FNM HPE Series User manual

Owner’s Manual
Marine Diesel Engines
HPE Series
HPE 40S/80/80SD/110/110JD
HPE/P 40/150/150JD/170/170JD/190/190JD
HPE/P 100/225/225JD/250/250JD/250H
HPE/P 300
HPEL 45/80/65/90

FNM® HPE Series 1
Table of contents
1 General information 3
1.1 About this manual 5
1.2 Guidance on identification of important information 6
1.3 Notes on FNM® engines servicing 7
1.4 Identification of your engine 9
1.5 General safety regulations 11
1.6 Main components of FNM® engine, HPE Series 15
1.7 Engine delivery 22
2 Using the FNM® engine, HPE series 23
2.1 Analog Instrument Panel 24
2.2 Digital Instrument Panel 27
2.3 First engine starting and sea trial 38
2.4 Engine starting and stopping operations 41
2.5 Throttle 49
2.6 Notes on daily use of the engine 58
3 Maintenance of FNM® engines, HPE Series 60
3.1 General information on maintenance 61
3.2 Periodic organization and frequency of maintenance operations 64
3.3 Details of maintenance operations 68

2 FNM® HPE Series
3.4 Engine treatment and maintenance products 98
3.5 Periods of engine inactivity 101
3.6 Other useful information for maintenance 106
3.7 Specifications of your engine 108
4 Maintenance booklet 129
4.1 Engine Identification Data | Dati identificativi del motore 130
4.2 Ordinary and Extraordinary Maintenance Register | Registro della manutenzione periodica programmata e
straordinaria 131

FNM® HPE Series 3
1General information

4 FNM® HPE Series
Dear customer
Fratelli Negri Motori (hereinafter FNM ) is pleased to thank you for choosing an engine of HPE range.
FNM® engines are designed and developed according to the demand and the needs of customers and builders of
pleasure and work boats.
CMD S.p.A., the company that produces and distributes worldwide the marine diesel engines with the FNM® brand,
offers a wide range of products and models according to each customer's request.
FNM engines ® are known around the world:
- for their performances;
- for their compact structure and outstanding power-to-weight ratio;
- for their long life and low fuel consumption.
This means that, when buying an FNM® engine, you have chosen not only a technologically advanced engine, but
also an engine designed to satisfy the anti-pollution standards and regulations.
Mariano Negri
CEO of CMD S.p.A.
Giorgio Negri
Sales Manager of FNM® brand

FNM® HPE Series 5
1.1 About this manual
This manual is integral part of the engine and is written by the manufacturer to inform the end user of
the procedures necessary for the proper use and maintenance of marine diesel engine FNM, HPE
Series.
Please keep this manual for the entire life of the product so that you always get quick information on
the engine during use.
The manufacturer reserves the right to modify this document without prior notice.
The observance of the installation procedures and routine maintenance in this manual and in the
installation manual ensures compliance at the declared performance at the and gas exhaust emission
and noise parameters for which your engine is approved in accordance with the Directives 2003/44/EC
and EPA/TIER/3.
This manual provides important information on maintenance, operations to be carried out periodically
and handling of your engine.
Before starting your engine, we advise you to read this manual in order to get the information
necessary to operate your engine.
The proper use of the FNM® engine, as well as proper maintenance plan during the period of activity
and inactivity of the engine, ensures its durability and performance.

6 FNM® HPE Series
1.2 Guidance on identification of important information
In the manual you will find a color guide that indicates the degree of importance of information for use
or maintenance of your FNM® engine.
There are three levels of importance:
Danger icon: dangerous situations that may compromise the safety of persons and
engine functionality.
Beware icon: indicates the need to follow the instructions as presented in this manual,
otherwise the engine functionality can be reduced.
Informations: indicates important technical information.
To these are added the environmental information, as indicated below:
Respect the environment, do throw away pollutants
The important information is shown in the rest of this manual with the color for one of these levels, as
shown above.

FNM® HPE Series 7
1.3 Notes on FNM® engines servicing
For your engine service and maintenance always refer to an authorized service centers and to
the FNM®service network. Only by using original spare parts and relying on our specialized staff you
can get the best performances from the engine and ensure a long life.
The FNM®service centers offer low costs and a high degree of specialization. Our service centers
ensure the correct operation of the engine according to all your expectations. Visit our website
www.fnm-marine.com to know the nearest service point.
The reliability of the total propulsion unit is dependent on the quality of the installation. Nearly all the
problems are caused by faults or inaccuracies which occur during the installation. FNM®is not
responsible for damages (engine and/or persons) caused by wrong installation.
Ask your installer the effective compliance of the installation of your engine, as well as a copy of the
installation form, necessary so as the warranty is held invalid for the FNM®service.
If the installer does not transmit the installation form to FNM®this may invalidate the warranty.
To get help on your engine and for warranty information, please feel free to contact FNM®at
[e-mail].

