New Holland LM A 415A LM425A LM435A LM445A Loader – COMPLETE SERVICE / REPAIR / SHOP MANUAL

NEW HOLLAND Repair Manual LM--A -- Loader Multipurpose CONTENTS SECTION 00 -- HEALTH, SAFETY, MAINTENANCE CHAPTER 1 -- General Safety & Product Identification CHAPTER 2 -- Specifications & Tooling

SECTION 10 -- ENGINE OVERHAUL CHAPTER 1 - Engine & Fuel System CHAPTER 2 -- Engine Removal

SECTION 21 -- TRANSMISSIONS CHAPTER 1 - 4X4 Compact Shuttle CHAPTER 2 -- Powershift Operating Lever CHAPTER 3 - Powershift Overhaul

SECTION 23 -- DRIVE LINES CHAPTER 1 -- Drive Shafts

SECTION 25 -- FRONT AXLE CHAPTER 1 -- Front Axle

SECTION 27 -- REAR AXLE CHAPTER 1 -- Rear Axle

SECTION 33 -- BRAKES CHAPTER 1 -- Brakes CHAPTER 2 - Trailer Brake Valve 604.55.181.01 09-- 2004

CONTENTS

SECTION 35 -- HYDRAULIC SYSTEMS CHAPTER 1 - Hydraulic Circuits & Components, Mechanical & Monoramp System CHAPTER 2 - Hydraulic Circuits & Components, Flow Sharing System CHAPTER 3 -- Casappa Hydraulic Pump CHAPTER 4 -- Hydraulic Cylinders CHAPTER 5 -- Smooth Ride Control System CHAPTER 6 -- Auxiliary Hydraulics

SECTION 39 -- CHASSIS CHAPTER 1 -- Frame, Chassis and Attachments

SECTION 41 -- STEERING CHAPTER 1 -- Hydrostatic Steering System

SECTION 50 -- CAB ENVIRONMENT CHAPTER 1 -- Heating System CHAPTER 2 - Air Conditioning

SECTION 55 -- ELECTRICAL SYSTEM CHAPTER 1 - Electrical System Introduction CHAPTER 2 - Wiring Diagrams, Harnesses and Connectors CHAPTER 3 -- Starting System CHAPTER 4 -- Charging System CHAPTER 5 - Battery CHAPTER 6 - Load Status System CHAPTER 7 - Monoramp Control System CHAPTER 8 -- Flow Sharing Control System CHAPTER 9 -- Smooth Ride Control System

SECTION 82 -- LOADER CHAPTER 1 - Overhaul

SECTION 90 -- CAB CHAPTER 1 - Overhaul 604.55.181.01 09-- 2004

SECTION 00 -- MAINTENANCE -- CHAPTER 1

SECTION 00 -- MAINTENANCE Chapter 1 -- General Instructions IMPORTANT NOTICE All maintenance and repair operations described in this manual should be carried out exclusively by NEW HOLLAND authorised workshops. All instructions detailed should be carefully observed and special equipment indicated should be used if necessary. Everyone who carries out service operations described without carefully observing these prescriptions will be directly responsible of deriving damages.

SHIMMING At each adjustment, select adjusting shims, measure them individually using a micrometer and then sum up recorded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on rated value indicated for each shim.

ROTATING SHAFT SEALS To correctly install rotating shaft seals, observe the following instructions: -- Let the seal soak into the same oil as it will seal for at least half an hour before mounting; -- Thoroughly clean the shaft and ensure that the shaft working surface is not damaged; -- Place the sealing lip towards the fluid. In case of a hydrodynamic lip, consider the shaft rotation direction and orient grooves in order that they deviate the fluid towards the inner side of the seal; -- Coat the sealing lip with a thin layer of lubricant (oil rather than grease) and fill with grease the gap between the sealing lip and the dust lip of double lip seals; -- Insert the seal into its seat and press it down using a suitable tool. Do no tap the seal with a hammer or a drift; -- Take care to insert the seal perpendicularly to its seat while you are pressing it. Once the seal is settled, ensure that it contacts the thrust element if required.; -- To prevent damaging the sealing lip against the shaft, place a suitable protection during installation.

‘O’ RINGS Lubricate the ‘O’ rings before inserting them into their seats. This will prevent the ‘O’ rings from rolling over during mounting which will jeopardise sealing.

SEALERS Apply NEW HOLLAND FLEXIBLE GASKET SEALANT 82995770 or a suitable equivalent, over the mating surfaces marked with an X. Before applying the sealer, prepare the surface as follows: -- remove possible scales using a metal brush; -- thoroughly degrease the surfaces using NEW HOLLAND DEGREASER 82995779, or a suitable equivalent.

BEARINGS It is advisable to heat the bearings to 80 to 90°C before mounting them on their shafts and cool them down before inserting them into their seats with external tapping.

SPRING PINS When mounting split socket spring pins, ensure that the pin notch is oriented in the direction of the effort to stress the pin. Spiral spring pins should not be oriented during installation. 604.55.181.00 09--2003

SECTION 00 -- MAINTENANCE -- CHAPTER 1 NOTES FOR SPARE PARTS Use exclusively genuine NEW HOLLAND spare parts, the only ones bearing this logo.

Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted in production. Only the NEW HOLLAND genuine spare parts can offer this guarantee. All spare parts orders should be complete with the following data: -- Vehicle model (commercial name) and frame number; -- engine type and number; -- part number of the ordered part, which can be found on the “Microfiches” or the “Spare Parts Catalogue”, which is the base for order processing. NOTES FOR EQUIPMENT Equipment which NEW HOLLAND proposes and shows in this manual are as follows: -- studied and designed expressly for use on NEW HOLLAND Vehicles; -- necessary to make a reliable repair; -- accurately built and strictly tested to offer efficient and long--lasting working means. We also remind the Repair Personnel that having these equipment means: -- work in optimal technical conditions; -- obtain best results; -- save time and effort; -- work more safely. NOTICES Wear limits indicated for some details should be intended as advised, but not binding values. The words “front”, “rear”, “right hand”, and “left hand” referred to the different parts should be intended as seen from the operator’s seat oriented to the normal sense of movement of the Vehicle. HOW TO MOVE THE VEHICLE WITH THE BATTERY REMOVED Cables from the external power supply should be connected exclusively to the respective terminals of the Vehicle positive and negative cables using pliers in good condition which allow proper and steady contact. Disconnect all services (lights, wind--shield wipers, etc.) before starting the Vehicle. If it is necessary to check the Vehicle electrical system, check it only with the power supply connected. At check end, disconnect all services and switch the power supply off before disconnecting the cables.

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SAFETY RULES PAY ATTENTION TO THIS SYMBOL This warning symbol points out important messages involving personal safety. Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and safeguard your safety and personal integrity. In this manual you will find this symbol together with the following key--words: WARNING (ATTENZIONE) -- it gives warning about improper repair operations and deriving potential consequences affecting the service technician’s personal safety. DANGER (PERICOLO) -- it gives specific warning about potential dangers for personal safety of the operator or other persons directly or indirectly involved. if they are certified operators to assist in the operation to be carried out.

TO PREVENT ACCIDENTS Most accidents and personal injuries taking place in workshops are due from non--observance of some simple and essential prudential rule and safety precautions. For this reason, IN MOST CASES THEY CAN BE AVOIDED. It suffices to foresee possible causes and act consequently with necessary caution and care. The possibility that an accident might occur with any type of machines should not be disregarded, no matter how well the machine in question was designed and built. A wise and careful service technician is the best precautions against accidents. Careful observance of this only basic precaution would be enough to avoid many severe accidents. DANGER: Never carry out any cleaning, lubrication or maintenance operations when the engine is running.

◊

Never operate the machine or use attachments from a place other than sitting at the operator’s seat.

◊

Never carry out any operation on the machine when the engine is running, except when specifically indicated.

◊

Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc.

◊

All repair and maintenance operations should be carried out with the greatest care and attention.

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Service stairs and platforms used in a workshop or in the field should be built in compliance with the safety rules in force.

◊

Disconnect the batteries and label all controls to warn that the Vehicle is being serviced. Block the machine and all equipment which should be raised.

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Never check or fill fuel tanks and accumulator batteries, nor use starting liquid if you are smoking or near open flames as such fluids are flammable.

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Brakes are inoperative when they are manually released for maintenance purposes. In such cases, the machine should be kept constantly under control using blocks or similar devices.

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The fuel filling gun should remain always in contact with the filler neck. Maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity buildup.

SAFETY RULES GENERALITIES ◊

Carefully follow specified repair and maintenance procedures.

◊

Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get hold into moving parts. We advise to use approved safety clothing such as anti--slipping footwear, gloves, safety goggles, helmets, etc.

◊

Never carry out any repair on the machine if someone is sitting on the operator’s seat, except

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SECTION 00 -- MAINTENANCE -- CHAPTER 1

◊

Use exclusively specified towing points for towing the Vehicle. Connect parts carefully. Ensure that foreseen pins and/or locks are steadily fixed before applying traction. Do not stop near towing bars, cables or chains working under load.

◊

In case of operations outside the workshop, drive the Vehicle to a flat area and block it. If working on an incline cannot be avoided, first block the Vehicle carefully. Move it to a flat area as soon as possible with a certain extent of safety.

◊

To transfer a failed Vehicle, use a trailer or a low loading platform trolley if available.

◊

To load and unload the machine from the transportation mean, select a flat area providing a firm support to the trailer or truck wheels. Firmly tie the machine to the truck or trailer platform and block wheels as required by the forwarder.

Ruined or plied cables and chains are unreliable. Do not use them for lifting or trailing. Always handle them wearing gloves of proper thickness.

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Chains should always be safely fastened. Ensure that fastening device is strong enough to hold the load foreseen. No persons should stop near the fastening point, trailing chains or cables.

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The working area should be always kept CLEAN and DRY. Immediately clean any spillage of water or oil.

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Do not pile up grease or oil soaked rags, as they constitute a great fire hazard. Always place them into a metal container.

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For electrical heaters, battery--chargers and similar equipment use exclusive auxiliary power supplies with a efficient ground to avoid electrical shock hazard.

◊

Always use lifting equipment and similar of appropriate capacity to lift or move heavy components.

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Pay special attention to bystanders.

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Never pour gasoline or diesel oil into open, wide and low containers.

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Never use gasoline, diesel oil or other flammable liquids as cleaning agents. Use non--flammable non--toxic proprietary solvents.

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Do not keep into your pockets any object which might fall unobserved into the Vehicle’s inner compartments.

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Wear protection goggles with side guards when cleaning parts using compressed air.

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Do not exceed a pressure of 2.1 bar, in accordance with local regulations.

Whenever there is the possibility of being reached by ejected metal parts or similar, use protection eye mask or goggles with side guards, helmets, special footwear and heavy gloves.

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Do not run the engine in a closed building without proper ventilation.

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Do not smoke, use open flames, cause sparks in the nearby area when filling fuel or handling highly flammable liquids.

◊

Do not use flames as light sources when working on a machine or checking for leaks.

Wear suitable protection such as tinted eye protection, helmets, special clothing, gloves and footwear whenever it is necessary to carry out welding procedures. All persons standing in the vicinity of the welding process should wear tinted eye protection. NEVER LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED.

◊

Move with caution when working under a Vehicle, and also on or near a Vehicle. Wear proper safety accessories: helmets, goggles and special footwear.

Metal cables with the use get frayed. Always wear adequate protections (heavy gloves, eye protection, etc.)

◊

Handle all parts with the greatest caution. Keep your hands and fingers far from gaps, moving gears and similar. Always use approved protective equipment, such as eye protection, heavy gloves and protective footwear.

◊

During checks which should be carried out with the engine running, ask an assistant to seat at the operator’s seat and keep the service technician under visual control at any moment.

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Before starting the Vehicle or its attachments, check, adjust and block the operator’s seat. Also ensure that there are no persons within the Vehicle or attachment operating range.

SECTION 00 -- MAINTENANCE -- CHAPTER 1 START UP ◊ Never run the engine in confined spaces which are not equipped with adequate ventilation for exhaust gas extraction. ◊ Never bring your head, body, arms, legs, feet, hands, fingers near fans or rotating belts. ENGINE ◊ Always loosen the radiator cap very slowly before removing it to allow pressure in the system to dissipate. Coolant should be topped up only when the engine is stopped or idle if hot. ◊ Do not fill up fuel tank when the engine is running, mainly if it is hot, to avoid ignition of fires in case of fuel spilling. ◊ Never check or adjust the fan belt tension when the engine is running. Never adjust the fuel injection pump when the Vehicle is moving. ◊ Never lubricate the Vehicle when the engine is running. ELECTRICAL SYSTEMS ◊ If it is necessary to use auxiliary batteries, cables must be connected at both sides as follows: (+) to (+) and (--) to (--). Avoid short--circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY FLAMMABLE. During charging, leave the battery compartment uncovered to improve ventilation. Avoid checking the battery charge by means of “jumpers” made by placing metallic objects across the terminals. Avoid sparks or flames near the battery area. Do no smoke to prevent explosion hazards. ◊ Prior to any service, check for fuel or coolant leaks. Remove these leaks before going on with the work. ◊ Do not charge batteries in confined spaces. Ensure that ventilation is appropriate to prevent accidental explosion hazard due to build--up of gases releaved during charging. ◊ Always disconnect the batteries before performing any type of service on the electrical system.

HYDRAULIC SYSTEMS ◊ Some fluid slowly coming out from a very small port can be almost invisible and be strong enough to penetrate the skin. For this reason, NEVER USE YOUR HANDS TO CHECK FOR LEAKS, but use a piece of cardboard or a piece of wood to this purpose. If any fluid is injected into the skin, seek medical aid immediately. Lack of immediate medical attention, serious infections or dermatosis may result. ◊ Always take system pressure readings using the appropriate gauges. WHEELS AND TYRES ◊ Check that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check possible damages to the rims and tyres. ◊ Keep off and stay at the tyre side when correcting the inflation pressure. ◊ Check the pressure only when the Vehicle is unloaded and tyres are cold to avoid wrong readings due to over--pressure. Do not reuse parts of recovered wheels as improper welding, brazing or heating may weaken the wheel and make it fail. ◊ Never cut, nor weld a rim with the inflated tyre assembled. ◊ To remove the wheels, block both front and rear Vehicle wheels. Raise the Vehicle and install safe and stable supports under the Vehicle in accordance with regulations in force. ◊ Deflate the tyre before removing any object caught into the tyre tread. ◊ Never inflate tyres using flammable gases as they may originate explosions and cause injuries to bystanders. REMOVAL AND INSTALLATION ◊ Lift and handle all heavy components using lifting equipment of adequate capacity. Ensure that parts are supported by appropriate slings and hooks. Use lifting eyes provided to this purpose. Take care of the persons near the loads to be lifted. ◊ Handle all parts with great care. Do not place your hands or fingers between two parts. Wear approved protective clothing such as safety goggles, gloves and footwear. ◊ Do not twine chains or metal cables. Always wear protection gloves to handle cables or chains.

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PRODUCT IDENTIFICATION Your machine and its major components are identified by various numbers and letters for recognition in After Sales Service. The following information provides the locations of these identification plates, stamped numbers and examples of what can be found on your machine. VEHICLE SERIAL NUMBER (1) The Serial Number is stamped at the front on the top of the right hand main frame. Example: *041716103* NOTE: The Serial Number and identification numbers of components may be required by your dealer when requesting parts or service. These numbers will also be required as an aid to identifying the machine if it is ever stolen, keep them safe.

1 1 VEHICLE IDENTIFICATION PLATE (2) The machine identification plate is located on the left hand of the seat pod. Record the data of your machine below. MODEL/TECHNICAL TYPE UNIT SERIAL NO. YEAR

2 2 ENGINE IDENTIFICATION (3) The engine identification information is located on the left hand side of the engine block. Record the information below for quick reference. MODEL NO. SERIAL NO. DATE CODE.

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FRONT AXLE IDENTIFICATION The serial number and axle type is printed on the plate (1), located on the front of the axle housing. Record the information below for quick reference. AXLE TYPE

SERIAL NO. 1 DATE CODE

TRANSMISSION IDENTIFICATION 4x4 POWER SHUTTLE The serial number and type is printed on the plate (1), on the lower right side of the transmission. Record the information below for quick reference. MODEL NO.

1 SERIAL NO. 2 DATE CODE

TRANSMISSION IDENTIFICATION 4x3 POWER SHIFT The serial number and type is printed on the plate (1), on the lower part of the transmission. Record the information below for quick reference. MODEL NO.

1 SERIAL NO.

0007001

3 DATE CODE

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REAR AXLE IDENTIFICATION The serial number is stamped on the plate (1) attached to the rear axle housing. Record the serial number below for quick reference. AXLE TYPE. SERIAL NUMBER. DATE CODE 4

IDENTIFICATION PLATES IN THE CAB The Cab Identification Plate with serial number and details are printed on the plate to the rear left hand side of the seat. Record the serial number below for quick reference.

