Series: Use and Maintenance Uso E Manutenzione Utilisation Et Entretien Betrieb Und Wartung Uso Y Mantenimiento

USE AND MAINTENANCE
USO E MANUTENZIONE
UTILISATION ET ENTRETIEN
BETRIEB UND WARTUNG
USO Y MANTENIMIENTO
NEF SERIES
POWER GENERATION ENGINES
Publication edited by:

FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print L31901148 - 10/2023
N45MNAA85
English
N45MNSA85
N45MNSA86
N45MNSX88
N45MNSX89
N45MNTA65
N45MNTA66
N45MNTX68
NEF45AM1A
NEF45AM2
NEF45SM1A
NEF45SM1F
English
NEF45SM1X
NEF45SM2A
NEF45SM2X
NEF45SM3
NEF45TM1A
NEF45TM2A
NEF45TM3
NEF45TM2X
USE AND MAINTENANCE
1 GENERAL INFORMATION
English
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety warnings symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Technical data of the engine NEF45 AM1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
External view NEF45 AM1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Technical data of the engine NEF45 AM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
External view NEF45 AM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Technical data of the engine N45MNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
External view N45MNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Technical data of the engine N45MNS - N45MNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
External view N45MNS - N45MNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Technical data of the engine NEF45SM1A/SM2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Technical data of the engine NEF45 SM1X/SM2X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Technical data of the engine NEF45TM1A/TM2A/TM2X/TM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
External view NEF45TM1A/TM2A/TM2X/TM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Technical data of the engine NEF45SM1F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
External view NEF45SM1F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Technical data of the engine NEF45SM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
External view NEF45SM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Identification plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2 USE
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Engine pre-heating (optional) NEF 45 AM1A/AM2A/SM1X/SM2X/SM1F/SM3/TM1A/TM2A/TM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Engine pre-heating (optional) N45MNA/MSA/MNS/MSS/MNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Starting and stopping the engine NEF 45 MNA/MSA/MNS/MSS/MNT/MST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Recognition of alarm statuses NEF 45 MNA/MSA/MNS/MSS/MNT/MST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
SWITCHING WORKING FREQUENCY NEF45 SM1A/SM2X/TM1A/TM2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
For correct engine use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Special warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3 INSPECTION AND MAINTENANCE
Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Refilling NEF45AM1A/SM1A/SM2A/SM1X/SM2X/TM1A/TM2A — N45MNA/MNS/MNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Refilling NEF45AM2/SM1F/SM3/TM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Main characteristics of oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Coolant fluid filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Programmed maintenance plan specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Safety notes - Check engine lubricant oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Check engine lubricant oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Safety notes - Check engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Engine coolant level check (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Safety note - Check that the heat exchanger is clean (radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Check the cleanliness of the heat exchanger (radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Safety notes - Checking and cleaning the oil vapour recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Check and clean oil vapour recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Safety notes - Check air filter and clean housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Check cleanliness of the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Safety notes - Water draining from fuel filter/pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Drain water from the fuel pre-filter/filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Safety notes - Draining condensate from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Drainage or suction of impurities from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Safety notes - Check condition of auxiliary belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Check tension and condition of ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Safety notes - Replace fuel filter(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Fuel filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Safety notes - Replace fuel pre-filter (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Fuel pre-filter replacement (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Safety notes - Replace engine lubricant oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Change engine lubricant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Safety notes - Replace engine lubricant oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Oil filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Safety notes - Replace blow-by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Replacing the blow-by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Safety notes - Change engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Change engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
English
Safety notes - Air filter replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Change air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Safety notes - Visually inspect the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Visually inspect turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Check the efficiency of the pre-post heating system (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Safety notes - Check integrity of exhaust pipe(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Check the condition of the exhaust duct(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Safety note - Check tightness and clean battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Check tightening and cleanliness of battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Safety notes - Check/top up electrolyte level in the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Check/top up electrolyte level in the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Safety notes - Replace auxiliary components belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Change the ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Safety Notes - Injector Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Injector calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Injection pump overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Safety notes - Adjustment of rocker arms-valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Valve/rocker arm clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Safety notes - Engine handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Moving the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Disposal of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 LONG PERIOD OF INACTIVITY

Preparing the engine for a long period of inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Start the engine after a long period of inactivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5 BEHAVIOUR IN EMERGENCY
For personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1 - GENERAL INFORMATION
English
Guarantee Liability
For the engine to perform at its best and to be covered by the FPT war- The manufacturer shall be held responsible provided that the checks and
ranty, pay close attention to the instructions provided in this manual; failure maintenance work indicated and described in this manual are carried out;
to observe the instructions could invalidate the warranty. it shall therefore be necessary to provide proof that such maintenance
work has been carried out. Non-routine maintenance work must by carried
Spare parts out by qualified technicians from workshops belonging to the FPT network,
using the tools and equipment that have been specifically provided.
Always use original FPT spare parts. This will enable the engine to run as
efficiently as it did originally.
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.
15
Safety Risk of intoxication or poisoning
Make sure that no combustible vapours or gasses are
The following information is intended to encourage caution when using
present in the area in which the engine is to operate.
the engine, so as to avoid damage to persons or property as a result of
Failure to comply with these prescriptions can result in the
improper or incorrect behaviour.
risk of serious injury
1) Danger to persons. Warnings - safety instructions for the operator and
maintenance personnel
Risk of intoxication or poisoning
The main sources of risk to the health and safety of the operator and main- Do not breathe fumes from liquids, fluids and solvents. Do
tenance personnel are related to: the environment in which the "finished" not breathe in engine exhaust fumes.
machine operates, the temperatures reached by the engine surfaces, the Failure to comply with these prescriptions can result in the
engine liquid-fluids, the toxicity of the liquid-fluids and the exhalation of risk of serious injury
exhaust gases.
There are also possible sources of risk: the presence of guards and sharp- Risk of burns
edged surfaces, the use of solvents and cleaning powders, high pressure The engine and the exhaust heat up during operation. Be-
of liquids-fluids in the engine circuits, the methods used for handling the fore working on the inside of the engine compartment, and
engine and components. to prevent the risk of burns, open the engine compartment
and let the components cool down to a temperature which
It is therefore essential to adhere to the following safety requirements.
allows them to be touched.
Risk of injury: risk of serious injury
Use designated PPE (gloves, safety shoes, glasses, etc.)
risk of serious injury Risk of injury:
Avoid contact with liquids and fluids when the engine is hot:
risk of burns.
Risk of injury: Failure to comply with these prescriptions can result in the
Use suitable clothing, preferably tight-fitting; do not wear risk of serious injury
chains, rings, etc.
16
Risk of injury: Risk of explosion
English
All flammable fluids and liquids must be handled with care Engine with CNG - LNG fuel systems: make the fuel system
according safe (LOTO) before
to the product safety data sheets. working on it; accidental leakage of gas from the system
In case of accidental contact, consult product safety data can cause it to explode.
sheets. Failure to comply could result in death or serious injury.
Store fluids and liquids in containers that comply with regu-
lations.
Failure to comply with these prescriptions can result in the Risk of injury:
risk of serious injury During maintenance work on the engine, pay careful atten-
tion to sharp parts and/or edges and/or surfaces such as
guards, heat shields (if present)
The engine oil is highly pollutant and harmful. In case of risk of serious injury
contact with the skin, wash thoroughly with soap and water.
Protect skin and eyes appropriately; work in accordance with
accident prevention regulations. Risk of injury:
Failure to comply with these prescriptions can result in the Due to the high pressure in the pipes which go from the high
risk of serious injury pressure pump to the rail and from the rail to the electro-
injectors, do not under any circumstances:
- disconnect the pipes with the engine running;
Fire risk - reuse the disassembled pipes.
Pay close attention to glowing parts and guards with warning Failure to comply with these prescriptions can result in the
pictograms. risk of serious injury
Risk of injury:
When the engine is hot, the pressure inside the cooling cir-
Fire risk! cuit can be such that it may expel the hot liquid in an ex-
Fire hazard: pay careful attention to flammable liquids, dusts tremely violent manner with the risk of burns. Only open the
and vapours. refill plug of the coolant tank when the engine is cold.
Failure to comply could result in death or serious injury. Failure to comply with these prescriptions can result in the
17
Risk of injury when lifting and carrying heavy loads! Risk of injury and accidents in the case of improper use!
Use suitable lifting equipment and load securing devices. Observe the maintenance instructions. If in any doubt, con-
Failure to comply could result in death or serious injury. tact the Service Network before proceeding.
Failure to comply could result in death or serious injury.
18
2) Risk of serious damage to the engine. Warnings - specifications for the General prescriptions
English
correct use and maintenance of the engine Extraordinary maintenance operations are the only to be car-
ried out by qualified personnel with the appropriate technical
The main warnings - specifications to be followed when working on the
knowledge and equipped with suitable working and protec-
engine in order to correctly carry out component replacement and/or en-
tion means. All the technical instructions are provided in the
gine maintenance operations are provided.
FPT repair and technical manuals.
Compliance with the following specifications will protect the engine from Non-compliance, full or partial, with these specifications may
damage. entail the risk of serious engine damage and may also, at
times, invalidate the warranty.
General prescriptions
For correct engine operation, only use recommended oils or
oils with the required characteristics. In the case of refilling,
Worn, damaged or consumable parts must be replaced with
do not mix oils with different characteristics. Failure to ob-
original FPT parts.
serve these indications will void the guarantee.
Non-compliance, full or partial, with these specifications may
entail the risk of serious engine damage and may also, at
Always keep the work area clean during workshop opera-
Before pressure washing mechanical parts, protect electrical
tions; immediately clean the surfaces of the work area from
connectors and
any liquids, fluids or oils which may have leaked.
any control units. Do not use excessive washing pressures
< 2 bar, keep the lance more
than 20 cm away from the engine.
19
General prescriptions General prescriptions
Before working on the electrical system, disconnect the bat- The components of the common rail system will be quickly
teries from the system. damaged if the fuel contains water or other impurities. Im-
Disconnect the ground cable and then the positive cable. mediately carry out the operation on the pre-filter to drain the
The order must be reversed when connecting water in the supply circuit.
the batteries. Do not reverse the polarity of the cables on Non-compliance, full or partial, with these specifications may
the battery; it can cause irreparable entail the risk of serious engine damage and may also, at
damage to control units. times, invalidate the warranty.
Failure to observe the indications provided could cause dam-
age to the engine.
Replace the auxiliary belt if abrasions, cracks or tears, oil or
General prescriptions fuel soiling can be seen
Do not start the engine with quick charger power packs. Non-compliance, full or partial, with these specifications may
Disconnect the battery from the electrical system before entail the risk of serious engine damage and may also, at
charging. times, invalidate the warranty.
Failure to observe the indications provided could cause dam-
age to the engine.
Make sure that the oil dipstick is fully inserted and that the
General prescriptions oil filler cap is fully tightened in a clockwise direction.
Do not utilize fast screw tightening tools. Non-compliance, full or partial, with these specifications may
Failure to observe the indications provided could cause dam- entail the risk of serious engine damage and may also, at
age to the engine. times, invalidate the warranty.
General prescriptions Maintenance not carried out correctly!

