Workshop Manual
LM732
TELEHANDLERS
RepairManual
DocumentN°.87474474A(I--2008)
THISWARNINGSYMBOLACCOMPANIESIMPORTANTMESSAGESINVOLVINGYOURSAFETY.
Readthesafetyinstructionscarefully,andfollowtheprecautionsrecommendedinorderto avoidpotentialrisksandsafeguardyourhealthandyoursafety.
YouwillfindthissymbolinthetextofthisManualwiththefollowingkeywords: WARNING-Cautionsintendedtoavoidunsuitablerepairoperationswithpotentialconsequences forthesafetyofthepersonperformingtherepair.
DANGER-Warningsspecificallyindicatingpotential dangersforthesafetyoftheoperatororofother personsdirectlyorindirectlyinvolved.
IMPORTANTWARNINGS
AllmaintenanceandrepairoperationslistedinthisManual mustbeperformedexclusivelybytheServiceNetwork oftheManufacturer,complyingstrictlywiththeindicationshereinandusingtheprescribedspecialtoolswhere indicated.
Anypersonperformingserviceoperationsdescribedin themanualandfailingtoabidestrictlybytheinstructions becomessolelyresponsibleforany consequentialdamagethatcouldoccur.
TheManufacturerandallorganizationsinthedistributionchainassociatedwiththeManufacturer,includingnational, regionalandlocaldealersthoughnotexcludingothers,declineallliabilityfordamagesattributabletoabnormalities intheoperationorresponseofparts and/orcomponentsnotapprovedbytheManufacturer,usedintheservicing and/orrepairofaproductbuiltor marketedbytheManufacturer. Inanyevent,nowarrantyofanydescriptionisofferedonorapplicabletotheproductbuiltormarketedbythe Manufacturer,inrespectofdamagesresultingfrom abnormaloperationorresponseofpartsand/orcomponentsnot approvedbytheManufacturer.
AVOIDACCIDENTS
Mostaccidentsandinjuriesthatoccurinandaroundfactories,onfarms,inthehomeorontheroads,arecaused byfailuretofollowsomesimpleandfundamentalruleregardingprecautionaryproceduresandsafety. Accordingly,INTHEMAJORITYOFCASES,ACCIDENTSCANBEAVOIDED:itissufficientsimplytoforesee thepossiblecauses,andexercisethenecessarycautionandprudence.
Whateverthetypeofequipment,andhoweverwelldesignedandbuilt,itisnotpossibletoeliminatetheriskof accidentcompletelywithoutadverselyaffectingcertain essentialfeaturesinstrumentalinprovidingreasonable levelsofaccessibilityandensuringsmoothoperation.
Acarefulandprudentoperatoristhebestinsuranceagainstanyaccident. Thecompleteobservanceofthissimplerulewillofitselfbesufficientinavoidingmanyseriousaccidents. Thisruleis:neverattemptanycleaning,lubricationormaintenanceoperationwiththemachineinmotion.
WARNING
Beforecommencinganykindofmaintenance,adjustmentorrepairworkonmachinesequippedwith attachmentsoperatedhydraulically,mechanicallyorbywireropes(suchasfrontloaders,dozers, scrapers,etc.)makecertaintheattachmentisloweredandrestingontheground. Iftheattachmentneedstobeintheraisedpositioninordertogainaccesstoonepartofthemachine oranother,itmustbesupportedintheraisedpositionbyseparateequipment,andnotheldwiththe machinecontrols.
MODELDESIGNATIONS
Themodelsmakinguptherangeoftelescopichandlers(Telehandlers)describedinthismanualareidentified inthetextbyreferencetothemaximumreachoftheboom.
Thevehicleslistedbelowmaynotbeavailableinallcountriesoronallmarkets.Foruptodateinformationon allmachines,consultyourauthorizeddealer.
SECTION55–ELECTRICALSYSTEM
Diagram7:Tip--overpreventionsystem/roofwiper53
Diagram8:Heater,radio/trailersocket/interiorlight55
Diagram9:Air--conditioning
GENERALINSTRUCTIONS
IMPORTANTNOTICE
AllmaintenanceandrepairoperationslistedinthisManualmustbeperformedexclusivelybytheService NetworkoftheManufacturer,complyingstrictlywiththeindicationshereinandusingtheprescribedspecialtools whereindicated.
