FPT NEF Series User guide

NEF
SERIES
G-DRIVE ENGINES
http://www.brizmotors.ru/equipment/iveco/gen200ma/
USE AND MAINTENANCE
FPT N67 TM7 Бриз Моторс

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ENGINE TECHNICAL DATA NEF67TM7
The technical code and serial number are specified on the nameplate
positioned on different parts of the engine, depending on the model:
flywheel case, tappet cover, coolant tank, etc.
(*)Net power at the flywheel in accordance with the standard ISO
8528. Test conditions: T 25 °C; atmospheric pressure 100 kPa;
relative humidity 30%.
C o d e NEF67TM7
Engine family F4
Cycle Diesel 4-stroke
Number and arrangement
of cylinders 6, in line
Bore x stroke 104 x 132 mm
Total displacement 6,728 cm3
Air supply Supercharged with turbocharger +
intercooler
Injection method Direct injection with rotary pump
Compression ratio 17.5 : 1
Cooling Liquid
Engine rotation direction Anti-clockwise (flywheel side view)
Control system Mechanical
Dry weight ~640 kg (G-Drive)
Electric system 12 V
Battery capacity 100 Ah
Pick-up current 60 A
Maximum input 3 kW
Discharge current
(EN 50342) 650 A
Performance (*) NEF67TM7
Non Emissions
Certified
50 Hz
Prime 176.5 kWm @ 1,500 rpm
Stand-by 194 kWm @ 1,500 rpm
60 Hz
Prime - kWm @ 1,800 rpm
Stand-by - kWm @ 1,800 rpm
Engine idle
speed unladen
50 Hz
60 Hz
1,500 rpm
- rpm
Maximum
engine rpm
unladen
50 Hz
60 Hz
1,570 rpm
- rpm
It is strictly forbidden to alter the aforesaid
characteristics and, in particular, to modify the
calibration of the injection pump or the characteristics
of the engine and its components. Failure to comply
with the above shall result in the loss of warranty, in
addition to FPT declining all responsibility.
Electric system 12 V

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NEF67TM7
1. Comburent air intake duct to turbocharger -2. Exhaust manifold -
3. Turbocharger - 4. Heat exchanger lubricant oil / coolant - 5. Exhaust
gas outlet duct from turbocharger – 6. Engine coolant outlet pipe -
7. Fan (radiator) - 8. Engine coolant inlet pipe - 9. Oil filter – 10. Electric
starter motor.
NEF67TM7
1. Coolant inlet plug - 2. Lubricant oil filler cap - 3. Comburent air
intake duct to engine - 4. Control valve (blow-by) - 5. Lifting eyelet -
6. Oil vapour breather pipe - 7. Rotary fuel supply pump - 8. Fuel
suction pump - 9. Fuel filter - 10. Heat exchanger external air / coolant.
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NEF67TM7
1. Turbocharger lubrication oil delivery pipe - 2. Fan control pulley -
3. Oil level dipstick - 4. Crankshaft pulley - 5. Water pump -
6. Alternator - 7. Automatic belt tensioner - 8. Lifting eyelet.
NEF67TM7
1. Air filter - 2. Comburent air intake duct to intercooler - 3. Lubricant
oil return pipe from turbocharger - 4. Engine mounts - 5. Lubricant oil
drain plug - 6. Oil sump - 7. Engine flywheel.
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LABELS
Some warning labels (below the description) are affixed to the engine.
Note: labels containing an exclamation mark highlight a potential
danger.
Hoisting point (engine only).
Fuel filling cap
(on the tank, if present).
Lubricant oil filling cap.
Lubricant oil level dipstick.
Risk of burns:
Expulsion of pressurized hot water.
Risk of burns:
Presence of parts at high temperature.
Risk of fire:
Presence of fuel.
Risk of injury
from moving parts:
Presence of fans, pulleys, belts and other
objects.

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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 air intake filter is not obstructed or clogged and
check, at the same time, that the visual indicator (1) on the filter is
not showing the “red” signal. The air filter clogging visual indicator
(1) signals when it is necessary to carry out maintenance in order
to protect and optimize filter operation. The sensor (1) remains
locked in the alarm position ("red") until it is reset.
Note: the required procedures for filter cleaning are specified
in the chapter CHECKS AND MAINTENANCE.
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ATTENTION!
Make sure that the environment where the engine will
operate is free of combustible vapours or gases. Make
sure that there is sufficient ventilation and a suitable
exhaust gas extraction system for closed environments.

