LM1340 LM1440 LM1740
TELEHANDLERS
ServiceManual
PrintN.603.67.010.02(I--2004)
THISALERTSYMBOLSIGNALSIMPORTANTMESSAGESINVOLVINGYOURSAFETY.
Readandheedcarefullythesafetyinstructionslistedandfollowtheprecautionsrecommendedtoavoid potentialrisksandtosafeguardyourhealthandyoursafety.
YouwillfindthissymbolinthetextofthisManualreferredtothefollowingkeywords:
WARNING --Cautionsdirectedtoavoidimproperrepairinterventionsinvolvingpotentialconsequencesfor theoperator’ssafety.
DANGER --Thesewarningsqualifyspecificallypotentialdangersforthesafetyoftheoperatororother personsdirectlyorindirectlyinvolved.
IMPORTANTNOTICE
AllmaintenanceandrepairinterventionsexplainedinthisManual mustbeperformedexclusivelybytheService OrganizationoftheManufacturer,observingstrictlytheinstructions explainedusing,whenevernecessary,the recommendedspecifictools.
Whoeverperformstheoperationsreportedwithoutfollowingexactlytheprecautionsisresponsibleonhisown,for thedamagesthatmayresult.
NeithertheFactorynoranyOrganizationsinitsDistribut ionNetwork,includingbutnotlimitedtonational,regional orlocaldistributors,areresponsibleforanyliabilityarisingfromanydamageresultingfromdefectscausedbyparts and/orcomponentsnotapprovedbytheFactoryforuseinmaintainingand/orrepairingproductsmanufacturedor merchandizedbytheFactory.
Inanycase,nowarrantyofanykindismadeorshallbeimposedwithrespecttoproductsmanufacturedor merchandizedbytheFactory,whenfailuresarecaused bytheuseofpartsand/orcomponentsnotapprovedbythe Factory.
AVOIDACCIDENTS
Mostaccidentsandinjuriesoccurringinindustry,onthefarm,athomeorontheroad,arecausedbythefailureof someindividualtofollowsimpleandfundamentalsafetyrulesorprecautions.Forthisreason,MOST ACCIDENTSCANBEPREVENTEDbyrecognizingtherealcauseandtakingthenecessaryprecautions,before theaccidentoccurs.
Regardlessofthecareusedindesignandconstructionofanytypeofequipment,theremaybeconditionsthat cannotbecompletelysafeguardedagainstwithoutinterferingwithreasonableaccessibilityandefficient operation.
Acarefuloperatoristhebestinsuranceagainstaccidents. Thecompleteobservanceofonesimplerulewould preventmanythousandsseriousinjurieseachyear.
Thisruleis:Neverattempttoclean,lubricateoradjustamachinewhileitisinmotion.
WARNING
Onmachineshavinghydraulically,mechanicallyand/orcablecontrolledequipment(suchasshowels, loaders,dozers,scrapersetc.)becertaintheequipmentisloweredtothegroundbeforeservicing, adjustingand/orrepairing.
Ifitisnecessarytohavetheequipmentpartiallyorfullyraisedtogainaccesstocertainitems,besure theequipmentissuitablysupportedbymeansotherthanthehydraulicliftcylinders,cableand/or mechanicaldeviceusedforcontrollingtheequipment.
MODELCODES
Thecompleterangeoftelescopichandlers(Telehandler)describedinthismanualisidentifiedinthetextby referencetothemaximumextensionofthetelescopicarm.
Thevehicleslistedbelowmaynotbeavailableinallcountriesormarkets,thereforeforthelatestinformation consultyourauthoriseddealer.
