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FPT F32 Series Technical And Repair Manual

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F32 TIER 3
SERIES
Industrial application
F32 MNS
F32 MNT
Technical and Repair manual

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Summary of Contents for FPT F32 Series

  • Page 1 F32 TIER 3 SERIES Industrial application F32 MNS F32 MNT Technical and Repair manual...
  • Page 2 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.
  • Page 3 F32 SERIES F32 SERIES Part 1 F32 Series Print P2D32F005 E Base - April 2009...
  • Page 4 F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 5: Table Of Contents

    F32 SERIES INTRODUCTION Introduction Page PREFACE ....... SYMBOLS ......
  • Page 6 INTRODUCTION F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 7: Preface

    F32 SERIES INTRODUCTION 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.
  • Page 8 INTRODUCTION F32 SERIES Removal Exhaust Disconnection Refitting Operation Connection Removal ρ Compression ratio Disassembly Fitting in place Tolerance Assembly Weight difference Tighten to torque Rolling torque Tighten to torque + angle value Rotation α Angle Press or caulk Angular value...

  • Page 9: General Warnings

    F32 SERIES INTRODUCTION 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.
  • Page 10 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.

  • Page 11: General Warnings On The Electric System

    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.

  • Page 12: Bonding And Screening

    INTRODUCTION F32 SERIES 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).

  • Page 13: Conversions Between The Main Units Of Measurement Of The International System And Most Used Derived Quantities

    F32 SERIES INTRODUCTION CONVERSIONS BETWEEN MAIN UNITS MEASUREMENT 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...

  • Page 14: Key Of Lecture Of The Headings And Footnotes

    INTRODUCTION F32 SERIES KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES Type of Section Page vehicle title number Basic edition referred to When month - year update Printout Language month - year editorial is present (revi) to the basic number...
  • Page 15 F32 SERIES Part 1 F32 SERIES Section General specifications Fuel Industrial application Overhaul and technical specifications Tools Appendix Safety prescriptions Print P2D32F005 E Base - April 2009...
  • Page 16 F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 17 F32 SERIES UPDATING Section Description Page Date of revision General specifications 12.2012 Industrial application 15, 19, 65, 66 12.2012 Overhaul technical 19, 25, 30, 31, 32, 33 12.2012 specifications Print P2D32F005 E Base - April 2009 Revi - 12.2012...
  • Page 18 F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 19 F32 SERIES SECTION 1 - GENERAL SPECIFICATIONS SECTION 1 General specifications Page CORRESPONDENCY BETWEEN TECHNICAL CODING AND COMMERCIAL CODING ..ENGINE VIEWS (for F5CE9454E*A005, F5CE9484D*A002 engines) ENGINE VIEWS (for F5CE5454B*A004 engines) ... . .
  • Page 20 SECTION 1 - GENERAL SPECIFICATIONS F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 21: Correspondency Between Technical Coding And Commercial Coding

    F32 SERIES SECTION 1 - GENERAL SPECIFICATIONS CORRESPONDENCY BETWEEN TECHNICAL CODING AND COMMERCIAL CODING Technical Code Commercial Code F5CE5454B*A004 F32 MNS.X F5CE9454E*A005 F5CE9484D*A002 F32 MNT.X Print P2D32F005 E Base - April 2009...

  • Page 22: Engine Views

    SECTION 1 - GENERAL SPECIFICATIONS F32 SERIES ENGINE VIEWS (for F5CE9454E*A005, F5CE9484D*A002 engines) Figure 1 128134 Figure 2 128135 Base - April 2009 Print P2D32F005 E...

  • Page 23: Engine Views (For F5Ce5454B*A004 Engines)

    F32 SERIES SECTION 1 - GENERAL SPECIFICATIONS ENGINE VIEWS (for F5CE5454B*A004 engines) Figure 3 128136 Figure 4 128137 Print P2D32F005 E Base - April 2009...

  • Page 24: Engine Lubrication System

    SECTION 1 - GENERAL SPECIFICATIONS F32 SERIES ENGINE LUBRICATION SYSTEM The lubrication system also comprises the heat exchanger, he centrifugal blower for the versions with turbosupercharger Forced circulation lubrication is controlled by the rotor oil and eventually the compressor if the compressed air system pump housed in the front part of the engine basement and is also fitted.

  • Page 25: Oil Pump

    F32 SERIES SECTION 1 - GENERAL SPECIFICATIONS Oil pump Figure 6 119405 PUMP SPECIFICATIONS Rotating speed 750 rpm - 4200 rpm Feed pressure 2 Bar - 4 Bar Rated flow 12.2 l/min - 75.9 l/min Oil type SAE 20/30 80 C Max.

  • Page 26: Engine Oil Filter

    SECTION 1 - GENERAL SPECIFICATIONS F32 SERIES Engine oil filter Figure 7 119406 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: 30 ±...

