FPT NEF Series User guide

NEF
SERIES
G-DRIVE ENGINES
Publication edited by:
FPT Industrial S.p.A.
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print L31900378 - 12.17
USE AND MAINTENANCE
USO E MANUTENZIONE
UTILISATION ET ENTRETIEN
BETRIEB UND WARTUNG
USO Y MANTENIMIENTO

1
ENGLISH
NEF SERIES
NEF45 SM1F
NEF67 TM1F
STAGE IIIA - TIER 3
USE AND MAINTENANCE
INTRODUCTION
We would like to thank you for buying an FPT product, and
compliment 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
instructions provided in the manual is the best way to guarantee
trouble-free, long term operation of the engine.
The contents of this manual refer to the standard configuration of the
engine, and the illustrations are purely indicative. Some instructions are
provided by giving the sequence of operations to be carried out in
order to allow the engine and/or its fittings to perform in a certain way.
In some cases they will be dependent on the configuration of the
commands and the set-up of the generator set on which the engine is
installed; for any points that differ from the contents of this manual,
please consult the instructions provided by the generator set
Manufacturer or a specific manual.
The information provided below was current at the date of
publication.
The Manufacturer reserves the right to make modifications at any time
without prior notice, for technical or commercial reasons or to update
the engines to comply with legal requirements in the various
Countries.
The Manufacturer declines all liability for any errors or omissions.
Please remember that the FPT Technical Service Network is available
to offer you its experience and professional skills, wherever you may be.

2
TABLE OF CONTENTS Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Engine technical data NEF45 SM1F . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine technical data NEF67 TM1F . . . . . . . . . . . . . . . . . . . . . . . . .9
Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
For proper use of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Special warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Run-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
CHECKS AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 20
Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Checks to be made during periods of use - how to proceed . .24
Scheduled maintenance - how to proceed . . . . . . . . . . . . . . . . .31
Unscheduled maintenance - how to proceed . . . . . . . . . . . . . . .40
Engine handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Disposal of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . 47
Preparing the engine for a long period of inactivity . . . . . . . . . . .47
Restarting the engine after a long period of inactivity . . . . . . . . .48
BEHAVIOUR IN AN EMERGENCY . . . . . . . . . . . . . . . . . . . 49

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ENGLISH
GENERAL INFORMATION
WARRANTY
In order to ensure that your engine gives the best possible
performance and to take advantage of the FPT warranty, you must
follow the indications provided in this publication with great care;
failure to do so may result in invalidation of the warranty.
SPARE PARTS
Always use Original FPT Spare parts. This is essential to keep the
engine in original running order.
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 entire life cycle of the engine.
RESPONSIBILITY
The Manufacturer's responsibility is subordinate to the performance of
the check and maintenance operations specified and described in this
manual; their performance must be demonstrated for this purpose.
Any necessary unscheduled maintenance operations must be carried
out by qualified FPT Network Workshop personnel, using the
specifically provided instruments and equipment.
SAFETY
The following information is designed to encourage caution to be
exercised when using the engine, in order to avoid material damage
and personal injury caused by improper or incorrect behaviour.
The engines must only be used for the purposes declared by the
Manufacturer.
Any tampering, modification and use of non-original spare parts
may compromise proper operation and safe use of the engine
;
never, under any circumstances make modifications to
the
wiring and to the units equipping the engine, or connect them
to other power systems.
Pay particular attention to moving parts of the engine, to high
temperature components and to circuits containing pressurised
fluids; its electrical equipment houses electrical currents and
voltage.
The exhaust fumes produced by the engine are bad for your health.

The engine must be handled using suitable lifting tackle, making use
of the lifting eyelets provided on the engine for that purpose.
The engine must not be started up and used until the generator set
in which it installed has satisfied all necessary safety requirements,
or until the generator set has been guaranteed to comply with local
laws and regulations.
The operations required to guarantee the best possible use and
preservation of the engine must only be carried out by persons of
proven experience, equipment with tools considered suitable by
FPT.
For the purpose of safety, further recommendations are given in the
CONTROLS AND MAINTENANCE section.

4
SAFETY WARNING SYMBOLS
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 danger: 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.

