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Owner`s Manual

1. HPE P 300 On the crankcase front side above the bell housing HPEL 45 HPEL 80 On the crankcase right side bell housing connection HPEL 65 90 10 FNM HPE Series 1 5 General safety regulations Read carefully the information contained in this chapter in order to avoid unpleasant incidents The manufacturer cannot be held responsible for any damage resulting from misuse of the engine from the failure to follow the indications contained in this manual and for every tampering with or change made without the manufacturer s authorization Do not drive the boat if you consume alcohol or other substances that may alter your state of attention and reflexes Use the engine only for the tasks authorized by the manufacturer do not tamper any device to obtain different performances Consult only technical staff with experience and specific technical skills The lack of these requirements could result in damage to people s safety as well as damage to the engine Pay attention to the meaning of the symbols and the labels applied Keep them visible and follow the warnings indicated Carry out the engine handling in accordance with the information provided directly on the engine and on the packaging During the engine lifting and transportation use means with appropriate load capacity During the installation the installer shall follow the manufacturer s instructions Do not make changes to the engine compo
2. Scheduled Interventions 1 3 322 2 5 ts che m 2 27 PEZE 5 User Operations Operazioni dell Utente FNM First Tagliando FNM Service Primo Tagliando FNM Annual FNM Advanced Service Tagliando Avanzato FNM Wintering Invernaggio Before first start after wintering 10 8 9 11004015 0100 195 Buiu ju6n gt gt Suoisuadsns pue U8LU8U I P 9J eueljisne 91 0 2 0 U9LUBU0JSU8 790 DUIU0ISU9 pue seg pa 012 21 1011 N uoneoyuqni syeys suajjadoid 80155 5 a 81010 01 0 010 2 x 3 suolssiwse pue 10 22 011 012111505 jueuieoede1 2i amp 0110526 Z 041 UOIZMASOS 191 95210 poe gt gt gt gt BOYLE s popuv Braye 0 P S 891J119 snjejs Aayeq 29 72 gt gt gt 01 05 0 ony 018 1 3uo z ds Buiurip pue uonoedsui 134 14 95910 eypjed alap eoyuan uonoedsu S89 pn gt D aye enboe gt lt erzung 51811 J8 BM MEYI aueia ya 25 2 opinbij Bayle uonoedsui juejo07 uolssiuisp 9 9J0 0UI ojo BIHA suoissiusuem gt lt pue 012905 s 9A9 10 arog
3. con sa Seles s E 282 28 65 gjs o S gt s 2 2 5 T Z2 8555547 S 2 S B 88 Ss ss 50 2 25 2 8 5 E D Prima dell avvio l invernaggio FNM HPE Series 66 9juezia s 1516 67 1 BuiseeJD Gulsa9 s 2 910959101 95 Mapoujeaia PwWajsis jap P3IJI A gt 108 JI yoayo lt 9D0U E9J9 N ID OULOJOW auoufid 0I66psse16ul 8 uoiuid Jauejs 2 229 nuauieiddoo2e auoizeoiugn 9 auoizeds uoneougn gt pue sBuijdnoo 21 gt lose eizijng sadid j9Bueuox3 awu enboe edwod ajuejiD 8U0IZD I SOS quaweoejde 19 dund seyem 00 jueuueoejde1 1341 10 gt ale enboe erzijng 212 J8 PM MEY Ipoue gt lt auoiznyysos juawasejd sepouy aew enboe edwod ejjap 017905 gt lt gt lt uon dsul jejjeduui duund 1972M 0108 4 2 0179051 gt gt gt eueuojnq 1 51018 gt gt _ SI2BERBBES 28 C s QS 2555 58 gt 5
4. Data Hourmeter Ore X Ordinary 2nd Service Ordinario 100h Secondo tagliando Date Data _ Advanced Avanzato 800h Hourmeter Ore L_ ordinary 3rd service Terzo Ordinario 100h tagliando Date Data L_ Advanced Avanzato 800h 132 FNM HPE Series Assistance Center Maintenance Hourmeter and Date Stamp and Signature Intervento Ore motore e Data pre ee Firma e Timbro del Centro Assistenza Hourmeter Ore L_ ordinary Ath service Quarto Ordinario 100h tagliando Date Data _ Advanced Avanzato 800h Hourmeter Ore T Ordinary 5th service Quinto Ordinario 100h tagliando Date Data Advanced Avanzato 800h Hourmeter Ore l Ordinary 6th service Sesto Ordinario 100h tagliando Date Data _ Advanced Avanzato 800h Hourmeter Ore T Ordinary 7th service Ordinario 100h Settimo tagliando Date Data _ Advanced Avanzato 800h FNM HPE Series 133 Assistance Center Maintenance Hourmeter and Date Stamp and Signature Intervento Ore motore e Data Firma Timbro del Centro Assistenza Hourmeter Ore lordinary 8th service Ottavo Ordinario 100h tagliando Date Data L_ Advanced Avanzato 800h Hourmeter Ore _ ordinary 9th service Nono Ordinario 100h tagliando Date Data Advanced Avanzato 800h Hourmeter O
5. Low pressure electric fuel pump sucks fuel from the low pressure line and sends it to the high pressure line Thermostat housing contains the thermostatic valve of the cooling circuit Sea water pump sucks water from the sea water intake and pushes it in the cooling circuit Alternator generates electric power the output voltage is 12 Volt Oil filler cap useful in filling the engine oil Lifting eyes allow the movement of the engine outside the engine compartment Engine label position Serial number position on the crankcase Oil drain valve FNM HPE Series Figure 1 FNM HPE 40S 80 80SD 110 110JD FNM 80 17 FNM HPE Series Figura 2 FNM 40 150 150JD 170 170JD 190 190JD FNM HPEL 65 90 FNM HPE Series 18 Figura 3 FNM HPE P 100 225 225JD 250 250JD 250H 19 FNM HPE Series 20 Figure 4 FNM HPE P 300 FNM HPE Series Figure 5 FNM HPEL 45 21 FNM HPE Series 1 7 Engine delivery At moment of receiving an HPE engine please check INFORMATION 22 The integrity of the packaging if the engine was supplied not installed the wood box must be integral the engine must be fixed on the wood support and secured to it The ECU box must be integral and with no obvious signs of breakage The engine wiring and any extensions must be integral with no cuts the Amphenol connector must be integral and all the pins of the connec
6. MARINE DIESEL ENGINES Owner s Manual HPE 40S 80 80SD 110 110JD e nc HPE P 40 150 150JD 170 170JD 190 190JD Marine Diesel Engines is 100 225 225JD 250 250JD 250H HPE Series HPE P 300 HPEL 45 80 65 90 Table of contents 1 General information k k cu cu About this manual Guidance on identification of important information Notes on FNM engines servicing Identification of your engine General safety regulations Main components of FNM engine HPE Series Engine delivery 2 Using the FNM engine HPE series Analog Instrument Panel Digital Instrument Panel First engine starting and sea trial Engine starting and stopping operations Throttle Notes on daily use of the engine 3 Maintenance of FNM engines HPE Series 3 1 3 2 3 3 General information on maintenance Periodic organization and frequency of maintenance operations Details of maintenance operations FNM HPE Series 3 4 Engine treatment and maintenance products 98 3 5 Periods of engine inactivity 101 3 6 Other useful information for maintenance 106 3 7 Specifications of your engine 108 4 Maintenance booklet 129 4 1 Engine Identification Data Dati identificativi del motore 130 4 2 and Extraordinary Maintenance Register Registro della manutenzione periodica programmata e straordinaria 131 2 FNM HPE Series 1 General information FNM HPE Series Dear customer Fratelli Negri Motori hereinafter FNM is
7. Do not exceed 3 the horizontal inclination during the test do not make the measurement in the presence of excessive loads on the bow stern or starboard port side of the boat such as to distort the test overtilting the boat engine assembly The engine is delivered with the correct amount of oil MAX excessive angles can distort the reading For installation with high angles make a reference mark on the level dipstick corresponding to the level achieved with the maximum amount of oil as shipped by the manufacturer 70 FNM HPE Series 3 3 1 2 Transmission oil level check To check the transmission oil level refer to the user manual provided by the manufacturer of your transmission 3 3 2 Coolant level check e Ordinary maintenance made by the boat user and the workshop staff To verify the coolant liquid level take care to the boat and or engine inclination 1 Unscrew the coolant fill cap then check that the fluid level is between minimum and maximum limits if present or not excessively low 2 f necessary top up to a maximum level In any case the coolant liquid level must be over the engine head to ensure a correct operation H Always verify the good seal of the filter cap to avoid leakage after reassembly Never refill the coolant circuit with sea water BEWARE 00 Be careful when opening the of the expansion tank pressurized liquid may splash 229 out and cause damage to property or persons F
8. minimum speed To prevent cylinders rusting FNM advises to spray or nebulize Vanguard storage 30 protective oil MIL L 2104 MIL L 21260A through the suction manifold dismounted air filter and spin the engine without starting it to facilitate oil suction this operation can be carried out by spinning the starter motor and consequently the engine with the fuel supply line disconnected to avoid starting and to facilitate only the movement lubrication of the internal parts Disconnect the electrical connections Push the red stop button on the ECU box Clean the engine metal parts and spray the engine metal parts and the engine leverages with a protective unlocking spray to prevent rust FNM advises to use Bardahl K9spray Lubricate the starter pinion and the mechanical connections grooved joints etc Dismount the belts and store them preventing their deformation Disconnect the fuel line inlet and outlet Spray the electrical connections with electrical connections protective spray Store the engine in a well aerated place avoiding humidity and steam to prevent rust forming For long storage of fuel in tank FNM advises to use Bardahl DAB IOSSO Diesel fuel antibacterial additives to prevent the proliferation of algae and deposits FNM HPE Series 20 For fuel winter storage FNM advises for very cold storage to use diesel fuel antifreeze additive FNM advises use of Bardahl Diesel Antifreeze Take care o
9. 278838587 a 7 gt _ 39 ses 55 BE Sse es eg SS 58 w lt tee Lx 55 55 55 k B a a ceo 5 EE m 5 D a Sos a is 2 2t 5 E ips e is 8 3 S 5 S S 52 BO 2 3 2 021119 9 010 4 2 auoissauuoaty uonoauuooe1 uM 23149913 euipases AUOIZOWL Jed ysnujue pue 1 25 10 aqueinqued oloyequas eizijng Burueo jan 51195910 as 910 ol6Gessei6u auorzeds queseud Jl syoyenjoe pue uomoedsui auiquny 0 U9UJBDD8JJJPJ ID 0pinbi oAnippe pluni66v uonippe ezeajrue UB 000 011559290 95 aeu enboe oAnippe papaau JI aAnippe 87881JI UP J9 eM enboe edwod 0100 55210 18 19 9 duund 021412 9 0100 082 auolssauuodsiq uonoeuuoosip 8214922 3 011 55929 s ojueinqjeo oAnppy pepeau JI 95910 euoijejsouug 90012114505 Buerda jejsouuJeu ddeqsesed uo z ds Buljdnoo 9141 914 2 9 UPJ9 1JJ9J auorzninsos jueujsopjdeJ UB 000 auolznquisip 3 uBu
10. 3ipu9 auolznyysos 2 09 5194 pue 5191210141 190 uonnquistq ueyjisne 81 6 2 euorzninsog gt 2 1 5190 S9IJ8IJIXTIV 2 g gt lt g N o e P E s 3 3 565 Z sls amp IE gt 5 mE N N i 535425985995 ES 25 2 lt l 55535 s lt g e o 8 E 2 ae paas a 5 2 52 Seles s 2 gt s i g2 27 Sm gt ES Pe 6 SS So s 2 a a D ic Interventions 3 3 Tagliando FNM Before first start after wintering Prima dell avvio Tagliando FNM Advanced Service Avanzato FNM User Operations Operazioni dell Utente FNM First Service Primo Wintering 2 2 e 2 5 2 2 27 5 Scheduled FNM Annual Tagliando Invernaggio l invernaggio FNM HPE Series 68 3 3 Details of maintenance operations 3 3 1 Engine and transmission oil levels check A Ordinary maintenance made by the boat user and the workshop staff For topping up the oil levels only uses the type specified in paragraph 3 4 Engine treatment and maintenance products on page 98 3 3 1 1 Engine oil level check The engines are filled by the manufacturer sent with the correct amount of oil in many cases it Em is not necessary to fill the engine with oil However some installations may affect
11. activated by the Command Station by means of the and buttons The command signals are transferred to the Actuator from the Command Station The relay board mounted in the actuator enables the in trim trim out and trailer functions The and buttons pressed together for at least 3 sec activate the trailer function that allows to pull the stern drive totally out of water 2 5 2 5 Emergency lever In an emergency you can quickly disable the electronic system and command the propulsion engines directly with the emergency mechanical levers that are already mounted on the actuator Simply unscrew the knob completely This procedure will allow you to control the gearbox manually using the B levers and with gas to a minimum 56 FNM HPE Series Figure 27 Electronic throttle control box emergency lever 2 5 2 6 ID Labels Under the base of each command station a level there are n 2 labels with the serial number and the code of the command station 2 5 2 7 Commands and meaning of indicator lights Command Signalling Meaning Engine LED If the LED is on the corresponding propulsion engine is idle a Command LED If it is OFF the Station does not command the system If it is ON the Station commands the system If the LED is blinking the navigation system is in WARM UP mode that means that Warm Sync LED the engines can be warmed up because the clutch is disengaged If the LED is lighted the system is i
