USE AND MAINTENANCE

USO E MANUTENZIONE
UTILISATION ET ENTRETIEN
BETRIEB UND WARTUNG
USO Y MANTENIMIENTO

NEF SERIES

G-DRIVE ENGINE

FPT Industrial S.p.A.

Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print L31900160 - 1^ Ed. 05.2013
NEF SERIES INTRODUCTION
We would like to thank you for buying an FPT product, and
compliment you on your choice of engine.
NEF45 TM3.S500 Before you carry out any operation involving the engine or its fittings,
please read the contents of this manual carefully; compliance with the
instructions provided in the manual is the best way to guarantee
trouble-free, long term operation of the engine.

ENGLISH
The contents of this manual refer to the standard configuration of the
engine, and the illustrations are purely indicative. Some instructions are
provided by giving the sequence of operations to be carried out in
order to allow the engine and/or its fittings to perform in a certain way.
In some cases they will be dependent on the configuration of the
commands and the set-up of the machine on which the engine is
installed; for any points that differ from the contents of this manual,
please consult the instructions provided by the machine Manufacturer
or a specific manual.
USE AND MAINTENANCE The information provided below was current at the date of
publication.
The Manufacturer reserves the right to make modifications at any time
without prior notice, for technical or commercial reasons or to update
the engines to comply with legal requirements in the various
Countries.
The Manufacturer declines all liability for any errors or omissions.

Please remember that the FPT Technical Service Network is available

to offer you its experience and professional skills, wherever you may be.

1
TABLE OF CONTENTS Page
 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Engine technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
 USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Engine pre-heating (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Switching of operating frequency . . . . . . . . . . . . . . . . . . . . . . . . . .9
For proper use of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Special warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
 CONTROLS AND MAINTENANCE . . . . . . . . . . . . . . . . . . 14
Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
How to proceed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Moving the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Disposal of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
 LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . 27
Preparing the engine for a long period of inactivity . . . . . . . . . . .27
Restarting the engine after a long period of inactivity . . . . . . . . .28
 BEHAVIOUR IN AN EMERGENCY . . . . . . . . . . . . . . . . . . . 29

2
 GENERAL INFORMATION SAFETY
The following information is intended to encourage caution when
using the engine, so as to avoid damage to persons or property as a
GUARANTEE result of improper or incorrect behaviour.
In order to ensure that your engine gives the best possible  The engines must only be used for the purposes indicated by the
performance and to take advantage of the FPT guarantee, you must Manufacturer.
follow the indications provided in this publication with great care;
 Any tampering, modification and use of non-original spare parts
failure to do so may result in invalidation of the guarantee.

ENGLISH
may compromise proper operation and safe use of the engine;
never, under any circumstances make modifications to
SPARE PARTS the wiring and to the units equipping the engine, or connect them
Always use Original FPT Spare parts. This is essential to keep the to other power systems.
engine in original running order.  Pay particular attention to moving parts of the engine, to high
The use of non-original spare parts will not only invalidate the temperature components and to circuits containing pressurised
guarantee, but will mean that FPT will not be considered liable in any fluids; its electrical equipment houses electrical currents and
way during the whole working life of the engine. voltage.
 The exhaust fumes produced by the engine are bad for your health.
LIABILITY  The engine must be handled using suitable lifting tackle, making use
of the U-bolts provided on the engine for that purpose.
The Manufacturer will only be considered liable subject to
performance of the control and maintenance operations indicated and  The engine must not be started up and used until the machine in
described in this manual; to this effect, proof that these operations which it installed has satisfied all necessary safety requirements, or
have been performed must be provided. Any special maintenance until the machine has been guaranteed to comply with local laws
operations that may be necessary must be carried out by qualified and regulations.
technicians from Workshops in the FPT Network, using the  The operations required to guarantee the best possible use and
instruments and equipment provided for the purpose. preservation of the engine must only be carried out by persons of
proven experience, equipment with tools considered suitable by
FPT .
For the purpose of safety, further recommendations are given in the
chapter CONTROLS AND MAINTENANCE.

3
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.

Risk of injury: failure to comply with these instructions

can result in the risk of serious injury. General risk: combines the risks of both the signs
described above.

Risk of serious damage to the engine: the partial Safeguarding the environment: indicates the
or total non-observance of these instructions could correct behaviour so that vehicle use is as
cause serious damage to the engine and may nullify the environmentally friendly as possible.
warranty.

