MOTORISATION

10
- MOTORISATION GENERAL
CHARACTERISTICS AND SPECIFICATIONS

- MOTORISATION CIRCUITS BLOCK DIAGRAM

- MOTORISATION COMPONENTS LOCATION

- MOTORISATION CONTROL AND

ADJUSTMENT

- ENGINE REMOVAL

- MOTORISATION TROUBLESHOOTING

- SPECIFIC MOTORISATION TOOLING

- ENGINE CHARACTERISTICS AND

SPECIFICATIONS

- ENGINE CONTROL AND ADJUSTMENT l647605FR

- ENGINE REMOVAL (ENGINE 854F ST4)

- ENGINE REFIT

- SPECIFIC ENGINE TOOLING

 10
ENGINE GENERAL CHARACTERISTICS AND
SPECIFICATIONS

Pages

CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POLLUTION MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POST-TREATMENT BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SCR SYSTEM PURGE TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE SENSOR DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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 ENGINE GENERAL CHARACTERISTICS AND
2 SPECIFICATIONS

CHARACTERISTICS

⇒⇒ 4 cylinders in line
⇒⇒ Firing order from flywheel: 1, 3, 4, 2
10

⇒⇒ Anti-clockwise (viewed from flywheel)

⇒⇒ 3.4 ℓ cubic capacity
⇒⇒ Electronic management
⇒⇒ Direct injection
⇒⇒ Turbo
⇒⇒ Compression ratio: 17:1
⇒⇒ Power 63 to 90 kW (85 to 120 hp)
⇒⇒ Maximum torque: 430 Nm at 1400 rpm
⇒⇒ Engine speeds: - idling: 850 rpm
- nominal laden: 2200 rpm
- max. unladen: 2360 rpm

POLLUTION MANAGEMENT

The Stage 4 pollution standard is complied with by optimising combustion to produce very little soot,
and addition of a NOx pollution control solution by adding DEF (Diesel Exhaust Fluid).
The management of DEF deposits in the exhaust system is performed by a reduction in heat losses from
the exhaust system and optimisation in DEF spraying.
A transparent strategy for the user makes it possible to convert the NOx and monitor the hydrocarbon
accumulation status: rapid heating (during the 20th min of operation) and exhaust heat management
(ETM: Exhaust Temperature Management) during normal operation by using the gas intake valve or
idling increased to 1100 rpm (if necessary) when the machine is stationary.
The engine can also be stopped instead of increased idling for the Stop & Go.
The injection of DEF takes place after reaching a temperature of 250°C at the SCR intake.
The engine will perform a transparent desulphating action to ensure that the post-treatment efficiency
is maintained. Mapping will modify the injection and action the gas intake valve.

Post-treatment diagram:

10-01-M265EN (21/07/2016)
 ENGINE GENERAL CHARACTERISTICS AND
SPECIFICATIONS 3

DEF
Injector

DOC + Mixer SCR

10
NOx Sensor Temperature Sensor NH3 Sensor

The SCR converts and reduces nitrogen oxide (NOx) by a reaction with the DEF (NH3).

Nox Sensor (SCR Out)

SCR outlet details: Temperature

Sensor

NH3 Ammonia
Sensor M18 Port

POST-TREATMENT BLOCK DIAGRAM

DEF TANK SENSORS

LEVELTEMPERATURE
DEF FLUID & QUALITY SENSOR

AUX RELAY SCR MAIN

ENGINE ECM
HEATER CONTROL UNIT Engine Coolant
RELAY Diverter Valve
TO ENGINE
COOLING
SYSTEM

DEF SUPPLY MODULE

HEATED DEF TO ENGINE
LINES COOLING
SYSTEM
INLET

OUTLET

NH3 SENSOR
MODULE
BACK FLOW

NOx SENSOR 1
UPSTREAM

NOx SENSOR 2
DOWNSTREAM

DEF
DOSING UNIT

Tailpipe outlet temperature

sensor

GAS FLOW DOC SCR AMOX

DOC INLET
TEMPERATURE SENSOR SCR inlet temperature
sensor

SCR SYSTEM PURGE TIME

SCR system shutdown begins when the machine’s ignition is switched off and lasts for about 30 seconds
(e set point on the battery cut-off ).