Serial No. Date Code

The ROPS and Fops details are printed on the certification plate and mounted with the Cab Plate. Record the serial number below for quick reference. Serial No. Date Code

The Engine details are printed on the certification plate‘s and mounted with the Cab Plate. Record the serial number below for quick reference. Serial No. Date Code

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IMPORTANT ECOLOGICAL CONSIDERATIONS The following are recommendations which may be of assistance:

3. Modern oils contain additives. Do not burn contaminated fuels and/or waste oils in ordinary heating systems.

• Become acquainted with and ensure that you understand the relative legislation applicable to your country. • Where no legislation exists, obtain information from suppliers of oils, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use and dispose of these substances.

4. Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources.

5. Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil but should be collected and disposed of safely.

6. Do not open the Air--Conditioning system yourself. It may contain gases which should not be released into the atmosphere. Your air conditioning specialist has a special equipment for discharging and charging the system.

HELPFUL HINTS 1. Avoid filling tanks using jerry cans or inappropriate pressurised fuel delivery systems which may cause considerable spillage.

2. In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which can be harmful to your health.

7. Repair any leaks or defects in the engine cooling or hydraulic system immediately.

8. Do not increase the pressure in a pressurised circuit as this may lead to a catastrophic failure of the system components.

9. Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, causing the loss of oils, coolant, etc.

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SERVICE TECHNIQUES GENERAL Clean the exterior of all components before carrying out any form of repair. Dirt and abrasive dust can reduce the efficient working life of a component and lead to costly replacement. Time spent on the preparation and cleanliness of working surfaces will pay dividends in making the job easier and safer and will result in overhauled components being more reliable and efficient in operation. Use cleaning fluids which are known to be safe. Certain types of fluid can cause damage to ‘O’ rings and cause skin irritation. Solvents should be checked that they are suitable for the cleaning of components and also that they do not risk the personal safety of the user. Replace ‘O’ rings, seals or gaskets whenever they are disturbed. Never mix new and old seals or ‘O’ rings, regardless of condition. Always lubricate new seals and ‘O’ rings with hydraulic oil before installation. When replacing component parts, use the correct tool for the job.

HOSES AND TUBES Always replace hoses and tubes if the cone end or the end connections on the hose are damaged. When installing a new hose, loosely connect each end and make sure the hose takes up the designed position before tightening the connection. Clamps should be tightened sufficiently to hold the hose without crushing and to prevent chafing. After hose replacement to a moving component, check that the hose does not foul by moving the component through the complete range of travel. Be sure any hose which has been installed is not kinked or twisted. Hose connections which are damaged, dented, crushed or leaking, restrict oil flow and the productivity of the components being served. Connectors which show signs of movement from the original swaged position have failed and will ultimately separate completely. A hose with a chafed outer cover will allow water entry. Concealed corrosion of the wire reinforcement will subsequently occur along the hose length with resultant hose failure.

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Ballooning of the hose indicates an internal leakage due to structural failure. This condition rapidly deteriorates and total hose failure soon occurs. Kinked, crushed, stretched or deformed hoses generally suffer internal structural damage which can result in oil restriction, a reduction in the speed of operation and ultimate hose failure. Free-moving, unsupported hoses must never be allowed to touch each other or related working surfaces. This causes chafing which reduces hose life.

‘O’ RING FLAT FACE SEAL FITTINGS When repairing ‘O’ ring face seal connectors, the following procedures should be observed.

WARNING: NEVER DISCONNECT OR TIGHTEN A HOSE OR TUBE THAT IS UNDER PRESSURE. IF IN DOUBT, ACTUATE THE OPERATING LEVERS SEVERAL TIMES WITH THE ENGINE SWITCHED OFF PRIOR TO DISCONNECTING A HOSE OR TUBE. 1. Release the fittings and separate the hose or tube assembly, then remove and discard the ‘O’ ring seal from the fitting. 2 Dip a new ‘O’ ring seal into clean hydraulic oil prior to installation. Install a new ‘O’ ring into the fitting and, if necessary, retain in position using petroleum jelly. 3. Assemble the new hose or tube assembly and tighten the fitting finger tight, while holding the tube or hose assembly to prevent it from turning. 4. Use two suitable wrenches and tighten the fitting to the specified torque according to the size of the fitting. Refer to the following torque chart. NOTE: To ensure a leak-free joint is obtained, it is important that the fittings are not over or under torqued.

SECTION 00 -- MAINTENANCE -- CHAPTER 1

SEALER SPECIFICATIONS The following sealers should be used as directed in the manual:

SEALERS

PART NUMBER TRADE DESCRIPTION

Anaerobic sealer

82995770/1

LOCTITE GASKET ELIMINATOR 518

RTV silicone sealer

82995775/6

LOCTITE SUPERFLEX 593, 595 or 596 LOCTITE ULTRA BLUE 587 DOW CORNING SILASTIC 732 GENERAL ELECTRIC RTV 103 OR 108

Pipe sealant

82995768

PST 592 PIPE SEALANT WITH TEFLON

Thread-locking compound

82995773

LOCTITE 271 THREADLOCKER/SEALANT (red)

HARDWARE TORQUE VALUES Check the tightness of hardware periodically. Use the following charts to determine the correct torque when checking, adjusting or replacing hardware on the Telehandler.

Make sure fastener threads are clean and not damaged.

NOTE: A torque wrench is necessary to properly torque hardware.

IMPORTANT: DO NOT use the values listed in the charts if a different torque value or tightening procedure is specified in this manual for a specific application. Torque values listed are for general use only.

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MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS -- LBF. FT (NEWTON-METRES -- Nm) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC HARDWARE AND LOCKNUTS UNPLATED

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL 8 CL.8 W/CL8.8 BOLT

15* (1.7)

19* (2.2)

23* (2.6)

30* (3.4)

33* (3.7)

42* (4.8)

16* (1.8)

51* (5.8)

67* (7.6)

79* (8.9)

102* (12)

115* (13)

150* (17)

56* (6.3)

124* (14)

159* (18)

195* (22)

248* (28)

274* (31)

354* (40)

133* (15)

M10

21* (28)

27* (36)

32* (43)

41* (56)

45* (61)

58* (79)

22* (30)

M12

36* (49)

46* (63)

55* (75)

72* (97)

79* (107)

102* (138)

39* (53)

M16

89* (121)

117* (158)

137* (186)

177* (240)

196* (266)

254* (344)

97* (131)

M20

175* (237)

226* (307)

277* (375)

358* (485)

383* (519)

495* (671)

195* (265)

M24

303* (411)

392* (531)

478* (648)

619* (839)

662* (897)

855* (1160)

338* (458)

SIZE

CLASS 8.8

CLASS 5.8

NOMINAL

CLASS 10.9

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

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CLOCK MARKING

SECTION 00 -- MAINTENANCE -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS -- LBF. FT (NEWTON-METRES -- Nm) FOR NORMAL ASSEMBLY APPLICATIONS

INCH HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL SIZE

UNPLATED or PLATED SILVER

PLATED W/ZnCr

1/4

55* (6.2)

5/16

SEA GRADE 5 PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

72* (8.1)

86* (9.7)

115* (13)

149* (17)

SEA GRADE 8 PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

112* (13)

121* (14)

178* (20)

229* (26)

250* (28)

LOCKNUTS GR.B w/GR5 BOLT

GR.C w/GR8 BOLT

NOMINAL SIZE

157* (18)

61* (6.9)

86* (9.8)

1/4

324* (37)

125* (14)

176* (20)

5/16

GOLD

3/8

17 (23)

22 (30)

26 (35)

34 (46)

37 (50)

48 (65)

19 (26)

26 (35)

3/8

7/16

27 (37)

35 (47)

42 (57)

54 (73)

59 (80)

77 (104)

30 (41)

42 (57)

7/16

1/2

42 (57)

54 (73)

64 (87)

83 (113)

91 (123)

117 (159)

45 (61)

64 (88)

1/2

9/16

60 (81)

77 (104)

92 (125)

120 (163)

130 (176)

169 (229)

65 (88)

92 (125)

9/16

5/8

83 (112)

107 (145)

128 174)

165 (224)

180 (244)

233 (316)

90 (122)

127 (172)

5/8

3/4

146 (198)

189 (256)

226 (306)

293 (397)

319 (432)

413 (560)

160 (217)

226 (306)

3/4

7/8

142 (193)

183 (248)

365 (495)

473 (641)

515 (698)

667 (904)

258 (350)

364 (494)

7/8

213 (289)

275 (373)

547 (742)

708 (960)

773 (1048)

1000 (1356)

386 (523)

545 (739)

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS

SEA GRADE 2

SEA GRADE 5

SEA GRADE 8 REGULAR

SEA GRADE 5

SEA GRADE 8

NUTS

HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION GRADE A NO NOTCHES GRADE B ONE CIRCUMFERENTIAL NOTCHE GRADE C TWO CIRCUMFERENTIAL NOTCHES GRADE A NO MARKS GRADE B THREE MARKS GRADE C SIX MARKS

GRADE IDENTIFICATION GRADE A NO MARKS GRADE B THREE MARKS GRADE C SIX MARKS MARKS NEED NOT BE LOCATED AT CORNERS

GRADE IDENTIFICATION

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NOTES

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SECTION 00 -- MAINTENANCE -- CHAPTER 2

SECTION 00 -- MAINTENANCE Chapter 2 -- Specifications, Data and Tooling The following data is for general guidance. Where specific data or dimensions are required and not quoted in this section, refer to the section in the Repair Manual relating to the component under repair.

ENGINE DATA

95 HP

Type

110 HP Diesel

Aspiration

Turbo

No. of cylinders

Turbo intercooled 4

Bore

104mm (4.09 in)

Stroke

132mm (5.19 in) 4485 (cm3) (272 cu.in)

Displacement Compression Ratio

17.5:1

Firing Order

1.3.4.2.

Idle Speed Maximum ‘No--Load’ Speed

rev/min rev/min

800 2430

Rated Speed

rev/min

2200

Maximum Torque (Nm) @ 1400 e.r.p.m.

398

480

Tappet Clearance (cold) -- Intake -- Exhaust

COOLING SYSTEM Type Fan Fan Belt Deflection: Turbo / Turbo Intercooled Drive Belt Deflection Air Conditioning Compressor Thermostat: Starts to Open at Radiator Cap

FUEL SYSTEM Injection Pump Type Cold Start Device Excess Fuel Device Fuel Shut Off Lift Pump

0.30 mm (0.011 in) 0.55 mm (0.021 in)

Pressurized Full Flow By--pass with Expansion Chamber 5 Blade 10--13mm 13--16 mm 79°C 0.50 bar

Rotary Inlet Manifold Grid Heater Automatic Solenoid Mechanical 604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

TRANSMISSION POWER SHUTTLE -- T4--2024 4x4= 4 Forward and 4 Reverse Gears Model

Ratio

Stall Speed

LM 415A Turbo

2.38

2160

LM 415A Turbo Intercooled

2.38

2160

LM 425A Turbo Intercooled

2.38

2160

LM 435A Turbo

2.38

2160

LM 435A Turbo Intercooled

2.38

2160

LM 445A Turbo

2.38

2160

POWER SHIFT -- T12000 4x3= 4 Forward and 3 Reverse Gears Model

Ratio

Stall Speed

LM 435A Turbo Intercooled

1.84

2160

ELECTRICAL SYSTEM

95 HP / 110 HP

Alternator Battery Type Battery Disconnect via the Isolator Switch Regulator Ground (Earth) Starting Motor Headlight Bulb Stop/Tail Light Bulb Interior Light Bulb Flasher Light Bulb Work Light Bulbs Instrument/Warning Light Bulbs Rocker Switch Bulbs

70 amp 12 volt, 165 ah on Negative / chassis cable Transistorised Negative (--) Positive Engagement, Solenoid Operated (3.0 kw) 40/45W H4 Halogen 5/21W Bayonet Cap 5W Festoon and 10W Bayonet Cap 21W Bayonet Cap 55W H3 Halogen 1.2W Capless 1.2W Capless

BRAKES Type Disc Diameter Parking Type

Wet Multi--Discs 8 per Axle 203.2mm (8 in) Single Disc on Driveline

STEERING Power Steering Type Pump Type System Pressure Wheel Toe--in

604.55.181.00 09-- 2003

Hydrostatic Gear 140 bar (2030 lb in2) 0 -- 2mm (0 -- 0.064 in)

SECTION 00 -- MAINTENANCE -- CHAPTER 2

FRONT AXLE Chassis Mounted Differential Lock (Power Shuttle Transmission) Differential Lock (Power Shift Transmission)

Rigid Limited Slip Limited Slip

REAR AXLE Chassis Mounted

Floating 10° Oscillation

HYDRAULIC SYSTEM Gear Pump Hydraulic System Pressure: Main System Pressure (All Models) Steering system Pressure (All Models)

Hydraulic System and Steering System Pressure 260 bar (3771 lb in2) Pressure 140 bar (2030 lb in2)

TORQUES

Nm.

lbf.ft.

Kgf.m

Wheel Nuts Cab/ROPS Attaching Bolts

540 380

400 280

55.3 38.7

RADIATOR COOLANTS Anti--freeze should be changed every 1200 hours or 24 months. NOTE:In order to reduce deposits and corrosion, water in the cooling system should not exceed the following limits: Totalhardness

Chloride

Sulphates

300 parts per million

100 parts per million

FOUR WHEEL DRIVE TYRE COMBINATIONS The tyres fitted to machines with four wheel drive have been carefully selected to match the gearing of the transmission and axles. When renewing worn or damaged tyres, always install tyres of the same make, model and size as those removed. The installation of other tyre combinations may result in excessive tyre wear, loss of usable power or severe damage to drive line components. If in doubt, consult your Dealer.

WEIGHT OF MACHINES 6 metre 2.9 tonne = 6250 kg unladen / 9050 kg rated 6 metre 3.3 tonne = 7160 kg unladen / 10460 kg rated 7 metre 3.1 tonne = 7265 kg unladen / 10365 kg rated 9 metre 3.0 tonne = 7455 kg unladen / 10455 kg rated IMPORTANT: The information shown is for general guidance when estimating machine weight and will not necessarily take into account tyres that may be fitted, fluid levels or additional equipment. To determine an accurate weight of your machine it will be necessary to place your machine onto an official weigh-bridge. 604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

4 LM 415A -- 6 METRE SERIES 2.9 TONNE A

1200 mm

47.2 in

45 mm

1.77 in

2660 mm

104.7 in

1770--1820 mm

69.6--71.6 in

1200 mm

47.2 in

125 mm

4.9 in

1050 mm

41.3 in

48.5°

4935 mm

194.2 in

44.0°

4785 mm

188.3 in

3575 mm

140.8 in

4355 mm

171.4 in

7510 mm

295.6 in

6135 mm

241.5 in

3840 mm

151.1 in

1930 mm

75.9 in

2450 mm

96.4 in

1930 mm

75.9 in

2610 mm

102.7 in

400 mm

15.7 in

4750 mm

187.0 in

475 mm

18.7 in

1290 mm

50.7 in

400 mm

15.7 in

3785 mm

149.0 in

1075 mm

42.3 in

2385 mm

93.8 in

865 mm

34.0 in

9.67°

1163 mm

45.7 in

147.24°

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

5 IMPORTANT: The above chart is based on a fork load centre of 0.5 metres and should not be used where a load centre of 0.6 metres is the normal reference. LM 415A -- 6 METRE SERIES 2.9 TONNE Breakout force at bucket teeth Standard lift height Rated capacity with standard attachment Load centre

= 4050 kg (8929 lb) = 5840 mm (230.3 in) = 2900 kg (6393 lb) = 500 mm (19.7 in) 604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

6 LM 425A -- 6 METRE 3.3 TONNE A

1200 mm

47.2 in

45 mm

1.77 in

2660 mm

104.7 in

1770--1820 mm

69.6--71.6 in

1200 mm

47.2 in

125 mm

4.9 in

1050 mm

41.3 in

48.5°

4945 mm

194.6 in

44.0°

4795 mm

188.7 in

3575 mm

140.8 in

4365 mm

171.8 in

7510 mm

295.6 in

6145 mm

241.9 in

3840 mm

151.1 in

1930 mm

75.9 in

2450 mm

96.4 in

1930 mm

75.9 in

2610 mm

102.7 in

400 mm

15.7 in

4750 mm

187.0 in

475 mm

18.7 in

1290 mm

50.7 in

400 mm

15.7 in

3785 mm

149.0 in

1085 mm

42.7 in

2385 mm

93.8 in

865 mm

34.0 in

9.67°

1163 mm

45.7 in

147.24°

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

7 IMPORTANT: The above chart is based on a fork load centre of 0.5 metres and should not be used where a load centre of 0.6 metres is the normal reference. LM 425A -- 6 METRE 3.3 TONNE Breakout force at bucket teeth Standard lift height Rated capacity with standard attachment Load centre