4
ENGINE TECHNICAL DATA
The technical code and serial number are specified on the nameplate Electrical system 12 V
positioned on different parts of the engine, depending on the model:
Battery capacity 100 Ah
flywheel case, tappet cover, coolant tank, etc.
Pick-up current 60 A
Code NEF45 TM3.S500
Maximum input 3 kW
Engine family F4
Discharge current
650 A

ENGLISH
Cycle 4-stroke diesel (EN 50342)
Number and arrangement
4, in line Performance (*) NEF45 TM3.S500
of cylinders
Without Prime - 107.2 kWm @ 1.500 rpm
Bore x stroke 104 x 132 mm 50 Hz Stand-by - 118.2 kWm @ 1.500 rpm
emissions
Total displacement 4,500 cm3 Prime - kWm @ 1.800 rpm
certificate 60 Hz Stand-by - kWm @ 1.800 rpm
Supercharged with turbocharger and Engine idle speed 50 Hz 1.500 rpm
Air system
intercooler unladen 60 Hz - rpm
Injection type Direct injection with rotary pump Maximum engine 50 Hz 1.570 rpm
rpm unladen 60 Hz - rpm
Compression ratio 17,5:1
Cooling Liquid It is strictly forbidden to alter the aforesaid
Engine direction of rotation Anticlockwise (seen from flywheel side) characteristics and, in particular, to modify the
calibration of the injection pump or the
Control system Mechanical characteristics of the engine and its components.
Dry weight ~500 kg (G-Drive) Failure to comply with the above shall result in the
loss of warranty, in addition to FPT declining all
responsibility.
(*)Net power at the flywheel in accordance with the standard ISO
8528. Test conditions: T 25 °C; atmospheric pressure 100 kPa;
relative humidity 30%.

5
 13_054_N 13_055_N

NEF45 TM3.S500 NEF45 TM3.S500

1. Heat exchanger/s - 2. Coolant filler cap - 3. Oil filler cap - 4. Engine 1. Exhaust manifold - 2. Turbocharger air intake - 3. Turbocharging air
air inlet manifold - 5. Oil vapour bleeder - 6. Lifting U-bolt - 7. Air outlet - 4. Turbocharger- 5. Exhaust outlet - 6. Lifting U-bolt -
filter - 8. Injection pump - 9. Fuel outlet connector to tank - 10. Fuel 7. Coolant outlet manifold from engine - 8. Location of thermostatic
inlet manifold from tank - 11. Fuel supply pump - 12. Oil dipstick - valve - 9. Engine coolant inlet connector sleeve - 10. Fan -
13. Fuel filter condensation drainage plug - 14. Fuel filter. 11. Alternator - 12. Lubricant oil discharge plug - 13. Oil filter -
14. Electrical starter motor.

6
SIGNS
Certain warning signs are affixed to the engine by the Manufacturer,
and their meanings are indicated below.
N.B. The signs with an exclamation mark on them underline a
potential danger.

ENGLISH
Lifting point (engine only). Danger of burning:
Expulsion of hot water under pressure.

Fuel Cap Danger of burning:

(on the fuel tank, if there is one). Presence of high temperature parts.

Oil Cap. Danger of fire:

Fuel present.

Danger of impact or catching

Oil dipstick. on moving parts:
Presence of fans, pulleys, belts or the like.

7
 USE Note: The procedures required to clean the filter are indicated
in the chapter CONTROLS AND MAINTENANCE.

PRELIMINARY CHECKS
Before starting the engine each time: CAUTION!
 Check the level of technical fluids (fuel, engine oil and coolant), and Make sure that no combustible vapours or gasses are
top-up if necessary. present in the area in which the engine is to operate.
 Make sure that the air intake filter is not obstructed or clogged and Ensure that closed areas are adequately ventilated and
check, at the same time, that the visual indicator (1) on the filter is fitted with a suitable exhaust extraction system.
not showing the “red” signal. The air filter clogging visual indicator
(1) signals when it is necessary to carry out maintenance in order
to protect and optimize filter operation. The sensor (1) remains
locked in the alarm position ("red") until it is reset.

13_074_N

8
ENGINE PRE-HEATING (optional) SWITCHING OF OPERATING FREQUENCY
The engines which require low start-up temperatures and an Based on the specific operational requirements of the engine, it is
immediate delivery of power may be equipped with an electrical possible to vary the adjustment of the rotary injection pump so as to
heating device enabling an increase in the temperature of the air obtain a different operating frequency:
entering the engine. The device is mounted on the intake manifold and - 1,500 rpm @ 50 Hz
is fitted with a coolant temperature sensor which interrupts the power
- 1,800 rpm @ 60 Hz
supply once the required temperature has been reached.
To switch from 50 Hz to 60 Hz it is necessary to turn the adjustment

ENGLISH
screw (1) of the “droop setting”, clockwise a number of turns
depending on the identification code of the pump indicated on the
nameplate.