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 ENGINE GENERAL CHARACTERISTICS AND
4 SPECIFICATIONS

ENGINE SENSOR DIAGRAM

Machine
ENGINE Harness Engine ECM

EIC 1
10

A
Fuel Injectors

EIC 2
Glow Plugs

K
Glow Plug
Controller
Main ECM Power Relay

GCU

Oil Pressure Switch

Intake manifold
pressure /
temperature
sensor

Fuse Box
Coolant Temperature Sensor

Fuel Metering Unit Fuel

Temperature
Sensor

NRS Actuator
Fuel Rail
Pressure
Sensor

NRS Position Sensor

Boost Electric Valve

Camshaft
Speed
Sensor

Crankshaft
Throttle Valve Speed
Actuator Sensor

Exhaust
Throttle Position Manifold
Sensor Temperature
Exhaust Gas Abs
Pressure Sensor Sensor

10-01-M265EN (21/07/2016)
 10
MOTORISATION CIRCUITS BLOCK DIAGRAM

Pages

ENGINE BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(06/07/2016) 10-02-M265EN
 MOTORISATION CIRCUITS BLOCK
2 DIAGRAM

ENGINE BLOCK DIAGRAM

10

Injection cycle

Intake
butterfly

Engine ECU

EGR Valve

EGR cooler

Air radiator

DOC+SCR/
AOC
Key Air outlet Turbo compressor

Cooled air circuit

Air intake
Intake air circuit

Exhaust gas circuit

Interaction between components

10-02-M265EN (06/07/2016)
 10
ENGINE COMPONENTS LOCATION

Pages

ENGINE SURROUNDINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DEF (DIESEL EXHAUST FLUID) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DEF ENVIRONMENT CAB SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WATER + AIR COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
DIESEL FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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 2 ENGINE COMPONENTS LOCATION

ENGINE SURROUNDINGS
Air filter

DEF Diesel oxidation

10

Selective Catalytic injector catalyst (DOC) + mixer

reduction (SCR)

Ammonia oxidation
catalyst (AOC)

Diesel filters

DEF (Diesel Exhaust Fluid) SYSTEM

Key:
1 - Exhaust outlet 8 - DEF reservoir
2 - DOC 9 - DEF gauge
3 - DEF injector 10 - DEF tank heater water circuit
4 - Mixer 11 - Heating valve
5 - SCR 12 - DEF injector cooler water circuit
6 - DEF hose 13 - DEF heating control unit
7 - DEF management module
5

Rear view:

2
7 13

12

10

10-03-M265EN (28/11/2016)
 ENGINE COMPONENTS LOCATION 3

10
5 8

9
4

3
2
10
1
12
11

13 7

Front machine

10
7
13
11

4
2
12
1

Front machine

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 4 ENGINE COMPONENTS LOCATION

DEF ENVIRONMENT CAB SIDE

10

DEF tank

DEF gauge

DEF heating Water circuit valve

control unit

DEF
management
module

DEF cooling/heating
circuit

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 ENGINE COMPONENTS LOCATION 5

ENGINE ELEMENTS

10
H

A F

B
E

C
D

Key:

A - Alternator F - Injection pump

B - Water pump G - Oil filter
C - Crankcase breather H - Turbocompressor
D - Fuel filter I - EGR cooler
E - Starter J - EGR valve

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 6 ENGINE COMPONENTS LOCATION

WATER + AIR COOLING CIRCUIT

D
10

C E

Key:

A - Engine
B - Turbocompressor
C - Expansion tank
D - Cooler
E - Intercooler

: Water circuit
A
: Air circuit

DIESEL FUEL CIRCUIT

To the fuel
filter

Totheinjection
pump Key:

Hot diesel
Cooled diesel

A - Engine
B - Fuel tank
A C - Cooler

10-03-M265EN (28/11/2016)
 10
ENGINE CONTROL AND ADJUSTMENT

Pages

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

–– ENGINE MECHANICAL TRANSMISSION SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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 2 ENGINE CONTROL AND ADJUSTMENT

ENGINE TIGHTENING TORQUES

ENGINE MECHANICAL TRANSMISSION SUSPENSION

10

32 ± 3.2 N.m
95 ± 9 N.m

10-04-M265EN (07/07/2016)
 10
ENGINE REMOVAL

Pages

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

STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ATTACHMENT BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR-CONDITIONING COMPRESSOR REMOVAL (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXHAUST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TURBOCOMPRESSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
–– REMOVE THE EXPANSION TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
–– HOSE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– DISCONNECT THE EXHAUST AND THE FUEL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
–– DISCONNECT, STARTER AND THE SEDIMENTATION TANK . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– REMOVE THE OIL FILTER TUBES AND HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
–– FIT THE LIFTING RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– UNCOUPLE THE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
–– STANDARD ENGINE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
–– REMOVE THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DEF (DIESEL EXHAUST FLUID) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
–– DEF MANAGEMENT MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
–– DEF TANK AND SENSOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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 2 ENGINE REMOVAL

PREPARATION AND SAFETY INSTRUCTIONS

Stabilize the machine on level ground.

Maneuver the machine a number of times in forward and reverse (wheels straight) in order to release
10

any stresses acting on the steering and tires.

Raise the boom to mid-height and install the safety wedge.

To remove the engine, turn the front and rear wheels to the right:

bb
Deactivate battery power supply by means of the battery cut-off.
Operate the battery cut-off no less than 30 seconds after turning off the ignition with the
ignition key.

Remove the covering plate in the boom foot boom well.

Disconnect the negative cable (Item 1) of the battery.

Open the engine bonnets.

1

Remove the hook cable (Item 1) and remove the lower bonnet.

Specific tooling:

- Pallet truck
- Jib crane (minimum 1000 kg)

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 ENGINE REMOVAL 3

STARTER REMOVAL

1
From the engine side.

10
2 Remove the ground cable (Item 1).

3 Remove the power supply cap and then release the cable (Item 2).

Remove the excitation cable cap (Item 3), then release the cable.

From the top of the engine.

Remove the three (Item 4) fixing screws for the starter (Item 5).

Remove the starter.

4

4
For the refit, perform the removal operations in the opposite
4
5 order.

ATTACHMENT BELT REMOVAL

1
Remove the 4 screws (Item 1) and remove the alternator casing
(Item 2).
2

Remove the 2 screws (Item 3) to remove the casing support

3 3
tab (Item 4).

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 4 ENGINE REMOVAL

Release and unscrew the belt tension adjusting screw (Item 5).

5 Undo the screw (Item 6) holding the alternator (Item 7).

10

12 Swivel the alternator (Item 8) and remove the belt (Item 9).
13 11

For the refit, perform the removal operations in the opposite

8 10
order.

Tension the belt, by bringing the adjustment lug (Item 10) into
9
contact with the fastening screw (Item 11).

Undo the adjustment screws (Item 12) by two turns and block
the lock nut (Item 13).

ALTERNATOR REMOVAL

3 The following operations must be performed:

2
⇒⇒ ATTACHMENT BELT REMOVAL
3

Disconnect X179 (Item 1).

1 Remove the holding screw (Item 2).

Remove the bolt (Item 3).

Remove the alternator (Item 4), unscrew the nut (Item 5) of the
6 ground cable (Item 6).

Remove the alternator.