Model LM1340 LM1440 LM1740 notstab. small stab. large stab. notstab. small stab. large stab. notstab. stab. Engine 88kW(120Cv) TurboAftercooler 88kW(120Cv) TurboAftercooler 88kW(120Cv) TurboAftercooler Max.lifting height (m) 12.300 12.450 12.450 13.300 13.550 13.550 16.240 16.600 Max.capacity (kg) at500mmfrom forkstop 4000 4000 4000 4000 4000 4000 4000 4000 Capacityatmax. height (kg) 2600 3600 4000 2800 3000 3600 700 2500 Extensionatmax. height (m) 1.200 0.500 0.000 1.000 0.500 0.300 2.000 1.000 Max.longitudinal extension (m) 8.650 9.330 12.540 Capacityatmax. extension (kg) 700 1700 1800 650 1400 1500 0 450 Weight (kg) 11050 11970 12340 Length (m) 5.850 6.070 6.135
Servicemanual LM1340--LM1440--LM1740 TELESCOPICHANDLERS 603.67.010.02 --01--2004 GENERALLISTOFCONTENTS SECTION00--GENERAL Description Page .............................................................................. Generalinstructions 1 Safetyrules 3 .................................................................................. Productidentification 6 Environmentalconsiderations 9 Maintenancetechniques 10 SECTION10--ENGINE Description Page Codingofenginesoforigin 3 Mainenginespecifications 4 ..................................................................... Generalenginespecifications 5 Generalities 7 ................................................................................. Descriptionofmainmechanicalcomponentsoftheengine13 Lubrication 24 .................................................................................. Cooling 29 Fuelandmechanicalinjection 31 ................................................................. Injectionassembly 33 Removaloftheenginetransmissiongroupfromthevehicle43 ........................................ Engineoverhaulonbench 46 Replacingtheinjectors 98 ....................................................................... Adjustmentofvalveclearance 100 Settingoftiming 101 ............................................................................. Timingoftheinjectionpump 102 Electricalcomponents 103 ....................................................................... Troubleshooting 104 Tooling 108 Data--Mountingplays 112
4 GENERALLISTOFCONTENTS 603.67.010.02 --01--2004 SECTION21--POWERSHIFTGEARBOX Description Page PowershiftGearbox4x4 2 ........................................................................ Drivingwiththepowershiftgearbox2 .............................................................. Gearboxassembly 5 ............................................................................ Idlergearcaseassembly 7 ...................................................................... Gearboxoperation 8 TransmissionandHydraulicoilcircuitdiagrams15 Modulationvalveoperation 31 Torqueconverterandheatexchangerhydraulicoilcircuit34 Troubleshootingprocedures 37 Pressuretestingclutchandhighpressurecircuit38 Pressuretestingtorqueconverterandcoolercircuit39 Checkpoints 40 Assemblyinstructions 42 Overhaul 45 Specialtools 104 SECTION25--FRONTAXLE Description Page Specifications 1 Description 2 Operation 3 Troubleshooting 4 Wheeltoe--incheck 5 Componentoverhaul 5 Frontaxleremovalprocedure 6 Frontaxleoverhaul 7 Axledrivepinionbearingadjustment52 Howtoinstallandadjusttheaxledrivepinion54 Frontdriveshaft 57
GENERALLISTOFCONTENTS 5 603.67.010.02 --01--2004 SECTION27--REARAXLE Description Page Specifications 1 Description 2 Operationdiagram 3 ............................................................................ Componentoverhaul 5 Rearaxleremovalprocedure 5 Overhaul 6 Specialtools 7 SECTION33--BRAKES Description Page Specifications 1 ................................................................................. Powerbrakes 2 Parkingbrake 3 ................................................................................ Brakediscadjustment 6 Troubleshooting 7 Brakesdisassembly 8 ........................................................................... SECTION35--HYDRAULICSYSTEM Description Page Technicaldata 2 ................................................................................ Descriptionandoperation 3 Steeringsystemhydrauliccircuit 3 Steeringvalve 4 Telescopicboomhydrauliccircuit 6 Componentoperation 11 ......................................................................... Frontloadercontrols 15 Powersteering(OSPQ) 19 Telescopicboomdistributor 21 Auxiliarycontroldistributor 24 ..................................................................... Cylinders 25 Arms 35 Workingplatform 43 Procedureforthecalibrationofthepersonnelcarrierplatformelectroniccontroller47 Specialtools 53 .................................................................................
GENERALINSTRUCTIONS
IMPORTANTNOTICE
AllmaintenanceandrepairinterventionslistedinthisManualmustbeperformedexclusivelybytheService NetworkoftheManufacturer,complyingstrictlywiththeindicationshereinandusing,whenrequired,the prescribedspecialtools.
Whoeverperformsserviceoperationsdescribedhereinwithoutcomplyingstrictlywiththeinstructionsbecomes solelyresponsibleforanyconsequentialdamagethatcouldoccur.
ADJUSTINGSHIMS
Foreachadjustmentselecttheadjustingshims,measuringthemonebyonewithamicrometerandaddingto gethersubsequently,thevaluesmeasured.Donotrelyonthemeasurementoftheentirepack,thatcouldbe wrong,orthenominalvalueindicatedoneachring.
SEALSFORROTATINGSHAFTS
Forcorrectinstallationofthesealsforrotatingshafts,pleasecomplywiththefollowingprecautions:
--priortoinstallation,keepthesealssoakingforatleasthalfanhourinthesameoiltheyaregoingtoseal;
--cleanthoroughlytheshaftandmakesurethatitsworkingfaceisundamaged;
--directthesealingliptowardthefluid;intheeventthelipisofthehydrodynamictype,thegroovesmustbe directedsothat,inrelationtotherotatingdirectionoftheshaft,theytendtoreturnthefluidtowardtheinside ofthesealingdevice;
--smearthesealinglipwithafilmoflubricant(oiltobepreferredtogrease)andfillwithgreasethegapbetween sealinglipanddustlipintwinlipseals;
--insertthesealinitsseat,pressingitwithapunchwithaflatface;neverstrikeitwithahammerormallet;
--whenpressingintheseal,makesurethatitisinsertedperpendicularlyinrelationtotheseatand,oncein position,makesurethat,whenrequired,itcontactstheshoulder;
--topreventthesealinglipofthesealbeingdamagedbytheshaft,insertappropriateprotectionduringthe installationofthetwoparts.
