ENGINE

10
- ENGINE COMPONENTS LOCATION

- ENGINE CONTROL AND ADJUSTMENT

- ENGINE REMOVAL

- ENGINE REFIT

- SPECIFIC ENGINE TOOLING

- ENGINE CHARACTERISTICS AND l647044EN

SPECIFICATIONS
(ENGINE V3307 - E3)
- ENGINE CONTROL AND ADJUSTMENTS

- ENGINE TROUBLESHOOTING

- SPECIFIC ENGINE TOOLING

 10
ENGINE COMPONENTS LOCATION

pages

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FAN CONTROL (FOR MLT 625-75 H / MLT-X 625-75 H ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . 3

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 2 ENGINE COMPONENTS LOCATION

ENGINE

Fuel pump and

10

filter Alternator and

belts

Oil filter

Starter

Turbo

Injection pump
Air filter

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 ENGINE COMPONENTS LOCATION 3

FAN CONTROL (For MLT 625-75 H / MLT-X 625-75 H only)

Fan control hydraulic Fan control hydraulic
motor pump

10
Engine coolant
temperature sensor
CC1
CAN
PPC
PSC
PPU
CC2

Hydrostatic pump ECU oil

temperature sensor

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 4 ENGINE COMPONENTS LOCATION
10

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 10
ENGINE CONTROL AND ADJUSTMENT

pages

MT 625 TURBO / MT 625 T COMFORT / MT-X 625 TURBO / MT-X 625 T COMFORT . . . . . A
MLT 625-75 H / MLT-X 625-75 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

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 2 ENGINE CONTROL AND ADJUSTMENT
10

10-04-m176EN (07/01/2014)
 ENGINE CONTROL AND ADJUSTMENT A1

MT 625 TURBO / MT 625 T COMFORT

MT-X 625 TURBO / MT-X 625 T COMFORT pages

10
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
A - CHANGING THE ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
–– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
B - CHANGING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
–– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
C - REPLACING THE CRANKSHAFT LIP SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
–– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5

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 A2 ENGINE CONTROL AND ADJUSTMENT

View A
10

A
w
Vie

A
B

Key:

A - Alternator belt (Replacement and adjustment e operator’s instructions)

B - Alternator
C - Starter

PREPARATION AND SAFETY INSTRUCTIONS

Operate the battery cut-off.

Open the engine bonnet.

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 ENGINE CONTROL AND ADJUSTMENT A3

1 A - CHANGING THE ALTERNATOR

1

2
REMOVAL

10
Undo the 4 screws (1) and take off the radiator protection grill (2).
1

Loosen the 2 screws (3) by two to three thread turns.

Pivot the alternator assembly (4) so as to free the belt (5)
from the alternator pulley.
3 5

Mark the position of the electrical wires and disconnect

the connectors (6).
6

Undo the 2 screws (3) and remove the alternator.

REFIT

Refit the alternator (4) with the 2 screws (3).

Refit the belt (6) then adjust the belt tension by pivoting the
alternator assembly (4). Refer to the operator’s instructions.
Retighten the 2 screws (3).
Reconnect the electrical connectors.
Refit the radiator protection grill (2).

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 A4 ENGINE CONTROL AND ADJUSTMENT
10

B - CHANGING THE STARTER

REMOVAL

2 Remove the 2 screws (1) and take off the engine bonnet locking
lug (2).

1 1

Disconnect the electrical connections (3).

Remove the 2 nuts (4).

4

Remove the starter (5).

3
4 5
3

REFIT

Proceed in reverse order to removal.

Insert the starter (5) onto the engine and fasten with the 2 nuts (4).

Reconnect the electrical connections (3).

Reattach the engine bonnet locking lug (2) with the 2 screws (1).

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 ENGINE CONTROL AND ADJUSTMENT A5

180°

10
C - REPLACING THE CRANKSHAFT LIP SEAL

Procedure applied as standard as from engine No. AUO138

(October 2010).

REMOVAL

- Remove the crankshaft pulley (1).

1

- Remove the worn seal (2).

2
bb Be careful not to damage the aluminium seal bearing surface.

REFIT

- Apply clean engine oil to the seal bearing surface (3).

- Oil the outside of the new seal.
- Insert the new seal into the crankcase.
3 NOTE: You can press the seal home using a special tool or 55 mm socket.

bb The seal must be pushed all the way in to the crankcase

housing to avoid the pulley rubbing on the seal.

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 A6 ENGINE CONTROL AND ADJUSTMENT

- Oil the inside of the new seal (4).

