GENUINE PARTS CATALOGUE CATALOGUE PIECES D’ORIGINE ORIGINAL ERSATZTEILKATALOG CATALOGO DE PIEZAS LEGITIMAS CATALOGO RICAMBI ORIGINALI This document has been printed from my e doc
MANITOU BF
Head office: 430, Rue de l’Aubinière 44150 Ancenis - FRANCE Share capital: 39,548,949 euros 857 802 508 RCS Nantes Tel: +33 (0)2 40 09 10 11 www.manitou.com
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This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU BF and may not be used without express and formal authorization. All rights are reserved.
•
La présente brochure n’est fournie qu’à titre consultatif, toute reproduction, copie, représentation, captation, cession, distribution, ou autre, partiellement ou en totalité, sous quelque format que ce soit est interdite. Les schémas, les dessins, les vues, les commentaires les indications, l’organisation même du document qui sont rapportés dans la présente documentation, sont la propriété intellectuelle de MANITOU BF. Toute infraction à ce qui précède est susceptible d’entraîner des condamnations civiles et pénales. Les logos ainsi que l’identité visuelle de l’entreprise sont la propriété de MANITOU BF et ne peuvent être utilisés sans autorisation expresse et formelle. Tous droits réservés.
•
Die vorliegende Broschüre dient allein zur Beratung. Nachdruck, Fotokopieren, Vervielfältigung, Darstellung, Erfassung, Überlassung, Verbreitung oder Sonstiges (ganz oder teilweise) in jeglicher Form sind verboten. Die Entwürfe, Zeichnungen, Bilder, Darstellungen, Ansichten, Kommentare, Hinweise und der Aufbau der Druckschrift selbst, die in der vorliegenden Dokumentation enthalten sind, sind geistiges Eigentum von MANITOU BF. Alle Verstöße gegen das Vorstehende können zu straf- oder zivilrechtlicher Verfolgung führen. Die Logos und Markenzeichen sowie Unternehmensund Produktbezeichnungen sind Eigentum von MANITOU BF und dürfen ohne ausdrückliche Genehmigung nicht verwendet werden. Alle Rechte vorbehalten.
•
Este folleto se ofrece a título meramente informativo y queda prohibida su reproducción, copia, representación, captación, cesión, distribución y demás, parcial o total, en el formato que sea. Los esquemas, dibujos, vistas, comentarios, indicaciones, la organización misma del documento aportado en esta documentación son propiedad intelectual de MANITOU BF. Cualquier infracción a lo antedicho puede acarrear condenas civiles y penales. Los logotipos y la identidad visual de la empresa son propiedad de MANITOU BF y no pueden utilizarse sin su autorización expresa y formaL. Reservados todos los derechos.
•
Il presente manuale è fornito esclusivamente a titolo di consultazione; è vietata qualsiasi riproduzione, copia, rappresentazione, acquisizione, cessione, distribuzione o altro, parziale o totale, e in qualsivoglia formato. Gli schemi, i disegni, le viste, i commenti, le indicazioni e l’organizzazione stessa del documento, riportati nella presente documentazione, sono proprietà intellettuale di MANITOU BF. Qualsiasi violazione a quanto riportato sopra è passibile di condanna civile e penale. I loghi e l’identità visiva dell’azienda sono di proprietà di MANITOU BF e non possono essere utilizzati senza previa autorizzazione espressa e formale. Tutti i diritti sono riservati.
