ENGINE REMOVAL FROM

DBM 2000 XS, DBM 2000 EV

and DBM 2500 EV
TRUCK MIXER

DBM-SMMO.01 VALID FROM SAV 741511

 INDEX

INTRODUCTION ......................................................................................................................... 1
NECESSARY TOOLS AND REPAIR TIMES............................................................................... 2
ENGINE REMOVAL FROM THE MACHINE ............................................................................... 3
 1 - INTRODUCTION

INDEX

SAFETY AND GENERAL INSTRUCTIONS...................................................................... 2

CONVERSION FACTORS ........................................................................................ 3

METRIC HARDWARE TORQUE SPECIFICATIONS ............................................................ 4

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS.............................................. 5

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 1 - INTRODUCTION

This manual provides the information necessary for a correct and safe way to carry out maintenance works
not included in the "INSTRUCTION HANDBOOK FOR OPERATING AND MAINTENANCE"; it is addressed to
qualified fitters, who know enough about mechanical components and the functioning of hydraulic and
electrical systems for the machine on which it is operating. The action necessary to implement and
enforce the policies related to the Environment and Health and Safety procedures are left to the
responsability of the workshop manager.

SAFETY AND GENERAL INSTRUCTIONS

CAUTION !!!
This machine is designed and manufactured according to Merlo S.p.A. specifications. To avoid accidents
and to ensure optimum performance, the machine must not be modified or altered unless approved by
Merlo, nor should it be used in conditions or for purposes which it is not designed for. All information,
illustrations and specifications in this manual are based on the latest product information available at
the time of publication. The right is reserved to make changes at any time without notice.

CAUTION !!!
Always ensure any work carried out on the vehicle is carried out on level ground. If this is not possible
the ground should be as level as possible and the vehicle should be chocked to prevent any possibility of
the vehicle rolling.

CAUTION !!!
Servicing of the machine shall only be carried out by skilled and competent personnel. For repair of parts
that are not part of the normal scheduling, refer MERLO S.p.A. technical service.

CAUTION !!!
Always wear suitable protective clothing and safety equipment when using lubricants (gloves, masks,
goggles, overalls, etc.). Extra care should be taken to avoid burns when working with hot fluids or
elements.

CAUTION !!!
Always dispose of oils, filters or other mediums in an environmentally friendly manner. Use official
organisations for the disposal of such fluids.

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 1 - INTRODUCTION

CONVERSION FACTORS

Units of Pressure Atm bar Pa Psi Nmm²

1 Atm 1 1 105 14,4 0,1
1 bar 1 1 10 5
14,4 0,1
1 Pa 0,00001 0,00001 1 0,000144 0,000001
1 Psi 0,069444 0,069444 6944,4 1 14,4
6
1 Nmm² 10 10 10 144 1

Units of Weight N daN kN Kg lbs

1N 1 0,1 0,001 0,102 0,225
1 daN 10 1 0,01 1,02 2,25
1 kN 1000 100 1 102 225
1 Kg 9,81 0,981 0,00981 1 2,205
1 lbs 4,448 0,448 0,00448 0,4536 1

Units of Torque Nm daNm kNm kgm lb-in

1 Nm 1 0,1 0,001 0,102 8,854
1 daNm 10 1 0,01 1,02 88,54
1 kNm 1000 100 1 102 8854
1 kgm 9,81 0,981 0,00981 1 86,8
1 lb-in 0,1129 0,01129 0,0001129 0,01152 1

Units of Length m cm yds inch ft

1m 1 100 1,094 39,37 3,280
1 cm 0,01 1 0,01094 0,3937 0,03280
1 yd 0,9144 91,44 1 36 3
1 inch 0,0254 2,54 0,0277 1 0,0833
1 ft 0,3048 30,48 0,333 12 1

