FPT CURSOR Series Use And Maintenance

Power generation engine

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Publication edited by:

FPT Industrial S.p.A

Via Puglia 15, 10156 Torino, Italia

www.fptindustrial.com

Print L31900385 - 06/18

USE AND MAINTENANCE

USO E MANUTENZIONE

UTILISATION ET ENTRETIEN

BETRIEB UND WARTUNG

USO Y MANTENIMIENTO

CURSOR

POWER GENERATION ENGINE

SERIES

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Summary of Contents for FPT CURSOR Series

Page 1 USE AND MAINTENANCE USO E MANUTENZIONE UTILISATION ET ENTRETIEN BETRIEB UND WARTUNG USO Y MANTENIMIENTO CURSOR SERIES POWER GENERATION ENGINE Publication edited by: FPT Industrial S.p.A Via Puglia 15, 10156 Torino, Italia www.fptindustrial.com Print L31900385 - 06/18...
Page 2 INTRODUCTION Thank you for preferring FPT and we congratulate you on your choice CURSOR SERIES of engine. Before performing any operation that involves the engine or its equipment, please carefully read the instructions contained in this manual; following these instructions is the best way to guarantee that C13ENTZW the engine will run perfectly for a long period of time.
Page 3 INDEX Page Page  GENERAL INFORMATION ......3  ENGINE FAULTS ........41 ...
Page 4 WARRANTY improper or incorrect behaviours. To ensure the best engine performance and rely on the FPT warranty,  The engines must only be used for the purposes declared by the the instructions provided in this publication must be followed carefully;...
Page 5 SAFETY WARNING 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. General danger: combines the risks of both the signs Risk of injury: failure to comply with these instructions described above.
Page 6 ENGINE TECHNICAL DATA The technical code and serial number are specified on the nameplate Electrical system 24 V positioned on different parts of the engine, depending on the model: Accumulators flywheel case, tappet cover, coolant tank. - capacity 180 Ah or greater C13ENTZW (Tier 4B) Electric Code...
Page 7 Failure to observe what is set forth above can cause the war- ranty to be cancelled, and FPT shall not be held responsible.
Page 8 14_117_C 14_116_C C13ENTZW C13ENTZW 1. Lifting eyelet - 2. Electronic control unit ECU - 3. Lubricant oil level dipstick - 4. Alternator - 5. Fuel filter - 6. Electric starter motor - 1. Heat exchanger lubricant oil - 2. Oil sump - 3. Oil sump drain plug - 7.
Page 9 14_119_C 14_118_C C13ENTZW C13ENTZW 1. Blow-by breather housing - 2. Engine flywheel - 3. Oil sump - 4. Oil 1. Turbocharger - 2. Thermostat unit and cylinder head water outlet sump drain plug - 5. Lubrication oil filter - 6. Electrically controlled pipe - 3.
Page 10 This plate highlights the fact that the engine must be installed with the corresponding ATS system by the bodybuilder. When installation has 17_575_C been completed, it must be removed. A. Commercial code B. Engine serial number TYPE-APPROVAL PLATE FPT Industrial S.p.A. 18_145_N...
Page 11 LABELS Some warning labels (below the description) are affixed to the engine. NOTE: labels containing an exclamation mark highlight a potential danger. Lifting point (engine only). Risk of burns: Expulsion of pressurized hot water. Fuel filling cap Risk of burns: (on the tank, if present).
Page 12  USE FOR PROPER USE OF THE ENGINE  Before starting the engine each time, check that the tank contains a sufficient amount of fuel. PRELIMINARY CHECKS  Avoid prolonging the duration of the start control. Each time before starting the engine: ...
Page 13 SPECIAL WARNINGS Fuel circuit Coolant circuit It is advisable to drain the water from the filters before the relevant warning light comes on. When the engine is running, check regularly that the engine coolant Do not use the engine if the tank only contains the quantity of fuel kept temperature does not reach the alarm threshold.
Page 14 Intake and exhaust circuit ATS system Regularly inspect the cleanliness of the air intake inlets and the exhaust This system is used to limit the nitrogen oxide (NOx) emissions in the ducts. The maintenance intervals indicated in this manual will vary exhaust within the limits required by standards, transforming the depending on the conditions of use of the engine.
Page 15  Use suitable, safe containers for used oil.  At the end of a repair, implement suitable measures to stop air intake The most qualified Service Centres are those included in the FPT by the engine if, after starting, the engine runs at uncontrolled speeds.
Page 16 Manufacturer of the generator set and by the Fitter of the electric generation system to ensure (4)Fuel tank not supplied by FPT. Refer to the data of supplier / maximum safety for maintenance personnel. manufacturer of the generator set.