  • Page 27: Engine Oil Vapour Recirculation

    F32 SERIES SECTION 1 - GENERAL SPECIFICATIONS ENGINE OIL VAPOUR RECIRCULATION Figure 8 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).

  • Page 28: Engine Cooling System

    SECTION 1 - GENERAL SPECIFICATIONS F32 SERIES - heat exchanger cooling the lubricant oil. This component ENGINE COOLING SYSTEM may vary depending on the specific engine fitting; For engines without external EGR - centrifugal water pump positioned in the front part of the The closed circuit forced circulation engine cooling system is engine basement;...

  • Page 29: For Engines With External Egr

    F32 SERIES SECTION 1 - GENERAL SPECIFICATIONS - heat exchanger cooling the lubricant oil. This component For engines with external EGR may vary depending on the specific engine fitting; The closed circuit forced circulation engine cooling system is - centrifugal water pump positioned in the front part of the composed of the following parts: engine basement;...

  • Page 30: Water Pump

    SECTION 1 - GENERAL SPECIFICATIONS F32 SERIES WATER PUMP Figure 11 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.

  • Page 31: Heat Exchanger

    F32 SERIES SECTION 1 - GENERAL SPECIFICATIONS HEAT EXCHANGER Figure 13 SECTION A-A SECTION B-B 119408 The heat exchanger within the engine cooling system has the duty to control the engine oil temperature, reducing it by absorbing heat throughout the engine cooling liquid.

  • Page 32: Egr Exhaust Gas Recycle System

    SECTION 1 - GENERAL SPECIFICATIONS F32 SERIES EGR EXHAUST GAS RECYCLE SYSTEM The exhaust gas can be partially recycled to cylinders to reduce maximum temperature values of combustion that produce nitrogen oxides (NOx). The exhaust gas recycle system (EGR) reduces combustion temperature and therefore is an efficient NOx emission control system.

  • Page 33: External E.g.r. System (For F5Ce5454 Engines)

    F32 SERIES SECTION 1 - GENERAL SPECIFICATIONS External E.G.R. system (for F5CE5454 engines) Figure 15 119409 1. Valve unit - 2. Heat exchanger - 3. Water pipe - 4. Exhaust gas pipe - 5. Intake manifold 6. Exhaust manifold - 7. Engine head.

  • Page 34: Boosting

    SECTION 1 - GENERAL SPECIFICATIONS F32 SERIES BOOSTING For engines without external EGR The boosting system is composed of the following parts: - Air filter; - Turbosupercharger. - An ”intercooler” radiator (if fitted) Figure 16 124466 Sucked air Heated compressed air...

  • Page 35: For Engines With External Egr

    F32 SERIES SECTION 1 - GENERAL SPECIFICATIONS For engines with external EGR The boosting system is composed of the following parts: - Air filter; - Turbosupercharger. Figure 17 EGR closed valve EGR open valve Sucked air Heated compressed air Engine exhaust gas...
  • Page 36 SECTION 1 - GENERAL SPECIFICATIONS F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 37 F32 SERIES SECTION 2 - SUPPLY SECTION 2 Supply Page SUPPLY ........
  • Page 38 SECTION 2 - SUPPLY F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 39 F32 SERIES SECTION 2 - SUPPLY SUPPLY The engine supply system consists of the following components: - Fuel tank (aboard the vehicle) - Fuel delivery and return pipes - Fuel pre-filter (if fitted, it is placed nearby the engine on the vehicle’s chassis)

  • Page 40: Pipe Layout

    SECTION 2 - SUPPLY F32 SERIES PIPE LAYOUT Figure 2 118976 1. Injector feed pipe - 2. Fuel exhaust pipe from injectors - 3. Supply rotary pump - 4. Union for pressure gauge pipe within LDA intake manifold - 5. KSB thermal bulb - 6. Solenoid valve - 7. Injector.

  • Page 41: Working System Description

    F32 SERIES SECTION 2 - SUPPLY Figure 3 119961 Working system description Then, the fuel reaches the valve controlling fuel pressure within the supply pump. The fuel (5) is primed from the fuel tank from the priming pump (6). The latter is fitted on the engine basement and is The distributor piston further increases such pressure and driven by the engine camshaft.

  • Page 42: Supply Pump

    SECTION 2 - SUPPLY F32 SERIES SUPPLY PUMP The rotary type supply pump is driven by a gear which is coupled to the engine camshaft gear. Identification coding example = rotary distributor piston pump = pump dimensions = four cylinder engines = distributor piston size in mm 1150 = no.

  • Page 43: Working System Description

    F32 SERIES SECTION 2 - SUPPLY WORKING SYSTEM DESCRIPTION Supply phase Figure 5 119415 1. Fuel supply pipe - 2. Solenoid valve - 3. Axial groove - 4. Compression chamber - 5. Fuel delivery pipe from pump to injectors - 6. Distributor piston - 7. End of delivery port - 8. Cursor - 9. Injector.

