Iveco F32 MNS, F32 MNT Service Manual
F32TIER3
SERIES
Industrial application
F32 MNS
F32 MNT
Technical and Repair manual
This publication provides unit and relevant component repair
data, specifications, instructions and methodologies.
This publication has been drawn up for qualified and
specialised personnel.
Before performing any operation check that the part relevant
to the unit on which you must work is available along with all
safety devices for accident-prevention, such as, goggles,
helmet, gloves, shoes, etc. and hoisting and transporting
equipment.
Operationsaretobeperformedbyfollowingtheindications
included here, using the special equipment indicated and
assuring proper repair, compliance with schedule and
operator's safety requirements.
Each repair must aim to restore operating efficiency and safety
in compliance with the FPT provisions.
FPT cannot be held liable for modifications, alterations or other
interventions non authorised by FPT on the vehicle and if the
unit is warranted the above mentioned interventions will cause
its expiration.
FPT is not liable for repairing interventions.
FPT will provide further details required to carry out the
interventions and all the instructions that are not included on
this publication.
Data included in this publication may not be up-to-date
therefore subject to Manufacturer's modifications that can be
added at any time for technical or commercial purposes and
also to meet new law regulations in other Countries.
If issues on this publication differ from what is actually noticed
on the unit, please get in touch with the FPT network before
starting any intervention”.
It is forbidden to copy this text or any of its parts and all
illustrations included.
Publication edited by:
FPT - Fiat Powertrain Technologies
www.fptpowertrain.com
Print P2D32F005 E -2
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Ed. 04.2009
Revi 04.2012
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F32 Series Part 1
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INTRODUCTION 1
Introduction
Page
PREFACE 3...............................
SYMBOLS 3.............................
- Warnings 3.............................
- Service operations 3......................
GENERAL WARNINGS 5...................
GENERAL WARNINGS
ON THE ELECTRIC SYSTEM 7.............
- Bonding and screening 8...................
CONVERSIONS BETWEEN THE MAIN UNITS
OF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND MOST USED DERIVED
QUANTITIES 9.........................
KEY OF LECTURE OF THE HEADINGS
AND FOOTNOTES 10...................
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INTRODUCTION 3
PREFACE
Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are
indicated in the general table of contents.
The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly
detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules.
The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly’s
electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the
control units peculiar to the electric system.
Section 1 describes the engines illustrating its features and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four separate parts:
1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the relating
specific duty.
2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating
specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and direct
instructions to identify the cause of the major inconveniences.
Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute such
operations.
The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order
to prevent serious accidents taking place.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained i nformation. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - Warnings
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
Danger of serious damage for the assembly
Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may
sometimes cause the warranty to become null and void.
General danger
!
It includes the dangers of above described signals.
Environment protection
Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect
the environment as much as possible.
NOTE
It indicates an additional explanation for a piece of information.
Service operations
Example
∅
Ø 1 = Seat of small end bush
1
Close applying the required torque
Closeapplyingtherequiredtorque+angular
Ø 2 = Seat of connecting rod bearings.
∅
2
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Removal
Disconnection
Refitting
Connection
Removal
Disassembly
Fitting in place
Assembly
ρ
Exhaust
Operation
Compression ratio
Tolerance
Weight difference
Tighten to torque Rolling torque
Tighten to torque + angle value Rotation
α
Press or caulk
Regulation
Adjustment
Angle
Angular value
Preload
Visual inspection
Fitting position check
Measurement
Value to find
Check
Equipment
Surface for machining
Machine finish
Interference
Strained assembly
Thickness
Clearance
Lubrication
Damp
Grease
Sealant
Adhesive
bar
Number of revolutions
Temperature
Pressure
Oversized
Higher than….
Maximum, peak
Undersized
Less than….
Minimum
Selection
Classes
Oversizing
Temperature < 0 °C
Cold
Winter
Temperature > 0 °C
Hot
Summer
Air bleeding
Intake
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GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
immediate superiors where a danger situation occurs which is not described.
!
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
Manual handling of loads must be appraised beforehand, because this not only depends on the weight but also on the
size and path.
Handling with mechanical means must be done with lifters that are suitable for weight, shape and volume. Hoisters, ropes
and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is
compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the c o-operator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly
follow all the safety indications found on the assembly.
INTRODUCTION 5
Do not leave the running assembly unattended when making repairs.
When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting
stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted
by means of a hoist.