Page 17 Main oil characteristics Oil quality SAE grade Base stock International Fuel sulphur content specifications API CJ-4 Premium 10W-40 Semi - Synthetic < 500 ppm ACEA E6/E9 API CH-4/ CI-4/CJ-4 Cold climate 5W-30 Synthetic < 500 ppm ACEA E4/E6 Not permitted Single-grade Replacement frequency Engine/Oil replacement frequency...
Page 18 FREQUENCIES Periodic maintenance Frequency The frequencies indicated below take into account factors of use of Ancillary belt replacement 1200 hours different engine uses; the most suitable duration of the maintenance intervals for the different applications shall be indicated by the Check turbocharger connection pipes and 1200 hours wastegate linkage...
Page 19 It is recommended that such operations are carried out No maintenance antici- AdBlue inlet filter to supply module pated (clean if neces- by qualified personnel of the FPT Technical Service Net- (100 μm) sary) work. Replace every 1200...
Page 20 ATS System filter location GUIDELINES  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 disconnection of the batteries, make sure the clamps have been securely reconnected on the poles.
Page 21 CHECKS TO BE MADE DURING PERIODS OF USE – HOW TO PROCEED Make sure that the dipstick is fully inserted and that the filler plug is tightened fully in the clockwise direction. Check the engine lubricant oil level Only proceed when the engine is not turning and is at low temperature in order not to run the risk of burns;...
Page 22 Engine coolant level check (demonstrative) Visual inspection of the engine Proceed only if the engine is not in operation and at low temperature, Perform a thorough check before start-up in order to obtain in order to prevent the risk of burns. maximum engine duration.
Page 23 Verification of the tightening and state of the Inspection of the exhaust duct/s auxiliary belt Visually check that the exhaust system for exhaust gases is not obstructed, corroded or damaged. Proceed only if the engine is not in operation and at low temperature, If a fault is found, carry out the necessary procedures to recondition in order to prevent the risk of burns.
Page 24 PERIODIC MAINTENANCE - HOW TO PROCEED Draining the water from the fuel pre-filter In there is a high risk of refuelling with fuel polluted with foreign bodies and water, the following check should be performed at each refuelling. Proceed when the engine is not running. ...
Page 25 Change engine lubricant oil Proceed only if the engine is not in operation and at low temperature, Ref. Description Torque in order to prevent the risk of burns. Oil drain plug 95 ± 10 Nm  Place a suitable container for collecting the spent oil under the oil sump next to the lubricant oil drain plug (3).
Page 26  Replace the filter element (2) and the O-ring seal (1) contained inside the filter body (4).  Carefully clean the surfaces  Moisten the O-ring seal (1) of the new filter with oil.  Tighten the drain plug (3) and the filter body (4) to the torque indicated in the table.
Page 27 Replacement of fuel pre-filter (demonstrative) Proceed only if the engine is not in operation and at low temperature, Dispose of consumable materials and parts in contact in order to prevent the risk of burns. with them (e.g. filters) in accordance with the law. ...
Page 28  Actuate the pump (2) located on the fuel pre-filter (responsibility of the manufacturer of the vehicle/outfitting) until the fuel comes Dispose of consumable materials and parts in contact out of the bleed screw (1) with no sign of any air bubbles; upon with them (e.g.
Page 29  Moisten the O-ring seal (1) of the filter with oil.  Insert the filter element (2) and tighten the relative bell-shaped support (3) to the torque indicated in the table.  Tighten the drain plug (4) to the torque indicated in the table. Do not fill the new filter until it has been positioned on the support: this prevents allowing impurities to enter and damage the circuit and injection system.
Page 30 Take utmost care to prevent any fuel from soiling the control belt  Tighten the bleeder screws to the prescribed torque. Ref. Description Torque Pre-filter bleeder screw 18 ±2 Nm Bleeder connection 18 ±2 Nm 14_125_C  Start the engine and allow it to idle for a few minutes to expel any residual air from the circuit.
Page 31 Replace the belt if there are any signs of abrasion, cracks or tears, oil or fuel stains . When the engine is off, but still hot, the belt may start to move without warning. Wait for the engine tempera- ture to decrease to prevent serious danger of an acci- dent.