12. drain again and fill the engine with new oil properly added with the proper additives till the oil level indicated by the dipstick is correct FNM HPE Series For the oil treatment FNM advises Bardahl Oil Treatment for long storage while for washing 1292 and storage it recommends Vanguard Storage 30 MIL L 2104B 6 After filling with oil and any additive start the engine and run for about 15 min at minimum RPM to support lubrication of the engine internal mechanism 7 Check the coolant Drain the circuit and fill with the proper mixture of antifreeze Read the coolant producer instructions and the mixing table INFORMATION 8 Check the fuel tank for dirt or deposits if necessary clean it additive to the fuel and take care to leave the tank empty after the treatment and cleaning NMA ENM advises Bardahl injector cleaner Respect the environment do throw away pollutants Z 9 Dismount the fuel filter and clean it if necessary replace it Fill the fuel filter with a proper mixture of fuel and additive for injector cleaning leave empty if new During the end of season or before the engine storage if possible add an injector cleaning oo FNM HPE Series 103 104 10 11 12 13 14 15 16 17 18 19 Fill a tank with a proper mixture of fuel and injectors additive like Bardahl Injector Cleaner Connect the fuel suction hose to the tank return line Run the engine for some minutes at the
13. engine HPE Series The main components present on HPE marine engines are listed below 1 10 Intercooler except HPEL45 Reduces the temperature of the compressed air from the compressor that flows into the engine intake duct using a bundle of finned tubes crossed by sea water Expansion tank contains engine coolant Oil sump contains engine lubrication oil Zinc anodes prevent the galvanic oxidation of metal parts Oil exchanger reduces the temperature of the engine lubrication oil Diesel fuel exchanger reduces the temperature of the fuel in the return line to the exchanger Air filter retains the impurities in the air intake Dual heat exchanger as an alternative to diesel fuel exchanger and in the presence of steering reduces the temperature of steering oil and diesel fuel Turbocharger except HPEL45 compresses the intake air exploiting the energy of exhaust gases through the use of a turbine compressor group Diesel fuel filter filters diesel fuel in inlet to the supply line of the engine It can be wall mounted in the engine compartment FNM HPE Series 15 16 11 12 13 14 22 Raiser reduces the temperature of the exhaust gases coming out of the turbine conveys fumes towards the exhaust and prevents the return of sea water into the turbine Starter starts the engine Water to water exchanger reduces the temperature of engine coolant through heat exchange with sea water
14. instrument The instrument is capable of displaying various information of the engine FNM HPE Series 29 When turned on the instrument performs the self control mode of check the operation of its electronics So it moves to normal mode and for factory settings it displays the battery voltage Volts the engine coolant temperature Coolant Tmp as shown in Figure 10 VOLTS 13 8 Volts Coolant Tmp 100 C Figure 10 CANBUS universal instrument normal mode The instrument has three operating modes Normal Selection and Setting 2 2 2 Normal Mode It is used during normal operation of the instrument The screen looks like the image in Figure 10 unless you set the screen of another view as a standard normal mode screen In normal mode the pressure of the arrow keys allows you increase or decrease the LCD contrast for better viewing 30 FNM HPE Series Pressing once the Mode button Wi allows you to enter the Selection mode Pressing simultaneously the Mode button and the up arrow button instead allows you to enter the Setting mode In normal mode when situations of potential danger or engine malfunction occur an alarm appears on the display The appearance of the alarm makes the buzzer ring and turns on the alarm lights placed behind the revolution counter CHECK ENGINE Figure 11 Alarm display example To disable the warning turn off the buzzer and the alarm lights and press the Mode b
15. the engine cool down if it is hot 3 Prepare a container to collect any leaks 4 Remove the sensor plug and the sensor from the filter take care to gasket Pay attention to possible fuel leakage 80 FNM HPE Series Figure 34 Removing the water in fuel presence sensor 5 Unscrew the filter using the appropriate wrench careful to follow procedures for disposal of the fuel filter in accordance with regulations Assemble the sensor on new filter and tighten the lower cap Fill the new filter with fuel Reassemble filter on the engine and open the fuel supply circuit o oN Bleed the fuel supply circuit Turn the key to 1 position and wait few seconds until the low pressure electric pump takes the circuit under pressure again Repeat the operation if necessary 10 Start the engine and check for any leaks FNM HPE Series 81 Don t smoke during the assembly disassembly operations 3 3 9 Air filter cleaning or replacement Q Ordinary maintenance made by the boat user and the workshop staff The air filter integrity and cleaning is important for the engine life and performances FNM engine series air filters are developed for marine applications When cleaning the filter elements only with compressed air never use pressures above 2 bar to avoid damaging them filters are dry and need no film of oil on the filtering part To remove the air filter INFORMATION 1 Stop the engine 2 Loosen t
16. the reading of 90 the oil level in the sump because of the particular circumstances of inclination If your engine oil level has is abnormal at the delivery inform your installer To check the engine oil level 00 Before working the engine or entering inside the engine compartment please make ona Sure you read the safety instructions 1 Make sure that the engine is stopped from at least 5 minutes to support the complete draining of oil in the sump 2 Extract the oil dipstick from the oil dipstick tube and clean it with blotting paper or similar 3 Reintroduce the oil dipstick in the guide pipe take it out and check the level FNM HPE Series 69 A If the oil level is between A and B it is not necessary to refill max B If the level of the indicator is less than B it is necessary to refill C If the oil is at level C or lower it is necessary to refill up to level A if possible any case the level must be equal to or m n greater than B Figure 28 Terminal part of the oil dipstick The level should never exceed the reference A The oil topping up is made through the oil fill cap on the engine During the use and the storage of lubricating oil take care for water and dirt contamination Take care to avoid the entrance of contaminants debris water during oil INFORMATION ili refilling To measure the engine oil level pay attention to the engine inclination both longitudinally and laterally
17. 00 BMW Longlife 98 Recommended products UW 3 4 2 Fuel characteristics Use only commercially available diesel according to DIN EN 590 Winter diesel fuel For winter use if used at temperatures lower than 0 C common diesel fuel may cause problems because it may become too dense and thick because of paraffin freezing For this reason during the winter we suggest that you use winter diesel fuel or antifreeze additives for diesel fuel In fact you may use this type of fuel without any problems up to temperatures between 15 and 22 C In countries with a different climate it is usually possible to find types of diesel fuel with different thermal properties 3 4 3 Paint For engine maintenance avoid to spray the turbocharger and touch up of small rusted parts use acrylic polyurethane based paint RAL 9006 For rusted engine parts 100 FNM HPE Series Remove the rust with abrasive paper or similar until the surface is perfectly clean Clean the surface accurately Spray the paint follow the producer instructions Paint is commonly toxic and flammable take care during use Aerate the room and read the 295 producer s instructions 3 4 4 Cleaning the panel FNM panels are specially designed for the marine environment Avoid using strong cleaning agents to clean them to prevent damage to surface finishes FNM HPE Series 101 3 5 Periods of engine inactivity If the engin
18. Extraordinary maintenance performed by qualified staff and authorized FNM service centers in possession of detailed technical information and specific equipment Interventions identified by the symbol shown on the side It is necessary to carry out every maintenance operation taking note of all the operations carried out in the Warranty and Maintenance booklet attached to the end of this manual page 129 62 FNM HPE Series 3 1 2 Safety Carefully follow the instructions below for each operations that you are going to do on FNM 290 diesel marine engines Always wear safety shoes and overalls Do not wear loose clothing rings bracelets and or necklaces near engines or moving parts Wear protective gloves and goggles during these operations filling batteries with acid solutions supply with inhibitors or anti freeze replacement or supply of the lubricating oil Ul Hot engine oil can cause burns It is recommended to carry out the interventions only 229 when it has reached a temperature below 50 When working in the engine room pay the utmost attention to your movements to prevent contact with rotating or high temperature parts Wear goggles when using compressed air The maximum air pressure used to clean is equal to 200kPa 2bar 30psi 2kg cm BEWARE Wear a protective helmet when working in an area with suspended loads or with systems at height of the head FNM HPE Series 63 oo DA
19. NGER 64 Use protective cream on your hands Replace immediately your suit if wet Keep the engine clean at all times removing stains of oil gas and coolants Put used rags in fireproof containers Do not leave foreign objects on the engine Prepare adequate and safe containers to collect exhaust oil After a repair take appropriate measures to stop the intake of air from the engine when after starting there is an uncontrolled increase in the engine rpm Avoid maintenance in the presence of electrical voltage check the effective grounding of all the equipment During diagnostic operations and maintenance make sure you have hands and feet dry whenever possible and use insulating boards FNM HPE Series 3 2 Periodic organization and frequency of maintenance operations FNM HPE marine engines require periodic maintenance to be kept always efficient The maintenance table is shown in the following pages The first two lines refer to inspections and operations that the user can and must do The remaining operations are handled by technical staff or an authorized FNM service point To avoid voiding the original warranty of your HPE engine always make interventions be carried out on the engine by the staff of a FNM authorized service point For information about individual maintenance operations See section 3 3 Details of maintenance operations on page 68 FNM HPE Series 65
20. NM HPE Series 71 3 3 3 Cleaning and inspection of sea water filters Q Ordinary maintenance made by the boat user and the workshop staff During the engine period of use check daily the sea water filter The filter should allow the smooth passage of water 100 liters minute at 4000 RPM Also check that the seawater intakes are clean from elements that can block the passage of water Close the sea water intake valve when you dismount the filter BEWARE For the filter cleaning 1 Open the sea water intake cap after closing the valve Figure 29 Sea water filter 72 FNM HPE Series 2 Clean or wash the filter with fresh water to remove the clogging elements Figure 32 Sea water filter cleaning under running water 3 Re close the filter and check for any leaks Always verify for the good seal of the filter cap to avoid leakage after reassembly 3 3 4 Fluids leakage check Q Ordinary maintenance made by the boat user and the workshop staff Periodically check that the engine does not lose any kind of fluid before during and after its operation FNM HPE Series 73 Check if there are drips from the engine on the bottom of the engine compartment if there are leaks from tanks and hoses and that all the ducts that depart from the engine sea water fuel steering oil are free of condensation When there is excessive reduction of any level while using the engine immediately shut down th
21. P225 225JD 47 8 4000 HPEL 65 66 4000 HPEL 90 91 4 2600 HPE P 40 2600 HPE P 230 2600 HPE 110 110JD 150 150JD De pe 157 2200 HPE 80 8050 338 2200 HPE P irons 560 2600 66 4000 HPEL 80 fi UM SEN 190 190JD 15A 12V 105A 12V 140A 12V 110A 12V 75 12V 3 2 40 45 7 5 3 2 65 1 5 65 C 1 5 C 80 1 5 C 65 C 1 5 C 7 5 7 5 8 5 14 0 7 5 90 24 0 gal min 100 26 6 gal min 90 24 0 gal min 1 3 kW 12V 1 8 kW 12V 2 6 kW 12V 1 3 kW 12V 188 240 295 335 150 FNM HPE Series 3 7 1 Specifications of transmissions The FNM marine engine is generally coupled to high reliability transmission systems For the use and maintenance of transmissions please refer to the manufacturer s manual In the following table you will individual producers FNM HPE Series find the specifications of the transmission oil as reported by the Transmission Oil Capacity liters excluded model exchangers ZF 45 2 5 ZF 45 1 3 0 ZF ZF 63 A ATF 4 0 ZF 63 3 6 ZF 63 3 8 TM 345 TM 345 A SAE 20W40 1 6 with standard exchanger SAE 20W40 Technodrive TM 485 A SAE 15W40 2 6 TM 880 A SAE 20W40 3 7 Seaprop 60 ATF 3 0 Bravo Quicksilver Bravo High Mercruiser ewr performance See the producer s manual Ki Gear Lube 111 The one specified is gear oil For all other fluids using the stern driv