  • Page 44: End Of Delivery Phase

    SECTION 2 - SUPPLY F32 SERIES End of delivery phase Figure 7 119417 1. Fuel feed pipe - 2. Compression chamber - 3. Fuel delivery pipe - 4. End of delivery pipe - 5. Cursor - 6. Distributor piston. The distributor piston (6) moving towards the T.D.C. connects the high pressure inner chamber to the pipe (1), thereby establishing pressure balance between the distributor piston inner chamber, the injectors’...

  • Page 45: L.d.a. Load Delivery Adjustment Device

    F32 SERIES SECTION 2 - SUPPLY L.D.A. Load Delivery Adjustment device Figure 9 119419 Working system The duty of the L.D.A. device is to adjust the fuel delivery depending on the air pressure within the intake manifold. Air pressure acts on the membrane (1), which is tied up to the setting pin (4). In the lower part of the setting pin (4) there is a conical housing (5) in which the feeling pin runs (6).

  • Page 46: Priming Pump

    SECTION 2 - SUPPLY F32 SERIES PRIMING PUMP The priming pump duty is to prime the fuel from the tank and convey it to the fuel supply pump. It is fitted on the engine basement and driven by the engine camshaft.

  • Page 47: Fuel Filter

    F32 SERIES SECTION 2 - SUPPLY FUEL FILTER The filter is placed nearby the supply pump and the priming pump. Its duty is to retain impurities and separate water from the fuel in which it is contained. At the bottom of the filtering cartridge there may be a water drainage device (3).
  • Page 48 SECTION 2 - SUPPLY F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 49 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION SECTION 3 Industrial application Page MAIN SPECIFICATIONS ....PART ONE - MECHANICAL COMPONENTS ..
  • Page 50 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Page - Engine cooling liquid temperature sensor (for F5CE5454 engines) ....- Oil pressure switch .....

  • Page 51: Main Specifications

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION MAIN SPECIFICATIONS Type F5CE9454E*A005 F5CE5454B*A004 F5CE9484D*A002 Cycle Diesel 4 strokes Turbocharged - Feeding Turbocharged Turbocharged intercooler Injection Direct N. of cylinders 4 on-line  Diameter Stroke +.. = Total displacement 3200 ρ 17  0.5 : 1 Compression ratio Max.
  • Page 52 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 53 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION DIAGNOSI PART ONE - MECHANICAL COMPONENTS Print P2D32F005 E Base - April 2009...
  • Page 54 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 55: Engine Disassembly On Bench

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION ENGINE DISASSEMBLY ON BENCH For F5CE5454 engines Figure 2 NOTE Engine disassembly operations to remove the engine from the vehicle are described in the specific section. Engine disassembly operations, as well as engine overhaul, must be executed by qualified engineers only, duly provided with the specific tools required.

  • Page 56: Cylinder 1 T.d.c. Search

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Cylinder 1 T.D.C. search For all engines Figure 4 Figure 6 124497 - Fit tool (1) 99360330 to flywheel housing to rotate the flywheel (must be used with a suitable wrench). 119720 - Remove the L.D.A. pipe. Remove the fast clutch fuel...

  • Page 57: Bosch Ve 4/12F Pump

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION BOSCH VE 4/12F Pump Figure 9 118976 1. Fuel delivery pipes - 2. Fuel recovery pipes - 3. Mechanical pump - 4. LDA - 5. Wax KSB - 6. Injectors. Print P2D32F005 E...
  • Page 58 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Figure 10 Figure 12 119721 - Place a container under the diesel fuel filter and unscrew 127697 the condense drainage faucet under said filter; - Loosen the screw (4) and the relevant screw nut on the completely drain the diesel fuel container therein.
  • Page 59 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Figure 15 Figure 17 124497 125127 - Remove the electromagnetic joint support (1) and the - Fit tool (1) 99360330 to the flywheel box and, using a water pump (2). wrench, lock the flywheel rotation.

  • Page 60: Timing Gearcase

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Timing gearcase Figure 19 127698 - Remove the rear part (1), of the timing gearcase cover. Figure 20 119115 - Remove the tappet rods (1). - Disassemble the cylinder head; loosen the cylinder head (3) fastening screws (2);...
  • Page 61 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Figure 21 Figure 23 119130 119117 - Turn the engine upside down. - Loosen the screws (1) and remove the oil pump (2). - Loosen the screws (2), disassemble the plate (3) and remove the oil pan (1).

  • Page 62: Rear Side Component Assembly

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Rear side component assembly Figure 27 Figure 26 119121 133190 - Fit the specific tool 99346259 (5) to the rear shank (6) of the engine drive shaft, fix it with the screws (4) and spline the new grommet (3) thereon.