“0--RING”TOROIDALSEALS
LubricateO--ringsbeforeinsertingthemintherelevantseatstopreventthembecomingtwistedandrolledduring installation,thusjeopardisingtheirsealingcapacity.
SELAINGCOMPOUNDS
MatingsurfacemarkedXmustbesmearedwithasealingcompoundrecommendedbytheManufactureroran adequateequivalent.
Priortoapplyingthecompound,preparethesurfacesinthefollowingmanner:
--removeallpossiblescalingwithametalbrush;
--degreasethesurfacesthoroughlyusingthedegreesingagentrecommendedbytheManufactureroran adequateequivalent.
BEARINGS
Wheninstallingbearings,itisrecommendedto:
--warmthemupto80° –90 °C(176–194 °F)beforeinstallingthemontherelevantshafts;
--coolthemdownbeforeinsertingthemintherelevantseatswithanouterfitting.
SPLITPINS
Wheninstallingsplitpins,makesurethatthecutispointinginthedirectionoftheloadonthepin. Ontheotherhand,spiralelasticpinsdonotrequireanyinstallationorientation.
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NOTESONSPAREPARTS
Usegenuine sparepartsguaranteedbytheManufacturer only. Genuinesparepartsaretheonlyonesensuringthesamequality,thesamelifeandthesamesafetyasthe originallymountedparts,sincetheyarethesameastheonesinstalledinproduction. Onlygenuinepartsfromthemanufacturerensurethisguarantee.
Ordersforsparepartsmustincludethefollowingindications:
--modelofthevehicle(commercialdesignation)andserialnumber;
--typeandnumberoftheengine;
--partnumberfortheitemordered,asprovidedbythe“Microfiches”orthe“SparePartCatalogue”,onwhich theorderisbased.
NOTESONTOOLING
ThetoolingthattheManufacturerrecommendsandillustratesinthisManualis:
--studiedanddesignedspecificallyforservicingvehiclesofthisrange;
--requiredtoensureareliablerepair;
--accuratelydevelopedandinspectedtoprovideeffectiveandlonglastingworking. Youarealsoremindedthatcorrecttoolingallowsyouto:
--tooperateunderoptimisedtechnicalconditions;
--toachievethebestresults;
--tosavetimeandeffort;
--toworkinsaferconditions.
WARNING
Thewearlimitsprovidedforsomeitemsmustbeconsideredasrecommendedvalues,butnotabsolutelybinding. Theindications“front”,“rear,“right”,“left”refertodifferentpartsasseenseatingfromintheoperator’sseat orientedinthenormaltraveldirectionofthevehicle.
HOWTOMOVEAVEHICLEWITHOUTBATTERIES
Thecablesoftheexternalpowersupplymustbeconnectedexclusivelytotherespectiveterminalsofthepositive andnegativecablesofthevehicle,usingefficientclampsprovidingadequateandsafecontact.Intheeventit isnecessarytochecktheoperationoftheelectricalsystemofthevehicle,doitexclusivelywiththepowersupply connected.Attheendoftheinspection,disconnectallactuatorsanddeactivatethepowersupplybefore disconnectingthecables.
603.67.010.02
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SAFETYRULES
PAYATTENTIONTOTHISSYMBOL
Thisalertsymbolannouncesimportantmessagesinvolvingyoursafety.
Readcarefullythesafetyinstructionslistedandfollowtheprecautionsrecommended toavoidpotentialrisksandtosafeguardyourhealthandyoursafety.
YouwillfindthissymbolinthetextofthisManualwiththefollowingkeywords:
WARNING --Cautionsintendedtoavoidimproperrepairinterventionsinvolving potentialconsequencesforthesafetyofthepersonnelperformingtherepairs.
DANGER --Thesewarningsqualifyspecificallypotentialdangersforthesafetyofthe operatororotherpersonsdirectlyorindirectlyinvolved.
AVOIDACCIDENTS
Mostaccidents,whethertheyoccurinworkshop,on thefarm,athomeorontheroad,arecausedbythe failureofsomeindividualstofollowsimpleandfundamentalsafetyrulesandprecautions.ForthisreasonMOSTACCIDENTSCANBEPREVENTEDby recognisingtherealcauseanddoingsomething aboutitbeforetheaccidentoccurs.
Regardlessofthecareusedinthedesignandconstructionofanytypeofequipment,therearemany conditionsthatcannotbecompletelysafeguarded againstwithouthinderingreasonableaccessibility andefficientoperation.
Acarefuloperatoristhebestinsuranceagainstan accident.
Thecompleteobservanceofonesimplerulewould preventmanyseriousaccidents.
DANGER. Neverattempttoclean,lubricateormaintainamachinewhileitisinmotion.
SAFETYRULES
SAFETYRULES
◊ Readandheedallsafetyrulesbeforeanyintervention.
◊ Donotwearrings,wristwatches,jewellery,and looseorhangingapparels,suchasties,torn clothing,scarves,unbuttonedorunzipped jacketsthatcancatchonmovingparts.Wear propersafetyequipmentasrecommendedfor thejob.Examples:hardhat,heavygloves,ear protection,safetyglassesorgoggles,reflector vests,respirator.Consultyouremployerforspecificsafetyequipmentrequirements.
◊ Donotperformanyserviceoperationonthe machinewithapersonseatedintheoperator’s compartment,unlessheisanauthorisedoper-
atorco--operatingintheoperationtobeperformed.
◊ Neverattempttooperatethemachineoritstools fromanypositionotherthanseatedintheoperator’sseat.
◊ Neverperformanyinterventiononthemachine withenginerunningunlessthisisprescribed.
◊ Cut--offtheengineandmakesurethatallpressuresinthehydraulicsystemsarereleased beforeremovingcaps,covers,valvesetc.
◊ Allserviceinterventionsmustbeperformedwith theutmostcareandattention.
◊ Shopand/orfieldserviceplatformsorladders mustbeconstructedandmaintainedinaccordancewithlocalandnationalregulations.
◊ Disconnectthebatteriesandtagallcontrolsto signalthataninterventionisinprogress.Block themachineandallequipmentthatmustbe lifted.
◊ Donotchecknorrefillfueltanks,aswellasbatteries,norusestartingfluidwhilesmokingor nearopenflamessincethesefluidsareflammable.
◊ Brakesareinactivewhenmanuallyreleasedfor serviceinterventions.Undersuchcircumstancesitisnecessarytomaintainthecontrolof themachineusingappropriateblocksorsimilar devices.
◊ Thefuel--fillingnozzlemustbekeptconstantly insidethefillingneck.Keepthiscontactfromthe beginningtotheendofthefuellingoperationto avoidthepossibilitythatsparksduetostatic electricityaregenerated.
◊ Useonlydesignatedtowingorattachingpoints. Usecareinmakingattachments.Makesurepins and/orlocksaresecurebeforepulling.Stayclear ofdrawbars,cablesorchainsunderload.
◊ Tomoveadisabledmachine,useatrailerora low--boy,ifavailable.
SECTION00--GENERAL 3 603.67.010.02 --01--2004
◊ Toload/unloadamachinefromtransporter, choosealevelsurfaceensuringfirmsupportto thewheelsoftruckortrailer.Anchorthemachine securelytothebedoftruckortrailerandblock wheelsortrackswithappropriatewedges.
◊ Useonlyapprovedgroundedauxiliarypower sourcesforheaters,chargers,pumpsandsimilarequipmenttoreducethehazardsofelectrical shocks.
◊ Liftandhandleheavypartswithaliftingdevice ofpropercapacity.
◊ Bewareofbystanders.
◊ Neverpourgasolineordieselfuelintoopen, wideandlowcontainers.
◊ Neverusegasoline,solventorotherflammable fluidtocleanparts.Useexclusivelyqualified, non--flammable,non--toxiccommercialsolvents.
◊ Whenusingcompressedairforcleaningparts, usesafetyglasseswithsideshieldsorgoggles.
◊ Limitpressureto2.1bar,inaccordancewith localandnationalregulations.
◊ Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaust fumes.
◊ Donotsmokeorpermitanyopenflamesorspark nearwhenre--fuellingorhandlingflammable materials.
◊ Donotuseanopenflameasalightsourceto lookforleaksorforinspectionanywhereonthe machine.
◊ Movewithextremecarewhenworkingunderthe machine,itsattachmentsandoronornear them.Alwayswearprotectivesafetyequipment asrequired,suchashardhat,goggles,safety shoes,earplugs.
◊ Whenperformingoperationsrequiringrunningof theengine,haveaqualifiedoperatorintheoperator’sseatatalltimeswiththemechanicon sight.Placethetransmissioninneutralandset thebrakesandsafetylock.
◊ Forfieldservice,movemachinetolevelground, ifpossible,andblockit.Ifworkonaninclineis absolutelynecessary,firstblockmachineandits attachmentssecurely,thanmoveittolevel groundassoonaspossiblewithacertainmargin ofsafety.
◊ Donottrustwornand/orkinkedchainsand cables:donotusethemforliftingorpullingoperations.Tohandlethem,alwaysuseheavy gloves.
