USE AND MAINTENANCE

USO E MANUTENZIONE

F5 SERIES

G-DRIVE ENGINES

Publication edited by:

FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print L31900881 - 09/2021
 English
F34SE1W F34SE1W.S552
F34SE1W F34SE1W.S554
USE AND MAINTENANCE
1 GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety warnings symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
External view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Identification plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 USE
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
For proper use of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Special warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3 INSPECTION AND MAINTENANCE

Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main characteristics of oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Coolant fluid filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Programmed maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Location of the ATS system filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Water in the fuel pre-filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check engine lubricant oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check tension and condition of ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Change engine lubricant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Change engine lubricant oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
 Change fuel pre-filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

English
Replace fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Clean the heat exchanger (radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Change air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Replacing the blow-by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Change the ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Visually inspect turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Visual inspection of the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Replace engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Change Supply Module main-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Move the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Disposal of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4 LONG PERIOD OF INACTIVITY

Preparing the engine for long periods of inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Start the engine after a long period of inactivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5 ENGINE MALFUNCTIONS
Engine fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
In the event of a fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

6 BEHAVIOUR IN EMERGENCY
For personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
SAE classification of oils in relation to the ambient temperatures of use of the engine/vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1 - GENERAL INFORMATION

English
INTRODUCTION The use of non-original spare parts not only invalidates the warranty, but
also means that FPT cannot be held responsible in any way during the
We would like to thank you for buying an FPT product, and compliment entire life cycle of the engine.
you on your choice of engine.
Before you carry out any operation involving the engine or its fittings,
please read the contents of this manual carefully; compliance with the in-
Liability
structions provided in the manual is the best way to guarantee trouble-free, The Manufacturer's responsibility is subordinate to the performance of the
long term operation of the engine. check and maintenance operations specified and described in this man-
ual; their performance must be demonstrated for this purpose. Any neces-
The contents of this manual refer to the standard configuration of the en-
sary extra-plan maintenance operations must be carried out by qualified
gine, and the illustrations are purely indicative.
FPT Network Workshop personnel, using the specifically provided instru-
Some instructions are provided by giving the sequence of operations to
ments and equipment.
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 Safety
installed; for any points that differ from the contents of this manual, please
consult the instructions provided by the machine Manufacturer or a spe- The following information is intended to encourage caution when using
cific manual. the engine, so as to avoid damage to persons or property as a result of
The information provided below was current at the date of publication. improper or incorrect behaviour.
The Manufacturer reserves the right to make modifications at any time
without prior notice, for technical or commercial reasons or to update the • The engines must only be used for the purposes declared by the Man-
ufacturer.
engines to comply with legal requirements in the various Countries.
The Manufacturer declines all liability for any errors or omissions. • Any tampering, modifications and use of non-original spare parts com-
promises the correct and safe operation of the engine; modifying the
Please remember that the FPT Technical Service Network is available to wiring and units in the engine or connecting them to other power supply
offer you its experience and professional skills, wherever you may be. systems is strictly prohibited.
• Pay particular attention to the moving parts of the engine, components
Guarantee that are at high temperatures and circuits containing pressurised fluids;
electrical currents pass through their electrical components and there-
For the engine to perform at its best and to be covered by the FPT war- fore they are live.
ranty, pay close attention to the instructions provided in this manual; failure
to observe the instructions could invalidate the warranty. • Engine exhaust fumes pose a health risk.
• The engine must be handled using a suitable hoist and lifting hooks
Spare parts specifically inserted on the engine.

Always use original FPT spare parts. This will enable the engine to run as
efficiently as it did originally.
5
• The engine must not be started or used if the electronic assembly in With regard to safety, other recommendations are provided in the IN-
which it is installed does not meet all the safety requirements, or if the SPECTION AND MAINTENANCE section.
electronic assembly does not comply with local regulations and laws.
• The work required to preserve the engine and guarantee that it per- Safety warnings symbols
forms at its best must only be carried out by people with proven expe-
rience and tools that FPT consider to be suitable. 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.

Risk of serious damage to the engine:

the partial or total non-observance of these instructions could cause serious damage to the engine and may nullify
the warranty.

General risk:
combines the risks of both the signs described above.

Safeguarding the environment:

indicates the correct behaviour so that vehicle use is as environmentally friendly as possible.

Technical data Code F34SE1W

Engine family F5
The technical code and serial number are indicated on a plate, which is
located on different parts of the engine, according to the model: flywheel Cycle Diesel 4-stroke
casing, tappet cover, other.
Number and arrangement of
4, in line
cylinders
6
 Code F34SE1W Type of engine (*) Power and Torque

English
Bore x stroke 99 mm x 110 mm CV) at 1800 RPM
93 kW ( 126 CV
F5BFL415A*B001
510 N·m ( 52 kgm at 1500 RPM
Total displacement 3400 cm³
F5BFL415B*B001 CV) at 2200 RPM
73 kW ( 99 CV
Pneumatic system Turbocharged - with Intercooler
430 N·m ( 44 kgm at 1400 RPM
Injection type Direct - Common Rail system
Compression ratio 17 : 1 (*) Net power to the flywheel in compliance with ISO 8528.
Cooling Liquid based
General prescriptions
Anticlockwise (seen from flywheel It is strictly prohibited to modify the characteristics indicated
Engine direction of rotation
side) above. If modifications are made, the warranty is invalidated
Dry weight - kg and FPT is in no way responsible.
Failure to comply completely or partially with these require-
ments may result in the risk of serious damage to the engine
Electric system and may even, on occasion, invalidate the warranty
Alternator
- Rated current 120 A
Electric starter motor
- Nominal power 4.2 kW

7
External view
1. EGR valve
2. lifting eyelets
3. Engine wiring
4. Fuel filter
5. Oil filter
6. Oil dipstick
7. Oil sump
8. Oil filling cap
9. Injection Pump
10. Engine control unit

NOTE: The engine lifting eyelets are sized to move the engine only. It is parts which make up the genset, for example, three-phase/single-phase
strictly prohibited to use these eyelets to lift the engine together with other electric machines, base, etc.

8
1. Turbocharger air outlet

English
2. Throttle body
3. Turbocharger
4. Alternator
5. Oil sump
6. Starter motor
7. Exhaust manifold
8. DOC+EGR
9. EGR heat exchanger

9
1. Throttle body
2. Lifting eyelet
3. Engine control unit
4. Blow-by filter
5. Auxiliary members' belt
6. Crankshaft pulley
7. Water pump
8. Radiator outlet pipe
9. Alternator
10. Radiator inlet pipe

NOTE: The engine lifting eyelets are sized to move the engine only. It is
strictly prohibited to use these eyelets to lift the engine together with other
parts which make up the installation.