The forced regeneration of the exhaust gas post-treatment In order to maintain the efficiency of the all parts of the en-
device is a procedure which must always be carried out by gine during use, the specifications indicated in this preven-
Service Centres and can only be activated via a diagnostics tive maintenance plan and the relevant replacement proce-
tool. dures must be carried out punctually.
Non-compliance, full or partial, with these specifications may Non-compliance, full or partial, with these specifications may
entail the risk of serious engine damage and may also, at entail the risk of serious engine damage and may also, at
times, invalidate the warranty. times, invalidate the warranty.
20
General prescriptions General risk, general prescriptions
English
If the installation of mechanical or electromechanical option- Engines must only be used for the applications declared by
als is required, always the manufacturer
refer to the "FPT Installation Guide" documents. Failure to comply completely or partially with these require-
Failure to observe the indications provided could cause dam- ments may result in the risk of serious damage to the engine
age to the engine and its electrical architecture. and may even, on occasion, invalidate the warranty
Warnings - specific requirements for marine applications

General risk, general prescriptions
The engine must not be started up and used unless it
meets the safety requirements for the machine on which it is General prescriptions
mounted and before it has been ascertained that it complies Each time the engine is started, check that the sea water
with local standards and regulations. intake valve is open. Dry operation of the sea water pump
Failure to comply completely or partially with these require- causes irreversible damage to the internal impeller within
ments may result in the risk of serious damage to the engine just a few seconds.
and may even, on occasion, invalidate the warranty Non-compliance, full or partial, with these specifications may
The engine must not be started up and used unless it
meets the safety requirements for the machine on which it is
mounted and before it has been ascertained that it complies
with local standards and regulations.
Failure to comply completely or partially with these require-
ments may result in the risk of serious damage to the engine
and may even, on occasion, invalidate the warranty
21
3) General danger. Warnings - safety instructions for the operator, main- General prescriptions
tenance personnel and for correct engine maintenance Before proceeding with any work on the engine, operation or
maintenance, carefully read the technical service documen-
The main warnings - specifications to be observed when working on the
tation, owner's manual and repair manual of both the engine
engine are provided in order to carry out maintenance operations on the
and the complete vehicle to learn all the functional and nec-
engine correctly, to avoid potential dangerous situations for the operator
essary notions for repairs
and maintenance personnel.
Failure to observe this indication could lead to serious per-
Compliance with the following specifications will also protect the engine sonal injury and damage to the engine.
from damage.
All flammable fluids and liquids must be handled with care
Maintenance checks and interventions must be carried out
according to the product safety data sheets.
with the engine switched off, unless specifically indicated by
Store fluids and liquids in containers that comply with regu-
the type of check or intervention. Becoming familiar with
lations.
some simple control and verification procedures is very im-
portant.
sonal injury and damage to the engine.
risk of serious injury and serious damages to the vehicle
Fire risk
Do not smoke or light open flames near batteries, flammable
Risk of injury and accidents in the case of improper use!
liquids and fluids.
Observe the maintenance instructions. If in any doubt, con-
tact the Service Network before proceeding.
Use the specific and general tools according to the speci-
Any intervention on the systems and any maintenance op-
fications of the respective user and maintenance manuals.
erations must be carried out by authorized technicians.
Check the state of wear and the suitability of the tools which
The equipment and tools used for fine-tuning, maintenance
are not subject to periodical checks.
or repair work must be approved by the manufacturer.
22
General prescriptions General specifications – engine stop
English
Handling of components during maintenance work must be In emergency situations, if present, switch off the engine
assessed in advance in order to choose the best solution to using the emergency stop button. Before working on the
be adopted according to weight, shape-volume and position engine, wait for the surfaces to cool down.
Failure to observe this indication could lead to serious risks Failure to observe this indication could lead to serious per-
to health and damage to the engine - component. sonal injury and damage to the engine.
General specifications (handling of components «> 25kg») General prescriptions

When lifting using a crane or hoist, pay careful attention to Always carry out interventions with the engine stopped; if
the affixing points. The items attached must be cantilevered. special circumstances require maintenance with the engine
Furthermore, the affixing point must be firm, to prevent struc- running, consider all the risks involved before proceeding.
tural yield during the lifting stages. Pay close attention to moving parts.
Failure to observe this indication could lead to serious per- Failure to observe this indication could lead to serious per-
sonal injury and damage to the engine. sonal injury and damage to the engine.
General specifications (engine lifting accessories) Risk of injury:

Lifting the engine by means of cranes or hoists must only Make sure that the guards of moving parts are correctly po-
be carried out using the engine lifting accessories on the en- sitioned and pay attention to the warning pictograms on the
gine. Use hoists or cranes with a lifting capacity appropriate engine.
to the weight of the engine. Do not stand under the manoeu- Failure to observe this indication could lead to serious per-
vring area during handling sonal injury and damage to the engine.
Pay close attention to the adhesive safety labels on the en-
General prescriptions gine.
Use only the specific equipment listed in the repair manual Failure to observe this indication could lead to serious per-
and standard equipment that complies with regulations. sonal injury and damage to the engine.
23
General prescriptions the engine, it is always necessary to ensure that these potential hazards
The safety guards should only be removed when the engine cannot occur. The specifications and functional descriptions in the operat-
is switched off and must always be reset correctly at the end ing and maintenance manual of the complete machine must be observed.
of the operation before starting the engine.
Affix appropriate signs at the machine control station indicating that the
engine - machine is being serviced; use appropriate devices that inhibit
accidental start-up of the engine.
The complete machine may have auxiliary devices such as emergency

General prescriptions switches/emergency functions; these are to be used in the event of an
Maintenance procedures requiring engine start-up, for ex- emergency.
ample during the forced regeneration procedure of ATS sys-
tems. When the engine is warm and in specific engine - machine assembly con-
The guards present on moving parts must be properly se- ditions, the belt pulleys of the auxiliary organs can rotate.
cured; wear sound-proof headphones.
Failure to observe this indication could lead to serious per- It is therefore essential to adhere to the following safety requirements
General specifications – engine stop
In emergency situations, if present, switch off the engine
General risk, general prescriptions using the emergency stop button. Before working on the
Always keep the engine clean; remove oil, fuel and coolant engine, wait for the surfaces to cool down.
stains. Failure to observe this indication could lead to serious per-
Failure to observe this indication could lead to serious personal injury and damage to the engine.
Risk of injury:
General risk, general prescriptions Always operate with a cold engine in order to prevent
Do not leave external objects on the engine. electromechanical engine components from activating sud-
Failure to observe this indication could lead to serious per- denly due to the temperatures reached by the engine.
sonal injury and damage to the engine. Failure to comply with these prescriptions can result in the
Warnings - safety and operating instructions related to the engine appli-

cation
Potentially dangerous conditions such as unexpected engine start-up may

occur as the application changes. Before proceeding with interventions on
24
Gen--set applications - Warnings - specific requirements
Gen
English
The work required to ensure the best possible use and
preservation of the engine must only be assigned to person- General prescriptions
nel with proven competence and equipped with tools whose The conditions which cause the emergency generator as-
suitability is recognised by FPT. sembly to start may occur unexpectedly. Always pay careful
Failure to observe this indication could lead to serious per- attention to the safety precautions indicated by the Manu-
sonal injury and damage to the engine. facturer of the assembly and the generator Bodybuilder to
ensure the maximum safety of the maintenance technicians
Failure to observe this indication could cause serious per-
sonal injury.
25
4) Safeguarding the environment. Warnings - requirements to protect the General risk, general prescriptions
environment Dispose of consumables in accordance with the law, for
example: filters, fluids and any rags - paper rags soaked
The main warnings - specifications for environmental protection are given.
in liquids and fluids. FPT Service Network workshops are
equipped for this.
Disposal of liquids Correct behavior will ensure that vehicle is used as environ-
Arrange containers to recover the coolant, diesel and oil from mentally friendly as possible
the power steering and fan control hydraulic systems.
Correct behavior will ensure that vehicle is used as environ-
mentally friendly as possible General prescriptions
Rags soaked in flammable liquids must be replaced in con-
tainers which are suitable and comply with current legisla-
tion.
mentally friendly as possible
26
Safety warnings symbols
English
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.
27
Technical data of the engine NEF45 AM1A TYPE--
TYPE
Gross stand stand--by
stand--by Gross stand
MODEL power (1500 power (1800
The technical code and serial number are indicated on a plate, which is APPROVAL
rpm) (*) rpm)
located on different parts of the engine, according to the model: flywheel -
casing, tappet cover, other. GENSET/ NEF45AM1A 47 kWm
2002/88
Code NEF45 AM1A
(*) Power at the flywheel in accordance with directive 97/68 CE (without
Engine series F4
fan), after 50 h of operation, tolerance ± 5%, fuel EN590;
Cycle Diesel 4-stroke
Test in accordance with specification ISO 3046/1, turbocharger inlet air
Number and arrangement of °C, atmospheric pressure 100 kPa
temperature 25 °C kPa, humidity 30
30%%. Also in
4, in line
cylinders compliance with DIN 6271 , BS 5514 , SAE J1349.
Bore x stroke 104 mm x 132 mm
All the data is based on engine operation with fuel system, water pump,
Total displacement 4500 cm³ lubricant oil pump and intake and exhaust restriction within or below, the
Air supply Natural aspiration limits indicated in the "data sheet".
Injection type Direct injection with rotary pump

Anticlockwise (seen from flywheel It is strictly prohibited to modify the characteristics indicated
Engine direction of rotation
side) above. If modifications are made, the warranty is invalidated
Speed regulator Mechanical and FPT is in no way responsible.
Dry weight - ments may result in the risk of serious damage to the engine
Electrical system 12 V
Accumulator/s
- capacity 100 A·h or greater
- discharge current ( EN 50342) 650 A or greater
28
External view NEF45 AM1A
English
Left side view
1. Heat exchanger
2. Coolant inlet plug
3. Lubricating oil filler cap
4. Engine air intake manifold
5. Injection pump
6. Air filter
7. Fuel outlet fitting to tank
8. Fuel inlet connector from the tank
9. Hand pump
10. Oil dipstick
11. Fuel filter with condensate drain plug
12. Fan
29
Right side view
1. Lifting hook
2. Exhaust manifold
3. Oil vapour breather
4. Exhaust gas outlet
5. Lifting hook
6. Engine coolant outlet connector
7. Thermostat valve location
8. Engine coolant inlet coupling sleeve
9. Alternator
10. Lubricant oil drain plug
11. Oil filter
12. Electrical starter motor
30
Technical data of the engine NEF45 AM2 TYPE--
TYPE
English
rpm) (*) rpm)
casing, tappet cover, other. Non Emissions NEF45AM2 52 kWm
Certified
Code NEF45 AM2
Engine idle 50 Hz 1500 RPM
Engine series F4
speed unladen 60 Hz – RPM
Maximum 50 Hz 1570 RPM
Number and arrangement of engine rpm 60 Hz – RPM
4, in line
cylinders unladen
Total displacement 4500 cm³ fan), after 50 h of operation, tolerance ± 5%, fuel EN590;
Air supply Natural
Injection type Direct injection with rotary pump °C, atmospheric pressure 100 kPa
30%%. Also in
Compression ratio 17.5 : 1 compliance with DIN 6271 , BS 5514 , SAE J1349.
Cooling Liquid based All the data is based on engine operation with fuel system, water pump,
lubricant oil pump and intake and exhaust restriction within or below, the
Anticlockwise (seen from flywheel
Engine direction of rotation limits indicated in the "data sheet".
side)
Speed regulator Mechanical
Dry weight ~ 400 kg (G-Drive) It is strictly prohibited to modify the characteristics indicated
above. If modifications are made, the warranty is invalidated
and FPT is in no way responsible.
Accumulator/s ments may result in the risk of serious damage to the engine
- capacity 100 A·h and may even, on occasion, invalidate the warranty
- pick-up current 60 A
- Maximum power rating 3 kW
- discharge current ( EN 50342) 650 A
31
External view NEF45 AM2
Left side view

3. Engine comburent air intake duct
4. Fuel supply rotating pump
5. Fuel suction pump
6. Fuel filter
7. External air / coolant heat exchanger
32
Right side view
English
1. Lifting hook
2. Exhaust manifold
3. Regulating valve (blow-by)
4. Oil vapour breather pipe
5. Engine coolant outlet pipe
6. Fan (radiator)
7. Engine coolant inlet pipe
8. Oil filter
9. Heat exchanger lubricant oil/coolant
10. Electric starter motor
33
Technical data of the engine N45MNA TYPE--
TYPE
rpm) (*) rpm)
casing, tappet cover, other. GENSET/ N45MNAA85 47 kWm
2002/88
Code N45MNA
Engine series F4
30%%. Also in
4, in line
Air supply Natural aspiration limits indicated in the "data sheet".

Risk of damage
Anticlockwise (seen from flywheel It is strictly forbidden to alter the aforesaid characteristics
side) and, in particular, to modify the stored data in the injection
Dry weight 380 kg (G-Drive) system's electronic units or the characteristics of the engine
and its components.
Electrical system 12 V ments may result in the risk of serious damage to the engine
Accumulator/s and may even, on occasion, invalidate the warranty
34
External view N45MNA
English
Left side view
1. Auxiliary assembly drive belt

2. Fuel filter
3. Oil filler cap
5. Engine air intake
6. Lifting hook
7. Injection Pump
8. Variator device for advance cold injection
10. Fuel delivery pump
11. Oil drain plug
12. Oil dipstick
13. Condensate draining plug from fuel filter.
35
Right side view
1. Exhaust manifold
4. Lifting hook
5. Engine coolant outlet
7. Alternator
8. Engine coolant inlet
9. Lubricant oil filter
36
Technical data of the engine N45MNS - N45MNT TYPE--
TYPE
English
rpm) (*) rpm)
casing, tappet cover, other. GENSET/ N45MNSA85. 74 kWm
2002/88
Code N45MNS - N45MNT GENSET/ N45MNSA86. 60 kWm -
Engine series F4 2002/88
TIER 3 N45MNSX88. - 69 kWm
TIER 3 N45MNSX89. - 59 kWm
Number and arrangement of
4, in line
cylinders GENSET/ N45MNTA65. 98 kWm -
Bore x stroke 104 mm x 132 mm 2002/88
GENSET/ N45MNTA66. 87 kWm -
Total displacement 4500 cm³
2002/88
Air supply Supercharged - Aftercooled (1)
TIER 3 N45MNTX68. - 98 kWm
Anticlockwise (seen from flywheel (*) Power at the flywheel in accordance with directive 97/68 CE (without
side) fan), after 50 h of operation, tolerance ± 5%, fuel EN590;
Dry weight 390 kg Test in accordance with specification ISO 3046/1, turbocharger inlet air
°C, atmospheric pressure 100 kPa
30%%. Also in
(1) Excluding versions N45 MNS / MSS compliance with DIN 6271 , BS 5514 , SAE J1349.
Electrical system 12 V All the data is based on engine operation with fuel system, water pump,
Accumulator/s
limits indicated in the "data sheet".
- capacity (*)) or higher
100 A·h ( 180 A·h (*)
- discharge current ( EN 50342) (*)) or higher
650 A ( 950 A (*)
Risk of damage
It is strictly forbidden to alter the aforesaid characteristics
(*) For N45MSS TIER 3 74 kW
and, in particular, to modify the stored data in the injection
system's electronic units or the characteristics of the engine
and its components.
37
External view N45MNS - N45MNT
Left side view
1. Auxiliary assembly drive belt