8 FNM® HPE Series
1.3.1 Spare Parts
The exclusive use of FNM®original spare parts is an essential condition for a good maintenance of the
engine. The use of non-original spare parts may cause the warranty to expire and it also exempts the
company CMD S.p.A (owner of the FNM®brand name and logo) from any responsibility.
1.3.2 Responsibility
The responsibility of the Manufacturer is subject to the correct execution of the “Maintenance
Procedures” operations that are described in this manual. For this purpose, it will be necessary to
demonstrate that all the maintenance procedures and operations have been carried out according to
the manual and that, in case of extraordinary maintenance, the procedures and operations have been
carried out by FNM®Service centers.
The information featured in this manual only refer to the engine itself; more specifically, the illustrations
serve as a pure indication and the instructions are described in a purely functional way with the
purpose of providing help and guidance in carrying out the ordinary maintenance. The execution of
such operations may vary based on the configuration of the controls and/or accessories of the boat
where the engine has been installed. The information featured in this manual is correct at the time of
printing. The Engine Manufacturer reserves the right to make modifications without notice at any time
for technical or commercial reasons as well as for the need to abide by new regulations or norms. The
Engine Manufacturer declines any responsibility that may arise from possible mistakes and/or
omissions during the installation.
It is forbidden to alter the characteristics of the engine and in particular the configuration of the control
unit (or ECU box) because such modifications and/or alterations will invalid the warranty and safety
terms.

FNM® HPE Series 9
1.4 Identification of your engine
The ID label is applied on your engine and on the control unit (or ECU box) in the position indicated in
the table below (see also paragraph Main components of FNM®engine, HPE Series on page 15):
Engine
Label location
HPE 40S/80/80SD/110/110JD
On the engine cover.
HPE/P 40/150/150JD/170/170JD/190/190JD
HPE/P 100/225/225JD/250/250JD/250H
On top of the engine, attached to the
intercooler housing.
HPE/P 300
On the cooled exhaust manifold on the right
side of the engine.
HPEL 45
On the engine cover.
HPEL 80
HPEL 65/90
The data on the ID label will include:
- Engine Type
- Engine Family
- Serial No.
- Year of manufacture
- Test speed (Rpm)
- Power in kW (kW)
- Horsepower (HP)
Costruzioni Motori Diesel SpA
Z.I. Valle di Vitalba
85020 Atella (PZ) Italy
Engine Type: HPE110
Engine Family: 13T4L550
Serial N°: 47110XX Year: 2011
Rpm: 4400 kW: 80.88 HP:110

10 FNM® HPE Series
The engine serial number is also printed on the engine block. The position is indicated in the table
below (see also paragraph Main components of FNM®engine, HPE Series on page 15):
Engine
Engine serial number position
HPE 40S/80/80SD/110/110JD
On the crankcase, right side, bell housing connection.
HPE/P 40/150/150JD/170/170JD/190/190JD
HPE/P 100/225/225JD/250/250JD/250H
HPE/P 300
On the crankcase, front side, above the bell housing.
HPEL 45
On the crankcase, right side, bell housing connection.
HPEL 80
HPEL 65/90

FNM® HPE Series 11
1.5 General safety regulations
Read carefully the information contained in this chapter in order to avoid unpleasant incidents.
The manufacturer cannot be held responsible for any damage resulting from misuse of the engine,
from the failure to follow the indications contained in this manual and for every tampering with or
changemadewithoutthemanufacturer’sauthorization.
Do not drive the boat if you consume alcohol or other substances that may alter your
state of attention and reflexes.
- Use the engine only for the tasks authorized by the manufacturer, do not tamper any device to
obtain different performances.
- Consult only technical staff, with experience and specific technical skills. The lack of these
requirementscouldresultindamagetopeople’ssafetyaswellasdamagetotheengine.
- Pay attention to the meaning of the symbols and the labels applied. Keep them visible and
follow the warnings indicated.
- Carry out the engine handling in accordance with the information provided directly on the
engine and on the packaging. During the engine lifting and transportation, use means with
appropriate load capacity.
- During the installation the installer shall follow the manufacturer’s instructions. Do not make
changes to the engine components for any reason!

