FPT N Series Use And Maintenance Download Page 1

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SERIES

INDUSTRIAL ENGINES

Publication edited by

Marketing - Adv. & Promotion

Print L31900041 - 09/07

USE AND MAINTENANCE

USO E MANUTENZIONE

UTILISATION ET ENTRETIEN

BETRIEB UND WARTUNG

USO Y MANTENIMIENTO

ECHANICAL

NJECTION

YSTEM

Summary of Contents for N Series

Page 1: ...STRIAL ENGINES Publication edited by Marketing Adv Promotion Print L31900041 09 07 USE AND MAINTENANCE USO E MANUTENZIONE UTILISATION ET ENTRETIEN BETRIEB UND WARTUNG USO Y MANTENIMIENTO MECHANICAL INJECTION SYSTEM ...

Page 2: ...e 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...

Page 3: ...er use of the engine 21 Special warnings 21 Running in 23 n USE G Drive appliance 24 Preliminary checks 24 Starting and stopping the engine 24 Engine pre heating optional 24 Board panel instrument readings 25 For proper use of the engine 25 Special warnings 26 Running in 28 n CONTROLS AND MAINTENANCE 29 Maintenance personnel 29 Accident prevention 29 Refuelling 30 Frequency 31 Page Requirements 33...

Page 4: ...void damage to persons or property as a result of improper or incorrect behaviour q The engines must only be used for the purposes indicated by the Manufacturer q Any tampering modification and use of non original spare parts may compromise proper operation and safe use of the engine never under any circumstances make modifications to the wiring and to the units equipping the engine or connect the...

Page 5: ...sel Number and arrangement of cylinders 4 in line Bore x stroke 104 x 132 mm Total displacement 4 500 cm3 Air system Natural induction Injection type Direct with rotating pump Engine direction of rotation Anticlockwise seen from flywheel side Dry weight 380 kg Electrical system 12 V Accumulator s capacity discharge current 100 Ah or above 650 A or above Performance N45 MNA MSA TIER 2 60 kW 81 CV 2...

Page 6: ...manifold from tank 10 Fuel supply pump 11 Oil drainage plug 12 Oil dipstick 13 Fuel filter condensation drainage plug N45 MNA N45 MSA 1 Exhaust manifold 2 Oil vapour bleeder 3 Exhaust outlet 4 Lifting U bolt 5 Engine coolant outlet 6 Location of thermostatic valve 7 Alternator 8 Engine coolant inlet 9 Lubricant oil filter 10 Electrical starter motor 9 10 11 12 13 1 2 3 4 5 6 7 8 05_591_N 8 9 10 1 ...

Page 7: ... Air system Supercharged and Aftercooled 1 Injection type Direct with rotating pump Engine direction of rotation Anticlockwise seen from flywheel side Dry weight 390 kg Electrical system 12 V Accumulator s capacity discharge current 100 Ah or above 650 A or above Performance N45 MNS MSS TIER 2 74 kW 100 CV 2 300 rpm 398 Nm 40 5 Kgm 1 400 rpm TIER 3 66 kW 90 CV 2 200 rpm 362 Nm 36 9 Kgm 1 400 rpm P...

Page 8: ...lug 12 Oil dipstick 13 Fuel filter condensation drainage plug N45 MNS MSS MNT MST 1 Exhaust manifold 2 Turbocharger air inlet 3 Turbocharging air outlet only for N45 MNT MST engines 4 Turbocharger 5 Turbocharger exhaust outlet 6 Engine air inlet 7 Lifting U bolt 8 Engine coolant outlet 9 Location of thermostatic valve 10 Alternator 11 Engine coolant inlet 12 Oil filter 13 Electric starter motor 9 ...

Page 9: ...placement 6 700 cm3 Air system Supercharged and Aftercooled 1 Injection type Direct with rotating pump Engine direction of rotation Anticlockwise seen from flywheel side Dry weight 530 kg Electrical system 12 V Accumulator s capacity discharge current 180 Ah or above 950 A or above Performance N67 MNA MSA TIER 2 81 kW 110 CV 2 500 rpm 440 Nm 45 Kgm 1 400 rpm Performance N67 MNT MST TIER 2 120 kW 1...

