FPT NF67TE8W.S550 User guide

NEF
SERIES
POWER GENERATION ENGINES
Publication edited by:
FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print L31900356 - 05/17
USE AND MAINTENANCE
USO E MANUTENZIONE
UTILISATION ET ENTRETIEN
BETRIEB UND WARTUNG
USO Y MANTENIMIENTO

1
ENGLISH
NEF SERIES
NF67TE8W.S550
F4HFA615A*D001
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
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Engine technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
For proper use of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Interconnection electrical unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Special warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Run-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CHECKS AND MAINTENANCE . . . . . . . . . . . . . . . 15
Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Checks (in period of use) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Periodic maintenance - how to proceed . . . . . . . . . . . . . . . . . . .26
Extraordinary maintenance - how to proceed . . . . . . . . . . . . . . .34
Moving the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Disposal of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . 37
Preparing the engine for a long period of inactivity . . . . . . . . . . .37
Restarting the engine after a long period of inactivity . . . . . . . . .38
ENGINE MALFUNCTIONS . . . . . . . . . . . . . . . . . . . . 39
BEHAVIOUR IN EMERGENCY . . . . . . . . . . . . . . . . . 40

3
ENGLISH
GENERAL INFORMATION
GUARANTEE
In order to ensure that your engine gives the best possible
performance and to take advantage of the FPT guarantee, you must
follow the indications provided in this publication with high attention;
failure to do so may result in invalidation of the guarantee.
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 will not only invalidate the
guarantee, but will mean that FPT will not be considered liable in any
way during the whole working life of the engine.
LIABILITY
The Manufacturer will only be considered liable subject to
performance of the control and maintenance operations indicated and
described in this manual; to this effect, proof that these operations
have been performed must be provided. Any extraordinary
maintenance operations that may be necessary must be carried out by
qualified technicians from Workshops in the FPT Network, using the
instruments and equipment provided for the purpose.
SAFETY
The following information is intended to encourage caution when
using the engine, so as to avoid damage to persons or property as a
result of improper or incorrect behaviour.
The engines must only be used for the purposes indicated 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 U-bolts 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
CHECKS 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 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.

5
ENGLISH
ENGINE TECHNICAL DATA
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.
(*)Net power to the flywheel in compliance with ISO 8528. Test
conditions: temperature 25 °C; atmospheric pressure 100 kPa;
relative humidity 30%.
Code NF67TE8W.S550
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 system Turbocharged - with intercooler
Injection type Direct - high pressure pump
supply and common rail system
Compression ratio 17.5 : 1
Cooling Liquid
Engine direction of rotation Anticlockwise
(seen from flywheel side)
Dry weight ~530 kg
Electrical system 24 V
Reccomanded Battery
capacity
- discharge current (EN 50342)
44 - 110 Ah
357 - 765 A
Electric starter motor
- Maximum output power 4 kW
Alternator
- Output 70 A
Performance (*) F4HFA615A*D001
NF67TE8W.S550
50 Hz
Stand-by 236 kWm (net) @ 1500 rpm
Prime 215 kWm (net) @ 1500 rpm
60 Hz
Stand-by 255 kWm (net) @ 1800 rpm
Prime 231 kWm (net) @ 1800 rpm
Any alteration of the above mentioned characteristics
is strictly prohibited, penalty invalidation of the
guarantee and absence of all liability on the part of
FPT.
Electrical system 24 V

6
NF67TE8W.S550
1. Turbocharger - 2. Air filter - 3. Blow-by filter - 4. Fuel high-pressure
pump - 5. Fuel filter - 6. Oil sump - 7. Pre-fuel filter - 8. Engine Control
Unit EDC17CV41 - 9. Grid heater - 10. Intake manifold - 11. Oil filler
cap
NF67TE8W.S550
1. Turbocharger - 2. Tappet cover - 3. Lifting eyelet - 4. Fan -
5. Alternator - 6. Crankshaft pulley with damper - 7. Engine oil filter -
8. Turbocharger lubrication oil return pipe - 9. Electric starter motor -
10. Interconnection Control Unit - 11. Heat exchanger lubricant oil /
coolant - 12. Exhaust manifold
17_053_N
17_054_N