4
For the refit, perform the removal operations in the opposite
order.

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 ENGINE REMOVAL 5

WATER PUMP REMOVAL

3

The following operations must be performed:

⇒⇒ ATTACHMENT BELT REMOVAL

10
2 4 2 Place a drain pan (Item 1)

1 Undo the screws (Item 2) on the protective casing (Item 3) under

the engine housing (Item 4).

Unscrew the two screws (Item 5) holding the pump (Item 6).
5

Remove the pump.

6

To refit check that there is no dirt on the contact surface (Item 7).

Then perform the removal operations in reverse order, while

adhering to the tightening torques expected for the MR engine.
7

AIR-CONDITIONING COMPRESSOR REMOVAL

(OPTION)
1

Remove the 4 screws (Item 1) and remove the alternator casing

2
(Item 2).

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 6 ENGINE REMOVAL

AIR-CONDITIONING COMPRESSOR REMOVAL (OPTION)

Loosen the adjustment screw (Item 3).

Tilt the compressor (Item 4) and remove the belt (Item 5).
10

3
9

5
4

7 AIR-CONDITIONING COMPRESSOR REMOVAL (OPTION)

6 X30
bb Only operators with skill certificates for handling
refrigerants may carry out work on the air-conditioning.
Otherwise please contact a specialist air-conditioning
company.

bb Draining of the air-conditioning circuit should take place

in a ventilated room and personal protective equipment
should be worn: full safety spectacles and rubber gloves.
8
Disconnect the connector (X30).

Unscrew the collar (Item 6) and remove the water hose (Item 7).
10

4 10
Drain the air-conditioning circuit and remove the high and low
pressure connectors (Item 8).

Remove the nut (Item 9).

Remove the compressor (Item 4).

Take off the two support tabs (Item 10) and retain them.

For the refit, perform the removal operations in the opposite

order.

bb For refilling the refrigerant e 110 – OPTIONS -

ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS

10-06-M265EN (28/11/2016)
 ENGINE REMOVAL 7

EXHAUST REMOVAL
1 2

1 DOC (Diesel Oxidation Catalyst) + Mixer REMOVAL

10
Remove the 3 collars (Item 1) from the DOC + mixer (Item 2).

Remove the collar (Item 3) and take off the DOC hose (Item 4)
pulling towards the SCR.
3

Remove the three front screws (Item 5) and the three rear screws
(Item 6) from the DOC + mixer support.

Remove the DOC + mixer (Item 2).

5 5

5 6 6
6

2 SCR (Selective catalytic reduction)/AOC (Ammonia Oxidation

Catalyst) REMOVAL
1

Remove the three screws (Item 1) and remove the casing (Item 2).
1

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 8 ENGINE REMOVAL

Disconnect connectors (X18) and (X321).

10

Disconnect the sensor (Item 3).

X18
X321

Unscrew the collar (Item 4) and remove the SCR/AOC assembly

(Item 5).

For the refit, follow the removal operations in the opposite order, adhering to the tightening torques
for the collars and the SCR/AOC assembly angle.

12N.m ± 1Nm

25N.m ± 2Nm
12N.m ± 1Nm 5°
°±
90

35N.m ± 2Nm

12N.m ± 1Nm
12N.m ± 1Nm

25N.m ± 2Nm Turbo

35N.m ± 2Nm

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 ENGINE REMOVAL 9

ENGINE HOUSING REMOVAL

2

Unclip the cylinder foot (Item 1) holding the engine bonnet

and open it completely with the engine bonnet (Item 2) resting

10
on the boom.

3 3
Undo the four screws (Item 3) of the mudguard plate (Item 4)
and remove it.
8

4 Remove the 2 screws (Item 5) from the cooler support (Item 6).

8 6

5 5

7
Support the engine housing with a pallet truck (Item 6) or sling
7
with two anchorage points (Item .7).
11 10
8
Unscrew the 2 rear screws, the 3 front screws (Item 8) and the
8 exhaust holder screw (Item 9).
6
Remove the engine housing.