22. Section 3 3 13 Sea water circuit cleaning on page 87 3 Drain the coolant from the circuit and disassemble the pipes 4 Remove the water to water exchanger from its support see the paragraph 1 6 Main components of FNM engine HPE Series on page 15 to identify the heat exchanger 5 Dismount the covers of the exchanger 6 Take care of the seal gaskets respect their integrity In any case replace them if damaged FNM HPE Series 93 7 Remove the bundle and clean the pipes with a brush Pay attention to the two O rings 8 After cleaning re assemble the assembly replacing the seal gaskets Verify the exchanger seal after the assembly 9 Reposition the exchanger on the bracket 10 Reposition the pipes and seal collars 11 Fill the coolant circuit 12 Start the engine letting it warm up to 80 C 13 Check for any leaks and if necessary drain air from the circuit 3 3 15 2 Cleaning the intercooler tube bundle To clean the intercooler follow these instructions INFORMATION 1 Stop the engine and let it cool down adequately 2 Drain the circuit unscrewing the anodes as described in section 3 3 13 Sea water circuit cleaning on page 87 3 Unscrew the collars of the intercooler hoses see the section 1 6 Main components of FNM engine HPE Series on page 15 to identify the intercooler and pull it out 94 FNM HPE Series 4 Remove the cap Pay attention not to damage the seal gasket
23. ace Wrong fuel quality or contaminated fuel Check fuel Drain and flush fuel tank Replace with new fuel Faulty glow plugs Check replace Incorrect lube oil SAE class or quality for ambient temperature Replace 122 FNM HPE Series Possible Fault Possible Remedy If the engine starts but runs unevenly or stops Almost empty fuel tank Fill the tank Wrong fuel quality or contaminated fuel Check fuel Drain and flush fuel tank Replace with new fuel Clogged fuel supply line Check clean Vent line of fuel supply tank clogged Check clean Air in fuel supply system Check and bleed Fuel filter clogged with water and or contamination Check or replace Leaking in the fuel supply line or fuel injection line Check replace Low battery voltage Recharge replace Fuel high pressure line regulator fault Replace Faulty fuel injection injectors pump Check replace if required Clogged exhaust Check FNM HPE Series 123 Possible Fault Possible Remedy If the engine does not reach maximum rpm under load Engine overloaded Check the propeller size incorrect propeller Dirty hull propeller Clean Insufficient comburent air Check Air in fuel supply system Check and bleed Fuel filter clogged with water and or contamination Check or replace Fuel pre filter clogged Clean replace Leaking in the f
24. aragraph 3 7 3 Meaning of the indicators on the digital panel on page 115 and paragraph 3 7 4 Troubleshooting on page 120 Check and resolve any problems before restarting to avoid serious engine damage FNM HPE Series 49 2 5 Throttle HPE marine engines are provided with an electronic throttle or with a mechanical throttle to control the engagement of the gear and the engine acceleration 2 5 1 Mechanical throttle The mechanical throttle can be installed on a wall or console It can also be equipped with a safety lanyard that causes the engine shutdown in case of accidental departure of the driver from the boat 02400209401 02400109401 a Throttle only button b Control handless c Power trim switch 4 Trailer switch a Neutral lock button b Throttle only button c Lanyard stop switch Figure 21 Mechanical throttle installed on the console in single and twin engine Figure 20 Wall mounted mechanical throttle configuration 50 FNM HPE Series The mechanical throttle can also be provided with a security system that does not allow starting the engine with the gear engaged The purpose of this is to avoid inadvertently starting the engine with propeller spinning causing damage to people in the water The elements of the mechanical throttle are as follows a Neutral lock button Prevents accidental gear engagement b Throttle only button With the command entered the throttle enables o
25. aulty turbocharger Check Repair Replace Excessive wear of cylinder piston piston rings Check compression refurbish engine 128 FNM HPE Series 3 7 5 Diagnosis All HPE engines are equipped with a plug for electronic diagnosis connection Make the diagnosis only to an authorized FNM service point FNM HPE Series 129 4 Maintenance booklet 130 FNM HPE Series 4 1 Engine Identification Data Dati identificativi del motore Thiss data is to be compiled by the dealer and is necessary to the customer to verify the engine warranty Questi dati sono da compilare a cura del rivenditore e sono necessary al cliente per verificare la garanzia del suo motore Engine type Modello motore Engine serial number Matricola motore Transmission type Modello trasmissione Transmission serial number Matricola trasmissione 1 Owner Name 1 Proprietario Sea trial date Data test a mare Dealer stamp and signature Timbro e firma del rivenditore FNM HPE Series 131 4 2 Ordinary and Extraordinary Maintenance Register Registro della manutenzione periodica programmata e straordinaria Assistance Center Maintenance Hourmeter and Date Stamp and Signature Intervento Ore motore e Data Firma e Timbro del Centro Assistenza 1st Service 30h Hourmeter Ore Primo tagliando 30h 30h Date
26. battery for the engine normal operation Indicates that the voltage is not enough for the proper functioning of all Voltmeter B electrical services At the restart the battery may not have the necessary elow 12V em voltage to start the engine During operation the alternator indicator light may turn on Alternator Lit engine off It is a condition of normal operation FNM HPE Series 113 Indicator or light indicator light Status Lit indicates running engine Meaning Indicates no recharge of the battery by the alternator Turn off the engine and check the belts status If the belts are in good condition the malfunction may depend on the regulator of the alternator or the alternator itself Contact a FNM service point Lit engine off It indicates the glow plugs preheating required to properly start the Glow plugs engine indicator light Blinking Indicates a critical engine failure Contact a FNM service point to make the diagnosis Off Indicates the normal operation of the engine Indicates low engine oil pressure At the same time the alarm buzzer of Low oil pressure the panel turns on indicator light On Turn off the engine immediately because the lubrication system is unable to work properly Check the engine oil level and the erroneous connection of the sensor to the electrical wiring Off Indicates the normal engine operation Indicates an engine overheating At the same time the alarm bu
27. cing For your engine service and maintenance always refer to an authorized service centers and to the FNM service network Only by using original spare parts and relying on our specialized staff you can get the best performances from the engine and ensure a long life The FNM service centers offer low costs and a high degree of specialization Our service centers ensure the correct operation of the engine according to all your expectations Visit our website www fnm marine com to know the nearest service point The reliability of the total propulsion unit is dependent on the quality of the installation Nearly all the problems are caused by faults or inaccuracies which occur during the installation FNM is not responsible for damages engine and or persons caused by wrong installation Ask your installer the effective compliance of the installation of your engine as well as a copy of the installation form necessary so as the warranty is held invalid for the FNM service If the installer does not transmit the installation form to FNM this may invalidate the warranty BEWARE To get help on your engine and for warranty information please feel free to contact FNM at service fnm cmdengine com FNM HPE Series 7 1 3 1 Spare Parts The exclusive use of FNM original spare parts is an essential condition for a good maintenance of the engine The use of non original spare parts may cause the warranty to expire and it also exempts t
28. ck and bleed lf not all cylinders are working Fuel filter clogged with water and or contamination Check or replace Leaking in the fuel supply line or fuel injection line Check replace Faulty injectors Check replace if required Locked suction valves Check replace if required FNM HPE Series 125 Possible Fault If the oil pressure is low Oil level too low Possible Remedy Raise the level Excessive inclination of engine Check Adjust Oil pressure apparently too low due to faulty oil pressure Check replace switch sensor or meter Incorrect lube oil SAE class or quality for ambient Replace temperature Oil leaks Check replace Clogged oil filter Replace Faulty oil pump Repair replace Oil level too high Reduce the level Excessive inclination of engine Check Adjust Insufficient comburent air Check Incorrect lube oil SAE class or quality for ambient Replace temperature Engine overloaded Check size of propeller Leak in lubricating oil system Repair replace Oil steams condenser clogged Replace Turbocharger oil leaks Replace or repair 126 FNM HPE Series Possible Fault Possible Remedy If the fuel consumption is excessive Incorrect fuel quality or dirty fuel Check fuel Drain and rinse fuel tank Replace with ne
29. dicates leakage of seawater from the saildrive seals Check the seal status FNM HPE Series 115 3 7 3 Meaning of the indicators on the digital panel If the installation includes a digital instrument panel consult this table to interpret the information that the system can display Display views Status Meaning Needle around 800 rounds Indicates the operation of the engine idle speed i e when the gear is not per minute inserted a sis ute Indicates the normal operation of the engine with gear engaged Crankshaft Indicates a too high regime of operation revolutions The Rev Limit Exceeded Critical indicator light turns on together with counter the alarm buzzer of the panel per minute Lower the position of the throttle to bring it up gradually to 0 and turn off the engine If the engine does not turn off act on the emergency red button located on the control box Between 12V and 15V Indicates the voltage of the battery for the engine normal operation Indicates that the voltage is not enough for the proper functioning of all Below 12V electrical services At the restart the battery may not have the necessary Volts voltage to start the engine During operation the Low System Voltage Amber Warning alarm turns on with the buzzer and the warning lights Indicates excessive voltage to the battery which can lead to electrical Above 15V short circuits The High Voltage Warning System alarm t
30. e always consult the producer s manual For transmissions that are not listed consult the data provided by the respective producer 112 FNM HPE Series 3 7 2 Meaning of the indicators on the analog panel The engine control panel has a number of indicators and indicator lights to monitor the operation If one of these should turn on see the table below for an explanation of the meaning Indicator or light Status Needle included between 1 and 6 bar Meaning Indicates the normal engine oil pressure Oil pressure T indicator Involves a loss of engine oil oran insufficient amount of engine oil The Needle below 1 bar Low Oil Pressure indicator light turns on together to the alarm buzzer of the panel Turn off the engine immediately and check the oil level Crankshaft Around 800 revolutions per Indicates the operation of the engine idle speed i e when the gear is not revolutions minute inserted counter Above 800 rpm Indicates the normal operation of the engine with gear engaged Between 75 C and 90 C Indicates the temperature of normal engine operation Engine coolant Indicates an operating temperature too high If the needle remains above temperature Above 90 C 90 C for a long time the Coolant high temperature indicator light turns on with the alarm buzzer of the panel Reduce the engine speed and if necessary stop the engine Between 12V and 16V Indicates the voltage of the
31. e engine and find the source of the leak 3 3 5 Fuel filter draining and inspection di Ordinary maintenance made by the boat user and the workshop staff The fuel filter of your engine may be on the engine itself or be placed on the wall in the engine compartment HPE P 300 To drain the fuel filter 1 Remove the water in fuel presence sensor plug from under the filter 74 FNM HPE Series Figure 30 Removing the water in fuel presence sensor 2 Use a small clean container of about half a liter to collect diesel fuel in excess Don t smoke during the operations 3 Unscrew the drain cap under the filter ad wait that fuel comes out Close when you notice that the fuel is clean and free of impurities or contamination of water Fuels such as waste oils are highly polluting Respect the environment and pay attention to the disposal of oil 4 Replace the cover re screwing it and replace the sensor connector avoid the formation of air bubbles in this part of the circuit otherwise you will have irregular operation of the engine To put the circuit under pressure after the drainage operations turn the ignition key to position 1 and wait that the electric pump stops working before turning on FNM HPE Series 75 In the low pressure circuit diesel fuel is kept under pressure by the electric pump Be careful to Repeat the operation if necessary 3 3 6 Battery status check Ordinary maintenance made by t