2. Fuel filter
3. Oil filler cap
6. Lifting hook
7. Injection Pump
8. Variator device for advance cold injection
10. Fuel delivery pump
11. Oil drain plug
12. Oil dipstick
13. Condensate drain plug from fuel filter
38
Right side view
English
1. Exhaust manifold
2. Turbocharger air inlet
3. Supercharging air outlet (only for engines N45 MNT/MST)
4. Turbocharger
5. Turbocharger exhaust gas outlet
6. Engine air intake
7. Lifting hook
8. Engine coolant outlet
9. Thermostatic valve location
10. Alternator
11. Engine coolant inlet
12. Lubricant oil filter
39
NEF45SM1A//SM2A
Technical data of the engine NEF45SM1A TYPE--
TYPE
rpm) (*) rpm)
located on different parts of the engine, according to the model: flywheel
casing, tappet cover, other. GENSET/ NEF45SM1A 60 kWm 67 kWm
2002/88
Code SM1A//SM2A
NEF45 SM1A GENSET/ NEF45SM2A 74 kWm -
Engine series F4 2002/88

Number and arrangement of fan), after 50 h of operation, tolerance ± 5%, fuel EN590;
4, in line
cylinders
Bore x stroke 104 mm x 132 mm °C, atmospheric pressure 100 kPa
30%%. Also in
Total displacement 4500 cm³ compliance with DIN 6271 , BS 5514 , SAE J1349.
Air supply Natural aspiration All the data is based on engine operation with fuel system, water pump,
Injection type Direct injection with rotary pump lubricant oil pump and intake and exhaust restriction within or below, the
Compression ratio 17.5 : 1
Anticlockwise (seen from flywheel General prescriptions
side) It is strictly prohibited to modify the characteristics indicated
Speed regulator Mechanical above. If modifications are made, the warranty is invalidated
Dry weight ~ 450 kg (G-Drive) Failure to comply completely or partially with these require-
Electrical system 12 V and may even, on occasion, invalidate the warranty
Accumulator/s
- capacity 100 A·h
— Discharge current ( EN 50342 ) 650 A
40
SM1X//SM2X
Technical data of the engine NEF45 SM1X TYPE--
TYPE
English
rpm) (*) rpm)
casing, tappet cover, other. Stage IIIA / Tier NEF45SM1X 59 kWm
3
Code NEF45SM1X//SM2X
NEF45SM1X Stage IIIA / Tier NEF45SM2X - 69 kWm
Engine series F4 3

Number and arrangement of fan), after 50 h of operation, tolerance ± 5%, fuel EN590;
4, in line
cylinders
Bore x stroke 104 mm x 132 mm °C, atmospheric pressure 100 kPa
30%%. Also in
Total displacement 4500 cm³ compliance with DIN 6271 , BS 5514 , SAE J1349.
Air supply Supercharged - Aftercooled All the data is based on engine operation with fuel system, water pump,
Injection type Direct injection with rotary pump lubricant oil pump and intake and exhaust restriction within or below, the
Anticlockwise (seen from flywheel General prescriptions
side) It is strictly prohibited to modify the characteristics indicated
Speed regulator Mechanical above. If modifications are made, the warranty is invalidated
Accumulator/s
41
NEF45TM1A//TM2A
Technical data of the engine NEF45TM1A TM2A//TM2X
TM2X// TYPE--
TYPE
TM3 MODEL power (1500 power (1800
APPROVAL
rpm) (*) rpm)
The technical code and serial number are indicated on a plate, which is GENSET/ NEF45TM1A 87 kWm 98 kWm
located on different parts of the engine, according to the model: flywheel 2002/88
casing, tappet cover, other.
GENSET/ NEF45TM2A 98 kWm 109 kWm
Code NEF45TM1A//TM2A
NEF45TM1A TM2A//TM2X
TM2X//TM3 2002/88
Engine series F4 Non Emissions NEF45TM2X - 98 kWm
Certified
Non Emissions NEF45TM3 120 kWm -
Number and arrangement of Certified
4, in line
cylinders
Bore x stroke 104 mm x 132 mm (*) Power at the flywheel in accordance with directive 97/68 CE (without
Air supply Supercharged - Aftercooled Test in accordance with specification ISO 3046/1, turbocharger inlet air
°C, atmospheric pressure 100 kPa
30%%. Also in
compliance with DIN 6271 , BS 5514 , SAE J1349.
Engine direction of rotation lubricant oil pump and intake and exhaust restriction within or below, the
side)
Speed regulator Mechanical
Dry weight ~ 500 kg (G-Drive) General prescriptions
It is strictly prohibited to modify the characteristics indicated
Accumulator/s Failure to comply completely or partially with these require-
- capacity 100 A·h ments may result in the risk of serious damage to the engine
- pick-up current 60 A and may even, on occasion, invalidate the warranty
— Discharge current ( EN 50342 ) 650 A
42
NEF45TM1A//TM2A
External view NEF45TM1A TM2A//TM2X
TM2X//TM3
English
Left side view
1. Heat exchanger(s)
4. Engine air intake manifold
6. Lifting hook
7. Air filter
8. Injection pump
11. Hand pump
12. Oil dipstick
13. Condensate drain plug from fuel filter
14. Fuel filter.
43
Right side view
1. Exhaust manifold
2. Turbocharger air intake
3. Supercharging air outlet
4. Turbocharger
6. Lifting hook
7. Engine coolant outlet connector
9. Engine coolant inlet coupling sleeve
10. Fan
11. Alternator
12. Lubricant oil drain plug
13. Oil filter
44
Technical data of the engine NEF45SM1F TYPE--
TYPE
English
rpm) (*) rpm)
casing, tappet cover, other. STAGE IIIA / NEF67SM1F 62 kWm
TIER 3
Code NEF45SM1F
Engine series F4
30%%. Also in
4, in line
Pneumatic system Turbocharged without intercooler limits indicated in the "data sheet".
Injection type Direct injection

Risk of damage
Anticlockwise (seen from flywheel It is strictly forbidden to alter the aforesaid characteristics
side) and, in particular, to modify the stored data in the injection
Speed regulator Mechanical system's electronic units or the characteristics of the engine
and its components.
Accumulator/s
- discharge current 650 A or greater
45
External view NEF45SM1F
Left side view
1. Oil vapour filter

2. Lifting hook
3. Air filter
4. Injection pump
5. Flywheel case
6. Priming pump
7. Oil recovery pump
8. Dipstick
9. Fuel filter
11. Oil filler cap
12. High-pressure pipes
13. Turbocharger air inlet
46
Right side view
English
1. Lifting hook
2. Coolant outlet pipe
3. Fan
4. Water pump
5. Coolant intake pipe
6. Oil sump
7. Oil recovery pump
8. Oil filter
9. Starter motor
10. Lubricant return pipe from turbocharger
11. Exhaust manifold
12. Air filter
13. Oil delivery to the turbocharger contact
14. Turbocharger
47
Technical data of the engine NEF45SM3 TYPE--
TYPE
rpm) (*) rpm)
casing, tappet cover, other. Non Emissions NEF45SM3 82 kWm
Certified
Code NEF45SM3
Engine idle 50 Hz 1500 RPM
Engine series F4
speed unladen 60 Hz – RPM
Maximum 50 Hz 1570 RPM
Number and arrangement of engine rpm 60 Hz – RPM
4, in line
cylinders unladen
Air supply Supercharged with turbocharger
Injection type Direct injection with rotary pump °C, atmospheric pressure 100 kPa
30%%. Also in
Compression ratio 17.5 : 1 compliance with DIN 6271 , BS 5514 , SAE J1349.
Cooling Liquid based All the data is based on engine operation with fuel system, water pump,
Engine direction of rotation limits indicated in the "data sheet".
side)
Speed regulator Mechanical General prescriptions
Dry weight ~ 450 kg (G-Drive) It is strictly prohibited to modify the characteristics indicated
Accumulator/s ments may result in the risk of serious damage to the engine
- capacity 100 A·h and may even, on occasion, invalidate the warranty
- discharge current ( EN 50342) 650 A
48
External view NEF45SM3
English
Left side view
1. Comburent air inlet 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
49
Right side view

3. Regulating valve (blow-by)
4. Lifting hook
5. Oil vapour breather pipe
6. Fuel supply rotating pump
7. Fuel suction pump
8. Fuel filter
9. External air / coolant heat exchanger
50
Identification plate 1. Box "A" Model
English
2. Box "B" S/N
3. RPM)
Box "C" Gross stand-by power ( 1500 RPM / 1800 RPM
4. Box "D" G-Drive weight
5. Box "E" Date
6. Box "F" P/N
51
2 - USE
Preliminary checks • Check and top up the level of the technical fluids, if necessary (fuel,
engine oil and coolant).
General risk, general prescriptions • Make sure that the air intake filter is not obstructed or clogged.
Before proceeding with the operation, please refer to the
section 'Warnings and safety instructions". • Make sure that the batteries are efficient and that the terminals are
correctly connected.
sonal injury and damage to the engine. Requirements
• Do not disconnect the battery supply while the engine is running.

Risk of injury:
• Do not perform arc welding near the engine without first removing its
Make sure there are no vapours of fuel or gas in the engine electrical wiring.
area. Check that all the areas are suitably ventilated and
equipped with a suitable extraction system. • After all maintenance operations that require disconnection of the bat-
Failure to comply with these prescriptions can result in the teries, make sure the clamps have been securely reconnected on the
risk of serious injury terminals.
• Do not use a battery charger to start the engine.
General prescriptions • Electrically disconnect the battery/ies from the network during charging.
Make sure there are no vapours of fuel or gas in the engine • Do not paint the devices, components and electrical connectors of the
area. Check that all the areas are suitably ventilated and engine equipment.
equipped with a suitable extraction system.
• Electrically disconnect the battery/batteries before performing any elec-
Failure to comply with these prescriptions can result in the trical work.
• Contact the manufacturer before installing any electronic equipment.
Risk of injury: Risk of damage

During maintenance work on the engine, pay careful atten- It is strictly prohibited to intervene on the calibration of the
tion to sharp parts and/or edges and/or surfaces such as injection pump (mechanical injection engines) and the elec-
guards, heat shields (if present) tronic control unit.
Failure to comply with these prescriptions can result in the It is strictly prohibited to tamper with the engine parameters.
risk of serious injury Its adjustment was carried out when the engine was tested
and according to its application..
Every time before starting the engine: ments may result in the risk of serious damage to the engine
52
pre--heating (optional) NEF 45 AM1A
Engine pre AM1A//AM2A
AM2A//SM1X
SM1X// heating element (2), raises the temperature of the air entering the engine.
English
SM2X//SM1F
SM2X SM1F//SM3
SM3//TM1A
TM1A//TM2A
TM2A//TM3 The device is mounted on the intake manifold and is fitted with a coolant
temperature sensor which interrupts the power supply once the required
engines requiring low temperature start-up and immediate power delivery temperature has been reached.
can be fitted with the heating device (1) which, by means of an electrical
53
pre--heating (optional) N45MNA
Engine pre N45MNA//MSA
MSA//MNS
MNS//MSS
MSS// heating device, which allows the temperature of the coolant to be raised or
MNT maintained at suitable values. The device is provided with a thermostat in
order to interrupt power supply when reaching the prescribed temperature.
( 230 V, single phase electrical device)
The engines for which low temperature start-up and immediate delivery
of power are required may be fitted with a 230 V single phase electrical
54
MNA//MSA
Starting and stopping the engine NEF 45 MNA MSA//MNS
MNS//MSS
MSS//MNT
MNT//MST
English
The methods for starting and stopping the engine described as follows
refer to a vehicle fitted with an FPT produced instrument panel The meth-
ods for starting and stopping shall vary, if the equipment or vehicle manu-
facturer has created a customised dashboard, depending on the various
options operated by such.
In these cases, refer to what is indicated in the specific documentation for

information regarding the start and stop sequences and the interpretation
of the indicator instruments.
55
Starting procedure from the main FPT panel (supplied upon request)
1. Insert the key in the ignition switch (1) and turn it clockwise to the
(1B) "Run" position. Once the indicator lights have been tested and
the beeper has stopped sounding, make sure that the analogue in-
struments are showing values that conform with the relevant phys-
ical parameters of temperature, battery voltage and oil pressure;
(information on how to interpret the indicators and alarms is given
in the relevant paragraph)
2. If the engine is fitted with a pre-heating system (optional) and the
engine temperature is lower than the minimum value foreseen for
it to come into operation, wait for the relevant indicator light to go
out.
3. Turn the key to the (1C) "Start" position, releasing it when the en-
gine has started, without accelerating.
4. Make sure that the "Alternator recharge" and "Oil pressure low"
indicators have turned off and that the analogue instruments are
showing values that conform with the relevant new physical pa-
rameters. If the pre-heating system has intervened, the relevant
indicator will turn on again to indicate that the post-heating phase
is in progress; the duration of this function is proportional to the
temperature value.
5. If the engine does not start, after releasing the key it will only be
possible to turn it back to the start position after first returning the
switch to the rest position 1A.
56
1. Key switch to start/stop the engine
English
2. Horn
3. Voltmeter
4. Rev counter and hour counter
5. Coolant temperature indicator
6. Engine oil pressure indicator
7. Alarm and indicator module
8. Management and diagnosis module
Detailed view of the key switch