- Oil the seal bearing.
10

- Refit the pulley tight up against the crankshaft (5).

5
6

bb Gently pull the pulley back 5 mm, than push it all the way
forward again (6), to avoid the lip of the seal becoming
trapped under the seal (see below).

Wrong
!
Right OK

- Refit the pulley fastening screw.

• Screw tightening torque: 255 to 274 N.m

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 ENGINE CONTROL AND ADJUSTMENT B1

MLT 625-75 H / MLT-X 625-75 H

pages

10
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
A - CHANGING THE FAN BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
–– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5
B - CHANGING AND ADJUSTING THE AIR CONDITIONER BELT . . . . . . . . . . . . . . . . . . . . . . . . . . B7
–– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
C - CHANGING AND ADJUSTING THE ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
–– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
D - ALTERNATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
–– e10 - ENGINE CONTROL AND ADJUSTMENT - PART A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
E - CHANGING THE FAN DRIVE HYDRAULIC ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9
–– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
–– TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
F - CHANGING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12
–– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12
–– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13
G - CHANGING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13
–– e10 - ENGINE CONTROL AND ADJUSTMENT - PART A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13
H - FAN CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B14
–– LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B14
–– I – FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B14
–– II – DESCRIPTION OF FAN REVERSAL HYDRAULIC ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B15
–– III – THE THREE MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B16
–– IV – CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B18
I - CRANKSHAFT LIP SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B20
–– e10 - ENGINE CONTROL AND ADJUSTMENT - PART A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B20

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 B2 ENGINE CONTROL AND ADJUSTMENT
10

D
180°

C A
G
D B

Key:

A - Fan belt
B - Air conditioner belt
C - Alternator belt
D - Alternator
E - Fan drive hydraulic engine
F - Water pump
G - Fuel filter
H - Starter

PREPARATION AND SAFETY INSTRUCTIONS

Operate the battery cut-off.

Open the engine bonnet.

Specific tooling

Special tool e 10 - Specific engine tooling

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 ENGINE CONTROL AND ADJUSTMENT B3

180°

10
A - CHANGING THE FAN BELT

REMOVAL

Unscrew the 2 screws (Item 1) and remove the engine box lower
1 cover (Item 2) (17 mm open-end wrench).

Undo the hose clip (Item 3) of the upper radiator hose (Item 4)
(Screwdriver).

Disconnect the hose from the radiator.

4

Keep the upper hose (Item 4) pointing upwards, a small amount

of coolant will leak from the radiator and the hose.

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 B4 ENGINE CONTROL AND ADJUSTMENT

Remove the expansion tank bracket (Item 5) with the expansion

tank still attached (Item 6) and connected to the hose (Item 7)
6 (13 mm socket).
10

Remove the radiator support bracket fastening screw (Item 8)

(13 mm socket).

Tip the radiator (Item 9) forwards as far as it will go and secure

it in this position (1 meter long strap).
9

10
Unscrew the 4 screws (Item 10) and remove the radiator
10 protection grill (Item 11) (13 mm socket).
11

10

10

10-04-M176EN (28/09/2015)
 ENGINE CONTROL AND ADJUSTMENT B5

Unscrew the fan's 4 fastening screws (Item 12).

Take off the fan (Item 13) (13 mm socket).
13

10
12

Cut the belt (Item 14), remove and dispose of it (Cutting pliers).

14

REFIT

Attach the special belt tool (Item 15) (e 10 - Specific engine

16 15
tooling) on the ribbed pulley (Item 16) and secure the tool with
17
the nut (Item 17).

Correctly position the new belt on the loose pulley (18) and pass
it just behind the nut (Item 19).

Install the guide hook (Item 20). It must be secured on the bracket
(Item 21) at one end and the belt must be placed on the other
end with the teeth directed inwards.
21

19

18 20

20

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 B6 ENGINE CONTROL AND ADJUSTMENT

Using a wrench (21 mm socket) on the pulley nut (Item 22) and

placing a thumb on the nut (Item 19) of the tool, perform a
19
rotational movement that will engage the belt onto the pulley.
22

bb
When the belt is installed on the pulley, remove the special tool.
10

Do not forget to remove and recover the guide hook

(Item 20).
20
Once the tooling is removed, turn the pulleys a number of times
by hand to check that the new belt is properly positioned in
the grooves.

Refit the different items in reverse order to removal.

Put in the correct amount of cooling liquid eInstruction manual.

Start the engine to check operation and set the heating to

maximum to bleed the cooling circuit.