13_066_N

9
FOR PROPER USE OF THE ENGINE SPECIAL WARNINGS
 Before starting the engine, check there is enough fuel in the fuel High coolant temperature
tank. In the event of an excessive temperature or the signalling of the alarm,
 Do not keep on starting. disengage the load and stop the engine in order to check the condition
 Do not idle for long periods since this increases the production of of the cooling circuit.
harmful emissions from the engine and does not guarantee its Moreover, check the following:
optimum performance.  tension of ancillary belt;
 The engine speed must be increased and decreased gradually so as  the thermostatic valve’s efficiency;
to permit normal combustion and the optimum functioning of all  the conditions of the heat exchanger (to be cleaned if necessary).
engine components.
 During use, check periodically that:
CAUTION!
- the temperature of the engine coolant does not reach the alarm
thresholds; When the engine is hot, pressure builds up in the
- the oil pressure remains within normal values. cooling circuits which may eject hot liquid violently,
 Actual power values must comply with the rated values reported resulting in a risk of burns.
in the technical documentation. Open the filler cap of the coolant tank only if necessary
and only when the engine is cold.
 Particular attention must be drawn on emergency power unit
engines, which must be submitted to frequent overhauls in order
to ensure their prompt start whenever required. Low lubricant oil pressure
Should the pressure indicated by the instrument be considered
insufficient or if the “low oil pressure” warning light comes on, stop the
engine and check the oil level. If necessary, top up the oil according to
the instructions contained in the section CHECKS AND
MAINTENANCE. If the fault persists, contact a Service centre.

10
Presence of water in the fuel filter Intake and exhaust circuit inefficiencies
It is advisable to drain the water from the filters before the relevant Inspect the cleanliness of the air intake circuit on a regular basis. The
warning light comes on. maintenance intervals indicated in this manual vary according to the
Avoid using the engine with only a small reserve of fuel in the fuel tank; conditions in which the engine is used.
this encourages the formation of condensation and makes it more In particularly dusty environments it is necessary to carry out
likely you will suck up dirt or air, resulting in engine stoppage. maintenance at more frequent intervals than indicated in the chapter
CONTROLS AND MAINTENANCE.

ENGLISH
Refuelling from drums or jerry cans may contaminate
the diesel, resulting in problems with the fuel supply CAUTION!
system; in these cases it is necessary to carry out
adequate filtration or sedimentation of any impurities Visually check that the exhaust circuit is not blocked or
present. damaged, so as to prevent dangerous fumes.

CAUTION!
Electrical start-up system irregularities
Never loosen the high pressure fuel circuit connectors Periodically check, particularly during the winter, to ensure that the
in any way. batteries are clean and in full working order, checking and topping up
as indicated in the chapter CONTROLS AND MAINTENANCE.
In the event of battery replacement, please observe the characteristics
contained in the section ENGINE TECHNICAL DATA.

Contact a specialised workshop and check battery and

recharging system efficiency if the voltmeter indicates a
voltage below 11 V (for 12 V rated systems), or 22 V
(for 24 V rated systems).

11
 REFUELLING
The batteries contain an acid solution that will burn the NEF45 TM3.S500
skin and corrode clothing; when checking them, always
Parts to be supplied litres (kg)
wear protective clothing, gloves and goggles, do not
(4)
smoke or use live flames in the vicinity, and make sure engine 8.5
that the room they are housed in is adequately Cooling circuit (1) (5)
G-Drive 18,5
ventilated.
(2) (3)
Lubrication circuit 12.8 (11.8)
Battery or alternator recharging faults
Periodic changing:
Periodically check or have someone check the cleanliness, wear and full oil sump at minimum level 5.5 (5.1)
tensioning of the drive belt. oil sump at maximum level 8.5 (7.8)

CAUTION! (1)Use a 50% mixture of water and PARAFLU 11 or the equivalent

corresponding to the specification SAE J1034.
The ancillary members are located under protective
grilles. Their removal must be carried out only when the (2)Use lubricants which meet the international standards ACEA E5-E7
engine is not turning. (high power engines). The oil used is considered to be acceptable
until a quantity equalling 0.1% of fuel consumption is reached.
RUNNING IN (3)The quantities indicated relate to the first refuel only and are
relative to the engine, oil sump and filter filling.
Thanks to modern engine construction technology, no particular
running in procedure is required. However, it is recommended that, (4)The quantities indicated only relate to the engine in its standard
for the first 50 hours, you do not use the engine at high power for long configuration.
periods. (5)The quantities indicated relate to the total capacity of the
generating set including the engine capacity, the radiator and the
pipes.

12
Coolant refilling Refuelling
For the initial engine start-up and in the cases in which the refilling of Use only diesel oil in accordance with EN 590 standard normally
the cooling circuit is required with a considerable quantity of coolant, commercially available. Fuel additives are not recommended.
proceed as follows: Use of additives can limit the guarantee performance offered for the
 Refill the engine and the exchanger until the exchanger is vehicle.
completely filled.
 With the coolant filler plug open, start the engine and let it idle for CAUTION!