Units of Power CV Hp Kw Watts

1 Cv 1 0,9863 0,7355 735,5
1 Hp 1,0139 1 0,7457 745,7
1 Kw 1,359 1,341 1 1000
1 Watt 0,00136 0,00134 0,001 1

Ohm's Law
I = Current intensity I=V/R
V = Electromotive force R=V/I
R = Resistance V=I*R

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 1 - INTRODUCTION

METRIC HARDWARE TORQUE SPECIFICATIONS

Tightening torque Ma of a given bolt or nut is the necessary torque to put the bolt under a given preloading.
Tightening torque valve should be used to adjust dynemometric wrenches to avoid fatigue failures.
The following table contains tightening torque specifications relative to external diameter of metric thread.
Figure are approximate.

Unit = Nm

TYPE OF BOLT

SIZE OF BOLT 8.8 10.9 12.9

Standards - Standards - Standards - Standards - Standards - Standards -
Loctite 242 Loctite 270 Loctite 242 Loctite 270 Loctite 242 Loctite 270
M6 x 1 9,5 – 10,5 10,5 – 11,5 14,3 – 15,7 15,2 – 16,8 16,2 – 17,8 18,1 – 20,0
M8 x 1,25 23,8 – 26,2 25,6 – 28,4 34,2 – 37,8 36,7 – 40,5 39,0 – 43,0 43,7 – 48,3
M10 x 1,5 48 – 53 52 – 58 68 – 75 73 – 81 80 – 88 88 – 97
M12 x 1,75 82 – 91 90 – 100 116 – 128 126 – 139 139 – 153 152 – 168
M14 x 2 129 – 143 143 – 158 182 – 202 200 – 221 221 - 244 238 – 263

COARSE M16 x 2 200 – 221 219 – 242 283 – 312 309 – 341 337 – 373 371 – 410
PITCH M18 x 2,5 276 – 305 299 – 331 390 – 431 428 – 473 466 – 515 509 – 562
M20 x 2,5 390 – 431 428 – 473 553 – 611 603 – 667 660 – 730 722 – 798
M22 x 2,5 523 – 578 575 – 635 746 – 824 817 – 903 893 – 987 974 – 1076
M24 x 3 675 – 746 732 – 809 950 – 1050 1040 – 1150 1140 – 1260 1240 – 1370
M27 x 3 998 – 1103 1088 – 1202 1411 – 1559 1539 – 1701 1710 – 1890 1838 – 2032
M30 x 3,5 1378 – 1523 1473 – 1628 1914 – 2115 2085 – 2305 2280 – 2520 2494 – 2757

M8 x 1 25,7 – 28,3 27,5 – 30,5 36,2 – 39,8 40,0 – 44,0 42,8 – 47,2 47,5 – 52,5
M10 x 1,25 49,4 – 54,6 55,2 – 61,0 71,5 – 78,5 78,0 – 86,0 86,0 – 94,0 93,0 – 103,0
M12 x 1,25 90 – 100 98 – 109 128 – 142 139 – 154 152 – 168 166 – 184
M12 x 1,5 86 – 95 94 – 104 120 – 132 133 – 147 143 – 158 159 – 175
M14 x 1,5 143 – 158 157 – 173 200 – 222 219 – 242 238 – 263 261 – 289

FINE M16 x 1,5 214 – 236 233 – 257 302 – 334 333 – 368 361 – 399 394 – 436
PITCH M18 x 1,5 312 – 345 342 – 378 442 – 489 485 – 536 527 – 583 580 – 641
M20 x 1,5 437 – 483 475 – 525 613 – 677 674 – 745 736 – 814 808 – 893
M22 x 1,5 581 – 642 637 – 704 822 – 908 903 – 998 998 – 1103 1078 – 1191
M24 x 2 741 – 819 808 – 893 1045 – 1155 1140 – 1260 1235 – 1365 1363 – 1507
M27 x 2 1083 – 1197 1178 – 1302 1520 – 1680 1672 – 1848 1834 – 2027 2000 – 2210
M30 x 2 1511 - 1670 1648 - 1822 2138 – 2363 2332 - 2577 2565 - 2835 2788 - 3082

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 1 - INTRODUCTION

SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS

Locking, sealing and lubricating materials referred to in this manual are the same used in the shop floor.
The table below gives an account of the typical applications of each single material, in order to facilitate
replacement with similar products marketed by different brand names with different trademarks.