7
ENGLISH
NF67TE8W.S550
1. Air filter - 2. Lifting eyelet - 3. Engine cable - 4. Fan control pulley -
5. Prefuel filter - 6. Fuel filter - 7. Crankshaft pulley with damper - 8. Oil
sump - 9. Water pump - 10. Automatic belt tensioner -
11. Turbocharger
NF67TE8W.S550
1. Air filter - 2. Air outlet pipe - 3. Turbocharger lubricant oil return
pipe - 4. Outlet water pipe - 5. Oil sump - 6. Engine flywheel
17_055_N
17_056_N

8
SIGNS
Certain warning signs are affixed to the engine by the Manufacturer,
and their meanings are indicated below.
N.B. 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.
Danger of burning:
Expulsion of hot water under pressure.
Danger of burning:
Presence of high temperature parts.
Danger of fire:
Fuel present.
Danger of impact or catching
on moving parts:
Presence of fans, pulleys, belts or the like.

9
ENGLISH
USE
PRELIMINARY CHECKS
Before starting the engine every time:
Check the level of technical fluids (fuel, engine oil and coolant), and
top-up if necessary.
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.
Make sure that the batteries are efficient and that the terminals are
correctly connected.
Note: the required procedures for filter cleaning are specified in the
CHECKS AND MAINTENANCE section.
FOR PROPER USE OF THE ENGINE
The running speed and power values must comply with the
specifications on the technical and commercial documentation.
During use, periodically check that:
- The engine coolant temperature does not reach the alarm
threshold.
- The oil pressure remains within normal values.
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.
1
17_122_N
CAUTION!
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.

10
INTERCONNECTION ELECTRICAL UNIT
In order to allow the unit's correct electrical functioning, an interconnection unit has been fitted to the engine. The engine electronic control system
and the power unit system depend from the aforesaid interconnection unit.
Some indications relating to its components and functions controlled by programming commutators are reported here following.
F5
F1
F2
JX
O N1234
O N1234
JP1
JP4
JP2
JP3
F3 F4 F6
F10
F8
F11
F7
F9
F13
J3
J7
J9
LD3
JS1
JS2
LD1
LD2
CN1
12 3 456789101112
12 3 45
12 3 45678
91012 3 45678
1234567
12 3 4567891011
ON
JP5
STR1
K3 K4
K5
K6 K7
K1
K2
K8
16_350_C

11
ENGLISH
Relay
K1 ATS intelligent sensor
K2 After run B
K3 Run
K4 Starter
K5 SCR heating
K6 Fuel filter heating
K7 Pre-fuel filter heating
K8 Starter control
CN1 Diagnose
Engine speed and accessory functions control
Programming of the functions here following is possible commuting
the position of the JP switches.
JP1(Engine speed selection) +JX (Connector: Engine speed
selection)
JP2: Mode selection
1500 rpm. (50 Hz)
1800 rpm. (60 Hz)
IDLE
Diagnostic position
Working position
(default)

12
JP3: Cold start heater relay
JP4: Cold start lamp
JP5: It CAN line
Connected
Not connected (default)
Connected
Not connected (default)
Connected
Not connected
(default)