  • Page 63: Front Side Component Installation

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Figure 29 Figure 31 α 119463 119733 Tighten the engine flywheel (2) fastening screws (1) in two SCHEME FOR THE APPLIANCE OF LOCTITE 5999 steps: SEALER - Step 1: 30  1.5 Nm torque setting ;...

  • Page 64: Timing

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Timing Figure 35 Figure 32 124497 - Fit tool (1) 99360330 to flywheel housing to rotate the flywheel (must be used with a suitable wrench). Figure 33 119125 132006 - Loosen the screws of the plate in which tool 99360612 - Seize the 45˚...

  • Page 65: Piston Projection Measurement

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Figure 36 Figure 38 119735 - Fit the ignition pump cogwheel (1) into its housing. 70221 - Fit the pre-set ignition pump into its housing on the engine, inserting the shaft into the gear hole.
  • Page 66 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Figure 40 Figure 41 119573 119115 - Fit the gasket (1) on the basement centring it taking the pins (2) as a reference. The gasket’s thickness must be NOTE Always use new screws for assembly.
  • Page 67 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Figure 42 Figure 43 α 125128 133184 - Reassemble the electromagnetic joint support (1). - Reassemble the pulley (2). HEAD SCREW LOCKING ORDER - Reassemble the pulley (3), tighten the fastening screw Screws 1,2,3,4,5,6: M15x1,5 6g x193 (4) to the prescribed torque setting.
  • Page 68 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Figure 45 Figure 47 122587 Before reassembly, check that the rocker arm rods must not be deformed; there must be no trace of wear or seizure on the spherical housings of the rocker arm adjusting screws as well as on the tappets (pointers);...
  • Page 69 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Each cylinder must be checked by taking it to the T.D.C. (top Figure 49 dead centre) at the end of compression and adjusting the clearance of both valves on the cylinder in question.
  • Page 70 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Figure 51 Figure 53 119721 - Reassemble the KSB water temperature sensor (6), the oil filter support (5), the priming pump (3), the diesel fuel filter support (2), the fuel filter (1) and the oil filter (4).
  • Page 71 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Figure 55 Figure 57 122571 119105 - Reassemble the pipe from the pump to the injector and - Reassemble the fuel exhaust pipes (1). tighten the brackets’ fastening screws (3). - Reassemble the pipe from the pump to the fuel filter (2) and from the fuel filter to the priming pump (1).
  • Page 72 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Figure 60 For F5CE5454 engines Figure 62 119130 - Assemble the oil pan (1) and fit the plate thereon (3). 119104 Tighten the fastening screws (2) to the prescribed torque setting. - Place the whole E.G.R. on the intake manifold, tighten the front side (5) and valve support (6) fastening screws to the prescribed torque pair.

  • Page 73: Checks And Inspections

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Checks and inspections Figure 64 The following checks must be executed after the engine fitting on vehicle. Check that the liquid refuelling or top up has been provided to the correct levels prescribed.

  • Page 74: Rocker Cover Blow-By Removal And Refitting

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Rocker cover blow-by removal and refitting Figure 67 Figure 65 133193 133191 - Secure the rocker cover (1) in a vice. - Unscrew the screws (2) from the tappets cover (1) with the blow-by filter and remove the plate guard (3).
  • Page 75 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Figure 69 Figure 71 133196 133194 Remove the blow-by (1) from the rocker cover (2). To remove the blow-by (1) from the rocker cover (2) it is necessary to free the elements from the hold of the sealant.
  • Page 76 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Figure 73 Figure 75 133200 133198 - Lean the complete cover assembly on a stiff surface. - By means of a plastic hammer make sure that the - Apply a regular layer of LOCTITE 510 all around the blow-by (2) goes completely inside its seat on the rocker blow-by body (1).
  • Page 77 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Figure 77 133191 - Refit the plate (3) on the tappets cover (1) with the blow-by filter and tighten the M5x10 screws (2). Print P2D32F005 E Base - April 2009...

  • Page 78: Rotary Feed Pump Disassembly And Assembly Procedure

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Rotary feed pump disassembly and assembly Figure 79 procedure NOTE This procedure prescribes that: - the fuel pipes (from the pumping elements to the injectors, recovering blow-by from the injectors to the pump and the supply from the priming pump) have all been removed;...
  • Page 79 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION BOSCH VE 4/12 F Pump Figure 83 Figure 81 128132 - From the pump side, loosen the fixing nuts (1) without removing them in order to enable moving the pump 128131 backwards using 99340025 extractor.
  • Page 80 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Figure 85 Figure 87 128132 128132 - Loosen screw (1) that prevents pump shaft rotation and insert spacer (2). Tighten screw (1)so that it locks spacer - Assemble the pump pre-set in its housing on the engine,...