Page 10: ...lug 12 Oil dipstick 13 Fuel filter condensation drainage plug N67 MNA MSA N67 MNT MST 1 Exhaust manifold 2 Oil vapour bleeder 3 Turbocharger air inlet 4 Turbocharging air outlet 5 Turbocharger 6 Turbocharger exhaust outlet 7 Lifting U bolt 8 Engine coolant outlet 9 Location of thermostatic valve 10 Alternator 11 Engine coolant inlet 12 Lubricant oil filter 13 Electrical starter motor Only for vers...

Page 11: ... 4 500 cm3 Air system Natural induction Injection type Direct with rotating pump Engine direction of rotation Anticlockwise seen from flywheel side Speed regulator Mechanical Dry weight 480 kg Electrical system 12 V Accumulator s capacity discharge current 100 Ah or above 650 A or above Performance N45 AM1A STAGE 2 Prime Stand by 40 kWm 1 500 rpm 44 kWm 1 500 rpm Performance N45 AM1 TIER 2 Prime S...

Page 12: ...k 11 Fuel filter with condensation drainage plug 12 Fan N45 AM1A AM1 1 Lifting U bolt 2 Exhaust manifold 3 Oil vapour bleeder 4 Exhaust outlet 5 Lifting U bolt 6 Coolant outlet manifold from engine 7 Location of thermostatic valve 8 Engine coolant inlet connector sleeve 9 Alternator 10 Lubricant oil discharge plug 11 Oil filter 12 Electrical starter motor 1 10 11 12 8 9 7 2 3 4 5 6 07_001_N 1 11 1...

Page 13: ...80 kg 500 kg Electrical system 12 V Accumulator s capacity discharge current 100 Ah or above 650 A or above Performance N45 SM1A N45 SM1 STAGE 2 Prime Stand by 53 5 kWm 1 500 rpm 59 kWm 1 500 rpm TIER 2 Prime Stand by 59 kWm 1 800 rpm 65 kWm 1 800 rpm Performance N45 SM2A N45 SM2 STAGE 2 Prime Stand by 66 kWm 1 500 rpm 73 kWm 1 500 rpm TIER 2 Prime Stand by 65 kWm 1 800 rpm 72 kWm 1 800 rpm Perfor...

Page 14: ...n drainage plug 14 Fuel filter Excluding versions SM N45 SM1A SM1 SM2A SM2 N45 TM1A TM1 TM2A TM2 TM2X 1 Exhaust manifold 2 Turbocharger air intake 3 Turbocharging air outlet 4 Turbocharger 5 Exhaust outlet 6 Lifting U bolt 7 Coolant outlet manifold from engine 8 Location of thermostatic valve 9 Engine coolant inlet connector sleeve 10 Fan 11 Alternator 12 Lubricant oil discharge plug 13 Oil filter...

Page 15: ... flywheel side Speed regulator Mechanical Dry weight SM TM 610 kg 640 kg Electrical system 12 V Accumulator s capacity discharge current 180 Ah or above 950 A or above Performance N67 SM1 Prime Stand by 110 kWm 1 500 rpm 121 kWm 1 500 rpm Prime Stand by 126 kWm 1 800 rpm 138 kWm 1 800 rpm Performance N67 TM2A N67 TM2 STAGE 2 Prime Stand by 114 kWm 1 500 rpm 125 kWm 1 500 rpm Prime Stand by 127 kWm...

Page 16: ...filter Excluding versions SM N67 SM1 TM2A TM2 TM3A TM3 TM1X 1 Exhaust manifold 2 Turbocharger air intake 3 Turbocharging air outlet 4 Turbocharger 5 Exhaust gas discharge 6 Lifting U bolt 7 Coolant outlet manifold from engine 8 Thermostatic valve location 9 Fan 10 Auxiliary member drive belt 11 Alternator 12 Engine coolant inlet sleeve 13 Lubricant oil discharge plug 14 Oil filter 15 Electrical st...

Page 17: ...rk on them underline a potential danger Lifting point engine only Fuel Cap on the fuel tank if there is one Oil Cap Oil dipstick Danger of burning Expulsion of hot water under pressure Danger of burning Presence of high temperature parts Danger of fire Fuel present Danger of impact or catching on moving parts Presence of fans pulleys belts or the like ...

Page 18: ...to clean the filter are indicated in the chapter CONTROLS AND MAINTENANCE STARTING AND STOPPING THE ENGINE The start up and shut down operations described below apply to an on board control panel manufactured by FPT if the Manufacturer of the vehicle or machine has fitted a customised instrument panel these operations may vary according to the various choices made during construction In these case...