◊ Besurechainsandcablesareanchoredandthe anchorpointsarestrongenoughtohandlethe expectedload.Keepexposedpersonnelclearof anchorpointsandcablesorchains.No bystandersareallowednearthehookingpoints, chainsorcables.
◊ Keeptheareawheremaintenanceoperations areperformedCLEANandDRY.Eliminate immediatelyallwaterandoilspillages.
◊ Donotpileupoilyorgreasyrags;theyrepresent afirehazard.Storeinaclosedmetalcontainer. Beforestartingmachine,check,adjustandlock theoperator’sseatformaximumcomfortand controlofthemachine.Besureexposed personnelintheareaofoperationareclearofthe machinebeforemovingitoritsattachments. Soundthehorn.
◊ Donotcarrylooseobjectsinpocketsthatmight fallunnoticedintoopencompartments.
◊ Wearproperprotectiveequipmentsuchas safetygogglesorsafetyglasseswithside shields,hardhat,safetyshoes,heavygloves whenmetalorotherparticlesareapttoflyorfall.
◊ Wearweldersprotectiveequipmentsuchas darksafetyglasses,helmets,protectiveclothing,glovesandsafetyshoes,whenweldingor burning.Weardarksafetyglassesnearwelding zones.DONOTLOOKATARCWITHOUT PROPEREYEPROTECTION.
◊ Steelcablesarefrayedafterprolongeduse; alwayswearappropriateprotections(heavy gloves,gogglesetc.).
◊ Handleallpartscarefully.Keephandsand fingersawayfromstructures,gearsormoving parts.Useandwearalwaystheappropriate protections,suchassafetygoggles,glovesand safetyshoes.
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STARTING
◊ Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaust fumes.
◊ Donotplacehead,body,limbs,feet,handsor fingers,nearrotatingfansorbelts.Beespecially alertnearpusherfans.
ENGINE
◊ Loosentheradiatorcapveryslowly,torelease pressurefromthesystem,beforeremovingit.All coolantleveltop--upsmustbeperformedwith engineinoperativeoratlowidle,ifwarm
◊ Donotrunenginewhenrefuellingandusecare iftheengineishotduetotheincreasedpossibilityofafireiffuelisspilled.
◊ Neverattempttocheckoradjustfanbeltswhen engineisrunning.Donotadjustenginefuel pumpwhenmachineismoving.
◊ Neverlubricatethemachinewithenginerunning.
ELECTRICALSYSTEM
◊ Shouldboosterbatteriesbeused,rememberto connectbothendsoftheboostercablesinthe propermanner(+)with(+)and(--)with(--).Avoid short--circuitsoftheterminals.Followthoroughly theinstructionsofthisManual.
Avoidshortcircuitingtheterminals.BATTERY GASISHIGHLYFLAMMABLE.Leavebattery boxopentoimproveventilationwhenrecharging batteries.Nevercheckchargebyplacingmetal objectsacrosstheposts.Keepsparksoropen flamesawayfrombatteries.Donotsmokenear batterytoguardagainstthepossibilityofcausing anexplosion.
◊ Beforeanyintervention,makesurethatthere arenofuelorelectrolyteleakages;eliminate thembeforeproceedingwithfurtherwork.
◊ Whenrechargingbatteriesinclosedambient, makesurethatthereisappropriateventilationto preventpossibleaccidentalexplosionsdueto theaccumulationofgasesgeneratedduringthe recharge.
◊ Beforeanyintervention,makesurethatthemain switchisOFF.
HYDRAULIC SYSTEM
◊ Fluidescapingunderpressurefromaverysmall holecanbealmostinvisibleandcanhavesufficientforcetopenetratetheskin.Useapieceof cardboardorwoodtosearchforsuspectedpressureleaks.DONOTUSEHANDS.Ifinjuredby escapingfluid,seeadoctoratonce.Serious infectionorreactioncandevelopifpropermedicaltreatmentisnotadministeredimmediately.
◊ Incasepressuresmustbemeasured,use instrumentsofadequatecapacity.Alwaysfollow therecommendedprocedures.
WHEELSANDTYRES
◊ Makesurethattheinflationpressureofthetyres isaccordingtothespecificationsissuedbythe Manufacturerandcheckitperiodically.
◊ Shouldthepressurebechanged,standonthe sideofthetyreatasafedistance.
◊ Pressurecheckoperationsmustbeperformed withunloadedmachineandcoldtyres.Never usereconditionedtyrerims,sinceeventual weldings,heat--treatmentsorrepairsnotperformedcorrectlycanweakenthewheel,thus causingsubsequentdamagesordangers.
◊ Donotperformtorchcuttingorweldingoperationsonrimswithinflatedtyresinstalled.
◊ Beforeoperatingontyres,blockallwheels,front andrear.Afterjackingthemachine,blockitwith standsaccordingtocurrentsafetyrulesand regulations.