  • Page 81: Cylinder 1 Tdc

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Power takeoff Injection pump static advance control on engine at cylinder 1 TDC Figure 89 Figure 88 (Demonstration) 128133 87720 For the engines with power takeoff, operate as follows: - loosen the 2 fastening screws (1) and remove the cover With injection pump inserted in its housing and retaining (2).
  • Page 82 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 83: Part Two - Electrical Equipment

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION PART TWO - ELECTRICAL EQUIPMENT Print P2D32F005 E Base - April 2009...
  • Page 84 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 85: Engine Cable For External Egr System

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION ENGINE CABLE FOR EXTERNAL EGR SYSTEM (for F5CE5454 engines) Figure 90 Print P2D32F005 E Base - April 2009...

  • Page 86: External Egr E.c.u. Electrical Layout

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES EXTERNAL EGR E.C.U. ELECTRICAL LAYOUT (for F5CE5454 engines) Figure 91 119452 Base - April 2009 Print P2D32F005 E...

  • Page 87: External Egr E.c.u. (For F5Ce5454 Engines)

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION External EGR E.C.U. (for F5CE5454 engines) Figure 92 119453 Technical specifications. Manufacturer Bitron Rated Voltage 13.5 V Actual Voltage 10 ÷ 16 V Working temperature -30 ÷ 100 ˚C Maximum current input <5 A EGR valve control signal PWM 140 ±...

  • Page 88: Pin Out Egr E.c.u

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Pin out EGR E.C.U. Ref. Description PWM output signal for EGR solenoid valve ECU Mass Mass for pre-heating (on) warning light ECU supply (+ 15) K line signal Intake manifold temperature and pressure sensor supply (5)

  • Page 89: Ksb - Bosch Pump Connection Cable

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION KSB - BOSCH PUMP CONNECTION CABLE Figure 93 120035 1. Interface - 2. KSB signal - 3. Air sensor - 4. Electrostop Print P2D32F005 E Base - April 2009...

  • Page 90: Engine Cooling Liquid Temperature Sensor

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Engine cooling liquid temperature sensor (for F5CE5454 engines) The sensor is fitted on the thermostat unit. It consists of two NTC thermistors with two reophores. Figure 94 Calibration Calibration Calibration 80 ˚C 20 ˚C 10 ˚C...

  • Page 91: Oil Pressure Switch

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Oil pressure switch Figure 95 75722 Characteristics Voltage: 12 ÷ 24 V Contact closure with decreasing pressure: 0.6 bar Contact opening with increasing pressure: 0.9 bar Print P2D32F005 E Base - April 2009...

  • Page 92: Cooling Liquid Temperature Sensor For Ksb

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Cooling liquid temperature sensor for KSB Figure 96 WIRING DIAGRAM 119455 Characteristics. 65  5 ˚C Contact closing temperature Maximum load on contacts Max 15A Base - April 2009 Print P2D32F005 E...

  • Page 93: Air Pressure Temperature Sensor

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Air pressure temperature sensor (for F5CE5454 engines) It consists of an NTC temperature sensor and a pressure sensor, both integrated in a single device. Figure 97 Mass +5 V Output signal (pressure) 119455...

  • Page 94: Engine Drive Shaft Sensor (For F5Ce5454 Engines)

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Engine drive shaft sensor (for F5CE5454 engines) It is an inductive type sensor placed on the front left side of the engine. It generates signals obtained by the magnetic flow lines closing up through the openings of a phonic wheel splined on the engine drive shaft.

  • Page 95: Egr Solenoid Valve (For F5Ce5454 Engines)

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION EGR Solenoid valve (for F5CE5454 engines) Figure 99 119458 A. Exhaust gas input - B. Exhaust gas output Figure 100 119459 * Pin-out bobbin * Pin-out potentiometer Resistance 8 ± 0.5 Total resistance 4 k...

  • Page 96: Starter

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Starter Figure 101 Manufacturer BOSCH Electrical system 12 V Rated output 3 kW 119464 Figure 102 119460 Base - April 2009 Print P2D32F005 E...

  • Page 97: Bosch 14V Alternator

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION BOSCH 14V Alternator Figure 104 Figure 103 88317 122578 WIRING DIAGRAM Specifications for use Vehicle electric system rated voltage: 12 V Suitable for coupling with battery of any capacity It must work with the battery connected.
  • Page 98 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 99: Part Three - Troubleshooting

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION PART THREE - TROUBLESHOOTING Print P2D32F005 E Base - April 2009...
  • Page 100 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 101: Diagnosis By Failure

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION DIAGNOSIS BY FAILURE NOTE In case of external EGR system failure, its operation is disabled and the related EGR failure indicator lamp flashes (if applicable). Print P2D32F005 E Base - April 2009...
  • Page 102 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 103 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Print P2D32F005 E Base - April 2009...
  • Page 104 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 105 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Print P2D32F005 E Base - April 2009...
  • Page 106 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 107: Part Four - Maintenance Planning

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION PART FOUR - MAINTENANCE PLANNING Print P2D32F005 E Base - April 2009...
  • Page 108 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...