Top-up with coolant once more.

Fit the engine box lower cover.

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 ENGINE CONTROL AND ADJUSTMENT B7

180°

10
B - CHANGING AND ADJUSTING THE AIR
CONDITIONER BELT
1
1 REMOVAL
2
Unscrew the 4 fastening screws (Item 1) and remove the radiator
protection grill (Item 2) (13 mm socket).

Loosen the belt tension adjustment screw (Item 3).

If necessary, loosen the compressor fixing bolts (Item 4).
Pivot the compressor (Item 5) towards the engine to free the
belt (Item 6).
6

3
5

REFIT

Place the belt in the grooves of the 2 pulleys (crankshaft and

compressor).
Adjust belt tension e Instruction manual.
Tighten the belt tension adjustment screw.
Check the tightening of the alternator fastening bolts.

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 B8 ENGINE CONTROL AND ADJUSTMENT

180°
10

C - CHANGING AND ADJUSTING THE ALTERNATOR

BELT

⇒⇒ Carry out the "Fan belt removal" operation e A

⇒⇒ Carry out the "Fan belt removal" operation e B

1

REMOVAL

Loosen the belt adjustment screw (Item 1) (12 mm socket).

2

If necessary, undo the alternator fastening screw (Item 2)

(14 mm socket).

Pivot the alternator towards the engine to free the belt.

2

REFIT

Place the belt in the grooves of the 3 pulleys (alternator, crankshaft

and water pump).
Adjust belt tension e Instruction manual.
Tighten the belt tension adjustment screw.
Check the tightening of the alternator fastening bolt.

D - ALTERNATOR REPLACEMENT

e10 - ENGINE CONTROL AND ADJUSTMENT - PART A

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 ENGINE CONTROL AND ADJUSTMENT B9

180°

10
E - CHANGING THE FAN DRIVE HYDRAULIC ENGINE

⇒⇒ R
 aise the boom to mid-height and secure in position
1
⇒⇒ Carry out the "Fan belt removal" operation e A

REMOVAL

3 2

Within the boom well (Item 1) unscrew the two fastening screws
2 (Item 2) (13 mm socket) and remove the protection plate (Item 3).

Disconnect the electrical connections to the electrovalves

(Item 4) located to the rear of the hydraulic engine.
4
The connectors are silkscreen printed with:
–– EV386 for the upper electrovalve.
–– EV385 the lower electrovalve.

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 B10 ENGINE CONTROL AND ADJUSTMENT

Place rags under the hydraulic engine.

Remove the two hoses (Item 5) connected to the hydraulic engine
(30 mm socket).
4
Slowly turn the nuts (Item 6) to release the residual pressure
(36 mm socket).
10

6 5

Loosen the ribbed pulley (Item 7) fastening nut (Item 7) (21 mm

socket and strap wrench).
Recover the nut and the Grower washer.
8
7

Position the pulley puller tool (Item 9) and slowly separate the
pulley (Item 8) from the hydraulic engine shaft.
Recover the pulley and the key located on the hydraulic engine's
tapered shaft.

Remove the 4 hydraulic engine fastening bolts (screw, washer

9
and nut) (Item 9) (13 mm sockets).
9

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 ENGINE CONTROL AND ADJUSTMENT B11

Remove the engine from its bracket and place it in the engine box
Unscrew the clamp (Item 10) securing the drain hose (Item 11)
(Screwdriver).
Remove and plug the drain hose.
Plug the hydraulic unit

10
10 Take the hydraulic engine out of the engine box via the central
opening.

11

REFIT
13

Insert the engine in the engine box via the central opening
12
(insert the electrovalve block first).
Connect the drain hose to the engine and tighten the hose clip.
14

Proceed in the reverse order to removal.

While checking the condition of the surface of the engine and

its support.

While checking the condition of the tapered bearing of the

engine shaft and the bore of the pulley.

If the hydraulic engine support has been removed, check

the alignment of the fan pulley (Item 12) and that of the fan
hydraulic engine (Item 13) with a metal straightedge (Item 14).
The maximum acceptable out-of-alignment is 1 mm.

Refit fan belt eA

TESTING

Start the engine and operate the fan reverse switch to check
that the fan turns properly in both directions.

e "H - FAN CONTROL OPERATION"

Switch off the engine and check the hydraulic oil level.