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ENGINE PRE-HEATING (optional)
The engines which require low start-up temperatures and an
immediate delivery of power may be equipped with an electrical
heating device enabling an increase in the temperature of the air
entering the engine. The device is mounted on the intake manifold and
is fitted with a coolant temperature sensor which interrupts the power
supply once the required temperature has been reached.
SWITCHING OF OPERATING FREQUENCY
Based on the specific operational requirements of the engine, it is
possible to vary the adjustment of the rotary injection pump so as to
obtain a different operating frequency:
- 1,500 rpm @ 50 Hz
- 1,800 rpm @ 60 Hz
To switch from 50 Hz to 60 Hz it is necessary to turn the adjustment
screw (1) of the “droop setting”, clockwise a number of turns
depending on the identification code of the pump indicated on the
nameplate.
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FOR PROPER ENGINE USE
Check there is sufficient fuel in the tank before each start.
Avoid prolonging the duration of the start control.
Do not idle for long periods since this increases the production of
harmful emissions from the engine and does not guarantee its
optimum performance.
The engine speed must be increased and decreased gradually so as
to permit normal combustion and the optimum functioning of all
engine components.
During use, check periodically that:
- the temperature of the engine coolant does not reach the alarm
thresholds;
- the oil pressure remains within normal values.
The speed and power values must comply with that specified in the
technical-commercial documentation.
Particular attention must be paid to engines that equip the
emergency generating units for which frequent efficiency checks are
required in order to guarantee their prompt start in all cases when
required.
SPECIAL WARNINGS
High coolant temperature
In the event of an excessive temperature or the signalling of the alarm,
disengage the load and stop the engine in order to check the condition
of the cooling circuit.
Also check and have the following checked:
the condition of the ancillary belt;
the operation of the thermostatic valve;
the cleanliness of the heat exchanger (radiator).
Low lubricant oil pressure
Should the pressure indicated by the instrument be considered
insufficient or if the “low oil pressure” warning light comes on, stop the
engine and check the oil level. If necessary, top up the oil according to
the instructions contained in the section CHECKS AND
MAINTENANCE. If the fault persists, contact a Service centre.
ATTENTION!
When the engine is hot, pressure builds up in the
cooling circuits which may eject hot liquid violently,
resulting in a risk of burns.
Open the filler cap of the coolant tank only if necessary
and only when the engine is cold.

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Presence of water in the fuel filter
It is advisable to drain the water from the filters before the relevant
warning light comes on.
Do not use the engine if the tank only contains the quantity of fuel kept
as reserve; this condition promotes the formation of condensate and
the intake of sludge or air, causing the engine to stop.
Intake and exhaust circuit inefficiencies
Regularly inspect the cleanliness of the air intake circuit. The
maintenance intervals indicated in this manual change with the
conditions of use.
Maintenance checks must be performed more frequently in
particularly dusty environments with regard to that stated in the
chapter CHECKS AND MAINTENANCE.
Electrical start-up system irregularities
Periodically check the cleanliness and efficiency of the batteries,
particularly during winter, by performing the checks and top-ups as
described in the chapter CHECKS AND MAINTENANCE.
In the event of battery replacement, please observe the characteristics
contained in the section ENGINE TECHNICAL DATA.
Refuelling from drums or jerry cans may contaminate
the diesel, resulting in problems with the fuel supply
system; in these cases it is necessary to carry out
adequate filtration or sedimentation of any impurities
present.
ATTENTION!
The couplings of the fuel circuit under high pressure
must not be loosened under any circumstances
ATTENTION!
Visually check that the exhaust circuit is not obstructed
or damaged to prevent noxious and dangerous fumes.
If the voltmeter indicates a voltage value lower than 11
V (for nominal 12 V systems), or 22 V (for nominal 24
V systems), contact a specialised workshop and have
the efficiency of the batteries and charging system
diagnosed.

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Battery or alternator recharging faults
Check or have checked periodically the state of cleanliness, wear and
the correct movement of the drive belt.
RUN-IN
Thanks to modern engine construction technologies, a particular run-
in procedure is not required. However, it is recommended to avoid
using the engine at high power for long periods during the first 50
hours.
CAPACITIES
NEF67TM7
(1)Use a 50% mixture of water and PARAFLU 11 or the equivalent
corresponding to the specification SAE J1034.
(2)Use lubricants which comply with the international specifications
ACEA E5-E7 (high power engines). Oil consumption is considered
acceptable up to quantities of 0.1% of fuel consumption.
(3)The quantities indicated refer to the first filling only and concern the
engine, oil sump and filter.
(4)The quantities indicated only refer to the engine in its standard
configuration.
(5)The quantities indicated refer to the total capacity of the generating
unit including the capacity of the engine, radiator and pipes.
The batteries contain an acid solution, which is caustic
to skin and corrosive for garments; while checking
them, wear protective garments, gloves and goggles, do
not smoke or permit open flames to come near them
and make sure that the room where they are located
is suitably ventilated.
ATTENTION!
The ancillary members are located under protective
grilles. Their removal must be carried out only when the
engine is not turning.
Parts to be refilled litres (kg)
Cooling circuit (1) engine (4) 10.5
G-Drive (5) 25.5
Lubrication circuit (2) (3)
Periodic replacement:
Sump at minimum level
Sump at maximum level
17.2 (15.8)
8 (7.4)
12 (11)