◊ Beforeremovingobjectsfromthetyretread, deflateit.
◊ Neverinflatetyreswithflammablegas; explosionsandseriousbodilyinjuriesmay result.
REMOVALSANDINSTALLATIONS
◊ Liftandhandleallheavypartswithliftingdevices ofadequatecapacity.Makesuethattheparts areattachedtoliftingdevicesareproperly slinged.Usetheliftingeyesprovided.Bewareof personsinthevicinity.
◊ Handleallpartscarefully.Keephandsand fingersawayfromstructures,gearsormoving parts.Useandwearalwaystheappropriate protections,suchsgoggles,glovesandsafety shoes.
◊ Preventchainsandcablesfromkinking.To handlethem,alwaysuseheavygloves.
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PRODUCTIDENTIFICATION
TheTelehandleranditsmaincomponentsareidentifiedbyvariousnumbersandlettersprovidingits identificationbytheServicenetwork.Thefollowing informationgivesthelocationoftheidentification plates,ofthenumbersstampedonthemachineand variousexamplesofwhatcanbefoundonthe machine.
VEHICLESERIALNUMBER
Theserialnumberisstampedonthefrontpartofthe machine,ontheuppersideofthemainframe,right side.
NOTE: Theserialnumberandtheidentification numberofthecomponentscanberequestedbythe DealerwhenSparePartsareorderedorinterventionsarerequired.Thesenumbersarealsorequired ashelpinidentifyingthemachineintheeventoftheft. Keeptheminasafeplace.
VEHICLEIDENTIFICATIONPLATES
Thevehicleidentificationplateislocatedontheleft sideoftheseatlocation.Recordherebelowthedata foryourmachine.
Theidentificationdataoftheengineareontheleft sideoftheenginecylinderblock.Pleaserecordhere belowthesedataforeasierconsultation,when required.
6 SECTION00--GENERAL 603.67.010.02 --01--2004
TH100025 1
TECHNICALTYPE/MODEL SERIALNO.OFVEHICLE YEAR TH001028 2 IDENTIFICATIONOFENGINE
MODELNO. SERIALNO. DATECODE TH100026 3
IDENTIFICATIONOFFRONTAXLE
Theserialnumberandtheaxletypeareindicatedon plate(1)locatedonthefrontsideoftheaxlehousing. Pleaserecordherebelowthedataindicatedfor fasterconsultationwhenrequired.
AXLETYPE
SERIALNO.
IDENTIFICATIONOF4x3POWERSHIFT TRANSMISSION
Theserialnumberandthemodelareindicatedon plate(1)locatedonthelowersideofthetransmission.Pleaserecordherebelowthedataindicated forfasterconsultationwhenrequired.
IDENTIFICATIONOFREAR TRANSMSSION
Theserialnumberisindicatedonplate(1)locatedon thelowersideofthereartransmission.Please recordherebelowthedataindicatedforfasterconsultationwhenrequired.
AXLETYPE
SERIALNO.
SECTION00--GENERAL 7 603.67.010.02 --01--2004
DATECODE
MODELNO. SERIALNO. DATECODE TH001030 1 4
DATECODE
IDENTIFICATIONPLATESINTHECAB
Thecabidentificationplatecontainsaseriesof furtherdetailsanditislocatedontheleftrearsideof theseat.Pleaserecordherebelowthedataindicated forfasterconsultationwhenrequired.
SERIALNO.
DATECODE
Thedatarelativetotheengineareindicatedonthe conformityplatesinstalledtogetherwiththeCab Plate.Pleaserecordherebelowtheserialnumber indicatedforfasterconsultationwhenrequired. SERIALNO.
8 SECTION00--GENERAL 603.67.010.02 --01--2004
DATECODE TH001058 5
ENVIRONMENTALCONSIDERATIONS
Thefollowingrecommendationscanbeuseful:
• Becomefamiliarandmakesureyouhavewell understoodtherelevantlegislationineffectin yourcountry.
• Intheeventnoregulationsexist,askforspecific informationwiththesuppliersoflubricants,antifreezeanddetergentsregardingtheireffectson humansandtheenvironmentandhowtostore, handleanddisposeofthesesubstancessafely.
4.Avoidspillagewhendrainingusedcoolantmixtures,engineoils,transmissionandhydraulic fluids,brakefluid.Afterdraining,donotmix brakefluidorfuelwithlubricants.Storethemina riskfreemanneruntilwhentheycanbedisposed ofinanadequateway,inaccordancewithlocal regulationsandtheresourcesavailable.
5.Moderncoolingmixtures,suchasantifreezeand otheradditives,mustbechangedeverytwo years.Maximumattentionmustbepaidtopreventthattheyspillovertheground.Theymustbe collectedanddisposedofsothatdonotcreate anydanger.