ENGLISH
approx. 1 minute. This helps to completely bleed the air contained
in the cooling circuit. Pay maximum attention when refuelling, making sure
 Stop the engine and then top up with coolant if necessary. that solid or liquid pollutants do not enter the tank;
please remember that smoking is prohibited while
refuelling. The couplings of the fuel circuit under high
The failure to observe the aforesaid procedure does not pressure must not be loosened under any
guarantee the presence of the correct quantity of circumstances.
coolant in the engine.
Low temperature diesel
At low temperatures the degree of fluidity of the diesel can become
CAUTION! low due to the separation of the paraffin resulting in the filters
becoming clogged.
When the engine is hot, pressure builds up in the EN590 specifications distinguish different classes of diesel fuel,
cooling circuits which may eject hot liquid violently, identifying the characteristics of those best suited to low temperatures.
resulting in a risk of burns. Open the filler cap of the It is entirely up to the Oil companies to comply with these regulations,
coolant tank only if necessary and only when the which foresee that fuels suited to the climactic and geographic
engine is cold. conditions of the various Countries be distributed.

13
 CONTROLS AND MAINTENANCE • replacing or topping up lubricant (hot engine oil may cause burns
and scalds. Only carry out these operations when the oil has
dropped to a temperature of below 50°C).
MAINTENANCE PERSONNEL  When working in the engine compartment, pay particular attention
The engine control and maintenance operations described in the to how you move, to avoid contact with moving parts or high
following chapter require training, experience and compliance with temperature components.
current safety regulations; for this reason they must be carried out by  Wear goggles and use high pressure air jets (maximum air pressure
special technicians, as indicated below. used to clean is 200 kPa (2 bar, 30 psi, 2 kg/cm2).
 Controls: by workshop technicians or the machine user if  Wear a protective helmet when working in an area were there are
necessary. suspended loads or systems installed at head-height.
 Periodic maintenance: by qualified personnel using  Use protective hand creames.
suitable equipment and adequate means of protection.
 Immediately replace wet overalls.
 Special maintenance: by qualified personnel from  Always keep the engine clean, removing oil, grease and coolant
Authorised Service Centres who have detailed technical stains.
information and specific equipment.
 Store cloths in flame-proof containers.
The most qualified Assistance Centres are those which make up the  Do not leave foreign bodies on the engine.
FPT Technical Assistance Network.
 Use suitable, safe containers for used oil.
 When completing a repair, make suitable provisions to stop the
ACCIDENT PREVENTION engine taking in air if, after start-up, an uncontrolled increase in
 Always wear heavy-duty footwear and overalls. engine speed were to occur.
 Never wear loose, flapping garments, rings, bracelets and/or
necklaces in the vicinity of engines or moving parts.
 Always wear protective gloves and goggles when:
• filling up batteries with acid solution
• refuelling with inhibitors or antifreeze

14
 FREQUENCY
Do not carry out maintenance operations when the NEF45 TM3.S500
electric power supply is turned on: always check to Controls when in use Frequency
ensure that the appliances are properly earthed.
During diagnosis and maintenance operations, make Check oil level in engine Daily
sure that your hands and feet are dry, and whenever Check engine coolant level Daily
possible use insulating stands.
Check cleanliness of the heat exchanger Daily

ENGLISH
Check that the air filter is clean 300 hours (2) (4)
The conditions provoking the emergency power unit
start may suddenly occur. Whenever executing checks Inspection of the exhaust duct/s Daily
and maintenance operations, strictly follow the safety Check tightening and cleanliness of battery
instructions prescribed by the unit’s Manufacturer and Six-months
clamps
power unit system’s outfitter to operate safely and
prevent injury. Check electrolyte level of the batteries Six-months

The maintenance intervals indicated below take into account the

typical working factors for various types of engine use; the most
suitable interval for maintenance operations for the various
applications will be indicated by the maintenance staff, according to the
way and working conditions in which the engine is used.

15
 Planned maintenance Frequency Special maintenance Frequency

Engine lubricant oil change 800 hours (3) (4) 1200 hours /
Change ancillary belt
3 years
Change oil filter 800 hours (3) (4) (5)

Clean heat exchanger 1200 hours

Change fuel filter 600 hours (1) (4) (5)