5
ENGLISH
ENGINE TECHNICAL DATA NEF45 SM1F
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 casing, tappet cover, other.
(*)Power at the flywheel in accordance with directive 97/68 EC
(without fan), after 50 hours' operation, tolerance ± 3%, fuel
EN590;
Test in accordance with specification ISO 3046/1, turbocharger
inlet air temperature 25 °C, atmospheric pressure 100 kPa,
humidity 30%.
Also in accordance with specification DIN 6271, BS 5514, SAE
J1349.
All data is based on engine operation, with fuel system, water
pump, lubrication oil pump, and restriction on suction and
discharge within (or below) the limits shown on the data sheet.
Additional loads estimated at 20 N from the minimum speed at
normal speed.
The fan operation cycle must be below 20%.
(1)The continuous power is that which a generating set is capable of
delivering continuously for an unlimited number of hours per year,
Cod e NEF45 SM1F
Engine family F4
Cycle Diesel, 4-stroke
Number and arrangement
of cylinders 4, in line
Bore x stroke 104 x 132 mm
Total displacement 4,500 cm3
Pneumatic system Turbocharged without intercooler
Injection Direct injection
Direction of rotation of the
engine
Anti-clockwise (seen from flywheel
side)
Speed regulator Mechanical
Dry weight ~450 kg (G-Drive)
Electrical system 12 V
Accumulator/s
- capacity
- discharge current
100 Ah or above
650 A or above
Performance [gross] (*) NEF45 SM1F
Stage IIIA
Tier 3
Continuous(1)
45 kWm @ 1500 rpm
Prime(2) 56.3 kWm @ 1500 rpm
Stand-by (3) 62 kWm @ 1500 rpm
Fan consumption 1.8 kWm @ 1500 rpm
Performance [net] (*) NEF45 SM1F
Stage IIIA
Tier 3
Continuous(1)
43.2 kWm @ 1500 rpm
Prime(2) 54.5 kWm @ 1500 rpm
Stand-by (3) 60 kWm @ 1500 rpm
Performance
conditions
Temperature °C
Altitude a.s.l. m
≤40
≤1000

6
according to the stated maintenance intervals and under standard
ambient conditions.
(2)The prime power is the maximum power available with varying
loads for an unlimited number of hours. The average power output
during a 24h period of operation must not exceed 80% of the
declared prime power according to the prescribed maintenance
intervals and at standard environmental conditions.
A 10% overload is permissible for 1 hour every 12 hours of
operation.
(3)The stand-by power is the maximum power available for a period
of 500 hours/year with a mean load factor of 90% of the declared
stand-by power.
No kind of overload is permissible for this use.
It is severely prohibited, under penalty of cancellation of
the warranty and of the responsibilities of FPT, to
change the characteristics indicated above.

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ENGLISH
NEF45 SM1F
1. Oil vapour filter - 2. Lifting eyelet - 3. Air filter - 4. Injection pump -
5. Flywheel housing - 6. Priming pump - 7. Oil extraction pump - 8. Oil
level dipstick - 9. Fuel filter - 10. Coolant inlet plug - 11. Oil filling cap
- 12. High pressure pipes - 13. Turbocharger air inlet
NEF45 SM1F
1. Lifting eyelet - 2. Coolant outlet pipe - 3. Fan - 4. Water pump -
5. Coolant scavenge pipe - 6. Oil sump - 7. Oil extraction pump -
8. Oil filter - 9. Starter motor - 10. Turbocharger lubricant oil return
pipe - 11. Exhaust manifold - 12. Air filter - 13. Oil delivery to
turbocharger contact - 14. Turbocharger
14_192_N
14_191_N

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NEF45 SM1F
1. Fan - 2. Oil level dipstick - 3. Crankshaft pulley - 4. Poly-V belt -
5. Alternator - 6. Exhaust gas pipe
NEF45 SM1F
1. Air filter - 2. Turbocharger - 3. Alternator - 4. Engine flywheel - 5. Oil
sump - 6. Oil extraction pump - 7. Oil level dipstick
14_193_N
14_194_N

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ENGLISH
ENGINE TECHNICAL DATA NEF67 TM1F
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 casing, tappet cover, other.
(*)Power at the flywheel in accordance with directive 97/68 EC
(without fan), after 50 hours' operation, tolerance ± 3%, fuel
EN590;
Test in accordance with specification ISO 3046/1, turbocharger
inlet air temperature 25 °C, atmospheric pressure 100 kPa,
humidity 30%.
Also in accordance with specification DIN 6271, BS 5514, SAE
J1349.
All data is based on engine operation, with fuel system, water
pump, lubrication oil pump, and restriction on suction and
discharge within (or below) the limits shown on the data sheet.
Additional loads estimated at 20 N from the minimum speed at
normal speed.
The fan operation cycle must be below 20%.
Code NEF67 TM1F
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
Pneumatic system Turbocharged with intercooler
Injection Direct injection
Direction of rotation of the
engine
Anti-clockwise (seen from flywheel
side)
Speed regulator Mechanical
Dry weight ~640 (G-Drive)
Electrical system 12 V
Accumulator/s
- capacity
- discharge current
180 Ah
800 A
Performance [gross] (*) NEF67 TM1F
Stage IIIA
Tier 3
Continuous(1)
94 kWm @ 1500 rpm
Prime(2) 117.5 kWm @ 1500 rpm
Stand-by (3) 129 kWm @ 1500 rpm
Fan consumption 4 kWm @ 1500 rpm
Performance [net] (*) NEF67 TM1F
Stage IIIA
Tier 3
Continuous(1)
90 kWm @ 1500 rpm
Prime(2) 113.5 kWm @ 1500 rpm
Stand-by (3) 125 kWm @ 1500 rpm
Performance
conditions
Temperature °C
Altitude a.s.l. m
≤40
≤1000