Anypersonperformingserviceoperationsdescribedinthemanualandfailingtoabidestrictlybytheinstructions becomessolelyresponsibleforanyconsequentialdamagethatcouldoccur.
SHIMS
Selecttheshimsforeachadjustment,measuringthemonebyonewithamicrometerandthenaddingtogether thevaluesmeasured:Donotrelyonthemeasurementoftheentirepack,whichcouldbewrong,orthenominal valueindicatedoneachwasher.
SEALSFORROTATINGSHAFTS
Forcorrectinstallationofthesealsonrotatingshafts,observethefollowingprecautions:
--priortoinstallation,soakthesealsforatleasthalfanhourinthesameoiltheywillbeexposedtoinoperation; --cleantheshaftthoroughlyandmakesurethatitsworkingsurfaceisundamaged; --directtheliptowardthefluid;inthecaseofahydrodynamiclip,theribsorgroovesmustbepositioned, relativetothedirectionofrotationoftheshaft,insuchawayastopropelthefluidtowardtheinsideofthe seal;
--smearthesealinglipwithafilmoflubricant(oilispreferabletogrease)andinthecaseofdoublelipseals, packthegapbetweenthesealinglipandthedustlipwithgrease; --insertthesealinitsseat,andpresshomeusingapunchwithaflatcontactface;neveronanyaccountstrike thesealwithahammerormallet;
--whenpressinghometheseal,makecertainitisinsertedperpendicularlyinrelationtotheseatand,once inplace,makecertainitisincontactwiththeshoulder,wherespecified; --topreventthelipofthesealbeingdamagedbytheshaft,interposesuitableprotectionmediaduringthe installationofthetwoparts.
O--RINGS
LubricateO--ringsbeforeinsertingthemintherelevantseatstopreventthemtwistingandrollinginthecourse ofinstallation,asthiswouldadverselyaffecttheirsealingaction.
SEALANTS
MatingsurfacesmarkedXmustbesmearedwithasealingcompoundrecommendedbytheManufacturer,or asuitableequivalent. Beforeapplyingthecompound,preparethesurfacesinthefollowingmanner: --removeanyencrustationswithametalbrush; --degreasethesurfacesthoroughlyusingthedegreasingagentrecommendedbytheManufacturer,ora suitableequivalent.
BEARINGS
Wheninstallingbearings,theringsshouldbe: --heatedto80° 90°Cbeforeshrinking(inner)ontotheshaft; --cooledbeforedriving(outer)intotheseat.
ROLLPINS
Wheninstallingrollpins,makesurethatthecutisfacinginthedirectionofthemechanicalforcebearingonthe pin. Spiralrollpins,ontheotherhand,canbefittedwithanyorientation.
NOTESONSPAREPARTS
Useonly genuinesparepartsguaranteedbytheManufacturer. Genuinesparepartsaretheonlyonesensuringthesamequality,thesamelifeandthesamesafetyasthe originalequipment,sincetheyarethesameasthoseinstalledinproduction. Onlygenuinepartsfromthemanufacturerensurethisguarantee. Ordersforsparepartsmustincludethefollowingindications: --modelofthevehicle(commercialdesignation)andchassisnumber; --typeandnumberoftheengine; --partnumberfortheitemordered,obtainablefromthe“Microfiches”orthe“SparePartCatalogue”,onthe basisofwhichallordersareprocessed.
NOTESONTOOLS
ThetoolsrecommendedbytheManufacturerandillustratedinthisManualare: --studiedanddesignedspecificallyforservicingvehiclesofthisrange; --requiredinordertoensureareliablerepair; --carefullyengineeredandstringentlytestedtoprovideeffectiveandlonglastingequipment. Rememberalsothatwhenproperlyequipped,therepairmechaniccan: --operateunderoptimumtechnicalconditions; --achievethebestresults; --savetimeandeffort; --workinsaferconditions.