Undo the holding screws (Item 10) and recover the engine
9
slinging rings (Item 11).

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 10 ENGINE REMOVAL

TURBOCOMPRESSOR REMOVAL

For removing the turbocompressor (Rep.1),

10

l 647605FR.

When refitting l 647605FR “Turbocompressor refit”.

bb IMPORTANT: It is essential to lubricate the bearings of

the turbo when assembling as shown (Item 2)

3
bb Check and clean the intake hose (Item 3) and exhaust
pipe before refitting them.

PERFORM THE START-UP PROCEDURE THAT ENSURES THE

CIRCUIT IS SUPPLIED WITH LUBRICATION BEFORE STARTING
THE ENGINE

• Open the fuse box cover (Item 4) in the engine housing.

• Remove fuse F56 (Item 5).
• Engage the starter for 15 seconds.
• Wait for 30 seconds.
4 • Re-engage the starter for 15 seconds.
• Replace fuse F56.
• Start the engine and leave it running for 2 minutes unloaded
(no hydraulics or transmission).

Note: The two minutes must be observed for the first start-up
after draining. The time delay period is subsequently shown
by the display of a pictogram on the dashboard screen
5
. Its duration is variable and is determined
according to the engine temperature.

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 ENGINE REMOVAL 11

ENGINE REMOVAL

The following operations must be performed:

10
⇒⇒ AIR-CONDITIONING COMPRESSOR REMOVAL (OPTION)
⇒⇒ ENGINE HOUSING REMOVAL

Remove the expansion tank.

Place a container under the radiator.

Unscrew the drain plug (Item 1) under the radiator (it remains
attached).
1
Open the expansion tank.

Unscrew the 3 screws against the side rail (Item 1).

Disconnect the liquid level connector (X258).

X258

1 1

Disconnect the hose (Item 2) and release the expansion tank

assembly on the radiator.

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 12 ENGINE REMOVAL

Hose removal
3 1

5 Unscrew the 2 collars at the ends of the turbo air intake hose
4
(Item 1) and the collar on the breather hose (Item 2). Remove the
retaining collar (Item 3), disconnect the air intake temperature
10

sensor (Item 4) and remove the air intake hose assembly (Item 1).
2 Remove the engine air intake hose (Item 5) by unscrewing the
2 collars at the ends.

Unscrew the 2 collars at the ends of the turbo air outlet tube
1
2 (Item 1) and the 2 tube tabs (Item 2) and remove it.
4
3

Remove the engine water outlet hose (Item 3) by unscrewing

5 the 2 collars at the ends and the retaining collar (Item 4).

Remove the drive belt cover (Item 5).

2

Remove the engine water inlet hose (Item 1) by unscrewing

the collar (Item 2). Remove the retaining collar (Item 3) of the
tab (Item 4).

3 2

5
Unscrew the collar (Item 5); remove the retaining collar (Item 6).

7
Unscrew the clamp of the cab hot water return hose (Item 7).

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 ENGINE REMOVAL 13

Disconnect the cab heating water outtake hose (Item 1) of the

engine crankcase.
1

10
Remove the retaining collar (Item 2) on the suspension jib.

Disconnect the exhaust and the fuel hoses

1
Unscrew the collars (Item 1) and remove the exhaust pipe
towards the DOC (Item 2).
2

Disconnect the supply hose (Item 1) and the injection return

hose (Item 2) behind.

1
2

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 14 ENGINE REMOVAL

Disconnect, starter and the sedimentation tank

From the engine side on the starter.

1

Remove the earth cable (Item 1).

10

Remove the power supply cap and then release the cable (Item 2).
3

Remove the excitation cable cap (Item 3), then release the cable.

X7 Disconnect the engine harnesses (X324), (X7) and (X8).

X324

X8

Disconnect the connector from the sedimentation tank (X61).