6.Donotunsealairconditioningsystembyyourselves,sincetheycancontaingasesthatmust notbereleasedintotheatmosphere.Thepersonnelspecialisedinairconditionersuses specialequipmenttochargeanddischargeair conditioningsystems.
Usefulindications
1.Donotfilltankswithinadequatecanistersordispensingpressurisedsystemsthatcouldcause considerablespillage.
2.Ingeneral,avoidthecontactoftheskinwithany fuel,oil,acid,solventetc.Themajorityofthem containsubstancedangerousforyourhealth.
3.Modernlubricantscontainadditives.Donotburn contaminatedfuelsand/orwedoilsinnormal heatingburners.
7.Repairatonceanyleakageordefectofthe enginecooling systemorhydraulicsystem.
8.Donotincreasethepressureofanypressurised system,sincethiscouldcauseseriousproblems tothecomponentsofthesystem.
9.Protecthoseswhenperforminganywelding, sinceasplashofweldingmaterialscouldpenetrateandburnthem,causingaholeorweakeningthewallwithsubsequentleakagesofoil, coolantetc.
SECTION00--GENERAL 9 603.67.010.02 --01--2004
MAINTENANCETECHNIQUES
GENERALNOTICES
Cleantheoutsideofallthecomponentspriortoperforminganytypeofrepair.Dirtandabrasivedustcan reducetheefficientlifeexpectancyofacomponent andresultinexpensiverepairs.
Thetimespentinpreparingandcleaningworking surfacesisgivingresults,makingworkeasierand safer,andthecomponentsoverhauledwillbemore reliableandoperatebetter.
Usecleaningfluidsproventobesafe.Sometypesof fluidcancauseseriousproblemstoO--Ringsandirritatetheskin.Itisnecessarytocheckthatthesolventsaresuitabletocleanthecomponentsandthat oftheyarefreeofrisksforthehealthofworkers.
ReplaceO--Rings,sealingringsandsealseverytime theyaremoved.NeveruseoldO--Ringsorsealsand newonestogether,independentlyfromtheirconditions.AlwayslubricatenewO--Ringsandsealswith hydraulicoilbeforeinstallingthem.
Whenreplacingcomponents,alwaysusethetooling requiredbythistypeofwork.
HOSESANDSTEELPIPES
Alwaysreplacehosesandsteelpipeswhenthetaper endorconnectionsaredamaged.
Whenanewhoseisinstalled,connectitwithout tighteningtheendsandmakesurethatitisroutedin thecorrectmanner,beforetighteningtheends.Fixturesmustbetightenedjustenoughtoholdthehose withoutsqueezingit,avoidingrubbingaswell.
Afterreplacingahoseofmovingcomponents,make surethatthehoseisnotdisturbedbythemovement ofthecomponentinanyposition.
Makesurethatallhosesinstalledarenotchokedor bent.
Ifhoseconnectionsaredamaged,dented,chokedor leaking,decreasetheflowofoilandtheproductivity oftherelevantactuators.Connectionsshowing signsofdisplacementfromtheiroriginalpre-pressedpositionmustbeconsideredasalready broken,sincetheyaregoingtofailorseparatesoon.
Ahosewitharaggedoutersleeveallowswaterto penetrate.Thus,hiddencorrosionofthereinforcing wirewilldevelopalongtheentirelengthofthehose, withthesubsequentfailureofthehoseitself.
Ifahoseswells,thisindicatesthatthereisaninternal leakageduetoastructuralfailure.Thiscondition deterioratesveryquicklyandcausesthefailureof thehose.
Clogged,squeezed,excessivelytensionedor deformedhosesaregenerallyeasilysubjecttoflow reduction,decrementoftheoperationalspeedofthe fluidandthefinalfailureofthehose.
Loosehosesmovefreelyandmustbeprevented fromtouchingeachotherandnearbysurfaces.This causesarubbingactionshorteningtheusefullifeof thehose.
CONNECTIONSWITHFRONTSEALING O--RINGS
Whenrepairingconnectionswithfrontsealing O--Rings,pleasecomplywiththefollowingprocedures.
WARNING:NEVERDISCONNECT,NOR TIGHTENAHOSEORASTEELPIPEUNDER PRESSURE.IFINDOUBT,MOVETHECONTROL LVERSSEVERALTIMESWITHTHEENGINE INOPERATIVEBEFOREDISCONNECTINGA HOSEORASTEELPIPE.
1.Loosentheconnectionsandseparatethehose orsteelpipe,thenremoveandeliminatethe O--Ringsfromtheconnection.
2.DipanewO--Ringinclean,hydraulicoilbefore installingit.InstallthenewO--Ringintheconnectionand,ifnecessary,holditinitsposition withvaseline.