Manitou BF French limited liability corporation with a Board of Directors Head office : 430 rue de l’Aubinière 44150 Ancenis - France Share capital : 39.548.949 euros 857 802 508 RCS Nantes www.manitou.com
POUR LES COMMANDES DE PIÈCES, PRÉCISEZ TOUJOURS : A - La référence du catalogue (Voir couverture) B - Numéro de la planche C - Repère de la pièce et quantité demandée D - Type de l’appareil, ainsi que son numéro dans la série EXEMPLE DE COMMANDE : Catalogue réf : 647 XXX Planche : 6 BA 122 Repère : 2
Qté : 1 Type de l’appareil : -N° dans la serie : --
A l’aide de ces informations, votre agent MANITOU pourra identifier la référence de la pièce que vous désirez. TO ORDER YOUR SPARE PARTS, ALWAYS STATE : A - The reference of the catalogue (See cover) B - Number of the figure C - Item of the part and quantity desired D - Type of the machine and its number in the serie EXAMPLE OF ORDER : Catalogue ref : 647 XXX Figure : 6 BA 122 Item : 2
Quantity : 1 Type of the machine : -Number in the serie : --
With the above information, your MANITOU dealer can identify the number and proper part required.
PARA LOS PEDIDOS DE RECAMBIOS, PRECISAR SIEMPRE : A - La referencia de catálogo (Ver portada) B - Número de la figura C - Señal de la pieza y cantidad deseada D - Tipo de la máquina, asi como su número en la serie EJEMPLO DE PEDIDOS Catalogo ref : 647 XXX Figura : 6 BA 122 Señal : 2
Cantidad : 1 Tipo de la taquina : -Número en la serie : --
mACHINE(S)
PER ORDINARE I PEZZI DI RICAMBIO, PRECISARE SEMPRE : A - Il riferimento del catalogo (Vedi copertina) B - Il numero della tavola C - Il riferimento del pezzo e la quantità richiesta D - Il tipo di macchina, e il suo numero nella serie ESEMPIO DI ORDINE : Catalogo rif. : 647 XXX Tavola : 6 BA 122 Riferimento : 2
PARTS CATALOGUE CATALOGUE PIÈCES ERSATZTEILKATALOG CATALOGO DE PIEZAS CATALOGO RICAMBI
Quantità : 1 Tipo di macchina : -N° nella serie : --
Con queste informazioni, il vostro agente MANITOU sarà in grado di identificare il riferimento del pezzo richiesto.
6 BA 122
Menge : 1 Stapler typ : -Seriennummer : --
647XXXC (XX/20XX)
Con estas informaciones, su agente MANITOU podrá identificar la referencia de la pieza que usted quiere.
FUR BESTELLUNGEN BITTE IMMER ANGEBEN : A - Nummer des Katalogs (Siehe Einband) B - Nummer der Seite C - Abbildung und Mengenbedarf D - Typ und Seriennummer des Staplers BESTELLUNGSBEISPIEL : Katalog nr : 647 XXX Seite : 6 BA 122 Abbildung : 2
A
B
D
FREIN A MAIN HANDBREMSE FRENO A MANO HANDBRAKE FRENO DE MANO
____________ 1
2
Nur mit Hilfe dieser Angaben kann ihr MANITOU Händler das gewünschte Teil heraus finden.
3 4
4
5
5 6
7
C
COMPLET REPAIR MANUAL MRT 2145 Easy 360 ST3B S1 / MRT 2145 Easy 400 ST3B S1
1
GENERAL INSTRUCTIONS AND SAFETY NOTICE GROUP 00 GENERAL INFORMATION, FEATURES AND SAFETY
571
ENGINE GROUP 10 ENGINE
581
TRANSMISSION GROUP 20 TRANSMISSION
627
AXLE ASSEMBLY - AXLE GROUP 30 AXLE
683
BRAKE GROUP 40 BRAKE
701
TELESCOPIC BOOM GROUP 50 BOOM
717
HYDRAULIC GROUP 70 HYDRAULIC
777
ELECTRICITY GROUP 80 LECTRICITY
853
DRIVER CAB GROUP 85 DRIVER'S CAB
1097
FRAME - BODY GROUP 90 FRAME-BODY
1115
647810EN (28/04/2016)
MRT 21 m EASY SERIES Repair manual
MRT 2145 Easy 360 ST3B S1 MRT 2145 Easy 400 ST3B S1
MANITOU BF B.P 10249 - 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11 Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97 www.manitou.com
2
647810EN
DATE OF ISSUE 28/04/2016
OBSERVATION - 1st ISSUE
THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY.
