circuit connectors. cuit can be such that it may expel the hot liquid in an ex- Failure to comply with these prescriptions can result in the tremely violent manner with the risk of burns.
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Page 20: Running In
Battery Battery Battery or or or alternator alternator charging alternator charging fault charging fault fault General prescriptions Contact a specialised workshop and check battery and Periodically check the cleanliness, condition and correct tensioning of the recharging system efficiency if the voltmeter indicates a drive belt. -
Page 21: Refuelling
Risk of burns (4) Fuel tank not supplied by FPT. Refer to the data provided by the genset When the engine is hot, pressure builds up in the cooling supplier/manufacturer. Use STANDARD fuel which meets the require- circuits which may eject hot liquid violently, resulting in a risk ments of standard ASTM D975 (maximum permitted sulphur content: <... -
Page 22: Refuelling
Risk of burns Risk of burns Open the filler cap of the coolant tank only if necessary and Pay maximum attention when refuelling, making sure that only when the engine is cold. solid or liquid pollutants Failure to comply with these prescriptions can result in the do not enter the tank;... -
Page 23: Main Characteristics Of Oil
Main characteristics characteristics of of of oil oil oil Main Main characteristics Oil Specifications Specifications Specifications (*) (*) International International International specifications specifications specifications 10W- - - 40 40 API API CJ CJ- - - 4 4 4 / / / API API CK CK- - - 4 4 4 ACEA ACEA E9... -
Page 24: Maintenance Personnel
By qualified personnel using suitable equipment and adequate protection tools. Non-routine maintenance: By qualified personnel from authorised service centres that have detailed technical information and specific equipment. The most qualified service centres are those that are part of FPT's technical service network. Accident Accident Accident prevention... -
Page 25: Frequencies
3000 Check tension and condition of 300 h h h / 6 months (*) (*) (*) Components not supplied by FPT. ancillary belt Exhaust duct(s) condition check 6 months (**) Respect the hour or time period interval, whichever is reached first. - Page 26 Supply module pre-filter ( 100 100 μm μm μm Clean with water at each oil to the FPT Service Network. or 70 70 μm μm μm (1) (1)) change interval (2)
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Page 27: Requirements
Requirements Requirements Requirements • Do not disconnect the battery supply while the engine is running • Do not perform arc welding near the engine without first removing its electrical wiring. • After all maintenance operations that require disconnecting the batteries, make sure that the terminals have been well secured on the poles. - Page 28 (2), check that the oil level is between the " Min" and Using the dipstick (2) " Max" levels. If the level is insufficient, it needs to be topped up with lubricating • oil as specified in 3 3 3 - - - 20 20: remove the lubricant oil filler cap (3) (3) and introduce the engine lubricating oil via the filler hole.
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Page 29: Check Coolant Level
Check of of of air air filter filter and and cleanliness cleanliness of of of housing housing (component (component not not supplied supplied by by by FPT) FPT) Check Check filter cleanliness housing (component supplied FPT) -
Page 30: Check Tension And Condition Of Ancillary Belt
Remove the air filter cover after having released the lock hooks. • Remove the filter element; make sure that dust does not enter the • sleeve during this operation. Make sure there are no impurities. Otherwise, clean the filter element •... -
Page 31: Check The Condition Of The Exhaust Duct(S)
Risk of injury: When the engine is off, but still hot, the belt may start to move without warning. Wait for the engine temperature to decrease to prevent serious danger of an accident. Failure to comply with these prescriptions can result in the risk of serious injury and serious damages to the vehicle Check Check the... -
Page 32: Water Drainage From The Fuel Pre-Filter (Component Not Supplied By Fpt)
Water drainage drainage from from the the fuel fuel pre pre- - - filter filter (component (component not not supplied supplied by by by FPT) FPT) Water Water drainage from fuel filter (component supplied FPT) The high risk of refuelling with fuel that is polluted by foreign bodies or water makes it advisable to carry out these control every time you refuel. - Page 33 Drainage or or or suction suction of of of impurities impurities from from fuel fuel tank tank Drainage Drainage suction impurities from fuel tank Perform the drainage/suction of water, condensation and impurities from the fuel tank/s by following the instructions contained in the manual sup- plied by the tank manufacturer.
- Page 34 Change engine engine lubricant lubricant oil oil oil Change Change engine lubricant Only proceed when the engine is not turning and is at low temperature in order not to run the risk of burns. (1) next Arrange a container to collect the spent oil beneath the oil sump (1) to the lubricant oil drain plug.
- Page 35 Oil filter filter change change filter change The filter must also be replaced when the lubricant oil is changed. Only use filters with a filtration level equivalent to the ones you are re- placing. Position a container to collect the used oil below the filter mount (1) (1).
- Page 36 Dispose of consumable materials and the parts in contact with them (for example filters) in accordance with the law. The work- shops of the FPT Service Network are equipped for this purpose. Correct behavior will ensure that vehicle is used as environmen-...
- Page 37 Start the engine and let it run idle for several minutes to eliminate any • residual air. NOTE: NOTE: NOTE: component not provided by FPT. The image may not show the actual component used. General prescriptions If the residual air bleed phase needs to be accelerated, use a hand pump also during start-up.
- Page 38 Replace fuel fuel filter filter Replace Replace fuel filter Only continue with the engine off and at a low temperature, to avoid the risk of burns. Arrange a container to collect the fuel below the filter bracket (1) (1). • Remove the filter (3) (3) by loosening it from its relative support.
- Page 39 Dispose of consumable materials and the parts in contact with them (for example filters) in accordance with the law. The work- shops of the FPT Service Network are equipped for this purpose. Correct behavior will ensure that vehicle is used as environmen-...
