manual montacargas y mani

ENGINE

- ENGINE CHARACTERISTICS AND SPECIFICATIONS

- ENGINE CONTROL AND ADJUSTEMENT

10

647016EN

(ENGINE 1104 D EURO 380 & 100 CV )

647017EN

(ENGINE 1104 D EURO 3(120 CV)

MR

MR

- ENGINE CHARACTERISTICS AND SPECIFICATIONS

- ENGINE CONTROL AND ADJUSTEMENT

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ENGINE CHARACTERISTICS AND SPECIFICATIONS

pages

ELECTRONIC CONTROL MODULE ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DEFINITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

REAR CONNECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ELECTRICAL SUPPLY AND PIN-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SENSOR AND PROBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

ENGINE EARTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

LOW PRESSURE FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

HIGH PRESSURE FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

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Module de commande lectronique(ECM)

ELECTRONIC CONTROL MODULE ECM

DEFINITION

The electronic control module (ECM) (1) is the regulator and computer for the fuel circuit. The ECM receives signals from the sensors to control the engines tuning and operating mode.The electronic circuit is made up of the ECM, sensors on the engine and inputs from the whole of the machine. The ECM is the computer. The personalization module is the computer software. The personalization module contains the performance curves.

The performance curves defi ne the following characteristics of the engine: Engine power Torque curves Engine speed (rpm) Engine noise Exhaust and emissions

J1

J2

REAR CONNECTOR

25 26 27 28 29 30 31 32

17 18 19 20 21 22 23 249 10 11 12 13 14 15 16

33 34 35 36 37 38 39 40

41 42 43 44 45 46 47 4849 50 51 52 53 54 55 56

57 58 59 60 61 62 63 64

7mm

1 2 3 4 5 6 7 8

Electronic control module (ECM)

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3ENGINE CHARACTERISTICS AND

SPECIFICATIONS

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ELECTRICAL SUPPLY AND PIN-OUT

ep:44ep:44

ep:45p

5726

573

19

ep:46p

ep:1

ep:43ep:43eee

ep:42p

22522

1110

TT

ZZ

NN

Z N N

P

N

G1

NN

NN

J

WWWWW

89 11

3063663

305

6606642

614615

613

647

6446

643650

64888

6554

6544651

653652

1K+-+ -

649

628

645

612

6466399

6416

64006388

6377

J1

J2

659658

657656

66631666

51

636

45

1716

19

864

5933

3458

5735

43

4756

39

5352

3742

10

4638

5522

2120

6241

5433

4543

6360

3835

4410

93

21

5957

40

4051

48

2526

1744

2423

2021

4518

1615

87

CC

142653

canale analogique

canale IVS

minj 4

inj 3m

minj 2

inj 1m

t eau

5Vp hui

m

vit pompe inj

v mot

alimt

air8V

5Vm

p airC

AN

GN

DC

AN

LC

AN

Hphm

+5Vsig

0Vval

+8V

prechstop

entsort

entB

at-B

at-B

at-B

at-B

at-w

arprech

+ ap cont

mp com

b5V

solm

dechm

J1939+J1939-

cdl-cdl+

batt-batt+

Bat+

Bat+

Bat+

Bat+

AF

WG E D C

W

M1

B30Y30

B29

B17

B19 B16

B18B15

R4H20

H21

H22

B6

B4

A19

F41

K16

Y31

Y32

Y34

P D ECM

Y33

Y35

B24

- +

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SPECIFICATIONS

- Negative power supply+ Positive power supplyA19 ECM EngineB4 Water in diesel fuel sensorB6 Engine air fi lter clogging pressure switchB15 Air intake pressure sensorB16 Fuel pressure sensorB17 Engine fl uid pressure sensorB18 Coolant liquid temperature sensorB19 Air intake temperature sensorB24 Accelerator TPS potentiometerB29 Primary speed sensorB30 Secondary speed sensorF41 Engine ECM fuseH20 PreheatH21 Engine pollutionH22 Fault stop engine immediatelyK16 Preheat relayP D ECM ECM diagnostic plugR4 Resistance 120 ohm 1/2 WY30 Electronic injector 1Y31 Electronic injector 2Y32 Electronic injector 3Y33 Electronic injector 4Y34 Injection pump electrovalveY35 Discharge electronic valve

KEY

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55 Signal

38 Masse

46 Alimentation 5V

2

1

3

ECM MoteurJ2

SENSOR AND PROBE

1

2 3

4

5

6

78

5V Power supplyWeightSignal

1 - Air pressure sensor

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SPECIFICATIONS

52 Signal

10 Alimentation 8V

2

1

ECM MoteurJ2

51 Signal

40 Masse

48 Alimentation 5V

2

1

3

ECM MoteurJ2

37 Alimentation

42 Signal

2

1

ECM MoteurJ2

57 Commande relais1

ECM MoteurJ1

Control relay

Signal Power supply


Alimentation 8VSignal

2 - Glow plug

3 - Air temperature sensor

4 - Fuel pressure sensor

5 - Speed sensor

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37 Alimentation

43 Signal

2

1

ECM MoteurJ2

56 Signal

39 Masse

47 Alimentation 5V

2

1

3

ECM MoteurJ2

53 Signal

10 Alimentation 8V

2

1

ECM MoteurJ2


Alimentation 8VSignal

Temperature signalPower supply

6 - Speed sensor

7 - Oil pressure sensor

8 - Water temperature sensor

+5Vsig0Vval+8V

1

4

2

6

5

3

canal analogique

canal IVS

4154334543

J1

1K+

-

+

-

A5

2024212322

9 - Longitudinal safety module

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SPECIFICATIONS

43 Alimentation 5V

33 Masse

44 Signal

2

1

3

ECM MoteurJ1

35 Retour

38 Signal

ECM MoteurJ1

SignalWeight+8V Power supply

SignalMasse

ENGINE EARTH

Ground PointOption 1 Ground PointOption 2

Ground Point Option 3

10 - Air fi lter clogging

11 - Water in diesel fuel sensor

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LOW PRESSURE FUEL CIRCUIT

Key:

(1) Primary fuel fi lter(2) Water separator(3) Diesel injection pump(4) Fuel-cooled ECM(5) Fuel cooler (option)(6) Secondary fuel fi lter(7) Injection pump(A) To the high pressure rail(B) Return from the high pressure rail pressure limiter(C) Return to fuel tank(D) Electronic unit injector return(E) Fuel feed from fuel tank

Fuel supplyLow PressureReturn to tankHigh Pressure

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SPECIFICATIONS

HIGH PRESSURE FUEL CIRCUIT

Key:

(1) Electronic Unit Injector(2) High pressure fuel collector(3) Fuel level sensor(4) Fuel pressure relief valve(5) Fuel pump(6) Injection pump electrovalve(7) Injection pump

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ENGINE CONTROL AND ADJUSTMENT

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ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FUEL CIRCUIT - 120PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ENGINE SILENTBLOCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUEL GAUGE ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

ALTERNATOR/CRANKSHAFT DRIVE BELT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

COOLING CIRCUIT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

FAN PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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FUEL CIRCUIT - 120PS

26 N.m 10%

ENGINE ASSEMBLY

ENGINE TIGHTENING TORQUES

6 daN.m 10%

1,8 daN.m 10%

6 daN.m 10%

3,6 daN.m 10%

3,6 daN.m 10%

1 daN.m 10%

3,6 daN.m 10%

22 N.m 5,5 N.m

3,5 daN.m + Loctite normal 243

10

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B

B

A

A

16

16

B-B

A-A

B-B

16

MLT 741 H T LSU

17 daN.m 10%

7 daN.m 10%

17 daN.m 10%

11 daN.m 10%

7 daN.m 10%

11 daN.m 10%

7 daN.m 10%

11 daN.m 10%

7 daN.m 10%

ENGINE SILENTBLOCS

Rear right engine mounting fi xing120 Cv version and H LSU

Mechanical transmission mounting Hydrostatic transmission mounting

Frontmachine

Engi

ne o

rient

atio

n

10

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- Position the gauge 1 (Fig. A) in the tank so that the spring 2 (Fig. C) enters the housing 3 (Fig. A) provided for this purpose at the bottom of the tank.

NOTE: To guide you, you can empty the tank and insert a light through the drain hole. 4 (Fig. A).

- A 12 to 14 mm gap A (Fig. B) between the top of the gauge and the tank indicates that the gauge is correctly positioned. If not, reposition the gauge.

- Position the top of the gauge to align the fi xing holes with the tappings on the tank. (The gauge can only be fi tted one way round as the holes are not equidistantly spaced) (Fig. D).

- If necessary remove the remnants of gasket sealant from the fi xing screws.

- Place a copper washer (Ref. 48 499) under the head of each of the fi ve screws 1 (Fig. D), then fi x the assembly to the tank.

- Connect the harness.- If removed earlier, re-fi t the drain plug, then re-fi ll the tank.

FUEL GAUGE ADJUSTMENT PROCEDURE

Fig.C

Fig.B

Fig.D

Fig.A

A

1

3

4

2

1

1

1

11

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ALTERNATOR/CRANKSHAFT DRIVE BELT ADJUSTMENT

T

F

T

F

X

Y

UPPER BELT RUN LOWER BELT RUN

Defl ection force

Static tension T Frequency Defl ection X Frequency Defl ection Y

1st tensioning 50N 2,1N 550N 50N 157Hz 5Hz 5mm 0,5 125Hz 5Hz 6,3mm 0,5

Retensioning 50N 2,1N 400N 50N 134Hz 4Hz 6,2mm 0,5 107Hz 4Hz 7,8mm 0,5

ALTERNATOR/CRANKSHAFT DRIVE BELT TENSION ADJUSTMENT PROCEDURE b Refer to the instructions

Upper belt run

Lower belt runI.C. engine

Alternator

Pump

Rota

tion m

oteur

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COOLING CIRCUIT ADJUSTMENT

FAN PULLEY

12

3

45

6

Key :

1 - Collet 2 - Fan pulley3 - Bracket4 - Bearing5 - Circlip6 - Hub7 - Fan

7

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REMOVAL AND RE-FITTING OF PULLEY COLLET (Ref. 1)

Removal:

- Remove the fan pulley bracket (Ref. 3)

- Remove the fan (Ref. 7)

- Loosen the 6 screws (Ref. 8) a few turns the tap their heads lightly to release the collet.

- Remove the collet (Ref. 1).

Assembly:

- Carefully clean the shaft and internal face of the pulley. Lightly oil all mating surfaces with mineral oil. (Do not use molybdenum disulfi de based oils)

- Locate the collet (Ref. 1) in the pulley (Ref. 2).

b Never drive the collet to the end stop on the pulley shoulder as this will make future removal very diffi cult.- Locate the assembly on the shaft.

- To prevent the collet from twisting, tighten the screws in diagonal sequence a quarter of a turn at a time, preferably using a torque wrench, up to 50% of the specifi ed torque, that is to 8,5 Nm.

- Repeat this procedure until the fi nal torque is reached.

Final torque: 17 Nm

- Remove the hub from the pulley (Ref. 6) using either a press, a long-nosed puller or a brass drift and a hammer

- When fi tting the new hub, use the same tools.

3

7

8

1

6

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FAN BELT

FAN BELT TENSIONING

1.5

1.5

1.1

1.1

- Inspect the fan belt for condition and replace it if necessary.

- Loosen the bolt (Ref. 9) on the tensioning pulley.

- Loosen the lock-nut (Ref. 10) and the bolt (Ref. 11).

- Bring the belt just into contact with pulley (Ref. 12) (on the telehandler, check this operation by feel).

- Make a mark on the head of screw (Ref. 11) and tighten, turning it 5 times.

- Tighten the lock-nut (Ref. 10).

- Retighten tensioning pulley bolt (Ref. 11).

b When changing the fan belt, retighten bolt (Ref. 11) one and a half turns, having allowed the diesel engine to idle for 30 minutes.

9

10

11

12

11

10

Permissible pulley misalignment:

Fan shaft Idler pulley shaft Engine orientation

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TABLE OF CONTENTS 10ENGINE CHARACTERISTICS AND SPECIFICATIONSENGINE CONTROL AND ADJUSTMENT

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