Turbocharger visual inspection 1200 hours

Drain water from the fuel pre-filter 300 hours (1)
Injector calibration 1800 hours
Drainage/suction of water, condensation
300 hours (1)
and impurities from the fuel tank/s Adjust play in valves-rocker arms 3000 hours
Check tension and condition of ancillary 1) Maximum period relating to the use of high quality fuel,
300 hours
belt (specification EN 590); this is reduced, basing on fuel contamination
and alarm signals caused by filter clogging and/or the presence of
1200 hours /
Change engine coolant water in the filter. The filter clogging signal indicates that the filter
2 years
must be replaced. If the warning light of water present in the filter
1200 hours / does not go off after drainage, then the filter must be replaced.
Change air filter
2 years (2) 2) The frequency depends on the ambient conditions and product
efficiency/wear. After long periods of engine inactivity, perform the
check before starting the engine.
The filter clogging signal indicates that the filter must be replaced.
(3)The frequencies are applicable for lubricants which meet the
international standards ACEA E5-E7 (high power engines).
4) To be performed every year even if the specified operating hours
interval has not been reached.
5) Only use filters with the following specifications:
- degree of filtering < 12 μm
- filtering efficiency 99.5% (ß > 200).

16
 REQUIREMENTS
In the event in which fuel is used with a sulphur  Do not disconnect the batteries with the engine running.
percentage greater than 0.5%, or oils are used which  Do not carry out arc welding operations in the vicinity of the engine
do not meet the specifications in the section FLUIDS, without first removing electrical cables.
then the replacement frequencies of the engine oil,  After each maintenance operation involving disconnection of the
engine oil filter and blow-by filter must be halved, or battery/batteries, make sure that the terminals have been properly
suitably adjusted, in accordance with the use and locked onto the poles.
operating conditions of the engine; please consult the

ENGLISH
personnel in charge of maintenance operations for  Do not use battery chargers to start the engine.
appropriate advice.  Do not paint the appliances, components and electrical connectors
equipping the engine.
 Disconnect the battery/batteries before any electrical operations.
The operations described above require the use of  Contact the Manufacturer before installing electronic equipment.
specific tools which guarantee safe and effective
results.
It is recommended that such operations are carried out Do not execute any operation which may change the
by qualified personnel of the FPT Technical Service ignition pump’s calibration.
Network. The ignition pump’s calibration has been carried out in
The unscheduled maintenance operations described in phase of engine system test based on its final use or
the relative table are under the exclusive responsibility destination.
of qualified personnel in possession of suitable
technical information and equipped with suitable work
tools and protective devices. The instructions for their
fulfilment are contained in the FPT technical and repair
manuals.

17
HOW TO PROCEED
Check oil level in engine
Only proceed with the engine stopped and at a low temperature, so
as to avoid the risk of burning.
 Take all necessary action to ensure that the machine is “level”.
 Using the dipstick (1), check that the oil level is between the "Min"
and "Max" levels.
 If the level is too low, top up through the inlet, after first removing
the relevant cap (2).

13_051_N

WARNINGS

 After topping up, make sure that the oil level does not exceed the
"Max" limit marked on the dipstick.
 Make sure that the dipstick is inserted properly and the filler cap
is turned in a clockwise direction until it stops turning completely.

18
Check coolant level Clean heat exchangers
Proceed only with engine not running and at low temperature to avoid Check that the radiator air inlets are free from dirt (dust, mud, straw,
any risk of burns. etc.).
 With the engine at low temperature, make sure that the fluid level Clean them if necessary, using compressed air or steam.
in the expansion tank is above the minimum level.
 Visually check that the fluid level is not more than 2/3 of the height
of the tank in order to enable any increase in volume of the fluid

ENGLISH
caused by the temperature increase.
 Top up the tank if necessary,
using clean water. Do not use
distilled water; see the table MAX
REFUELLING.
MIN
Note: If the refill operations occur
frequently a diagnosis of the cooling
circuit is necessary. 05_585_N

In the event that only the heat exchanger without the expansion tank
is available on the vehicle, refill it if necessary, paying attention that the
fluid does not saturate the internal volume of the exchanger in order
to enable any increase in volume of the fluid caused by the 05_609_N
temperature increase.

CAUTION!
CAUTION!
The use of compressed air makes it necessary to use
When the engine is warm, a pressure liable to cause hot
suitable protective equipment for the hands, face and
liquid to be expelled with extreme violence is created
eyes. Please see the prescriptions in the paragraph on
within the cooling circuits. This results in a danger of
ACCIDENT PREVENTION.
burning.

19
Cleaning the air filter
Only proceed with the engine stopped. WARNING
 Remove the filter cover (1) after first unscrewing the locking
handle. Take care to ensure that the parts are reassembled correctly.
Imperfect assembly might result in unfiltered air being sucked into the
 Remove the external cartridge (2), after unfastening the second engine, causing serious damage.
locking handle; during this operation, take care to ensure that no
dust get into the sleeve.
 Check that there is no dirt. If there is, clean the filter element as
indicated below.
 Blow dry compressed air through the filter element, from the inside
outward (maximum pressure 200 kPa). Do not use detergents; do
not use diesel.
 Never use tools to beat the filter element, and check its condition
before replacing it.
05_590_N
 Replace the filter if any breakages or tears are found. 1 2 3
 Check that the gasket at its base is in good condition. Some filter
systems are fitted with a second filter element (3) which does not
require cleaning; this must be replaced at least once every 3
changes in the main element.
 Reassemble by repeating the above operations in reverse order.
 Set up the mechanical blockage indicator for operation by pressing
the button located on the top part of the indicator. This operation is
not necessary if there is an electrical sensor.