13
ENGLISH
SPECIAL WARNINGS
Coolant circuit
When the engine is running, regularly check that the engine coolant
temperature does not reach the alarm threshold.
In case the temperature detected is excessive, disconnect the load and
stop the engine to check the cooling circuit status.
If the temperature is considered too high, reduce speed and stop to
check the state of the cooling system circuits.
Check the following:
a) the tension of the auxiliary member drive belt;
b) the thermostatic valve’s efficiency;
c) the conditions of the heat exchanger (to be cleaned if necessary).
Lubrication circuit
Regularly check that the oil pressure keeps within normal values. In
case the value detected is too low, check the oil level and refill if
necessary following the instructions reported in the CHECKS AND
MAINTENANCE section.
If the condition persists, contact the Authorised Service Centre.
Fuel circuit
Avoid using the engine with small reserve of fuel in the fuel tank. Thus
the vapour condensation is encouraged and makes the engine more
likely to inhale dirt or air, resulting in engine stoppage.
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 particular dusty environments it is necessary to carry out
maintenance within more frequent intervals than indicated in the
CHECKS AND MAINTENANCE section.
CAUTION!
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 when the engine is cold.
CAUTION!
While refuelling, always pay attention to ensure that no
solid or liquid pollutants enter the fuel tank; remember
that smoking and live flames are prohibited during
refuelling.
CAUTION!
Never loose the high pressure fuel circuit connectors in
any way.

14
Electric starter system
Check periodically the cleanliness and efficiency of the batteries,
particularly during winter, as indicated in the CHECKS AND
MAINTENANCE section. Top up if necessary.
In the event of battery replacement, observe the characteristics
contained in the ENGINE TECHNICAL DATA chapter.
RUN-IN
Thanks to modern engine design technology, no particular run-in
procedure is required.
However, for the first 50 hours, it is not recommended to operate the
engine at high power for long periods.
CAUTION!
Visually check that the exhaust circuit is not obstructed
or damaged to prevent the formation of noxious and
harmful fumes inside the ducts.
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).
Th
e 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.

15
ENGLISH
CHECKS AND MAINTENANCE
MAINTENANCE PERSONNEL
The engine control and maintenance operations described in the
following chapter require training, experience and compliance with
current safety regulations. 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 generator set user.
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 Assistance Centres are those which make up the
FPT Technical Assistance Network.
ACCIDENT PREVENTION
Always wear heavy-duty footwear, gloves and suits.
Never wear loose, flapping garments, rings, bracelets and/or
necklaces close to engines or moving parts.
Always wear protective gloves and goggles when:
• filling up batteries with acid solution
• check cleanliness of battery clamps and terminals
• refilling with inhibitors or antifreeze
• replacing or topping up lubricant (hot engine oil may cause
burns and scalds. Only carry out these operations when the oil
has dropped to a temperature of below 50°C).
While working in the engine compartment, pay particular attention
on movements, to avoid contact with moving parts and high
temperature components.
Wear safety goggles while using compressed air jets. Maximum air
pressure used to clean is 200 kPa (2 bar, 30 psi, 2 kg/cm2).
Wear a protective helmet when working in an area were there are
suspended loads or systems installed at/above head-height.
Use protective hand creames.
Immediately replace wet gloves.
Always keep the engine clean removing oil, fuel and coolant stains.
Store cloths in flame-proof containers.
Do not leave external objects on the engine.
Use suitable, safe containers for used oil.
Once the repair activities are completed, take the necessary steps
to stop engine air suction in case of uncontrolled increase in engine
speed after start-up.
Do not carry out maintenance operations when the
electric power supply is turned on: always check to
ensure that the appliances are properly earthed.
During diagnosis and maintenance operations, make
sure that your hands and feet are dry, and whenever
possible use insulating stands.

16
REFILLING
(*) It is prohibited to mix fluids of different brands and origins inside
the circuit.
(1) The quantities refer to the engine in standard configuration. The
coolant should comply with ASTM D-6210 standard.
Concentrated coolants should be used as a 50% mixture in water.
FPT suggest to use original PETRONAS products.
(2) see 'Main oil features'; recommended brand: PETRONAS
The consumption of oil is considered acceptable up to a quantity
of 0.1% of fuel consumption.
(3) The quantities indicated refer to the first filling only and are relative
to the engine, oil sump and filter refilling.
(4) Fuel tank not supplied by FPT.Consult supplier / generator set
manufacturers data.
Only use fuels which comply with ASTM D975 or EN 590
international standards.
(5) The quantities shown are relative to the total capacity of the G-
Drive including engine capacity.
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.
Parts to be supplied NF67TE8W.S550
litres (kg)
Cooling circuit: (*)(1)
motor (4)
G-Drive (5)
10.5 (9.45)
25.5 (22.95)
Lubrication circuit: (2)(3)
total capacity 17.2 (15.48)
Periodic changing:
oil sump at minimum level
oil sump at maximum level
8 (7.2)
12 (10.8)
Fuel tank (4) - (-)