= 4050 kg (8929 lb) = 5900 mm (232.3 in) = 3300 kg (7275 lb) = 500 mm (19.7 in) 604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

8 LM 435A -- 7 METRE SERIES 3.1 TONNE A

1200 mm

47.2 in

45 mm

1.77 in

2660 mm

104.7 in

1770--1820 mm

69.6--71.6 in

1635 mm

64.3 in

125 mm

4.9 in

1485 mm

58.4 in

48.5°

5380 mm

211.8 in

44.0°

5230 mm

205.9 in

3575 mm

140.8 in

4365 mm

171.8 in

7945 mm

312.7 in

6580 mm

259.0 in

4190 mm

164.9 in

1930 mm

75.9 in

2450 mm

96.4 in

1930 mm

75.9 in

2610 mm

102.7 in

400 mm

15.7 in

5100 mm

200.7 in

475 mm

18.7 in

1290 mm

50.7 in

400 mm

15.7 in

3785 mm

149.0 in

1085 mm

42.7 in

2385 mm

93.8 in

865 mm

34.0 in

10.49°

1163 mm

45.7 in

146.42°

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

9 IMPORTANT: The above chart is based on a fork load centre of 0.5 metres and should not be used where a load centre of 0.6 metres is the normal reference. LM 435A -- 7 METRE SERIES 3.1 TONNE Breakout force at bucket teeth Standard lift height Rated capacity with standard attachment Load centre

= 4050 kg (8929 lb) = 6720 mm (264.6 in) = 3100 kg (6834 lb) = 500 mm (19.7 in) 604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

10 LM 445A -- 9 METRE 3.0 TONNE A

1200 mm

47.2 in

45 mm

1.77 in

2660 mm

104.7 in

1770--1820 mm

69.6--71.6 in

1700 mm

66.9 in

125 mm

4.9 in

1550 mm

61.0 in

48.5°

5445 mm

214.3 in

44.0°

5295 mm

208.4 in

3575 mm

140.8 in

4365 mm

171.8 in

8010 mm

315.3 in

6645 mm

261.6 in

4240 mm

166.9 in

1930 mm

75.9 in

2450 mm

96.4 in

1930 mm

75.9 in

2610 mm

102.7 in

400 mm

15.7 in

5150 mm

202.7 in

475 mm

18.7 in

1290 mm

50.7 in

400 mm

15.7 in

3785 mm

149.0 in

1085 mm

42.7 in

2385 mm

93.8 in

865 mm

34.0 in

10.89°

1163 mm

45.7 in

122.23°

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

11 IMPORTANT: The above chart is based on a fork load centre of 0.5 metres and should not be used where a load centre of 0.6 metres is the normal reference. LM 445A 9 METRE 3.0 TONNE Breakout force at bucket teeth Standard lift height Rated capacity with standard attachment Load centre

= 3750 kg (8267 lb) = 8850 mm (348.4 in) = 3000 kg (6600 lb) = 500 mm (19.7 in) 604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

LUBRICANTS AND COOLANTS

--30 °C --25 °C

The correct engine oil viscosity grade is dependent upon ambient temperature. Refer to the chart on the right when selecting oil for your engine.

Sulphur Content %

Oil Change Period

Below 0.5

Normal

0.5 -- 1.0

Half the normal

above 1.0

One quarter normal.

AMBRA NH -- RECOMMENDED FLUIDS AND APPLICATION

New Holland Specification

+20 °C

+40 °C

SAE 5W--30

NOTE: In areas where prolonged periods of extreme temperatures are encountered, local lubricant practices are acceptable; such as the use of SAE 5W30 in extreme low temperatures or SAE 50 in extreme high temperatures. Sulphur in Fuel The engine oil change period is shown in section 3. However, locally available fuel may have a high sulphur content, in which case the engine oil change period should be adjusted as follows:--

--15 °C

SAE 10W--30

SAE 15W--40

--22 °F

--13 °F

+5 °F

+68 °F

+104 °F

NOTE; The use offuelwith a sulphur contentabove 1.3% is not recommended. Internation Approximate Quantities Specificational

ENGINE -- Oil Ambra Super Gold (15W40) . . . . . . . . . NH 330 G . . . . . . .

API CF-4/SG, CCMC D4,

Ambra Super Gold (10W30) . . . . . . . . . NH 324 G . . . . . . .

or MIL--L--2104E . . . . . . . . (including engine oil filter)

13.6 Litres (3.6 U.S. gals)

POWER SHUTTLE TRANS -- Oil Ambra Hydrodex . . . . . . . . . . . . . . . . . . NH 530 A . . . . . . . .

ATF DEXRON II D--LEVEL

11 Litres (2.7 U.S.gals)

ATF DEXRON II D--LEVEL

11 Litres (2.7 U.S.gals)

API GL4, ISO 46/68

8.5 Litres (2.2 U.S.gals)

API GL 5 , MIL--L--2105 D

0.6 Litres (1.12 U.S.pint)

API GL 5 , MIL--L--2105 D

1.0 Litres (2.0 U.S.pint)

ISO VG 46, DIN 51524

125 Litres (31 U.S.gals)

POWER SHIFT TRANS -- Oil Ambra Hydrodex . . . . . . . . . . . . . . . . . . NH 530 A . . . . . . . . FRONT & REAR AXLE -- Oil Ambra Multi F (20W30) . . . . . . . . . . . . . NH 420 A . . . . . . . . TRANSFER BOX -- Oil Ambra Hypoide 90 (80W90) . . . . . . . . . NH 520 A . . . . . . . . FRONT/REAR AXLE HUBS -- Oil Ambra Hypoide 90 (80W90) . . . . . . . . . NH 520 A . . . . . . . . LOADER -- HYDRAULIC -- Oil Ambra Hydrosystem 46 HV . . . . . . . . . NH 646 H . . . . . . . ENGINE RADIATOR COOLANT Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H2O . . . . . . . . . . . . . . . . . . 12 Litres (2.9 U.S.gals)

Ambra Agriflu . . . . . . . . . . . . . . . . . . . . . NH 900 A . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . 12 Litres (2.9 U.S.gals)

BRAKE -- Oil 85808072 . . . . . . . . . . . . . . . . . . . . . . . . NH 610 A . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . 1 Litre (2.0 U.S.pints)

JIB PADS -- GREASE .................................. .................

HDM . . . . . . . . . . . . . . . . . . As Required

FUEL TYPE Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604.55.181.00 09-- 2003

. . . . . . . . . . . . . . . . . . . . . . . 122 Litres (30 U.S.gals)

SECTION 00 -- MAINTENANCE -- CHAPTER 2

TYRE PRESSURES The tables are for guidance only but relate to Dunlop and Goodyear tyres as recommended by the manufacturer. For exact information regarding inflation pressures and loads for your particular tyres, consult your tyre manufacturer. MODEL

TYRE SIZE

FRONT REAR

6 metre 2.9 tonne

400/70--20 10 ply

FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR FRONT REAR

400/80--24 10 ply 15.5 -- 24 12 ply 17.5 X 24 10 ply 15.5 -- 25 12 ply 6 metre 3.3 tonne

400/70--20 10 ply 400/80--24 10 ply 15.5 -- 24 12 ply 17.5 X 24 10 ply 15.5 -- 25 12 ply

7 metre 3.1 tonne

400/70--20 10 ply 400/80--24 10 ply 15.5 -- 24 12 ply 17.5 X 24 10 ply 15.5 -- 25 12 ply

9 metre 3.0 tonne

400/70--20 10 ply 400/80--24 10 ply 15.5 -- 24 12 ply 17.5 X 24 10 ply 15.5 -- 25 12 ply

PRESSURE (bar) 2.75 2.75 2.75 2.75 2.7 2.7 2.75 2.75 2.7 2.7 3.0 3.0 2.75 2.75 2.7 2.7 2.75 2.75 2.7 2.7 3.0 3.0 2.75 2.75 2.7 2.7 3.2 3.2 2.7 2.7 3.5 3.5 2.75 2.75 2.7 2.7 3.2 3.2 2.7 2.7

AXLE WEIGHT (Unladen Static, kg) 2840 3410 2840 3410 2840 3410 2840 3410 2840 3410 2705 3935 2705 3935 2705 3935 2705 3935 2705 3935 2830 4020 2830 4020 2830 4020 2830 4020 2830 4020 3285 3875 3285 3875 3285 3875 2830 4020 2830 4020

AXLE WEIGHT (Rated Dynamic, kg) 7810 1240 7810 1240 7810 1240 7810 1240 7810 1240 8335 1505 8335 1505 8335 1505 8335 1505 8335 1505 7800 1850 7800 1850 7800 1850 7800 4020 7800 4020 8780 1380 8780 1380 8780 1380 7800 4020 7800 4020

The above figures reflect the approximate weight of a standard machine less attachments. 604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

TYRE SIZE

FRONT REAR

PRESSURE (lbf in2)

6 metre 2.9 tonne

400/70--20 10 ply

40 40 40 40 39 39 40 40 39 39 44 44 40 40 39 39 40 40 39 39 44 44 40 40 39 39 46 46 39 39 51 51 40 40 39 39 46 46 39 39

400/80--24 10 ply 15.5 -- 24 12 ply 17.5 X 24 10 ply 15.5 -- 25 12 ply 6 metre 3.3 tonne

400/70--20 10 ply 400/80--24 10 ply 15.5 -- 24 12 ply 17.5 X 24 10 ply 15.5 -- 25 12 ply

7 metre 3.1 tonne

400/70--20 10 ply 400/80--24 10 ply 15.5 -- 24 12 ply 17.5 X 24 10 ply 15.5 -- 25 12 ply

9 metre 3.0 tonne

400/70--20 10 ply 400/80--24 10 ply 15.5 -- 24 12 ply 17.5 X 24 10 ply 15.5 -- 25 12 ply

AXLE WEIGHT (Unladen Static, (lb) 6261 7518 6261 7518 6261 7518 6261 7518 6261 7518 5963 8675 5963 8675 5963 8675 5963 8675 5963 8675 6239 8862 6239 8862 6239 8862 6239 8862 6239 8862 7242 8543 7242 8543 7242 8543 6239 8862 6239 8862

The above figures reflect the approximate weight of a standard machine less attachments.

604.55.181.00 09-- 2003

AXLE WEIGHT Rated Dynamic, (lb) 17218 2734 17218 2734 17218 2734 17218 2734 17218 2734 18375 3318 18375 3318 18375 3318 18375 3318 18375 3318 17196 4079 17196 4079 17196 4079 17196 8863 17196 8863 19356 2601 19356 2601 19356 2601 17196 8863 17196 8863

SECTION 00 -- MAINTENANCE -- CHAPTER 2

TOOL LISTING AND APPLICATIONS GENERAL Tools (*= New Tool) Number Application 1.

Multi Meter

General Electrics

2. Internal Micrometer

Engine Bores, General

3. Dial Indicator Eccentricity checking

Valve Seats, General

4. Injector Tester

Fuel Injectors

5. Dial Indicator Concentricity, End Floats

Crankshaft Seals, General

6. Internal Bore Gauge

Valve Guides, General

7. Bearing Heater

Bearing Fitting, General

8. 3 Legged Puller

General

9. Spring Compressor

Valve Springs

10. Square

Valve Springs

11. Bearing Puller

General

12. Piston Ring Remover

Pistons

13. Splitting Kit

Machine Disassembly

LOCALLY MANUFACTURED Tools (*= New Tool) Application 14. Holding Bracket

Rear Axle Pinion Nut Removal Aid

15. Torque Fixture *

Axle Pinion Rolling Resistance Setting

TRANSMISSION POWERSHUTTLE 16. Lifting Bracket

Transmission End Cover

17. Spring Retainer

Gear Shift Detent Springs

18. Bearing Installer 35mm *

Transmission Idler and Output Shaft Bearing Installation

19. Bearing Installer 40mm *

4WD Bearing, Counter Shaft, Transmission Input Shaft Front Bearing Installation

20. Bearing Installer 50mm *

Transmission Input Shaft Rear Bearing Installation

21. Oil Pump Seal *

Transmission Oil Pump Seal Installation

22. Bush Installer *

Transmission Input Shaft Bush Installation

23. Gauge Tool Bolt *

380000700

24. Fitting * 25. Compression Tool *

Aid Measurement Of Shaft End Floats 9/16in ORFS to test transmission clutch and system pressure and Torque Convertor.

380000679

Transmission Clutch Pack 604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

TRANSMISSION POWERSHIFT 26. Compression Tool

380000711

Clutch Packs

27. Pressure Gauge Adapter

297404

Transmission Clutches

28. Valve Sleeve Wrench

380000606

Transmission Regulating Valve 40 bar / 600 lbf/in2

29. Pressure Gauge

AXLE 30. Seal Removal Tool

Axle

31. Seal Removal Tool

Hub

32. Seal Locating Tool

297141 & 291896

33. Bush Removal Tool

Hub

Axle

34. Bush Locating Tool

297144 & 291896

Axle

35. Seal Locating Tool

297141 & 291896

Axle

36. Seal Locating Tool

297410

Hub

37.Pinion Nut Wrench

297410

Pinion

HYDRAULIC SYSTEMS 38. Flowmeter

200 Litre/min

39. Pressure Gauges

400 bar & 60 bar

40. Servo Pressure Test Adapter

380001667 & 380000493

Servo Circuit

41. Steering Pressure Test Adapter

380001668 & 380000493

Steering Circuit

297451

Lift Cylinder Lock

43. Solenoid Test Adapter

380001666

Mono Ramp Control System

44. Test Harness

380001665

Mono Ramp Control System

380001710

Engine Removal

TELESCOPIC BOOM 42. Safety Support

ELECTRICAL SYSTEM

ENGINE 45. Engine Lifting Bracket

Refer to Section 10, Engines for additional special tool information.

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

General Tools

TA6010056

TA6010018

TA6010040

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2 General and Locally Manufactured Tools

TA6010011

0009001

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

Locally Manufactured Tools

mm 110 95 45

10 (x4) 5

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2 Powershuttle Transmission Tools 10mm 15cm

9cm

20mm

O = 18mm x 3 12cm

35mm 18mm 11.5cm 9cm

23mm 18mm

0011002

45mm

35mm

150mm

0011001

50mm

300mm 40mm 19

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

Powershuttle Transmission Tools 60mm

50mm

150mm

0012001

70mm 21

22mm

Tool No -- 380000700

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

x2 0013002

Fitting Size -- 9/16in ORFS

0013003

Tool No -- 380000679

Powershift Transmission Tools

Tool No -- 380000711

0013001

Tool No -- 297404

604.55.181.00 09-- 2003

0013004

SECTION 00 -- MAINTENANCE -- CHAPTER 2

Powershift Transmission Tools

Tool No -- 380000606

0014001

0014003

Axle Tools

0014005

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

Axle Tools

0015001

0015002

Tool No -- 297141 + 291896

0015005

Tool No -- 297144 + 291896 604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

Axle Tools

0016001

Tool No -- 297144 + 291896

Tool No -- 297409

Tool No -- 297410

Hydraulic Flow and Pressure

0016002

Minimum 120 L/min

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

x 2 = 400 bar 6000 lbf/in2

x 2 = 60 bar 800 lbf/in2

0017001

Tool No. 380001667 + 380000493

Tool No. 380001668 + 380000493

NOTE: Adaptors tool number 380001667 & 380001668 are drilled to accept male--female adaptor tool number 380000493.

604.55.181.00 09-- 2003

Adaptor tool number 380000493: Male thread: M10 x 1 Female thread: 7/16 UNF

SECTION 00 -- MAINTENANCE -- CHAPTER 2

Telescopic Boom

Tool No -- 297451

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2 Electrical

Tool No. 380001665

Tool No. 380001666

Engine

Tool No. 380001710

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

List of special tools required for the various operations described in the Engine Section. 380000301

Rotating stand for overhaul operations

380000665

Front crankshaft seal extractor

380000663

Rear crankshaft seal extractor

380000671

Injector removal tool

380000666

Front crankshaft seal installation tool

380000664

Rear crankshaft seal installation tool

380000221

Piston ring pliers (65 -- 110 mm)

380000302

Valve spring tool

380000667

Camshaft bushing drift

380001298

Mounting brackets for engine stand

380000364

Dial gauge base

380000304

2 Gauges for angular timing

380000103

Connecting rod distortion measuring tool

380000228

Dial gauge (0--5 mm)

380001005

Dial gauge (0--10 mm)

380000914

Dial gauge holder for rotary injection pump timing

380000979

Fuel injection pump gear puller

604.55.181.00 09-- 2003

SECTION 00 -- MAINTENANCE -- CHAPTER 2

NOTES

604.55.181.00 09-- 2003

SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 -- ENGINE Chapter 1 -- Engine CONTENTS Operation

Description

Page

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lubrication diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 10 001 10

Engine Component Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

10 001 53

Engine Dimensional Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . 27

10 102 70

Crankshaft front seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

10 102 74

Crankshaft rear seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

10 106 12

Valve tappet and rocker arm clearance -- Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

10 218 30

Engine injector removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

10 246 14

Bosch injection pump removal and replacement, timing and system bleeding . . . . . . . . . 88

10 402 10

Coolant pump removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

10 406 10

Engine radiator removal and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1

GENERAL SPECIFICATIONS

4 Cylinders

Engine, technical type: --

model LM415A -- type F4GE0454C*D602 (BOSCH pump)

See data on page 7

model LM415A -- type F4GE0484G*D602 (BOSCH pump)

See data on page 6

model LM425A -- type F4GE0484G*D602 (BOSCH pump)

See data on page 6

model LM435A -- type F4GE0454C*D602 (BOSCH pump)

See data on page 7

model LM435A -- type F4GE0484G*D602 (BOSCH pump)

See data on page 6

model LM435A -- type F4GE0484G*D603 (BOSCH pump)

See data on page 6

model LM445A -- type F4GE0454C*D602 (BOSCH pump)

See data on page 7

Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

diesel, 4--stroke

Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

direct

Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston diameter --

model LM415A -- LM425A -- LM435A -- LM445A . . . . . . . .