WARNING
Thewearlimitsindicatedforsomeitemsmustbeconsideredasrecommendedvalues,butnotabsolutely binding.Theindications“front”,“rear,“right”,“left”refertothedifferentpartsasseenfromapositionsittingin thedriverseatandfacinginthenormalforwarddrivedirectionofthevehicle.
HOWTOMOVEAVEHICLEWITHOUTBATTERIES
Thecablesoftheexternalpowersupplymustbeconnectedexclusivelytotherespectiveterminalsofthepositive andnegativecablesonthevehicle,usingefficientclampsthatwillprovideasecureandstablecontact.Switch offallelectricalloads(lights,wipers,etc.)beforeproceedingtostartthevehicle.Shoulditbenecessarytocheck theoperationofthevehicle’selectricalsystem,thismustbedoneonlywiththepowersupplyconnected;Having completedthecheck,switchoffallloadsanddeactivatethepowersupplybeforedisconnectingthecables.
SAFETYRULES
PAYATTENTIONTOTHISSYMBOL
Thiswarningsymbolaccompaniesimportantmessagesinvolvingyoursafety.
Readthesafetyinstructionscarefully,andfollowtheprecautionsrecommendedin ordertoavoidpotentialrisksandsafeguardyourhealthandyoursafety. YouwillfindthissymbolinthetextofthisManualwiththefollowingkeywords:
WARNING --Cautionsintendedtoavoidunsuitablerepairoperationswithpotential consequencesforthesafetyofthepersonperformingtherepair.
DANGER --Warningsspecificallyindicatingpotentialdangersforthesafetyofthe operatororofotherpersonsdirectlyorindirectlyinvolved.
AVOIDACCIDENTS
Mostaccidentsandinjuriesthatoccurinandaround workshopsarecausedbyfailuretofollowsome simpleandfundamentalruleregarding precautionaryproceduresandsafety.Accordingly, INTHEMAJORITYOFCASES,ACCIDENTSCAN BEAVOIDED:itissufficientsimplytoforeseethe possiblecauses,andexercisethenecessarycaution andprudence.
Whateverthetypeofequipment,andhoweverwell designedandbuilt,itisnotpossibletoeliminatethe riskofaccidentcompletely.
Acarefulandprudentmechanicisthebestinsurance againstanyaccident.
Thecompleteobservanceofthissimplerulewillof itselfbesufficientinavoidingmanyserious accidents.
DANGER. Neverattempttoclean,lubricateor maintainamachinewiththeenginerunning.
SAFETYRULES
GENERAL
◊ Followthespecifiedmaintenanceandrepair procedurescarefully.
◊ Donotwearrings,wristwatches,jewellery,and looseorhanginggarments,suchas:ties,torn clothing,scarves,unbuttonedorunzipped jacketsthatcouldbecomecaughtandentangled inmovingparts.Wearpropersafetyclothingand protectivegear,forexample:non--slipfootwear, gloves,safetyglassesorgoggles,hardhats,etc.
◊ Donotperformanyserviceoperationonthe machinewithpersonsoccupyingthedriverseat, unlesstheseareauthorizedoperatorsassisting withtheworkinhand.
◊ Neverattempttooperatethemachineorits attachmentsfromanypositionotherthanseated inthedrivingposition.
◊ Neverperformanyoperationonthemachine withtheenginerunning,unlessindicatedinthe manual.
◊ Shutofftheengineandmakecertainthatthere isnopressureinthehydrauliccircuitsbefore removingcaps,covers,valvesetc.
◊ Allserviceoperationsmustbeperformedwith theutmostcareandattention.
◊ Step--laddersandaccessplatformsusedinthe workshoporinthefieldmustbeconstructedand maintainedinaccordancewithaccident preventionregulations.
◊ Disconnectthebatteriesandtagallcontrolsto signalthatservicingisinprogress.Immobilize themachineandanyattachmentthatmustbe lifted.
◊ Donotcheckorrefillfueltanks,ortopup batteries,orusestartingfluidwhensmokingor nearanakedflame,sincethefluidsinquestion areflammable.