12 FNM® HPE Series
- Before using the engine for the first time simulate a few trial maneuvers to identify the controls
and their main functions, especially those related to start -stop operations. Do not keep using
the engine if anomalies are detected.
- In case of anomaly, stop immediately the engine or reduce the speed as far as possible. Start
again only when the normal operating conditions are restored.
- Keep the engine and related components in conditions of maximum efficiency and carry out the
maintenance operations established by the manufacturer and repeated in this manual.
- Replace only original spare parts. Use only oil, lubricants and grease recommended by the
manufacturer in accordance with the specifications of this manual.
- Pay attention to the disposal of polluting residues (used oil, diesel fuel, etc.) following the local
legislation and disposal procedures.
- Do not unscrew the expansion tank cap of the cooling system when the engine is hot! Slowly
turn until any steam under pressure comes out, and then remove the cap.
- Do not start the engine without the air filter: the detachment of rotor parts of the compressor
during operation could cause damage to persons, furthermore any aspirated particles could
damage the blades. Avoid contact of hands with the rotor.
- Do not touch the turbocharger and the turbine cover with hands immediately after using the
engine, risk of burns. Let engine cool before interacting with the hot parts.

FNM® HPE Series 13
- Do not smoke near the battery compartment and the fuel tank! The battery can release
flammable gases. Wrong battery connection could provoke sparks and explosion.
- Don’tprovokeshortcircuits,electricalrisk.
- If you use pressure water jet to clean the engine never point this to rubber pipes or electrical
connections.
- Use proper protection (clothing, gloves, etc.) during maintenance and/or work on the engine.
- During maintenance operations provide correct ventilation. Avoid stagnation of toxic and/or
flammable vapors.
- Do not remove the protections included in your engine (such as housing or protective coatings),
to avoid danger of fires.
1.5.1 Residual risks
Potential/additional risks to persons:
Risk of injury: do not put hands in any moving parts (pulleys, flywheel, belts, etc.).
Risk of burns: attention to hot surfaces (exhaust manifold, turbocharger, raiser, etc.)

14 FNM® HPE Series
Risk of poisoning: watch out for oil splashes, hot fuel and battery acids in case of
malfunction: use gloves and safety glasses.
Risk of shock: use safety shoes when lifting the engine and/or working in the engine
compartment.
FNM ® is not responsible for damage caused by misuse of the engine and the failure to follow
procedures issued, as well as for damage caused by unauthorized personnel.

FNM® HPE Series 15
1.6 Main components of FNM® engine, HPE Series
The main components present on HPE marine engines are listed below.
(1) Intercooler (except HPEL45): Reduces the temperature of the compressed air from the
compressor that flows into the engine intake duct using a bundle of finned tubes crossed
by sea water.
(2) Expansion tank: contains engine coolant.
(3) Oil sump: contains engine lubrication oil.
(4) Zinc anodes: prevent the galvanic oxidation of metal parts.
(5) Oil exchanger: reduces the temperature of the engine lubrication oil.
(6) Diesel fuel exchanger: reduces the temperature of the fuel in the return line to the
exchanger.
(7) Air filter: retains the impurities in the air intake.
(8) Dual heat exchanger (as an alternative to diesel fuel exchanger and in the presence
of steering): reduces the temperature of steering oil and diesel fuel.
(9) Turbocharger (except HPEL45): compresses the intake air exploiting the energy of
exhaust gases through the use of a turbine-compressor group.
(10) Diesel fuel filter: filters diesel fuel in inlet to the supply line of the engine It can be wall-
mounted in the engine compartment.

16 FNM® HPE Series
(11) Raiser: reduces the temperature of the exhaust gases coming out of the turbine, conveys
fumes towards the exhaust and prevents the return of sea water into the turbine.
(12) Starter: starts the engine.
(13) Water to water exchanger: reduces the temperature of engine coolant through heat
exchange with sea water.
(14) Low-pressure electric fuel pump: sucks fuel from the low pressure line and sends it to
the high pressure line.
(15) Thermostat housing: contains the thermostatic valve of the cooling circuit.
(16) Sea water pump: sucks water from the sea water intake and pushes it in the cooling
circuit.
(17) Alternator: generates electric power, the output voltage is 12 Volt.
(18) Oil filler cap: useful in filling the engine oil.
(19) Lifting eyes: allow the movement of the engine outside the engine compartment.
(20) Engine label position
(21) Serial number position on the crankcase
(22) Oil drain valve