17
ENGLISH
Main oil features
Interval change
* On PowerGeneration application the interval can be extended to 800h pending on field test result and specific selected lube oil be used (high
performance, premium quality).
Oil Quality SAE grade Base Stock International Spec. 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
Mineral Semi
Synthetic Semi
Synthetic
API CI-4 /
CH-4
ACEA E7 / E5
< 1,000 ppm
Low specs
15W-40
10W-30
10W-40
Mineral
API CF, ACEA E2/E3
API CF, ACEA E2/E3
API CE
< 1,000 ppm
Not Allowed Monograde
Engine/ODI Premium & Cold Climate Standard Low specs
NEF 600 h or 12 months* 500 h or 12 months 300 h or 12 months

18
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 ASTM D975 or EN 590
standard normally commercially available. Fuel additives are not
recommended.
Use of additives can limit the guarantee performance offered for the
equipment.
Low temperature diesel
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.
ASTM D975 or EN590 specifications distinguish different classes of
diesel fuel, identifying the characteristics of those best suited to low
temperatures.
It is entirely up to the Oil companies to comply with these regulations,
which foresee that fuels suited to the climactic and geographic
conditions of the various Countries be distributed.
The failure to observe the aforesaid procedure does not
guarantee the presence of the correct quantity of
coolant in the engine.
CAUTION!
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.
CAUTION!
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.

19
ENGLISH
MAINTENANCE SCHEDULE
The maintenance intervals indicated below take into account the
typical working factors for various types of engine use; the most
suitable interval for maintenance operations for the various
applications will be indicated by the maintenance staff, according to the
way and working conditions in which the engine is used.
FREQUENCY
The maintenance intervals indicated below take into account the
typical working factors for various types of engine use; the most
suitable interval for maintenance operations for the various
applications will be indicated by the maintenance staff, according to the
way and working conditions in which the engine is used.
1. In any case, whenever the indicator is Red.
2. See Main oil features table for recommended products & adjusted
service interval.
3. EN 590; ASTM D975
4. Valid only for the recommended fluids.
5. Interval to be halved for ambient condition with high dust
concentration.
6. Coolant according to ASTM D 6210 specification; 50% mixture in
water in case of concentrated product.
Controls in periods of use
Frequency
Hours Temporal
Engine lubricant oil level check - Daily
Engine coolant level check - Daily
Engine visual inspection * 50 15 days
Air filter and housing cleanness check * - 1 month (1)
Tension and condition check of auxilary
members' belt * 300 6 months
Electrolyte level in batteries check * 300 6 months
Exhaust duct(s) condition check - 6 months
Blow-by system condition check * 300 6 months
Periodic maintenance Frequency
Hours Temporal
Water drainage from the fuel pre-filter* 50 1 week
Condensed water drainage from fuel
tank * 50 1 week
Heat exchanger (radiator) cleaning - 6 months
Turbocharger visual inspection - 6 months
Engine lubricant oil replacement * 600 1 year (2)
Lubricant oil filter replacement * 600 1 year (2)
Fuel pre-filter replacement* 600 1 year (3)(8)
Fuel filter replacement * 600 1 year (3)(7)
Blow-by filter replacement * 900 1 year (4)
Air filter replacement * 1,200 2 years (5)
Auxilary members' belt replacement 1,200 3 years (5)