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Coolant refilling
For the initial engine start-up and in the cases in which the refilling of
the cooling circuit is required with a considerable quantity of coolant,
proceed as follows:
Refill the engine and the exchanger until the exchanger is
completely filled.
With the coolant filler plug open, start the engine and let it idle for
approx. 1 minute. This helps to completely bleed the air contained
in the cooling circuit.
Stop the engine and then top up with coolant if necessary.
Refuelling
Use only diesel oil in accordance with EN 590 standard normally
commercially available. Fuel additives are not recommended.
Use of additives can limit the guarantee performance offered for the
vehicle.
Diesel oil for low temperatures
At low temperatures the degree of fluidity of the diesel can become
low due to the separation of the paraffin resulting in the filters
becoming clogged.
Standard EN590 defines different diesel classes, identifying the
characteristics of those most suitable for use at low ambient
temperatures.
It is entirely the responsibility of the oil companies to comply with the
regulations regarding the distribution of fuels suitable for the climatic
and geographical conditions of the various countries.
The failure to observe the aforesaid procedure does not
guarantee the presence of the correct quantity of
coolant in the engine.
ATTENTION!
When the engine is hot, pressure builds up in the
cooling circuits which may eject hot liquid violently,
resulting in a risk of burns. Open the filler cap of the
coolant tank only if necessary and only when the
engine is cold.
ATTENTION!
Pay maximum attention when refuelling, making sure
that solid or liquid pollutants do not enter the tank;
please remember that smoking is prohibited while
refuelling. The couplings of the fuel circuit under high
pressure must not be loosened under any
circumstances.

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CHECKS AND MAINTENANCE
MAINTENANCE PERSONNEL
The engine check and maintenance operations specified in this chapter
require preparation, skill and compliance with safety standards;
therefore, they must be carried out by responsible personnel, as
indicated below.
Checks to be made during periods of use: by workshop
personnel or if necessary by the machine user.
Periodic maintenance: by qualified personnel
equipped with proper work tools and suitable
protections.
Unscheduled maintenance: by qualified Service
Centre personnel in possession of precise technical
information and specific equipment.
The most qualified Service Centres are those included in the FPT
Technical Support Network.
ACCIDENT PREVENTION
Always wear safety footwear and overalls.
Do not wear loose clothing, rings, bracelets and/or necklaces near
the engines or moving parts.
Wear protective gloves and goggles while:
• filling the batteries with acid solution
• check cleanliness of battery clamps and terminals
• filling up inhibitors or antifreeze
• changing or filling the lubricant oil (hot engine oil can cause burns). It
is recommended to perform these operations only when their
temperature is lower than 50 °C).
When working in the engine compartment, pay maximum
attention to all movements to avoid coming into contact with
rotating or hot components.
Wear goggles when using compressed air (the maximum air
pressure used for cleaning is 200 kPa (2 bar, 30 psi, 2 kg/cm2).
Wear a protective helmet if working in an area with suspended
loads or overhead systems.
Use protective creams for hands.
Immediately replace wet overalls.
Always keep the engine clean, removing spots of oil, diesel and
coolant.
Return oily rags to fire-proof containers.
Do not leave foreign objects on the engine.
Use adequate and safe containers for the spent oil.
At the end of a repair, implement suitable measures to stop air intake
by the engine if, after starting, the engine runs at uncontrolled speeds.