(1A) "REST" position allowing the key to be removed
(1B) Stable "RUN" position
(1C) Unstable "START" position
57
(STOP) Unstable position used in EXCITED STOP set-ups for engines
fuelled by a mechanical injection pump.
Stopping the engine from the FPT control panel

Before stopping the engine it is recommended to keep it running at idle
and unloaded for a few minutes; this will permit a uniform reduction in
temperature and prevent harmful thermal shocks.
The stop methods depend on the type of equipment.
With "unexcited" stop circuit:

• Turn the key switch to the (1A) REST position
With "excited" stop circuit:

• Turn the ignition key to the (STOP) position
In the absence of FPT control panels, always follow the instructions pro-
vided by the Manufacturer of the vehicle.
re--start the engine:

Should you intend to re
1. (1A), thereby resetting
Return the key switch to the rest position (1A)
all the on-board panel functions (only essential for electronically
controlled engines).
2. Turn the key to the (1C) "Start" position, releasing it when the en-
gine has started, without accelerating.
3. Proceed as described previously.
58
MNA//MSA
Recognition of alarm statuses NEF 45 MNA MSA//MNS
MNS// Some types of engine and relevant equipment only make functions in-
English
MSS//MNT
MSS MNT//MST dicated in the key available. If the machine Manufacturer uses different
technical options, there may also be further changes to the above.
Signal and alarm diagram
Operation
The FPT instrument panel contains the indicator lights used to indicate
the state of operation of the engine. Light-up of these indicators is piloted When the key is turned in the switch to position 1B, an efficiency test is
by electronic circuits, which have a simultaneous alarm timer and storage performed, for 5 s, on all the indicator lights, with the exception of the
function. "Pre-post heating" indicator, while at the same time the beeper sounds.
During start-up and for the following 15 s, all synoptic functions are dis-
abled; after this period of time has passed, every critical state detected by
the engine sensors will cause the relative luminous indicator to turn on.
Some alarms that are critical for engine efficiency will also activate an
acoustic warning in addition to switching on the relative optical indicator
and will automatically stop the engine:
• Maximum permitted rotation speed exceeded
• High coolant temperature
• Low oil pressure
• Engine coolant low level.
ATTENTION: If there are momentary stops of the engine, pay attention to
the diagram and to the presence of any alarm signals. Do not attempt to
restart the motor until the cause of the fault condition has been eliminated
7A. Maximum allowed rotation speed exceeded (on request) - 7B. Air or the correct operating conditions have been restored.
filter blocked - 7C. Fuel low level - 7D. Coolant temperature high - 7E.
Oil pressure low - 7F. Alternator malfunction - 7G. Engine coolant low
Pre--post heating.
level - 7H. Pre
59
SM1A//SM2X
SWITCHING WORKING FREQUENCY NEF45 SM1A SM2X//TM1A
TM1A//TM2A
If needed, it is possible to set the operational frequency of the generator

set at 50 Hz or 60 Hz by acting on the rotary injection pump of the en-
dothermic engine.
Working frequency of the current generator 50 Hz @ 1500 RPM of the

endothermic engine.
Working frequency of the current generator 60 Hz @ 1800 RPM of the

endothermic engine.
The nameplate (1) shows the identification code of the rotary pump.
Through this code, in the "DROOP SETTING" ADJUSTMENT table on

the following page, it is possible to identify the rpm needed by the ad-
justment screw for selecting the operational frequency.
60
"DROOP SETTING" ADJUSTMENT
English
G-Drive Non Emission Certified Injection pump type (Stanadyne Screw turns at 50 Hz from end of Screw turns at 60 Hz from end of
identification plate) travel position (clockwise) travel position (clockwise)
NEF 45 SM1A DB 4427-6301 3 9
NEF 45 TM1A DB4429-5954 2 9
NEF 45 TM2A DB 4429-6298 3 6
ATTENTION: The following procedure must be carried out by qualified per-

sonnel. Before proceeding with the operations read the instructions carefully
and, in case of doubt, contact the FPT service network.
1. "Droop setting" adjusting screw

2. Engine minimum speed adjusting screw
3. Accelerator lever
4. Engine maximum speed adjustment screw
Unscrew the "Droop Setting" adjusting screw (1) until reaching the end
limit, making sure not to damage the adjustment system.
61
Depending on the desired working frequency, tighten the screw (1) by
the number of complete revolutions indicated in the "DROOP SETTING"
table.
ROTATION SPEED STABILISATION

Once the operation to adjust the working frequency of the current gen-
erator has been completed, it is necessary to stabilise the speed of the
endothermic engine by acting on the screws (2) and (4)(4).
Without an electrical load, start the engine, loosen the adjustment screw
(4) and accelerate the engine by means of the lever (3) until the endother-
mic engine has reached a speed of 1560 RPM or 1860 RPM RPM.
When this engine speed is reached, the generator operational frequency

should be 52 Hz or 62 Hz respectively.
Act on the engine idle speed adjusting screw (2) to block the accelerator
level in the new position.
Securely lock the adjusting screws (2) and (4) using the appropriate lock
nuts.
(4): 3.5 – 4 N·m

Tightening torque of the screw locking nuts (2) and (4) N·m.
62
For correct engine use • The operational speed and power values must comply with specifica-
English
tions shown in the technical and commercial documentation.
• It is not advisable to leave the engine running at idling speed waiting
for it to reach the operational temperature; it is preferable to gradually During operation, check periodically that:
increase the engine load after approximately one minute from ignition. The engine coolant temperature does not reach the alarm threshold.
• Do not leave the engine running at idling speed for a long time; this The oil pressure remains within the normal set range.
increases the production of polluting emissions and does not ensure
the best performance.
• The engine speed must be gradually increased and decreased, in order
to allow regular combustion and correct operation of all engine compo-
nents.
63
Special warnings Fuel circuit
Coolant circuit Avoid using the engine when there is little fuel reserve in the tank. This
results in an increase in vapour condensation and means that the engine
When the engine is running, regularly check that the temperature of the is more likely to breathe in dirt or air, causing the engine to stop.
engine coolant does not reach the warning threshold.
If the temperature detected is too high, disconnect the load and turn the Contamination, fire
engine off to check the status of the cooling circuit. When refuelling, always make sure that no solid or liquid
pollutants enter the fuel tank; remember that it is prohibited
to smoke or use naked flames when refuelling.
When the engine is hot, the pressure inside the cooling cir- risk of serious injury and serious damages to the vehicle
cuit can be such that it may expel the hot liquid in an ex-
tremely violent manner with the risk of burns. Only open the
refill plug of the coolant tank when the engine is cold.
Risk of burns
Never loosen the high pressure fuel circuit connectors.
If the temperature is considered too high, reduce speed and stop to check
the state of the cooling system circuits.
Exhaust gas and air intake circuits
Check the following:
Regularly check the cleanliness of the air intake circuit. The maintenance
A. transmission belt tension of the auxiliary unit; intervals in the manual vary depending on the conditions of use of the
B. efficiency of the thermostatic valve; engine.
C. conditions of the heat exchanger (clean if necessary). In particularly dusty environments, maintenance must be carried out at
more frequent intervals to those indicated in the CHECKS AND MAINTE-
Lubrication circuit NANCE section.
Regularly check that the oil pressure remains within the expected normal
values. If the value is too low, check the oil level and refill if necessary Risk of injury:
following the indications provided in the CHECKS AND MAINTENANCE Visually check that the exhaust circuit is not blocked or dam-
section. aged, so as to prevent dangerous fumes.
If the condition persists, contact the Service Centre. risk of serious injury
64
start--up system
Electrical start Risk of skin irritation or allergic reactions
English
The batteries contain an acid solution that will burn the skin
Periodically check that the batteries are clean and efficient, particularly
and corrode clothing; when checking them, do not smoke or
during winter, as indicated in the CHECKS AND MAINTENANCE section.
use live flames in the vicinity, and make sure that the room
Top up if necessary.
they are housed in is adequately ventilated.
If replacing the battery, follow the indications provided in the section 1-28 Failure to comply with these prescriptions can result in the
Contact a specialized workshop and check the battery and
the efficiency of the charging system if the voltmeter shows
a voltage below 11 V (for systems with a rated voltage of 12
V), or 22 V (for systems with a rated voltage of 24 V).
65
Running in
Thanks to modern engine design technology, no particular run-in proce-
dure is required.
66
3 - INSPECTION AND MAINTENANCE
English
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:
by workshop technicians or the engine user if necessary.
Regular maintenance:
By qualified personnel using suitable equipment and adequate
protection tools.
Non-routine maintenance:
By qualified personnel from authorised service centres that
have detailed technical information and specific equipment.
The most qualified service centres are those that are part of FPT's technical
service network.
67
NEF45AM1A//SM1A
Refilling NEF45AM1A SM1A//SM2A
SM2A//SM1X
SM1X//SM2X
SM2X//TM1A
TM1A// (1) The quantities refer to the engine in the standard configuration. The
N45MNA//MNS
TM2A — N45MNA MNS//MNT coolant must be compliant with standard ASTM D-6210. Concentrated
coolants must be used as a 50 50%
% solution in water.
Parts to be refilled NEF45AM1A//
NEF45AM1A
SM1A//SM2A
SM1A SM2A// (2) See "Main oil specifications". Oil consumption is considered accept-
SM1X//SM2X
SM1X SM2X// 0.1%
able when it is up 0.1 % of fuel consumption.
TM1A//TM2A —
TM1A
N45MNA//MNS
MNS// (3) The quantities indicated refer to the first refilling only and are relative
N45MNA
to refilling the engine, oil sump and filter.
MNT
Cooling system (*) (1) (4) The indicated quantities are related to the engine only in the standard
Engine (4) 8.5 L configuration.
G-Drive (5) 18.5 L
(5) The quantities indicated refer to the total capacity of the generating
Lubricating system (2) (3) kg)
12.8 L ( 11.8 kg unit including the capacity of the engine, radiator and pipes.
Periodic changing: engine
sump at minimum level oil kg)
7 L ( 6.5 kg (6)Fuel tank not supplied by FPT. Refer to the data provided by the genset
(6)
sump at maximum level kg)
11.5 L ( 10.5 kg supplier/manufacturer. Only use fuel which complies fully with interna-
tional standards ASTM D975 or EN 590.
Fuel tank (6) –
(*) It is prohibited to mix fluids of different brands and origins in the circuit.
68
NEF45AM2//SM1F
Refilling NEF45AM2 SM1F//SM3
SM3//TM3 50%
(1) Use a 50 % mixture of water and coolant corresponding to the specifi-
English
cation SAE J1034.
Parts to be refilled NEF45AM2//
NEF45AM2
SM1F//SM3
SM1F SM3// (2) Use lubricants which comply with the international specifications ACEA
TM3 E5-E7 (high power engines).
Cooling system (*) (1) (3) The quantities indicated refer to the first refilling only and are relative
Engine (4) 8.5 L to refilling the engine, oil sump and filter.
G-Drive (5) 18.5 L
Lubricating system (2) (3) kg)
12.8 L ( 11.8 kg (4) The indicated quantities are related to the engine only in the standard
configuration.
Periodic changing: engine
sump at minimum level oil kg)
5.5 L ( 5.1 kg (5) The quantities indicated refer to the total capacity of the generating
sump at maximum level kg)
8.5 L ( 7.8 kg unit including the capacity of the engine, radiator and pipes.
Fuel tank (6) –
(6)Fuel tank not supplied by FPT. Refer to the data provided by the genset
(6)
supplier/manufacturer. Only use fuel which complies fully with interna-
(*) It is prohibited to mix fluids of different brands and origins in the circuit. tional standards ASTM D975 or EN 590.
69
Main characteristics of oil
Product recommended by FPT (*) — International specifications
15W--40 API CI
15W CI--4 /ACEA E7 (FPI9.LUBR001
(FPI9.LUBR001--T2 E7) (STD.)
15W--40 API CK
15W CK--4 /ACEA E7 (FPI9.LUBR001
(FPI9.LUBR001--T2 E7) (STD.)
10W--40 API CJ
10W CJ--4 / API CK
CK--4 ACEA E9 (FPI9.LUBR001
(FPI9.LUBR001--TLS CK4) (PREM.)
10W--40 API CK
10W CK--4 /ACEA E9 (FPI9.LUBR001
(FPI9.LUBR001--TLS CK4) (PREM.)
0W--40 API CK
0W CK--4 (FPI9.LUBR001
(FPI9.LUBR001--TLS CC) (COLD CLIM. PREM.)
To identify the product recommended by FPT refer to the Oil