10
1. Turbocharger

English
2. DOC+SCR
3. Alternator
4. Starter motor
5. Flywheel
6. Oil filter
7. Fuel filter

NOTE: The engine lifting eyelets are sized to move the engine only. It is
strictly prohibited to use these eyelets to lift the engine together with other
parts which make up the installation.

11
Identification plate
1. FPT code
2. FPT code and bar code
3. Client Code with engine registration number
4. Client Code with date of manufacture (mm/yy)
5. Space for bar code
6. Engine serial number
7. Month and year of manufacture
8. Engine theoretical code
9. FPT code

12
Signs NOTE: Labels containing an exclamation mark highlight a potential dan-

English
ger.
Some warning labels (below the description) are affixed to the engine.

Risk of burns:
Lifting point (only the engine).
Expulsion of pressurised hot water.

Fuel filling cap Risk of burns:

(on the tank, if present). Presence of parts at high temperature.

Risk of fire:
Lubricant oil filling cap.
Presence of fuel.

Risk of injury
Lubricant oil level dipstick. from moving parts:
Presence of fans, pulleys, belts or other.

13
2 - USE
Preliminary checks

Each time before starting the engine:

• Check and top up the level of the technical fluids, if necessary (fuel,
engine oil and coolant).
• Make sure that the exhaust gas systems is efficient and that the in-
take air filter(s) is/are not clogged.
• Make sure that the batteries are efficient and that the terminals are
correctly connected.

General prescriptions
If frequent top-ups are necessary, the cooling circuit must be di-
agnosed.
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

NOTE: The maintenance procedures are found instead in the CHECKS AND
MAINTENANCE section.

General prescriptions
Make sure there are no vapours of fuel or gas in the engine area.
Check that all the areas are suitably ventilated and equipped with
a suitable extraction system.
Failure to comply with these prescriptions can result in the risk of
serious injury and serious damages to the vehicle

14
For proper use of the engine Risk of burns

English
When the engine is hot, pressure builds up in the cooling
• Before starting the engine each time, check that the tank contains a
circuits which may eject hot liquid violently, resulting in a risk
sufficient amount of fuel.
of burns.
• Avoid prolonging the duration of the start control. Failure to comply with these prescriptions can result in the
• Follow the indications provided in the maintenance schedule. risk of serious injury and serious damages to the vehicle

• During use, check periodically that:

○ The temperature of the engine coolant does not reach the alarm Risk of burns
thresholds; Open the filler cap of the coolant tank only if necessary and
only when the engine is cold.
○ The oil pressure remains within the expected normal values;
Failure to comply with these prescriptions can result in the
• The speed and power values must comply with indications specified in risk of serious injury and serious damages to the vehicle
the technical-commercial documentation.
• Particular attention must be paid to engines that equip the emergency If the temperature is too high, reduce the speed and turn it off to check the
generator sets for which frequent efficiency checks are required in order
status of the cooling system circuit.
to ensure they start promptly whenever required.
Check the following:
General prescriptions A. the tension of the drive belt for the ancillary components;
If using in extremely dusty environments and on the basis of
the final configuration of the B. the efficiency of the thermostatic valve;
current generator, soundproofed or without sound-proof cas- C. the heat exchanger conditions (clean if necessary).
ing, suitable protections are required for most sensitive com-
ponents. Lubrication circuit
Failure to comply completely or partially with these require-
ments may result in the risk of serious damage to the engine Regularly check that the oil pressure remains within the expected normal
and may even, on occasion, invalidate the warranty values. If the value is too low, check the oil level and refill if necessary
following the indications provided in the CHECKS AND MAINTENANCE
section.
Special warnings
If the conditions persist, contact the authorised service centre.
Coolant circuit
Fuel circuit
When the engine is running, regularly check that the temperature of the
engine coolant does not reach the warning threshold. Avoid using the engine when there is little fuel reserve in the tank. This
results in an increase in vapour condensation and means that the engine
If the temperature detected is too high, disconnect the load and turn the is more likely to breathe in dirt or air, causing the engine to stop.
engine off to check the status of the cooling circuit.
15
 start--up system
Electric start
Contamination, fire
When refuelling, always make sure that no solid or liquid
Periodically check that the batteries are clean and efficient, particularly
pollutants enter the fuel tank; remember that it is prohibited
during winter, as indicated in the CHECKS AND MAINTENANCE section.
to smoke or use naked flames when refuelling.
Recharge if necessary.
Failure to comply with these prescriptions can result in the
risk of serious injury and serious damages to the vehicle
General prescriptions
Contact a specialised workshop to have the battery and
Risk of burns charging system checked if the voltmeter shows a voltage
Never loosen the high pressure fuel circuit connectors. of less than 11 V (for 12 V systems).
Failure to comply with these prescriptions can result in the Failure to comply completely or partially with these require-
risk of serious injury and serious damages to the vehicle ments may result in the risk of serious damage to the engine
and may even, on occasion, invalidate the warranty

Exhaust gas and air intake circuits

Risk of skin irritation or allergic reactions
Regularly check the cleanliness of the air intake circuit. The maintenance The batteries contain an acid solution that will burn the skin
intervals in the manual vary depending on the conditions of use of the and corrode clothing; when checking them, always wear pro-
engine. tective clothing, gloves and goggles.
Failure to comply with these prescriptions can result in the
In particularly dusty environments, maintenance intervals must be carried risk of serious injury
out more frequently than indicated in the CHECKS AND MAINTENANCE
section.
Risk of skin irritation or allergic reactions
Risk of burns The batteries contain an acid solution that will burn the skin
Visually check that the exhaust circuit is not clogged or dam- and corrode clothing; when checking them, do not smoke or
aged, to prevent hazardous or toxic emissions inside the use live flames in the vicinity, and make sure that the room
pipes. they are housed in is adequately ventilated.
Failure to comply with these prescriptions can result in the Failure to comply with these prescriptions can result in the
risk of serious injury and serious damages to the vehicle risk of serious injury

ATS system
Running in
This system is used to maintain the nitrogen oxide (NOx) emissions in
the exhaust within the limits required by standards, transforming the nitro- Thanks to the new engine technology, no running-in is required.
gen oxide into inert compounds: nitrogen (N2) and water vapour (H2O).
Regularly clean the filters at the intervals specified in the CHECKS AND
MAINTENANCE section.
16
3 - INSPECTION AND MAINTENANCE

English
Maintenance personnel
The engine control and maintenance operations described in the following
chapter require training, experience and compliance with current safety reg-
ulations. For this reason, the following operations must be carried out by
special technicians.