Page 32 Check turbocharger connection pipes and wastegate linkage  Only proceed when the engine is not turning and is at low temperature so as not to run the risk of burns. Turbocharger lubricant pipe tightness check  Check the tightening torque of the connections (1,2) and perform a visual inspection to check for any oil leaks.
Page 33 Turbocharger gasket seal check Wastegate linkage check  Check that there are no deposits of soot between the intake  Check that the wastegate control linkage is fully tightened, manifold and the turbocharger. Replace the gasket if required. lubricated and not deformed. ...
Page 34 UNSCHEDULED MAINTENANCE - HOW TO PROCEED Dispose of consumable materials and parts in contact with them (e.g. filters) in accordance with the law. Check tappets clearance and adjust if necessary Adjustment of the play between the rocker arms and the intake and exhaust valve control rods must be performed with great care.
Page 35 The operations described above require the use of expansion tank is a few centimetres below the filling hole. specific tools which guarantee safe and effective results. It is recommended that such operations are carried out by qualified personnel of the FPT Technical Service Network.
Page 36 ENGINE HANDLING  If there is an external level indicator on the heat exchangers, proceed with the top-up making sure that the coolant does not The engine must only be removed and installed by Service Centre completely fill the exchanger. This is to allow an increase in the personnel.
Page 37 SCHEDULED MAINTENANCE FOR THE ATS Filter disassembly SYSTEM - HOW TO PROCEED  Unscrew and remove the filter cover (1). Change Supply Module main-filter  Remove the equalizing element (2). To prevent damage to the pump and dosing module, the supply module contains a filter which removes any impurities from the AdBlue.
Page 38 Filter assembly  Insert the appropriate tool (1) in the correct direction in the filter, based on the colour of the filter supplied.  Carefully clean with water the contact surface (1).  Insert the appropriate tool (1) until a click is felt which indicates the ...
Page 39  Assembly a new equalizing element (2).  Carefully clean the filter cover (1).  Tighten the filter cover (1) to a torque of 20 ± 5 Nm. 14_188_C Check that the filter cover and the contact surface of the supply module are not cracked or damaged. If necessary, replace any damaged components.
Page 40  LONG PERIOD OF ENGINE 7. Drain the residual 30/M protective oil from the sump, which can be INACTIVITY reused for another 2 preparations. 8. Place warning notices of ENGINE WITHOUT OIL on the engine and dashboard. PREPARING THE ENGINE FOR A LONG 9.
Page 41 ENGINE START-UP AFTER A LONG PERIOD OF INACTIVITY 1. Drain the residual protective oil from the sump. 2. Add the type and quantity of lubricant oil to the engine as specified in the REFUELLING table. 3. Drain the protective fluid CFB from the fuel circuit bringing to a close the operations as indicated in point 3 of the PREPARATION OF THE ENGINE FOR A LONG PERIOD OF INACTIVITY.
Page 42  ENGINE FAULTS The Electronic Unit that manages and controls all engine operations is able to detect the occurrence of faults and adopt strategies to proceed in a safe manner. The event, signalled by the switching on of the EDC Fault indicator on the dashboard involves the programmed limitation of power within the thresholds determined based on the severity of the situation.
Page 43  BEHAVIOURS IN CASE OF  Do not remove the shreds of clothing that adhere to the skin; EMERGENCY  If the burns are caused by liquids, quickly but carefully remove the clothing saturated with the hot liquid;  Cover the burn with an anti-burn pack or with a sterile bandage. The user of the vehicle, which has been constructed according to safety regulations, is able to operate safely by following the indications Carbon monoxide (CO) poisoning...
Page 44 Electrocution Corrosion The engine's 24 V electrical system does not involve electrocution Skin corrosion is caused by contact with substances with a high degree risks. However, if there is a short circuit caused, for example, by a of acidity or basicity. metal tool, there may be risks of burning due to the overheating of the For personnel performing maintenance on electrical devices, this is object as a result of the conduction of electric current.
Page 45 RECOMMENDED OPERATING TEMPERATURE RANGE The viscosity index to be used depends on the ambient temperature, as shown in the figure below: 17_076_N A: Engine oil sump heater or cooling block recommended in this range Note: Cold start capabilities are strongly correlated with the quality of the diesel.

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