  • Page 109: Scheduled Maintenance

    F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION SCHEDULED MAINTENANCE Servicing Plan Engine lubrication frequency has been calculated presuming the use of fuel with content of Sulphur < 0.5%. WARNING! In case of use of fuel containing a percentage of Sulphur e > 0.5 %, the engine oil replacement interval must be halved.

  • Page 110: Checks Not Included In Maintenance Planning-Daily Checks

    SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Checks not included in maintenance planning-daily checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle’s drivers.
  • Page 111 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Check of fuel system Lubricating system check The check must be executed both when the engine The check must be executed both when the engine disconnected and when it is running. disconnected and when it is running.
  • Page 112 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Each cylinder must be checked by taking it to the T.D.C. (top Check of belt’s tear and wear status dead centre) at the end of compression and adjusting the Carefully verify the belt’s surface in order to detect any sign of clearance of both valves on the cylinder in question.
  • Page 113 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Oilmotor and filter replacement Whereas you replace the lubrication oil, it is necessary to re- place the filter. Figure 109 Warning: We recommend to wear proper protec- tions because of high motor service temperature.
  • Page 114 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Fuel filter replacement Bleeding procedure: Figure 111 During this operation don’t smoke and don’t use free flames. Avoid to breathe the vapors coming from filter. After filters replacement the supply equipment deaeration must be carried out.
  • Page 115 F32 SERIES SECTION 3 - INDUSTRIAL APPLICATION Alternator belt replacement Warning: with switched off motor (but still hot) the belt can operate without advance notice. Wait for the motor temperature lowering to avoid very serious accidents. Figure 112 127697 - Loosen screw (4) and the relevant nut on belt stretching bracket (3).
  • Page 116 SECTION 3 - INDUSTRIAL APPLICATION F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 117 F32 SERIES SECTION 4 - MECHANICAL OVERHAUL SECTION 4 Mechanical overhaul Page GENERAL SPECIFICATIONS ....DATA - ASSEMBLY SLACKS ....
  • Page 118 SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Page - Bushes .......

  • Page 119: General Specifications

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL GENERAL SPECIFICATIONS Type 4 CYLINDERS Cycle Diesel 4 strokes Power See the specifications reported in Section 3 Injection Direct Number of cylinders  Bore Stroke +.. = Total displacement 3200 TIMING 19  30’...

  • Page 120: Data - Assembly Slacks

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES DATA - ASSEMBLY SLACKS Type 4 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS  1 1 99 to 99.02 Cylinder barrels 1 Spare pistons  1 type: Size  1 Outside diameter 98.908 to 98.918 ...
  • Page 121 F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Type 4 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS 2.21 Split ring slots 2.05 to 2.07 2.54 to 2.56 * theoretical measurement -0.25 on a Ø of 96 S 1* 2.068 to 2.097 Split rings 1.970 to 1.990...
  • Page 122 SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Type 4 CYLINDERS CYLINDER UNIT AND CRANKSHAFT COMPONENTS   Crankshaft bearing pins  1 No. 1-2-3-4 76.182 to 76.208  1 No. 5 83.182 to 83.208  2 Big end bearing pins 64.015 to 64.038...
  • Page 123 F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Type 4 CYLINDERS CYLINDER HEAD — TIMING SYSTEM  1 Valve guide seats on  1 cylinder head 12.960 to 12.995   2 0.023 to 8.038 Valve guides  3 12.950 to 12.985 ...
  • Page 124 SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Type 4 CYLINDERS CYLINDER HEAD — TIMING SYSTEM Valve spring height: free spring 44.6 under a load equal to: 270 N 528 N 23.8 Injector protrusion 1.7 to 2.35 Seat for camshaft no. 1 bushes (flywheel side) 59.222 to 59.248...
  • Page 125 F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Type 4 CYLINDERS CYLINDER HEAD — TIMING SYSTEM  1 Tappet cap housing 15,000 ÷ 15,018  1 on block  2 Tappet cap outside   2 diameter: 15.924 to 15.954  3 15.960 to 15.975...

  • Page 126: Engine Overhaul

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES ENGINE OVERHAUL Figure 3 ENGINE DISASSEMBLY ON BENCH To execute the operations described here following, it is necessary to fit the engine on the rotary stand after having removed all the appliance’s specific components (see Section 3 of the herein manual).

  • Page 127: Repairs

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL REPAIRS Figure 6 CYLINDER UNIT Checks and measurements Figure 9 119548 Loosen the fastening screws (1) and disassemble the camshaft (3) holding plate (2). 70166 Once completed the engine disassembly, carefully clean the NOTE Note down the plate assembly position (2).

  • Page 128: Checking Head Base Surface On Cylinder Unit

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Check the crankshaft bearing seats proceeding as follows: Figure 11 - fit the crankshaft bearing caps on the supports without bearings; - tighten the fastening screws to the prescribed torque setting; α - with a suitable comparator, check that the inner barrel diameter corresponds to the prescribed value.