647810EN
3
HOW TO USE THIS REPAIR MANUAL ? 1 00
ENGINE
00
GENERAL, CHARACTERISTICS AND SAFETY
10
2 GENERAL, CHARACTERISTICS AND SAFETY
20
- GENERAL INSTRUCTIONS AND SAFETY NOTICE
30
TRANSMISSION
40
AXLE
50
BRAKE
70
BOOM
80
HYDRAULIC
85
ELECTRIC
FRAME - BODY
90
OPTIONS - ATTACHMENTS
110
DRIVER’S CAB
4
3
General instructions and safety notice
00
00
4
RULES FOR MAINTENANCE Do not carry out any work on the machine unless you have followed a suitable training course and have the knowledge required for it. Make sure you have taken into consideration all the indicator plates on the machine and in the instruction manual.
GENERAL INSTRUCTIONS AND SAFETY NOTICE
Be careful not to burn yourself when touching hot liquids or parts when operations have to be done before the machine has had time to cool down.
pages PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1 2
Before carrying out any operation on an electrically powered component, activate the battery cut-off. If the telehandler does not have a battery isolation device, disconnect the battery connecters then re-assemble them.
Before carrying out any welding operations, think about disconnecting computers. ECU
A machine operating in a contaminated environment should be specifically equipped. Moreover, local safety notices deal with maintenance and repair work on such machines.
(29/09/2011)
00-M173EN
M
R
547982 : See the repair manual N° 547982.
70 - HYDRAULIC : See the group N° 70 called «Hydraulic».
00-M173EN
(29/09/2011)
BOOM
HYDRAULIC
ELECTRICITY
00 10 20 30
FRAME - BODY
90
OPTIONS - ATTACHMENTS
110
DRIVER'S CAB
40
BRAKE
50
AXLE
70
TRANSMISSION
80
ENGINE
85
GENERAL
- GENERAL SAFETY STANDARDS - GENERAL FEATURES
00
GENERAL INFORMATION, FEATURES AND SAFETY
00 GENERAL INSTRUCTIONS AND SAFETY NOTICE
page PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(14/03/2016)
00-00-M260EN
00
2
GENERAL INSTRUCTIONS AND SAFETY NOTICE
PREAMBLE This chapter deals with the general instructions and safety notice during inspection and maintenance work. Other instructions and warnings are indicated in each chapter concerned. In order to reduce accident risks, make sure to: - Follow the instructions in the truck operating and maintenance manual. This manual should be found in all trucks. - Please follow all safety instructions. - Use the appropriate tools for any work to be performed. - Use original Manitou spare parts. Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily harm and even death. An efficient, dependable and profitable combination will be formed if the operator follows the safety manual correctly and the machine is serviced properly. When you see this symbol: It means: Danger! Attention! Your safety, somebody else’s or the safety of the lift truck itself is at risk.
The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions given in the safety manual are not exhaustive. At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself when you repair, service or drive it. Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other than those specified.
00-00-M260EN
(14/03/2016)
MAINTENANCE POSITION
2
4
1
3
Before carrying out any repair procedure: 1 - Place the machine on a flat surface and chock the wheels. 2 - Turn off the engine and remove the ignition key. 3 - Cool down the motor of the forklift truck. 4 - Take all the pressure out of the circuits concerned. (14/03/2016)
3
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
00-00-M260EN
GENERAL INSTRUCTIONS AND SAFETY NOTICE
00
4
RULES FOR MAINTENANCE
Do not carry out any work on the machine unless you have followed a suitable training course and have the knowledge required for it. Make sure you have taken into consideration all the indicator plates on the machine and in the instruction manual.
Be careful not to burn yourself when touching hot liquids or parts when operations have to be done before the machine has had time to cool down.
1 2
Before carrying out any operation on an electrically powered component, activate the battery cut-off. If the telehandler does not have a battery isolating switch, disconnect the battery terminals then gather them. efore carrying out any welding operations, think of B disconnecting computers.