configurator using the QR-Code indicated
70
Coolant fluid filling
English
To start the engine and if the coolant circuit needs to be filled with a
significant amount of coolant, proceed as indicated below:
• Refill the engine and the heat exchanger until the cooling circuit has
been completely refilled using fluids.
• With the coolant filler cap open, start the engine and let it idle for
approx. 1 min
min. This helps to fully expel the air in the cooling circuit.
• Stop the engine and top up with the required amount.
The failure to observe the aforesaid procedure does not guaran-
tee the presence of the correct quantity of coolant in the engine.
Failure to comply completely or partially with these requirements
may result in the risk of serious damage to the engine and may
even, on occasion, invalidate the warranty
Risk of burns
When the engine is hot, pressure builds up in the cooling circuits
which may eject hot liquid violently, resulting in a risk of burns.
Failure to comply with these prescriptions can result in the risk of
serious injury and serious damages to the vehicle
Risk of burns
Open the filler cap of the coolant tank only if necessary and only
when the engine is cold.
71
Refuelling
Only use diesel that complies with the ASTM D975 or EN 590 standard
and which is generally commercially available. Fuel additives are not
recommended.
The use of additives can limit the warranty services offered for the vehi-
cle.
Risk of burns
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.
Winter diesel
The degree of fluidity of the diesel oil can may be reduced at low tem-
peratures due to the separation of the paraffin. This results in the filters
becoming clogged.
The ASTM D975 or EN590 specifications distinguish different classes of

diesel fuel, identifying the characteristics of those that are best adapted
to low temperatures.
Oil companies must respect these standards, which provide for the dis-
tribution of fuels adapted to the climatic and geographical conditions in
various countries.
72
Programmed maintenance plan specs Periodic maintenance Frequency
English
The maintenance intervals shown below take into consideration typical Check ancillary belt conditions 300 h (6)
work factors for the various types of use of the engine; The most suitable and tension
maintenance interval for the various applications will be indicated by the Fuel filter change 600 h (1) (4) (5)
maintenance personnel based on the working methods and conditions in
which the engine is used. Replacing the fuel pre-filter 600 h (1) (4) (5)
Engine lubricant oil replacement 600 h (2) (4) (8)
Checks to be made during periods Frequency
of use Change oil filter 600 h (3) (4) (5)
Check the level of engine lubricant Daily Check and clean the oil vapour 600 h
oil recirculation valve
Check the engine coolant level Daily Engine coolant replacement 1200 h / 2 years
Check the cleanliness of the heat Daily Replace the air filter 1200 h / 2 years (2)
exchanger (radiator) Replacement of blow-by 1200 h
Inspection of the exhaust duct/s Daily recirculation valve
Check tightening and cleanliness Every six months

Extraordinary maintenance Frequency
of battery clamps
Visual inspection of turbocharger 1200 h (7)
Check the electrolyte solution Every six months
level in the batteries Check efficiency of the pre-post 1200 h
heating system (if installed)
The frequencies indicated below take into account factors of use of differ- Heat exchanger (radiator) 1200 h
ent engine uses; the most suitable duration of the maintenance intervals cleaning
for the different applications will be indicated by the maintenance person-
nel based on the use and operating conditions of the engine. Replace ancillary belt 1200 h / 3 years
Injector calibration 1800 h
Periodic maintenance Frequency
Injection pump overhaul 3600 h
Check air filter is clean 300 h (2) (4)
Adjustment of valve/rocker arm 3600 h
Drain water from the fuel 300 h (1) clearance
pre-filter/filter
Drainage/suction of water, 300 h (1) (1) Maximum period when using good quality fuel, (standard EN 590); this
condensation and impurities from is reduced based on fuel contamination and the alarm signals due to filter
the fuel tank/s clogging and/or the presence of water in the pre-filter. The filter clogging
signal indicates that the filter must be replaced. Failure to of the water
73
in pre-filter signal to deactivate after draining indicates that it needs to be General prescriptions
replaced. If using fuels with a sulphur percentage greater than 0.5%,
the intervals for changing the engine oil, engine oil filter and
(2) Frequency is a function of environmental conditions and product ef-
blow-by filter must be halved or suitably modified; please
ficiency/wear. After long periods of inactivity, carry out the check before
refer to the FPT Service Network for support.
start-up. The filter clogging signal indicates that the filter must be replaced.
(3) Frequencies are valid for lubricants as indicated in the FLUIDS table ments may result in the risk of serious damage to the engine
68.
3-68 and may even, on occasion, invalidate the warranty
(4) To be performed every year even if the operating hours expected are
not met. General prescriptions
The operations indicated above require the use of specific
(5) Only use filters with the following characteristics: equipment which will guarantee that the result is safe, ef-
- degree of filtering < 12 μm fective and of a good quality. It is recommended that these
99.5%
- filtering efficiency 99.5 % (ß > 200). operations are carried out by qualified personnel belonging
to the FPT Service Network.
(6) Referred to engines without automatic tensioners Failure to comply completely or partially with these require-
(7) Required by oil vapour recirculation.
(8) To identify the product recommended by FPT, consult the Oil Config-
urator via the QR-Code below
74
Safety notes - Check engine lubricant oil level Risk of injury:
English
Use suitable clothing, preferably tight-fitting; do not wear
General risk, general prescriptions chains, rings, etc.
Before proceeding with the operation, please refer to the Failure to comply with these prescriptions can result in the
section 'Warnings and safety instructions". risk of serious injury
Risk of damage
Make sure that the dipstick is inserted completely and that
Risk of burns the oil filler cap is completely tightened in a clockwise direc-
Only carry out the following operation when the engine parts tion.
have cooled down. Failure to comply completely or partially with these require-
Failure to comply could result in death or serious injury. ments may result in the risk of serious damage to the engine
Risk of injury:
75
Check engine lubricant oil level
Only proceed with the engine stopped and at a low temperature, so as
to avoid the risk of burning.
• Use the oil dipstick (1) to check that the lubricant oil level is between
the "Min" and "Max" limits.
• If the level is insufficient, it must be topped up with lubricant oil meet-
ing international specifications, as indicated in the FLUIDS section
on page 3-68 68: remove the lubricant oil plug (2) and pour engine lu-
bricant oil through the hole.
• Use the oil dipstick to check that the lubricant oil level (1) does not
exceed the "Max" limit.
76
Safety notes - Check engine coolant level General prescriptions
English
If refilling is required frequently, cooling circuit
General risk, general prescriptions diagnostics need to be carried out.
Before proceeding with the operation, please refer to the Failure to comply completely or partially with these require-
section 'Warnings and safety instructions". ments may result in the risk of serious damage to the engine
Failure to observe this indication could lead to serious per- and may even, on occasion, invalidate the warranty
Risk of burns
Risk of burns Only carry out the following operation when the engine parts
When the engine is hot, pressure builds up in the cooling have cooled down.
circuits which may eject hot liquid violently, resulting in a risk Failure to comply could result in death or serious injury.
of burns.
risk of serious injury and serious damages to the vehicle Risk of injury:
Risk of burns risk of serious injury
Open the filler cap of the coolant tank only if necessary and
only when the engine is cold.
Failure to comply with these prescriptions can result in the Risk of injury:
risk of serious injury and serious damages to the vehicle Use suitable clothing, preferably tight-fitting; do not wear
chains, rings, etc.
77
Engine coolant level check (example)
Only proceed with the engine stopped and at a low temperature, so as to
avoid the risk of burning.
• With the engine at low temperature, make sure that the fluid level in the
expansion tank is above the minimum level.
• Visually check that the fluid level is not more than 2/3 of the height of
the tank in order to allow any increase in volume of the fluid caused by
the temperature increase.
• Top up the tank if necessary, using clean water. Do not use distilled
68.
water; see the FLUIDS table on the page 3-68
NOTE: If the refill operations occur frequently a diagnosis of the cooling

circuit is necessary.
If the version has an external level indicator on the heat exchanger, pro-
ceed with the top up making sure that the liquid does not completely fill
the exchanger. This is to ensure that the volume of the liquid can increase
as the temperature increases.
78
Safety note - Check that the heat exchanger is clean Risk of burns
English
(radiator) Only carry out the following operation when the engine parts
have cooled down.
General risk, general prescriptions Failure to comply could result in death or serious injury.
section 'Warnings and safety instructions".
Failure to observe this indication could lead to serious per- Risk of injury:
sonal injury and damage to the engine. When the engine is hot, the pressure inside the cooling cir-
cuit can be such that it may expel the hot liquid in an ex-
tremely violent manner with the risk of burns. Only open the
Risk of injury: refill plug of the coolant tank when the engine is cold.
Use designated PPE (gloves, safety shoes, glasses, etc.) Failure to comply with these prescriptions can result in the
Failure to comply with these prescriptions can result in the risk of serious injury
79
Check the cleanliness of the heat exchanger (radiator)
Make sure that the air inlet surfaces of the radiators are free from impu-
rities (dust, mud, straw, etc.).
Clean them if necessary using compressed air or steam.
80
Safety notes - Checking and cleaning the oil vapour General risk, general prescriptions
English
recirculation valve Before carrying out the procedure, put on the appropriate
personal protective equipment (especially protective gloves,
General risk, general prescriptions ear protectors and glasses).
Before proceeding with the operation, please refer to the Failure to comply with these prescriptions can result in the
section 'Warnings and safety instructions". risk of serious injury and serious damages to the vehicle
Risk of burns
Only carry out the following operation when the engine parts
have cooled down.
81
Check and clean oil vapour recirculation valve
Only proceed when the engine is not in operation.
Disconnect the oil vapour recovery pipe (1) of the oil vapour recirculation
(4).
valve support (2) from the tappet cover (4)
Carefully clean the internal surfaces and relative parts.
Replace the sealing gaskets (3) and refit the parts.
Tighten the screws.
82
Safety notes - Check air filter and clean housing Risk of burns
English
General risk, general prescriptions have cooled down.
Before proceeding with the operation, please refer to the Failure to comply could result in death or serious injury.
sonal injury and damage to the engine. General prescriptions
Make sure that the components are refitted correctly. In-
correct fitting could cause the engine to intake unfiltered air
General risk, general prescriptions which could lead to serious damage.
Before carrying out the procedure, put on the appropriate Failure to comply completely or partially with these require-
personal protective equipment (especially protective gloves, ments may result in the risk of serious damage to the engine
ear protectors and glasses). and may even, on occasion, invalidate the warranty
83
Check cleanliness of the air filter
Only proceed when the engine is not running.
1. Remove the air filter cover (3) after having released the two quick-
(2).
closing hooks (2)
2. (1); make sure that dust does not enter
Remove the filter element (1)
the sleeve during this operation.
3. Make sure there are no impurities. Otherwise, clean the filter ele-
ment according to the instructions provided below.
4. Blow dehumidified compressed air through the filter element, from
kPa).
the inside outwards (maximum pressure 200 kPa
5. Check the condition of the air filter before refitting it. Replace it if
broken or torn.
6. Check the condition of the gasket at its base.
7. Correctly position the filter element (1) in its seat.
8. Replace the air filter cover (3) and lock it in place using the two
(2).
quick release hooks (2)
84
filter//pre
Safety notes - Water draining from fuel filter pre--filter Risk of burns
English
sonal injury and damage to the engine. Fire risk
Pay close attention to glowing parts and guards with warning
pictograms.
General risk, general prescriptions Failure to comply with these prescriptions can result in the
Before carrying out the procedure, put on the appropriate risk of serious injury
ear protectors and glasses).
Failure to comply with these prescriptions can result in the Fire risk!
risk of serious injury and serious damages to the vehicle Fire hazard: pay careful attention to flammable liquids, dusts
and vapours.
The components of the common rail system will be quickly
damaged if the fuel contains water or other impurities. Im-
mediately carry out the operation on the pre-filter to drain the
water in the supply circuit.
85
pre--filter
Drain water from the fuel pre filter//filter
In the case of a high risk of refuelling with fuel polluted with foreign agents
and water, the following check should be performed at each refuelling.