Checks in periods of use:

by workshop personnel or if necessary by the genset operator.
Periodic maintenance:
by qualified personnel using suitable equipment and adequate
means of protection.
Extraordinary maintenance:
by qualified personnel from Authorised Service Centres who
have detailed technical information and specific equipment.

The most qualified Service Centres are those included in the FPT Tech- • Mask with respirator and filter, compliant with current regulations, on
nical Service Network. the basis of the solvents used and their product safety sheets.
• All the maintenance operations are to be carried out with the engine off
Accident prevention and after having checked that the temperature of the engine surfaces
°C.
do not exceed 40 °C
• Always wear safety footwear, gloves and suits.
• Wear a protective helmet if working in an area with suspended loads
• Do not wear loose clothing, rings, bracelets and/or necklaces near the or overhead systems.
engines or moving parts.
• Use protective creams for hands.
• Wear protective gloves and goggles while:
• Immediately replace wet gloves.
○ filling the batteries with acid solution
• Always keep the engine clean, removing spots of oil, diesel and coolant.
○ cleaning clamps and battery terminals
• Return oily rags to fire-proof containers.
○ filling up with anti-corrosion and antifreeze fluids
• Do not leave foreign objects on the engine.
○ changing or filling the lubricant oil (hot engine oil can cause burns.
It is recommended to perform these operations only when their tem- • On the basis of the safety sheets of the products handled, use PPE
perature is lower than 40 °C°C). which is suitable for the aforementioned substances and compliant with
current regulations.
○ the use of compressed air and/or pressurised steam jets.

17
• Use containers which are compliant with environmental and safety Risk of injury:
standards in force for the collection of spent liquids and fluids. While carrying out checks and maintenance operations,
strictly observe the requirements indicated by the Manufac-
At the end of the maintenance interventions, make sure that all parts
turer of the power generator and installer of the electricity
which have been removed are correctly refitted. Before starting the
generation system, to ensure maximum safety for mainte-
engine:
nance personnel.
• restore all safety protections which were previously removed; Failure to comply with these prescriptions can result in the
• check that no tools, equipment or other generic items used during main- risk of serious injury
tenance have been left on the engine and/or in the engine compart-
ment;
Refilling
• Make sure that all necessary precautions are taken allowing the engine
to be switched off immediately if it begins to malfunction. Parts to be refilled litres (kg)
These operations must be carried out by competent personnel, certified Cooling circuit (1) –
according to current regulations in force in the country of use of the unit -
Lubrication circuit (2)
and which differ depending on the type of connection to the distribution -
Total capacity (3)
network.
Periodic changes: engine
sump at minimum level kg)
6 L ( 5.28 kg
Risk of injury:
Sump at maximum level kg)
8 L ( 7.04 kg
Do not carry out maintenance interventions with the power
supply active: always check equipment grounding. During Fuel tank (4) —
diagnostics and maintenance, make sure that your hands
and feet are dry and if possible use isolating supports.
50%
(1) Use a mix of 50 % purified water and organic coolant – FULL - OAT
Failure to comply with these prescriptions can result in the
(Organic Acid Technology).
risk of serious injury
3-20
(2) For the oil specifications, refer to the table of the oils (3 20).

Risk of electrocution (3) The amounts indicated refer only to the first fill of the engine, oil sump
Before carrying out any maintenance, set the selector to and filter.
OFF and disconnect the battery. This will prevent the emer-
gency genset from activating unexpectedly. (4) Fuel tank not supplied by FPT. Refer to the data supplied by the sup-
Failure to comply with these prescriptions can result in the plier/manufacturer of the genset. Only use fuel which meets the require-
risk of serious injury ments of international standards ASTM D975 or EN 590. The Manufac-
turer of the genset is responsible for any information regarding fuel tank
capacity as it is subject to variations based on the configuration of the gen
set itself.

18
The quantities indicated refer to the total capacity of the G-Drive including

English
the capacity of the engine, radiator and pipes.

19
Main characteristics of oil
Oil Specifications (*) International specifications
10W--40 API CJ
10W CJ--4 / API CK
CK--4 ACEA E9
(FPI9.LUBR001--TLS CK4) (STD.)
(FPI9.LUBR001
10W--40 API CK
10W CK--4 /ACEA E9
309
(FPI9.LUBR001--TLS CK4) (STD.)
(FPI9.LUBR001
0W--40 API CK
0W CK--4 (FPI9.LUBR001
(FPI9.LUBR001--TLS
CC) (COLD CLIM. PREM.)

(*) For the oil specifications, please refer to https://www.fptindus-

trial.com/global/en/service/fluids/oils-and-coolants

20
Coolant fluid filling Refuelling

English
For the initial engine start-up and in the cases in which the refilling of Only use diesel that complies with the ASTM D975 or EN 590 standard
the cooling circuit is required with a considerable quantity of coolant, and which is generally commercially available. Fuel additives are not rec-
proceed as follows: ommended.
• Refill the engine and the exchanger until the exchanger is completely The use of additives can limit the warranty services offered for the equip-
filled. ment.
• With the coolant filler cap open, start the engine and let it idle for approx.
min. This helps to completely blowing off the air contained in the
1 min Risk of burns
cooling circuit. Pay maximum attention when refuelling, making sure that
• Stop the engine and then top up with coolant if necessary. solid or liquid pollutants
do not enter the tank; please remember that smoking is pro-
hibited while
General prescriptions
refuelling.
The failure to observe the aforesaid procedure does not
Failure to comply with these prescriptions can result in the
guarantee the presence of the correct quantity of coolant in
risk of serious injury and serious damages to the vehicle
the engine.
Failure to comply completely or partially with these require-
ments may result in the risk of serious damage to the engine Winter diesel
and may even, on occasion, invalidate the warranty
The degree of fluidity of the diesel oil can may be reduced at low tem-
peratures due to the separation of the paraffin. This results in the filters
Risk of burns becoming clogged.
When the engine is hot, pressure builds up in the cooling
circuits which may eject hot liquid violently, resulting in a risk The ASTM D975 or EN590 specifications distinguish different classes of
of burns. diesel fuel, identifying the characteristics of those that are best adapted to
Failure to comply with these prescriptions can result in the low temperatures.
risk of serious injury and serious damages to the vehicle
Oil companies must respect these standards, which provide for the dis-
tribution of fuels adapted to the climatic and geographical conditions in
various countries.
Risk of burns
Open the filler cap of the coolant tank only if necessary and
only when the engine is cold.
Failure to comply with these prescriptions can result in the
risk of serious injury and serious damages to the vehicle