ECU
A machine operating in a contaminated environment (toxic or harmful to human health) should be specifically equipped. Moreover, local safety notices deal with maintenance and repair work on such machines.
00-00-M260EN
(14/03/2016)
5
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
Never step on a part of the machine that has not been designed for it.
Never wear clothes, jewellery or objects that could get caught during work and cause accidents. Always wear protection glasses, gloves, safety shoes as well as any other protection required for the work to be carried out.
Carrying out maintenance procedures close to a mobile object, make sure to fix it.
When changing, or draining oils or fuel, or any other operation with liquids, solids, gases that are harmful to the environment, make sure the necessary precautions are taken to avoid contaminating the environment.
(14/03/2016)
00-00-M260EN
GENERAL INSTRUCTIONS AND SAFETY NOTICE
00
6
When lifting or shoring a component of the machine, make sure the equipment used is suitable for at least the load for which it is subjected by the component and that it meets the national standards for lifting devices. When using a jack, make sure it is used on a flat, uniform surface, is sturdy enough to support the load, that its lifting capacity is sufficient and that it is correctly placed and positioned under the machine.
Make sure no object or tool which could cause an accident is left in the machine.
Never control any leaks using a hand.
max. min.
MAX
Never adjust a component to over the maximum capacity indicated by the manufacturer.
MIN 00-00-M260EN
(14/03/2016)
00 GENERAL CONTROL AND ADJUSTMENT
page STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(14/03/2016)
00-04-M260EN
2
GENERAL CONTROL AND ADJUSTMENT
00
STANDARD TIGHTENING TORQUES Standard tightening torque to be used when not otherwise indicated in the removal and refitting operations: - The following tightening torques are given for hexagon head screws without flanges and cylinder head hexagon socket screws. - The torques are given for a friction coefficient μ = 0,20 corresponding to dry-fitted zinc-plated fasteners and for torque tools having a ± 20 % class C tightening torque accuracy (equivalent to pneumatic screwdrivers). Screw / Nut Assembly Norm NF E25-030-1. Tightening torque in N•m (±20%) Ø x “coarse” pitch
Grade 8,8
Grade 10.9
Ø x “fine” pitch
Grade 8,8
Grade 10.9
M3 x 0,5
1
1,5
-
-
-
M4 x 0,7
2,4
3,5
-
-
-
M5 x 0,8
4,8
7,1
-
-
-
M6 x 1
8,2
12,1
-
-
-
M8 x 1,25
20
30
M10 x 1,5
40
59
M8 x 1
22
32
M10 x 1,25
43
63
M10 x 1
46
68
M12 x 1,5
74
108
M12 x 1,75
69
102
M12 x 1,25
78
115
M14 x 2
111
163
M14 x 1,5
123
181
M16 x 2
175
256
M16 x 1,5
190
279
M18 x 2,5
240
352
M18 x 1,5
279
410
M20 x 2,5
341
501
M20 x 1,5
391
574
M22 x 2,5
470
691
M22 x 1,5
531
780
M24 x 3
588
864
M24 x 2
659
967
M27 x 3
874
1284
M27 x 2
965
1418
M30 x 3,5
1181
1735
M30 x 2
1351
1984
M33 x 3,5
1614
2371
M33 x 2
1821
2674
M36 x 4
2068
3037
-
-
-
bb bb
For hexagon screws with flanges: Apply an increased torque of +10%. (Standard NF E 25-030-1) Where washers are used, the following coefficient is to be applied (FD E 25-502) : - Smooth tapered washer (CL): +5% - Spring (or Grower) washer without jaws (W) : +10% - Conical, internal teeth (CDJ-JZC) : +15%
00-04-M260EN
(14/03/2016)
10
ENGINE
- POSITION OF THE ENGINE COMPONENTS - CHECKING AND ADJUSTING THE ENGINE - REMOVING THE ENGINE - REINSERTING THE ENGINE
- FEATURES AND TECHNICAL SPECIFICATIONS OF THE ENGINE - CHECKING AND ADJUSTING THE ENGINE - TROUBLESHOOTING IN THE ENGINE - SPECIAL TOOLS FOR THE ENGINE