• Place a container under the filter or pre-filter to collect the fluid.
• Unscrew the valve plug (1) located at the bottom of the oil filter or pre-
filter; in some configurations the plug includes a sensor for detecting
water in the Diesel.
• Drain the liquid until only "diesel" can be seen.
• Close the cap, tightening it fully by hand.
• Dispose of the drained fluids according to current requirements.
86
Safety notes - Draining condensate from fuel tank Risk of burns
English
sonal injury and damage to the engine. Fire risk
Pay close attention to glowing parts and guards with warning
pictograms.
Failure to comply with these prescriptions can result in the Fire risk!
risk of serious injury and serious damages to the vehicle Fire hazard: pay careful attention to flammable liquids, dusts
and vapours.
The components of the common rail system will be quickly
damaged if the fuel contains water or other impurities. Im-
mediately carry out the operation on the pre-filter to drain the
water in the supply circuit.
87
Drainage or suction of impurities from fuel tank
Perform the drainage/suction of water, condensation and impurities from
the fuel tank/s by following the instructions contained in the manual sup-
plied by the tank manufacturer. Proceed as necessary based on the
structure or location of the tank: engines that operate in adverse envi-
ronments and conditions and/or that are refuelled using drums or jerry
cans, require more attention when cleaning the tank.
88
Safety notes - Check condition of auxiliary belts Risk of burns
English
sonal injury and damage to the engine. Risk of injury:
Risk of injury: risk of serious injury
Make sure that the guards of moving parts are correctly po-
sitioned and pay attention to the warning pictograms on the
engine. Risk of injury:
Failure to observe this indication could lead to serious per- Use suitable clothing, preferably tight-fitting; do not wear
sonal injury and damage to the engine. chains, rings, etc.
89
Check tension and condition of ancillary belt
1. Only proceed when the engine is not turning and is at low temperature
so as not to run the risk of burns.
2. Remove the protective grilles of the fan by acting on the relevant retain-
ers.
3. Ensure that the belt is not worn, soiled with oil or fuel, or showing signs
of tears. Otherwise arrange for it to be replaced (see the paragraph
ANCILLARY BELT REPLACEMENT on the page 3-117 117).
4. Use the appropriate tool to check the tension of the new ancillary belt at
the intermediate point of the branch between the guide pulley and the
fan control pulley. The correct tensioning should correspond to 245 +/-
10 Hz ( 1200 +/- 100 N). Should it prove necessary to reset the tension
of the ancillary belt, proceed as follows:
1. Remove the fan together with spacer.
2. Loosen the bolt (1) anchoring the alternator to its lower mount and
the screw (2) securing the alternator to the bracket.
3. (3), then
Turn the adjustment screw (4) to tighten the ancillary belt (3)
tighten the relative lock nut. For engines without a screw tensioner
it is necessary to rotate the alternator in order to obtain the pre-
scribed tension.
4. Use the appropriate tool to check the tension of the new ancillary
belt at the intermediate point of the branch between the guide pul-
ley and the fan control pulley. The correct tensioning should cor-
respond to 245 +/- 10 Hz ( 1200 +/- 100 N).
5. Repeat the aforesaid procedure if necessary.
6. Once the specified tension has been reached, tighten the alternator
fastening screw (2) to the bracket and the alternator anchor bolt (1)
to its lower bracket to the torque of 43 +/- 6 N.
5. Reposition the fan, together with spacer, in its seat and the protective
grilles and tighten the relative fasteners.
90
Safety notes - Replace fuel filter(s) Risk of burns
English
During this operation, do not smoke or use naked flames.
Do not breathe in vapours from the filter.
Failure to comply with these prescriptions can result in the General prescriptions
risk of serious injury and serious damages to the vehicle Do not fill the new fuel filter until it has been positioned on the
support, to prevent any damaging impurities from entering
the fuel circuit and injection system.
Risk of electrocution Failure to comply completely or partially with these require-
Pay attention to the electric fuel pre-heater (if installed) and ments may result in the risk of serious damage to the engine
the relative electric connections. and may even, on occasion, invalidate the warranty
If the residual air bleed phase needs to be accelerated, use
General prescriptions a hand pump also during start-up.
Make sure that the fuel coming from the bleed plug or drain Failure to comply completely or partially with these require-
screw does not dirty the transmission belt of the auxiliary ments may result in the risk of serious damage to the engine
organs and do not dispose of it in the environment. Never and may even, on occasion, invalidate the warranty
loosen the common rail and high pressure fuel pipe connec-
tors.
Failure to comply with these prescriptions can result in the General risk, general prescriptions
risk of serious injury and serious damages to the vehicle Eliminate the consumables and any materials in contact with
them (for example, filters) in accordance with current regu-
lations.The FPT Technical Service Network workshops are
equipped for this purpose.
91
Fuel filter change
Proceed only with engine not running and at low temperature to avoid
any risk of burns.
• Place a container below the filter bracket (1) to collect the diesel.
• Remove the filter (2) by loosening it from its relative support.
• Replace the filter element and the O-ring sealing gasket inside the
(2).
filter (2)
• Carefully clean the surfaces of the support (1) in contact with the
O-ring seal.
• Moisten the O-ring seal of the new filter.
• (1).
Screw the new filter (2) onto the support (1)
92
Residual air bleeding procedure:
English
• Loosen the fuel outlet fitting (1) located on the top of the filter .
• Make sure that the discharge of diesel does not soil the ancillary belt
and does not leak into the surroundings.
• Operate the fuel suction pump lever (3) until the fuel (2) coming out
is free from any residual air.
• Correctly tighten the previously loosened coupling.
• Start the engine and let it run idle for a few minutes to remove any
residual air.
93
pre--filter (if present)
Safety notes - Replace fuel pre Risk of burns
Failure to comply with these prescriptions can result in the General prescriptions
risk of serious injury and serious damages to the vehicle Do not fill the new fuel filter until it has been positioned on the
support, to prevent any damaging impurities from entering
the fuel circuit and injection system.
Risk of electrocution Failure to comply completely or partially with these require-
Pay attention to the electric fuel pre-heater (if installed) and ments may result in the risk of serious damage to the engine
the relative electric connections. and may even, on occasion, invalidate the warranty
If the residual air bleed phase needs to be accelerated, use
General prescriptions a hand pump also during start-up.
Make sure that the fuel coming from the bleed plug or drain Failure to comply completely or partially with these require-
screw does not dirty the transmission belt of the auxiliary ments may result in the risk of serious damage to the engine
organs and do not dispose of it in the environment. Never and may even, on occasion, invalidate the warranty
loosen the common rail and high pressure fuel pipe connec-
tors.
Failure to comply with these prescriptions can result in the General risk, general prescriptions
risk of serious injury and serious damages to the vehicle Eliminate the consumables and any materials in contact with
94
pre--filter replacement (if present)
Fuel pre
English
Only proceed when the engine is not rotating.
• (3), remove the whole
If the filter is equipped with a water sensor (3)
sensor from its seat.
• Remove the pre-filter by unscrewing it.
• Check that the performance levels of the new filter meet the engine
requirements (for example, comparing them with the previous levels).
• Moisten the sealing gasket of the new filter with diesel or engine oil.
• Screw the new filter onto the support by hand until coming into contact
with the gasket, then tighten an extra 3/4 turn.
• Place the water sensor in its seat, ensuring that the thread is coupled
correctly.
• Loosen the bleed screw (1) located on the pre-filter support and op-
erate the hand pump (2) until the supply circuit is full. Make sure the
fuel coming out is not dispersed into the environment.
• Fully tighten the bleed screw.
• Start the engine and let it run idle for a few minutes to remove any
residual air.
• Check the efficiency of the filter support ground connection.
NOTE: If the residual air bleeding phase needs to be speeded up, use the hand pump during start-up.
95
Safety notes - Replace engine lubricant oil General prescriptions
For correct engine operation, only use recommended oils or
General risk, general prescriptions oils with the required characteristics. In the case of refilling,
Before proceeding with the operation, please refer to the do not mix oils with different characteristics. Failure to ob-
section 'Warnings and safety instructions". serve these indications will void the guarantee.
Failure to observe this indication could lead to serious per- Failure to comply completely or partially with these require-
sonal injury and damage to the engine. ments may result in the risk of serious damage to the engine

Before carrying out the procedure, put on the appropriate Risk of damage
personal protective equipment (especially protective gloves, Make sure that the dipstick is inserted completely and that
ear protectors and glasses). the oil filler cap is completely tightened in a clockwise direc-
Failure to comply with these prescriptions can result in the tion.
risk of serious injury and serious damages to the vehicle Failure to comply completely or partially with these require-
Risk of burns
have cooled down. General risk, general prescriptions
Failure to comply could result in death or serious injury. Eliminate the consumables and any materials in contact with
96
Change engine lubricant oil
English
any risk of burns.
• Place a suitable container for collecting the spent oil under the oil
sump in the area of the lubricant oil drain plug (see the figures in the
ENGINE TECHNICAL DATA chapter).
• (3); then extract the oil level dip-
Unscrew the lubricant oil drain plug (3)
stick (1) and remove the lubricant oil filler plug (2) to facilitate the flow
of the engine lubricant oil.
• Wait until the oil sump has completely emptied, then retighten the
(3).
lubricant oil drain plug (3)
• Refill through the filler hole on the tappet cover of cylinder no. 1,
using lubricant oil meeting the specifications, as shown in the FLUIDS
table.
• Use the oil dipstick to check that the lubricant oil level (1) does not
exceed the "Max" limit.
• (2).
Re-tighten the lubricant oil plug (2)
• The oil filter must be replaced when the engine lubricant oil is
100).
changed (see paragraph 3-100
97
MANUAL PUMP FOR EXTRACTING OIL FROM ENGINE SUMP (optional)
On request, the engine can be fitted with a manual pump (2) for extracting
oil from the sump.
• To operate the pump, the pumping unit grip (1) must be raised and
lowered repeatedly.
• The pump is supported by a bracket (3) and the suction pipe (4) is
connected to the oil drain hole in the engine sump (5) with a fitting.
• A fitting (6) on the pump delivery allows a pipe to be installed to evac-
uate oil from the engine compartment.
98
Safety notes - Replace engine lubricant oil filter General prescriptions
English
Always carry out interventions with the engine stopped; if
General risk, general prescriptions special circumstances require maintenance with the engine
Before proceeding with the operation, please refer to the running, consider all the risks involved before proceeding.
section 'Warnings and safety instructions". Pay close attention to moving parts.
Failure to observe this indication could lead to serious per- Failure to observe this indication could lead to serious per-
sonal injury and damage to the engine. sonal injury and damage to the engine.
General prescriptions Risk of skin irritation or allergic reactions

Always carry out interventions with the engine stopped; if The engine oil is highly pollutant and harmful.
special circumstances require maintenance with the engine In case of contact with skin, wash thoroughly with water and
running, consider all the risks involved before proceeding. detergent.
Pay close attention to moving parts. Suitably protect skin and eyes; take measures as set forth
Failure to observe this indication could lead to serious per- by safety regulations.
sonal injury and damage to the engine. Failure to comply with these prescriptions can result in the
Risk of burns
Only carry out the following operation when the engine parts General risk, general prescriptions
have cooled down. Eliminate the consumables and any materials in contact with
Failure to comply could result in death or serious injury. them (for example, filters) in accordance with current regu-
99
Oil filter change
Only proceed when the engine is not turning and is at low temperature
so as not to run the risk of burns.
• Drain the spent lubricant oil (see ENGINE LUBRICANT OIL RE-
PLACEMENT paragraph on page 3-97 97).
• Place a container for collecting the spent oil under the filter support
(1).
(1)
• Remove the filter (2) by loosening it from its relative support.
• Replace the filter element and the O-ring sealing gasket inside the
(2).
filter (2)
• Carefully clean the surfaces of the support (1) in contact with the
O-ring seal.
• Moisten the O-ring seal of the new filter.
• (1).
Screw the new filter (2) onto the support (1)
100
blow--by filter
Safety notes - Replace blow Risk of burns
English

Before carrying out the procedure, put on the appropriate
101
blow--by filter
Replacing the blow
Disconnect the oil vapour recovery pipe from the blow-by filter (1) (1).
Unscrew the screws and remove the blow-by filter (1) from the tappet
(3).
cover (3)
Clean the contact surfaces carefully.
Install a new gasket seal (2) and install the blow-by filter (1) on the tappet
(3).
cover (3)
Tighten the screws.
102
Safety notes - Change engine coolant Risk of burns
English
When the engine is hot, pressure builds up in the cooling
General risk, general prescriptions circuits which may eject hot liquid violently, resulting in a risk
Before proceeding with the operation, please refer to the of burns.
section 'Warnings and safety instructions". Failure to comply with these prescriptions can result in the
Failure to observe this indication could lead to serious per- risk of serious injury and serious damages to the vehicle
Risk of burns
General risk, general prescriptions Only carry out the following operation when the engine parts
Before carrying out the procedure, put on the appropriate have cooled down.
personal protective equipment (especially protective gloves, Failure to comply could result in death or serious injury.
risk of serious injury and serious damages to the vehicle General prescriptions
Failure to observe the procedure described above will not
guarantee the presence
Risk of burns of the correct quantity of coolant in the engine.
Open the filler cap of the coolant tank only if necessary and Failure to comply completely or partially with these require-
only when the engine is cold. ments may result in the risk of serious damage to the engine
Failure to comply with these prescriptions can result in the and may even, on occasion, invalidate the warranty
103
Change engine coolant
Only proceed with the engine off and at a low temperature, to avoid the
risk of burns.
• Place a container for collecting coolant below the heat exchanger
(radiator).
• Remove the pressurization cap from the expansion tank.
• Loosen the retaining elements and remove the sleeves connecting
the engine cooling circuit to the heat exchanger.
• Open the plug and drain the coolant from the heat exchanger (radia-
tor) and wait until it is completely empty.
• After draining, reconnect the cooling circuit, ensuring that the sleeves
are perfectly sealed.
• Refill the engine and the heat exchanger until the cooling circuit has
been filled completely with a solution of 5050%% water as indicated in
68. Do not fill the expansion tank to the brim.
the section 3-68
• With the coolant filler plug open, start the engine and let it idle for
approximately one minute. This helps to completely blowing off the
air contained in the cooling circuit.
• Stop the engine and refill if necessary.
• When the engine is cold, make sure that the coolant is a few cen-
timetres below the filling hole.
If the level indicator is located outside the heat exchangers, top up the
coolant if necessary, but make sure that the coolant does not completely
fill the internal volume of the exchanger as you need to allow the coolant
volume to expand following the increase in temperature.
104
Safety notes - Air filter replacement Risk of burns
English
sonal injury and damage to the engine. General prescriptions
Make sure that the components are refitted correctly. In-
correct fitting could cause the engine to intake unfiltered air
General risk, general prescriptions which could lead to serious damage.
Before carrying out the procedure, put on the appropriate Failure to comply completely or partially with these require-
personal protective equipment (especially protective gloves, ments may result in the risk of serious damage to the engine
ear protectors and glasses). and may even, on occasion, invalidate the warranty
105
Change air filter
1. Remove the air filter cover (3) after having released the two quick-
(2).
closing hooks (2)
2. (1); make sure that dust does not enter
Remove the filter element (1)
the sleeve during this operation.
3. Replace the filter element and the relative gasket at its base.
4. Correctly position the filter element (1) in its seat.
5. Replace the air filter cover (3) and lock it in place using the two
(2).
quick release hooks (2)
106
Safety notes - Visually inspect the turbocharger Risk of burns
English