X61

1
Remove the oil filter tubes and harnesses
3
1 Unscrew the nuts (Item 1) from the oil filter hydraulic tubes;
remove the oil filter support (Item 2).
3
Unclip the exhaust and alternator harnesses (Item 3), and place
4
them on the radiators.
2
Remove the clip support lugs (Item 4).

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 ENGINE REMOVAL 15

2
Fit the lifting rings

Fit the 3 lifting rings, use the 2 screws on the engine (Item 1)
to attach the ring (Item 2), (e § ENGINE HOUSING REMOVAL
to attach the rings on the engine housing).

10
1 1

Take the screws of the exhaust and alternator harness support

3
brackets to attach the rings (Item 3), place them so as to be able
to insert the lifting hooks through them.

Support the engine with the help of a jib crane.

Sling the engine at the 3 anchorage points

Support the engine with the help of a jib crane.

4 4
Uncouple the gearbox
3 3

2
Support the gearbox, unscrew the 13 screws:
2
2
⇒⇒ Item 1: 50 mm long
5
5 ⇒⇒ Item 2: 60 mm long
2
⇒⇒ Item 3: 70 mm long with nut
2 2 ⇒⇒ Item 4: 40 mm long
2 2
1
2 centering pins (Item 5).

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 16 ENGINE REMOVAL

1 Remove the engine

Unscrew the 4 suspension jib gearbox screws (Item 1).

Unscrew the 2 screws from the silent blocks (Item 2).
Unscrew the 4 suspension arm screws on the engine (Item 3).
10

2 Remove the side rails; gently pull the engine to disconnect it

1
from the gear box.
3
For refitting perform the operations for removal in reverse order
adhering to the tightening torques e 10 - MOTORISATION
2 CONTROL AND ADJUSTMENT and e 20 - TRANSMISSION
3
CONTROL AND ADJUSTMENT.

Standard engine change

When replacing the engine:

1 - Remove the engine control unit in front of the cooler and attach it to the removed engine
2 - Retain the following items from the removed engine, together with their screws:

⇒⇒ T he harness fastening lug under the alternator, the ground lugs, the two exhaust and alternator
harness support lugs
⇒⇒ The 2 connecting oil tubes, the tube support;
⇒⇒ The oil hose clamp bracket, the 2 heating circuit connectors;
⇒⇒ The bell housing and the coupling flange, recover the centering pins;
⇒⇒ The drive belt cover, the 2 supports.
⇒⇒ The hose support bracket.

90°

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 ENGINE REMOVAL 17

COOLER REMOVAL

The following operations must be performed:

12

10
⇒⇒ ENGINE HOUSING REMOVAL
13

Drain the coolant (Item 12) through the bleed screw (Item 13)
under the cooler.

Remove the engine water outlet hose (Item 14). Unscrew the
collar (Item 15).

17 Remove the engine air outlet hose (Item 16). Unscrew the collar
15
14
(Item 17).
16 18
Remove the transmission oil inlet hose (Item 18).

Loosen the collar (Item 19).

20

Loosen the collar (Item 20).

Remove the air intake hose (Item 21).

19
21

Unscrew the air outlet hose (Item 22). Unscrew the two retaining
22 rings (Item 23).

23
23

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 18 ENGINE REMOVAL

Remove the hose (Item 24), undo the retaining ring (Item 25)
using a flathead screwdriver.
29
27
Unscrew the screw (Item 27), 13 mm spanner of the preheating
control box (Item 26).
10

28

26
Remove the harness (Item 28) from its housing (Item 29).

24 25

Remove the transmission oil inlet hose (Item 30).

30

Remove the transmission oil outlet hose (Item 31).

33 31
Remove the hydraulic oil outlet hose (Item 32).
32

Remove the two flexible hoses (Item 31 and 32), and hold them
34
in the air to avoid draining the gear box and the oil tank.

Remove the hose (Item 33). Unscrew the collar (Item 34).

Remove the fan engine oil outlet hose (Item 35).