l 647173
(ENGINE 854E-E34TA)
10 POSITION OF THE ENGINE COMPONENTS
page ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 WATER + AIR COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 INTAKE AND EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 HYDRAULIC OIL COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(14/03/2016)
10-03-M260EN
2
POSITION OF THE ENGINE COMPONENTS
10
ENGINE COMPONENTS
EGR valve Butterfly valve Fuel filter
Alternator
Engine cooling water pump Injection pump
10-03-M260EN
(14/03/2016)
3
10
POSITION OF THE ENGINE COMPONENTS
Butterfly valve EGR valve Injection pump
Fuel filter
Engine cooling water pump
Turbocharger
(14/03/2016)
Alternator
10-03-M260EN
4
POSITION OF THE ENGINE COMPONENTS
WATER + AIR COOLING CIRCUIT
10
Key: WATER CIRCUIT AIR CIRCUIT
Engine vent (Blow-By)
Radiator
Intercooler EGR valve
Turbocharger
10-03-M260EN
Engine
(14/03/2016)
POSITION OF THE ENGINE COMPONENTS
5
INTAKE AND EXHAUST
10
Air cleaner
DPF differential pressure sensor
Turbocompressor intake
Diesel particulate filter (DPF)
Gas exhaust
Exhaust pipe
Temperature sensor Engine vent DPF inlet temperature sensor
DOC
DPF
Catalyst inlet temperature sensor
(14/03/2016)
10-03-M260EN
6
POSITION OF THE ENGINE COMPONENTS
10
HYDRAULIC OIL COOLING CIRCUIT
Radiator T2
Hydraulic fluid tank
S
T2
S
Fan motor
T1
Hydrostatic motor
T1
70 - Hydraulics
Hydrostatic pump
10-03-M260EN
(14/03/2016)
POSITION OF THE ENGINE COMPONENTS
7
10
FUEL CIRCUIT
Fuel tank
Engine
Fuel prefilter
(14/03/2016)
10-03-M260EN
10 10-03-M260EN
(14/03/2016)
10 CHECKING AND ADJUSTING THE ENGINE
page PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 A - REMOVING THE ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 B - REMOVING THE ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 C - REMOVING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 D - REMOVING THE EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 E - REMOVING THE INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 F - REMOVING THE ENGINE COOLING WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 ASSEMBLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
(14/03/2016)
10-04-M260EN
CLICK HERE TO
DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual. • You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO
DOWNLOAD THE COMPLETE MANUAL
2
CHECKING AND ADJUSTING THE ENGINE
COMPONENTS LOCATION
10
E
D
A
C B F Legend: A - Alternator belt B - Alternator C - Starter motor D - EGR valve E - Injectors F - Engine cooling water pump
PREPARATION AND SAFETY INSTRUCTIONS Deactivate the ignition key and disconnect the negative pole from the battery. 10-04-M260EN
(14/03/2016)
3
10
CHECKING AND ADJUSTING THE ENGINE
A - REMOVING THE ALTERNATOR BELT Open the hood and remove the lower guard (Ref. 1) after unscrewing the screws (Ref. 2) and the nuts (Ref. 3).
3
2
1
Slacken the screws (Ref. 4) to remove the guard (Ref. 5) on the alternator belt.
4
5
Remove the bracket (Ref. 6) supporting the guard after unscrewing the screws (Ref. 7) and the washers (Ref. 8). 6
7 8
(14/03/2016)
10-04-M260EN
4
CHECKING AND ADJUSTING THE ENGINE Unscrew the belt tensioner screw (Ref. 9). Slacken the screws (Ref. 10) to free the alternator (Ref. 11).
10
9
10
11
Turn the alternator (Ref. 11) to slacken and remove the belt (Ref. 12). 11
To reassemble, repeat the operation in reverse order. 12
10-04-M260EN
(14/03/2016)
5
10
CHECKING AND ADJUSTING THE ENGINE
B - REMOVING THE ALTERNATOR Carry out operation A. 3
2 3
Disconnect the connector (Ref. 1). Remove the fixing screw (Ref. 2). Slacken the screws (Ref. 3).