21
Programmed maintenance
Extraordinary maintenance Frequency
The frequencies indicated below take into account factors of different en-
gine uses; the most suitable duration of the maintenance intervals for Auxiliary members' belt replacement 3000 h
the different applications will be indicated by the maintenance personnel
based on the use and operating conditions of the engine. Visually inspect turbocharger 1200 h
Visual inspection of the alternator 3600 h
Checks in periods of use Frequency Engine coolant replacement 3000 h (2)

Check for water in the fuel pre-filter Daily (*) Component not supplied by FPT
(*)
1. Maximum period relating to the use of high quality fuel (specification
Engine lubricant Oil level check Daily ASTM D975 or EN 590); this is reduced in the event of fuel contamina-
Engine coolant level check Daily tion and alarm signals caused by filter clogging and/or the presence of
water in the pre-filter. The filter clogging signal indicates that the filter
must be replaced. If the warning light of water present in the pre-filter
Scheduled maintenance Frequency does not go off after drainage, then the pre-filter must be replaced.
2. The frequency is a function of the environmental conditions and prod-
Check tension and conditions of 600 h uct wear/efficiency. After long periods of inactivity of the engine, carry
auxiliary parts belt out the checks before starting the engine. If the warning signal is given
indicating that the filter is clogged, the filter must be replaced.
Change engine lubricant oil 600 h (2) (3)
3. 3-20
For the oil specifications, refer to the table of the oils (3 20).
Replace lubricant oil filter 600 h (2) (3)
Change fuel pre-filter (*) 600 h (1) General prescriptions
Replace fuel filter 600 h (1) If using fuels with a sulphur percentage greater than 0.5%,
the intervals for changing the engine oil, engine oil filter and
Heat exchanger (radiator) cleaning 600 h blow-by filter must be halved or suitably modified; please
(*) refer to the FPT Service Network for support.
Air filter replacement (*) 1200 h (2) Failure to comply completely or partially with these require-
ments may result in the risk of serious damage to the engine
Replace blow-by filter 1800 h and may even, on occasion, invalidate the warranty

22
General prescriptions Scheduled maintenance for the ATS

English
Action
The operations indicated above require the use of specific system
equipment which will guarantee that the result is safe, ef-
fective and of a good quality. It is recommended that these Supply module main filter Replace every
operations are carried out by qualified personnel belonging 3000 h or 2 years
to the FPT Service Network. (whichever occurs
Failure to comply completely or partially with these require- first)
ments may result in the risk of serious damage to the engine
and may even, on occasion, invalidate the warranty

23
Location of the ATS system filters
1. Main Supply Module pump
2. μm)
Supply Module main filter ( 30 μm
3. Pressure sensor
4. μm)
Supply Module backflow-filter ( 103 μm
5. μm)
Dosing injector filter ( 36 μm
6. Dosing Module
7. AdBlue tank
8. μm)
Supply Module pre-filter ( 70 μm
9. μm)
Tank pre-filter ( 100 μm
10. Supply Module
11. μm)
Supply Module inlet filter ( 103 μm
12. Recirculation pump

24
Requirements • Electrically disconnect the battery/batteries before performing any elec-

English
trical work.
• Do not disconnect the battery supply while the engine is running.
• Contact the Manufacturer before installing any electronic equipment.
• Do not perform arc welding near the engine without first removing its
electrical wiring.
General prescriptions
• After performing all maintenance operations that require disconnection Do not carry out operations which could change the calibra-
of the batteries, make sure the clamps have been securely reconnected tion of the injection pumps. Calibration of the injection pump
on the poles. has been carried out during the engine system tests on the
basis of use and final destination.
• Do not use a battery charger to start the engine.
Failure to comply completely or partially with these require-
• Electrically disconnect the battery/ies from the network during charging. ments may result in the risk of serious damage to the engine
• Do not paint the devices, components and electrical connectors of the and may even, on occasion, invalidate the warranty
engine equipment.

25
 pre--filter
Water in the fuel pre
pre--filter
Water drainage from the fuel pre
Due to the high risk of refuelling with fuel polluted with foreign agents
and water, the following check should be performed at each refuelling.
Proceed with the engine off.

• (2).
Place a container for collecting liquids under the pre-filter (2)
• Unscrew the valve plug (1) located at the bottom of the filter; in some
fittings the plug includes the fuel water sensor.
• Drain the liquid until only "diesel" can be seen.
• Fully re-tighten the plug manually.
• Dispose of the drained fluids according to current requirements.

General prescriptions
Clean the oil cap before performing the operation so as to mini-
mize the risk of contaminating the system.
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

26
Check engine lubricant oil level

English
Hazard warning
Before starting, make sure you have suitable PPE (gloves, shoes,
glasses, overalls).
Failure to comply with these prescriptions can result in the risk of
serious injury

Only proceed with the engine stopped and at a low temperature, so as

to avoid the risk of burning.

• Take all the necessary precautions to ensure that the vehicle is on a

level surface.
• Remove the dipstick (1) and check that the oil level is between the
"MIN" and "MAX" limits.
• If it is difficult to assess the oil level, clean the dipstick (1) with a clean
cloth and insert it fully into its seat (2) (2). Remove the dipstick (1) and
check the level.

27
 • If the level is too low, top-up with the specified oil as indicated in the
table 3-18
• (2).
Unscrew the plug (1) and introduce oil through the filler (2)
• Use the dipstick (3) to check that the oil does not exceed the "MAX"
level.

General prescriptions
Clean the oil cap before performing the operation so as to mini-
mize the risk of contaminating the system.
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 damage
Make sure that the dipstick is inserted completely and that the oil
filler cap is completely tightened in a clockwise direction.
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

28
Check coolant level does not saturate the internal volume of the exchanger in order to enable

English
any increase in volume of the fluid caused by the temperature increase.
Only proceed when the engine is not running and is at low temperature
in order to avoid the risk of burns.
Risk of burns
• Remove the pressurisation cap of the expansion tank When the engine is hot, pressure builds up in the cooling
circuits which may eject hot liquid violently, resulting in a risk
• When the engine is cold, make sure that the level of the fluid in the
expansion tank is above the minimum level. of burns.
Failure to comply with these prescriptions can result in the
• Top-up the tank if necessary according to the indications provided in risk of serious injury and serious damages to the vehicle
REFILLING on the page 3-18

General prescriptions Risk of burns

If refilling is required frequently, cooling circuit Open the filler cap of the coolant tank only if necessary and
diagnostics need to be carried out. only when the engine is cold.
Failure to comply completely or partially with these require- Failure to comply with these prescriptions can result in the
ments may result in the risk of serious damage to the engine risk of serious injury and serious damages to the vehicle
and may even, on occasion, invalidate the warranty

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

29
Check tension and condition of ancillary belt

Hazard warning
Before starting, make sure you have suitable PPE (gloves,
shoes, glasses, overalls).
Failure to comply with these prescriptions can result in the
risk of serious injury

• Wait for at least 15 minutes with the engine running at idle. Then with
the engine off and the belt temperature stabilised at 23 +/- 5 °C °C, use
a suitable tool to check the tension of the auxiliary unit drive belt. The
correct static tension of the auxiliary drive belt (4) must fall within the
range indicated below:

30
 • Use a suitable tool to check the tension of the auxiliary unit drive belt.

