FPT F Series User guide

F
SERIES
G-DRIVE ENGINES
Publication edited by
Marketing - Adv. & Promotion
Print L31900466 - 04/2019
USE AND MAINTENANCE
USO E MANUTENZIONE

F34TE1WF34TE1W
F34TE1W
USEUSE
USE ANDAND AND MAINTENANCEMAINTENANCE MAINTENANCE
English

1GENERALINFORMATION
Guarantee..............................................................................................5
Spareparts.............................................................................................5
Liability................................................................................................5
Safety.................................................................................................5
Safetywarningssymbols....................................................................................6
Enginetechnicaldata......................................................................................7
Externalview............................................................................................9
Identi󰘰cationplate........................................................................................13
Signs................................................................................................15
2USE
Preliminarychecks.......................................................................................16
Forproperuseoftheengine................................................................................17
Interconnectioncontrolunit.................................................................................19
Specialwarnings........................................................................................23
Runningin.............................................................................................24
3INSPECTIONANDMAINTENANCE
Maintenancepersonnel....................................................................................25
Accidentprevention......................................................................................25
Re󰘰lling...............................................................................................26
Maincharacteristicsofoil...................................................................................28
Coolant󰘱uid󰘰lling........................................................................................29
Refuelling.............................................................................................30
Programmedmaintenance..................................................................................31
Requirements...........................................................................................32
Checkofwaterpresenceinpre-󰘰lterorinfuel󰘰lter(componentnotsuppliedbyFPT)........................................33
Checkenginelubricantoillevel..............................................................................34
Checkenginecoolantlevel.................................................................................36
Checktensionandconditionofancillarybelt.....................................................................37
Changeenginelubricantoil.................................................................................39
Changeenginelubricantoil󰘰lter..............................................................................41
Changefuelpre-󰘰lter......................................................................................43

Replacefuel󰘰lter........................................................................................44
Changeair󰘰lter.........................................................................................46
Cleantheheatexchanger(radiator)...........................................................................47
Replacingtheblow-by󰘰lter.................................................................................48
Changetheancillarybelt...................................................................................51
Visuallyinspectturbocharger................................................................................54
Visualinspectionofthealternator.............................................................................55
Clean/replaceradiatorpressurecap...........................................................................56
Changeenginecoolant....................................................................................57
Movetheengine.........................................................................................58
Disposalofwaste........................................................................................59
4LONGPERIODOFINACTIVITY
Preparingtheengineforalongperiodofinactivity.................................................................60
Enginestart-upafteralongperiodofinactivity....................................................................62
5ENGINEMALFUNCTIONS
Enginefault............................................................................................63
Intheeventofafault:.....................................................................................64
6BEHAVIOURINEMERGENCY
Forpersonalsafety.......................................................................................65
SAEclassi󰘰cationofoilsinrelationtotheambienttemperaturesofuseoftheengine/vehicle...................................67
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1 1
1- - -GENERAL GENERAL GENERALINFORMATION INFORMATION INFORMATION
Guarantee Guarantee
Guarantee
FortheenginetoperformatitsbestandtobecoveredbytheFPTwar-
ranty,paycloseattentiontotheinstructionsprovidedinthismanual;failure
toobservetheinstructionscouldinvalidatethewarranty.
Spare Spare
Spareparts parts parts
AlwaysuseoriginalFPTspareparts.Thiswillenabletheenginetorunas
ef󰘰cientlyasitdidoriginally.
Theuseofnon-originalsparepartsnotonlyinvalidatesthewarranty,but
alsomeansthatFPTcannotbeheldresponsibleinanywayduringthe
entirelifecycleoftheengine.
Liability Liability
Liability
Themanufacturershallbeheldresponsibleprovidedthatthechecksand
maintenanceworkindicatedanddescribedinthismanualarecarriedout;
itshallthereforebenecessarytoprovideproofthatsuchmaintenance
workhasbeencarriedout.Non-routinemaintenanceworkmustbycarried
outbyquali󰘰edtechniciansfromworkshopsbelongingtotheFPTnetwork,
usingthetoolsandequipmentthathavebeenspeci󰘰callyprovided.