35

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 ENGINE REMOVAL 19

Remove the fan engine (Item 37) oil inlet hose (Item 36).

10
36

37

Remove the bulkhead adapter (Item 38).

Remove the diesel fuel hoses (Item 39) and pass them to the
39 other side of the radiator to attach them.
38

39 Note: Mark one of the two hoses to avoid mistaking them during
reassembly.

Remove the diesel filter support (Item 40); remove the two
fastening screws (Item 41).

43 Remove the fuse box support (Item 42); remove the two screws
43
(Item 43).
42

40

41

41

Attach the radiator (Item 44) with a strap (Item 45) suspended
46
45 from a stand (Item 46).

44

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 20 ENGINE REMOVAL

Remove the fixing screw (Item 47) between the top of the
radiator and the frame.

Pay attention to the chocks (Item 48) and rubber seals.

10

47

48

Remove the fixing screw (Item 49) between the bottom of the
radiator and the frame.

Pay attention to the chocks (Item 50) and rubber seals.

50
49

Remove the radiator (Item 51) by backing out the crane.

For the refit, follow the removal operations in reverse order,

51 adhering to the tightening torques, and fill up.

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 ENGINE REMOVAL 21

DEF (Diesel Exhaust Fluid) SYSTEM

DEF management module removal

10
Unscrew the rear cab casing (Item 1) and remove it.

Disconnect the 3 supply and return hoses (Item 2) for the DEF
management module.
Disconnect the 4 connectors (X315, X316, X317, X322) (Item 3)
Loosen the 3 screws (Item 4) and remove the DEF management
3
3
module.

2
4
For the refit, perform the removal operations in the opposite
2
order.
3
2
3
3

DEF tank and sensor removal.

bb Diesel exhaust fluid is corrosive. Protect the bodywork,

steering cylinder and the axle.

3
bb Wear personal protective equipment (gloves and safety
glasses).
2
Place a drain pan under the DEF tank.
Unscrew the drain plug (Item 1) and open the filler cap (Item 2).

Unscrew the 3 screws of the DEF cover (Item 3) and remove it.

Disconnect the hoses (Item 4) and connector X314 (Item 5).

1 Unscrew the 2 screws of the DEF sensor (Item 6) and remove it.

Unscrew the 2 screws of the DEF tank (Item 7) and remove it.

For the refit, perform the removal operations in reverse order

4
6 and fill up.
4

4
5 7

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 22 ENGINE REMOVAL
10

10-06-M265EN (28/11/2016)
 10
MOTORISATION TROUBLESHOOTING

Pages

STRATEGY AND INDUCEMENT BEHAVIOR FOR BRINGING UP TO STANDARD . . . . . . . . . 2

GENERAL INFORMATION ABOUT INDUCEMENT CORRECTIONS . . . . . . . . . . . . . . . . . . . . . .2
ERROR INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IGNITION SWITCH ENGAGING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
START-UP CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
LACK OF POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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 2 MOTORISATION TROUBLESHOOTING

Strategy and inducement behavior for bringing up to standard

Inducement corrections for DEF (Diesel Exhaust Fluid) levels:

–– When the DEF volume reaches 5% the engine will slow progressively for 40 minutes up to 35% torque
10

and 60% speed.

–– When the DEF volume reaches 0% the engine will slow progressively for 30 minutes up to 0% torque
and idling.
–– When the first poor quality DEF is detected a warning is issued by display of an indicator lamp.
–– When the poor quality DEF continues to be detected for 50 min, the engine will slow progressively
for 40 minutes up to 35% torque and 40% speed.
–– When the poor quality DEF continues to be detected for 120 min, the engine will slow progressively
for 30 minutes up to 0% torque and idling.
It may be necessary to restart the machine after it has been stopped for 2 min and the DEF tank has
been refilled.
The ECU may require 10 min to ensure correct readings from the sensor.