104 mm (4.09 in.)

Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132 mm (5.19 in.)

Total displacement: --

model LM415A -- LM425A -- LM435A -- LM445A . . . . . . . .

Compression ratio for models LM415A -- LM425A -- LM435A -LM445A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4485 cm3 (273.67 in3.) 17,5:1

Maximum power: --

model LM415A -- type F4GE0454C*D602 . . . . . . . . . . . . . .

71 kW (95 HP)

model LM415A -- type F4GE0484G*D602 . . . . . . . . . . . . . .

82 kW (110 HP)

model LM425A -- type F4GE0484G*D602 . . . . . . . . . . . . . .

82 kW (110 HP)

model LM435A -- type F4GE0454C*D602 . . . . . . . . . . . . . .

71 kW (95 HP)

model LM435A -- type F4GE0484G*D602 . . . . . . . . . . . . . .

82 kW (110 HP)

model LM435A -- type F4GE0484G*D603 . . . . . . . . . . . . . .

82 kW (110 HP)

model LM445A -- type F4GE0454C*D602 . . . . . . . . . . . . . .

71 kW (95 HP)

Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2200 rev/min

Maximum torque: model LM415A -- type F4GE0454C*D602

398 (Nm) (89.47 lbf)

Maximum torque: model LM415A -- type F4GE0484G*D602

480 (Nm) (107.90 lbf)

Maximum torque: model LM425A -- type F4GE0484G*D602

480 (Nm) (102.90 lbf)

Maximum torque: model LM435A -- type F4GE0454C*D602

398 (Nm) (89.47 lbf)

Maximum torque: model LM435A -- type F4GE0484G*D602

480 (Nm) (107.90 lbf)

Maximum torque: model LM435A -- type F4GE0484G*D603

480 (Nm) (107.90 lbf)

-- Maximum torque: model LM445A -- type F4GE0454C*D602 Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

398 (Nm) (89.47 lbf) 1400 rev/min

Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

pressed in sheet metal (continued)

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1

3 (cont)

GENERAL SPECIFICATIONS Lubrication

....................................

4 Cylinders forced, with gear pump

Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

from crankshaft

Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . .

2:1

Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mesh filter on oil intake and filtering cartridge on delivery line

Normal oil pressure with motor warmed--up at slow idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 bar (17.4 psi)

at fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 bar (55.1 psi)

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with coolant circulation

Radiator on models LM415A--LM425A--LM435A--LM445A . . .

with ??? lines of vertical pipes with copper fins

Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . .

4 blades : steel

Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

centrifugal vane--type

Coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Middle green section . . . . . . . . . . . . . . . . . . . . . . Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with coloured scale divided into three sections Cold Normal working conditions Overheating -- Buzzer Warning

Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . .

1:1.977

Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

via thermostat valve

initial opening

81 ± 2 °C (177.8 ± 35.6 F°)

Timing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight--tooth gears Intake: --

start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10° ± 30’

end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10° ± 30’

Exhaust: --

start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64°

end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26°

Valve--rocker arm clearance (with engine cold): --

intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 ± 0.05 mm (0.01 ± 0.001 in)

exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.55 ± 0.05 mm (0.02 ± 0.001 in)

For further timing system technical data . . . . . . . . . . . . . . . . . . .

See page 10 (continued)

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1 (cont)

GENERAL SPECIFICATIONS

4 Cylinders

Fuel system Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

dual cartridge dry air filter, with clogged filter indicator with centrifugal pre--filter and automatic dust ejector

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with double diaphragm

Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump Minimum fuel flow rate with pump shaft rotating at 1800 rpm .

127.6 l/h

Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

engine timing

BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rotating distributor type

All--speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

centrifugal counterweights

Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hydraulic

For further fuel system technical data: Fixed advance (pump setting for start of delivery before TDC) -- Pressure setting -- Injection order, and other information regarding the BOSCH pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

604.55.181.00 09 2003

refer to the data for the relevant engine type in the table on page 2

SECTION 10 -- ENGINE -- CHAPTER 1

FUEL SYSTEM DATA Turbocharger: --

For version F4GE0454C*D602: -- type HOLSET HX25W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TB11H/A085BXL

For versions F4GE0484G*D602 -- F4GE0484G*D603: -- type HOLSET HX25W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TB11K/A06BXL

Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rotating distributor with speed governor and advance regulator incorporated

BOSCH pump: --

model LM415A -- type F4GE0454C*D602 . . . . . . . . . . . . . .

VE 4/12 F 1100 L 954 -- 504063450

model LM415A -- type F4GE0484G*D602 . . . . . . . . . . . . . .

VE 4/12 F 1100 L 942 -- 504054020

model LM425A -- type F4GE0484G*D602 . . . . . . . . . . . . . .

VE 4/12 F 1100 L 942 -- 504054020

model LM435A -- type F4GE0454C*D602 . . . . . . . . . . . . . .

VE 4/12 F 1100 L 954 -- 504063450

model LM435A -- type F4GE0484G*D602 . . . . . . . . . . . . . .

VE 4/12 F 1100 L 942 -- 504054020

model LM435A -- type F4GE0484G*D603 . . . . . . . . . . . . . .

VE 4/12 F 1100 L 942 -- 504054020

model LM445A -- type F4GE0454C*D602 . . . . . . . . . . . . . .

VE 4/12 F 1100 L 954 -- 504063450

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

anti--clockwise

Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--3--4--2 (For all models)

LM415A+

LM425A

LM435A

LM445A

Fuel injectors: BOSCH type . . . . . . . . . . . . . . . . . . . . . . . --

F4GE0454C*D602 . . . . . . . . . . . . . .

504045835 DSLA 145 P 1235

F4GE0484G*D602 . . . . . . . . . . . . . .

504063465 DSLA 145 P 1174

F4GE0484G*D603 . . . . . . . . . . . . . .

504063465 DSLA 145 P 1174

Number of nozzle holes . . . . . . . . . . . . . Nozzle hole diameter mm. --

F4GE0454C*D602 . . . . . . . . . . . . . .

0,205

F4GE0484G*D602 . . . . . . . . . . . . . .

0,223

F4GE0484G*D603 . . . . . . . . . . . . . .

0,223

Calibration pressure bar . . . . . . . . . . . . .

260 to 274 260 to 274 260 to 274 260 to 274 (377 to 397 in) (377 to 397 in) (377 to 397 in) (377 to 397 in)

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1

MOD. LM415A -- LM425A -- LM435A -- CALIBRATION DATA OF BOSCH INJECTION PUMP TYPE VE 4/12 F 1100 L 942 ASSEMBLY DATA

CALIBRATION TEST CONDITIONS

Pump timing on engine: delivery start 0° ± 1° before T.D.C. of cylinder 1 on compression stroke. Plunger pre--lift for pump timing on engine: mm 1 from B.D.C. (with tools 380001004 -- 380000229).

Test bench conforming to ISO 4008/1 .../2 Injectors conforming to ISO 7440--A61 -(1.688.901.027 with calibrated pad ∅ 0.5 mm). Injector pressure setting 247 to 253 bar (350 to 366 psi). Fuel supply pressure: 0.35 bar (5.07 psi) Pipes (conforming to ISO 4093.2): mm 6 x 2 x 450. Test liquid: ISO 4113 at a temperature of 55° ± 1°C (131° ± 33.8°F) at outlet.

ASSEMBLY DIMENSIONS SYMBOL

SVS (max)

37,9 to 40,9 40,9 to 45,9 (1.49 to 1.61 (1.61 to 1.80 in) in)

1. CALIBRATION DATA Rpm 1.1

Advance stroke

900

1.2

Fuel pressure

900

1.3

Max. delivery without pressure

500

1.3

Max. delivery with pressure

700

1.4

Minimum

1.5

Starting

1.6 1.7

L.D.A. hPa

Values mm

1200

6,0--7,4

bar

1200

79,7--85,7

cc/1000

108,0--113,0

cc/1000

1200

3,5

375

3,5--17,5

cc/1000

4,5

100

80,0--120,0

cc/1000

Peak speed

1290

max. 3,0

cc/1000

1200

Start delivery

1100

Delivery difference

Advance difference

1200 hPa

--(11,5--21,5)

--(0,6--0,8)

depending on load

0,6--1,6

Difference cc/1000

2. TEST VALUES 2.1 2.2

Advance

Rpm

LDA=1200 hPa

Fuel pressure

Rpm

LDA=1200 hPa

bar

Backflow

Rpm

500

1100

cc/10 sec

39,0--83,0

97,0--147,0

LDA=1200 hPa 2.3

KSB=0 Volt KSB=0 Volt

900

1100

0,6--1,6

1,6--2,6

500

900

4,9--6,3

5,9--7,4

Delivery

Rpm

cc/1000

hPa

Lever on peak p speed p stop p

1290

max. 3,0

1200

1100

90,5--96,5

1200

700

108,0--113,0

1200

500

102,0--108,0

450

500

79,7--85,7

375

3,5--17,5

420

max. 3,0

100

80,0--120,0

280

84,0--98,0

Minimum Starting curve

604.55.181.00 09 2003

KSB=12 Volt

100 3,0--4,4

KSB=12 Volt

100 2,8--4,2

SECTION 10 -- ENGINE -- CHAPTER 1

MOD. LM415A -- LM435A -- LM445A -- CALIBRATION DATA OF BOSCH INJECTION PUMP TYPE VE 4/12 F 1100 L 954 ASSEMBLY DATA

CALIBRATION TEST CONDITIONS

Pump timing on engine: delivery start 0° ± 0.5° before T.D.C. of cylinder 1 on compression stroke. Plunger pre--lift for pump timing on engine: mm 1 from B.D.C. (with tools 380001004 -- 380000229).

Test bench conforming to ISO 4008/1 .../2 Injectors conforming to ISO 7440--A61 -(1.688.901.027 with calibrated pad ∅ 0,5 mm). Injector pressure setting 247 to 253 bar (358 to 366 in). Fuel supply pressure: 0.35 bar. (5.07 psi) Pipes (conforming to ISO 4093.2): mm 6 x 2 x 450. Test liquid: ISO 4113 at a temperature of 55° ± 1°C (131° ± 33.8°F) at outlet.

ASSEMBLY DIMENSIONS SYMBOL

SVS (max)

36,9 to 40,9 (1.45 to 1.61 in.)

39,3 to 45,3 (1.54 to 1.78 in.)

1. CALIBRATION DATA Rpm

L.D.A. hPa

Values

Difference cc/1000

1.1

Advance stroke

1100

2,1--3,3

1200

1.2

Fuel pressure

1100

6,9--8,3

bar

1200

1.3

Max. delivery without pressure

500

96,5--102,5

cc/1000

1.3

Max. delivery with pressure

800

103,0--109,0

cc/1000

1200

3,5

1.4

Minimum

400

4,0--16,0

cc/1000

6,0

1.5

Starting

100

80,0--120,0

cc/1000

1.6

Peak speed

1270

max. 3,0

cc/1000

1200

1.7

Start delivery

1100

Delivery difference

Advance difference

1000 hPa

--(9,0--21,0)

--(0,7--0,9)

depending on load

2. TEST VALUES 2.1 2.2

Advance

Rpm

LDA=1000 hPa

Fuel pressure

Rpm

LDA=1000 hPa

bar

Backflow

Rpm

500

1100

cc/10 sec

39,0--83,0

103,0--158,0

Delivery

Rpm

cc/1000

hPa

Lever on peak p speed p stop p

1270

max. 3,0

1000

1100

91,0--97,0

1000

800

103,0--109,0

1000

600

98,0--104,0

450

500

96,5--102,5

400

4,0--16,0

LDA=1000 hPa 2.3

Minimum Starting curve

KSB=0 Volt KSB=0 Volt

470

max. 3,0

100

80,0--120,0

300

109,0--125,0

850

1100

0,8--2,0

2,1--3,3

500

1100

5,1--6,5

6,9--8,3

KSB=12 Volt

100 3,0--5,4

KSB=12 Volt

100 3,2--4,2

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1

CRANKCASE/CYLINDER BLOCK DATA

mm (inch)

Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cast--iron monobloc with cylinder liners, crankshaft, camshaft and tappets

Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104,000 to 104,024 (4.094 to 4.095 in.)

Oversized cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .

104,500 to 104,524 (4.114 to 4.115 in.)

Main journal half bearing seat diameter

no. 1--5

87,982 to 88,008 (3.463 to 3.464 in.)

internal no. 2--3--4

87,977 to 88,013 (3.463 to 3.465 in.)

-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59,222 to 59,248 (2.331 to 2.332 in.)

-- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59,222 to 59,248 (2.331 to 2.332 in.)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59,222 to 59,248 (2.331 to 2.332 in.)

Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . .

16,000 to 16,030 (0.629 to 0.631 in.)

external

Camshaft bushing seat diameter:

CRANKSHAFT AND BEARINGS DATA

mm (inch)

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

balanced with integral counterweights

Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82,990 to 83,010 (3.267 to 3.268 in.)

Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,250 -- 0,500 (0.006 to 0.019 in.)

Main journal half bearing thickness . . . . . . . . . . . . . . . . . . . . . . . . .

2,456 to 2,464 (0.096 to 0.096 in.)

Main half bearing undersizes (internal diameter) . . . . . . . . . . . . . .

0,250 -- 0,500 (0.0098 -- 0.0004 in.)

Clearance between bearings and main journal

no. 1--5

0,041 to 0,119 (0.0016 to 0.004 in.)

no. 2--3--4

0,041 to 0,103 (0.001to 0.004 in.)

Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68,987 to 69,013 (2.716 to 2.717 in.)

Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,250 -- 0,500 (0.009 to 0.019 in.)

Standard connecting rod half bearing thickness . . . . . . . . . . . . . . .

1,955 to 1,968 (0.076 to 0.077 in.)

Connecting rod half bearing undersizes (internal diameter) . . . . .

0,250 -- 0,500 (0.009 to 0.019 in.)

Bearing to crankpin clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,033 to 0,041 (0.0012 to 0.0016 in.)

Standard crankshaft thrust washer width . . . . . . . . . . . . . . . . . . . .

37,280 to 37,380 (1.467 to 1.471 in.)

Width of main bearing for thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25,980 to 26,480 (1.022 to 1.042 in.)

Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . .

37,475 to 37,545 (1.475 to 1.478 in.)

Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,172 to 0,240 (0.006 to 0.009 in.)

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SECTION 10 -- ENGINE -- CHAPTER 1 CONNECTING ROD DATA

9 mm (inch)

Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

printed in steel, oblique--cut type

Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . .

40,987 to 41,013 (1.613 to 1.614 in.)

Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . .

41,279 to 41,553 (1.625 to 1.635 in.)

Interference between small end bushing and seat . . . . . . . . . . .

0,266 to 0,566 (0.010 to 0.022 in.)

Inside diameter of small end bushing (measured after fitting) .

38,019 to 38,033 (1.496 to 1.497 in.)

Diameter of big end bearing seats . . . . . . . . . . . . . . . . . . . . . . . .

72,987 to 73,013 (2.873 to 12.874 in.)

Connecting rod--crankpin end float . . . . . . . . . . . . . . . . . . . . . . . .

0,100 to 0,330 (0.003 to 0.012 in.)

PISTON DATA Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (inch) light alloy with three compression rings, including two seal rings and one scraper ring

Standard piston diameter, measured at 61 mm from skirt base and perpendicularly to the gudgeon pin axis . . . . . . . . . . . . . . . .

103,730 to 103,748 (4.083 to 4.084 in.)

Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . .

0,252 to 0,294 (0.009 to 0.001 in.)

Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,500 (0.019 in.)

Piston protrusion at TDC from cylinder block face . . . . . . . . . . .