107
Visually inspect turbocharger
In order to detect a possible fault, visually check the turbine and com-
pressor impellers and the corresponding inlet and outlet ducts.
108
Check the free rotation: apply a hand torque to the shaft in order to check
English
the free rotation and eliminate any causes of friction.
Check the inner part of the compressor, verifying the presence of any
wear signs.
109
In section (1) of the figure there are no signs of wear on the compressor,
while section (2) shows signs of contact between the inducer and the
internal diameter of the compressor.
Visually check the conditions of the turbine and compressor impeller.
In section (1) of the figure the rotor is not damaged, while in the section
(2) you can see the rotor damaged due to a foreign object.
pre--post heating system (if present)

Check the efficiency of the pre
To check the efficiency of the pre-post heating system refer to an autho-
rised Service centre.
110
Safety notes - Check integrity of exhaust pipe(s) Risk of injury:
English
Before proceeding with the operation, please refer to the risk of serious injury
Use suitable clothing, preferably tight-fitting; do not wear
chains, rings, etc.
Risk of burns Failure to comply with these prescriptions can result in the
Only carry out the following operation when the engine parts risk of serious injury
have cooled down.
Check the condition of the exhaust duct(s)

Visually check that the discharge system of exhaust gases is not clogged
not 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.
111
Safety note - Check tightness and clean battery terminals General prescriptions
If all elements of the battery need to be refilled with a signif-
General risk, general prescriptions icant amount of distilled water, contact the specialized per-
Before proceeding with the operation, please refer to the sonnel for a diagnostics check to be carried out on the effi-
section 'Warnings and safety instructions". ciency of the battery and charging system.
Failure to observe this indication could lead to serious per- Failure to comply completely or partially with these require-
sonal injury and damage to the engine. ments may result in the risk of serious damage to the engine
Risk of burns
Do not smoke or bring open flames near the batteries during Risk of injury:
the check and make sure that the room in which the work is Use designated PPE (gloves, safety shoes, glasses, etc.)
performed is suitably ventilated. Failure to comply with these prescriptions can result in the
Failure to comply with these prescriptions can result in the risk of serious injury
Risk of injury:
Risk of damage All flammable fluids and liquids must be handled with care
The batteries contain sulphuric acid which is highly caustic according to the product safety data sheets.
and corrosive. Always wear gloves and protective glasses In case of accidental contact, consult product safety data
while topping up. If possible, ensure that the check is carried sheets.
out by specialised personnel. Store fluids and liquids in containers that comply with regu-
Failure to comply with these prescriptions can result in the lations.
risk of serious injury and serious damages to the vehicle Failure to comply with these prescriptions can result in the
112
Check tightening and cleanliness of battery terminals
English
Check that the battery terminals and cable terminals are clean, well tight-
ened 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
(indicated by the "-").
• Loosen the nut and remove the clamp from the positive terminal (in-
dicated by the "+").
• With a metal brush or fine sand paper, clean the cable terminals and
the battery terminals until they shine.
• Smear the cable clamps with Vaseline and insert them onto the bat-
tery terminals making sure that the positive pole is connected first,
followed by the negative pole, and then tighten each clamp.
Check the cables and terminals 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.
113
Check//top up electrolyte level in the
Safety notes - Check General prescriptions
batteries If all elements of the battery need to be refilled with a signif-
icant amount of distilled water, contact the specialized per-
General risk, general prescriptions sonnel for a diagnostics check to be carried out on the effi-
Before proceeding with the operation, please refer to the ciency of the battery and charging system.
section 'Warnings and safety instructions". Failure to comply completely or partially with these require-
Failure to observe this indication could lead to serious per- ments may result in the risk of serious damage to the engine
sonal injury and damage to the engine. and may even, on occasion, invalidate the warranty
Risk of burns Risk of injury:

Do not smoke or bring open flames near the batteries during Use designated PPE (gloves, safety shoes, glasses, etc.)
the check and make sure that the room in which the work is Failure to comply with these prescriptions can result in the
performed is suitably ventilated. risk of serious injury
Risk of injury:
All flammable fluids and liquids must be handled with care
Risk of damage according to the product safety data sheets.
The batteries contain sulphuric acid which is highly caustic In case of accidental contact, consult product safety data
and corrosive. Always wear gloves and protective glasses sheets.
while topping up. If possible, ensure that the check is carried Store fluids and liquids in containers that comply with regu-
out by specialised personnel. lations.
Failure to comply with these prescriptions can result in the Failure to comply with these prescriptions can result in the
risk of serious injury and serious damages to the vehicle risk of serious injury
114
Check//top up electrolyte level in the batteries
Check
English
Place the batteries on a level surface, then proceed as follows.
• Visually check that the fluid level is between the "Min" and "Max"
limits; if there are no references, check that the electrolyte covers
the lead plates inside the elements.
• Use distilled water to top-up only the elements in which the level is
below the minimum.
• To recharge the battery, contact specialised technical staff.
• If, with the engine running, there is a voltage of less than 22 V, check
the efficiency of the battery recharging system.
• In this situation, make sure that the poles and terminals are clean,
correctly secured and protected with Vaseline.
Some types of battery have a single cover for all the inspection plugs.
To access the elements, use a lever as shown in the figure.
115
Safety notes - Replace auxiliary components belt Risk of injury:
Make sure that the guards of moving parts are correctly po-
General risk, general prescriptions sitioned and pay attention to the warning pictograms on the
Before proceeding with the operation, please refer to the engine.
section 'Warnings and safety instructions". Failure to observe this indication could lead to serious per-
Failure to observe this indication could lead to serious personal injury and damage to the engine.
Risk of burns
General risk, general prescriptions Only carry out the following operation when the engine parts
Before carrying out the procedure, put on the appropriate have cooled down.
personal protective equipment (especially protective gloves, Failure to comply could result in death or serious injury.
The safety guards should only be removed when the engine
is switched off and must always be reset correctly at the end
of the operation before starting the engine.
116
Change the ancillary belt
English
any risk of burns.
• Remove the protective grilles and the fan together with the spacer by
undoing the relative fasteners.
• Loosen the bolt (1) anchoring the alternator to its lower mount and
the screw (2) securing the alternator to the bracket.
• Unscrew the adjustment screw (4) to loosen and remove the ancillary
(3).
assembly belt (3)
• Fit the new ancillary belt inside the shoulders of all the pulleys, in the
following order: damper, guide pulley, fan control pulley, alternator,
water pump.
• Set the tension of the new ancillary belt by turning the adjustment
(4), then tighten the relative lock nut. For engines without a
screw (4)
screw tensioner it is necessary to rotate the alternator in order to
obtain the prescribed tension.
• Tighten the alternator fastening screw (2) to the bracket and the al-
ternator anchor bolt (1) to its lower bracket to the torque of 43 +/-
N·m.
6 N·m
• Fully rotate the crankshaft twice to ensure that the new ancillary belt
has been correctly fitted.
• Use the appropriate tool to check the tension of the new ancillary belt
at the intermediate point of the branch between the guide pulley and
the fan control pulley. The correct tensioning should correspond to
245 +/- 10 Hz ( 1200 +/- 100 N).
• Repeat the aforesaid procedure if necessary.
• Reposition the fan, together with spacer, in its seat and the protective
grilles and tighten the relative fasteners.
117
Safety Notes - Injector Calibration Risk of burns
118
Injector calibration
English
The injectors require periodic cleaning and calibration of the exact injec-
tion pressure, by adding or replacing the shim washers inserted under
the spring; check the injection pressure by using a hand operated pump
equipped with a pressure gauge which, operated by the lever, enables
the injector calibration pressure to be obtained and which is displayed on
the pump pressure gauge at the moment in which diesel delivery occurs.
During the test it is also possible to note whether the direction of the jet is
correct and whether the injectors show any signs of fuel leakage. Clean
the injectors using a metal brush to remove the carbon deposits from the
nozzle tips.
Injection pump overhaul

To overhaul the injection pump refer to an authorised Service centre.
119
arms--valve clearance
Safety notes - Adjustment of rocker arms General risk, general prescriptions
General risk, general prescriptions personal protective equipment (especially protective gloves,
Before proceeding with the operation, please refer to the ear protectors and glasses).
section 'Warnings and safety instructions". Failure to comply with these prescriptions can result in the
Failure to observe this indication could lead to serious per- risk of serious injury and serious damages to the vehicle
120
Valve//rocker arm clearance adjustment
Valve
English
The adjustment of the clearance between the rocker arms and the intake
and exhaust valve control bridges must be carried out extremely carefully
(1), a box wrench (3) and a feeler gauge (2)
using an Allen wrench (1) (2).
The values to be checked are detailed below:

Intake valve: 0.25 +/- 0.05 mm
Exhaust valve: 0.50 +/- 0.05 mm
121
Safety notes - Engine handling General specifications (engine lifting accessories)
Lifting the engine by means of cranes or hoists must only
General risk, general prescriptions be carried out using the engine lifting accessories on the en-
Before proceeding with the operation, please refer to the gine. Use hoists or cranes with a lifting capacity appropriate
section 'Warnings and safety instructions". to the weight of the engine. Do not stand under the manoeu-
Failure to observe this indication could lead to serious per- vring area during handling
sonal injury and damage to the engine. Failure to observe this indication could lead to serious per-

122
Moving the engine
English
The operations necessary to disconnect and subsequently reconnect the
engine must be carried out only by technicians from Service Centres.
When lifting the engine only, use the U-bolts indicated in this manual in
the section ENGINE TECHNICAL DATA on page 1-28 and marked on
the engine with special stickers.
Lifting must be carried out using a rocker arm that keeps the metal cables
supporting the engine parallel, using all the U-bolts provided simultane-
ously; the use of a lower number of lifting eyelets is not permitted.
The engine lifting system must have a capacity and size suited to the
weight and dimensions of the engine; check that there is no interference
between the lifting system and other accessories.
Do not lift the engine before removing the transmission members that
are coupled to it.
123
Disposal of waste
The engine is composed of parts and elements that, if discarded, could
case environmental damage.
The materials listed below must be handed over to specialised Collection
Centres:
• Starter batteries.
• Used lubricants.
• Mixtures of water and antifreeze.
• Filters.
• Additional cleaning materials (e.g. greasy or fuel-soaked cloths).
The laws in force in the various countries provide for severe penalties for
lawbreakers.
124
4 - LONG PERIOD OF INACTIVITY
English
Preparing the engine for a long period of inactivity

Before proceeding with the operation, please refer to the section
'Warnings and safety instructions".
Failure to observe this indication could lead to serious personal
injury and damage to the engine.

Before carrying out the procedure, put on the appropriate per-
sonal protective equipment (especially protective gloves, ear pro-
tectors and glasses).