20
Drain water from the fuel filter/pre-filter Check/top up electrolyte level in batteries
The high risk of refuelling with fuel that is polluted by foreign bodies Place the batteries on a level surface, then proceed as follows.
and water makes it advisable to carry out this control every time you  Visually check that the fluid level is between the “Min” and “Max”
refuel. limits; in the absence of references, check that the fluid covers the
Proceed with the engine stopped. Lead plates inside the elements.
 Place a container under the filter or pre-filter to collect the fluid.  Top up with distilled water only those elements in which the level
 Unscrew the water bleeding screw (1) in the lower part of the filter. is below the minimum.

ENGLISH
 Drain off liquid until only “diesel” can be seen.  Contact specialised technical staff if the battery needs recharging.
 Tighten the bleeding screw as far as possible by hand.  Have the efficiency of the battery recharging system tested if a
 Dispose of the drained fluids according to current requirements. voltage of less than 11 V (for 12 V rated systems) or 22 V (for
24 V rated systems) is detected with the engine running.
 On this occasion, make sure that the terminals and clamps are
clean, properly locked and protected by vaseline.

CAUTION!

The batteries contain sulphuric acid, which is extremely

caustic and corrosive; always wear protective gloves and
goggles when topping them up. Whenever possible it is
recommended that this control be carried out by
specialised personnel.
Do not smoke or use live flames near the batteries
during the control, and make sure that the room you are
working in is adequately ventilated.
13_052_N

21
 Check tension and state of the auxiliary member
drive belt
Only proceed with the engine stopped and at a low temperature, so
as to avoid the risk of burning.
 Check that the belt is not torn or worn, and that there are no
lubricants or fuel on it. If this is not the case, replace them.
Should it be necessary to restore tension in the belt, proceed as
follows:
 Loosen the alternator fastening nut (1) and screw (2).
 Screw in the micrometric screw (3) and lock the relative counter
nut.
 Using a suitable tool, check the tension of the belt at the
13_078_N
intermediate point (4) of the branch between the pulley and the
Some types of battery have a single cover for all the inspection plugs. water pump pulley.
To access the elements, use a lever as shown in the figure.  The correct tension is 245 ± 10 Hz (1200 ± 100 N).
 When the correct tension has been obtained, tighten the alternator
screw and bolt to a torque of 43 ± 6 Nm.

22
 Change oil
Only proceed with the engine stopped and at a low temperature, so
as to avoid the risk of burning.
 Place a container under the drainage plug to collect the used oil
(see illustrations in the chapter ENGINE TECHNICAL DATA).
 Unscrew the plug and wait until the sump has emptied completely,
then fasten the plug in place again.

ENGLISH
 Fill up through the feeder hole (2) on the timer cover or elsewhere
(opt.), using the types and amounts of oil indicated in the table
REFUELLING.
 Using the dipstick (1), check that the oil level is between the "Min"
and "Max" levels.
 Dispose of used oil according to current requirements.

13_053_N

For engines without a screw tensioner proceed, after loosening the

fixing screws (1) and anchor bolt, by turning the alternator as shown
in the figure until the required tension is reached, after which tighten
the fixing screws and anchor bolt firmly. 13_051_N

23
Change oil filter Change fuel filter/s
Only proceed with the engine stopped and at a low temperature, so Only proceed with the engine stopped and at a low temperature, so
as to avoid the risk of burning. as to avoid the risk of burning.
Only use filters with a filtration level equivalent to the ones you are Only use filters with a filtration level equivalent to the ones you are
replacing (see section FREQUENCY). replacing (see section FREQUENCY).
 Place a container under the filter support (1), to collect the used oil.  Remove the filter/s (1) by unscrewing it.
 Unscrew the filter and remove it (2).  Check that the new filter has performance levels that satisfy the
 Carefully clean the surfaces of the support that are in contact with needs of the engine (e.g. by comparing them with the old one).
the seal gasket.  Damp the new filter seal with diesel or engine oil.
 Damp the new seal gasket with a thin layer of oil.  Hand screw the new filter into place until the seal gasket touches
 Hand screw the new filter into place until the seal gasket touches the support, then lock by a further 3/4 of a turn.
the support, then lock by a further 3/4 of a turn.  Pay particular attention to the electrical fuel pre-heater (if available)
 Dispose of the old filter according to current requirements. and relevant electrical connection.