1
Pull the alternator (Ref. 4), unscrew the nut (Ref. 5) to release the earth wire (Ref. 6). 5
Remove the alternator. 6
To reassemble, repeat the operation in reverse order.
4
(14/03/2016)
10-04-M260EN
CHECKING AND ADJUSTING THE ENGINE
10
6
C - REMOVING THE STARTER MOTOR Open the hood and remove the lower guard (Ref. 1) after unscrewing the screws (Ref. 2) and the nuts (Ref. 3).
3
2
1
Slacken the nut (Ref. 4) to free the earth wire (Ref. 5) from the starter motor (Ref. 6). Disconnect the cable (Ref. 5) from the remote control switch (Ref. 7).
7 4
6
5
Disconnect the cable (Ref. 8) from the starter motor (Ref. 6). Slacken the screws (Ref. 9) and the washers (Ref. 10) and remove the starter motor (Ref. 6).
8
To reassemble, repeat the operation in reverse order. 6 9
10
10-04-M260EN
(14/03/2016)
7
10
CHECKING AND ADJUSTING THE ENGINE
D - REMOVING THE EGR VALVE Slacken the screws (Ref. 1) and remove the guard (Ref. 2) on the EGR valve (Ref. 3).
3
1
2
9
5
8
4
12
8
6
12
7
12 11
Place a suitable-sized container under the engine crankcase to collect the liquid. Slacken the fixing screws (Ref. 4) and disconnect the tube (Ref. 5). Remove the fixing screw (Ref. 6) and disconnect the tube (Ref. 7). Remove the two fixing screws (Ref. 8) and disconnect the accordion hose (Ref. 9). Slacken the clamp (Ref. 10) by unscrewing the screw (Ref. 11). Remove the three screws (Ref. 12) fixing the EGR valve (Ref. 3).
10
Lift the valve (Ref. 3) and disconnect the connector (Ref. 13). Remove the EGR valve. 3
To reassemble, repeat the operation in reverse order. 13
(14/03/2016)
10-04-M260EN
CHECKING AND ADJUSTING THE ENGINE
10
8
E - REMOVING THE INJECTORS Carry out operation D.
1
4
Disconnect the connector (Ref. 1) by pulling on the yellow tab.
5 6
2
3
Remove the block (Ref. 2) and the tube (Ref. 3) from the top, at the back of the injector. Unscrew the injector feed pipe (Ref. 4). Remove the screw (Ref. 5) of the flange (Ref. 6). Remove the injector. To reassemble, repeat the operation in reverse order. l 647173.
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10
CHECKING AND ADJUSTING THE ENGINE
F - REMOVING THE ENGINE COOLING WATER PUMP 4
Carry out operation A. Slacken the screws (Ref. 1) and the washers (Ref. 2) of the guard (Ref. 3) of the engine crankcase (Ref. 4).
2 1 3
Slacken the two screws (Ref. 5) which fix the pump (Ref. 6). Remove the pump. To reassemble, repeat the operation in reverse order, applying a tightening torque of 25 Nm to the screws.
6
5
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CHECKING AND ADJUSTING THE ENGINE
ENGINE TIGHTENING TORQUE
10
ASSEMBLING THE ENGINE
43 Nm + apply “Loctite 243” 49 Nm + apply “Loctite 243”
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10 REMOVING THE ENGINE
page PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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REMOVING THE ENGINE
10
REMOVING THE ENGINE
GENERAL INFORMATION The sequence for disassembly operations must be followed to access the various components. Mark all the hydraulic pipes and electrical connections with a marker pen, before disassembling, to ensure correct positioning in the reassembly phase.
bb
Discharge pressure from the hydraulic circuit before disconnecting the tubes. Plug all the hydraulic pipes and orifices to prevent impurities from contaminating the hydraulic circuit.