Observe the maintenance instructions. If in any doubt, contact
the Service Network before proceeding.
Risk of injury:
Make sure that the guards of moving parts are correctly posi-
tioned and pay attention to the warning pictograms on the engine.
125
Risk of injury:
During maintenance work on the engine, pay careful attention to
sharp parts and/or edges and/or surfaces such as guards, heat
shields (if present)
serious injury
Fire risk!
Fire hazard: pay careful attention to flammable liquids, dusts and
vapours.
Always carry out interventions with the engine stopped; if special
circumstances require maintenance with the engine running, con-
sider all the risks involved before proceeding. Pay close attention
to moving parts.
126
In the case of a planned period of inactivity that lasts longer than two
English
months, to prevent the interior parts of the engine and some components
of the injection system from oxidising, prepare the engine as follows:
1. Drain the lubricant from the sump, after first warming up the engine.
2. Fill the engine with protective oil (compliant with standard MIL-L-
2160B type 2 ISO 3498/ 6743-4 HM) until it reaches the "minimum"
level on the dipstick. Start the engine and let it run at idle for approx.
min.
5 min
3. Drain the fuel from the injection circuit, from the filter and from the
injection pump pipes.
4. Connect the fuel circuit to a tank containing CFBprotective liquid (
ISO 4113), and introduce the liquid by pressurising the circuit and
min, after excluding the operation
driving the engine for approx. 2 min
of the injection system. The required operation may be completed
by directly polarising terminal 50 of the electric starter motor with
positive voltage equal to that of the nominal system voltage, using
the specifically provided conductor.
5. Spray around 45 g of protective oil ( 10 g per litre of displacement)
on the turbocharger inlet manifold, when carrying out pressurised
refilling operations as described in the previous point.
6. Close all the suction, delivery, ventilation and bleeder openings in
the engine with suitable plugs, or seal them with adhesive tape.
7. Drain the residual protective oil from the sump. This oil can be
used again for a further 2 preparation operations.
8. Place warning notices of ENGINE WITHOUT OIL on the engine
and dashboard.
9. Drain the coolant if it has not been mixed with a sufficient amount
of anti-freeze and anti-corrosion additive and affix a sign indicating
that the operation is in progress.
127
In the event of prolonged inactivity, the operations described must be
repeated every 6 months, following the procedure given below:
A. drain the protective oil from the sump;
B. repeat the operations from point 2 to point 7.
To protect the external parts of the engine, spray the OVER 19 AR pro-
tective liquid on the unpainted metal parts such as the flywheel, pulleys,
etc., and do not spray it on belts, connector cables and electrical equip-
ment.
128
Start the engine after a long period of inactivity
English
Before proceeding with the operation, please refer to the section
'Warnings and safety instructions".

Before carrying out the procedure, put on the appropriate per-
sonal protective equipment (especially protective gloves, ear pro-
tectors and glasses).

Observe the maintenance instructions. If in any doubt, contact
the Service Network before proceeding.
Risk of injury:
Make sure that the guards of moving parts are correctly posi-
tioned and pay attention to the warning pictograms on the engine.
129
Risk of injury:
During maintenance work on the engine, pay careful attention to
sharp parts and/or edges and/or surfaces such as guards, heat
shields (if present)
serious injury
Fire risk!
Fire hazard: pay careful attention to flammable liquids, dusts and
vapours.
Always carry out interventions with the engine stopped; if special
circumstances require maintenance with the engine running, con-
sider all the risks involved before proceeding. Pay close attention
to moving parts.
1. Drain residual protective oil from the sump.
2. Fill the engine, as prescribed, with lubricant of the type and amount in-
dicated in the FLUIDS table on page 3-68 68.
3. Drain the CFB protective fluid from the fuel circuit bringing to a close
the operations as indicated in point 3 of the PREPARATION OF THE
ENGINE FOR A LONG PERIOD OF INACTIVITY on page 4-125 125.
4. Remove the plugs and/or seals from the engine's intake, discharge, ven-
tilation and bleeder holes, restoring normal conditions of use. Connect
the turbocharger intake inlet to the air filter.
130
5. Connect the fuel circuit to the machine fuel tank, completing the oper-
English
ation as shown in step 4 of section PREPARING THE ENGINE FOR
A LONG PERIOD OF INACTIVITY on page 4-125 125. During the refilling
operations connect the fuel return pipe to a collection tank in order to
prevent any residue of the protective fluid CFB from flowing to the ma-
chine tank.
6. Check the engine and top up with coolant as recommended; bleed if

necessary.
7. Start the engine and let it idle until completely stabilised.
8. Check that the indications on the dashboard are plausible and that there
are no alarm signals.
9. Shut down the engine.
10. Remove the labels of ENGINE WITHOUT OIL from the engine and
dashboard.
131
5 - BEHAVIOUR IN EMERGENCY
For personal safety • If the burns are caused by liquids, quickly but carefully remove the cloth-
ing saturated with the hot liquid.
General risk, general prescriptions • Cover the burn with a special burn dressing or sterile bandage.
section 'Warnings and safety instructions". Carbon monoxide intoxication (CO)
sonal injury and damage to the engine. Carbon monoxide from the engine exhaust is without smell, and is dan-
gerous both because it causes intoxication, and because when combined
with air it forms an explosive mixture.
The user of a machine that has been constructed according to safety reg-
ulations, when following the instructions provided in this manual and the In closed rooms, carbon monoxide is extremely dangerous, as it can reach
indications given on the engine labels, will be working in safe conditions. critical concentrations within a very short time.
Should improper conduct result in accidents, always request the interven- When assisting an intoxicated person in a closed room:
tion of trained first aid specialists immediately.
• Ventilate the room immediately, to reduce the concentration of gas.
In an emergency and while awaiting the arrival of first aid specialists, follow • When entering the room, hold your breath, do not light flames, lights or
the instructions given below. ring electric doorbells or phones, to avoid the risk of explosion.
In case of fire • Carry the intoxicated person out into the fresh air or into a well ventilated
room, resting him on one side if he is unconscious.
Extinguish the fire using the fire-fighting equipment foreseen, and in the
Electrocution
manner indicated by Fire prevention authorities (fire-fighting equipment
for certain machines and equipment is compulsory under current safety The 12 V or 24 V electrical system of the engine does not involve the
legislation). risk of electrocution, however, in the event of a short-circuit caused, for
example, by a metal tool, there is a risk of burns due to the overheating
Burns and scalds
of the object through which the electric current flows. In that case:
• Extinguish any flames on the burned person's clothing, by: • Remove the object that caused the short circuit by using means that
provide sufficient isolation
○ flooding with water;
○ use of powder extinguishers, without directing the jet towards the • If present, use the main switch to cut off the power supply.
face;
Injuries and fractures
○ covers or rolling the victim on the ground.
Take necessary steps if abnormal behaviours of the engine or the entire
• Do not remove any shreds of clothing that might adhere to the skin;. set-up of the generating set are found. While doing so, pay maximum
132
attention to ensure the security of the people around the generating set For electric maintenance technicians these are typically caused by acid
English
and its surroundings. from batteries; in these circumstances, proceed as follows:
• If the victim is bleeding, compress the injury externally until the rescuers • Remove any clothing soaked in the caustic substance.
arrive.
• Wash thoroughly with flowing water, without spraying uninvolved parts.
• If there is any suspicion of a fracture, do not move the injured part and
only move the patient if absolutely necessary. If either battery acid, lubricants or diesel come into contact with the eyes:
wash your eyes with water for at least 20 min min, keeping the eyelids open
Caustic burns so that the water flows over the eyeball (move the eye in all directions to
wash more thoroughly).
Skin corrosion is caused by contact with substances with a high degree
of acidity or basicity.
133
134
English
###_Index_###
C
Change air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Change engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Change engine lubricant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Change the ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Check/top up electrolyte level in the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Check and clean oil vapour recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Check cleanliness of the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Check engine lubricant oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Check tension and condition of ancillary belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Check the cleanliness of the heat exchanger (radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Check the condition of the exhaust duct(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Check the efficiency of the pre-post heating system (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Check tightening and cleanliness of battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Coolant fluid filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
D
Disposal of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Drainage or suction of impurities from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Drain water from the fuel pre-filter/filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
E
Engine coolant level check (example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Engine pre-heating (optional) N45MNA/MSA/MNS/MSS/MNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine pre-heating (optional) NEF 45 AM1A/AM2A/SM1X/SM2X/SM1F/SM3/TM1A/TM2A/TM3 . . . . . . . . . . . . . . . 53
External view N45MNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
External view N45MNS - N45MNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
External view NEF45 AM1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
External view NEF45 AM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
External view NEF45SM1F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
External view NEF45SM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
External view NEF45TM1A/TM2A/TM2X/TM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
F
For correct engine use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
For personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Fuel filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Fuel pre-filter replacement (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
G
Guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
I
Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Injection pump overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Injector calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
L
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
M
Main characteristics of oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Moving the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
O
Oil filter change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
P
Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Preparing the engine for a long period of inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Programmed maintenance plan specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
R
Recognition of alarm statuses NEF 45 MNA/MSA/MNS/MSS/MNT/MST . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Refilling NEF45AM1A/SM1A/SM2A/SM1X/SM2X/TM1A/TM2A — N45MNA/MNS/MNT . . . . . . . . . . . . . . . . . . . 68
Refilling NEF45AM2/SM1F/SM3/TM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Replacing the blow-by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Running in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
English
S
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety note - Check that the heat exchanger is clean (radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Safety note - Check tightness and clean battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Safety notes - Adjustment of rocker arms-valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Safety notes - Air filter replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Safety notes - Change engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Safety notes - Check/top up electrolyte level in the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Safety notes - Check air filter and clean housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Safety notes - Check condition of auxiliary belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Safety notes - Check engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Safety notes - Check engine lubricant oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Safety notes - Checking and cleaning the oil vapour recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Safety notes - Check integrity of exhaust pipe(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Safety notes - Draining condensate from fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Safety notes - Engine handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Safety Notes - Injector Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Safety notes - Replace auxiliary components belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Safety notes - Replace blow-by filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Safety notes - Replace engine lubricant oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Safety notes - Replace engine lubricant oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Safety notes - Replace fuel filter(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Safety notes - Replace fuel pre-filter (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Safety notes - Visually inspect the turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Safety notes - Water draining from fuel filter/pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Safety warnings symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Special warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Starting and stopping the engine NEF 45 MNA/MSA/MNS/MSS/MNT/MST . . . . . . . . . . . . . . . . . . . . . . . . 55
Start the engine after a long period of inactivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
SWITCHING WORKING FREQUENCY NEF45 SM1A/SM2X/TM1A/TM2A . . . . . . . . . . . . . . . . . . . . . . . . 60
T
Technical data of the engine N45MNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Technical data of the engine N45MNS - N45MNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Technical data of the engine NEF45 AM1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Technical data of the engine NEF45 AM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Technical data of the engine NEF45SM1A/SM2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Technical data of the engine NEF45SM1F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Technical data of the engine NEF45 SM1X/SM2X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Technical data of the engine NEF45SM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Technical data of the engine NEF45TM1A/TM2A/TM2X/TM3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
V
Valve/rocker arm clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Visually inspect turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Series: Use and Maintenance Uso E Manutenzione Utilisation Et Entretien Betrieb Und Wartung Uso Y Mantenimiento

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Series: Use and Maintenance Uso E Manutenzione Utilisation Et Entretien Betrieb Und Wartung Uso Y Mantenimiento

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USE AND MAINTENANCE

POWER GENERATION ENGINES

Publication edited by:

4 LONG PERIOD OF INACTIVITY

General prescriptions Maintenance not carried out correctly!

Warnings - specific requirements for marine applications

General specifications (handling of components «> 25kg») General prescriptions

General specifications (engine lifting accessories) Risk of injury:

The complete machine may have auxiliary devices such as emergency

Warnings - safety and operating instructions related to the engine appli-

Potentially dangerous conditions such as unexpected engine start-up may

Risk of serious damage to the engine:

Safeguarding the environment:

Injection type Direct injection with rotary pump

1. Coolant inlet plug

Injection type Direct injection with rotary pump

1. Auxiliary assembly drive belt

1. Auxiliary assembly drive belt

Cycle Diesel 4-stroke

Cycle Diesel 4-stroke

Injection type Direct injection

1. Oil vapour filter

1. Comburent air inlet duct to turbocharger

1. Coolant inlet plug

• Do not disconnect the battery supply while the engine is running.

Risk of injury: Risk of damage

In these cases, refer to what is indicated in the specific documentation for

4. Rev counter and hour counter

5. Coolant temperature indicator

6. Engine oil pressure indicator

7. Alarm and indicator module

8. Management and diagnosis module

Detailed view of the key switch

(1B) Stable "RUN" position

(1C) Unstable "START" position

Stopping the engine from the FPT control panel

The stop methods depend on the type of equipment.

With "unexcited" stop circuit:

With "excited" stop circuit:

re--start the engine:

If needed, it is possible to set the operational frequency of the generator

Working frequency of the current generator 50 Hz @ 1500 RPM of the

Working frequency of the current generator 60 Hz @ 1800 RPM of the

Through this code, in the "DROOP SETTING" ADJUSTMENT table on

ATTENTION: The following procedure must be carried out by qualified per-

1. "Droop setting" adjusting screw

ROTATION SPEED STABILISATION

When this engine speed is reached, the generator operational frequency

(4): 3.5 – 4 N·m

To identify the product recommended by FPT refer to the Oil

The ASTM D975 or EN590 specifications distinguish different classes of

Check tightening and cleanliness Every six months

NOTE: If the refill operations occur frequently a diagnosis of the cooling

Clean them if necessary using compressed air or steam.

Only proceed when the engine is not in operation.

General risk, general prescriptions

General prescriptions Risk of skin irritation or allergic reactions

General risk, general prescriptions

General risk, general prescriptions

pre--post heating system (if present)

Check the condition of the exhaust duct(s)

In the event of dirty cable clamps and battery terminals:

Risk of burns Risk of injury: