manual montacargas y mani
TRANSCRIPT
-
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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ENGINE CHARACTERISTICS AND SPECIFICATIONS
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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ENGINE CHARACTERISTICS AND SPECIFICATIONS
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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5ENGINE CHARACTERISTICS AND
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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ENGINE CHARACTERISTICS AND SPECIFICATIONS
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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7ENGINE CHARACTERISTICS AND
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
5V Power supplyWeightSignal
Alimentation 8VSignal
2 - Glow plug
3 - Air temperature sensor
4 - Fuel pressure sensor
5 - Speed sensor
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ENGINE CHARACTERISTICS AND SPECIFICATIONS
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
5V Power supplyWeightSignal
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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9ENGINE CHARACTERISTICS AND
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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ENGINE CHARACTERISTICS AND SPECIFICATIONS
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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11ENGINE CHARACTERISTICS AND
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 CHARACTERISTICS AND SPECIFICATIONS
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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
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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
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5ENGINE CONTROL AND ADJUSTMENT
- 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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7ENGINE CONTROL AND ADJUSTMENT
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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9ENGINE CONTROL AND ADJUSTMENT
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