32. e remains inactive for a long period you need to protect it from oxidation and freezing FNM advises its customers who want to personally carry out the preparatory work to the inactivity of the engine to follow the instructions below 3 5 1 1 102 Operations to prepare the engine inactivity Dismount clean and remount the heat exchangers preventing in this way to leave them exposed to oxidizing substances Check and if necessary replace the zinc anodes Dismount and spray the sea water pump impeller with silicon grease spray or replace if necessary Connect the engine suction line to the fresh water line Take care to the water flow the sea water pump flow at maximum engine speed is around 100 liters min Let the engine run for about 15 min at 800 RPM to aid the circuit cleaning Fill a proper tank with an opportune mixture of water and antifreeze fluid depending on the degree of protection that you would like to offer circuits and connect the sea water suction pipe to the tank Start the engine at 800 RPM and wait for the mixture sucked by the pump to fill completely the sea water circuit until it comes out of the exhaust riser Drain the old oil from the sump and fill with clean oil appropriate for cleaning Then start the engine when the engine is still warm drain the oil that is in the sump and repeat the operation this oil can be used for another two or three times After the lubrication circuits washing operation
33. er and put the engine to minimum rpm to facilitate the antifreeze additive aspiration in the cooling circuits up to overboard discharge In the case of applications with stern drive follow the same operation using the casings on the suction intakes of the stern drive and sucking from a tank containing the antifreeze mixture FNM HPE Series 89 Figure 38 Casings for cleaning the circuit in applications with stern drive The coolant fluid is polluting Use appropriate precautions 7 to avoid releasing it into rivers or the sea The sea water freezing in the cooling circuit causes damage to the circuit itself BEWARE During the winter in areas where temperatures are particularly cold you should follow the instructions below to avoid the circuit freezing when the engine is not used for short periods 1 Drain the circuit 2 Close the sea water intake valve 3 Unscrew the zinc anodes on the cover of the water to water exchanger and on the intercooler cover Facilitate the release of water from the circuit by unscrewing also the anode on the cover of the exhaust manifold 90 FNM HPE Series 3 3 14 Oil filter change Ordinary maintenance made by the boat user and the workshop staff To change the oil filter follow the instructions carefully INFORMATION 1 Turn off the engine and let it cool down adequately 2 Prepare a container to collect any leaks Take care to dismount the oil filter only after removin
34. f running Check the fluids levels Fuel Engine oil Coolant Before starting the engine make sure at last that in the engine room there is no presence of combustible gases or vapors 2 4 2 Engine ordinary use analog panel To carry out the engine ordinary startup follow these instructions 1 Check the indicator lights and the engine preheating When turning the key to position l the alternator and oil pressure indicator lights are ON the alarm buzzer is ON 42 FNM HPE Series Oly 7 N N 5 NS A N A Beep Figure 12 Situation of the panel with engine off key to position I The glow plugs indicator light remains ON during this step until the engine pre heating is completed according to the ambient temperature After few seconds the light turns OFF It is now possible to start the engine position Il 2 Start the engine Turn and hold the key in position and release immediately when you hear that the engine starts FNM HPE Series 43 Figure 13 Hold the key to position Il until the engine starts Avoid the engine starter overload release the key after max 5 sec if engine doesn t start B BEWARE 44 Repeat the operation if necessary 3 Engine functioning While the engine is running in normal functioning conditions all the lights and the buzzer must be OFF 0 2 el Figure 14 T
35. f the engine storage room out of the boat or maintain the boat engine room dry and 290 free from salt vapor 3 5 2 Operations to restore the engine after periods of inactivity After a period of inactivity it is necessary to carry out few maintenance interventions before starting the engine again to ensure its efficiency and duration 1 Verify the battery charge level conditions Make sure that the battery voltage is greater than 12 Volt 2 Make sure that the electric contacts are intact and properly greased with basic grease Assure the correct electrical connections 3 Carry out the engine electronic diagnosis at the first starting after a long period of inactivity gt Check the oil level conditions and if necessary top up or replace with synthetic FNM SAE 5 40 Verify the clogging level and if necessary replace the oil filter Check the coolant level and if necessary top up Drain the sea water circuits Verify and if necessary replace or clean the fuel filter Clean the air filter FNM HPE Series 105 9 Verify the belts and tighteners status 10 Verify the integrity of the sea water pump impeller 11 Check the integrity of the anodes in order to provide a correct one 12 Verify and if is necessary grease the starter pinion with white grease for gears Bardahl Viscogrease and the turbocharger actuator leverages 13 Keep the engine on for some minutes then turn it off and check aga
36. f the throttle to bring it up gradually to 0 and turn off REV LIMIT Displayed the engine If the engine does not turn off act on the emergency red EXCEEDED button located on the control box CRITICAL If the problem recurs make the engine be checked by an authorized FNM service point Indicates overheating of the engine above 100 C At the same time the alarm buzzer of the panel turns on Turn off the engine immediately and Alarm check if the sea water filter is clogged the sea water valve is opened and HIGH ENGINE Displayed the coolant is sufficient Also check the cooling system and any losses TEMP CRITICAL verify that the impeller of the sea water pump is in good condition Bleed air from the cooling system and check the connection of the sensor to the electrical wiring 120 FNM HPE Series 3 7 4 Troubleshooting In the following table you will find divided by the issue the list of possible faults that cause a malfunction of your engine complete with the action to be taken to resolve it Possible Fault Possible Remedy The starter will not crank Control lever not in neutral Put operating lever in neutral The emergency stop button is pushed in ECU Box Release it Check charge the battery and check the alternator and its Faulty or discharged battery too low voltage Fuses blown Replace Loose or corroded connections in the starting circuit Clean and tighten the con
37. g Screen 8 FNM HPE Series In Selection mode pressing the down arrow allows to switch from screen 1 to screen 2 and so on Pressing the up arrow allows you to go back Screen 8 is displayed only if there are errors or warnings to report The information you can see are the following 1 Volts is the operating voltage of the battery in volts 2 Trim is the position proportional to the trim inclination angle 0 The Trim location information is only available in applications that require the adjustment of the seme trim such as the stern drive 3 Press is the engine oil pressure in bar or PSI 4 Engine Hour is the total number of running hours of your marine engine Fuel Level and Fuel Left it is an indication of the fuel level in the tank 6 Water Press is the engine coolant pressure ND Dm x 7 Fuel Used is the amount of fuel used since last reset of the instrument Information relating to the fuel Fuel Level Fuel Left Fuel Used are available only with a u special float for the level measurement Get information from your installer if it is installed on SWE your boat 8 Trans Gear shows the current gear engaged in the transmission 9 Trans Temp Indicates the current oil temperature in the transmission FNM HPE Series 35 10 Trans Press indicates the current oil pressure in the transmission Information relating to the transmission Trans Gear Trans Temp and Tran
38. g oil from the sump during the engine oil change operation 3 Unscrew the filter using the appropriate wrench 4 Clean the housing with blotting paper or a dry cloth 5 Lubricate the rubber O ring seal and the ring seat before remounting the filter cover FNM HPE Series 91 92 Figure 39 New oil filter lubrication Reposition the new filter and re screw it Fill the engine with new oil Turn the engine ON and leave it running at minimum RPM for few minutes until it reaches the working temperature Increase the speed until reaching the maximum and check the oil pressure level Check for any leaks Respect the environment Exhaust oils are strongly polluting Follow the local regulations for disposal FNM HPE Series 3 3 15 Cleaning the tube bundles Periodic maintenance performed by qualified personnel equipped with appropriate work tools and adequate means of protection Your marine engine is equipped with a different tube bundle exchangers for cooling different fluid circuits and improve overall performance Each of these must be thoroughly cleaned to prevent incrustations that after long time can block the fluid flow and lead to engine damage 3 3 15 1 Cleaning the tube bundle of the water to water exchanger To clean the tube bundle follow these indications INFORMATION 1 Stop the engine and close the sea water circuit inlet valve 2 Drain the sea water circuit as described in
39. gine diagnosis with the installer so that it acquires the reference data These data must be copied into the installation form in order to validate the FNM engine warranty 5 Check for any leaks verify the correct operation of the sea water pump the proper flow of water from the engine exhaust all the lights on the instrument panel are off and there is no audible alarm Check also the oil pressure coolant temperature and battery charging status 6 If you heard strange noise vibration or black smoke stop immediately the engine and refer to assistance point 7 Take the command of the boat 8 Verify that all persons are on board and then engage the gear Do not exceed the speed of the engine during the first hours of operation On each occasion in which the engine is used for a long period at high revs FNM advises not to turn it off at once but to let it operate at low RPM without gear engaged for at least another two minutes in order to facilitate gradual cooling of the stressed parts turbine etc avoiding any thermal stress FNM HPE Series 4 2 4 Engine starting and stopping operations Below are listed the operation to carry out for the normal operation of your FNM HPE marine engine 2 41 Preliminary operations at the ordinary engine startup Make sure that the sea water inlet valve is open The dry run of the sea water pump causes irreparable damage to the impeller and serious damage to the engine after a few minutes o
40. he company CMD S p A owner of the FNM brand name and logo from any responsibility 1 3 2 Responsibility The responsibility of the Manufacturer is subject to the correct execution of the Maintenance Procedures operations that are described in this manual For this purpose it will be necessary to demonstrate that all the maintenance procedures and operations have been carried out according to the manual and that in case of extraordinary maintenance the procedures and operations have been carried out by FNM Service centers The information featured in this manual only refer to the engine itself more specifically the illustrations serve as a pure indication and the instructions are described in a purely functional way with the purpose of providing help and guidance in carrying out the ordinary maintenance The execution of such operations may vary based on the configuration of the controls and or accessories of the boat where the engine has been installed The information featured in this manual is correct at the time of printing The Engine Manufacturer reserves the right to make modifications without notice at any time for technical or commercial reasons as well as for the need to abide by new regulations or norms The Engine Manufacturer declines any responsibility that may arise from possible mistakes and or omissions during the installation It is forbidden to alter the characteristics of the engine and in particular the configuratio
41. he boat user and the workshop staff 00 Be careful when operating near the battery compartment Disconnect the battery cables ona before working on it i Do not smoke near the battery Flammable gases could be left by the battery DANGER 3 3 6 1 Batteries that are maintenance free This type of battery is equipped with an indicator of the battery charge status 1 Depending on the color of the indicator you can see the level of battery charge 76 FNM HPE Series Green color charge level above 65 No maintenance required Dark color charge level below 65 Recharge immediately Yellow color replace the battery Figure 31 Maintenance free batteries The data are for information always read the producer s instructions BEWARE Never try to refill with any type of fluid with this type of battery 3 3 6 2 Traditional lead acid batteries To check the electrolyte level refer to the level marks on the battery side To refill 1 Remove the caps on the upper part FNM HPE Series TT Figure 32 Traditional lead acid batteries Acid liquids contained use appropriate protections 2 The electrolyte level should cover the plates If the level is insufficient fill up to Max level with distilled water 4 Replace the caps after the charging cycle Battery state of charge could influence the engine performance Avoid discharging excessively the batteries Grease the battery poles with bas