05_610_N

13_098_N

24
 Change coolant
WARNING Only proceed with the engine stopped and at a low temperature, so
as to avoid the risk of burning.
Do not fill up the new filter before it is fitted to the support, to avoid  Provide suitable containers to ensure that no coolant is dispersed
inserting harmful impurities into the injection system and circuit. into the environment.
 Loosen the seal elements, remove the sleeves connecting the
Check exhaust pipe/s for damage engine circuit to the heat exchanger and wait until it has emptied

ENGLISH
Visually check that the exhaust system is not blocked or damaged. completely. When empty, repair the circuit making sure that the
 Make sure that there is no risk of dangerous fumes within the sleeves are perfectly sealed.
machine. Contact the Manufacturer if necessary.  Fill up the circuit as indicated in the table REFUELLING.
 Refill the engine and the heat exchanger until complete top up.
Impurity drainage or suction from fuel tank  With the filler cap open, start the engine and keep it idling for nearly
Proceed taking into consideration the constraints of the tank’s one minute. This phase facilitates the cooling liquid air bleed.
placement and structure.  Stop the engine and top up again.
The engines working in harsh environments and conditions and/or to
be refuelled from cans or barrels require even more accurate tank
cleaning.

Change auxiliary member belt

Please refer to the information provided for checking the belt tension.

Air filter replacement

Refer to the instructions provided for air filter cleaning.

25
MOVING THE ENGINE
The operations necessary to disconnect and subsequently reconnect
the engine must only be carried out by technicians from Service
Centres.
When lifting the engine only, use the U-bolts indicated in this manual
in the section ENGINE TECHNICAL DATA and marked on the engine
with special stickers.
Lifting must be carried out using a rocker arm that keeps the metal
cables supporting the engine parallel, using all the U-bolts provided
simultaneously; the use of a single U-bolt only is not allowed.
The engine lifting system must have a capacity and size suited to the
weight and dimensions of the engine; check that there is no
interference between the lifting system and the engine components.
Do not lift the engine before removing the transmission members that
are coupled to it.

DISPOSAL OF WASTE
The engine is made up of parts and elements that, if discarded, may
cause damage to the environment.
The materials listed below must be handed over to specialised
Collection Centres; the laws in force in the various Countries foresee
severe penalties for transgressors:
 Starter batteries.
 Used lubricants.
 Mixtures of water and antifreeze.
 Filters.
 Additional cleaning materials (e.g. greasy or fuel-soaked cloths).

26
 LONG PERIODS OF INACTIVITY 7. Drain the residual 30/M protective oil from the sump. This oil can
be used again for a further 2 preparation operations.
8. Fit signs reading "ENGINE WITHOUT OIL" to the engine and to
PREPARING THE ENGINE FOR A LONG the on-board control panel.
PERIOD OF INACTIVITY 9. Drain the coolant, if it has not been mixed with suitable antifreeze
In order to prevent oxidation of the internal parts of the engine and and corrosion inhibitors, and affix a sign to indicate the fact.
of certain components in the injection system, when the engine is
expected to be inoperative for periods of more than two months, the In the event of prolonged inactivity, the operations described must be

ENGLISH
following operations must be carried out in preparation for this: repeated every 6 months, following the procedure given below:
1. Drain the lubricant from the sump, after first warming up the A) drain the 30/M protective oil from the sump;
engine. B) repeat the operations described from point 2 to point 7.
2. Fill the engine with protective oil type 30/M (or alternatively oil that
complies with MIL 2160B type 2 specifications), up to the Should you intend to protect external parts of the engine, proceed by
"minimum" level indicated on the dipstick. Start the engine and keep spraying OVER 19 AR protective liquid on unpainted metal parts, such
it running for approximately 5 minutes. as the flywheel, pulleys and the like, avoiding belts, connector cables
3. Drain the fuel from the injection circuit, from the filter and from the and electrical equipment.
injection pump pipes.
4. Connect the fuel circuit to a tank containing CFB (ISO 4113)
protective fluid, and feed in the fluid by putting the circuit under
pressure and running the engine for approximately 2 minutes, after
first disabling the injection system. This operation can be performed
by polarising terminal 50 of the starter motor with a positive
voltage equivalent to the rated voltage of the system, using a
conductor provided for that purpose.
5. Nebulise approximately -- g of 30/M protective oil (10 g per litre
displacement) into the turbocharger suction inlet, during the
pressurised filling operation described in the previous point.
6. Close all the suction, delivery, ventilation and bleeder openings in
the engine with suitable plugs, or seal them with adhesive tape.