◊ Brakesareinactivewhenreleasedmanuallyfor servicingpurposes:inthissituation,keepthe machineundercontrolusingwheelchocksor similardevices.
◊ Thegunofthefillerhosemustalwaysremainin contactwiththetankfillerpipewhenrefuelling. Maintainthiscontactthroughouttherefuelling operationsoastoavoidanypossibilityofsparks beinggeneratedwiththebuild--upofstatic electricity.
◊ Whentowing,useonlythedesignatedhitchpoints. Exercisecarewhencouplingtrailedloads:Make surepinsand/orlocksaresecurebeforepulling. Stayclearofdrawbars,cablesorchainsunder load.
◊ Tomoveamachinewhenbrokendown,usea traileroralow--loader,ifavailable.
◊ Whenloading/unloadingamachinefroma transportvehicle,selectalevelsurfaceaffording firmsupporttothewheelsofthetruckortrailer. Anchorthemachinesecurelytothebedofthe truckortrailerandlockthewheelsasspecified bythecarrier.
◊ Useonlyapprovedgroundedauxiliarypower sourcesforheaters,chargers,pumpsandsimilar equipmenttoreducethehazardsofelectrical shocks.
◊ Liftandhandleallheavypartswithlifting equipmentofsuitableratedcapacity.
◊ Bewareofbystanders.
◊ Neverpourgasolineordieselfuelintoopen, wideandlowcontainers.
◊ Neverusegasoline,fueloilorotherflammable liquidsascleaningfluids:useonlyproprietary non--flammableandnon--toxicsolvents.
◊ Whenusingcompressedairforcleaningparts,use safetyglasseswithsideshieldsorgoggles.
◊ Limitpressureto2.1bar,inaccordancewith localandnationalregulations.
◊ Donotruntheengineinenclosedareaswithout properventilation.
◊ Donotsmoke,useanakedflameorcause sparksintheimmediatevicinitywhenrefuelling orhandlingreadilyflammablematerials.
◊ Donotuseanakedflameasalightsourcewhen lookingforleaksorcarryingoutinspectionson themachine.
◊ Movewithextremecarewhenworkingunderthe machine,andonoraroundthemachine.Always wearprotectivesafetyequipmentasindicated: hardhat,goggles,safetyfootwear.
◊ Whencarryingoutinspectionsthatrequirethe enginetoberunning,enlisttheassistanceofan operator,whoshouldremaininthedriverseat throughoutandkeepthemechanicinsightatall times.
◊ Foroperationsoutsidetheworkshop,setthe machineonlevelground,ifpossible,and immobilizethewheels.Ifworkonaninclineis absolutelynecessary,immobilizethemachine initially,thenmoveittolevelgroundassoonas thiscanbedonewithareasonablemarginof safety.
◊ Bewareofchainsorwireropesthatarepinched andbent:donotusethemforliftingortowing. Alwayswearsuitablythickgloveswhenhandling chainsandropes.
◊ Chainsmustbefirmlysecured:makecertainthe couplingisstrongenoughtoholdtheenvisaged load.Theremustbenooneinthevicinityofthe coupling,chainsortowropes.
◊ Theareawheremaintenanceoperationsare carriedoutmustalwaysbekeptCLEANand DRY.Clearupanypuddlesofwateroroilspills immediately.
◊ Donotpileupoilyorgreasyrags:theserepresent aseriousfirehazard.Alwaysplacetheminametal container.
◊ Beforesettingthemachineoritsattachmentsin motion,check,adjustandlockthedriverseat.
87474474A --01--2008
Also,makecertainthereisnoonewithinthe rangeofactionofthemachineorits attachments.
◊ Donotcarrylooseobjectsinpocketsthatmight fallunnoticedintocompartmentsinternallyofthe machine.
◊ Wearproperprotectiveequipmentsuchas safetygogglesorsafetyglasseswithside shields,hardhat,safetyshoes,heavygloves whenmetalorotherparticlesareliabletoflyor fall.
◊ Ifrepairsinvolveweldingortorch--cutting,wear theproperaccidentpreventionequipmentforthe purpose:tintedgoggles,hardhat,overalls, weldingglovesandboots.Darkglassesshould alsobewornbypersonsotherthanthewelder, whenstandingneartheweldingorcuttingarea. NEVERLOOKATTHEWELDINGARC WITHOUTSUITABLEEYEPROTECTION.