42. he collar at the base of the filter 3 Pull out the air filter 4 Clean the filtering sponge or replace the part For the HPE P 300 engine alternatively it is possible to clean the metal filter with appropriate products 5 Reassemble the filter and tighten the collar 82 FNM HPE Series 00 Never start the engine without the air filter in place It can produce serious damage to 229 the engine 3 3 10 Engine and transmission oil change Ordinary maintenance made by the boat user and the workshop staff To change engine and transmission oil comply with the procedures listed below 3 3 10 1 Engine oil change 1 Turn off the engine 2 If you have used recently used it let the engine cool down for at least 20 minutes to help oil flowing in the sump 3 Prepare a container of proper capacity to collect exhaust oil 4 Connect a hose to the drain valve on the sump The exhaust valve position changes depending on the model of your engine and is indicated in Chapter 1 6 Main components of FNM engine HPE Series on page 15 5 Connect a pump to the hose end then open the drain valve 6 Open the oil refill cap to facilitate the suction The cap is located on top of the engine and is described in section 1 6 Main components of FNM engine HPE Series on page 15 7 Operate on the pump to transfer the oil FNM HPE Series 83 8 Disconnect the pump and close the valve 9 Refill the engine with new
43. he indicator lights on the panel are turned off when the engine is functioning properly FNM HPE Series 4 Engine stop Turn counterclockwise the key to position 0 to turn off the engine 0 hemi Figure 15 Move the key to 0 to turn off the engine If the lights indicate the presence of a fault or an anomaly immediately reduce speed 00 and turn off the engine Consult paragraph 3 7 2 Meaning of the indicators on the analog ong panel on page 112 and paragraph 3 7 4 Troubleshooting on page 120 Check resolve any problems before restarting to avoid serious engine damage 2 4 3 Engine ordinary use digital panel To carry out the engine ordinary startup follow these instructions FNM HPE Series 45 46 Check the indicator lights and the engine preheating When you turn the key in position 1 the instrument starts the automatic test and the display shows The Self Test Mode Is In Operation The test mode lasts 10 seconds during which time the buzzer sounds three times and the instrument flashes Do not start the engine during the instrument testing phase Self Test Mode Is In Operation Figure 16 Situation of the panel with engine off key to position The glow plugs alarm PRE HEAT CHECK on the instrument or the related indicator light if included in the panel is turned on during the initial phase until the complete pre heating of the engine the time depends on ambien
44. ic grease periodically The battery electrolyte status can be measured with a manual densimeter 78 FNM HPE Series 3 3 7 Anodes consumption check and replacement Ordinary maintenance made by the boat user and the workshop staff Zinc anodes prevent oxidation of engine metal parts They are positioned in different parts of the sea water circuit Replace the anodes if the sacrificial zinc cartridge see the picture below is consumed over the 50 the length of the new part is around 15 mm The zincs consumption depends on many ambient factors and engine connections FNM uses pure zinc anodes that can be used in the marine environment Figure 33 Zinc anode Follow the instruction to disassemble 1 Stop the engine 2 Unscrew the anodes only after closing the sea water circuit valve 3 Replace the anodes if the consumption of the sacrificial part is greater than 50 less than 8 mm Together with the anodes replace also the copper washer In the re tightening always use thread sealant type LOXEAL 1810 FNM HPE Series 79 Take care when reassembling to maintain the electrical continuity contact between the metal o parts 4 Reopen the sea water circuit and verify for leaks 3 3 8 Fuel filter replacement Ordinary maintenance made by the boat user and the workshop staff To replace the fuel filter follow the instructions 1 Turn OFF the engine and take care to close the fuel suction line 2 Let
45. in the engine oil and coolant levels 14 Check for any leaks The engine is now ready to resume normal operation 106 FNM HPE Series 3 6 Other useful information for maintenance 3 6 1 Wiring and electrical parts The ECU Electronic Control Unit BOX contains the electronic control unit of the engine the electric connections and relays the red stop button the Amphenol plugs for the engine wiring the fuses indicator lights The degree of protection of the box is IP 67 that prevents damage from dust and splashing water Press the Red Stop Button in case of emergency and in every emergency condition that could cause damage to persons Take care to disconnect the ECU box by pushing the stop button during long inactivity period during the battery replacement and during all operations on the engine It is advisable to let carry out any operation on the engine and in particular on the electrical 0 Wiring by authorized personnel The ECU box is equipped with a LED indicators panel to indicate the fuses integrity status The fuses are on the connectors of the circuit in order to make the replacement procedure easier In order to replace the fuses refer to the following table FNM HPE Series 107 108 Fuse Service Or F7 F8 OC F9 Or F11 F10 F4 Or j OCW F5 Or F2 F1 Fuse F Fuel heating Fuse F8 Low pressure fuel pump Fuse F9 Glow pl
46. ine cleaning to remove salt and anti rust treatment Electrical wiring reconnection FNM HPE Series 3 4 Engine treatment and maintenance products Here are some warnings on the type and quality of products to be used for normal engine treatment 3 41 Maintenance products For the engine maintenance products read and follow the instructions indicated by producers or turn to FNM service Some products and use are linked to the operating temperatures Type of fluid Recommended product Engine oil FNM XTC SAE 5w40 Synthetic Bardahl XTC SAE 5w40 Synthetic Transmission oil for ZF gearbox Consult section 3 7 1 Transmission Transmission oil for Technodrive gearbox specifications on page 110 Transmission oil for Mercruiser stern drive Engine oil additive Bardahl 2 Oil Treatment Fuel additive long storage BARDAHL DAB 10550 Fuel Anti Bacterial Fuel winter storage Bardahl Diesel Antifreeze Fuel Additive Bardah Diesel Injector Cleaner Metal protector unlocker Bardahl Spray K9 Grease for gears Bardahl Viscogrease ZEP 2000 Grease Spra Turbine lubrication 7 Red lithium n 1 long storage washing cylinder Vanguard Storage 30 oil MIL L 2104B FNM HPE Series 99 Be careful not to mix different types of engine oil FNM engine oil equivalent characteristics recommended Synthetic Multigrade SAESW40 ACEA A3 B3 B4 API SL SM CF MB 229 3 VW 505 00 502
47. ired periodically Maintain the battery compartment aerated and dry to avoid risk of fire Discharge the sea water circuit by draining through the zinc anodes if the engine isn t utilized for a long time and if exposed to high temperature parts Toxic and flammable vapors may be created in the battery compartment aerate care avoid short circuits Short circuit can cause damage to people engine oo DANER the battery compartment Avoid all risks of fire 60 FNM HPE Series 3 Maintenance of FNM engines HPE Series FNM HPE Series 61 3 1 General information on maintenance FNM marine engines of HPE class require some regular operations to ensure long engine life and avoid incurring the dangers to the engine itself and the people on board 3 1 1 Staff responsible for maintenance The pages will describe the procedures necessary to carry out regular maintenance The control and maintenance operations indicated below require training competence and compliance with the standards required for safety therefore they must be completed by staff involved as indicated below e Ordinary maintenance made by the boat user and the workshop staff The interventions are marked by the symbol shown the side Periodic maintenance performed by qualified personnel equipped with appropriate work tools and adequate means of protection These interventions are marked by the symbol shown the side
48. lable also on the website www faria instruments com FNM HPE Series 37 38 Select Default Screen Function 1 Select Gauge Range Function 6 Low Fuel Alarm Function 11 Set Set Fuel Tank Amount Full Of Fuel Function 2 Function 3 Function 4 Select Select Select Fuel Display Fuel Tank Sender Units Size Function 7 Function 8 Function 9 Software Id 8 Revision Minigatewa y 1939 PGFXxxx Function 12 Function 13 Figure 11 Possible functions of the Setting Mode Organize User Screens Function 5 Fuel Tank Calibrate Function 10 FNM HPE Series 2 3 First engine starting and sea trial 2 3 1 Checks and preliminary operations Follow the directions before starting the engine for the first time INFORMATION It is preferable and highly recommended to follow the directions together with your installer BEWARE 1 Check the weather conditions do not put into the sea if the sea is too rough bad weather is forecasted 2 Make sure you have carefully read this instruction manual The information contained in it will be useful in the management of your engine 3 Check the fuel supply line and the presence of any leaks Be careful to avoid sharp bends or kinks along the fuel supply line Also be sure that the line is clean and free of air bubbles 4 Verify if you need to lubricate or grease the pinion of the starter and transmission couplings 5 Check and verify the co
49. lified personnel equipped with appropriate work tools and adequate means of protection The position of the sea water pump varies depending on the model of your engine You can verify the position in paragraph 1 6 Main components of FNM engine HPE Series on page 15 The pump shaft is driven in rotation by the movement of the crankshaft The function of the sea water pump is to draw water from the sea intake and to put it into circulation in the cooling systems heat exchangers exhaust manifold etc Water circulation is ensured by the rotation of a rubber impeller nitrile into the center housing of the pump The indications on the suction side are shown on the cover of the pump The impeller never rotates without water for more than 1 minute dry rotation increase the impeller temperature and quickly wears the vanes Pay attention to the extreme conditions of the impeller to prevent engine overheating g It is necessary that you have a backup impeller on board to replace in case of damage during navigation INFORMATION To dismount the impeller 1 Stop the engine and close the sea water intake valve 2 Remove the fastening screws from pump cap take care to the gasket 86 FNM HPE Series 3 Remove the impeller with the appropriate puller Mark the impeller with a pen on the side at sight to reposition it only if it isn t damaged in the same way 4 If the impeller is too worn pr
50. n Synchro mode With the right lever both FNM HPE Series 57 Command Signalling Meaning engines are controlled and the right trim device controls both trims if any If both the levers of the Station which has the command are in neutral position and Warm up you press for 3 seconds the warm sync button the WARM UP function is activated Acquisition of the If you press the Command button for 3 seconds the station takes the command of command I the system only if the control lever is in neutral Situation of system fault 58 FNM HPE Series 2 6 Notes on daily use of the engine Please follow these instructions to ensure the daily use of FNM marine engines in total safety Take care to maintain the engine room dry and well aerated Residual water in bilge could vaporize and condensate on the engine vapor created in this process damages the protection varnish Humidity and corrosive vapor damage the electrical connections Bilge water may wet engine parts during the boat navigation The engine room shall be well aerated and the aeration holes must guarantee a good air ventilation In this way long life is guaranteed to the engine protection varnish to the plastic and rubber parts increases the engine performances and prevents excessive overheating of hot parts exhaust turbine etc Always keep the engine room dry and well ventilated INFORMATION The ventilation holes must ensure a g
51. n of the control unit or ECU box because such modifications and or alterations will invalid the warranty and safety terms 8 FNM HPE Series 1 4 Identification of your engine The ID label is applied on your engine and on the control unit or ECU box in the position indicated in the table below see also paragraph Main components of FNM engine HPE Series on page 15 Engine Label location HPE 405 80 8050 110 110 0 HPE P 40 150 150JD 170 170J0 190 190JD On the engine cover HPE P 100 225 225JD 250 250JD 250H On top of the engine attached to the intercooler housing On the cooled exhaust manifold on the right bios side of the engine HPEL 45 HPEL 80 On the engine cover HPEL 65 90 The data on the ID label will include FNM HPE Series Engine Type Engine Family Serial No Year of manufacture Test speed Rpm Power in kW kW Horsepower HP Costruzioni Motori Diesel SpA 7 1 Valle di Vitalba 85020 Atella PZ Italy Engine Type HPE110 Engine Family 13T4L550 Serial N 47110XX Year 2011 Rpm 4400 kW 80 88 HP 110 The engine serial number is also printed on the engine block The position is indicated in the table below see also paragraph Main components of FNM engine HPE Series on page 15 HPE 405 80 8050 110 110 0 HPE P 40 150 150JD 170 170JD 190 190JD On the crankcase right side bell housing connection HPE P 100 225 225JD 250 250JD 250H