3.Installanewhoseorsteelpipeandtightenmanuallytheconnectionholding,atthesametime, thepipestilltopreventitfromturning.
4.Usetwowrenchestotightentheconnectionto thetorqueprescribedforitssize.Pleasereferto thetabletofollowforthetighteningtorques.
NOTE:toensurethatajointdoesnotleak,itis importantthattheconnectionsareneither excessivelytightenednortoolittle.
10 SECTION00--GENERAL 603.67.010.02 --01--2004
SPECIFICSEALINGCOMPOUNDS
Thefollowingsealingcompoundsmustbeused,complyingwiththeindicationsprovidedbytheManual:
SEALANTSCOMMERCIALNAME
AnaerobicsealantLOCTITE518(liquidgasket)
RTVsiliconsealantLOCTITESUPERFLEX593,595or596
LOCTITEULTRABLUE587DOWCORNINGSILASTIC 732GENERALELECTRICRTV103or108
PipesealantPST592(pipesealantwithteflon)
Lockingcompoundfor threads
LOCTITE271/RED(sealant/lockingforthreads)
TIGHTENINGVALUESFORFASTENERS
Checkperiodicallythatthefastenersareproperly tightened.
Baseduponthetablestofollow,determinethecorrecttighteningtorquewhenpartsofthefastening componentsarechecked,adjustedorreplaced.
IMPORTANT:DONOTusethevalueslistedinthe tableswhentheManualindicatesadifferenttorque
ortighteningprocedureforaspecificapplication.The torquevaluesareprovidedforgeneraluseonly. Makesurethatthethreadsofthefastenersareclean andundamaged.
NOTE: useatorquewrenchtotightenfastenerscorrectly.
SECTION00--GENERAL 11
--01--2004
603.67.010.02
MINIMUMTIGTENINGTORQUESFORFASTENERS
INNEWTON--METRES(Nm) FORNORMALINSTALLATIONAPPLICATIONS METRICBOLTSANDLOCKNUTS CLASS5.8
M814182228314015
M1028364356617930
M124963759710713853
M16121158186240266344131
M20237307375485519671265
M244115316488398971160458
IDENTIFICATION
HEXSCREWS(WITHOUTNUT)ANDROUNDHEADBOLTS CLASS5.6ANDHIGHER
IDENTIFICATIONOFTHEMANUFACTURER
HEXNUTSANDTIGHTENINGNUTS CLASS05ANDHIGHER
IDENTIFICATIONOFTHEMANUFACTURER
12 SECTION00--GENERAL 603.67.010.02 --01--2004
M41.72.22.63.43.74.81.8 M65.87.68.91213176.3
NOMINAL DIMENSION NOT PLATED PLATED Zn/Cr NOT PLATED NOT PLATED PLATED Zn/Cr PLATED Zn/Cr LOCKNUT CL8 withBOLT CL8.8
MARKING COMMERCIALCLASS
CLASS8.8CLASS10.9
COMMERCIALCLASS
GRADEIDENTIFICATION
GRADEA:NOCUTS
GRADEB:ONEPERIMETERCUT
GRADEC:TWOPERIMETERCUTS
GRADEIDENTIFICATION
GRADEA:NEWMARK
GRADEB:THREEMARKS
GRADEC.SIXMARKS
THEMARKSARENOTCOMPULSORILY LOCATEDINTHECORNERS
GRADEA.NOMARKS
GRADEB:LETTERB GRADEC:LETTERC
GRADEIDENTIFICATION
SECTION00--GENERAL 13 603.67.010.02 --01--2004 IDENTIFICATION SCREWS(WITHOUTNUT) ANDROUNDHEADEDSCREWS LOCKNUTS 1289373742960104813565237391 7/81932484956416989043504947/8 3/41982563063974325602173063/4 5/81121451742242443161221725/8 9/1681104125163176229881259/16 1/257738711312315961881/2 7/16374757738010441577/16 3/823303546506526353/8 5/1613172026283714205/16 1/46.28.19.71314186.99.81/4 MINIMUMTIGTENINGTORQUESFORFASTENERS INNEWTON--METRES(Nm) FORNORMALINSTALLATIONAPPLICATIONS INCHMEASUREMENTSCREWSANDLOCKNUTS GRADESAE2GRADESAE5GRADESAE8 LOCKNUTS NOMINAL DIMENSION NOMINAL DIMENSION NOT PLATED OR SILVER PLATED NOT PLATED OR SILVER PLATED NOT PLATED OR SILVER PLATED NOT PLATED OR SILVER PLATED PLATED Zn/Cr GOLD PLATED Zn/Cr GOLD PLATED Zn/Cr GOLD PLATED Zn/Cr GOLD
GRADESAE5 GRADESAE8
HEXNUTS GRADESAE5 HEXNUTS GRADESAE8
GRADESAE2
NORMALNUTS
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