When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document,
as well as all the specific safety standards provided for.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 16-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
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Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 16-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled
parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Self-locking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80°C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
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GENERALWARNINGS ON THE ELECTRIC SYSTEM
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
!
always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
INTRODUCTION 7
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
NOTE
Connectors present must be seen from cable side. Connectors views contained i n the manual are representative of cable
side.
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Bonding and screening
Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying
then to have their centering tidily and properly made (Figure 1, re. M).
Further, following warnings are to be compulsorily observed for electronic components:
- Electronic central units must be connected to system bonding when they are provided with a metallic shell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.
- Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation.
Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
- Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
- If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
- Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR
d. DISTANCE ! 0
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INTRODUCTION 9
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
Pa
2
2
according to ratio 1:1
1 bar = 1.02 kg/cm
1 kg/cm
1bar = 10
2
= 0.981 bar
5
Where accuracy is not particularly needed:
- Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1
1 kgm = 10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm
2
1 kg/cm
=1bar.
Temperature
0° C=32° F
1° C = (1 x 1.8 + 32) ° F
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KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES
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Type of
vehicle
Section
title
Page
number
Printout
number
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Language
Publication
Basic edition referred to
month - year editorial
phase closing
When month - year update
is present (revi) to the basic
edition
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Part 1
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Section
General specifications
Fuel 2
Industrial application 3
Overhaul and technical specifications 4
Tools 5
Safety prescriptions Appendix
1
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UPDATING
Section Description Page Date of revision
3
3
4
Industrial application
Mechanical overhaul
21, 64
30, 31, 32, 33
January 2010
April 2012
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SECTION 1 - GENERAL SPECIFICATIONS 1
SECTION 1
General specifications
Page
CORRESPONDENCY BETWEEN TECHNICAL
CODING AND COMMERCIAL CODING 3....
ENGINE VIEWS
(for F5CE9454E*A005, F5CE9484D*A002 engines) 4..
ENGINE VIEWS
(for F5CE5454B*A004 engines) 5.............
ENGINE LUBRICATION SYSTEM 6.............
- Oil pump 7.............................
- Engine oil filter 8.........................
ENGINE OIL VAPOUR RECIRCULATION 9......
ENGINE COOLING SYSTEM 10.................
- For engines without external EGR 10..........
- For engines with external EGR 11............
WATER PUMP 12............................
THERMOSTAT 12............................
- Working system 12........................
HEAT EXCHANGER 13.......................
EGR EXHAUST GAS RECYCLE SYSTEM 14........
- Internal EGR operating on the intake valves
(for F5CE9454, F5CE9484 engines) 14.........
- Intake cam profile 14......................
- External E.G.R. system
(for F5CE5454 engines) 15..................
- Working system 15........................
BOOSTING 16..............................
- For engines without external EGR 16..........
- For engines with external EGR 17............
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SECTION 1 - GENERAL SPECIFICATIONS 3
CORRESPONDENCY BETWEEN TECHNICAL CODING AND COMMERCIAL CODING
Technical Code Commercial Code
F5CE5454B*A004
F5CE9454E*A005
F5CE9484D*A002 F32 MNT.X
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SECTION 1 - GENERAL SPECIFICATIONS
ENGINE VIEWS (for F5CE9454E*A005, F5CE9484D*A002 engines)
Figure 1
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Figure 2
128134
128135
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ENGINE VIEWS (for F5CE5454B*A004 engines)
Figure 3
SECTION 1 - GENERAL SPECIFICATIONS 5
Figure 4
128136
128137
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SECTION 1 - GENERAL SPECIFICATIONS
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ENGINE LUBRICATION SYSTEM
Forced circulation lubrication is controlled by the rotor oil
pump housed in the front part of the engine basement and
driven by the toothed gear splined on the shank of the engine
drive shaft.
From the oil pan, the lubrication oil is distributed to the engine
drive shaft, the camshaft and the valve control.
Figure 5
The lubrication system also comprises the heat exchanger, he
centrifugal blower for the versions with turbosupercharger
and eventually the compressor if the compressed air system
is also fitted.
All the above mentioned components vary depending on their
use and therefore will be illustrated in the specific section.