27
RESTARTING THE ENGINE AFTER A LONG
PERIOD OF INACTIVITY
1. Drain the residual 30/M protective oil from the sump.
2. Fill the engine, as prescribed, with lubricant of the type and amount
indicated in the table REFUELLING.
3. Drain the CFB protective fluid from the fuel circuit, carrying out this
operation as indicated under point 3. of PREPARING THE ENGINE
FOR A LONG PERIOD OF INACTIVITY.
4. Remove the plugs and/or seals from the suction, delivery,
ventilation and bleeder openings in the engine, restoring it to a
normal state of use. Connect the turbocharger suction inlet to the
air filter.
5. Connect the fuel circuits to the machine’s fuel tank, completing the
operations as indicated in point 4. of PREPARING THE ENGINE
FOR A LONG PERIOD OF INACTIVITY. During filling operations,
connect the fuel return pipe to a collection tank, so as to prevent
any residual CFB protective fluid from flowing into the machine's
fuel tank.
6. Check the engine and fill it up with coolant as prescribed, bleeding
it if necessary.
7. Start the engine and keep it running until the idling speed rate has
stabilised completely.
8. Check that the instruments on the on-board control panel/s are
showing plausible values, and that no alarms are shown.
9. Stop the engine.
10.Remove the "ENGINE WITHOUT OIL" signs from the engine and
from the on-board control panel.

28
 BEHAVIOUR IN AN EMERGENCY 2. Do not attempt to remove pieces of clothing that may have stuck
to the skin;
The user of a machine that has been constructed according to safety 3. In the case of scalding, immediately but carefully remove any
regulations, when following the instructions provided in this manual clothing that may be soaked in the hot liquid;
and the indications given on the engine labels, will be working in safe 4. Cover the burn with a special burn dressing or sterile bandage.
conditions.
Should improper conduct result in accidents, always request the Carbon monoxide intoxication (CO)
intervention of trained first aid specialists immediately.

ENGLISH
Carbon monoxide from the engine exhaust is without smell, and is
In an emergency and while awaiting the arrival of first aid specialists,
dangerous both because it causes intoxication, and because when
follow the instructions given below.
combined with air it forms an explosive mixture.
In closed rooms, carbon monoxide is extremely dangerous, as it can
Engine malfunctions reach critical concentrations within a very short time.
When operating with a malfunctioning engine, take the greatest When assisting an intoxicated person in a closed room:
possible care when manouevering and make sure that all those aboard 1. Ventilate the room immediately, to reduce the concentration of
are holding firmly to safe hand-holds. gas.
2. When entering the room, hold your breath, do not light flames,
In case of fire
lights or ring electric doorbells or phones, to avoid the risk of
Extinguish the fire using the fire-fighting equipment foreseen, and in explosion.
the manner indicated by Fire prevention authorities (fire-fighting
3. Carry the intoxicated person out into the fresh air or into a well
equipment for certain machines and equipment is compulsory under
ventilated room, resting him on one side if he is unconscious.
current safety legislation).

Burns and scalds

1. Extinguish any flames on the burned person's clothing, by:
• throwing water over them;
• using a powder fire-extinguisher, without directing the jet at the
person's face;
• covering with blankets or rolling the victim on the ground.

29
Electrocution Injuries and fractures
A. The engine's electrical 12 V electrical system does not involve the The vast number of possible circumstances and the specific nature of
risk of electrocution, however, in the event of a short-circuit operations required means that the intervention of a medical team is
caused, for example, by a metal tool, there is a risk of burning due necessary.
to overheating of the object through which the electrical current 1. In the event of bleeding, keep the edges of the wound pressed
runs. In these circumstances: together until help arrives.
1. Remove the object that caused the short-circuit, using means that 2. If there is any suspicion of a fracture, do not move the injured part
provide sufficient heat insulation. and only move the patient if absolutely necessary.
2. Switch off the power at the main switch, if there is one.
B. The electric generator systems (generator units) normally produce Caustic burns
high voltages that are liable to result in extremely dangerous Caustic skin burns are caused by contact with extremely acid or
current levels. In the event of medium or high voltage electrocution: alkaline substances.
1. Turn off the power supply at the main switch before touching the For electric maintenance technicians these are typically caused by acid
victim. If this is not possible, use equipment that is both safe and from batteries; in these circumstances, proceed as follows:
adequately insulated when touching the victim; remember that 1. Remove any clothing soaked in the caustic substance.
touching a victim of electrocution is also extremely dangerous for 2. Wash the area with lots of running water, avoiding parts that have
the person giving aid. not been burned.
2. Proceed as indicated by the competent authorities (cardiac If either battery acid, lubricants or diesel come into contact with the
massage, mouth-to-mouth resuscitation, etc.) eyes: wash the eyes with water for at least 20 minutes, keeping the
eyelids open so that the water flows over the eyeball (move the eye
in all directions to wash more thoroughly).

30