LM1330 LM1333
LM1330 LM1333
TELEHANDLERS
WorkshopManual
PrintN.87755818(I--2008)
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.
ATTENTION
Onmachineshavinghydraulically,mechanicallyand/orcablecontrolledequipment(suchasshowels, loaders,dozers,scrapersetc.)becertaintheequipmentisloweredtothegroundbeforeservicing,adjustingand/orrepairing. Ifitisnecessarytohavetheequipmentpartiallyorfullyraisedtogainaccesstocertainitems,besure theequipmentissuitablysupportedbymeansotherthanthehydraulicliftcylinders,cableand/ormechanicaldeviceusedforcontrollingtheequipment.
MODELCODES
Thecompleterangeoftelescopichandlers(Telehandler)describedinthismanualisidentifiedinthetextby referencetothemaximumextensionofthetelescopicarm.
Thevehicleslistedbelowmaynotbeavailableinallcountriesormarkets,thereforeforthelatestinformation consultyourauthoriseddealer.
Model
LM1330 LM1333 nostab. Smallstab. Engine 74kWTurbochargedwithAftercooler
WorkshopManual
SECTION55--ELECTRICALSYSTEM
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.
“O--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.
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.
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,unlessheisanauthorisedoperatorco--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.
◊ 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.
STARTING
◊ Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaustfumes.
◊ Donotplacehead,body,limbs,feet,handsor fingers,nearrotatingfansorbelts.Beespecially alertnearpusherfans.
87751818 --01--2008
ENGINE
◊ Loosentheradiatorcapveryslowly,torelease pressurefromthesystem,beforeremovingit.All coolantleveltop--upsmustbeperformedwith engineinoperativeoratlowidle,ifwarm
◊ Donotrunenginewhenrefuellingandusecare iftheengineishotduetotheincreasedpossibilityofafireiffuelisspilled.
◊ Neverattempttocheckoradjustfanbeltswhen engineisrunning.Donotadjustenginefuel pumpwhenmachineismoving.
◊ Neverlubricatethemachinewithenginerunning.
◊ IMPORTANT: Inaccordancewithdirectivesno. 2000/25/ECoftheEuropeanUnionandno.40 CFRPart.89oftheU.S.A.itisprohibitedtomake anytypeofalterationontheengine,includingunloadinguncertifiedsoftware.Anyalterationmade onanengineorfuelsupplysystemfoundnotcomplyingwithcurrentspecificationsinvolves: legally, thattheengineisillegalinthatmarket andisnotprotectedbyinsurance,thewarranty ontheengineandsupply systembecomesvoid; inaccordancewithwhatdeclaredbythecertificates,thecustomercanbeconfrontedbyelevatedcostsforthereconditioningoftheengine; technically,possibleoverloadsontheengine components;possibleprematurewearoftheengineduetoexcessiveloadonthecomponents ortheuseofcontaminatedoil.Onlypersonnel authorisedbytheManufacturercanperformrepairsonthefuelsupply system.Repairscanbe performedonlyusingthespecificationsprovided bytheManufacturer.
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.
PRODUCTIDENTIFICATION
TheTelehandleranditsmaincomponentsareidentifiedbyvariousnumbersandlettersprovidingits identificationbytheServicenetwork.Thefollowing informationgivesthelocationoftheidentification plates,ofthenumbersstampedonthemachineand variousexamplesofwhatcanbefoundonthemachine.
VEHICLESERIALNUMBER
Theserialnumber(1)isstampedonthefrontpartof themachine,ontheuppersideofthemainframe, rightside.
NOTE: Theserialnumberandtheidentification numberofthecomponentscanberequestedbythe DealerwhenSparePartsareorderedorinterventionsarerequired.Thesenumbersarealsorequired ashelpinidentifyingthemachineintheeventoftheft. Keeptheminasafeplace.
VEHICLEIDENTIFICATIONPLATES
Thevehicleidentificationplateislocatedontheleft sideoftheseatlocation.Recordherebelowthedata foryourmachine.
TECHNICALTYPE/MODEL
IDENTIFICATIONOFENGINE
F4GE9484F*J600
101HP(74Kw)withAftercooler
Theidentificationdataoftheenginearelocatedon therightsideoftheenginecrankcase.Recordthe informationbelowforquickreferenceincaseofnecessity.
MODELNo.
SERIALNo.
TH00R077
FRONTAXLEIDENTIFICATION
Theserialnumberandaxletypeisprintedonthe plate(1)locatedonthefrontoftheaxlehousing. Recordtheinformationbelowforquickreferencein thecaseofnecessity.
AXLETYPE
SERIALNo.
DATECODE
4x3POWERSHIFTTRANSMISSION
IDENTIFICATION
Theserialnumberandtypeisprintedontheplate(1), onthelowersideofthetransmission.Recordthe informationbelowforquickreferenceinthecaseof necessity.
MODELNo.
SERIALNo.
DATECODE
IDENTIFICATIONOFREARAXLE
Theserialnumberisindicatedonplate(1)secured onthereartransmissionhousing.Copyherethe serialnumber,forapromptconsultationincaseof necessity.
AXLETYPE
SERIALNo.
DATECODE
IDENTIFICATIONOFCAB
Thecabidentificationplateincludestheserial numberandadditionaldataandislocatedonthe frontsideoftheseat.Pleasecopyherebelowthe serialnumberforapromptconsultationincaseof necessity.
SERIALNo.
DATECODE
87751818 --01--2008
TH00R016
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.
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 LEVERSSEVERALTIMESWITHTHEENGINE 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.
SPECIFICSEALINGCOMPOUNDS
Thefollowingsealingcompoundsmustbeused,complyingwiththeindicationsprovidedbytheManual:
SEALANTSCOMMERCIALNAME
AnaerobicsealantLOCTITE518(liquidgasket)
RTVsiliconsealantLOCTITESUPERFLEX593,595or596 LOCTITEULTRABLUE587DOWCORNINGSILASTIC 732GENERALELECTRICRTV103or108
PipesealantPST592(pipesealantwithteflon)
Lockingcompoundforboom padsscrewthreads
LOCTITE243/BLUE
TIGHTENINGVALUESFORFASTENERS
Checkperiodicallythatthefastenersareproperly tightened.
Baseduponthetablestofollow,determinethecorrecttighteningtorquewhenpartsofthefastening componentsarechecked,adjustedorreplaced.
IMPORTANT:DONOTusethevalueslistedinthe tableswhentheManualindicatesadifferenttorque
ortighteningprocedureforaspecificapplication.The torquevaluesareprovidedforgeneraluseonly. Makesurethatthethreadsofthefastenersareclean andundamaged.
NOTE: Useatorquewrenchtotightenfastenerscorrectly.
IDENTIFICATION
HEXSCREWS(WITHOUTNUT)ANDROUNDHEADBOLTS
CLASS5.6ANDHIGHER
IDENTIFICATIONOFTHEMANUFACTURER
IDENTIFICATIONOFTHEMANUFACTURER MINIMUMTIGHTENINGTORQUESFORFASTENERS
HEXNUTSANDTIGHTENINGNUTS
CLASS05ANDHIGHER
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