English
The correct static tension of the auxiliary drive belt (4) must fall within
the range indicated below:
• Static voltage (Value measured (N/rib/spam) / Control frequency (Hz)
@ 23 +/- 5 °C )
Minimum (57/100)
Nominal (75/115)
Maximum (93/132)
• If necessary, regulate the tension of the belt (4) as described below.
• Loosen the bolt (5) anchoring the alternator to its lower mount and
the screw (3) fastening the tensioning bracket to the crankcase.
• Proceed with tensioning the auxiliary drive belt (4) by tightening the
adjustment screw (7) until the tensioning bracket (2) reaches the po-
sition of maximum adjustment extension available, as shown in the
figure
• Fully rotate the crankshaft twice to ensure that the ancillary drive belt
(4) has settled.
• Tighten the screw (3) fastening the tensioning bracket (2) to the
crankcase to a torque of 50 N·m ± 5
• Tighten the bolt (5) anchoring the alternator to its lower mount to a
torque of 41 N·m ± 5.
• Turn the adjustment screw (7) two full turns anti-clockwise, then
tighten the relative locking nut (1) to a torque of 20 N·m ± 3

NOTE: The static tension of the belt is measured in the intermediate point (A) of the branch between the crankshaft pulley and the fan drive pulley.
• Fit the protective grille correctly inserting the anti-vibration plugs.
Tighten the fastening screws .

31
Change engine lubricant oil

Hazard warning
Before starting, make sure you have suitable PPE (gloves,
shoes, glasses, overalls).
Failure to comply with these prescriptions can result in the
risk of serious injury

Only proceed when the engine is not running and is at low temperature
in order to avoid the risk of burns.
• Place a suitable container for catching oil below the engine lubricant
(4).
oil drain plug (4)
• In order to facilitate engine lubricant oil drainage, remove the oil dip-
(1).
stick (2) and remove the engine lubricant oil filler plug (1)
• Drain the engine lubricant oil by removing the plug (3) from the oil
sump.
• Wait for the oil sump (5) to drain completely then screw on the oil
(4).
drain plug (3) again together with a new gasket (4)
• Top-up through the filler pipe (6) using lubricant oil compliant with the
indications on the page 3-18 .
• Use the dipstick (2) to check that the level of engine lubricant oil does
not exceed the "Max" limit.
• If it is difficult to read the level, clean the dipstick using a thread-free
cloth and replace the dipstick (2) in its seat. Remove it again and
check the level.
• (1).
Insert the dipstick and close the lubricant filler cap (1)

32
 English
General risk, general prescriptions
Eliminate the consumables and any materials in contact with them
(for example, filters) in accordance with current regulations.The
FPT Technical Service Network workshops are equipped for this
purpose.
Correct behavior will ensure that vehicle is used as environmen-
tally friendly as possible

Change engine lubricant oil filter

Hazard warning
Before starting, make sure you have suitable PPE (gloves, shoes,
glasses, overalls).
Failure to comply with these prescriptions can result in the risk of
serious injury

The filter must also be replaced when the lubricant oil is changed.

Only use filters with a filtering degree equal to the original filter (see the
MAINTENANCE SCHEDULE on the page 3-22 22).

Only proceed when the engine is not running and is at low temperature
in order to avoid the risk of burns.

33
 • Disconnect the connector (3) for the engine cable from the low oil
pressure sensor (2)
• (1).
Position a container to collect the used oil below the filter mount (1)
• Remove the low oil pressure sensor (2) from the filter mount (1)

• Use the specific tool to unscrew and remove the oil filter (3) from the
(2).
filter mount (1) and recover the gasket (2)
• (2).
Replace the oil filter (3) and the gasket (2)
• Carefully clean the surfaces of the support that are in contact with
(2).
the gasket (2)
• Moisten the gasket (2) with a thin layer of oil and place it in its seat
(3).
on the oil filter (3)
• Manually tighten the oil filter (3) on the mount (1) until fit up against
(2).
the gasket (2)
• Using the specific tool, tighten the oil filter (3) further to a torque of
18 N·m ± 2
• Operate the engine for a few minutes and then check the level using
the dipstick. If necessary, top up to compensate for the quantity of
oil used to fill up the filtering cartridge.
• Fit the oil low pressure sensor onto the filter support and connect the
engine cable connector to the oil low pressure sensor.

34
 English
Risk of injury:
Given the high operating temperature of the engine, it is recom-
mended that suitable protection is worn. The engine oil reaches
extremely high temperatures: always wear protective gloves.
Failure to comply with these prescriptions can result in the risk of
serious injury

Risk of skin irritation or allergic reactions

The engine oil is highly pollutant and harmful.
In case of contact with skin, wash thoroughly with water and de-
tergent.
Suitably protect skin and eyes; take measures as set forth by
safety regulations.
Failure to comply with these prescriptions can result in the risk of
serious injury

General prescriptions
For correct engine operation, only use recommended oils or oils
with the required characteristics. In the case of refilling, do not
mix oils with different characteristics. Failure to observe these
indications will void the guarantee.
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

General risk, general prescriptions

Eliminate the consumables and any materials in contact with them
(for example, filters) in accordance with current regulations.The
FPT Technical Service Network workshops are equipped for this
purpose.
Correct behavior will ensure that vehicle is used as environmen-
tally friendly as possible

35
 pre--filter
Change fuel pre
Component not supplied by FPT.

36
Replace fuel filter

English
Hazard warning
Before starting, make sure you have suitable PPE (gloves,
shoes, glasses, overalls).
Failure to comply with these prescriptions can result in the
risk of serious injury

Only proceed when the engine is not running and is at low temperature
in order to avoid the risk of burns.
• (2).
Position a container to collect the diesel below the fuel filter (2)
• Unscrew and remove the fuel filter (2) from the relative filter bracket
(1) and recover the gasket .
• Replace the fuel filter (2) and the gasket .
• Moisten the gasket of the fuel filter (2) with a thin layer of engine oil.
• Manually tighten the fuel filter (2) on the bracket (1) until it makes
contact with the gasket.
• Using the specific tool, further tighten the oil filter (2) to a torque of
20 N·m ± 3
• After replacing the fuel filter (2) there may be oil bubbles in the fuel
circuit.
• Bleed the residual air from the fuel filter (2) by loosening the breather
screw (3) and connecting it to a suitable container with a transparent
flexible pipe.
• Start the manual fuel pre-filter pump until the fuel leaving the breather
screw is completely free of air bubbles.
• (3).
Tighten the breather screw (3)
• Start the engine and let it run idle for a few minutes to remove any
residual air.