52. nections Starter relay is not operated due to too low voltage caused by Install an auxiliary starter relay a very long intermediate cable from engine to control panel Wrong engine electric ground connection Inspect review Faulty starter switch or faulty starter relay Check replace Faulty starter motor or pinion does not engage Check replace the starter motor Seized components Repair Water in the cylinders Repair FNM HPE Series 121 Possible Fault Possible Remedy If the engine spins but does not start no smoke comes out from the exhaust Fuel supply valve closed Open Almost empty fuel tank Fill the tank Air in fuel supply system Check and bleed Fuel filter clogged with water and or contamination Check or replace Fuel pre filter clogged Clean replace Fuses burnt Check replace Leaking in the fuel supply line or fuel injection line Check replace Vent line of fuel supply tank clogged Check clean Clogged exhaust Check Fuel low pressure electrical pump is not working Check the electrical connection check the pump clean or replace Fuel electric pressure regulator clogged Unclog replace Faulty ECU Diagnosis replace If the engine spins but does not start smoke comes out from the exhaust Air in fuel supply system Check and bleed the air Intake air filter clogged Clean repl
53. nel turns on The reason for which the indicator light turns on can be ENGINE Displayed Problem on injection system malfunction Engine over heating Make a diagnosis at a FNM authorized service point Alarm Indicates a serious malfunction of the engine At the same time the ENGINE alarm buzzer of the panel turns on EMERGENCY pee Turn off the engine immediately and check it Make a diagnosis at a STOP FNM authorized service point 118 FNM HPE Series Display views Status Meaning Indicates low engine oil pressure less than 0 7 bar At the same time Alarm the alarm buzzer of the panel turns on LOW OIL dum cs PRESSURE Displayed Turn off the engine immediately because the lubrication system is unable to work properly Check the engine oil level and the erroneous CRITICAL Ae connection of the sensor to the electrical wiring Indicates an excessive electrical voltage above 15V and a problem with Alarm the battery or the alternator Displayed Turn off the engine immediately to prevent short circuits or electrical SYSTEM Amber PAD 9 Warning overloads Make the engine be checked by an authorized FNM service point Indicates a low voltage less than 12V and a problem with the battery or the alternator When switching off the engine it may fail to start Displayed engine running The most common cause is due to the alternator not cha
54. nents for any reason FNM HPE Series 11 12 Before using the engine for the first time simulate a few trial maneuvers to identify the controls and their main functions especially those related to start stop operations Do not keep using the engine if anomalies are detected In case of anomaly stop immediately the engine or reduce the speed as far as possible Start again only when the normal operating conditions are restored Keep the engine and related components in conditions of maximum efficiency and carry out the maintenance operations established by the manufacturer and repeated in this manual Replace only original spare parts Use only oil lubricants and grease recommended by the manufacturer in accordance with the specifications of this manual Pay attention to the disposal of polluting residues used oil diesel fuel etc following the local legislation and disposal procedures Do not unscrew the expansion tank cap of the cooling system when the engine is hot Slowly turn until any steam under pressure comes out and then remove the cap Do not start the engine without the air filter the detachment of rotor parts of the compressor during operation could cause damage to persons furthermore any aspirated particles could damage the blades Avoid contact of hands with the rotor Do not touch the turbocharger and the turbine cover with hands immediately after using the engine risk of burns Let engine cool before interacti
55. ng with the hot parts FNM HPE Series Do not smoke near the battery compartment and the fuel tank The battery can release flammable gases Wrong battery connection could provoke sparks and explosion Don t provoke short circuits electrical risk If you use pressure water jet to clean the engine never point this to rubber pipes or electrical connections Use proper protection clothing gloves etc during maintenance and or work on the engine During maintenance operations provide correct ventilation Avoid stagnation of toxic and or flammable vapors Do not remove the protections included in your engine such as housing or protective coatings to avoid danger of fires 1 5 1 Residual risks Potential additional risks to persons Risk of injury do not put hands any moving parts pulleys flywheel belts etc 00 Risk of burns attention to hot surfaces exhaust manifold turbocharger raiser etc DANGER FNM HPE Series 13 Risk of poisoning watch out for oil splashes hot fuel and battery acids in case of ona malfunction use gloves and safety glasses Risk of shock use safety shoes when lifting the engine and or working in the engine 229 compartment FNM is not responsible for damage caused by misuse of the engine and the failure to follow procedures issued as well as for damage caused by unauthorized personnel 14 FNM HPE Series 1 6 Main components of FNM
56. nly the accelerator without engaging the gear c Lanyard stop switch Turns off the engine in case the conductor accidentally moves away from the driver s seat d Control handle Allows controlling the engines engaging the gear and acting on the accelerator e Trim Tilt Activates the trim pump f Trailer Activates the trim pump and pulls the stern drive completely out of the water 2 5 2 Flexball electronic throttle The electronic throttle works similarly as the mechanical throttle allowing the command depending on the configuration of one or two engines Moving the lever 16 forward or reverse from the neutral position the system respectively engages the forward or reverse gear The accelerator has a stroke of 67 both in forwards or reverse gear FNM HPE Series 51 Folle Marcia avanti Marcia indietro Figure 23 Flexball electronic throttle stroke Figure 22 Flexball electronic throttle for twin engine On the lever there is a membrane control keypad consisting of 4 buttons and 4 status indicator LEDs 52 FNM HPE Series Figure 24 Flexball electronic throttle control keypad In installations with single engine both LEDs near the Engine buttons refer to the same engine In systems with two engines the engine button and the corresponding LED refer to the physical location on the keypad namely the button and the LED on the righ
57. o eoueuajureu euoryppe 10 000 Sju 0 uoege pue abed sjy fd00 Notes FNM HPE Series 137 Notes 138 FNM HPE Series Notes FNM HPE Series 139 Notes 140 FNM HPE Series Document 6 045 320 1 HPE Series Owner s Manual ENG Language Release Update Date 0 First release 21 03 2012 1 Added Glow Plug signaling at the pages 27 28 and 29 31 05 2012 FNM HPE Series 141 MARINE DIESEL ENGINES To obtain service FNM Service C M D Costruzioni Motori Diesel S p A Nucleo Industriale Valle di Vitalba 85020 Italia Tel 39 0972 715757 int 183 Fax 39 0972 715696 Email service fnam cmdengine com Web www fnm marine com Printed in Italy Order code 6 045 320 1 Rev 1 dated 31 05 2012 CMD S p A All rights reserved FNM is a registered trademark of C M D Costruzioni Motori Diesel S p A
58. oil pressure inside the transmission Boost Press Between 0 and 3 bar Indicates the operating pressure of the turbocharger Throttle or Indicate the percentage corresponding to the position of the throttle Engine Load MEON U ANG BUD relative to ie 4 i i Coolant Temp Between 75 C and 90 C Indicates the temperature of normal engine operation FNM HPE Series 117 Display views Status Meaning Indicates an operating temperature too high If the needle remains above Above 90 C 90 C for a long time the High Engine Temp Critical alarm turns on together with the buzzer and the warning lights Turn off the engine immediately and check the coolant level Glow plugs Lit engine off It indicates the glow plugs preheating required to properly start the indicator light if present engine Blinking Indicates a critical engine failure Contact a FNM service point to make the diagnosis Transmission oil anomaly indicator light Off Indicates normal operation On stern drive or gearbox installations Indicates the low level of oil in the transmission Check and fill the transmission system with proper lubricant then start the engine again If the problem persists contact an authorized FNM service point On Saildrive installations Indicates leakage of seawater from the Saildrive seals Check the seal status Indicates a failure of the engine At the same time the alarm buzzer of the pa
59. oil up to proper level Respect the environment Exhaust oils are strongly 2 polluting Follow the local regulations for disposal 3 3 10 2 Transmission oil change To properly change oil in your transmission carefully follow the instructions indicated in the use and maintenance manual of the manufacturer You can refer to Chapter 3 7 1 Specifications of transmissions on page 110 for specifications on oil to use 3 3 11 Service belts inspection and tensioning Ordinary maintenance made by the boat user and the workshop staff Always be careful when working on the belts To check the status of the service belt it is necessary to remove the belts cover from your engine Follow the instructions 1 Remove the cover located on the front of the engine Attention In case of HPE P 40 150 150JD 170 170JD 190 190JD and HPEL 65 90 it is also necessary to remove the whole intercooler and its support 84 FNM HPE Series J Attention In case of HPE 80 80SD 110 110JD and HPEL 45 it is necessary instead to remove the sea water pump fixing unit 2 Loosen the belt tensioner 3 Verify the belt status If it is worn as shown in the figure it should be replaced Figure 35 Worn service belt 4 Reassemble the belt then tighten the tensioner 5 Reassemble the belt cover FNM HPE Series 85 3 3 12 Sea water pump impeller inspection and replacement Periodic maintenance performed by qua
60. ood flow of air but should prevent the entrance of salt water and dirt in the engine room The seals of doors and hatches must prevent the entrance of water in the engine room Engine room ventilation in respect of what discussed above could be even forced Take care of the distance between the turbocharger and the plastic part The turbocharger heats up during use and may damage the plastic and fiberglass parts follow the installation manual instructions Insulate with a coating that ensures good thermal protection to structures and bulkheads of the boat next to the hot parts of the engine to reduce the risk of fire Take care to oil or fuel leaks The oil or fuel may come into contact with the turbocharger during operation resulting in fire FNM HPE Series 59 Take care to the turbocharger protection varnish The housing of the turbocharger is painted with heat resistant varnish Excessive use and high temperatures could remove this protection Periodically check the housing of the turbocharger and if necessary spray with new varnish resistant to high temperatures The turbocharger heats up during use Be careful to avoid fire hazards Never rapidly increase the speed of the engine if the engine does not reach the correct 599 temperature Electrical electronic parts are affected by moisture and the attack of corrosive agents attention to the state of battery charge recharge during the engine inactivity if requ
61. ovide for replacement 5 When using a new impeller lubricate it with silicon spray grease before mounting it v 4 a E 55 e e Figure 36 Lubrication of the impeller Install the new impeller on the grooved shaft Re close the pump cap and replace the seal gasket if possible Open the sea water intake valve Restart the engine and check for any leaks Use only original FNM spare parts BEWARE FNM HPE Series 87 3 3 13 Sea water circuit cleaning Periodic maintenance performed by qualified personnel equipped with appropriate work tools and adequate means of protection Keep sea water circuits clean from salt deposits and from any external intrusion to ensure proper cooling of the engine In any case you should run the engine with fresh water for at least 5 minutes every 50 hours in order to prevent the accumulation of salt deposits in the cooling circuits related to the sea water section The seawater system cleaning must be done even during the winter season operations After flushing the circuits and after circulated fresh water in the cooling circuit sea water circulation side to avoid freezing during long rest of the engine in cold weather conditions we recommend to 1 Close the sea water tap 2 Open the sea water filter cap 88 FNM HPE Series Figure 37 Sea water filter opening 3 Insert the antifreeze liquid antifreeze mixture in the filt