  • Page 129: Timing System

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL TIMING SYSTEM Camshaft Figure 12 119551 MAIN DATA ABOUT CAMSHAFT PINS BUSH The surface of the camshaft pins and of cams must be extremely smooth. In case any trace of meshing or scratches are detected, replace the shaft and the relevant bushes.
  • Page 130 SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Figure 15 Sec. A-A 125129 MAIN DATA OF THE CAMSHAFT BUSH AND RELEVANT SEAT * Quota to obtain after bush fixing. Base - April 2009 Print P2D32F005 E...

  • Page 131: Bush Replacement

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Bush replacement Tappet - camshaft assembly Figure 18 Figure 16 70176 70174 Lubricate the tappets (1) and fit them into the relevant seats on within the crankcase. Use the beater 99360362 (2) and handgrip 99370006 (3) to disassemble and replace the bush (1).

  • Page 132: Engine Drive Shaft

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES ENGINE DRIVE SHAFT Figure 21 Measurement of main journals and crankshaft bearing pins Figure 23 119555 Check the camshaft axial shaft (1). The prescribed value is 0.23 ± 0.1 3 mm. 119557 Figure 22...
  • Page 133 F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Figure 25 119558 ENGINE DRIVE SHAFT MAIN TOLERANCES TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL Roundness ○ SHAPE Cilindricity /○/ Parallelism Verticality DIRECTION Straightness POSITION Concentricity or coaxiality Circular oscillation OSCILLATION Total oscillation LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS GRAPHIC SYMBOL ...

  • Page 134: Crankshaft Bearing Assembly

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Crankshaft bearing assembly Crankshaft assembly Figure 26 Figure 27 119547 Assemble the engine drive shaft (2). 125130 NOTE If it is not necessary to replace the crankshaft bearings, these shall be reassembled in the same Figure 28 order and position they were before disassembly.

  • Page 135: Checking Output Shaft Shoulder Clearance

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Checking output shaft shoulder clearance Figure 29 Figure 31 70187 Tighten the pre-lubricated screws (1) and tighten them in three subsequent phases: phase with torque wrench setting at 50 ± 2.5 Nm. with torque wrench setting at 80 ± 4 Nm.
  • Page 136 SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Figure 33 Figure 34 126311 126312 Using pincers 99360183 (1), remove the snap rings (2) from Remove the piston pin (2) grommet using the round the piston. tippedpliers (1). Figure 35 119561 MAIN DATA OF THE PISTON, PINS AND SNAP RINGS * Quota detected on Ø...

  • Page 137: Piston Pins

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Piston pins Figure 39 Figure 36 18857 128140 Measurement of the piston pin diameter (1) throughout a Check the slack between the grommets (3) of the 2nd and micrometer (2). 3rd slots and relevant housing on the piston (2) using calliper and gauges (1).

  • Page 138: Connecting Rods

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Figure 41 Figure 43 70194 Measurement of slack between the snap ring ends (2) fitted into the cylinder barrel (3) throughout gauge calliper (1). Connecting rods Figure 42 119563 A. Class of weight - B. Part number - C. Date of production (DD/MM) - D.

  • Page 139: Bushes

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Bushes Figure 46 Check that the connecting rod shoe bush is not loose and that there is no trace of meshing or scratches otherwise replace it. Disassembly and reassembly must be executed using a suitable beater.

  • Page 140: Fitting Connecting Rod-Piston Assembly Into

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Figure 48 Figure 50 119566 SCHEME FOR CORRECTLY FIXING THE 70200 CONNECTING ROD-PISTON UNIT INTO THE HOLLOW Fit the half bearings (1) on the connecting rod and cap. - The snap rings’ openings must be misaligned by 120º;...

  • Page 141: Piston Projection Check

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Check manually that the connecting rods are slidingaxially on Figure 52 the output shaft pins. Piston projection check α NOTE See page 17 of Section 3. 70204 - lubricate the fastening screws (1) with engine oil and tighten them to the prescribed torque setting (50 ±...

  • Page 142: Cylinder Head

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES CYLINDER HEAD Figure 55 Valve disassembly Figure 54 119567 Valve disassembly must be executed using tool 99360268 (1) to slightly press the plate (3) so that, compressing the spring (4), it is possible to remove the half cone (2). Then remove the plate (3) and the spring (4).

  • Page 143: Cylinder Head Base Surface Check

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL VALVES Cylinder head base surface check Figure 58 Any deformation detected on the whole length of the EXHAUST INTAKE cylinder head must not exceed 0.20 mm. VALVE VALVE In case higher value is detected, grind the cylinder head in order to obtain the prescribed value.

  • Page 144: Valve Guide

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES VALVE GUIDE Valve guide replacement Figure 61 Valve guide assembly and disassembly is performed with beater 99360288. Insert the valve guide in the cylinder head so that they stick out from it for 8.1 ÷ 8.9 mm.