37
 Risk of injury:
During this operation, do not smoke or use naked flames. Do not
breathe in vapours from the filter.
Failure to comply with these prescriptions can result in the risk of
serious injury

General prescriptions
Do not fill the new fuel filter until it has been positioned on the
support, to prevent any damaging impurities from entering the
fuel circuit and injection system.
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

General risk, general prescriptions

Eliminate the consumables and any materials in contact with them
(for example, filters) in accordance with current regulations.The
FPT Technical Service Network workshops are equipped for this
purpose.
Correct behavior will ensure that vehicle is used as environmen-
tally friendly as possible

38
Clean the heat exchanger (radiator)

English
Component not supplied by FPT

Hazard warning
Before starting, make sure you have suitable PPE (gloves, shoes,
glasses, overalls).
Failure to comply with these prescriptions can result in the risk of
serious injury

The surfaces of the heat exchanger (radiator) come into contact with
external air and may be subjected to deposits and impurities. Clean them
if necessary using compressed air or steam.

39
Change air filter
Component not supplied by FPT

Hazard warning
Before starting, make sure you have suitable PPE (gloves, shoes,
glasses, overalls).
Failure to comply with these prescriptions can result in the risk of
serious injury

Only proceed when the engine is not running.

• (1).
Remove the air filter cover (1)
• (2); during this operation, take care to ensure that
Remove the filter (2)
no dust enters the sleeve.
• Position the filter (2) in its seat.
• (1).
Fit the air filter (2) cover (1)

NOTE: Make sure the parts are fitted correctly. Incorrect assembly can cause the engine take in
unfiltered air causing serious damage to the engine.
Failure to observe these indications, fully or in part, can cause serious damage to the engine and can also invalidate the warranty where applicable

40
 blow--by filter
Replacing the blow

English
Hazard warning
Before starting, make sure you have suitable PPE (gloves, shoes,
glasses, overalls).
Failure to comply with these prescriptions can result in the risk of
serious injury

The blow-by filter was devised and designed for collecting, filtering and
condensing lubricant oil vapours.
Only proceed with the engine stopped and at a low temperature, so as
to avoid the risk of burning.
Use a suitable container to collect the oil.

• (1).
Undo the nut (1)
• (3).
Disconnect the coupling (3)
• (2).
Remove the vapour recirculation pipe (2)

41
 • Unscrew the nuts (6) and remove the cover (5) of the blow-by filter,
together with the diaphragm valve and breather pipe.
• Release the safety circlip (4) and remove the blow-by (1) filter from
(2).
the threaded bush (3) and spindle (2)
• Replace and install the new blow-by filter (1) on the spindle (2) with
(4).
the threaded bushing (3) and secure it with the flexible circlip (4)
• Fit the cover (5) of the blow-by filter with the diaphragm valve and
breather pipe. Tighten the nuts (6) to a torque of 10 N·m ± 1 Nm
• Fit the oil vapour recirculation pipe, connect the relative fittings and
screw on the nut.

42
Change the ancillary belt

English
Hazard warning
Before starting, make sure you have suitable PPE (gloves, shoes,
glasses, overalls).
Failure to comply with these prescriptions can result in the risk of
serious injury

Only proceed when the engine is not turning and is at low temperature
so as not to run the risk of burns.

• Loosen the bolt (5) anchoring the alternator to its lower mount and
the screw (3) fastening the tensioning bracket to the crankcase.
• Loosen the locking nut (1) and unscrew the screw (7) adjusting the
tensioning bracket (2) to loosen and remove the auxiliary drive belt
(4).
(4)
• Replace the auxiliary drive belt (4) with a new one.
• Make sure that all the components of the pulleys and the guide rollers
are clean and free of wear or damage. If necessary, replace the worn
or damaged components.
• make sure that the pulleys and guide rollers are free of dirt and ac-
cumulations from the old belt.
• Fit the new auxiliary unit drive belt (4) inside the shoulders of all the
pulleys, in the following order: crankshaft pulley, fan drive pulley,
alternator, water pump. Make sure that the belt is centred on all the
pulleys.

43
 • Proceed with tensioning the auxiliary drive belt (4) by tightening the
adjustment screw (7) until the tensioning bracket (2) reaches the po-
sition of maximum adjustment extension available, as shown in the
figure. The correct static tension of the auxiliary unit drive belt (4)
must fall within the range indicated below.
• Static voltage (Value measured (N/rib/spam)
Minimum (57)
Nominal (77)
Maximum (104)
• Fully rotate the crankshaft twice to ensure that the ancillary drive belt
(4) has settled.
• Tighten the screw (3) fastening the tensioning bracket (2) to the
crankcase to a torque of 45 N·m ± 5.
• Tighten the bolt (5) anchoring the alternator to its lower mount to a
torque of 41 N·m ± 5.
• Turn the adjustment screw (7) two full turns anti-clockwise, then
tighten the relative locking nut (1) to a torque of 20 N·m ± 5

Risk of damage
Replace the ancillary belt if there is any sign of abrasion, cracks
or tears, oil or fuel stains.
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 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

44
Visually inspect turbocharger

English
Hazard warning
Before starting, make sure you have suitable PPE (gloves, shoes,
glasses, overalls).
Failure to comply with these prescriptions can result in the risk of
serious injury

Only proceed when the engine is not turning over.

• Check for any cracks on the turbocharger.

• Visually check that the rotors of the turbine (7) and the compressor
(3) and the relative inlet and outlet pipes are not clogged or damaged.
Replace if they are.
• Check that none of the blades are bent or damaged in the rotors of
(3).
the turbine (7) and the compressor (3)
• (1), (6) and carry out a visual in-
Check the tightening of the fittings (1)
spection to check for any oil leaks.
• (1),
In the event of any oil leaks, replace the gaskets of the fittings (1)
(6).
(6)
• Check that there are no deposits of soot between the intake manifold
and the turbocharger. Replace the turbocharger gasket if necessary.
• Check the turbocharger gasket for any signs of rupture or damage
and replace it if necessary.
• Check the wastegate actuator (5) is fully tightened, lubricated and
not deformed.
• Check that the pipes (2) and (4) of the wastegate valve (5) are not
blocked or damaged, otherwise replace them. Carry out a visual
inspection and check for any air leaks.