◊ Wireropeswillfraywithprolongeduse:always wearsuitableprotectivegearwhenhandling them(heavygloves,gogglesetc.).
◊ Handleallpartscarefully.Keephandsand fingersawayfromnarrowgaps,gearsormoving parts.Alwaysuseandweartheappropriate protectivegear,suchassafetygoggles,gloves andsafetyshoes.
STARTING
◊ Donotruntheengineinenclosedareasnot equippedwithventilation systemsofsufficient capacitytoremoveexhaustgases.
◊ Donotplacehead,body,limbs,feet,handsor fingersneartofansorbeltswhenthese componentsareinrotation.
ENGINE
◊ Beforeremovingtheradiatorcap,unscrewvery slowlytoreleasepressurefromthesystem.The levelofcoolantmustbetoppeduponlywiththe engineatstandstill,orifwarm,turningoverat idlespeed.
◊ Donotrefuelwiththeenginerunning,especially ifhot,asthiswillincreasetheriskoffireinthe eventoffuelbeingspilled.
◊ Neverattempttocheckoradjustfanbeltswhen theengineisrunning. Neveradjustthefuelinjectionpumpwiththe machineinmotion.
◊ Neverlubricatethemachinewiththeengine running.
◊ IMPORTANT:Accordingtodirectivesno. 2000/25/ECoftheEuropeanUnionandno.40 CFRPart.89oftheU.S.,itisprohibitedto tamperwiththeengineinanyway,includingthe downloadofnon--certifiedsoftware.Any tamperingwithanengineorwithitsfuelfeed systemnotpermissibleunderthecurrent specificationswillmean: inlegalterms, thattheengineislongerin
compliancewithstatutoryregulationsor protectedbyinsurance,andwarrantyonthe engineandfuel systemisinvalidated;depending onwhatisdeclaredinthecertificates,the customercouldbefacedwithveryhighcoststo restoretheenginetoitsoriginalcondition; inengineeringterms, possibleoverloadingof enginecomponents;theriskofearlyengine wear,duetotheexcessiveloadoncomponents andtotheuseofcontaminatedoil.Onlypersons approvedbytheManufacturerareauthorizedto carryoutrepairsonthefuelsystem.Such repairscanbecarriedoutonlyusingthe specificationssuppliedbytheManufacturer.
ELECTRICALSYSTEMS
◊ Shoulditbenecessarytouseboosterbatteries, remembertoconnectbothendsofthebooster cablesasspecified:(+)with(+)and(--)with(--). Avoidshort--circuitingtheterminals.THEGAS RELEASEDFROMBATTERIESISHIGHLY INFLAMMABILE.Whenrechargingbatteries, leavethebatterycompartmentopentoimprove ventilation.Nevercheckthebatterychargeby improvising“jumpers”withmetalobjectsplaced acrosstheterminals.Avoidsparksornaked flamesanywherenearthebatteries.Refrain fromsmokingtoavoidtheriskofexplosion.
◊ Beforeanyworkiscarriedout,makesurethat therearenofuelorcoolantleaks:eliminateany suchleaksbeforeproceeding.
◊ Donotrechargebatteriesinanenclosed environment:makecertainthereissufficient ventilationtopreventtheriskofaccidental explosionsoccurringduetotheaccumulationof gasesgeneratedduringrecharges.
◊ Alwaysdisconnectthebatteriesbeforedoing anyworkontheelectricalsystem.
HYDRAULIC SYSTEMS
◊ Fluidescapingunderpressurefromaverysmall holecanbealmostinvisible,andprojectedwith sufficientforcetopiercetheskin.Accordingly, useapieceofcardboardorwoodtosearchfor suspectedpressureleaks.NEVERSEARCH FORLEAKSWITHBAREHANDS.Ifescaping fluidshouldpenetratetheskin,seekmedical adviceimmediately.Seriousinfectionorallergic
skinreactionscandevelopifpropermedical treatmentisnotadministeredstraightaway.