Pressurized oil
Dropping oil
127695
LUBRICATION SYSTEM DIAGRAM
1. Oil filter - 2. Oil pump - 3. Heat exchanging unit - 4. Heat exchanger -
5. Turbosupercharger lubrication feed pipe
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Oil pump
Figure 6
SECTION 1 - GENERAL SPECIFICATIONS 7
119405
PUMP SPECIFICATIONS
Rotating speed 750 rpm - 4200 rpm
Feed pressure 2Bar-4Bar
Rated flow 12.2 l/min - 75.9 l/min
Oil type SAE 20/30
Max. oil temperature 80 °C
1. Main gear - 2. Secondary gear - 3. Pump unit - 4. Drive shaft - 5. Secondary shaft
6. Cover - 7. Internal rotor - 8. External rotor - 9. Bush.
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SECTION 1 - GENERAL SPECIFICATIONS
Engine oil filter
Figure 7
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1. Protective cover - 2. Cartridge
Booster pressure: 20 bar (ISO 4548/3)
Dynamic pressure: 0-15 bar (1Hz) > 50,000 cycles (ISO 4548/5)
Operating temperature: -40 / + 140 ˚C
Torque wrench setting: 32.5 ± 2.5 Nm
Maximum flow: 50 l/min.
Load loss at the end of life cycle: 2.5 bar
Accumulation: > 15 gr with 2.5 bar load loss (ISO 16889)
119406
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ENGINE OIL VAPOUR RECIRCULATION
Figure 8
SECTION 1 - GENERAL SPECIFICATIONS 9
119407
1. Valve - 2. Breather - 3. Tappet cover
On the tappet cover (3) there is a valve (1) having the duty to cause condensation of oil vapours making them drop by gravity
on the underlying tappet cover (3).
The remaining non condensed vapours will be duly conveyed through the breather (2), for instance by suction (appropriate
connection must be provided by the outfitter).
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SECTION 1 - GENERAL SPECIFICATIONS
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ENGINE COOLING SYSTEM
For engines without external EGR
The closed circuit forced circulation engine cooling system is
composed of the following parts:
- expansion tank: position, form and dimensions may vary
depending on the engine fitting;
- radiator dissipating the heat absorbed by the engine
cooling liquid. This component’s position and dimensions
may vary depending on the outfit;
- fan increasing the radiator’s cooling power. This
component may vary depending on the specific engine
fitting;
Figure 9
- heat exchanger coolingthe lubricant oil. This component
may vary depending on the specific engine fitting;
- centrifugal water pump positioned in the front part of the
engine basement;
- thermostat controlling cooling liquid circulation.
Closed thermostat
Open thermostat
Water inflow
Engine cooling water
Water outflow from thermostat
120018
ENGINE COOLING SYSTEM DIAGRAM
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SECTION 1 - GENERAL SPECIFICATIONS 11
For engines with external EGR
The closed circuit forced circulation engine cooling system is
composed of the following parts:
- expansion tank: position, form and dimensions may vary
depending on the engine fitting;
- radiator dissipating the heat absorbed by the engine
cooling liquid. This component’s position and dimensions
may vary depending on the outfit;
- fan increasing the radiator’s cooling power. This
component may vary depending on the specific engine
fitting;
Figure 10
- heat exchanger coolingthe lubricant oil. This component
may vary depending on the specific engine fitting;
- centrifugal water pump positioned in the front part of the
engine basement;
- thermostat controlling cooling liquid circulation.
Closed thermostat
Open thermostat
Water inflow
Engine cooling water
Water outflow from thermostat
118983
ENGINE COOLING SYSTEM DIAGRAM
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SECTION 1 - GENERAL SPECIFICATIONS
ATERPUMP
Figure 11
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120047
WATER PUMP SECTION
1. Hub - 2. Shaft with bearing - 3. Pump unit - 4. Sheath - 5 . Impeller.
The water pump is a centrifugal blade turbine type pump. The pump’s bearing (2) is connected to the impeller’s shaft as a whole.
Water tight between the pump unit (3) and the shaft (2) is ensured by the sheath (4).
THERMOSTAT
Figure 12
119412
THERMOSTAT DIAGRAM
Working system
When the engine is cool, water output from the front part of the cylinder head flows into an inlet containing the thermostat, which
cuts out water circulation to the radiator. This way, water circulation will only be possible in the pump-enginecircuit, insofar allowing
engine heat-up quickly. The thermostat valve starts opening at nearly 80 ˚C, allowing water circulation into the radiator and also
obstructing direct return towards the engine. Check the thermostat efficiency and replace it in case of doubtful functioning.
1. Stroke starts at 79˚ ±2˚C
2. 7 mm stroke at 94˚±2˚C
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