Inducement corrections of the electrical system:

–– When an initial fault is detected the engine will slow progressively for 25 minutes up to 75% of torque
(slight inducement).
–– When the fault continues to be detected for 120 min, the engine will slow progressively for 40 minutes
up to 35% torque and 40% speed (severe inducement).
–– When the fault continues to be detected for 90 min, the engine blocks in idle progressively for
30 minutes up to 50% torque and idling (strong inducement).
–– After correcting the active error code, the machine should return to normal status.
–– When the fault returns within a period of 40 hours the engine will adopt strong inducement.
After correcting the electrical problem the machine should operate with the engine at high revs and
under heavy load to ensure that the system is fully operational after treatment.

Inducement corrections of the EGR (Exhaust Gas Recirculation) system:

–– When an initial fault is detected the engine will slow progressively for 30 minutes up to 75% torque.
–– When the fault continues to be detected for 240 min, the engine will slow progressively for 30 minutes
up to 50% torque and 50% speed.
After correcting the electrical problem the machine should operate with the engine at high revs and
under heavy load to ensure that the system is fully operational after treatment.

Inducement corrections of the SCR (Selective Catalytic Reduction) system:

–– When an initial fault is detected the engine will slow progressively for 25 minutes up to 75% torque.
–– When the fault continues to be detected for 90 min, the engine will slow progressively for 40 minutes
up to 35% torque and 60% speed.
–– When the fault continues to be detected for the next 90 min, the engine will slow progressively for
30 minutes up to 0% of torque and idling.

General information about inducement corrections

bb Inducement corrections are a protection to ensure the engine functions correctly within the
legal pollution control limits.

Only the SCR system inducement corrections require reinitialisation to ensure a sufficient emission
protection level.
Full power and full speed are required to ensure that the SCR system is fully operational.
10-08-M265EN (07/07/2016)
 MOTORISATION TROUBLESHOOTING 3

Error indicator lamp

The error indicator lamp is installed at the driver's position. The fault light can issue the following signals:
Operating control

10
– Ignition working, fault indicator lamp comes on for approx. 2 seconds then goes off.
– No reaction when ignition switched on, check the fault indicator lamp.
The indicator lamp does not come on
– After testing the indicator lamps, an indicator lamp that is not lit indicates no faults and no anomalies
within the limits of the test.
Indicator lamp permanently lit
System error.
– Limited operation.
– When the indicator lamp is permanently lit, a monitored reading (e.g. coolant temperature, lubricating
oil pressure) is no longer within the acceptable range.
According to the type of error, the engine power may be reduced by the electronic controller to protect
the engine.

IGNITION SWITCH ENGAGING TEST

Preheat lamp, engine fault lamp and the special "engine stop" lamp come on.

START-UP CONDITIONS

If the engine fails to start, this could be due to:

–– The ECU power supply.
–– Missing or incorrect engine speed sensor response. The engine injection starts as soon as sensor
synchronisation is confirmed, otherwise it has difficulty starting with only one sensor;
–– Insufficient fuel rail pressure at start-up;
–– The fuel supply pressure with the engine running is less than 4 b.

LACK OF POWER

If the engine lacks power, check:

–– The error codes;
–– That the fuel supply system is not obstructed or leaking;
–– That the circuits are not overheating.

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 4 MOTORISATION TROUBLESHOOTING

ENGINE ERROR CODES

10

o 80 - ELECTRICAL TROUBLESHOOTING

10-08-M265EN (07/07/2016)
 10
SPECIFIC MOTORISATION TOOLING

Pages

ELECTRONIC TENSION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ADDITIONAL ENGINE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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 2 SPECIFIC MOTORISATION TOOLING

ELECTRONIC TENSION METER

Electronic tension meter (Ref 895692) for controlling belt tension.
10

ADDITIONAL ENGINE TOOLS

l 647605 (ENGINE ST4) - SPECIAL TOOLS

10-09-M265EN (22/06/2016)