0,280 to 0,520 (0.011 to 0.020 in.)

Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37,994 to 38,000 (1.495 to 1.496 in.)

Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . .

38,010 to 38,016 (1.4964 to 1.4966 in.)

Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,010 to 0,022 (0.0003 to 0.0008 in.)

Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . .

0,019 to 0,039 (0.0007 to 0.0015 in.)

Piston ring groove depth: -- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2,705 to 2,735 (0.106 to 0.107 in.)

-- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2,440 to 2,460 (10.09606 to 0.09608 in.)

-- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4,030 to 4,050 (0.158 to 0.159 in.)

Piston ring thickness: -- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2,560 to 2,605 (0.100 to 0.102 in.)

-- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2,350 to 2,380 (0.092 to 0.093 in.)

-- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3,977 to 3,990 (0.156 to 0.157 in.)

(continued)

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SECTION 10 -- ENGINE -- CHAPTER 1 (cont)

PISTON DATA

mm (inch)

Piston ring groove clearance (measured vertically): -- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,100 to 0,175 (0.003 to 0.006 in.)

-- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,060 to 0,110 (0.002 to 0.004 in.)

-- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,040 to 0,073 (0.001 to 0.1002 in.)

Assembly clearance between piston ring ends in cylinder sleeves: -- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,30 to 0,40 (0.0011 to 0.0015 in.)

-- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,60 to 0,80 (0.0023 to 0.0031 in.)

-- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,30 to 0,55 (0.0011 to 0.0021 in.)

Spare piston ring oversizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,500 (0.019 in.)

VALVE TIMING GEAR DATA

mm (inch)

Inside diameter of camshaft bearings (fitted and reamed): -- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54,083 to 54,147 (2.129 to 2.131 in.)

-- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54,083 to 54,147 (2.129 to 2.131 in.)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54,083 to 54,147 (2.129 to 2.131 in.)

Diameter of camshaft journals: . -- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53,995 to 54,045 (2.125 to 0.127 in.)

-- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53,995 to 54,045 (2.125 to 0.127 in.)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53,995 to 54,045 (2.125 to 0.127 in.)

Clearance between camshaft journals and bushings . . . . . . . . . .

0,038 to 0,152 (0.0014 to 0.0059 in.)

Camshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,230 ± 0,130 (0.009 ± 0.005 in.)

Crankshaft to camshaft teeth clearance . . . . . . . . . . . . . . . . . . . . .

0,076 to 0,280 (0.002 to 0.011in.)

TAPPET DATA

mm (inch)

Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16,000 to 16,030 (0.629 to 0.631 in.)

Outside diameter of standard tappets . . . . . . . . . . . . . . . . . . . . . . .

15,929 to 15,959 (0.627 to 0.628 in.)

Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,041 to 0,101 (0.0016 to 0.0039 in.)

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1 ROCKER ARM -- VALVE DATA

11 mm (inch)

Rocker--arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18,963 to 18,975 (0.746 to 0.747 in.)

Rocker--arm shaft seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19,000 to 19,026 (0.748 to 0.749 in.)

Rocker arm bore to shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . .

0,025 to 0,063 (0.0009 to 0.0024 in.)

Valve clearance for normal running (engine cold): -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,300 to 0,050 (0.011 to 0.001 in.)

-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,550 to 0,050 (0.002 to 0.001 in.)

Cam lift: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6,045 (0.237 in.)

-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7,239 (0.284 in.)

CYLINDER HEAD DATA Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (inch) in cast iron with fitted valve seats and seats for injectors and thermostat valve

Maximum face re--grinding depth that can be removed from the cylinder head in the event of reboring . . . . . . . . . . . . . . . . . . . . .

0,130 (0.005 in.)

Diameter of valve stem seat in cylinder head . . . . . . . . . . . . . . . . .

8,019 to 8,039 (0.315 to 0.355 in.)

Valve stem diameter

.....................................

7,960 to 7,980 (0.313 to 0.314 in.)

Assembly clearance between valve stem and seat . . . . . . . . . . . .

0,039 to 0,079 (0.001 to 0.003 in.)

Valve seat angle in head: --

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60°

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45°

Valve face angle: --

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60°

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45°

Diameter on head for fitting valve seat: --

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46,987 to 47,013 (1.48 to 1.85 in.)

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43,637 to 43,663 (1.717 to 1.719 in.)

Valve seat insert outside diameter: --

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47,063 to 47,089 (1.855 to 1.853 in.)

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43,713 to 43,739 (1.720 to 1.722 in.)

Valve stand--in relative to cylinder head face --

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,336 to 1,072 (0.013 to 0.042 in.)

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,104 to 0,840 (0.004 to 0.033 in.)

Interference between valve seat and head: --

inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,050 to 0,102 (0.001 to 0.004 in.)

exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0,050 to 0,102 (0.001 to 0.004 in.) (continued)

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SECTION 10 -- ENGINE -- CHAPTER 1

(cont)

CYLINDER HEAD DATA

mm (inch)

Valve head diameter: -- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44,870 to 45,130 (1.766 to 1.776 in.)

-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41,870 to 42,130 (1.766 to 1.776 in.)

Inlet and exhaust valve springs: --

free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63,500 (2.499 in.)

length under load of 329 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49,020 (1.929 in.)

length under load of 641 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38,200 (1.503 in.)

Injector protrusion relative to head face: D injectors BOSCH DSLA 145 P 1174 -BOSCH DSLA 145 P 1253 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION SYSTEM DATA Pressure relief valve spring

Not adjustable

mm (inch)

...............................

spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66,000 (2.598 in.)

length under load of 136.9 N ± 10.5 . . . . . . . . . . . . . . . . . . . . .

41,250 (1.624 in.)

For further lubrication technical data

604.55.181.00 09 2003

see page 3

SECTION 10 -- ENGINE -- CHAPTER 1

TIGHTENING TORQUES PARTS TO BE TIGHTENED

Thread

Flywheel casing retaining bolts (2, fig. 107) . . . . . . . . . . . . .

Tightening torque Nm

kgm

M 12 x 1,75 x 100 M 16 x 1,50 x 80 M 16 x 1,50 x 100 M 12 x 1,75 x 78

80 ± 10 200 ± 20 200 ± 20 80 ± 10

8±1 20 ± 2 20 ± 2 8±1

Oil sump retaining bolts (2, fig. 105) . . . . . . . . . . . . . . . . . . .

M 10 x 1,50 x 45 M 10 x 1,50

50 ± 5 70 ± 5

5 ± 0,5 7 ± 0,5

Rocker arm support retaining bolts (2, fig. 94) . . . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Tappet cover retaining bolts (1, fig. 136 -- 137) . . . . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Exhaust manifold retaining bolts (3, fig. 133) . . . . . . . . . .

M 10 x 1,50

53 ± 5

5,3 ± 0,5

Intake manifold retaining bolts (2, fig. 136 -- 137) . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Oil cooler retaining bolts (5, fig. 129) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Coolant pump retaining bolts (2, fig. 127) . . . . . . . . . . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Coolant inlet manifold retaining bolts (2, fig. 125) . . . . . . . .

M 10 x 1,50

45 ± 10

4,5 ± 1

Thermostat valve assembly retaining bolts (5, fig. 83) . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Fan support retaining bolts (3, fig. 128) . . . . . . . . . . . . . . . .

M 8 x 1,25 x 50 M 10 x 1,50 x 25

25 ± 5 45 ± 5

2,5 ± 0,5 4,5 ± 0,5

Injector fastener (1, fig. 92) . . . . . . . . . . . . . . . . . . . . . . . . .

60 ± 5

6,0 ± 0,5

Fuel pump retaining bolts (5, fig. 135) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Turbine retaining bolts (2, fig. 133) . . . . . . . . . . . . . . . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Alternator retaining bolts (3, fig. 130) . . . . . . . . . . . . . . . .

M 10 x 1,50

45 ± 5

4,5 ± 0,5

Starter motor retaining bolts (5, fig. 139) . . . . . . . . . . . . . . .

M 10 x 1,50

55 ± 5

5 ± 0,5

Camshaft plate retaining bolts (3, fig. 58) . . . . . . . . . . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Injection pump retaining bolts (3, fig. NO TAG) . . . . . . . . . .

M 8 x 1,25

12 ± 5

1,2 ± 0,5

Injection pump gear retaining nut (1, fig. 117) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 14 x 1,5

90 ± 5

9,0 ± 0,5

Oil pump gear retaining bolts (2, fig. 120) . . . . . . . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Crankcase base plate retaining bolt (5, fig. 104) . . . . . . .

M 10

43 ± 5

4,3 ± 0,5

Timing gear cover retaining bolts (1, fig. 82) . . . . . . . . . .

M 8 x 1,25

25 ± 5

2,5 ± 0,5

Camshaft gear retaining bolts (1, fig. 98) . . . . . . .

M 8 x 1,25

36 ± 4

3,6 ± 0,4

24 ± 4

2,4 ± 0,4

Front cover retaining bolts (1, fig. 122) . . . . . . . . . . . . . . .

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1

TIGHTENING TORQUES TO ANGLE PARTS TO BE TIGHTENED

Thread

Tightening torque Nm

kgm

Angle

Main bearing cap bolts (1, fig. 66) . . . . . . . . . . phase 1

M12 x 1.5

50 ± 6

5,0 ± 0,6

phase 2

M12 x 1.5

80 ± 6

8,0 ± 0,6

phase 3

M12 x 1.5

90° ± 5°

phase 1

M 10 x 1.25

30 ± 5

3,0 ± 0,5

phase 2

M 10 x 1.25

50 ± 5

5,0 ± 0,5

phase 3

M 10 x 1.25

60° ± 5°

M 12 x 1,75 x 70

50 ± 5

5,0 ± 0,5

90°

M 12 x 1,75 x 140

40 ± 5

4,0 ± 0,5

180°

M 12 x 1,75 x 180

70 ± 5

7,0 ± 0,5

180°

Bolts fastening pulley on crankshaft (4, fig. 124) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1,25

50 ± 5

5,0 ± 0,5

90° ± 5°

Engine flywheel retaining bolts (1, fig. 115 -- 116) . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1,25

30 ± 5

3,0 ± 0,5

60° ± 5°

Big end cap bolts (1, fig.) 78) . . . . . . . . . . . . . . .

Cylinder head bolts (1, fig. 99) . . . . . . . . . . . . . Note:

For the tightening sequence, see page 53, fig. 100.

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1

TOOLS

WARNING The operations described in this section can only be carried out with ESSENTIAL tools listed below. To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.

List of special tools required for the various operations described in this Section. 380000301

Rotating stand for overhaul operations

380000665

Front crankshaft seal extractor

380000663

Rear crankshaft seal extractor

380000671

Injector removal tool

380000666

Front crankshaft seal installation tool

380000664

Rear crankshaft seal installation tool

380000221

Piston ring pliers (65 -- 110 mm)

380000302

Valve spring tool

380000667

Camshaft bushing drift

380001298

Mounting brackets for engine stand

380000364

Dial gauge base

380000304

2 Gauges for angular timing

380000103

Connecting rod distortion measuring tool

380000228

Dial gauge (0--5 mm)

380001005

Dial gauge (0--10 mm)

380000914

Dial gauge holder for rotary injection pump timing

380000979

Fuel injection pump gear puller

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1

1 1. 2. 3. 4. 5.

Views of Telehandler engines F4GE0484G*D602 and F4GE0484G*D603 of 82 kW (110 HP) Turbocharger 6. Coolant Outlet Exhaust Manifold 7. Coolant Pump Timing Gear Housing 8. Alternator Starter Motor 9. Thermostat Housing Oil Filter

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1

2 Views of Telehandler engine F4GE0454C*D602 of 71 kW (95 HP) 10. Blow--by Valve 14. Fuel Injection Pump 11. Inlet Tube (less Intercooler) 15. Fuel Filter 16. Fuel Lift Pump 12. Rocker Covers 13. Inlet Grid Heater

604.55.181.00 09 2003

SECTION 10 -- ENGINE -- CHAPTER 1

Oil return path under gravity Oil path under pressure Oil filling MIF0902A

3 Lubrication diagram

Forced--circulation lubrication is accomplished by the following components: -- oil pump, housed at the front of the crankcase, driven by the straight--tooth gear keyed onto the shank of the crankshaft; -- water / oil cooler, housed in the crankcase;

604.55.181.00 09 2003

----

oil pressure control valve incorporated in the cooler assembly; by--pass valve to cut off clogged oil filter, incorporated in the cooler assembly; cartridge oil filter.

SECTION 10 -- ENGINE -- CHAPTER 1

Coolant leaving the thermostat Coolant recirculating in the engine Coolant entering the pump MIF0904A

4 Cooling system diagram

The forced circulation, closed--circuit engine cooling system is composed of the following components: -- a lubricating oil cooler;

---

a centrifugal coolant pump housed at the front of the crankcase; a thermostat valve governing coolant circulation.

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SECTION 10 -- ENGINE -- CHAPTER 1

MIF0903A

5 Detail of cylinder head with valve seats fitted

1. Exhaust manifold 2. Intake manifold 3. Air heater

604.55.181.00 09 2003

4. Fitted valve seats 5. Thermostat valve 6. Injector

SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING Problems Engine does not start.

Possible Causes 1. Battery partially discharged. 2. Battery terminal corroded or loose.

Engine stalls.

Solutions Check and recharge Replace if necessary.

batteries.

connections Clean, inspect and tighten terminal nuts. Replace terminals and nuts if excessively corroded.

3. Injection pump timing incorrect.

Adjust injection pump timing.

4. Impurities or water in fuel lines.

Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.

5. No fuel in tank.

Fill tank.

6. Fuel supply pump malfunction.

Check and necessary.

7. Air in fuel system.

Check fuel lines, unions, supply pump, filters and injection pump for air; then bleed the air from the circuit.

8. Starter motor faulty.

Repair or replace starter motor.

9. Thermostarter faulty.

Check and replace thermostarter if necessary.

1. Slow idling speed too low.

Adjust slow idling speed.

replace

pump

2. Injection pump delivery irregular. Check injection pump delivery on test bench. 3. Impurities or water in fuel lines.

Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.

4. Fuel filters clogged.

Replace the filter cartridges.

5. Incorrect valve -- rocker arm Adjust the clearance between the clearances. rocker arms and the valves. 6. Burnt or cracked valves.

Replace the valves.

7. Air in fuel system.

Check fuel lines, unions, supply pump, filters and injection pump for air; then bleed the air from the circuit.

8. Injection pump drive mechanism Replace damaged parts. damaged. (continued)

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SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING (cont)

Problems Engine overheating.

Possible Causes

Solutions

1. Coolant pump malfunction.

Overhaul pump necessary.

and

replace

2. Thermostat faulty.

Replace the thermostat.

3. Radiator inefficient.

Remove internal deposits by flushing. Check for leaks and repair.

4. Deposits in cylinder head and Flush out coolant system. crankcase coolant passages. 5. Coolant pump and fan drive belt Check and adjust belt tension. slack. 6. Coolant level low.

Top up expansion tank with specified coolant mixture.

7. Incorrect engine timing.

Check and adjust engine timing.

8. Injection pump calibration Calibrate pump on test bench to incorrect -- delivering too much or values specified in calibration tables. too little fuel. 9. Air filter clogged.

Clean filter unit and replace filter element if necessary.

Engine lacks power and 1. Injection pump timing incorrect. runs unevenly.

Adjust injection pump timing.

2. Auto advance regulator injection pump damaged.

in Overhaul injection pump and adjust on test bench to values specified in calibration table.

3. Control valve journal worn.

Overhaul injection pump and adjust on test bench to values specified in calibration table.

4. Injection pump delivery irregular. Overhaul injection pump and adjust on test bench to values specified in calibration table. 5. All--speed governor damaged.

Overhaul injection pump and adjust on test bench to values specified in calibration table.

6. Injectors partially obstructed or Clean and overhaul injectors and damaged. adjust pressure setting. 7. Impurities or water in fuel lines.

Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank. (continued)

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SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING (cont)

Problems

Possible Causes 8. Fuel supply pump damaged.

Solutions Replace fuel supply pump.

9. Incorrect valve -- rocker arm Adjust the clearance between the clearances. rocker arms and the valves. 10. Cylinder compression low.

Test compression and engine if necessary.

overhaul

11. Air filter clogged.

Clean filter unit and replace filter element if necessary.

12. Tie--rod in linkage between Adjust to correct length. accelerator and injection pump incorrectly adjusted. 13. Fast idling speed screw on Adjust fast idling speed screw. injection pump incorrectly adjusted. Engine produces abnormal knocking noises.

1. Injectors partially obstructed or Clean and overhaul injectors and damaged. adjust pressure setting. 2. Impurities accumulating in fuel Clean fuel lines and replace severely lines. dented pipes; clean injection pump if necessary. 3. Injection pump timing incorrect.

Adjust injection pump timing.