Safety Safety
Safety
Thefollowinginformationisintendedtoencouragecautionwhenusing
theengine,soastoavoiddamagetopersonsorpropertyasaresultof
improperorincorrectbehaviour.
•TheenginesmustonlybeusedforthepurposesdeclaredbytheMan-
ufacturer.
•Tampering,modi󰘰cationsandtheuseofnon-originalsparepartscould
adverselyaffecttheproperoperationoftheengineanditssafetyduring
use;changesmustnotbemadetothewiringandtheunitsthatequip
theengineaswellasitsconnectionstoexternalelectricalnetworks.
•Payattentiontotheengine'smovingparts,thoseatahightempera-
tureandthecircuitswithpressurised󰘱uids;itselectricalequipmentis
asourceofelectricalvoltageandcurrents.
•Theexhaustgasemittedbytheengineisharmfultohealth.
•Theenginemustonlybehandledwithsuitableliftingdevicesandusing
thespeci󰘰ceyeboltsprovidedontheengine.
•Theenginemustnotbestartedandusedbeforesatisfyingthesafety
requirementsfortheequipmentinwhichitisinstalledandbeforeen-
suringcomplianceofthelatterwiththestandardsandlocallaws.
•Theoperationsrequiredforguaranteeingthebeststateofuseand
preservationoftheenginemustbecarriedoutbypersonnelwithproven
experienceusinginstrumentsconsideredappropriatebyFPT.
AdditionalsafetyrecommendationscanbefoundintheCHECKSAND
MAINTENANCEchapter.
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Safety Safety
Safetywarnings warnings warningssymbols symbols symbols
Youwill󰘰ndthesesymbolsonthefollowingpages;followtheinstructions
towhichtheyrefer,foryourownsafetyandthatofyourengine.
Risk Risk
Riskof of ofinjury: injury: injury:
failuretocomplywiththeseinstructionscanresultintheriskofseriousinjury.
Risk Risk
Riskof of ofserious serious seriousdamage damage damageto to tothe the theengine: engine: engine:
thepartialortotalnon-observanceoftheseinstructionscouldcauseseriousdamagetotheengineandmaynullify
thewarranty.
General General
Generalrisk: risk: risk:
combinestherisksofboththesignsdescribedabove.
Safeguarding Safeguarding
Safeguardingthe the theenvironment: environment: environment:
indicatesthecorrectbehavioursothatvehicleuseisasenvironmentallyfriendlyaspossible.
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Engine Engine
Enginetechnical technical technicaldata data data
Thetechnicalcodeandtheserialnumberareindicatedonadataplate
locatedindifferentpartsoftheenginedependingonthemodel:󰘱ywheel
housing,tappetcover,other.
Code Code
CodeF34TE1W F34TE1W F34TE1W
EnginefamilyF5HFL464D*F019
Cycle4-strokediesel
Numberandarrangementof
cylinders4,inline
Borexstroke99 99
99mm mm mmx110 110 110mm mm mm
Totaldisplacement3400 3400
3400cm³ cm³ cm³
AirsupplyTurbocharged
InjectiontypeElectronicallycontrolledcommon
rail
Compressionratio16.5:1
CoolingLiquidbased
DirectionofrotationoftheengineAnticlockwise(seenfrom󰘱ywheel
side)
ControlsystemElectronic
Dryweight470 470
470kg kg kg(G-Drivecon󰘰guration)
Electrical Electrical
Electricalsystem system system12 12
12V V V
Batterycapacity–
Pick-upcurrent–
Startermotormaximumoutput4.2 4.2
4.2kW kW kW
Perfor- Perfor-
Perfor-
mance mance
mance
[gross] [gross]