10
(1)The continuous power is that which a generating set is capable of
delivering continuously for an unlimited number of hours per year,
according to the stated maintenance intervals and under standard
ambient conditions.
(2)The prime power is the maximum power available with varying
loads for an unlimited number of hours. The average power output
during a 24h period of operation must not exceed 80% of the
declared prime power according to the prescribed maintenance
intervals and at standard environmental conditions.
A 10% overload is permissible for 1 hour every 12 hours of
operation.
(3)The stand-by power is the maximum power available for a period
of 500 hours/year with a mean load factor of 90% of the declared
stand-by power.
No kind of overload is permissible for this use.
It is severely prohibited, under penalty of cancellation of
the warranty and of the responsibilities of FPT, to
change the characteristics indicated above.

11
ENGLISH
NEF67 TM1F
1. Oil vapour filter - 2. Lifting eyelet - 3. Air filter - 4. Injection pump -
5. Priming pump- 6. Oil sump - 7. Fuel filter - 8. Coolant inlet plug -
9. Oil filling cap - 10. High-pressure pipes
NEF67 TM1F
1. Exhaust gas pipe - 2. Lifting eyelet - 3. Fan - 4. Water pump -
5. Alternator - 6. Crankshaft pulley - 7. Poly-V belt - 8. Oil sump -
9. Oil filter - 10. Oil extraction pump - 11. Electric starter motor -
12 Turbocharger lubricant oil return pipe - 13. Air filter - 14. Lubricant
oil delivery pipe to turbocharger - 15. Turbocharger
14_200_N
14_199_N

12
NEF67 TM1F
1. Air filter - 2. Oil vapour filter - 3. Lifting eyelet - 4. Fuel filter - 5. Fan
pulley - 6. Guide pulley belt tensioner - 7. Oil level dipstick -
8. Crankshaft pulley - 9. Oil sump - 10. Oil extraction pump -
11. Water pump - 12. Alternator - 13. Automatic belt tensioner -
14. Lifting eyelet - 15. Exhaust gas pipe
NEF67 TM1F
1. Turbocharger - 2. Alternator - 3. Engine flywheel - 4. Oil sump -
5. Air filter
14_201_N
14_202_N

13
ENGLISH
SIGNS
Several warning signs are affixed to the engine by the manufacturer
and their meaning is indicated below.
Note: The signs with an exclamation mark on them underline a
potential danger.
Lifting point (engine only).
Fuel Cap
(on the fuel tank, if there is one).
Oil Cap.
Oil dipstick.
Risk of burns:
Expulsion of hot water under pressure.
Risk of burns:
Presence of high temperature parts.
Risk of fire:
Fuel present.
Danger of impact or catching
on moving parts:
Presence of fans, pulleys, belts or the like.

14
USE
PRELIMINARY CHECKS
Each time before starting the engine:
Check and refill technical fluids level if necessary (fuel, engine oil and
coolant).
Make sure that the air intake filter is not obstructed or clogged,
checking at the same time that the mechanical indicator on the filter
does not show the "red" signal. If the engine has an electric clogging
sensor, the alarm will be produced upon start due to the luminous
indicator placed on the instrument panel.
Note: The procedures required to clean the filter are indicated
in the CHECKS AND MAINTENANCE section.
FOR PROPER USE OF THE ENGINE
Before starting the engine each time, check that the tank contains
a sufficient amount of fuel.
Avoid prolonging the duration of the start control.
Follow the prescriptions shown on the maintenance plan.
During use, periodically check 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.
ATTENTION!
Make sure that no fuel vapours or gasses are present
in the area in which the engine should be operated.
Ensure that closed areas are adequately ventilated and
fitted with a suitable exhaust extraction system.
In case of use in extremely dusty environments and
according to the final configuration of the generator,
soundproofed or without hood, special protections
must be provided on the most sensitive components.

15
ENGLISH
SPECIAL WARNINGS
Coolant circuit
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.
Moreover, check the following:
the tension of the ancillary belt;
the thermostatic valve's efficiency;
the conditions of the heat exchanger (to be cleaned if necessary).
Lubrication circuit
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 the authorised Service
centre.
Fuel circuit
It is advisable to drain the water from the filters before the relevant
warning light comes on.
Avoid using the engine with a small fuel reserve in the tank as this
encourages the formation of condensation and makes it more likely
you will suck up dirt or air, resulting in engine stop.
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.
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!
Never loose the high pressure fuel circuit connectors in
any way.