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 B12 ENGINE CONTROL AND ADJUSTMENT

180°
10

F - CHANGING THE WATER PUMP

⇒⇒ D
 raining the cooling system
e Instruction manual

⇒⇒ Carry out the "Alternator belt removal" operation eC

REMOVAL

Loosen the 4 screws (Item 1) and remove the fan support pulley
cover (5 mm hexagon socket screw key).
1

Unscrew the 4 screws (Item 2) and remove the fan support pulley
and the alternator drive pulley (5 mm Allen key).

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 ENGINE CONTROL AND ADJUSTMENT B13

Unscrew the 7 screws (Item 3) and remove the water pump

casing (12 mm socket).

10
3

Remove and discard the water

4 4 pump seal (Item 4).

REFIT

⇒⇒ Proceed in the reverse order to removal.

⇒⇒ Observe the tightening torque when attaching the pump casing: Repair manual
M
R

MR 647044.

⇒⇒ Top-up with coolant.

⇒⇒ Alternator belt refit eC

⇒⇒ Fan belt refit eA

G - CHANGING THE STARTER

e10 - ENGINE CONTROL AND ADJUSTMENT - PART A

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 B14 ENGINE CONTROL AND ADJUSTMENT

H - FAN CONTROL OPERATION

LOCATION
10

Fan direction reversal

electrovalve
Fan control hydraulic Fan control hydraulic
engine pump

Fan speed control

electrovalve

I – FUNCTION

⇒⇒ To adjust the speed of the engine cooling fan according to the temperature (engine and
transmission).

⇒⇒ To temporarily reverse the direction of flow to unclog the bonnet intake grilles.

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 ENGINE CONTROL AND ADJUSTMENT B15

II – DESCRIPTION OF FAN REVERSAL HYDRAULIC engine

2
1 - Hydraulic engine

10
2 - Fan direction reversal electrovalve.
3 - Fan speed control electrovalve.
4 - Pressure port (P)
5 - Tank return (R) 4

Engine hydraulic diagram:

MHRV: Fan reversal hydraulic engine

P: From pump
R: Tank return
EvV: Fan speed control electrovalve MHRV V
P EvS RF
8 cm³/tr
EvS: Fan direction reversal electrovalve EvV
C
V: Fan R 160b
+5
0

RF: Radiator

The control unit is equipped with two electrovalves and a one way valve.

The EvV proportional relief valve adjusts the speed of rotation of the hydraulic engine.
The full propeller rotational speed must be achieved when the relief valve is not energized.

The EvS 4/2 on-off control valve defines the direction of rotation of the hydraulic engine. When the coil
is not energized, the engine's direction of rotation corresponds to the "normal cooling" mode direction
of rotation.

The one way valve C prevents hydraulic engine cavitation, in particular during engine shutdown phases.

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 B16 ENGINE CONTROL AND ADJUSTMENT

III – THE THREE MODES OF OPERATION

"Reversal" mode (reverse propeller rotation)

The reversal of propeller rotation is temporary. In this mode, the proportional coil of the relief valve
10

(control valve) is fully energized, thus reducing the speed of rotation of the propeller. The direction
reversal electrovalve (reversal valve) is then energized, reversing the direction of rotation of the engine.
The relief valve power supply is gradually reduced to a 0 % control value, thus allowing the speed of
rotation of the cooling fan to increase. The ventilation system is then in "reversal" mode, serving to
unclog the engine bonnet grilles. A similar procedure restores the propeller's direction of rotation to
cooling mode.

The reversal cycle can be performed at any coolant temperature

Whenever the cab fan reversal switch is pressed, the system will only be activated after 15 seconds when
the engine is cold and after 5 seconds when the engine is hot to avoid overloading the engine at start-up.
Operation of 3 minute time delay:
–– The system does not allow reversals to be performed within a period of less than 3 min.
–– If the switch is pressed, reversals will occur every 3 minutes.
–– If the switch is pressed within the 3 minute period (e.g.: the previous reversal was performed 1 minute
ago), the system will ignore it

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 ENGINE CONTROL AND ADJUSTMENT B17

10
"Optimized cooling" mode: speed of rotation of the propeller adjusted to suit the operating conditions

The reversal valve is not powered in this mode.

The relief valve coil is energized proportionally (PWM signal), thus reducing the speed of rotation of
the propeller below the "maximum" speed. This operating mode is conditioned by the temperature
parameters (fluid temperatures, etc.).

"Maximum cooling" mode

In this mode, none of the coils are energized. The full pump flow is sent to the engine without any
adjustment, thus ensuring that the propeller speed of rotation is proportional to the engine speed.
The operating mode ensures "maximum" truck cooling.

(28/09/2015) 10-04-M176EN
 B18 ENGINE CONTROL AND ADJUSTMENT

IV – CONTROL

The fan control management module is connected to the truck's other electronic components via a
CAN network.
It directly controls the hydraulic unit's electrovalves.
10

It is connected to the fan drive control switch situated in the cab.

The engine fan speed is adjusted according to the engine coolant and the hydraulic oil temperatures.

Fan control system architecture diagram:

IHM

MHRV
Hydraulic ECU
EV

Engine temperature
sensor
EvV

Switch
CC1
CAN
PPC
PSC
PPU

Hydraulic oil temperature

CC2

sensor in transmission ECU

Components:

⇒⇒ Engine-mounted coolant temperature sensor.

⇒⇒ MMI (Man-Machine Interface) displays and transmits the engine coolant temperature signal to
the hydraulic ECU via the CAN.
⇒⇒ Oil temperature sensor in the hydrostatic pump ECU gives the ECU temperature from which the
oil temperature is deduced.
⇒⇒ Hydraulic ECU
⇒⇒ Fan speed control electrovalve (EvV) mounted beneath the hydraulic unit (MHRV);
⇒⇒ Fan direction reversal electrovalve (EV) mounted above the hydraulic unit (MHRV);
⇒⇒ Fan control switch.

10-04-M176EN (28/09/2015)
 ENGINE CONTROL AND ADJUSTMENT B19

Fan speed value:

Hydraulic oil T°C % Fan speed / Engine speed

Below 65 °C 0 % = fan must rotate at minimum speed
Between 65 °C and 75 °C From 0 to 16 %

10
Between 75 °C and 90 °C From 16 to 46 %
Above 90 °C From 46 to 100 %

Engine water T°C % Fan speed / Engine speed

Below 80 °C 0 % = fan must rotate at minimum speed
Between 80 °C and 95 °C From 0 to 36 %
Between 95 °C and 100 °C From 36 to 76 %
Above 100 °C From 76 to 100 %

The ECU will select the more unfavorable value between the coolant temperature and the hydraulic oil
temperature.

Electrical values for the electrovalves’ signal i 80 - Electrical characteristics and specifications

Fan speed measurements with electrovalves disconnected

(maximum fan speed achieved according to engine speed):

Engine speed Maximum fan speed

(rpm) (rpm)
870 1 180
1 300 1 780
1 500 2 068
1 700 2 370
2 000 2 848
2 500 3 050
2 750 3 100

E.g.: if oil is at 70 °C and the coolant at 90 °C, the ECU will select the least favorable valve (90 °C), the fan
will run at 36 % of its maximum speed (3100 rpm) thus, for a max. engine speed (2750 rpm) approx.:
3100 x 0,36 = 1116rpm.

Above 110 °C = indicator comes on and the buzzer sounds.

(28/09/2015) 10-04-M176EN
 B20 ENGINE CONTROL AND ADJUSTMENT

I - CRANKSHAFT LIP SEAL REPLACEMENT

e10 - ENGINE CONTROL AND ADJUSTMENT - PART A

10

10-04-M176EN (28/09/2015)
 10
ENGINE REMOVAL

pages

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ORDER OF DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
COMPLETE “BOX + ENGINE ASSEMBLY” REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SUCTION STRAINER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

(06/02/2012) 10-06-M176EN
 2 ENGINE REMOVAL
10

Key:

A - Box + engine assembly

PREPARATION AND SAFETY INSTRUCTIONS

Stabilize the machine on level ground.
Perform several manoeuvres in forward gear and reverse gear (wheels straight) in order to release any
stresses acting on the steering and tyres.

Turn the wheels towards the left for ease of disassembly.

Raise the boom to mid-height and secure in position.

bb
Deactivate battery power supply by means of the cut-off switch.

For engine assembly removal, check the condition of the suction strainer. Replace if necessary.

Specific tools:

- Pallet truck
- Floor crane (minimum 1000 Kg)

10-06-M176EN (06/02/2012)
 ENGINE REMOVAL 3

ORDER OF DISMANTLING

Stage 1 HYDRAULIC PUMP REMOVAL

10
Stage 2 COMPLETE “BOX + ENGINE ASSEMBLY” REMOVAL

Stage 3 COOLER REMOVAL

Stage 4 ENGINE REMOVAL

Stage 5 HYDROSTATIC PUMP REMOVAL

(06/02/2012) 10-06-M176EN
 4 ENGINE REMOVAL
10

HYDRAULIC PUMP REMOVAL

bbe 70 “Hydraulic components removal”

10-06-M176EN (06/02/2012)
 ENGINE REMOVAL 5

10
COMPLETE “BOX + ENGINE ASSEMBLY” REMOVAL
1

3 Drain the oil tank.

Disassemble the turbo exhaust line (1) du turbo (2) by taking
3
2 3 out the 4 screws (3).

7 Remove the fuel filter (4), by taking out the 2 screws (5).
Remove the windscreen washing fluid tank (6), by taking out
the 2 screws (7).
5
6 Remove the windscreen washing fluid tank support bracket (8)
by taking out the 4 screws (9).

Unscrew the clamp (10) then remove the suction hose (11) from
the filter.

Help:

e 20 - Transmission schematic diagrams

10

11

(06/02/2012) 10-06-M176EN
 6 ENGINE REMOVAL

Remove the draining hose (12) from the hydrostatic pump (13)
(36 mm wrench).

Help:
10

e 20 - Transmission schematic diagrams

13

12

Remove the boost hose (Item 14) from the hydrostatic pump
13 (Item 13) (17 mm wrench).

Help:

e 20 - Transmission schematic diagrams

14

15 On the oil tank (15), remove the tank return hose (16)
(24+27 mm wrenches).

Help:

16
e 20 - Transmission schematic diagrams

20
18
19
Disassemble the tubes (17) from the cooler (18) (36 mm wrench).
Provide a container for leaking oil.
17 Remove the clamp (19) using a 6 mm Allen key.

10-06-M176EN (06/02/2012)
 ENGINE REMOVAL 7

Remove the cooler/frame attachment screw (20).

20

10
On the oil tank (15), unscrew the cooler/tank hose (21)
15 (32+36 mm wrenches).

21
F
R

Remove the front mudguard (22), by taking out the 3 screws (23).

23

23
22
23

Remove the cover plate (24) by taking out the 4 screws (25).

25 25

24

25
25

(06/02/2012) 10-06-M176EN
 8 ENGINE REMOVAL

Remove the protective guard (26) by taking out the 4 screws (27).
10

27

26

Disconnect the electrical connectors (X260, X261) from the

X19 hydrostatic motor (28).
X310
Disconnect the 2 Motor/Frame interface connectors (X19, X310).
28

X261
X260

Cut the 2 ties (29).

29

Unscrew the High and Low Pressure hoses (30) on the hydrostatic
engine (28).

Help:

e 20 - Transmission schematic diagrams

30

28

30

10-06-M176EN (06/02/2012)
 ENGINE REMOVAL 9

Disconnect the 2 “Frame Ground” terminals (31).

31

10
Disconnect the accelerator cable (32).

32

Remove the fuel supply hose (33). Fit plug to prevent loss of fuel.

33

Remove the fuel return hose (34).

34

(06/02/2012) 10-06-M176EN
 10 ENGINE REMOVAL

Take up the load of the engine box (35), on pallet truck (36).
10

35

36

38
37

37

37

35

37

Remove the 5 screws (37) attaching the engine box (35) on the frame (38).

Carefully remove the complete “box + engine” assembly (39)

with the pallet truck (36) perpendicular to the longitudinal axis
of the machine.

39

36

10-06-M176EN (06/02/2012)
 ENGINE REMOVAL 11

10
3

SUCTION STRAINER REMOVAL

Using a screwdriver (1), remove the clamp (2) from the hose (3).
1
2

Unscrew the filter (4) using a pin wrench (5).

(06/02/2012) 10-06-M176EN
 12 ENGINE REMOVAL
10

COOLER REMOVAL

2
Drain the cooler.
Remove the clamp (1) from the lower hose (2).
1

Repeat the operation for the upper hose (3).

Unscrew the clamp (4) from the expansion tank hose (5).

10-06-M176EN (06/02/2012)
 ENGINE REMOVAL 13

Using a 13 mm wrench, unscrew the 2 screws (6) that hold the

6
cooler in position (7) on the box (8).
7

10
6
8

Remove the cooler (7).

(06/02/2012) 10-06-M176EN
 14 ENGINE REMOVAL
10

ENGINE REMOVAL

bb Using a lifting system that can support a minimum load

of: 1000 Kg.

Move the floor crane (1) close to the engine.

4 Introduce the 2 hooks (2) on the sling lugs (3) then straighten
the chains (4) so as to secure the engine in a stable position (5).

2 3

Undo the clamp (6) from the air hose (7) then remove it.

10-06-M176EN (06/02/2012)
 ENGINE REMOVAL 15

Remove the 2 attachment screws (10) from the first silent block
(11) (19 mm socket).

10
10

11 10

Remove the 2 attachment screws (12) from the second silent

block (13) (19 mm socket).

12

13
12

Remove the 2 attachment screws (14) from the third silent-block

(15) (19 mm socket).

14
15

14

Lift the engine (5) with the floor crane (1), and remove it from
the engine box.
Then remove the engine making sure that it is secured for perfect
stability.

(06/02/2012) 10-06-M176EN
 16 ENGINE REMOVAL
10

HYDROSTATIC PUMP REMOVAL

Remove the 2 screws (1) from the hydrostatic pump (2)

(22 mm wrench).

2
Remove the hydrostatic pump.

10-06-M176EN (06/02/2012)
 10
ENGINE REFIT

pages

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ORDER OF REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDROSTATIC PUMP REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
COOLER REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COMPLETE “BOX + ENGINE” ASSEMBLY REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HYDRAULIC PUMP REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LEVELS - VERIFICATION - TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

(06/02/2012) 10-07-M176EN
 2 ENGINE REFIT
10

Key:

A - Box + engine assembly

PREPARATION AND SAFETY INSTRUCTIONS

Stabilize the machine on level ground.
Perform several manoeuvres in forward gear and reverse gear (wheels straight) in order to release any
stresses acting on the steering and tyres.

Turn the wheels towards the left for ease of reassembly.

Raise the boom to mid-height and secure in position.

bb
Deactivate battery power supply by means of the cut-off switch.

If the whole engine is refitted, check the condition of the suction strainer. Replace it if necessary.

Specific tools:

- Pallet truck
- Floor crane (minimum 1000 Kg)

10-07-M176EN (06/02/2012)
 ENGINE REFIT 3

ORDER OF REASSEMBLY

Stage 1 HYDROSTATIC PUMP REFIT

10
Stage 2 ENGINE REFIT

Stage 3 COOLER REFIT

Stage 4 COMPLETE “BOX + ENGINE” ASSEMBLY REFIT

Stage 5 HYDRAULIC PUMP REFIT

(06/02/2012) 10-07-M176EN
 4 ENGINE REFIT
10

HYDROSTATIC PUMP REFIT

Attach the hydrostatic pump (1) to the engine (2) with the
2 screws (3) (22 mm wrench).

1
Tighten to the correct torque: 17.5 daN.m ±10 %.

3
Connect the 2 High pressure pipes on to the hydrostatic pump (1).
2

10-07-M176EN (06/02/2012)
 ENGINE REFIT 5

10
4 4 ENGINE REFIT
2 2

1
bb Using a lifting system that can support a minimum load
of: 1000 Kg.

Bring the lifting crane close to the engine (1).

Place the 2 hooks (2) on the sling lugs (3) then pull the chains
(4) to hold the engine in position (1).

Lift the engine (1) with the floor crane (5).

5
Then place the engine in its box (6) ensuring that it is correctly
aligned with the silent-block holes.

6
1

(06/02/2012) 10-07-M176EN
 6 ENGINE REFIT

Order of installation of silent blocks

70 N.m ±10%
3
10

110 N.m ±10%

7 daN.m ±10%
y
110 N.m ±10% 27 mm
x 1

110 N.m ±10% 7 daN.m ±10%

2
70 N.m ±10%

Stage A - Silent-block 1:
Fixed in X and Y.
Stage B - Silent-block 2:
Sight through silent-block hole to adjust in Y axis, sight through engine support bracket hole
to adjust in X axis.
Stage C - Silent-block 3:
Sight through silent-block hole to adjust in Y axis, sight through engine support bracket hole
to adjust in X axis.

Mount the 2 attachment screws (7) of the first silent block (8)
(19 mm socket).

Comply with torque tightening: 7 daN.m ± 10 %.

8 7

Mount the 2 attachment screws (9) of the second silent block

(10) (19 mm socket).

Comply with torque tightening: 7 daN.m ± 10 %.

9
10

10-07-M176EN (06/02/2012)
 ENGINE REFIT 7

Mount the 2 attachment screws (11) of the third silent block (12)
(19 mm socket).

Comply with torque tightening: 7 daN.m ±10 %.

10
11

12
11

Refit the air hose (13) on the air filter (14).

Tighten the clamp (15).

14

15

13

(06/02/2012) 10-07-M176EN
 8 ENGINE REFIT
10

COOLER REFIT
2
1

Place the cooler (1) on the engine box (4).