PREPARATION AND SAFETY INSTRUCTIONS Park the vehicle on a horizontal surface, rest the stabilizers on the ground to ensure utmost stability and safety (do not switch off the I.C. engine). Specific tools: –– Crane for lifting (5000 kg. minimum). –– Hydraulic jack 10-06-M260EN
(14/03/2016)
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REMOVING THE ENGINE
3
Unscrew the screws (Ref. 1) and nuts (Ref. 2) and disconnect the gas spring (Ref. 3) from the engine hood (Ref. 4).
2 1 3
4
Slacken the screws (Ref. 5) and remove the hood (Ref. 4) from the vehicle.
5
4
Slacken the screws (Ref. 6) and nuts and remove the front guard (Ref. 7). 6
7
Slacken the screws (Ref. 8) and nuts and remove the lower guard (Ref. 9).
8 9
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REMOVING THE ENGINE
4
REMOVING THE ENGINE
10
Disconnect the battery wires (Ref. 10).
10
Slowly loosen the cap on the filler opening (Ref. 11) to discharge all the pressure and allow the liquid to flow out easily. Remove the cap of the cooling system filler opening.
bb
Before opening the filler cap, wait for the circuit components to cool down.
11
Place containers large enough to hold the quantity of liquid to be collected under the engine compartment. Slacken the clamp (Ref. 12) and remove the hose (Ref. 13) from the lower pipe (Ref. 14), carry out the operation slowly to discharge overpressure from the system, let the liquid drain out of the cooling system, emptying it completely.
13
12
14
Slacken the clamp (Ref. 15) and remove the hose (Ref. 16) from the lower pipe (Ref. 17).
16
17 15
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REMOVING THE ENGINE
5
Slacken the clamp (Ref. 18) and remove the hose (Ref. 13) from the engine.
10
18
13
Slacken the clamp (Ref. 19) and remove the hose (Ref. 16) from the engine. 19
16
Slacken the screws (Ref. 20) which secure the iron tubes (Ref. 14 and 17) on the front of the engine.
20
Slacken the screws (Ref. 21) which secure the iron tubes (Ref. 14 and 17) on the rear of the engine. 21
17 14
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6
REMOVING THE ENGINE Slacken the screws and remove the collars (Ref. 22) which blocking the iron tubes (Ref. 14 and 17).
10
17
22
14
Slacken the clamp (Ref. 23) to remove the hose (Ref. 24) of the air filter (Ref. 25) from the engine. 23
24
25
Unscrew the collar (Ref. 26) to free the tube (Ref. 27). 27
26
Slacken the clamp (Ref. 28) to remove the hose (Ref. 27) from the engine. 27 28
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29 25
Detach the connectors (Ref. 29 and 30) from the air filter (Ref. 25).
31
Slacken the screws (Ref. 31) to remove the air filter (Ref. 25) from the engine compartment. 25
34
33
Slacken the clamp (Ref. 32) to remove the tube (Ref. 33) from the air cooler radiator (Ref. 34).
32
Slacken the clamp (Ref. 35) to remove the hose (Ref. 36). 35 36
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10
REMOVING THE ENGINE
10-06-M260EN
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8
REMOVING THE ENGINE Disconnect the tube (Ref. 36) from the engine.
10
36
Slacken the clamp (Ref. 37) to disconnect the tube (Ref. 38) from the air cooler radiator (Ref. 34).
38
37
Disconnect the connector (Ref. 39) from the radiator fan.
39
Slacken the screws (Ref. 40) to remove the air cooler radiator (Ref. 34) from the engine compartment.
34
40
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REMOVING THE ENGINE
9
41
10
Remove the collars (Ref. 41) to free the iron tube (Ref. 42) from the chassis.
42
Disconnect the connections (Ref. 43 and 44) from the engine control unit. 43
44
Slacken the screws (Ref. 45) and remove the connector support (Ref. 46) from the engine.
45
46
Disconnect the connector (Ref. 47) present on the alternator.