45
Visual inspection of the alternator

Hazard warning
Before starting, make sure you have suitable PPE (gloves, shoes,
glasses, overalls).
Failure to comply with these prescriptions can result in the risk of
serious injury

Only proceed when the engine is off.

• Visually check that the alternator is not damaged, otherwise replace

it.
• Check there are no unusual noises while the engine is running.
• Check that the alternator fastening bolts are tightened.
• Inspect the battery cable connections on the rear side of the alterna-
tor. Make sure it is clean and tightened.

46
Replace engine coolant coolant does not overfill the internal volume of the exchanger in order

English
to allow the expansion of coolant volume as a result of the temperature
Only proceed when the engine is not running and is at low temperature in increase.
order to avoid the risk of burns.
General prescriptions
• Place a container for collecting coolant under the heat exchanger (ra-
diator). Failure to observe the procedure described above will not
guarantee the presence
• Remove the pressurisation cap from the expansion tank. of the correct quantity of coolant in the engine.
• Loosen the retaining elements and remove the sleeves connecting the Failure to comply completely or partially with these require-
engine cooling circuit to the heat exchanger. ments may result in the risk of serious damage to the engine
and may even, on occasion, invalidate the warranty
• Drain the coolant from the heat exchanger (radiator) and wait until it is
completely empty.
• Once emptied, refit the cooling circuit making sure the sleeves are per- Risk of burns
fectly sealed. When the engine is hot, pressure builds up in the cooling
• Fill the engine and heat exchanger until the cooling circuit is completely circuits which may eject hot liquid violently, resulting in a risk
18. Do not fill the expansion
full, as specified in the table on the page 3-18 of burns.
tank to the brim. Failure to comply with these prescriptions can result in the
risk of serious injury and serious damages to the vehicle
• With the coolant filler cap open, start the engine and let it idle for approx.
one minute. This helps to completely blowing off the air contained in
the cooling circuit.
Risk of burns
• Stop the engine and top up with more coolant, if necessary. Open the filler cap of the coolant tank only if necessary and
only when the engine is cold.
• When the engine is cold, make sure that the coolant in the expansion
tank is a few centimetres below the filling hole. Failure to comply with these prescriptions can result in the
risk of serious injury and serious damages to the vehicle
In the event of an externally located level indicator as regards the heat
exchangers, proceed with the top up operation by making sure that the

47
 main--filter
Change Supply Module main
main--filter
Change Supply Module main

When installing the Supply Module on the vehicle, take into account the
minimum aperture for replacing the filter. The minimum value is approx.
mm.
140,7 mm

48
Removal

English
(1).
• Unscrew and remove the filter cover (1)

49
 (1).
• Remove the equalizing element (1)

(1)into the filter in the correct direction.

• Insert the appropriate 27 mm tool (1)

50
• Insert the appropriate 27 mm tool (1) until a click can be heard indicating

English
that the filter (2) has engaged completely.

51
 (1).
• Remove the filter (1)

52
Assembly

English
(1).
• Carefully clean with water the contact surface (1)

53
 (1).
• Moisten the gasket and fit the new filter (1)

54
 (1).
• Assembly a new equalizing element (1)

English
55
 (1). Tighten the filter cover to a torque of
• Carefully clean the filter cover (1)
N·m.
20 +/- 5 N·m

When installing the Supply Module on the vehicle, take into account the
minimum aperture for replacing the filter. The minimum value is approx.
mm.
140,7 mm

56
Move the engine

English
The operations necessary to disconnect and subsequently reconnect the
engine must be carried out only by technicians from authorised Service
Centres.

Use the lifting eyelets (1) indicated in the figure when moving the engine.

Use a designated hoist, in compliance with the regulations and lifting ca-
pacity suitable for the weight of the engine with the radiator, connecting it
to the lifting eyelets on the engine. Adjust the hoist so that the individual
chains, when taut, do not rotate around the axes when the engine is being
lifted and moved.
NOTE: for further details, please refer to the Service Manual.
NOTE: Do not lift the G-DRIVE unit until all the elements coupled to the
flywheel have been removed.

57
Disposal of waste • Starter batteries.

The engine is composed of parts and elements that, if discarded, could • Used lubricants.
case environmental damage. • Mixtures of water and antifreeze.

The materials listed below must be handed over to specialised Collection • Filters.
Centres; the laws in force in the various countries provide for severe • Additional cleaning materials (e.g. greasy or fuel-soaked cloths).
penalties for lawbreakers:

58
4 - LONG PERIOD OF INACTIVITY

English
Preparing the engine for long periods of inactivity 6. Close all of the engine's intake, discharge, ventilation and bleeder
holes with plugs or seal them with adhesive tape.
In order to prevent oxidation of the engine internal elements and of
7. Drain the residual protective oil from the sump. which can be used
certain components of the injection system, when you intend to keep
for an additional 2 preparations.
the engine stopped for more than two months, carry out the following
preparatory interventions: 8. Place warning notices of ENGINE WITHOUT OIL on the engine and
dashboard.
1. Drain the lubricant oil from the sump after heating the engine.
9. Drain the coolant, if it has not been mixed with appropriate antifreeze
2. Fill the engine with protective oil (compliant with standard MIL-L-
and anti-corrosive fluids, and hand a sign warning about this specific
2160B tipo 2 / ISO 3498/6743-4 HM) until it reaches the "minimum"
operation.
level on the dipstick. Start the engine and let it run at idle for approx.
min.
5 min In the case of prolonged inactivity, repeat these operations every 6
3. Drain the fuel from the injection circuit, from the filter and from the months, according to the following procedure:
injection pump channels. A. drain the protective oil from the sump;
4. Connect the fuel circuit to a tank containing CFBprotective liquid ( B. repeat the operations from point 2 to point 7.
ISO 4113), and introduce the liquid by pressurising the circuit and
min, after excluding the operation
driving the engine for approx. 2 min If you intend to protect the external parts of the engine, spray all non-
of the injection system. The required operation may be completed painted metal parts such as flywheel, pulleys, and other, with protective
by directly polarising terminal 50 of the electric starter motor with fluid (Anticorit), making sure to avoid spraying on belts, connector cables,
positive voltage equal to that of the nominal system voltage, using and electric equipment. Protect the connectors and electric connections
the specifically provided conductor. using VCI spray. Wrap the engine in a VCI bag with hygroscopic salt filled
5. Spray approximately 35 g of protective oil ( 10 g per litre of displace- bags.
ment) in the air intake manifold, during the pressurised filling opera-
tion described in the previous point.