Using a 13 mm wrench, mount the 2 screws (2 and 3) that hold

3 the cooler in place (1) on the engine box (4).
4

Refit the expansion pan hose (5).

Tighten the clamp (6).

Refit the upper hose (7) on the cooler (1).

Tighten the clamp (8).

10-07-M176EN (06/02/2012)
 ENGINE REFIT 9

Refit the lower hose (9) on the cooler (1).

Tighten the clamp (10).

1
9

10
10

(06/02/2012) 10-07-M176EN
 10 ENGINE REFIT
10

COMPLETE “BOX + ENGINE” ASSEMBLY REFIT

Position the complete “box + engine” assembly (1) against the

2
truck frame (2) using a palette truck (3).

2
4

Install the 5 screws (4) securing the engine box (5) to the frame (2).

10-07-M176EN (06/02/2012)
 ENGINE REFIT 11

Reconnect the fuel return hose (6) to the engine.

10
6

Reconnect the fuel supply hose (7) to the engine.

Refit the accelerator cable (8) on its bracket (9).

Attach the 2 “Frame Ground” terminals (10) to the frame (2).

10
2

(06/02/2012) 10-07-M176EN
 12 ENGINE REFIT

Refit the 2 High pressure and Low pressure hoses (11) to the
hydrostatic engine (12).

Help:
11
10

12 e 20 - Transmission schematic diagrams

11

X19
X310
Connect the electrical connectors (X260, X261) of the hydrostatic
12 motor (12).
Connect the 2 Motor/Frame interface connectors (X19, X310).
Place ties to hold the electrical harnesses in place.

X261
X260

Refit the protective guard (15) with the 4 screws (16).

16

15

Refit the cover plate (17). Attach it to the frame with the 4
screws (18).

18 18

17

18
18

10-07-M176EN (06/02/2012)
 ENGINE REFIT 13

Refit the front mudguard (19) by inserting the 3 screws (20).

10
20

20
19
20

21 On the oil tank (21), screw on the cooler/tank hose (22)

(32+36 mm wrenches).

22
F
R

Insert the cooler/frame attachment screw (23).

23

23
Assemble the manifold (24) on the cooler (25) (36 mm wrench).
25
26
Reposition the clamp (26) with a 6 mm Allen key.

24

(06/02/2012) 10-07-M176EN
 14 ENGINE REFIT

On the oil tank (21), connect the tank return hose (27)
21
(24+27 mm wrenches).

Help:
10

27
e 20 - Transmission schematic diagrams

7 Reconnect the boost hose (28) of the hydrostatic pump (29)

(17 mm wrench).

8
Help:

e 20 - Transmission schematic diagrams

Reconnect the drainage hose (30) of the hydrostatic pump (29)

(36 mm wrench).

Help:

29 e 20 - Transmission schematic diagrams

30

Reconnect the suction hose (30).

Tighten the clamp (31).

Help:

31

30
e 20 - Transmission schematic diagrams

10-07-M176EN (06/02/2012)
 ENGINE REFIT 15

Refit the windscreen wiper fluid tank support bracket (32) with
35 the 4 screws (33).
Refit the windscreen wiper fluid tank (34) with the 2 screws (35).
37
Refit the fuel filter (36) with the 2 screws (37).

10
34

33

36

32

Position the exhaust line (38) on the turbo (39). Tighten the 4
screws (40).
38
Connect all the other electrical harnesses.
40

40
39 40

HYDRAULIC PUMP REFIT

bb 70 “Hydraulic components refit”

(06/02/2012) 10-07-M176EN
 16 ENGINE REFIT

LEVELS - VERIFICATION - TESTING

- Top up the coolant level (cooler).

10

- Fill up the oil level (80L: capacity of main hydraulic tank).

- Verify and control all previous assemblies, especially the electrical harness connections.
- Operate the battery cut-off switch.
- Start and run the truck until the operating temperature is reached.
- Perform a few directional movements.
- Remove the boom suspension security system.
- Lower/Raise the boom.
- Check the levels again and top up the oil if required.

10-07-M176EN (06/02/2012)
 10
SPECIFIC ENGINE TOOLING

pages

FAN BELT FITTING TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(06/02/2012) 10-09-M176EN
 2 SPECIFIC ENGINE TOOLING

FAN BELT FITTING TOOL

Tool for facilitating elastic belt installation (Ref. 894113).
10

10-09-M176EN (06/02/2012)