[gross](*) (*) (*)
F34TE1W F34TE1W
F34TE1W
Continuous
Power(1) (1)
(1)
39.4 39.4
39.4kW kW kW@1800 1800 1800RPM RPM RPM
PrimePower(2) (2)
(2)49 49 49kW kW kW@1800 1800 1800RPM RPM RPM
Not
emissioned
Stand-byPower
(3) (3)
(3)
54 54
54kW kW kW@1800 1800 1800RPM RPM RPM
Fan
consumption2.2 2.2
2.2kW kW kW@1800 1800 1800RPM RPM RPM
Perfor- Perfor-
Perfor-
mance mance
mance[net] [net] [net]
(*) (*)
(*)
F34TE1W F34TE1W
F34TE1W
Continuous
Power(1) (1)
(1)37.2 37.2
37.2kW kW kW@1800 1800 1800RPM RPM RPM
PrimePower(2) (2)
(2)46.8 46.8 46.8kW kW kW@1800 1800 1800RPM RPM RPM
Not
emissioned
Stand-byPower
(3) (3)
(3)51.8 51.8
51.8kW kW kW@1800 1800 1800RPM RPM RPM
Perfor-
mancecon-
ditions
Temperature°C
Altitudea.s.l.m≤40 40
40
≤1000 1000
1000
(*) (*)
(*)Poweratthe󰘱ywheelinaccordancewithdirective97/68CE(without
fan),after50 50
50h h hofoperation,tolerance±3 3 3% % %fuelEN590;
Testincompliancewithspeci󰘰cationISO3046/1,turbochargerinletair
temperature25 25
25°C °C °C,atmosphericpressure100 100 100kPa kPa kPa,humidity30 30 30% % %-Also
incompliancewithspeci󰘰cationsDIN6271,BS5514,SAEJ1349.
Allthedataarebasedonengineoperationwithfuelsystem,waterpump,
lubricantoilpumpandintakeandexhaustrestrictionwithinorbelow,the
limitsindicatedinthe"datasheet".
Additionalloadsestimatedat20 20
20N·m N·m N·mfromidlespeedtonominalspeed.
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(1) (1)
(1)TheContinuouspoweristhatwhichageneratingsetiscapableofde-
liveringcontinuouslyforanunlimitednumberofhoursperyear,according
tothespeci󰘰edmaintenanceintervalsandunderstandardambientcon-
ditions.
(2) (2)
(2)PrimePoweristhemaximumpoweravailablewithvariableloadsfor
alimitednumberofhours.Themeanpowerdeliveredduringaperiod
of24 24
24h h hmustnotexceed80 80 80% % %oftheprimepowerdeclaredbetweenthe
speci󰘰edmaintenanceintervalsandinstandardambientconditions.An
overloadof10 10
10% % %ispermittedfor1 1 1h h hevery12 12 12h h hofoperation.
(3)Stand-bypoweristhemaximumpoweravailableforaperiodof500
hours/yearwithameanloadfactorof90 90
90% % %ofthedeclaredstand-bypower.
Notypeofoverloadispermittedforthis.
Generalprescriptions
Itisseverelyprohibited,underpenaltyofcancellationofthewar-
rantyandoftheresponsibilitiesofFPT,tochangethecharacter-
isticsindicatedabove.
Failuretocomplycompletelyorpartiallywiththeserequirements
mayresultintheriskofseriousdamagetotheengineandmay
even,onoccasion,invalidatethewarranty
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External External
Externalview view view
F34 F34
F34(F5HFL464D*F019) (F5HFL464D*F019) (F5HFL464D*F019)
1.Air󰘰lter
2.Liftingeyelet
3.Enginewiring
4.DOC+PMCat
5.Oil󰘰lter
6.Fuel󰘰lter
7.Oildipstick
8.Oilsump
9.Oil󰘰llingcap
10.Injectionpump
11.Radiator
12.Enginecontroller
13.Liftingeyelet
NOTE: NOTE:
NOTE:
The lifting eyelets are sized to move the engine only. It is not
permitted to use these eyelets to lift the engine together with other parts
that make up the genset, for example single - phase / three - phase electric
machines, lower crankcase, etc.