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FREQUENCIES
NEF67TM7
The frequencies indicated below take into account factors of use of
different engine uses; the most suitable duration of the maintenance
intervals for the different applications will be indicated by the
maintenance personnel based on the use and operating conditions of
the engine.
Do not perform maintenance in the case of live
electrical voltage: check the condition of the
equipment's ground connection. During the diagnostics
and maintenance operations, make sure your hands
and feet are dry and use insulating footboards if
possible.
The conditions that cause an emergency generator set
to start can occur suddenly. While performing checks
and maintenance, comply strictly with the
requirements indicated by the Manufacturer of the
generator set and by the Fitter of the electric
generation system to ensure maximum safety for
maintenance personnel.
Checks in periods of use Frequency
Check the engine lubricant oil level Daily
Check engine coolant level Daily
Check the cleanliness of the heat exchanger
(radiator) Daily
Inspection of the exhaust duct/s Daily
Inspection of air filter Monthly (2)
Check tightening and cleanliness of battery
clamps Six-months
Check electrolyte level of the batteries Six-months
Check condition of the blow-by filter Six-months

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1) Maximum period relating to the use of high quality fuel,
(specification EN 590); which is reduced in the event of fuel
contamination and alarm signals caused by filter clogging and/or the
presence of water in the filter. The filter clogging signal indicates
that the filter must be replaced. If the warning light of water present
in the filter does not go off after drainage, then the filter must be
replaced.
2) The frequency depends on the ambient conditions and product
efficiency/wear. After long periods of engine inactivity, perform the
check before starting the engine.
The filter clogging signal indicates that the filter must be replaced.
3) The frequencies are applicable for lubricants which meet the
international standards ACEA E5-E7 (high power engines)
4) To be performed every year even if the specified operating hours
interval has not been reached.
5) Only use filters with the following specifications:
- degree of filtering < 12 μm
- filtering efficiency 99.5% (ß > 200).
Periodic maintenance Frequency
Change engine lubricant oil 800 hours (3) (4)
Change oil filter 800 hours (3) (4) (5)
Replace the fuel filter 600 hours (1) (4) (5)
Drain the water from the fuel filter 150 hours (1)
Drainage/suction of water, condensation
and impurities from the fuel tank/s 150 hours (1)
Change blow-by filter 900 hours
Change the engine coolant 1200 hours /
2 years
Change air filter 1200 hours /
2 years (2)
Unscheduled maintenance Frequency
Change the auxiliary device belt 1200 hours /
3 years
Visual inspection of turbocharger 1200 hours
Clean the heat exchanger (radiator) 1200 hours
Injector calibration 1800 hours
Adjustment of valve/rocker arm clearance 3000 hours

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REQUIREMENTS
Do not disconnect the battery supply while the engine is running.
Do not perform arc welding near the engine without first removing
its electrical wiring.
After all maintenance operations that require disconnection of the
batteries, make sure the clamps have been securely reconnected
on the poles.
Do not use a battery charger to start the engine.
Do not paint the devices, components and electrical connectors of
the engine equipment.
Electrically disconnect the battery/batteries before performing any
electrical work.
Contact the Manufacturer before installing any electronic
equipment.
In the event in which fuel is used with a sulphur
percentage greater than 0.5%, or oils are used which
do not meet the specifications in the section FLUIDS,
then the replacement frequencies of the engine oil,
engine oil filter and blow-by filter must be halved, or
suitably adjusted, in accordance with the use and
operating conditions of the engine; please consult the
personnel in charge of maintenance operations for
appropriate advice.
The operations described above require the use of
specific tools which guarantee safe and effective
results.
It is recommended that such operations are carried out
by qualified personnel of the FPT Technical Service
Network.
The unscheduled maintenance operations described in
the relative table are under the exclusive responsibility
of qualified personnel in possession of suitable
technical information and equipped with suitable work
tools and protective devices. The instructions for their
fulfilment are contained in the FPT technical and repair
manuals.
Do not perform any operation that would change the
calibration of the injection pump.
It was adjusted during the engine test phase and based
on its destination.