◊ Whensystempressuresmustbemeasured,use theproperinstruments.
WHEELSANDTYRES
◊ Makecertainthattyresarecorrectlyinflatedto thepressureindicatedbytheManufacturer. Checkperiodicallyforpossibledamagetorims andtyres.
◊ Whencorrectingtheinflationpressure,standto onesideofthetyreatasafedistance.
◊ Checktheinflationpressureonlywiththe machineunladenandwiththetyrescold,to avoidanerroneouslyhighgaugereading.Never usereconditionedwheelcomponents,asabadly welded,brazedorheat--treatedrepaircould weakenthestructureandleadtofailure.
◊ Neveruseatorchtocutorweldawheelrimwith thetyrefittedandinflated.
◊ Beforeremovinganywheel,immobilizethe machinefrontandrearonallhubs.Having jackedupthemachine,positionsolidstands underneathtopreventitfalling,inaccordance withcurrentsafetyregulations.
◊ Deflatethetyrebeforeattemptingtoremove objectslodgedinthetread.
◊ Neverinflatetyreswithflammablegases;this couldproduceexplosionsandcauseinjuryto bystanders.
REMOVALSANDREFITMENTS
◊ Liftandhandleallheavypartswithlifting equipmentofsuitableratedcapacity.Make certainthatpartsaresupportedbysuitable slingsandhooks.Usetheeyeboltsprovidedfor thepurpose.Lookoutforpersonsstandingnear theloadbeinglifted.
◊ Handleallcomponentswithgreatcare.Never placehandsorfingersbetweenonepartand another.Alwaysweartype--approvedsafety gearandclothing:glasses/goggles,glovesand industrialfootwear.
◊ Donottwistchainsorwireropes.Alwayswear protectivegloveswhenhandlingropesorchains.
PRODUCTIDENTIFICATION
TheTelehandleranditsmaincomponentsare designatedusingvariousnumbersandletters allowingidentificationofthemachinebytheService network.Thefollowinginformationgivesthelocation ofidentificationdataplatesandofnumbersstamped onthemachine,providingvariousexamplesofthe detailsthatcanbefound.
CHASSISNUMBER
Thechassisnumberisstampedonthefrontofthe machine,onthetoppartofthemainframe,right handside.
NOTE: Whenorderingsparepartsorrequesting maintenanceonthemachine,theDealermayaskfor thechassisnumberandfortheidentification numbersofthecomponentsinvolved.These numbersarealsorequiredasanaidtoidentification ofthemachineintheeventoftheft.Keepthemina safeplace.
VEHICLEIDENTIFICATION DATAPLATES
Themachineidentificationdataplateislocatedatthe frontoftheseatwell.Recordthedetailsofyour machinebelow.
TECHNICALTYPE/MODEL
VEHICLECHASSISN
IDENTIFICATIONOF74kW TURBOCHARGEDENGINE
Theengineidentificationdataislocatedontheright handsideofthecrankcase.Recordtheinformation inthisspace,toallowquickreferenceincaseof necessity.
FRONTAXLEIDENTIFICATION
Theserialnumberandtypeoftheaxleareindicated ontheplatelocatedatthefrontoftheaxlehousing. Recordtheinformationinthisspace,toallowquick referenceincaseofnecessity.
AXLETYPE
SERIALN°
DATECODE
4x3POWERSHIFTIDENTIFICATION
Theserialnumberandmodelareprintedontheplate (1),ontheundersideofthetransmissionhousing. Recordtheinformationinthisspace,toallowquick referenceincaseofnecessity.
MODELN
REARAXLEIDENTIFICATION
Theserialnumberisindicatedonthedataplate securedtothereartransmissionhousing.Record theinformationinthisspace,toallowquickreference incaseofnecessity.
AXLETYPE
SERIALN°
DATECODE
CABIDENTIFICATIONDATAPLATE
Thecabidentificationdataplateshowstheserial numberandotherdetails,andislocatedonthefront oftheseat.Recordtheinformationinthisspace,to allowquickreferenceincaseofnecessity.