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F34 F34
F34(F5HFL464D*F019) (F5HFL464D*F019) (F5HFL464D*F019)
1.Throttlebody
2.Turbochargerairoutlet
3.Alternator
4.Oilsump
5.Startermotor
6.Interfacecontrolunit
7.Turbocharger
8.Exhaustmanifold
9.EGRvalve
10.EGRheatexchanger
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F34 F34
F34(F5HFL464D*F019) (F5HFL464D*F019) (F5HFL464D*F019)
1.Liftingeyelet
2.Radiatorinletpipe
3.Fan
4.Blow-by󰘰lter
5.Auxiliarymemberbelt
6.Crankshaftpulley
7.Waterpump
8.Radiatoroutletpipe
9.Interfacecontrolunit
10.Alternator
NOTE: NOTE:
NOTE:
The lifting eyelets are sized to move the engine only. It is not
permitted to use these eyelets to lift the engine together with other parts
that make up the genset, for example single - phase / three - phase electric
machines, lower crankcase, etc.
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F34 F34
F34(F5HFL464D*F019) (F5HFL464D*F019) (F5HFL464D*F019)
1.Air󰘰lter
2.Flowvalve
3.DOC+PMCat
4.Turbocharger
5.Interfacecontrolunit
6.Flywheel
7.Fuel󰘰lter
8.Oil󰘰llingcap
9.Oil󰘰lter
10.Liftingeyelet
NOTE: NOTE:
NOTE:
The lifting eyelets are sized to move the engine only. It is not
permitted to use these eyelets to lift the engine together with other parts
that make up the genset, for example single - phase / three - phase electric
machines, lower crankcase, etc.
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Identi󰘰cation Identi󰘰cation
Identi󰘰cationplate plate plate
1.FPTcode
2.FPTcodeandbarcode
3.ClientCodewithengineregistrationnumber
4.ClientCodewithdateofmanufacture(mm/yy)
5.Spaceforbarcode
6.Engineserialnumber
7.Monthandyearofmanufacture
8.Enginetheoreticalcode
9.FPTcode
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•Box"A":Model
•Box"B":Engineserialnumber
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Signs Signs
Signs
Somewarninglabels(belowthedescription)areaf󰘰xedtotheengine.
NOTE: NOTE:
NOTE:
Labels containing an exclamation mark highlight a potential dan-
ger.
Lifting Lifting
Liftingpoint point point(only (only (onlythe the theengine). engine). engine).Risk Risk
Riskof of ofburns: burns: burns:
Expulsion Expulsion
Expulsionof of ofpressurised pressurised pressurisedhot hot hotwater. water. water.
Fuel Fuel
Fuel󰘰lling 󰘰lling 󰘰llingcap cap cap
(on (on
(onthe the thetank, tank, tank,if if ifpresent). present). present).
Risk Risk
Riskof of ofburns: burns: burns:
Presence Presence
Presenceof of ofparts parts partsat at athigh high hightemperature. temperature. temperature.
Lubricant Lubricant
Lubricantoil oil oil󰘰lling 󰘰lling 󰘰llingcap. cap. cap.Risk Risk
Riskof of of󰘰re: 󰘰re: 󰘰re:
Presence Presence
Presenceof of offuel. fuel. fuel.
Lubricant Lubricant
Lubricantoil oil oillevel level leveldipstick. dipstick. dipstick.
Risk Risk
Riskof of ofinjury injury injury
from from
frommoving moving movingparts: parts: parts:
Presence Presence
Presenceof of offans, fans, fans,pulleys, pulleys, pulleys,belts belts beltsor or orother. other. other.
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2 2
2- - -USE USE USE
Preliminary Preliminary
Preliminarychecks checks checks
Beforestaringtheengineeachtime:
•Checkandtopupthelevelofthetechnical󰘱uids,ifnecessary(fuel,
engineOilandcoolant).
•Makesurethatthebatteriesareef󰘰cientandthattheterminalsare
correctlyconnected.
•Checkthatthecoolantandfuelcircuitconnectorsareintactandthere
isnosignofanyleaks.Checkthatthepipecollarsareef󰘰cient.