4. Crankshaft knocking due to Re--grind crankshaft journals and excessive play in one or more crankpins. Fit oversize shell bearings main or big--end bearings or and thrust washers. excessive endfloat. 5. Crankshaft out of balance.

Check crankshaft alignment and balance; replace if necessary.

6. Flywheel bolts loose.

Replace any bolts that have worked loose and tighten all bolts to the specified preliminary and angular torque values.

7. Connecting rod axes not parallel. Straighten connecting rods, check axes parallelism; replace con rods if necessary. 8. Pistons knock due to excessive Rebore cylinder liners and fit oversize wear. pistons. 9. Noise caused by excessive play Fit oversize gudgeon pin, rebore of gudgeon pins in small--end and piston seats and small--end bushings. piston bushings. Loose fit of Replace with new bushings. small--end bushing. 10. Excessive tappet / valve noise.

Check for broken springs or excessive play between valve stems and guides, cam followers and bores; adjust valve clearances. (continued)

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SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING (cont)

Problems

Possible Causes

Solutions

Engine produces excessive 1. Maximum delivery of injection Calibrate pump on test bench to black or dark grey smoke. pump too high. values specified in calibration tables. 2. Injection pump delivery Adjust injection pump timing or check excessively retarded or automatic advance regulator. automatic advance regulator damaged. 3. Injection pump delivery Adjust injection pump timing. excessively advanced. 4. Injectors partially obstructed or adjusted.

or totally Clean and overhaul injectors and incorrectly adjust pressure setting.replace if necessary.

5. Air filter clogged.

Clean filter unit and replace filter element if necessary.

6. Loss of engine compression due Replace damaged parts or, to: necessary, overhaul the engine. -- piston rings sticking; -- cylinder liner wear; -- worn or incorrectly adjusted valves. 7. High--pressure damaged. Blue, grey--blue or grey--white smoke.

fuel

lines Inspect and replace if necessary.

1. Injection pump delivery Adjust injection pump timing or check excessively retarded or automatic advance regulator. automatic advance regulator damaged. 2. Injectors obstructed or damaged. Clean, overhaul and calibrate injectors, replace if necessary. 3. Oil leaking past piston rings due Replace damaged parts or, to sticking rings or cylinder liner necessary, overhaul the engine. wear.

4. Oil leaking through the inlet valve Overhaul cylinder head. guides due to guide or valve stem wear 5. Engine does not reach correct Replace the thermostat. operating temperature (thermostat faulty). Engine runs on after switching off.

1. Engine stop damaged.

electromagnet Replace electromagnet.

2. All--speed governor damaged.

604.55.181.00 09 2003

Overhaul injection pump and adjust on test bench to values specified in calibration table.

SECTION 10 -- ENGINE -- CHAPTER 1

ENGINES F4GE0454C -- F4GE0484G OVERHAUL CODING OF SOURCE ENGINES

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SECTION 10 -- ENGINE -- CHAPTER 1

Engine Access The LMA telehandler has a hinged engine hood, which when opened, provides access to all routine service points and external components. The engine overhaul described in pages 27 to 84 assumes that the engine has been removed from the telehandler. Pages 85 onwards describe operations that can be carried out without removing the engine.

7 Engine Removal The engine must be removed with the transmission as a unit as the chassis mounts are shared between the two assemblies Engine removal is described in Chapter 2.

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SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 001 53

ENGINE DISASSEMBLY The figures refer to the F4GE0454C*D602 version of 71 kW (95 HP). The revision is to highlight and describe the specific parts of the F4GE0484G*D602 and F4GE0484G*D603 versions of 82 kW (110 HP).

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes. 1. Remove the bonnet support bracket rear retaining bolts. 2. Drain off the engine oil by removing the plug from the sump and the oil filler plug. 3. Detach the fan unit from the fan pulley. 4. To be able to fit the bracket 380001298 (for fixing the engine to the overhaul stand) to the crankcase, it is necessary to remove the wiring (1) from the left--hand side of the engine.

MIF0905A

9 5. To be able to fit the bracket 380001298 to the crankcase on the right--hand side, remove the starter motor (5), oil filter (3), clamp (4), and turbine oil return pipe (1). 6. Secure the engine to the rotary stand 380001298. Remove the oil delivery pipe (2).

MIF1084A

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SECTION 10 -- ENGINE -- CHAPTER 1

For version F4GE0454C*D602 of 71 kW (95 HP) 7. Remove the intake manifold (2). 8. Disconnect the engine oil vapour recovery pipe from the blow--by (3). 9. Remove the tappet covers (1). 10. Remove the pipes with the quick--fit coupling (6) and (8). 11. Remove the piping from the LDA system (5). 12. Remove the fuel filter (7). 13. Remove the heater (4). 14. Remove the control unit for the heater (10). 15. Remove the fuel filter support (9).

MIF0907A

For versions F4GE0484G*D602 -F4GE0484G*D602 of 82 kW (110 HP) Perform the same operations 7. to 15. listed above.

MIF0908A

12 16. Act on the fork (1) as shown in the figure 13 (part B) and remove the fitting. To avoid deformation, with the fitting removed, put the fork (1) back in the locking position (part A). NOTE: Figure 13 shows the connectors for the low--pressure pipes (6 and 8, figs. 11 and 12). A = Pipe locking position on connector. B = Pipe removal position on connector. MIF0909A

13 17. Remove the injector feed pipe (4) from the injection pump (3). 18. Remove the brackets on the cylinder head of the pipe assembly (1), (2) and (6). 19. Remove the priming pump (5).

MIF0910A

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SECTION 10 -- ENGINE -- CHAPTER 1

20. Detach the fuel pipe assembly (1) from the injectors. 21. Remove the fuel outlet pipe (2) from the injectors removing the screw (3) and the seal (4).

MIF0911A

15 For version F4GE0454C*D602 of 71 kW (95 HP) 22. Remove the screws (2) and the turbine (1). 23. Remove the exhaust manifold (3).

MIF0912A

16 For version F4GE0484G*D602 -F4GE0484G*D603 of 82 kW (110 HP) Perform the same operations 22. to 23. listed above.

MIF0913A

17 24. Remove the belt (3) of the auxiliary members acting on the alternator bracket (9). 25. Remove the alternator (7), fan pulley (2) and the guide pulley (4). Remove the support (1) of the pulley (2) and the oil cooler (8). 26. Remove the coolant pump (6). 27. Remove the engine cooling system fitting (5) from the crankcase. NOTE: The coolant pump (6) cannot be overhauled. It must be replaced if there is any irregular operation. MIF0914A

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SECTION 10 -- ENGINE -- CHAPTER 1

28. Lock the flywheel to stop it turning, remove the fixing screws (1) from the pulley (2).

MIF0915A

19 Removing the crankshaft front seal (Op. 29. to 33.) 29. Apply tool 380000665 (4) on the front shank (2) of the crankshaft. 30. Perforate the inner seal (1) with a drill bit Ø 3.5 mm (0.13 in) through the guide holes of the tool (4), for a depth of 5 mm (0.19 in.). 31. Secure the tool 380000665 (4) to the seal (1) with the screws (3) provided. 32. Extract the seal (1) by screwing down the screw (5). MIF0916A

20 33. Fit the tie rod (3) of the tool 380000665 to the outer seal (1) as shown in the figure 21 and with the lever (4), extract it from the front cover (2). 34. Take off the front cover.

MIF0917A

21 35. Remove the oil gear pump (1). NOTE: The oil pump (1) cannot be overhauled. It must be replaced if there is any irregular operation.

MIF0918A

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SECTION 10 -- ENGINE -- CHAPTER 1

36. Release the engine flywheel. 37. Use an assistant to slowly turn over the engine while pressing on the timing pin (3). The engine is at TDC No 1 cylinder on compression when the pin engages with the hole in the pump drive gear.

23 38. Remove the cover (1) from the gear casing (2) (part A). 39. Lock the engine flywheel. 40. Partially slacken the nut (4) fixing the injection pump gear (3) (part B).

MIF0921A

24 41. Slacken the pump locking bolt (2 -- Fig 23) and remove the spacer (1 -- Fig 23).

25 42. Tighten the pump locking bolt to lock the pump drive shaft. Remove the injection pump gear retaining nut (4 -- Fig 24).

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SECTION 10 -- ENGINE -- CHAPTER 1

43. Remove the three nuts (2) (3) and (5) securing the injection pump (1) to the flywheel casing (4) and extract it from its housing with tool 380000979 appropriately fitted to the gear (3 -Fig 24).

MIF0922A

27 44. Remove the screws (2) fixing the engine flywheel (1) to the crankshaft.

MIF0923A

28 45. Screw two pins (2) of the appropriate length into the holes in the crankshaft (3). 46. Extract the engine flywheel (1) so it can be slung with the lift and put it away in a specific container.

MIF0925A

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SECTION 10 -- ENGINE -- CHAPTER 1

Removing the crankshaft rear seal (Op. 49. to 52.) 47. Extract the seal, applying tool 380000663 (3) onto the rear shank (1) of the crankshaft. 48. Perforate the inner seal (5) with a drill bit Ø 3.5 mm (0.13 in.) through the guide holes of the tool 380000663 (3), for a depth of 5 mm (0.19 in.). 49. Secure the tool 380000663 (3) to the seal (5) by screwing down the screws (2) supplied. 50. Extract the seal (5) by screwing down the screw (4). MIF0927A

30 51. Take out the screws (2) and remove the flywheel casing (1). NOTE: Note down the assembly position of the screws (2) as they have different sizes.

MIF0929A

31 52. Turn the engine over, take out the screws (2) and remove the oil sump (1).

MIF0930A

32 53. Take out the screws (1) and (3) and remove the oil suction rose (2). 54. Take out the screws (5) and remove the stiffening plate (4).

MIF0931A

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SECTION 10 -- ENGINE -- CHAPTER 1

55. Take out the screws (1) and remove the gears (3) and (4) from the camshaft (2).

MIF0932A

34 56. For each cylinder, remove the rocker arm assembly (1) loosen the adjuster nuts (3), unscrew the adjusters (4) and take out the screws (2).

MIF0933A

35 57. Extract the injectors (2) with tool 380000671 (1).

MIF0934A

36 58. Take out the screws (1) fixing the head to the crankcase.

MIF0935A

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SECTION 10 -- ENGINE -- CHAPTER 1

59. Hook the metal cables to the brackets (1) and (2) and detach the cylinder head from the crankcase with the hoist.

MIF0936A

38 60. Valves are removed with tool 380000302 (1), applying pressure on the cap (3) so that, by compressing the springs (4), it is possible to remove the cotters (2). Then remove the cap (3) and springs (4). Repeat this operation on all valves (5).

MIF0946A

39 61. Remove the intake manifold cover and extract the oil seals (1) fitted on the valve stems. To remove the valves, turn the head over. NOTE: Mark the inlet and exhaust valves before removing them.

MIF0947A

40 NOTE: The inlet valves differ from the exhaust valves in the size of the head and there being an additional reference mark (1) on the stem. A = Inlet valve. B = Exhaust valve.

MIF0948A

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SECTION 10 -- ENGINE -- CHAPTER 1

62. Remove the thermostat valve (3) from the governor body (1) taking out the screws (5) and the brackets (2) and (4).

MIF0949A

42 63. Take out the screws (2) and remove the timing gear box (1). NOTE: Note down the assembly position of the screws (2) as they have different sizes.

MIF0937A

43 64. Take out the screws (1) securing the connecting rod caps (2) and remove them. 65. Extract the pistons together with the connecting rods from the top of the crankcase. NOTE: Keep the half bearings in their respective housings since, if they are used, they must be mounted in the position found upon disassembly.

MIF0938A

44 66. Remove the rings (1) from the piston (3) with the pliers 380000221 (2).

MIF0950A

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SECTION 10 -- ENGINE -- CHAPTER 1

67. The piston pin (1) retaining rings (2) should be removed using a marking tool (3).

MIF0951A

46 68. Take out the screws (1) and remove the main bearing caps (2).

MIF0939A

47 69. The penultimate main bearing cap (1) and the related mounting have the half bearing (2) equipped with a shoulder. Remove the pistons with the connecting rods. NOTE: Note down the assembly position of the top and bottom half bearings since, if they are reused, they must be mounted in the position found upon disassembly.

MIF0940A

48 70. Using tool 380000671 (1) and a lift, remove the crankshaft (2) from the crankcase.

MIF0941A

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SECTION 10 -- ENGINE -- CHAPTER 1

71. Remove the main half bearings (1); 72. Take out the screws (2) and remove the oil nozzles (3).

MIF0942A

50 73. Take out the screws (1) and remove the plate (3) retaining the camshaft (2). NOTE: Note down the assembly position of the plate (3).

MIF0943A

51 74. Carefully extract the camshaft (1) from the crankcase.

MIF0944A

52 75. Extract the tappets (1) from the crankcase.

MIF0945A

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SECTION 10 -- ENGINE -- CHAPTER 1

76. To remove and renew the front and rear bushings (1) of the camshaft, use the tool 380000667 (2).

MIF0952A

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SECTION 10 -- ENGINE -- CHAPTER 1

40 GENERAL NOTES ---

After disassembling the engine, thoroughly clean the parts. Engine assembly operations should be carried out in reverse order to the disassembly operations described on pages (27--39). Pages (40--65) show the assembly operations that require extra attention in order to assemble parts correctly. The torque settings are shown on page 13--14.

ALSO REMEMBER THAT: ----

When partially or fully disassembling the engine, all seals must be replaced. Before inserting rotating parts and seals in seats, lubricate the parts with engine oil. When fitting the oil filter, lubricate the seal with engine oil.

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts and use appropriate tools to align fixing holes. Wear suitable safety clothing -- safety goggles, gloves and shoes.

ENGINE ASSEMBLY ON THE BENCH FITTING THE BUSHINGS

(Disassembly operation 76.) -- To remove and renew the front and rear bushings (1) of the camshaft, use the drift 380000667 (2) and grip (3). NOTE: The bushings (1) must be directed so that the lubrication holes coincide with the holes in the seats in the crankcase. MIF0952A

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SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE TAPPETS

(Disassembly operation 75.) -- Lubricate the tappets (1) and fit them in their seats in the crankcase.

MIF0953A

FITTING THE CAMSHAFT

(Disassembly operation 73. to 74.) -- Lubricate the bushings supporting the camshaft and mount the camshaft (1) taking care that, during this process, the bushings or the supporting seats do not get damaged.

MIF0944A

57 --

Position the plate (1) retaining the camshaft (2) with the slot facing towards the top of the crankcase and the punchmark facing the operator. Tighten the screws (3) to the prescribed torque stated on page 13.

MIF0955A

58 --

Check that the end float of the camshaft (1) comes within the tolerance range prescribed on page 10.

MIF0956A

59 604.55.181.00 - 10 - 2003

SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE OIL NOZZLES

(Disassembly operation 72.) -- Fit the nozzles (2) and tighten the retaining bolts (1).

MIF0957A

FITTING THE CRANKSHAFT

(Disassembly operations 68. to 71.) -- If any sign of seizure, scoring or ovality is found on the main journals or crankpins, they must be reground. Before reconditioning the pins (1), use a micrometer (2) to measure the pins of the shaft and according to the undersizes given on page 8 define the diameter to which the pins must be reduced.

MIF0958A

61 --

Check that the toothing of the gear (1), splined onto the crankshaft (2) is neither damaged nor worn; if it is, remove it with the a suitable extractor (3). When fitting a new gear it must be heated for 10 minutes in an oven at a temperature of 180 °C and splined onto the crankshaft interposing the key.

MIF0961A

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SECTION 10 -- ENGINE -- CHAPTER 1

NOTE: If the main journals of the crankshaft are undersized it is necessary to replace the main bearings of the same undersize class made. The main bearings (1) are supplied as spare parts with an undersized inside diameter of 0.250 -- 0.500 mm (0.009 -- 0.019 in.). NOTE: Do not modify the bearings in any way. Carefully clean the main half bearings (1) with a lubrication hole and fit them into their respective seats. The penultimate main half bearing (1) is equipped with semi--circular thrust washers. --

MIF0962A

Fit the crankshaft (3) with the gears (1) and (2).

MIF0963A

64 --

Check the clearance between the main journals of the crankshaft and their respective bearings, proceeding as follows: -- Make sure that all parts are perfectly clean and remove all traces of oil. -- Position a length of calibrated wire (3) on the crankshaft journals (4), parallel to the crankshaft centreline. -- Fit the caps (1) complete with half bearings (2) on the relevant supports. MIF0964A

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SECTION 10 -- ENGINE -- CHAPTER 1

44 --

Insert the pre--lubricated screws (1) and tighten them in three successive stages. 1st and 2nd phase with a torque wrench to the torque given on page 14.

MIF0965A

3rd stage with tool 380000304 (1) positioned as in the figure, further tighten the screws (2) with an angle of 90° ± 5°.