DENOMINATION APPLICATION
Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for
Loctite 242 medium-strength locking. Before using it, completely remove any lubricant by using the
specific activator.
The oleo compatible alternative to “242”. Does not require the activation of lubricated
Loctite 243
surfaces.
Anaerobic product for very-high strength locking of screw and nuts. Before using it,
Loctite 270 completely remove any lubricant by using the specific activator. To remove parts, it may
be necessary to heat them at 80°C approx.
Anaerobic product suitable for high-strength locking and sealing of large threaded parts,
Loctite 275 bolts and stud bolts, for pipe sealing and for protecting parts against tampering; suitable
for sealing coupling surfaces with a maximum diametrical clearance of 0,25 mm.
Anaerobic product for the hermetic sealing of flanged units and screw holes
Loctite 510
communicating with fluids. Can seal clearances between flanges up to 0,2 mm.
Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to
M80. Before using it, completely remove any lubricant by using the specific activator. After
Loctite 577
polymerisation, disassembly may result rather difficult, so heating may be necessary for
larger diameters.
Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints. Can glue
Loctite 638
together parts with clearance ranging between 0,1 e 0,25 mm.
Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints. Can
Loctite 648
glue together parts with radial clearance below 0,1 mm.
Lithium-based Applied to bearing, sliding parts and used to lubricate seals or parts during assembly.
grease
Highly adhesive synthetic grease, with silicone compounds added. Applied to adjustment
Silicone-based
screws with hole communicating with oil-type fluids. Used when frequent adjusting is
grease
required.

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 2 - NECESSARY TOOLS AND REPAIR TIMES

INDEX

STANDARD TOOLS.............................................................................................. 2

REPAIR TIMES ................................................................................................... 3

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 2 - NECESSARY TOOLS AND REPAIR TIMES

STANDARD TOOLS

Spanner Hexagon head driver

80 - 41 - 24 - 22
10
19 - 15 - 13 - 10

Click lever Sliding lever

Bush external exagone Bush inner exagone

10 24 - 13 - 10

Torque wrench Extension

L = 100 mm
L = 200 mm

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 2 - NECESSARY TOOLS AND REPAIR TIMES

REPAIR TIMES

OPERATION DESCRIPTION ENVISAGED TIME REQUIRED

ENGINE REMOVAL

Complete extraction of the engine 2 hours and 30 minutes

Complete re-assembly 4 hours

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 3 - ENGINE REMOVAL FROM THE MACHINE

CAUTION!!!
Refer to "SAFETY AND GENERAL INSTRUCTIONS", Chapter "INTRODUCTION".

WARNING !!
Before carrying out any work on the batteries, read carefully the instructions provided in the
"OPERATION AND MAINTENANCE HANDBOOK", chapter "MAINTENANCE", paragraph "ELECTRICAL SYSTEM",
and chapter "EVERY 50 HOURS", paragraph "BATTERIES".

Remove the locking nuts of the bonnet hinges (A)

and the fastening screw of the gas cylinder (B); pull
the hinges out of their seats, then remove the
bonnet (two people are required for this operation).

Disconnect the battery terminals: first the negative

(-), then the positive (+).

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 3 - ENGINE REMOVAL FROM THE MACHINE

NOTE !!! Before removing the pipes, it is advisable to mark the position of each of them, in order
to male reinstallation easier.

1) Remove all the pipes from the drum rotation pump:

(A - B) FEEDING LINE TO THE HYDRAULIC MOTOR FOR DRUM ROTATION
(C) DRAINAGE INTO THE HYDROSTATIC TRANSMISSION OIL TANK
(D) INTAKE FROM THE IN-LINE FILTER
(E) WASHING FROM THE IN-LINE FILTER

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 3 - ENGINE REMOVAL FROM THE MACHINE

2) Remove the solenoid valves controlling the drum rotation direction from the pump.

3) Disconnect the inching control cable.

4) Remove screw (A) from bracket (D), loosen nut (B) and unscrew the two Allen screws (C).

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 3 - ENGINE REMOVAL FROM THE MACHINE

5) Disconnect spring (E) and remove bracket (D).

6) Disconnect the two pipes of the cooling system from the filter support.

7) Cut the clamps and disconnect the connector of the hydraulic oil level indicator.

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 3 - ENGINE REMOVAL FROM THE MACHINE

8) Disconnect the hydraulic oil tank drain pipe

from the filter support.

9) Disconnect both the hydrostatic pump draining pipe and the hydrostatic motor draining pipe from the
filter support.

10) Disconnect the draining pipe to the thermocontact block and the power brake return pipe from the
hydraulic oil tank.

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 3 - ENGINE REMOVAL FROM THE MACHINE

11) Remove the fastening screws of the hydraulic oil tank support.

12) Remove the hydraulic oil tank together with its

support.

13) Disconnect the following pipes from the

hydrostatic pump:

- Draining pipe.

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 3 - ENGINE REMOVAL FROM THE MACHINE

- Feeding and draining lines of the main valve controlling the gearbox and the differential locking
device.

- Two maximum pressure lines.

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 3 - ENGINE REMOVAL FROM THE MACHINE

14) Remove the solenoid valves placed underneath

the hydrostatic pump.

15) Remove the connector of the hydrostatic

transmission oil temperature sensor.

CAUTION !!! Before removing the

hydrostatic pump, support it with a suitable
device that prevents it from falling to the ground
once it is taken out of its seat.

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 3 - ENGINE REMOVAL FROM THE MACHINE

16) Unscrew the fastening bolts that secure the pump support flange to the Diesel engine.

17) Cautiously remove the hydrostatic pump and rest it on a workbench, paying attention not to damage it.

18) Unscrew the clamps and remove the radiator hoses.

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 3 - ENGINE REMOVAL FROM THE MACHINE

19) Remove the fastening clamp and remove the

engine air intake pipe.

20) Remove the muffler manifold from the engine; remove the extension pipe.

21) Disconnect the accelerator cables.

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 3 - ENGINE REMOVAL FROM THE MACHINE

22) Remove the Diesel feed pipes.

23) Remove the engine cooling pipes.

24) Remove the pipes from the service pump.

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 3 - ENGINE REMOVAL FROM THE MACHINE

25) In the battery compartment, disconnect the two pins from the cable issuing from the engine, then remove
the relay plate.

26) In the engine compartment pull out the battery positive cable and the cables connected to the relay
plate, poking them through the hole on the chassis.

27) Disconnect the earth plait.

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 3 - ENGINE REMOVAL FROM THE MACHINE

CAUTION !!! For safety reasons hitch and

support the thermal engine with a suitable
device, to be hitched to the hoisting points on the
engine.

28) Remove the fastening screws that secure the engine mount to the chassis.

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 3 - ENGINE REMOVAL FROM THE MACHINE

29) Remove the diesel engine; hoist it paying

attention not to hit the blades of the radiator
cooling fan and the radiator. Rest the engine on
a suitable support.

ENGINE REINSTALLATION ON THE MACHINE

For reinstallation carry out all the operations described in the previous paragraph in reverse order. Please note
the following:
- While reinstalling the engine on the machine, pay attention not to hit the radiator cooling fan on the
radiator itself.

- Once the reinstallation procedure is complete, check the hydrostatic oil level and fill it up if
necessary, following the instructions provided in the Operator's Manual, Chapter 16.

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