•Makesurethattheintakeair󰘰lterisnotcloggedorblocked,alsocheck-
ingthatthevisualindicator(1) (1)
(1)onthe󰘰lterdoesnotshowthe"red"sig-
nal.Theair󰘰ltercloggedvisualindicator(1) (1)
(1)showswhenmaintenance
needstobecarriedoutandoptimises󰘰lteroperation.Thesensor(1) (1)
(1)
staysintheblockedalarmposition("red")untilitisreset.
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Iftheair󰘰lterisclogged,ensureitiscleaned:
•Removetheair󰘰ltercover(4) (4)
(4)afterhavingreleasedthetwoquick-clos-
inghooks(3) (3)
(3).
•Removethe󰘰lter(5) (5)
(5).Duringthisoperation,takecaretoensurethatno
dustentersthesleeve.
•Checktherearenoimpuritiespresent.Ifthereare,cleanthe󰘰lterele-
mentasindicatedbelow.
•Blowdehumidi󰘰edcompressedaironthe󰘰lteringelement,working
fromtheinsideout(maximumpressure200 200
200kPa kPa kPa).
•Checktheconditionoftheair󰘰lterbeforere󰘰ttingit.Replaceifthereis
anysignthatitisbrokenorthereareanytears.
•Checktheconditionofthegasketatitsbase.
•Some󰘰ltersystemsare󰘰ttedwithasecond󰘰lterelement(1) (1)
(1)which
doesnotrequirecleaning.
•Positionthe󰘰lter(5) (5)
(5)initsseat.
•Replacethecover(4) (4)
(4)oftheair󰘰lterandlockitinplaceusingthetwo
quickreleasehooks(3) (3)
(3).
Riskofdamage
Donotusedetergentsordieseltocleantheair󰘰lter.Never
strikethe󰘰lterelement
withtools.
Makesurethatthepartsare󰘰ttedcorrectly.Incorrectas-
semblycouldcausetheenginetotakein
un󰘰lteredair,causingseriousdamagetotheengine.
Failuretocomplycompletelyorpartiallywiththeserequire-
mentsmayresultintheriskofseriousdamagetotheengine
andmayeven,onoccasion,invalidatethewarranty
For For
Forproper proper properuse use useof of ofthe the theengine engine engine
•Beforestartingtheengineeachtime,checkthatthetankcontainsa
suf󰘰cientamountoffuel.
•Avoidprolongingthedurationofthestartcontrol.
•Followtheindicationsprovidedinthemaintenanceplan.
•Duringuse,checkperiodicallythat:
○thetemperatureoftheenginecoolantdoesnotreachthealarm
thresholds;
○theoilpressureremainswithintheexpectednormalvalues;
•Thespeedandpowervaluesmustcomplywithindicationsspeci󰘰edin
thetechnical-commercialdocumentation.
•Particularattentionmustbepaidtoenginesthatequiptheemergency
generatorsetsforwhichfrequentef󰘰ciencychecksarerequiredinorder
toensuretheystartpromptlywheneverrequired.
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Generalprescriptions
Ifusinginextremelydustyenvironmentsandonthebasisof
the󰘰nalcon󰘰gurationofthe
currentgenerator,soundproofedorwithoutsound-proofcas-
ing,suitableprotectionsarerequiredformostsensitivecom-
ponents.
Failuretocomplycompletelyorpartiallywiththeserequire-
mentsmayresultintheriskofseriousdamagetotheengine
andmayeven,onoccasion,invalidatethewarranty
18

Interconnection Interconnection
Interconnectioncontrol control controlunit unit unit
Topermitthecorrectelectricoperationofthecontrolunit,aconnection
unithasbeeninstalledintheengine.Theconnectionunitcontrolsthe
engine'selectroniccontrolsystemandthepowerunitsystem.
Someinformationisprovidedbelowconcerningitscomponentsandfunc-
tionsthatarecontrolledbyprogrammingswitches.
Remote-controlswitches(K1) (K1)
(K1)ATSauxiliarysensor
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