SERIALN°
DATECODE
TH001264
Identificationofattachments
Awiderangeofattachmentsisavailableforthe Telehandler.
Eachattachmentapprovedbythemanufacturer carriesanidentificationdataplateindicatingthetype ofattachmentandtherelativespecifications.
WARNING
Onlytheattachmentsapprovedbythemanufacturer canbeusedonthismachine.Themanufacturer declinesallliabilityintheeventofanymodificationor adaptationbeingmadeto attachments withoutthe Manufacturer’s knowledge.
Thedetailsindicatedontheplatesmountedtothe attachmentsarethefollowing:
• Attachmenttype
• Load
• Dateofmanufacture
• Unladenweight
• Serialnumber
ENVIRONMENTALCONSIDERATIONS
Thefollowingrecommendationscanbeuseful:
• Becomefamiliarwithpertinentlegislation currentlyoperativeinthecountryofuse,andbe certainitisproperlyunderstood.
• Intheeventthatnostatutoryregulationsexist, askforspecificinformationfromthesuppliersof lubricants,fuel,antifreezeandcleaning compoundsregardingtheireffectsonhumans andontheenvironment,andhowtostore, handleanddisposeofthesesubstancessafely.
4.Avoidspillagewhendrainingoffspentengine coolant,engine,gearboxandhydraulicoils, brakefluids,etc.Afterdrainingoff,donotmix brakefluidsorfuelswithlubricants.Storethem safelyandwithoutriskuntilsuchtimeastheycan bedisposedofproperly,inaccordancewithlocal regulationsandaspermittedbyavailable resources.
5.Moderncoolantcompounds,suchasantifreeze andotheradditives,mustbereplacedeverytwo years.Greatcaremustbetakentoensurethat thesesubstancesdonotpenetratethesoil;they mustbecollectedanddisposedofinsuchaway astopresentnodanger.
6.Donotopenuptheair conditioningsystem unassisted:itmaycontaingasesthatmustnot bereleasedintotheatmosphere.Specialist HVACtechniciansusespecialequipmentto dischargeandrechargeairconditioning systems.
Usefulindications
1.Donotfilltanksfromjerrycansorusing ineffectivepressurizeddeliverysystemsthat couldcauseextensivespillage.
2.Ingeneralavoidskincontactwithallfuels,oils, acids,solvents,etc.Mostofthesecontain substancesharmfultohealth.
3.Modernlubricantscontainadditives.Donotburn contaminatedfuelsand/orwasteoilsinnormal heatingsystems.
7.Anyleaksordefectsoftheenginecooling systemorhydraulicsystemmustberepaired withmaximumurgency.
8.Donotincreasethepressureofanypressurized circuit,sincethiscouldcauseseriousfailureof systemcomponents.
9.Protecthoseswhenweldingoperationsarein progress,sinceasplashofweldmetalcan penetrateandburn,weakenandultimately pierceahosewall,causingoil,coolantetc.to leakfromthecircuit.
MAINTENANCETECHNIQUES
GENERAL
Cleantheoutsideofallcomponentsbefore proceedingwithanytypeofrepair.Dirtandabrasive dustcanreducetheefficientlifeexpectancyofa componentandresultinexpensiverepairs.
Thetimespentinpreparingandcleaningwork surfaceswillgiveresultsintermsofmakingthework easierandsafer,andthecomponentsoverhauled willbemorereliableandoperatebetter.
Usecleaningfluidsproventobesafe.Sometypesof fluidcancauseseriousdamagetoO--ringsand irritatetheskin.Alwayscheckthatsolventsare suitableforcleaningcomponents,andcarrynorisks forthehealthandsafetyoftheuser.
ReplaceO--ringsandallothertypesofsealingrings everytimetheyaredisplaced.NeveruseoldO--rings orsealsandnewonestogether,whatevertheir condition.AlwayslubricatenewO--ringsandseals withhydraulicoilbeforeinstalling.
Whenreplacingcomponents,alwaysusethetool appropriatetothetypeofworkinhand.
HOSESANDPIPES
Alwaysreplacehosesandpipeswhenthesplayed endorfittingsaredamaged.