16
Air intake and exhaust gas circuits
Inspect the cleanliness of the air intake circuit on a regular basis. The
maintenance intervals indicated in this manual vary according to the
conditions in which the engine is operated.
In particularly dusty environments the maintenance frequency must be
increased from that shown in section CHECKS AND
MAINTENANCE.
Electric ignition system
Periodically check, particularly during the winter, to ensure that the
batteries are clean and in full working order, checking and topping up
as indicated in the CHECKS AND MAINTENANCE section.
In the event of battery replacement, observe the characteristics
contained in the ENGINE TECHNICAL DATA chapter.
Battery or alternator recharging faults
Periodically check the cleanliness, condition and correct tensioning of
the drive belt.
RUN-IN
Thanks to the new engine technology, no running-in is required.
ATTENTION!
Visually check that the exhaust circuit is not blocked or
damaged, so as to prevent dangerous fumes.
Contact a specialised workshop and check battery and
recharging system efficiency if the voltmeter indicates a
voltage below 11 V (for 12 V rated systems), or 22 V
(for 24 V rated systems).
ATTENTION!
The batteries contain an acid solution that will burn the
skin and corrode clothing; when checking them, always
wear protective clothing, gloves and goggles, do not
smoke or use live flames in the vicinity, and make sure
that the room they are housed in is adequately
ventilated.
ATTENTION!
The auxiliary units are located under protective grilles.
Their removal must be carried out only when the
engine is not turning.

17
ENGLISH
REFILLING
(*) It is prohibited to mix fluids of different brands and origins inside
the circuit.
(1)The quantities refer to the standard configuration of the engine.
The coolant must comply with ASTM D-6210 standards.
Concentrated coolants must be used as a mixture with 50% water.
FPT recommends using original PETRONAS products.
(2)see "Main oil features"; Recommended brand: PETRONAS.
(3)The quantities indicated relate to the first refill only and are relative
to the engine, oil sump and filter filling.
(4)Fuel tank not supplied by FPT. Refer to the data of supplier /
manufacturer of the generator set.
Use only fuels that comply with international standards ASTM
D975 or EN 590.
(5)The quantities shown are relative to the total capacity of the G-
Drive including engine capacity.
Parts to be refilled NEF45
SM1F
litres (kg)
Coolant Circuit (1) (*) engine (4) 8.5
G-Drive (5) 18.5
Lubrication circuit(2)
total capacity(3)
Periodical changes:
oil sump at minimum level
oil sump at maximum level
12.8 (11.8)
5.5 (4.95)
8.5 (7.65)
Fuel tank (4) -
NEF67
TM1F
litres (kg)
Circuit cooling (1) engine (4) 10.5
G-Drive (5) 25.5
Lubrication circuit (1) (*)
total capacity(3)
Periodical changes:
oil sump at minimum level
oil sump at maximum level
17.2(15.48)
8 (7.2)
12 (10.8)
Fuel tank (4) -
NEF67
TM1F
litres (kg)

18
Main oil characteristics
Replacement frequency
Oil quality SAE grade Base stock International
specifications
Fuel sulphur content
Premium 10W-40 Semi - Synthetic API CJ-4
ACEA E6/E9 < 500 ppm
Cold climate 5W-30 Synthetic
API CH-4/
CI-4/CJ-4
ACEA E4/E6
< 500 ppm
Standard
15W-40
10W-30
10W-40
Semi - Mineral
Semi - Synthetic
Synthetic
API CI-4 /
CH-4
ACEA E7 / E5
< 1,000 ppm
Low specifications
15W-40
10W-30
10W-40
Mineral
API CF, ACEA E2/E3
API CF, ACEA E2/E3
API CE
< 1,000 ppm
Not permitted Single-grade
Engine/Oil replacement
frequency
Premium and cold climate Standard Low specifications
NEF 600 h or 12 months 500 h or 12 months 300 h or 12 months

19
ENGLISH
Coolant refilling
To start up the engine and when the cooling circuit needs topping up
with a considerable amount of coolant, proceed as indicated below:
Refill the engine and the exchanger until the exchanger is
completely filled.
With the coolant filler plug open, start the engine and let it run at
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.
The use of additives can limit the warranty services offered for the
vehicle.
Diesel oil for low temperatures
The degree of fluidity of the diesel oil can may be reduced at low
temperatures due to the separation of the paraffin. This results in the
filters becoming clogged.
EN590 specifications distinguish different classes of diesel fuel,
identifying the characteristics of those best suited to low temperatures.
Oil companies must respect these standards, which provide for the
distribution of fuels adapted to the climatic and geographical
conditions in various countries.
The failure to observe the aforesaid procedure does not
guarantee the presence of the correct quantity of
coolant in the engine.
WARNING
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.
WARNING
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.