- Page 40 Change the the ancillary ancillary belt belt Change Change ancillary belt Only proceed when the engine is not turning and is at low temperature in order not to run the risk of burns. (8) with the appropriate tool (6) (6) and Act on the automatic belt tensioner (8) remove the belt (2) (2) from alternator (7)
- Page 41 Replacing the the blow blow- - - by by by filter filter Replacing Replacing blow filter The filter in question serves to collect, filter and condense lubrication oil vapours. The filter body (2) (2) contains two filter cartridges (3) (3). To check the filter elements, remove the cover (1) (1) and remove the car- tridges (3)
- Page 42 Apply a manual torque to the shaft to check that it turns smoothly and for any sticking effect. Check for any wear in the supercharger's internal housing.
- Page 43 There are no signs of wear on the internal diameter of the super- charger There are signs of contact between the impeller and the internal diameter of the supercharger Visually check the integrity of the supercharger blades and turbine. There are no signs of wear on the internal diameter of the super- charger There are signs of contact between the impeller and the internal diameter of the supercharger...
- Page 44 Clean the the heat heat exchanger exchanger (radiator) (radiator) Clean Clean heat exchanger (radiator) The surfaces of the heat exchanger (radiator) come into contact with external air and may be subjected to deposits and impurities (dust, mud, straw, etc.). Clean them if necessary using compressed air or steam. Risk of injury: When using compressed air, it is required to use suitable personal protections for hands, face and eyes.The requirements can be...
- Page 45 Valves/ / / rocker rocker arms arms clearance clearance adjustment adjustment Valves Valves rocker arms clearance adjustment The clearance between the beams and the intake and exhaust valve control rods must be carefully adjusted using a hex key (1) (1), a box wrench (3) and a feeler gauge (2) (2).
- Page 46 Change engine engine coolant coolant Change Change engine coolant Only proceed with the engine stopped and at a low temperature, so as to avoid the risk of burning. Place a container for collecting coolant under the heat exchanger • (radiator). Remove the pressurization cap from the expansion tank.
- Page 47 General prescriptions The failure to observe the aforesaid procedure does not guaran- tee the presence of the correct quantity of coolant in the engine. Failure to comply completely or partially with these requirements may result in the risk of serious damage to the engine and may even, on occasion, invalidate the warranty Risk of injury: When the engine is hot, the pressure inside the cooling circuit can...
- Page 48 Moving the the engine engine Moving Moving engine The operations necessary to disconnect and subsequently reconnect the engine must be carried out only by technicians from Service Centres. When lifting the engine only, use the U-bolts indicated in this manual in the section ENGINE TECHNICAL DATA on page 1 1 1 - - - 7 7 7 and marked on the engine with special stickers.
- Page 49 Schedule maintenance maintenance for for the the ATS ATS system system - - - how how to to to Schedule Schedule maintenance system Filter Filter disassembly Filter disassembly disassembly proceed proceed proceed • Unscrew and remove the filter cover (1) (1).
- Page 50 • Assembly a new equalizing element (2) (2). (1). • Carefully clean the filter cover (1) (1) to a torque of 20 20 + + + / / / - - - 5 5 5 N·m N·m. • Tighten the filter cover (1) N·m Filter Filter...
- Page 51 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 In the case of a planned period of inactivity that lasts longer than two...
- Page 52 7. Drain the residual protective oil from the sump. This oil can be used again for a further 2 preparation operations. 8. Place warning notices of ENGINE WITHOUT OIL on the engine and dashboard. 9. Drain the coolant if it has not been mixed with a sufficient amount of anti-freeze and anti-corrosion additive and affix a sign indicating that the operation is in progress.
- Page 53 Check the engine and top up with coolant as recommended; bleed if necessary. Start the engine and let it idle until completely stabilised. Check that the indications on the dashboard are plausible and that there are no alarm signals. Stop the engine. Remove the warning notices of ENGINE WITHOUT OIL from the en- gine and dashboard.
- Page 54 5 5 5 - - - ENGINE ENGINE MALFUNCTIONS ENGINE MALFUNCTIONS MALFUNCTIONS Engine Engine Engine fault fault fault the supply, within certain limits, set according to the seriousness of the specific case. The electronic control unit that manages and controls all operations of the engine can recognise any malfunction and implement specific strategies In the case of temporarily malfunctions, the performance reduction will in order to operate in full safety conditions.
- Page 55 6 6 6 - - - BEHAVIOUR BEHAVIOUR IN IN IN EMERGENCY BEHAVIOUR EMERGENCY EMERGENCY Behaviour Behaviour in in in emergency Behaviour emergency emergency conditions conditions conditions In closed areas, carbon monoxide is very dangerous because it can reach a critical concentration in a short period of time. By following the instructions supplied in this manual and the indications shown on the engine labels, the user of a machine manufactured accord- If aiding a poison victim in a closed room:...
- Page 56 For personnel performing maintenance on electrical devices, this is If either battery acid, lubricants or diesel come into contact with the eyes: typically caused by acid escaping from the batteries; in this circumstance wash your eyes with water for at least 20 20 min min, keeping the eyelids open proceed as follows:...
- Page 57 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 temperatures of of of use temperatures use of of of the the engine engine engine/ / / vehicle vehicle vehicle The viscosity index to be used depends on the ambient temperature, as...
- Page 58 Check coolant level ..........28 Check of air filter and cleanliness of housing (component not supplied by FPT) ..... . . 28 Check tension and condition of ancillary belt .
- Page 59 Guarantee ........... . . Liability .
- Page 60 Visually inspect turbocharger ..........40 Water drainage from the fuel pre-filter (component not supplied by FPT) ......31...
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