47
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REMOVING THE ENGINE
10
Disconnect the connections (Ref. 48) of the alternator.
48
Disconnect the connector (Ref. 49) from the starter motor.
49
Disconnect the main connector (Ref. 50). 50
Slacken the screws (Ref. 51) and disconnect the tube (Ref. 52) from the exhaust manifold. 52
51
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REMOVING THE ENGINE
11
53
10
54
Disconnect the earth wires (Ref. 53) on the LH side of the engine compartment. 55
Disconnect the earth wires (Ref. 54) on the RH side of the engine.
Disconnect the pipe (Ref. 55) from the fuel pump.
Slacken the screws (Ref. 56) to remove the engine support (Ref. 57).
56
57
60
59
Slacken the screws (Ref. 58) which block the hydrostatic pump (Ref. 59) on the engine (Ref. 60).
58
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REMOVING THE ENGINE
10
Lever (Ref. 61) to disconnect the pump (Ref. 59) completely from the engine.
59 61
Place a hydraulic jack (Ref. 62) under the hydrostatic pump (Ref. 59) to hold it in position and facilitate reassembly of the engine. 59
62
Slacken the screws (Ref. 63) which block the engine on the rear supports. 63
Slacken the screws (Ref. 64) which block the engine on the front supports. 64
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REMOVING THE ENGINE
13
Slacken the clamps (Ref. 65) and remove the pipe (Ref. 66) from the turbocompressor (Ref. 67) to make room for the overhead crane hooks.
10
66
65
67
Secure the engine to an overhead crane. Pull gently to make sure no tubes or wires are still attached to it, detaching those that are still connected. Remove the engine from the vehicle.
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REMOVING THE ENGINE
10
14
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10 REINSERTING THE ENGINE
page PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REINSERTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
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REINSERTING THE ENGINE
10
REINSERTING THE ENGINE
GENERAL INFORMATION Reposition all the pipes and connections correctly according to the markings made with a marker pen during the disassembly.
PRELIMINARY OPERATIONS Prepare the structural work, checking to make sure the threaded holes have been drilled correctly; remove the burrs from the bushes for the pins, grind and smooth weld drips in the area where the sliding blocks are to be housed.
PREPARATION AND SAFETY INSTRUCTIONS Park the vehicle on a horizontal surface, resting the stabilizers on the ground to ensure utmost stability and safety. Specific tools: –– Crane for lifting (5000 kg. minimum). –– Hydraulic jack. 10-07-M260IT
(14/03/2016)
REINSERTING THE ENGINE
3
Place the engine (Ref. 1) on the vehicle with the help of an overhead crane.
1
Insert the tube (Ref. 2) on the turbo-compressor (Ref. 3) and tighten the clamp (Ref. 4). 2
4
3
Tighten the screws (Ref. 5) to fix the engine on the front supports.
5
Tighten the screws (Ref. 6) to fix the engine on the rear supports.
6
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REINSERTING THE ENGINE
4
REINSERTING THE ENGINE
10
1
7
Refit the hydrostatic pump (Ref. 7) that was earlier placed on a hydraulic jack during the removal phase, on the engine (Ref. 1), securing it by means of the screws meant for the purpose (Ref. 8).
8
Refit the engine support (Ref. 9) by means of the screws (Ref. 10).
10
9
Connect the pipe (Ref. 11) to the fuel pump. 11
Connect the earth wires (Ref. 12) on the RH side of the engine.
Connect the earth wires (Ref. 13) on the LH side of the engine compartment.
13
12
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5
Connect the tube (Ref. 14) on the exhaust manifold by means of the screws (Ref. 15).
10
14
15
Connect the main connector (Ref. 16). 16
Connect the connector (Ref. 17) on the starter motor.
17
Connect the connections (Ref. 18) on the alternator.
18
(14/03/2016)
10-07-M260IT
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DOWNLOAD THE COMPLETE MANUAL
• Thank you very much for reading the preview of the manual. • You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO
DOWNLOAD THE COMPLETE MANUAL