Whenanewhoseisinstalled,connectitwithout tighteningtheendsandmakesurethatitissettledin thecorrectlyposition,beforetighteningthefittings. Clipsmustbetightenedjustenoughtoholdthehose withoutpinchingthewall,andavoidrubbingcontact. Afterreplacingahoseattachedtoamovingpart, makecertainthatthehoseisnotdisturbedbythe movementofthepartinanyofthevariouspositions itcanassume.
Makesurethatnoneofthehosesinstalledis restrictedorbent.
Anyhosefittingsthataredamaged,defaced, pinchedorleakingwillrestricttheflowofoiland impairtheproductivityofthehydraulicservicesto whichtheyareconnected.Fittingsshowingsignsof displacementfromtheiroriginalcrimpedposition mustbeconsideredasalreadybroken,astheywill soonfailorbecomedetached.
Ahosewitharaggedoutersleeveallowswaterto penetrate.Asaresult,thebraidreinforcementwill corrodeunnoticedalongtheentirelengthofthe hose,resultingultimatelyinfailureofthehoseitself.
Ifahoseswells,thisindicatesthatthereisinternal leakageduetoastructuralfailure.Thiscondition deterioratesveryquicklyandwillsoonleadtothe failureofthehose.
Hosesthatarerestricted,pinched,tootautor deformedwillingeneralbereadilysubjecttointernal structuraldamagethatcanresultinalowerrateof flowandreducedoperatingspeed,andlead ultimatelytoirreparablefailureofthehose.
Unsupportedandfreelymovablehosesmustbe preventedfromcontacteitherwithoneanotheror withadjacentworkingsurfaces.Suchcontact producesarubbingactionthatwillshortentheuseful lifeofthehose.
FITTINGSWITHFRONTSEALING O--RINGS
WhenrepairingfittingswithfrontsealingO--rings,the followingproceduresshouldbeobserved.
CAUTION:NEVERDISCONNECTANDNEVER TIGHTENAHOSEORPIPEWHENUNDER PRESSURE.IFINDOUBT,MOVETHECONTROL LEVERSREPEATEDLYWITHTHEENGINE SWITCHEDOFFBEFOREDISCONNECTINGA HOSEORPIPE.
1.Loosenthefittingsandseparatethehoseor pipe,thendetachthefittingandremovethe O--ring.
2.DipanewO--ringincleanhydraulicoilbefore installingit.PositionthenewO--ringinthefitting, holdingitinplacewithvaselineifnecessary.
3.Installthenewhoseorpipeandhand--tightenthe fitting,whileholdingthehoseorpipesteadyto preventitturning.
4.Usingtwowrenchesofsuitabletype,tightenthe fittingtothetorqueprescribedforitssize.Refer tothetablefurtheronfortighteningtorques.
NOTE:toensurethataconnectionwillnotleak, itisimportantthatthefittingsaretightened neithertoomuchnortoolittle.
SPECIFICSEALINGCOMPOUNDS
Thefollowingsealingcompoundsmustbeused,followingtheindicationsgivenintheManual:
SEALANTSPROPRIETARYNAME
AnaerobicsealantLOCTITE518(gasketmaker)
RTVsiliconesealantLOCTITESUPERFLEX593,595or596 LOCTITEULTRABLUE587DOWCORNING SILASTIC732GENERALELECTRICRTV103 or108
PipesealantPST592(pipesealantwithteflon)
Lockingcompoundforboom padsscrewthreads
LOCTITE243/BLUE
TIGHTENINGVALUESFORTHREADEDFASTENERS
Checkperiodicallythatthreadedfastenersare properlytightened.
Refertothefollowingtablestodeterminethecorrect tighteningtorquewhenthreadedfastenersonthe Telehandlerarechecked,adjustedorreplaced.
IMPORTANT:DONOTusethevalueslistedinthe tableswhentheManualindicatesadifferenttorque
ortighteningprocedureforaspecificapplication.The torquevaluesareprovidedforgeneraluseonly. Makesurethatthethreadsoffastenersareclean andundamaged.
NOTE: toensurenutsandboltsareproperly tightened,atorquewrenchmustbeused.
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