Page 19: ... Battery recharge and Oil pressure low indicators have turned off and that the analogue instruments are showing values that conform with the relevant new physical parameters If the pre heating system has intervened the relevant indicator will turn on again to indicate that the post heating phase is in progress the duration of this function is proportional to the temperature value 5 If the engine d...

Page 20: ... electronically controlled engines 2 Turn the key to position 1C Start and release it once the engine has started without accelerating 3 Proceed as described previously RECOGNISING ALARMS Indicator and alarm synoptics The FPT instrument panel contains the indicator lights used to indicate the state of operation of the engine Light up of these indicators is piloted by electronic circuits which have...

Page 21: ...r and cause automatic shutdown of the engine Maximum allowed rotation speed exceeded Coolant temperature high Oil pressure low Engine coolant level low ENGINE PRE HEATING optional 230 V single phase electrical device The engines for which low temperature start up and immediate delivery of power are required may be fitted with a 230 V single phase electrical heating device which allows the temperat...

Page 22: ... commercial documentation During use periodically check that 1 The engine coolant temperature does not reach the alarm threshold 2 The oil pressure remains within normal values SPECIAL WARNINGS Coolant circuit When a state of Coolant temperature high and Engine coolant level low is found this triggers stoppage of the engine in these cases check the efficiency of the circuit components remembering ...

Page 23: ...rvals with respect to the indications provided in the chapter CONTROLS AND MAINTENANCE Electrical recharging and start up system Periodically check particularly during the winter to ensure that the batteries are clean and in full working order checking and topping up as indicated in the chapter CONTROLS AND MAINTENANCE Should it be necessary to replace the batteries always respect the capacity and...

Page 24: ... is required However it is recommended that for the first 50 hours you do not use the engine at high power for long periods CAUTION The batteries contain an acid solution that will burn the skin and corrode clothing when checking them always wear protective clothing gloves and goggles do not smoke or use live flames in the vicinity and make sure that the room they are housed in is adequately venti...

Page 25: ...the realization of the power unit control panel and working system Their full and detailed description should be provided by the power unit system outfitters or by the power unit manufacturer Once the start phase is concluded carefully follow the instructions provided by the unit s measurement instruments checking that the values detected correspond to the normal working rated ones ENGINE PRE HEAT...

Page 26: ...le since this has negative effects to the engine performance q Actual power values must comply with the rated values reported in the technical documentation q When operating the engine regularly check that the cooling liquid temperature does not exceed the threshold value the oil pressure keeps within normal values q Particular attention must be drawn on emergency power unit engines which must be ...

Page 27: ... proceed as follows q Refill the engine and the heat exchanger until complete top up q With the filler cap open start the engine and keep it idling for nearly one minute This phase facilitates the cooling liquid air bleed q Stop the engine and top up again Further information on the cooling liquid technical specifications and quantity prescribed are reported in the CONTROLS AND MAINTENANCE section...

Page 28: ...lly check particularly during the winter to ensure that the batteries are clean and in full working order checking and topping up as indicated in the chapter CONTROLS AND MAINTENANCE Should it be necessary to replace the batteries always respect the capacity and minimum discharge current intensity requirements CAUTION When refuelling always pay great care to ensure that no solid or liquid pollutan...

Page 29: ...required However it is recommended that for the first 50 hours you do not use the engine at high power for long periods CAUTION The batteries contain an acid solution that will burn the skin and corrode clothing when checking them always wear protective clothing gloves and goggles do not smoke or use live flames in the vicinity and make sure that the room they are housed in is adequately ventilate...

Page 30: ...Always wear protective gloves and goggles when filling up batteries with acid solution refuelling with inhibitors or antifreeze 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 q When working in the engine compartment pay particular attention to how you move to avoid contact with movi...

Page 31: ... fuel consumption CAUTION Do not carry out maintenance operations when the electric power supply is turned on always check to ensure that the appliances are properly earthed During diagnosis and maintenance operations make sure that your hands and feet are dry and whenever possible use insulating stands CAUTION The conditions provoking the emergency power unit start may suddenly occur Whenever exe...

Page 32: ...res It is entirely up to the Oil companies to comply with these regulations which foresee that fuels suited to the climactic and geographic conditions of the various Countries be distributed FREQUENCY 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 applicati...