  • Page 145: Cylinder Head Reassembly

    F32 SERIES SECTION 4 - MECHANICAL OVERHAUL Cylinder head reassembly CYLINDER HEAD ASSEMBLY Figure 65 Figure 63 119573 Check that the cylinder head and crankshaft coupling 119572 surfaces are clean. Do not foul the cylinder head gasket. Lubricate the valve stems (1) and fit them in the relevant...

  • Page 146: Torque Setting

    SECTION 4 - MECHANICAL OVERHAUL F32 SERIES TORQUE SETTING TORQUE PART Motor vent cover fastening (M6x1 6g x 18) 10±1 1±0.1 Side plug (M6) 40±4 4±0.4 Side plugs (M22) 50±5 5±0.5 Front plug (M35) 40±4 4±0.4 Sump fastening 70±7 7±0.7 Threaded cap with O-ring 50±5...
  • Page 147 F32 SERIES SECTION 4 - MECHANICAL OVERHAUL TORQUE PART ”Cylinder head fastening (M15x 1.5 6g x 193) First phase 130±6.5 13±0.65 Second phase 90˚ Third phase 70˚ ”Cylinder head fastening (M12x 1.5 6g x 165) First phase 65±3.25 6.5±0.325 Second phase 90˚...
  • Page 148 SECTION 4 - MECHANICAL OVERHAUL F32 SERIES TORQUE PART Collector fastening screw nuts 28±2.8 2.8±0.28 Oil delivery inlet fixing 25±2.5 2.5±0.25 Delivery pipe fastening screw nut 28±2.8 2.8±0.28 Exhaust pipe fixing to heat exchanger 25±2.5 2.5±0.25 Exhaust pipe fixing to turbo 15±1.5...
  • Page 149 F32 SERIES SECTION 4 - MECHANICAL OVERHAUL TORQUE PART Support fastening to block (M10x1.5 6g x 50-60) 50±5 5±0.5 Alternator fastening (screw + nut) 50±5 5±0.5 Push rod fixing 50±5 5±0.5 Alternator push rod fixing (screw + nut) 50±5 5±0.5 Support fastening to block (M10x1.5 6g x 35)
  • Page 150 SECTION 4 - MECHANICAL OVERHAUL F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 151 F32 SERIES SECTION 5 - TOOLS SECTION 5 Tools Pagina TOOLS ........
  • Page 152 SECTION 5 - TOOLS F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 153 F32 SERIES SECTION 5 - TOOLS TOOLS TOOL No. DEFINITION Revolving stand for overhauling units (1000daN capacity, 120 daN/m 99322205 torque) 99340025 Tool to remove output shaft front gasket 99346258 Tool for fitting output shaft front gasket 99346259 Tool for fitting output shaft rear gasket...
  • Page 154 SECTION 5 - TOOLS F32 SERIES TOOL No. DEFINITION 99360183 Pliers for removing/refitting piston rings (65 — 110 mm) 99360268 Tool for removing/refitting engine valves 99360288 Beater for valve guide disassembly and reassembly 99360292 Shrink fitter for gasket assembly 99360330...
  • Page 155 F32 SERIES SECTION 5 - TOOLS TOOL No. DEFINITION 99360500 Tool for crankshaft lifting 99360605 Ring for plunger introduction into the cylinder barrel (60 ÷ 125 mm) 99360612 Tool for engine T.D.C. positioning 99361043 Brackets for fastening engine to revolving stand 99322205...
  • Page 156 SECTION 5 - TOOLS F32 SERIES TOOL No. DEFINITION Dial gauge holder for rotary injection pump timing (use with 99395100 99395603) 99395216 Pair of gauges with 1/2” and 3/4” square head for angle tightening Dial gauge (0 ÷ 5 mm)
  • Page 157 F32 SERIES SECTION 5 - TOOLS TOOL No. DEFINITION 99389818 Dynamometric wrench (150 -800 Nm) with 3/4” square coupling 99390310 Sleeker for valve guide Print P2D32F005 E Base - April 2009...
  • Page 158 SECTION 5 - TOOLS F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 159 F32 SERIES APPENDIX Appendix Page SAFETY PRESCRIPTIONS ....Print P2D32F005 E Base - April 2009...
  • Page 160 APPENDIX F32 SERIES Base - April 2009 Print P2D32F005 E...
  • Page 161 F32 SERIES APPENDIX - Do not execute any intervention if not provided with SAFETY PRESCRIPTIONS necessary instructions. Standard safety prescriptions - Do not use any tool or equipment for any different Particular attention shall be drawn on some precautions that operation from the ones they’ve been designed and...
  • Page 162 - Do not modify fuel systems or hydraulic system unless - Collect exhaust oils in adequate specially provided FPT specific approval has been released. Any containers with hermetic sealing ensuring that storage is unauthorized modification will compromise warranty...

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