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CHECKS TO BE MADE DURING PERIODS OF
USE – HOW TO PROCEED
Check the engine lubricant oil level
Only proceed when the engine is not turning and is at low
temperature in order not to run the risk of burns.
Use the oil level dipstick (1) to check that the lubricant oil level is
between the "Min" and "Max" limits.
If the level is insufficient, it is necessary to top up with lubricant oil
which meets the international specifications ACEA E5-E7 (high
power engines), as indicated in the section FLUIDS: remove the
lubricant oil cap (2) and pour engine lubricant oil through the hole.
Use the oil level dipstick (1) to check that the quantity of lubricant
oil does not exceed the "Max" limit.
Make sure that the oil dipstick is fully inserted and that
the oil filler cap is fully tightened in a clockwise
direction.
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Check engine coolant level
Only proceed when the engine is not turning, and is at low
temperature, so as not to run the risk of burns.
Remove the pressurization cap from the expansion tank.
Check that the coolant in the expansion tank is above the minimum
level.
If necessary, top up the expansion tank with a mixture of 50%
water and PARAFLU 11, as contained in the section FLUIDS. Do
not fill the expansion tank to the brim.
When the engine is cold, make sure that the coolant in the
expansion tank is a few centimetres below the filling hole.
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 coolant does not overfill the internal volume of the exchanger in
order to allow the expansion of coolant volume during increases in
temperature.
Check the cleanliness of the heat exchanger
(radiator)
Check that the air intake surfaces of the radiators are free of impurities
(dust, mud, straw etc.).
Clean them if necessary using compressed air or steam.
If frequent coolant top-ups are necessary, the cooling
circuit must be diagnosed.
ATTENTION!
When the engine is hot, pressure builds up in the
cooling circuits which may eject hot liquid violently,
resulting in a risk of burns.
Open the filler cap of the coolant tank only if necessary
and only when the engine is cold.
When using compressed air, it is required to use
suitable personal protections for hands, face and eyes.
The requirements can be found in the ACCIDENT
PREVENTION paragraph.
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Inspection of the exhaust duct/s
Visually check that the exhaust gas / exhaust system is not obstructed
or damaged.
Make sure that there is no risk of harmful fumes in the environment
where the engine is being worked on. Contact the manufacturer if
necessary.
Inspection of air filter
Only proceed when the engine is not turning over.
Remove the cover (3) of the air filter after having undone the two
quick release catches (2).
Remove the filter element (1); make sure that dust does not enter
the sleeve during this operation.
Make sure there are no impurities. Otherwise, clean the filter
element according to the instructions provided below.
Blow dehumidified compressed air on the filtering element, working
from the inside outwards (maximum pressure 200 kPa).
Check the condition of the air filter before refitting it. Replace it if
broken or torn.
Check the condition of the gasket at its base.
Position the filter element (1) in its seat.
Replace the cover (3) of the air filter and lock it using the two quick
release catches (2).
Do not use detergents or diesel to clean the air filter.
Never strike the filter element with tools.
The imprecise assembly of the air filter may result in
the intake of unfiltered air and therefore cause serious
damage to the engine.
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Check tightening and cleanliness of battery clamps
Check that the battery terminals and cable clamps are clean, well
tightened and protected by Vaseline.
In the event of dirty cable clamps and battery terminals:
Loosen the nut and remove the clamp from the negative terminal
(marked with a "-").
Loosen the nut and remove the clamp from the positive terminal
(marked with a "+").
Use a wire brush or fine grade sand paper to clean the cable clamps
and the battery terminals until they are shiny.
Smear the cable clamps with Vaseline and insert them onto the
battery terminals making sure that the positive pole is connected
first, followed by the negative pole, and then tighten each clamp.
Check the cables and clamps for signs of wear and corrosion; replace
them if in poor condition.
Visually check the condition of the battery: the terminals must not
show signs of deterioration and the body must not be damaged,
otherwise they should be replaced.
Check electrolyte level of the batteries
The batteries used are of reduced maintenance type. Therefore, under
normal conditions of use, no top up of the electrolyte is required.
However, the routine checking of the electrolyte level is
recommended. Proceed after positioning the batteries on a horizontal
surface.
Visually check that the electrolyte level is between the "Min" and
"Max" reference marks on the batteries; in the absence of any
reference marks, make sure the liquid covers the lead plates
contained in the elements by approx. 5 mm.
Only use distilled water to top up the elements whose level is
below the minimum.
If the battery must be recharged, contact a specialised workshop.
Wear protective glasses and gloves.
A specialised workshop should be contacted if all the
battery elements need topping up with a considerable
quantity of distilled water and the diagnostics of the
battery recharging system's efficiency should be
performed.
The batteries contain sulphuric acid which is highly
caustic and corrosive; during the top up operations
protective glasses and gloves must be worn, as well as
an apron to protect clothing. If possible, have this check
performed by qualified personnel.

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Some batteries have a single cover for the inspection plugs. To access
the elements, use a lever as shown in the figure.
Check condition of the blow-by filter
Only proceed when the engine is not turning over.
Disconnect the oil vapour recovery pipe from the blow-by filter (2).
Remove the screws (1) and detach the blow-by filter (2) from the
cylinder tappet cover 5-6 (3); retain the seal.
Check that the blow-by filter (2) is not clogged; Otherwise replace it.
Clean the contact surfaces carefully.
Install the seal and fit the blow-by filter (2) on the cylinder tappet cover
5-6 (3).
Tighten the screws (1).
ATTENTION!
During the checks do not smoke or allow naked flames
near the batteries. Ensure that the work area is suitably
ventilated.
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