59
Start the engine after a long period of inactivity LONG PERIOD OF INACTIVITY. During the filling operations, con-
nect the tank fuel return pipe to a collection container to prevent the
1. Drain the residual protective oil from the sump. residual CFB protective liquid from flowing into the tank.
2. Fill the engine, as prescribed, with lubricant of the type and amount 6. Check the engine and fill it up with coolant as prescribed.
indicated in the REFILLING table on page 3-18 18.
7. Start the engine and keep it running at the idling speed.
3. Drain the CFB protective fluid from the fuel circuit, acting as indicated
in point 3 of the section entitled PREPARING THE ENGINE FOR A 8. Check that the instruments on the on-board control panel/s are
LONG PERIOD OF INACTIVITY. showing plausible values, and that no alarms are shown.

4. Remove the plugs and/or seals from the engine's intake, discharge, 9. Stop the engine.
ventilation and bleeder holes, restoring normal conditions of use. 10. Remove the "ENGINE WITHOUT OIL" signs from the engine.
Connect the air inlet tube to the air filter.
5. Connect the fuel circuits to the genset fuel tank, completing the oper-
ations as indicated in point 4 of PREPARING THE ENGINE FOR A

60
5 - ENGINE MALFUNCTIONS

English
Engine fault

The electronic control unit which oversees the control and management
of all engine operations is able to recognise a fault and adopt strategies
which allow the vehicle still to be driven safely.

The event, signalled by activation of the EDC MALFUNCTION indicator

light on the on-board control panels, causes the scheduled limitation of
the supply, within certain limits, set according to the seriousness of the
specific case.

In the case of temporary malfunctions the reduction in performance will

remain in force until the engine is stopped.

61
In the event of a fault: General risk, general prescriptions
If these conditions occur, only continue driving if absolutely
Malfunction in the recharging system
necessary and with extreme care.
The electronic engine control units are programmed to increase the speed Failure to comply with these prescriptions can result in the
if the electrical system voltage reaches the values considered at the limit risk of serious injury and serious damages to the vehicle
of efficiency. In that case, check the state of the battery or batteries and
if necessary, have diagnostics performed for the system components.
General risk, general prescriptions
Never leave the engine running idle for long periods of if the
General risk, general prescriptions
generator set is not in operation.
The electronic control unit of the engine adopts safety strate-
Failure to comply with these prescriptions can result in the
gies using the genset once it has verified the conditions
risk of serious injury and serious damages to the vehicle
which could compromise engine integrity.
Failure to comply with these prescriptions can result in the
risk of serious injury and serious damages to the vehicle

62
6 - BEHAVIOUR IN EMERGENCY

English
For personal safety Carbon monoxide (CO) poisoning

The user of the machine, manufactured according to safety regulations, The carbon monoxide contained in the exhaust gas of the engine is dan-
following the instructions given in this manual and assisted by the indica- gerous not only because it causes poisoning but also because it forms an
tions on the engine labels, operates in safe conditions. In the event that explosive mixture with the air. In closed environments, carbon monoxide
incorrect behaviour causes accidents, immediately request the interven- is extremely dangerous as it can reach critical concentration levels in a
tion of personnel specialised in first aid. The following instructions are very short space of time.
provided to assist in the event of an emergency and while awaiting the
arrival of the rescue team. If aiding a poison victim in a closed room:
• Immediately ventilate the room to reduce the concentration of gas.
Engine fault
• When accessing the room, the rescue teams must hold their breath,
If proceeding with the engine in a faulty state, pay maximum attention not light flames, turn on lights or activate electric bells or telephones in
to the manoeuvres and check that any people on-board are secured to order to prevent explosions.
secure grips.
• Bring the poison victim to safety in a ventilated room, or in the open air,
placing the victim on his/her side if unconscious.
Fire
Electrocution
Put out the fire using the designated devices and according to the meth-
ods indicated by the competent authorities (fire suppression equipment The 24V electrical system of the engine does not carry the risk of electro-
for some cars and vehicles has been made mandatory by current safety cution. However, in the event of a short circuit caused, for example, by a
regulations). metal tool, there may be the risk of burns caused by the object overheat-
ing due to conduction of the electric current.
Burns
In that case:
• Put out the flames on the clothing of the burn victim by:
• Remove the object that caused the short circuit using device that pro-
○ flooding with water;
vide sufficient thermal insulation.
○ use of powder extinguishers, without directing the jet towards the
face; • If present, use the main switch to cut off the power supply.

○ covers or rolling the victim on the ground. Injuries and fractures

• Do not remove the shreds of clothing that adhere to the skin; The seriousness of the cases and the specific nature of the interventions
• If the burns are caused by liquids, quickly but carefully remove the cloth- means that medical professionals must intervene.
ing saturated with the hot liquid;
• If the victim is bleeding, compress the injury externally until the rescue
• Cover the burn with an anti-burn pack or with a sterile bandage. team arrives.

63
• If there is a possibility of fractures, do not move the affected part and • Remove the clothing saturated with the caustic substance.
transfer the injured person very carefully and only if absolutely neces-
• Wash thoroughly with running water, without spraying uninvolved parts.
sary.
If the eyes have been affected, either from the battery acid or from the
Corrosion lubricant oil or diesel: wash the eye with water for at least 20 minutes
keeping the eyelids open so that the water flows onto the eyeball (move
Skin corrosion is caused by contact with substances with a high degree
your eye in all directions to help the water move across the whole eye).
of acidity or basicity.

For personnel performing maintenance on electrical devices, this is

typically caused by acid escaping from the batteries. In this case, act
as follows:

64
SAE classification of oils in relation to the ambient

English
engine//vehicle
temperatures of use of the engine
The viscosity index to be used depends on the ambient temperature, as
shown in the figure below:

A. Installation of engine coolant heating system with heater on NOTE: Cold start capabilities are strongly correlated with the quality of the
the crankcase is recommended diesel.

65
66
 English
###_Index_###

A
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

C
Change air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Change engine lubricant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Change engine lubricant oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Change fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Change Supply Module main-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Change the ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Check coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check engine lubricant oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Check tension and condition of ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Clean the heat exchanger (radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Coolant fluid filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

D
Disposal of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

E
Engine fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
External view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

F
For personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
For proper use of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

G
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

I
Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
In the event of a fault: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

L
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Location of the ATS system filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

M
Main characteristics of oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Move the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

P
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preparing the engine for long periods of inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Programmed maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

R
Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replace engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Replace fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Replacing the blow-by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

S
SAE classification of oils in relation to the ambient temperatures of use of the engine/vehicle . . . . . . . . . . . . . . . . . 65
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety warnings symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Start the engine after a long period of inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
 T

English
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

V
Visual inspection of the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Visually inspect turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

W
Water in the fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26