MIF0966A

67 -- Remove the support caps. The clearance between the main bearings and the relevant journals is measured by comparing the width of the calibrated wire (2), at the point of greatest crushing, with the graduation of the scale on the case (1) containing the calibrated wire. The numbers shown on the scale indicate the mating clearance in millimetres. Check that the clearance is the one prescribed on page 8, then lubricate the main bearings and permanently mount the supports, tightening the retaining bolts as described above. MIF1075A

68 The crankshaft assembly end float is checked by setting a dial gauge (2) with a magnetic base on the crankshaft (3) as shown in the figure, the normal assembly clearance must come within the tolerance prescribed on page 8. If the clearance is found to be any greater, change the main half bearings of the penultimate rear thrust bearing support (1) and check the clearance again between the crankshaft journals and main half bearings.

MIF1076A

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SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE CONNECTING ROD -- PISTON ASSEMBLY

(Disassembly operations 66. to 67.) -- The following references are cut into the crown of the piston: 1. Spare part number and design modification number. 2. Arrow showing the direction of assembly of the piston in the cylinder liner, it must face the front of the crankcase(auxiliary member side). 3. Date of manufacture. 4. Stamping indicating testing of the 1st groove insert. --

MIF0967A

Using the pin (3) connect the piston (2) to the connecting rod (4) so that the reference arrow (1) for fitting the piston (2) in the cylinder liner is facing as described in point 2.

MIF0968A

71 --

Insert the rings (2) retaining the pin (1).

MIF1060A

72 --

To fit the rings (1) on the piston (3) use tool 380000221 (2).

NOTE: The piston rings (see page 9 to 10) are supplied as spare parts in the following sizes: -- standard, marked with yellow paint; -- oversized by 0.5 mm (0.19 in.) and marked with yellow/green paint.

MIF0969A

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SECTION 10 -- ENGINE -- CHAPTER 1

46 --

Fit the half bearings (1) on the connecting rod and cap.

NOTE: If the crankpins of the crankshaft are undersized it is necessary to replace the big end bearings of the same undersize class made. Do not modify the half bearings in any way.

MIF0970A

FITTING THE PISTON CONNECTING ROD ASSEMBLIES IN THE CYLINDER LINERS

(Disassembly operation 65.) -- Lubricate the pistons well, including the piston rings and the inside of the cylinder liners. -- With the aid of a piston ring clamp (2), fit the connecting rod--piston assemblies (1) in the cylinder liners.

MIF0971A

75 ----

The ring openings must be staggered apart by 120°; The connecting rod/piston assemblies must all have the same weight; The arrow (1) stamped on the crown of the pistons must face the auxiliary member side of the engine and the recess in the piston skirt must correspond to the position of the oil nozzles.

MIF0972A

76 To measure the clearance proceed as follows: -- Carefully clean the parts and remove all traces of oil. -- Position a length of calibrated wire (2) on the crankshaft journals (1); -- Fit the connecting rod caps (3) with the relevant half bearings (4).

MIF1077A

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SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE CONNECTING ROD CAPS

(Disassembly operation 64.) -- Tighten the screws (1) previously lubricated with engine oil with a torque wrench (2) to the torque prescribed on page 14.

MIF0973A

78 --

Fit tool 380000304 (1) on the socket wrench and further tighten the bolts (2) as prescribed on page 14.

MIF0974A

79 --

Remove the cap and determine the clearance by comparing the width of the calibrated wire (1) against the graduated scale printed on the packet (2) containing the wire.

MIF1078A

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SECTION 10 -- ENGINE -- CHAPTER 1

Check that the clearance is the one prescribed on page 8, then lubricate the big end half bearings and permanently mount them, tightening the connecting rod cap retaining bolts as described on page 14. NOTE: Before permanently fitting the connecting rod cap retaining bolts, check that their diameter, measured at the centre of the length of the thread, is no less than 0.1 mm (0.003 in.) of the diameter measured at approximately 10 mm (0.393 in.) from the end of the bolt. Check by hand that the connecting rods (1) run axially on the crankshaft journals and their end float measured with a feeler gauge (2) is as prescribed on page 9.

MIF1079A

FITTING THE TIMING GEAR CASING

(Disassembly operation 63.) -- Carefully clean the timing gear box (1) and the crankcase. Cleaning the surface to seal is both necessary and unavoidable in order to obtain an effective seal. Apply LOCTITE 5999 sealant onto the box to form a bead with a diameter of a few mm.It must be uniform (no lumps), with no air bubbles, thin areas or breaks. Any flaws must be corrected in as short a time as possible. Avoid using excess material to seal the joint. Too much sealant would tend to come out on both sides of the joint and clog the lubricant passageways. After applying the sealant, the joints require immediate assembly (10 -- 20 minutes). -- Refit the box to the crankcase. -- Tighten the retaining bolts in the position found during disassembly.

604.55.181.00 - 10 - 2003

MIF0975A

SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE THERMOSTAT VALVE

(Disassembly operation 62.) -- Assemble the thermostat valve (3) to its associated body (1) and to the bracket (2) with the screws (5). Fit the bracket (4).

MIF0949A

FITTING THE CYLINDER HEAD

(Disassembly operations 58. to 61.) -- Lubricate the valve stem and insert into the relevant valve--guides according to the position marked during disassembly. -- Fit the seals (1).

MIF1091A

84 --

Position the following parts on the cylinder head: spring (4) and top cap (3): using tool 380000302 (1) compress the spring (4) and retain the parts to the valve (5) with the cotters (2).

MIF0946A

85 ---

Check that the mating surfaces (1) of the cylinder head and crankcase are clean. Do not dirty the cylinder head gasket.

NOTE: Before reusing the cylinder head retaining bolts, check they show no sign of deterioration or deformation and replace them if they do.

MIF1009A

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SECTION 10 -- ENGINE -- CHAPTER 1

Using the dial gauge 380000228 (1) fitted with its base 380000364 (2), check the protrusion of the pistons (3) at T.D.C. from the cylinder block face is within the tolerance limits prescribed on page 9.

MIF1080A

87 Since there are two type of head gasket, to choose its thickness (1.25 mm (0.049 in.) Type A and 1.15 mm (0.045 in.) Type B) make the following measurements: -- for each piston, as shown in the figure, at a distance of 45 mm (1.77 in.) from the centre of the piston, measure its protrusions S1 and S2 from the top face of the crankcase and then calculate the mean: Scyl1 =

S1 + S2 2

Repeat this operation for pistons 2, 3 and 4 and calculate the mean value: S=

MIF1086A

Scyl1 + Scyl2 + Scyl3 + Scyl4 4

If S is > 0.40 mm (0.015 in.) use the gasket type A. If S is < 0.40 mm (0.015 in.) use the gasket type B. --

After installing the gasket, fit the cylinder head on the crankcase, screwing down the screws (1) without tightening them to torque.

MIF1089A

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SECTION 10 -- ENGINE -- CHAPTER 1 --

Before inserting the control rods, check that the spherical seat (1) of contact with the rocker arm adjuster screw and the spherical end (2) of contact with the tappet show no sign of wear; if there is, then change them. The inlet and exhaust valve control rods are identical and can therefore be interchanged.

MIF1011A

90 --

Spread LOCTITE 5999 sealant between the cover (2) and the manifold (3) and tighten the screws to the torque prescribed on page 13.

MIF1094A

FITTING THE INJECTORS

(Disassembly operation 57.) -- On the injector (1), mount a new seal (2) lubricated with Vaseline and a new washer (3). -- Fit the injectors 2, 3, 4 in the seats on the cylinder head and tighten them to the torque prescribed on page 13. NOTE: Injector 1 will be fitted after doing the injection pump timing.

MIF1063A

FITTING THE ROCKER ARM ASSEMBLY

(Disassembly operation 56.) -- Check that the spindle (2) / rocker arm (1) coupling surfaces are neither too worn nor damaged.

Main spindle--rocker arm data (mm)

MIF1012A

93 604.55.181.00 - 10 - 2003

SECTION 10 -- ENGINE -- CHAPTER 1

52 --

Check that the tappet adjusters are unscrewed to prevent them sticking on the rods when fitting the rocker arm assembly (1). Then mount the rocker arm assembly comprising the support and spindles and secure them to the head without tightening the bolts (2) to torque. The screws (2) should be tightened to torque in the phase of tightening the cylinder head.

MIF1013A

FITTING THE TIMING GEAR

(Disassembly operation 55.) -- Use a marker pen to mark the tooth of the driving gear (1) mounted on the crankshaft (2) on the side of which the reference mark (→) is stamped for timing.

MIF0977A

95 --

Direct the crankshaft (3) and camshaft (4) so that when mounting the driven gear (1) on the camshaft, the marks stamped on the gears (1 and 2) coincide.

MIF0978A

96 --

Place the dial gauge (1) on the timing gear (2) and check that the clearance between the gears (2) and (3) is between 0.076 to 0.280 mm (0.002 to 0.011 in.).

MIF01087A

97 604.55.181.00 - 10 - 2003

SECTION 10 -- ENGINE -- CHAPTER 1 --

Insert the screws (1) fixing the gears (2) to the camshaft (3) and tighten them to the torque prescribed on page 13.

MIF0979A

98 --

Tighten the cylinder head fixing screws in the sequence shown in Figure 100.

MIF1014A

99 --

Tightening sequence for cylinder head bolts: 1st stage of tightening with a torque wrench: M12 x 1.75 x 70 bolt: 50 Nm to 5 Nm (ref. 3--6--11--14) (11.2 to 1.12 lbf) M12 x 1.75 x 140 bolt:

40 Nm to 5 Nm (8.99 to 1.12 lbf) (ref. 1--2--7--8--9--10--15--16--17--18) M12 x 1.75 x 180 bolt: (ref. 4--5--12--13)

70 Nm to 5 Nm (15.7 to 1.12 lbf)

2nd stage tightening to an angle of 90° for all the screws rd 3 stage additional tightening to an angle of 90° for 140 and 180 mm (5.51 and 7.08 in.) long bolts only. A = fan side

MIF1015A

100

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SECTION 10 -- ENGINE -- CHAPTER 1

54 --

---

Adjust the clearance between the rocker arms and valves using an Allen wrench (1), box wrench (2) and feeler gauge (3). The working clearance is given on page 11. Take the cylinder where the clearance is to be adjusted into the combustion phase; this cylinder’s valves are closed while they balance those of the symmetrical cylinder. The symmetrical cylinders are 1 -- 4 and 3 -- 2. -- FIRING ORDER 1 -- 3 -- 4 -- 2 Balance valves of cylinder no.

Adjust valve clearance of cylinder no.

2 MIF1016A

101

Turn the crankshaft to bring it into the condition of the No 1 cylinder at TDC. The engine is at TDC No 1 cylinder on compression when the pin engages with the hole in the pump drive gear. Fit the injection pump and secure it with the screws.

102

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SECTION 10 -- ENGINE -- CHAPTER 1 --

Spline the gear (1) transmitting drive to the pump and provisionally tighten the nut (2).

MIF0982A

103

FITTING THE ROSE PIPE

(Disassembly operations 53. to 54.) -- Fit the plate (4), rose pipe (2) and tighten the fixing screws (3, 5 and 11).

MIF0931A

104

FITTING THE OIL SUMP

(Assembly operation 52.) -- Place the new seal on the crankcase. -- Fit the oil sump (1). -- Insert the screws (2) and tighten them to the torque prescribed on page 13.

MIF0930A

105 Tightening sequence for engine oil sump bolts -- First phase: from 1 to 16 -- Second phase: from 17 to 32

80366

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SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE FLYWHEEL CASING

(Assembly operations 51.) -- Carefully clean the mating surfaces of the flywheel casing (1) and the timing gear casing. -- Cleaning the surface to seal is both necessary and unavoidable in order to obtain an effective seal. -- Apply LOCTITE 5999 sealant onto the box (1) to form a bead with a diameter of a few mm. -- It must be uniform (no lumps), with no air bubbles, thin areas or breaks. -- Any flaws must be corrected in as short a time as possible. -- Avoid using excess material to seal the joint. -- Too much sealant would tend to come out on both sides of the joint and clog the lubricant passageways. -- After applying the sealant, the joints require immediate assembly (10 -- 20 minutes). -- Refit the casing to the crankcase, screw down the fixing screws (2) in the position found upon disassembly and tighten them to the prescribed torque as shown on page 13.

MIF0986A

106

MIF0987A

107

FITTING THE CRANKSHAFT REAR SEAL

(Assembly operations 47. to 50.) -- Fit part (4) of tool 380000664 on the rear shank (3) of the crankshaft. Secure it with the screws (5) and spline the new seal (6) onto it. -- Position part (1) on part (4), screw down the nut (2) until the seal (6) is completely fitted in the flywheel casing.

MIF0928A

108

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SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE FLYWHEEL

(Assembly operations 44. to 46.) For versions F4GE0484G*D602 of 82 kW (110 HP) and F4GE0454C*D602 of 71 kW (95 HP) -- Check the clutch plate mating surface; turning is required if there is any scoring. -- Check the state of the teeth of the crown gear (2). If you find any breakage or excessively worn teeth, replace it. Mount the new one, previously heated to a temperature of 150 °C (302 °F) for 15--20 min. MIF0989A

109 For version F4GE0484G*D603 of 82 kW (110 HP) Perform the same operations as in the preceding figure. NOTE: The nominal thickness of the engine flywheel is 70.5 mm (2.77 in.).

MIF0990A

110 For versions F4GE0484G*D602 of 82 kW (110 HP) and F4GE0454C*D602 of 71 kW (95 HP) -- Screw two pins (2) of the appropriate length into the holes in the shaft (3) and, using the sling, mount the engine flywheel (1).

MIF0925A

111 For version F4GE0484G*D603 of 82 kW (110 HP) Perform the same operations as in the preceding figure.

MIF0926A

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SECTION 10 -- ENGINE -- CHAPTER 1

For versions F4GE0484G*D602 of 82 kW (110 HP) and F4GE0454C*D602 of 71 kW (95 HP) -- Spline the flywheel (1) onto the crankshaft, tightening the screws (2) by hand. -- Lock the flywheel appropriately before tightening the relevant screws to torque.

MIF0923A

113 For version F4GE0484G*D603 of 82 kW (110 HP) Perform the same operations as in the preceding figure.

MIF0924A

114 For versions F4GE0484G*D602 of 82 kW (110 HP) and F4GE0454C*D602 of 71 kW (95 HP) -- Tighten the bolts (1) securing the engine flywheel (2) in two stages as described on page 14: 1st phase, tightening with torque wrench to a torque of 30 ± 5 Nm (6.74 ± 1.12 lbf); 2nd phase, tightening to angle of 60° ± 5°. NOTE: Tightening to an angle is done with tool 380001001. MIF0994A

115 For version F4GE0484G*D603 of 82 kW (110 HP) Perform the same operations as in the preceding figure.

MIF0995A

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SECTION 10 -- ENGINE -- CHAPTER 1 --

Tighten the retaining nut (1) with the torque wrench (2) to 20 Nm.

MIF0983A

117 ---

Remove the pre--setting screw (2) and insert the “L” spacer (1). Fully screw down the screw. Now tighten pump gear retaining nut to 90 Nm.

MIF0920A

118 --

Spread sealant (1) as shown in the figure (A, Figure 119) and fit the cover (2) (B, Figure 119), tightening the screws to torque.

MIF0984A

119

FITTING THE OIL PUMP

(Disassembly operation 35.) -- Fit the oil pump (1). -- Insert the tightening screws (2) and tighten them to the torque prescribed on page 13.

MIF0996A

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SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE FRONT COVER

(Disassembly operation 34.) -- Fit the seal (2) on the front cover (1), carefully clean the surface for mating with the crankcase and spread LOCTITE 5999 sealant on it.

MIF0999A

121 ---

Carefully clean the crankcase surface for mating with the front cover (2) and fit this on. Insert the screws (1) and tighten them to the torque prescribed on page 13.

MIF1000A

122

FITTING THE CRANKSHAFT FRONT SEAL

(Disassembly operations 29. to 33.) -- Fit part (4) of tool 380000666 on the front shank (3) of the crankshaft. Secure it with the screws (5) and spline the new seal (6) onto it. Position part (1) on part (4), screw down the nut (7) until the seal (6) is completely fitted in the front cover (2).

MIF1001A

123

FITTING THE CRANKSHAFT FRONT PULLEY AND GUIDE PULLEY

(Disassembly operation 28.) -- Spline the pulley (1) with the spacer onto the crankshaft and tighten the screws (4) to torque and angle (see page 14), using tool 380000304. -- Secure the guide pulley (3) to the front cover with the screws (2), tightening them to torque.

MIF1003A

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SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE COOLING SYSTEM UNION

(Assembly operation 27.) -- Position the cooling system fitting so that the pins (3 and 4) are against the crankcase. -- Tighten the screws (1 and 2).

MIF1005A

125

FITTING THE COOLANT PUMP

(Assembly operation 26.) -- Fit a new seal (2) onto the coolant pump (1).