62. pleased to thank you for choosing an engine of HPE range FNM engines are designed and developed according to the demand and the needs of customers and builders of pleasure and work boats CMD S p A the company that produces and distributes worldwide the marine diesel engines with the FNM brand offers a wide range of products and models according to each customer s request FNM engines are Known around the world for their performances for their compact structure and outstanding power to weight ratio for their long life and low fuel consumption This means that when buying an FNM engine you have chosen not only a technologically advanced engine but also an engine designed to satisfy the anti pollution standards and regulations Mariano Negri Giorgio Negri CEO of CMD S p A Sales Manager of FNM brand 4 FNM HPE Series 1 1 About this manual This manual is integral part of the engine and is written by the manufacturer to inform the end user of the procedures necessary for the proper use and maintenance of marine diesel engine FNM HPE Series Please keep this manual for the entire life of the product so that you always get quick information on the engine during use The manufacturer reserves the right to modify this document without prior notice The observance of the installation procedures and routine maintenance in this manual and in the installation manual ensures compliance at the declared performance at
63. quipped with appropriate work tools and adequate means of protection The pinion of the starter must be greased with grease for gears During engine operation grease is expelled from the pinion so the pinion must be greased periodically Unscrew the mounting screws and disconnect the electrical connections of the starter 96 FNM HPE Series Figure 40 Electrical wiring of the starter Remove the starter from the housing Clean the pinion with paper or a clean cloth and grease again Figure 41 Starter pinion Reassemble the starter and electrical connections FNM HPE Series 97 3 3 17 Other advanced maintenance operations il 98 Periodic and extraordinary maintenance The following operations can be performed only by qualified and authorized FNM service centers in possession of detailed technical information and specific equipment Lubrication of the crankshaft and propeller Engine alignment and engine mounts retorque Bolts tightening Wiring inspection Mechanical couplings inspection and lubrication Mercathode system verification Steering system greasing Auxiliary belts replacement Timing belts timing belts tensioners and timing chain tensioners replacement Engine coolant replacement Flexible coupler inspection Thermostatic valves replacement Antifreeze fuel additive Electrical wiring disconnection Turbine inspection and actuator greasing if present Fuel tank cleaning Eng
64. quisition procedure the station is enabled to command the boat BEWARE 2 5 2 2 Engine Warm up If both levers are in neutral by pressing for 3 seconds the Warm Sync button of station which has the command you enter in Warm up mode In Warm up mode the Warm Sync LED is blinking and it is possible to accelerate the engine with clutch disengaged After positioning again both levers in neutral and pressing the Warm Sync button for other 3 seconds the function is disabled and the Warm Sync LED stops flashing 2 5 2 3 Synchro mode operation This function is available only for twin engine systems BEWARE This function allows to command both engines at the same speed and direction with only one lever With both levers in neutral position press the Engine buttons at the same time for 3 seconds The command of both engines is now on the right lever In Synchro mode operation the Warm Sync and Command LEDs are always lighted on except for the neutral position where all the LEDS are permanently ON FNM HPE Series 55 Bringing the two levers in neutral while pressing the Engine buttons for 3 seconds the command of the individual engines will be assigned again to the respective levers The Warm Sync LED is off again 2 5 2 4 Trim control unit stern drive application Figure 25 Trim control for twin engine installation Figure 26 Trim control for single engine installation The trim command if included in your configuration can be
65. re l Ordinary 10th service Ordinario 100h Decimo tagliando Date Data L_ Advanced Avanzato 800h Hourmeter Ore _ ordinary Ordinario 100h tagliando Date Data _ Advanced Avanzato 800h 134 FNM HPE Series Assistance Center Maintenance Hourmeter and Date Stamp and Signature Intervento Ore motore e Data r bp Firma e Timbro del Centro Assistenza Hourmeter Ore T Ordinary 1 Ordinario 100h Date Data _ Advanced tagliando Avanzato 800h Hourmeter Ore T Ordinary cud Ordinario 100h Tredicesimo Date Data Advanced tagliando Avanzato 800h Hourmeter Ore _ Ordinary Ordinario 1000 Date Data Advanced tagliando Avanzato 800h Hourmeter Ore L_ ordinary WE Ordinario 100h Date Data Advanced tagliando Avanzato 800h FNM HPE Series 135 Maintenance Intervento Assistance Center Stamp and Signature Firma e Timbro del Centro Assistenza Hourmeter and Date Ore motore e Data Notes Note Type Tipo Hourmeter Ore Date Data Hourmeter Ore Date Data Hourmeter Ore Date Data Hourmeter Ore Date Data 136 FNM HPE Series suoneJedo 00 190 0119101 je rufejje e 9 eured ejsenb 10090105 suorered
66. rging the battery Turn off the engine and check the belts status If the belts are in LOW SYSTEM good condition the malfunction may depend on the regulator of the VOLTAGE Amber ae Warning alternator or the alternator itself Contact a FNM service point Displayed engine off Indicates a too low voltage less than 10V of the battery likely resulting in difficulty to restart the engine Contact an authorized FNM service point to verify the electrical system and engine FNM HPE Series 119 Display views Alarm WATER IN FUEL Status Meaning Indicates an obstruction in the fuel filter At the same time the alarm buzzer of the panel turns on The reason for which the indicator light turns on can be Manie neo Displayed Water presence in the engine fuel filter Required Malfunction of the water in fuel sensor f f f Check and drain the fuel filter If the problem persists make a diagnosis by an authorized FNM service point Indicates excessive pressure of the turbocharger to the engine greater Alarm than 3 bar Lower the position of the throttle to bring it up gradually to 0 HIGH BOOST Displayed and turn off the engine If the problem persists when turned on keep low PRESSURE RPM without accelerating excessively and make the engine be checked by an authorized FNM service point Indicates a rotation speed of the engine too high higher than 4500 rpm Alarm Lower the position o
67. rrect installation of electrical connections J Wrong connection may cause short circuits and cause damage to persons and to the 229 engine FNM HPE Series 39 Check the battery integrity and the correct state of charge Turn ON the battery main switch Check the sea water circuit and verify that the valve is open Check the belts and tighteners status O uv O Check all the engine oil levels and verify that they are correct then check the fuel level in the tank 10 Turn ON the red button on ECU box and verify that all the LEDs are lighted 11 Verify the lever command status and that it is in Neutral position 12 Verify the oil level in the gearbox or in the stern drive 13 Check the correct propulsion engine assembly alignment Compile the installation form all parts with the installer and make sure that it is sent it to the engine manufacturer after the first engine start and boat test in the sea in order to start the SHWE guarantee 2 3 2 First engine start To carry out the actual first engine start 1 Start the engine turning the key to position for some seconds Figure 12 Situation of the panel with engine off key to position 40 FNM HPE Series 2 on page 42 and then to position II when the light of the glow plugs turn off Figure 13 Hold the key to position II until the engine starts on page 43 3 Let the engine warm up for few minutes at minimum RPM 4 Carry out the en
68. s 5 Pull off the tube bundle Pay attention to the fins during the tube bundle dismounting operations to not affect the exchanger performances 6 Clean inside the tubes with a cleaning brush remove any salt incrustations and wash with fresh water 7 Clean the outer part and the fins of the tube bundle from oil deposits using fuel and then dry preferably with compressed air max 2 bar 8 Reposition the tube bundle in the housing take care of the fins during the bundle placing in the casing Properly position all the gaskets and the O rings into the housing at the base of the casing 9 Reposition the cap 10 Reposition the inlet pipes and screw the pipe clamps 11 Verify for any leaks after tightening the screws 3 3 15 3 Cleaning the fuel exchanger To clean the exchanger follow the instructions INFORMATION 1 Stop the engine and close the sea water circuit valve 2 Empty the sea water circuit by unscrewing the anodes as described in paragraph 3 3 13 Sea water circuit cleaning on page 87 FNM HPE Series 95 3 Remove the sleeves and covers of the fuel exchanger see paragraph 1 6 Main components of FNM engine HPE Series on page 15 to identify it 4 Clean inside the tubes with a cleaning brush and rinse with water 5 Reposition the lateral caps take care to gaskets 6 Check for any leaks 3 3 16 Grease the engine starter pinion Periodic maintenance performed by qualified personnel e
69. s Press 8 available only with the sensors properly installed on the transmission Get information from your installer they are installed on your boat BEWARE 11 Boost Press shows the current engine boost pressure turbocharger boost pressure 12 Throttle or Engine Load show the percentage relative to the position of the throttle 13 Coolant Tmp shows the engine coolant temperature For more information about the displayed information and warning views that may appear see the paragraph 3 7 3 36 FNM HPE Series Meaning of the indicators on the digital panel on page 115 2 2 4 Setting Mode The setting mode allows you to set all the parameters of the instrument In normal mode pressing simultaneously the Mode button and the up arrow button allows you to enter the Setting mode Pressing the Mode button a or staying for more than 40 seconds in the Selection mode without pressing any key makes it return to Normal mode In Setting mode the arrow keys v can be used to display alternative screens containing other functions that allow you to set the instrument To enter a function press and hold the arrow keys simultaneously for at least 2 seconds Use the same key combination to give a confirmation and the Mode button to go back The functions which can be modified on the instrument are shown in the figure below For more information consult the manual of digital instrument avai
70. t refer to the right engine while the button and the LED on the left refer to the left engine 2 5 2 1 Acquisition of the command The electronic throttle allows taking the control of the boat from any position after the acquisition of control with that position FNM HPE Series 53 To acquire the command with stopped boat INFORMATION 1 2 3 4 Position all the command stations in neutral Keep the Command button pressed for at least 1 second The Command LED will light and the Warm Sync LED will begin blinking Now you are in the warm up mode i e the gearboxes are disabled It is only possible to accelerate to carry out the engines preheating operation To definitely take the command of the station you must reposition the levers in neutral position and hold the Warm Sync button for 2 seconds Now the command lever is enabled and ready for use To acquire the navigation command INFORMATION 1 54 Synchronize the 2 levers of the station of which you want to acquire the command with respect to the station which has the command the Engine led starts blinking when the lever of the calling station is in phase with the lever of the station that has the command with an accuracy of 10 degrees when both levers are synchronized and therefore the corresponding Engine leds are blinking it is possible to acquire the command by pressing the Command button for 2 seconds FNM HPE Series Once finished the command ac
71. t temperature At the end of the preheating phase it turns off Do not start the engine if the glow plugs alarm or its indicator is not turned off FNM HPE Series It is now possible to start the engine position 11 2 Start the engine Turn and hold the key in position Il and release immediately when you hear that the engine starts Figure 17 Hold the key to position II until the engine starts 0 Avoid the engine starter overload release the key after 5 sec if engine doesn t start Repeat the operation if necessary The digital instrument sometimes as in the case of low battery voltage can redo the test mode 3 Engine functioning While the engine is running in normal functioning conditions all the lights and the buzzer must be OFF FNM HPE Series 47 48 VOLTS 13 8 Volts Coolant Tmp 100 C Figure 18 The indicator lights on the panel are turned off when the engine is functioning properly The digital instrument is in normal operating mode for default it shows the battery voltage Volts the engine coolant temperature Coolant Tmp 4 Engine stop Turn counterclockwise the key to position 0 to turn off the engine FNM HPE Series II Figure 19 Move the key to 0 to turn off the engine If the lights or the alarms of the CANBUS universal instrument indicate the presence of a Ul fault or an anomaly immediately reduce speed and turn off the engine Consult 128 p