Page 33: ...EFUELLING table 5 Only use filters with the following characteristics filtration level 12 μm filtering efficiency ß 200 Planned maintenance Frequency Check state and tension of belt 300 hours 2 Change oil 600 hours 3 4 Change oil filter s 600 hours 3 4 5 Change fuel filter s 600 hours 3 1 5 Change fuel pre filter 600 hours 3 1 Check exhaust pipe s for damage Half yearly Impurity drainage suction f...

Page 34: ... when recharging 6 Do not paint the appliances components and electrical connectors equipping the engine 7 Disconnect the battery batteries before any electrical operations 8 Contact the Manufacturer before installing electronic equipment on board two way radios and the like WARNING The extraordinary maintenance operations described hereunder fall within the exclusive competence of manufacturer s ...

Page 35: ...k 1 check that the oil level is between the Min and Max levels q If the level is too low top up through the inlet after first removing the relevant cap 2 05_608_N 2 1 WARNINGS q After topping up make sure that the oil level does not exceed the Max limit marked on the dipstick q Make sure that the dipstick is inserted properly and the filler cap is turned in a clockwise direction until it stops tur...

Page 36: ...t 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 temperature increase Clean heat exchangers Check that the radiator air inlets are free from dirt dust mud straw etc Clean them if necessary ...

Page 37: ...ilter element and check its condition before replacing it q Replace the filter if any breakages or tears are found q 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 q Reassemble by repeating the above operations in reverse orde...

Page 38: ... the Min and Max limits in the absence of references check that the fluid covers the Lead plates inside the elements q Top up with distilled water only those elements in which the level is below the minimum q Contact specialised technical staff if the battery needs recharging q Have the efficiency of the battery recharging system tested if a voltage of less than 11 V for 12 V rated systems or 22 V...

Page 39: ...lternator to its lower support q Proceed to tighten the tensioner 2 locking the counternut q On reaching the required tension lock the fixing screws and bolt For engines without a screw tensioner proceed after loosening the fixing screws 1 and anchor bolt turning the alternator as shown in the figure until the required tension is reached after which tighten the fixing screws and anchor bolt firmly...

Page 40: ...e Min and Max levels q Dispose of used oil according to current requirements Change oil filter Only proceed with the engine stopped and at a low temperature so as to avoid the risk of burning Only use filters with a filtration level equivalent to the ones you are replacing see section FREQUENCY q Place a container under the filter support 1 to collect the used oil q Unscrew the filter and remove i...

Page 41: ... q Loosen the fuel outlet manifold located on the upper part of the filter 2 q Make sure that any diesel coming out will not dirty the auxiliary member drive belt or be dispersed into the environment q Use the pre filter hand pump until the diesel coming out is free from any residual air or perform the same operation using the mechanical feed pump 3 q Lock the manifold loosened as above to the req...

Page 42: ...nutes to eliminate any residual air q Check the efficiency of the earthing connection of the filter support 4 Note Should it be necessary to accelerate the bleeding phase the hand pump can be used during start up Check exhaust pipe s for damage Visually check that the exhaust system is not blocked or damaged q Make sure that there is no risk of dangerous fumes within the machine Contact the Manufa...

Page 43: ...HNICAL 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 ...

Page 44: ...he 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 wi...

Page 45: ... 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 coolan...

Page 46: ...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 2 Do not attempt to remove pieces of clothing that may have stuck to the skin 3 In the case of scalding immediately but carefully remove any clothing that may be soaked in the hot liquid 4 Cover the burn ...

Page 47: ...erous for the person giving aid 2 Proceed as indicated by the competent authorities cardiac massage mouth to mouth resuscitation etc Injuries and fractures The vast number of possible circumstances and the specific nature of operations required means that the intervention of a medical team is necessary 1 In the event of bleeding keep the edges of the wound pressed together until help arrives 2 If ...

Page 48: ...47 ENGLISH 6 6 6 6 6 6 6 6 PLQHUDO EDVH 6 VHPLV QWKHWLF EDVH 6 VHPLV QWKHWLF EDVH 6 V QWKHWLF EDVH 6 V QWKHWLF EDVH ...

Page 49: ...65 DIN 40050 IEC 529 IP 66 Saline mist resistance Reference standard IEC 60068 2 52 IEC 60068 2 52 Electric and electromagnetic characteristics Operating voltage excluding polarity inversions min 9 V max 32 V min 9 V max 32 V Maximum allowed overvoltage 60 V per 1 ms 60 V per 1 ms Maximum allowed current on main control panel 1 1 A 12 V 1 A 24 V 310 mA 12 V 200 mA 24 V Maximum allowed current on s...

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