72. the and gas exhaust emission and noise parameters for which your engine is approved in accordance with the Directives 2003 44 EC and EPA TIER 3 This manual provides important information on maintenance operations to be carried out periodically and handling of your engine Before starting your engine we advise you to read this manual in order to get the information necessary to operate your engine The proper use of the FNM engine as well as proper maintenance plan during the period of activity and inactivity of the engine ensures its durability and performance FNM HPE Series 5 1 2 Guidance on identification of important information In the manual you will find a color guide that indicates the degree of importance of information for use or maintenance of your FNM engine There are three levels of importance Danger icon dangerous situations that may compromise the safety of persons and engine functionality Beware icon indicates the need to follow the instructions as presented in this manual seme Otherwise the engine functionality can be reduced Informations indicates important technical information INFORMATION To these are added the environmental information as indicated below Respect the environment do throw away pollutants The important information is shown in the rest of this manual with the color for one of these levels as shown above 6 FNM HPE Series 1 3 Notes on FNM engines servi
73. ting system of the engine is active at the start up Alternator indicator light lights up when the alternator is not charging the battery FNM HPE Series 9 Voltmeter measures the battery voltage in volts 10 Engine oil pressure indicator measures the engine oil pressure in bar or psi 11 Crankshaft revolutions counter measures the engine crankshaft speed rotation in RPM 12 Coolant thermometer measures the engine coolant temperature in C and F 13 Hourmeter clock indicates the number of hours that the engine has run Each panel has an alarm buzzer that signals the situations of potential danger For information on the operating status of indicators and indicator lights on the engine panel refer to chapter 3 7 2 Meaning of the indicators on the analog panel on page 112 FNM HPE Series 25 26 Figure 6 Complete analog instrument panel Figure 7 Analog instrument panel in separate configuration FNM HPE Series 2 2 Digital Instrument Panel If your FNM HPE engine is equipped with digital instruments it can have an instrument panel complete with key lock lights and indicators Figure 8 Complete digital instrument panel on page 29 or only an instrument panel with lock key and indicators Figure 9 Analog instrument panel in separate configuration on page 29 with separate digital instruments depending on the type of installation In both cases all indicators are also a
74. tor must be correctly positioned The instrument panel and connection cable must be integral Any fluids leaks At the time of shipment engines are bench tested and packaged according to internal specifications FNM is not responsible for damages caused by the carrier transport company FNM HPE Series 2 Using the FNM engine HPE series FNM HPE Series 23 2 1 Analog Instrument Panel If your FNM HPE engine is equipped with an analog instrument panel it can have an instrument panel complete with key lock indicators and indicator lights Figure 7 Analog instrument panel in separate configuration on page 26 or only an instrument panel with lock key and indicator lights Figure 7 on page PAGEREF Ref320107452 h 26 with separate analog instruments depending on the type of installation In both cases all indicators are also available as an option The elements present on the instrument panels are as follows 1 2 3 4 5 6 7 8 24 Key Lock allows to start and stop the engine Test Button allows checking the indicator lights operation on the panel Backlight turns on or off the backlight of the panel Fuse Protects the panel instruments against overcurrent Coolant high temperature indicator light xk lights up when the coolant is too hot Oil low pressure indicator light A lights up when the oil pressure is too low Glows plugs indicator light 00 lights up when the prehea
75. uel supply line or fuel injection line Check replace Incorrect lube oil SAE class or quality for ambient temperature Replace Wrong fuel quality or contaminated fuel Check fuel Drain and flush fuel tank Replace with new fuel Oil level too high Reduce the level Leak in the air manifold Dirty intercooler Check replace and clean Clogged exhaust Check clean Damaged turbocharger Replace Dirty injectors Check replace if required Transmission Check 124 FNM HPE Series Possible Fault If the engine overheats excessively Possible Remedy damaged impeller Seacock closed Open Leaks in the sea water suction system Check replace Sea water filter clogged Check clean Sea water impeller damaged Check replace Coolant level too low Check fill up Leaks in the coolant circuit Check Heat exchanger damaged or clogged by rubber parts of the Oil level too high Reduce the level Oil level too low Raise the level Insufficient comburent air Check clean the filter Engine becomes apparently overheated as a result of faulty Air in fuel supply system Check replace temperature switch sensor or meter Faulty thermostat Check replace Faulty coolant pump Check clean Faulty oil filter dirty oil exchanger Replace Faulty turbo compressor Check replace Che
76. ugs main relay Fuse F11 Pin 4 ECU Fuse F10 Pin 5 ECU Fuse F4 Key on Fuse F3 EOBD Diagnosis Fuse F5 Main relay Fuse F2 Not Used Fuse F1 Not Used FNM HPE Series 3 7 Specifications of your engine FNM HPE Series PE 40S 80 80SD 0 110JD BUE den 00 D PE P 300 PEL 4 PEL 80 PEL 65 00 0 250JD 250 4 4 5 4 4 1248 1910 2387 2988 1248 69 6 82 0 82 0 95 8 69 6 82 0 90 4 90 4 104 0 82 0 Four stroke diesel engine 17 6 1 18 1 17 6 1 Direct Common Rail Injection Turbine with variable geometry i ac coed none 16 Valve DOHC 20 Valve DOHC 16 Valve DOHC 1 3 4 2 1 2 4 5 3 1 3 4 2 800 850 800 750 800 750 850 800 850 4000 4200 4000 4200 4000 4200 4000 4200 109 Maximum power kW rpm Maximum torque Nm rpm Alternator Engine oil capacity without filter I Thermostatic valve Cooling capacity I Sea water pump flow l min Engine starter Wet weight excluding transmission kg 110 HPE P HPE 40S 80 80SD HPE P 110 110JD pd u 100 225 225JD HPE P 300 HPEL 45 HPEL 80 HPEL 65 90 250 250JD 250H 29 4 3200 HPE P 40 110 4000 HPE P 80 8 4000 4400 HPE 150 150D 184 4200 110 110D 125 4000 HPE P HPE P250 250D 58 8 4000 HPE 80 170 170JD 80 8 3000 HPE P250H 217 4000 33 3000 55 1 3800 HPE 8050 140 4000 HPE P 165 4000 66 4000 HPEL 80 190 190JD HPE
77. urns on with the buzzer and the warning lights Turn off the engine immediately Trim From 0 to 8 units Indicates the position relative to the Trim inclination angle Oil press Value between 0 7 and 6 bar Indicates the engine oil normal pressure 116 FNM HPE Series Display views Status Meaning Involves a loss of engine oil or an insufficient amount of engine oil The Value below 0 7 bar Low Oil Pressure alarm Turns on with the buzzer and the warning lights Turn off the engine immediately and check the oil level Indicates the total number of hours of use that has the engine since it Engine Hour Over Oh was first turned on Bug llaqa From aa nii Indicates the amount of fuel still in the tank Each unit represents 1 8 of the fuel maximum volume that can be contained Water Press Greater than 0 bar Indicates the engine coolant pressure Fuel Left Greater than 0 litres Indicates the amount of fuel still available in the tank Fuel Used Greater than 0 litres Indicates the amount of fuel used since last reset Fuel Inst Greater than 0 liters hour Indicates the engine fuel time consumption in liters per hour Forward Indicates the forward gear engaged Trans Gear Neutral Indicates the neutral position Reverse Indicates reverse gear engaged Trans Temp From 60 to 150 C Indicates the oil temperature inside the transmission Trans Press From 0 to 40 bar Indicates the
78. utton q The alarm will recur after 15 minutes if not resolved Once disabled the alarms they can still be consulted on the last screen of the Selection mode FNM HPE Series 31 Consult the possible alarm messages that be displayed 3 7 3 32 FNM HPE Series Meaning of the indicators on the digital panel on page 115 2 2 3 Selection Mode The Selection mode allows you to check the parameters that are not normally shown on the instrument From normal mode pressing once the Mode button lt a allows you to enter the Selection mode Pressing the Mode button or staying for more than 4 seconds the Selection mode without pressing any key makes it return to Normal mode In Selection mode the arrow keys can be used to display alternative screens containing other parameters monitored by the instrument FNM HPE Series 33 34 VOLTS 13 8 Volts Coolant Tmp 100 C Screen 1 displayed in Normal Mode Fuel Level Throttle 33 Screen 5 Oil Press 2 76 bar Fuel Used 10 Ltrs Screen 2 Engine Load 20 TRIM l u n J1 n Screen 6 Trans Gear 2 Forward Trans Temp 165 Screen 3 Engine Hour 35 Hrs Fuel Level l i i EEE 7 Figure 10 Possible displays in Selection mode Trans Press 13 8 bar Boost Press 0 3 bar Screen 4 ALARM SCREEN WILL DISPLAY ENGINE and LOCAL Alarms When occurin
79. vailable as an option The elements present on the instrument panels are as follows 1 Key Lock allows to start and stop the engine 2 Crankshaft revolutions counter measures the engine crankshaft speed rotation in RPM 3 CANBUS universal instrument allows to display all the engine operating parameters The integrated display allows to view also the alarms related to the engine Consult the table on page 116 for a list of the situations reported and the management of situations of potential danger The instrument also has a buzzer and some warning lights to indicate anomaly situations 4 Mode Button M To change the operating mode of the CANBUS universal instrument 5 Direction buttons to scroll through menus views of the CANBUS universal instrument 6 Glows plugs indicator light 06 lights up when the preheating system of the engine is active at the start up FNM HPE Series 27 7 Transmission oil anomaly indicator light lights up when the transmission has low oil pressure or the level of the oil tank is below the minimum 8 Other indicator lights Optionals depend on boat installation 28 FNM HPE Series MARINE DIESEL ENGINES Figure 9 Analog instrument panel in separate configuration Figure 8 Complete digital instrument panel 2 2 1 The universal CANBUS instrument The digital instrument panel features a LCD display and some buttons that make up the CANBUS universal
80. w fuel Insufficient comburent air Check Fuel leaks Check and repair Faulty injector injector pump Check replace if required Oil level too high Reduce the level Excessive inclination of engine Check Adjust Faulty injectors sprayers Check replace Oil level too high Reduce the level Leaking from turbo compressor oil seal Check replace the seal If black smoke comes out of the exhaust full load Insufficient intake air dirty air filter Check clean Leak in the air manifold Check replace Dirty intercooler Check clean Incorrect oil level Check Engine overloaded max rpm is not reached Check sizes of propeller and or boat weight Engine overloaded dirty propeller boat hull Excessive Check and clean if required weight on board Turbocharger actuator blocked Unblock replace Faulty turbo compressor Check replace FNM HPE Series 127 Possible Fault Possible Remedy If white smoke comes out of the exhaust full load Air in fuel supply system Check and bleed Wrong fuel quality or contaminated fuel Check fuel Drain and flush fuel tank Replace with new fuel Water in fuel system Check water separator Faulty glow plugs Check replace Faulty injector injection pump Check replace if required Vapors condensing at the exhaust for very low ambient temperature Oil level too high If you find burnt oil traces at the exhaust Check F
81. zzer of High coolant the panel turns on Turn off the engine immediately and check if the sea temperature On water filter is clogged the sea water valve is opened and the coolant is indicator light sufficient Also check the cooling system and any losses verify that the impeller sea water pump is in good condition Bleed air from the cooling system and check the connection of the sensor to the electrical wiring Generic failure Off Indicates normal operation 114 FNM HPE Series Indicator or light indicator light Status On Meaning The reason for which the indicator light turns on can be Problem on injection system ECU malfunction Engine over heating The FNM authorized service point must make an immediate diagnosis Water in fuel indicator light Off Indicates normal operation On The indicator light may turn on for Water presence in the fuel filter Malfunction of the water in fuel sensor Check and drain the fuel filter If the problem persists make a diagnosis by an authorized FNM service point Transmission oil anomaly indicator light Off Indicates normal operation On stern drive or gearbox installations Indicates the low level of oil in the transmission Check and fill the transmission system with proper lubricant then turn on the engine again If the problem persists contact an authorized FNM service point On saildrive installations In

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