MIF0997A

126 ---

Mount the coolant pump (1); Screw down the screws (2) and tighten them to the torque prescribed on page 13.

MIF0998A

127

FITTING THE FAN--ALTERNATOR PULLEY

(Disassembly operation 25.) -- Fit the coolant temperature sensor (1) screwing it down with a torque wrench. -- Fit the fan pulley support (2) with the screws (3), tightening them to the torque given on page 13.

MIF1027A

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SECTION 10 -- ENGINE -- CHAPTER 1

62 --

Fit on the crankcase: a new gasket (1), the cooler (2), a new gasket (3) and the oil filter mounting (4). Insert the screws (5) and tighten them to the torque prescribed on page 13.

MIF1004A

129 --

Refit the bracket (1) to secure the alternator (2) to the crankcase. Tighten the alternator fixing screws (3) to the torque specified on page 13.

MIF1006A

130 --

Fit the fan pulley (2) on the support (1) with the screws (3), tightening them to torque.

MIF1028A

131

FITTING THE AUXILIARY MEMBER DRIVE BELT

(Disassembly operation 24.) -- Fit the Poly--V belt (2) on the crankshaft pulley, guide pulley (3), coolant pump (4), alternator (5) and on the fan pulley (1). NOTE: Tension the belt correctly as indicated in operation 10 414 10.

MIF1092A

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SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE EXHAUST MANIFOLD -TURBINE

(Disassembly operations 22. and 23.) -- Mount the exhaust manifold (4) and tighten the screws (3) to the torque prescribed on page 13. -- Fit the turbine (1) with the screws (2).

MIF1088A

133 Tightening sequence for exhaust manifold bolts

80363

Tightening sequence for turbocharger nuts and bolts Sequence: -- Pre--tightening 4--3--1--2 -- Tightening 1--4--2--3

84364

FITTING THE INJECTOR FEED PIPES

(Assembly operations 20. to 21.) -- Fit the injector feed pipe assembly (1). Fit the injector fuel outlet pipes (2), using the seals (4) and tighten the screws (3).

MIF0911A

134

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SECTION 10 -- ENGINE -- CHAPTER 1

FIT THE PRIMING PUMP -- FEED PIPES

(Disassembly operations 17. to 19.) -- Fit the priming pump (5). -- Fit the injector feed pipes (4) of the injection pump (3), secure the brackets fixing the pipe assembly (1), (2) and (6) on the cylinder head.

MIF0910A

135

FITTING THE PIPES BETWEEN THE FUEL SUPPLY AND INJECTION PUMPS, PRE--HEATING SYSTEM AND TAPPET COVER

(Disassembly operations 7. to 16.) For version F4GE0454C*D602 of 71 kW (95 HP) -- Fit the fuel filter mounting (9). -- Fit the control unit for the heater (10). -- Fit the heater (4). -- Fit the fuel filter (7). -- Fit the LDA system piping (5). -- Connect the pipes with the quick--fit coupling (6) and (8) following the guidelines of fig. 138. -- Fit the tappet covers (1). -- Connect the engine oil vapour recovery pipe to the blow--by (3). -- Fit the intake manifold (2).

604.55.181.00 - 10 - 2003

MIF0907A

136

SECTION 10 -- ENGINE -- CHAPTER 1

For versions F4GE0484G*D602 -F4GE0484G*D602 of 82 kW (110 HP) Perform the same operations as in the preceding figure.

MIF0908A

137 --

Press the clip (1) in the direction of the arrow (part B) and connect the low--pressure pipe. Put the clip back in its locking position (part A).

NOTE: Figure 138 shows the connectors for the low--pressure pipes (6) and (8) of figures 136 and 137. A = Pipe locking position on connector. B = Coupling pipe removal position.

MIF0909A

138

FITTING THE STARTER MOTOR

(Disassembly operations 5. and 6.) -- Fit the oil delivery pipe (2). -- Fit the turbine oil return pipe (1), the clamp (4), oil filter (3) and starter motor (5).

MIF1084A

139 ----

Fit the wiring (1). Fit the fan unit to the fan pulley. Add engine oil through the filler plug.

Insert the bonnet support bracket front and rear bolts. MIF0905A

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SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS (CYLINDER BLOCK, LINERS)

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes. Checks and measurements After disassembling the engine, thoroughly clean the crankcase assembly. Use the specific lifting rings for transporting the assembly. Carefully check the crankcase is not cracked. Check the condition of the plugs (3, fig. 144) on the crankcase. If they are rusty or if there is the slightest doubt about their seal, change them. Examine the surfaces of the cylinder liners; they should show no scoring, ovality, taper or excessive wear. To check the internal diameter of the cylinder liners for ovality, taper and wear, use the bore gauge (1), fitted with a dial gauge zero--set on the ring gauge (2) of the diameter of the cylinder liner. NOTE: If the ring gauge is not available, use a micrometer.

MIF1030A

141 Measurements must be taken for each single liner, at three different heights on the liner and on two orthogonal faces: one parallel to the longitudinal axis of the engine (A) and the other perpendicular (B); maximum wear is generally found on this face in correspondence with the first measurement. If you find any ovality, taper or general wear outside the tolerance given on page 9, bore and recondition the cylinder liners. The cylinder liners must be reground in relation to the diameter of the pistons supplied as spare parts (oversized by 0.5 mm (0.019 in.) over the nominal value) and to the assembly clearance prescribed on page 9.

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MIF1031A

142

SECTION 10 -- ENGINE -- CHAPTER 1

MIF1032A

143 TOLERANCES

CHARACTERISTIC SUBJECT OF TOLERANCE

SHAPE

Cilindricity

ORIENTATION

Perpendicularity

POSITION

Location

GRAPHIC SYMBOL /f/

NOTE: If regrinding, all the liners must have the same oversize 0.5 mm (0.019 in.). Check the main bearing seats, proceeding as follows: -- fit the main bearing caps on the supports without bearings;

tighten the retaining bolts to the prescribed torque; -- using an appropriate dial gauge for interiors, check that the diameter of the seats is as prescribed on page 8. If the measurement is any greater, change the crankcase.

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SECTION 10 -- ENGINE -- CHAPTER 1

Check that the head mating surface, on the cylinder block, has no deformation. This check can be made, after taking out the grub screws (2), with a calibrated rule (1) and feeler gauge (4). After having located deformed areas, level off the mating surface using a grinding machine. The flatness error must be no greater than 0.075 mm (0.0029 in.). NOTE: The crankcase can be faced only after making sure that, after machining, the protrusion of the piston from the cylinder liner is no greater than as prescribed on page 9. Check the condition of the cylinder block plugs (3); if they are rusty or if there is the slightest doubt about their seal, change them. After facing, restore the bevel of the cylinder liners as shown in Figure 143.

604.55.181.00 - 10 - 2003

MIF1033A

144

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS CRANKSHAFT

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes. Crankshaft Clean all parts carefully before proceeding with the operations described below. Carefully examine the crankshaft. If even slight cracks are found, replace the crankshaft. -- If any sign of seizure, scoring or too much ovality is found on the main journals or crankpins, they must be reground. Before reconditioning the pins (1), use a micrometer (2) to measure the pins of the shaft to define the diameter to which the pins must be reduced. NOTE: It is advised to note the values on a chart. See figure 146. --

The undersize classes are 0.250--0.500 mm (0.009--0.019 in.). MIF0958A

145

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SECTION 10 -- ENGINE -- CHAPTER 1

NOTE: The main journals and crankpins must always be reconditioned to the same undersize. After undersizing, mark the main journal and the crankpin with a stamp on the side of the crank No. 1. Undersized crankpins with the letter M. Undersized main journals with the letter B. Undersized crankpins and main journals with the letters MB.

MIF0959A

146 Chart on which to note the measurements of the crankshaft main journals and crankpins * Nominal value

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SECTION 10 -- ENGINE -- CHAPTER 1

MIF0960A

147 *

Measured on a radius greater than 45.5 mm (1.79 in.).

** ↗ 0,50 between adjacent main journals.

TOLERANCES SHAPE ORIENTATION POSITION OSCILLATION

MAIN CRANKSHAFT TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE Circularity Cilindricity Parallelism Perpendicularity Straightness Concentricity or coaxiality Circular oscillation Total oscillation Taper

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS

CRITICAL

GRAPHIC SYMBOL f /f/ //

GRAPHIC SYMBOL 

IMPORTANT SECONDARY

604.55.181.00 - 10 - 2003

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -- CONNECTING RODS

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes. Main data (mm) of the connecting rod, piston pin bushing and half bearings *

Inside diameter to be measured after installing in the small end and regrinding with a reamer. ** Cannot be measured free. NOTE: The connecting rod -- connecting rod cap mating surfaces are knurled for a better coupling. It is therefore recommended not to remove the knurling. Each connecting rod is marked: -- On the body and cap with a number indicating their coupling and the cylinder in which it is mounted. -- In the event of replacement, number the new rod with the same number as the replaced connecting rod. On the body of the connecting rod with a letter indicating the weight class of the connecting rod mounted in production: -- V, 1600g to 1640g (marked in yellow); -- W, 1641g to 1680g (marked in green); -- X, 1681g to 1720g (marked in blue). Connecting rods are supplied as spare parts in class W and marked in green. Removing material is not permissible.

MIF1043A

148

Bushings Check that the bushing in the small end has not come loose and shows no sign of scoring or seizure. If this is not so, change it. Disassembly and assembly are performed with a suitable drift. When driving in, make sure that the oilways in the bushing and small end coincide. Using a reamer, regrind the bushing to obtain the prescribed diameter.

MIF1044A

149

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SECTION 10 -- ENGINE -- CHAPTER 1

Checking connecting rods Check the parallelism of the connecting rod (2) axes using instrument 380001003 (4) as follows. Fit the connecting rod (2) on the self--centring spindle (3) of tool 380001003 (4) and lock it with the screw (5). Put the spindle (3) on the “V” prisms, setting the connecting rod (2) on the stop bar (1).

MIF1045A

150 Checking twisting Check the twist of the connecting rod (2) by comparing two points (A and B) of the pin (4) on the horizontal plane of the connecting rod axis. Position the support (1) of the dial gauge (5) so that this pre--loads by ∼ 0.5 mm (0.019 in.) on the pin (4) at point A and reset the dial gauge (5). Move the spindle (3) with the connecting rod (2) and on the opposite side (B) of the pin (4) compare any deviation: the difference between A and B must be no greater than 0.08 mm (0.003 in.). MIF1046A

151 Checking bending Check the bend of the connecting rod (3) by comparing two points (C and D) of the pin (4) on the vertical plane of the connecting rod axis.Position the vertical support (2) of the dial gauge (1) so that this rests on the pin (4) at point C as shown in the figure. Swing the connecting rod to and fro, seeking the highest position of the pin and reset the dial gauge (1) in this condition. Move the spindle with the connecting rod (3) and on the opposite side D of the pin (4) repeat the check for the highest point. The difference between points C and D must be no greater than 0.08 mm (0.003 in.).

MIF1047A

152 604.55.181.00 - 10 - 2003

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS REPAIRS -- PISTONS

AND

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes. Clean all parts carefully before proceeding with the operations described below.

MIF1034A

153 Normal dimensions (mm) piston data Measuring the piston diameter Using a micrometer (2) measure the diameter of the piston (1), and check the cylinder liners to determine the state of wear of the liners and pistons (see pages 8 and 9). If the clearance is not between 0.252 to 0.294 mm (0.009 to 0.0115 in.), it will be necessary to ream, rebore the liners and fit oversize pistons and rings (see pages 8 and 9). NOTE: The diameter must be measured at a distance of 61 mm (2.40 in.) from the base of the piston skirt.

604.55.181.00 - 10 - 2003

MIF1035A

154

SECTION 10 -- ENGINE -- CHAPTER 1

Clearance between the piston and the cylinder liner can be measured with a feeler gauge (1), as shown in the figure 155.

MIF1036A

155 Piston pins Measuring the piston pin (2) diameter using a micrometer (1). When fitting pins on pistons, check that the clearance between the gudgeon pin and its bore in the piston is within the tolerance specified on page 9.

MIF1037A

156 Conditions for correct pin--piston coupling Lubricate the pin (1) and the piston pin boss seat with engine oil; the pin must go into the piston with a light pressure of the fingers and must not drop out.

MIF1038A

157 Piston rings Using a micrometer (1) check that the thickness of the 1°--2°--3° ring (2) comes within the tolerances stated on page 9.

MIF1039A

158 604.55.181.00 - 10 - 2003

SECTION 10 -- ENGINE -- CHAPTER 1

Using a feeler gauge (2), check that the clearance between the rings and their seats on the piston come within the tolerances prescribed on page 10.

MIF1040A

159 Measuring the clearance X of the V--ring Due to the special shape of the first seal with a trapezoidal cross--section, the clearance between the groove and the ring should be measured as follows; Make the piston (1) protrude from the crankcase so that the ring (3) at issue comes approximately halfway out of the cylinder liner (2). In this position, using a feeler gauge, check the clearance (X) between the ring and the groove: this clearance must be as prescribed on page 10.

MIF1041A

160 Measure the clearance between the ends of the piston rings (2) introduced in the cylinder liner (3) using a feeler gauge (1), checking it is as prescribed on page 10.

MIF1042A

161

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SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -- CAMSHAFT AND VALVES

MIF1048A

162 Decarbonizing, checking and grinding valves Remove all carbon deposits from the valves (2) using a wire brush (1). Check that the valves show no signs of seizure, cracking or burning. If necessary, grind the bevels on the valve heads using a grinding machine, removing as little material as possible.

MIF1049A

163 Using a micrometer (2) measure the valve stem (1) and check it comes within the range of tolerance given on page 11.

MIF1050A

164

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SECTION 10 -- ENGINE -- CHAPTER 1

MIF1052A

165 Dimensions (mm) of valve seats

MIF1051A

Dimensions (mm) of valve seat housings If the valve seats cannot be reconditioned by just regrinding, they can be replaced with the ones supplied as spare parts. Using a specific tool and taking care not to nick the cylinder head, remove as much material as possible from the valve seats until it is possible to extract them from the cylinder head with the aid of a punch.

604.55.181.00 - 10 - 2003

166

Heat the cylinder head to 80 to 100 °C (176 to 212 °F) and, using a suitable drift, insert the new valve seats, previously cooled. Then, regrind the valve seats according to the values given in Figure 165. A = Exhaust valve. B = Inlet valve.

SECTION 10 -- ENGINE -- CHAPTER 1

After regrinding, with the base 380000364 (2) and dial gauge 380000228 (1), check that the valve recessing (3) in relation to the top face of the cylinder head comes within the tolerance prescribed on page 11.

MIF1053A

167

VALVE SPRINGS The figure shows the main data for checking the inlet and exhaust valve springs. Before assembly, check the valve spring flexibility using a suitable tool. Compare the elastic deformation and load data with those of the new springs stated in the following table. Height mm (inches) H(free) 63.50 (2.49) H1 49.02 (1.92) H2 38.20 (1.50)

Under a load of N No load P1 329 P2 641

MIF1054A

168

Tappets The figure gives the main data, in mm, of the tappets and their seats in the crankcase.

MIF1055A

169

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SECTION 10 -- ENGINE -- CHAPTER 1

80 Camshaft

MIF1056A

170 Camshaft data The data given refer to the normal pin diameter (dimensions in mm) The support journal surfaces on the shaft and cams must be finely honed; if there are signs of seizing or scoring, replace the shaft and relative bushings. Checking cam lift and pin alignment Set the shaft on tailstocks and, using a dial gauge with a 1/100 mm scale placed on the central support, check that the alignment error is no greater than 0.04 mm (0.001 in.); change the shaft if it is. Check the diameter of the supporting pins of the camshaft (2) with the micrometer (1) on two orthogonal axes.

MIF1057A

171

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SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -- CYLINDER HEAD

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes. Use tool 380000302 to remove and refit valve springs. Clean all parts carefully before proceeding with the operations described below. Cylinder head mating surface check The mating surface of the head (1) with the cylinder block should be checked with a rule (2) and a feeler gauge (3). The deformation measured on the full length of the cylinder head must be no greater than 0.20 mm (0.007 in.). If it is any higher, regrind the cylinder head according to the dimensions and warnings given in the following figure.

MIF1058A

172

Cylinder head thickness The nominal thickness A of the cylinder head is 95 ± 0.25 mm (3.74 ± 0.009 in.) the maximum permissible amount of metal removed must not exceed the thickness B of 0.13 mm (0.005 in). NOTE: After regrinding, check the valve recessing and if necessary regrind the valve seats to obtain the recessing prescribed on page 11.

MIF1059A

173 TOLERANCES

CHARACTERISTIC SUBJECT OF TOLERANCE

SHAPE

Flatness

Cylinder head hydraulic seal check Check the hydraulic seal using the appropriate tools. Using a pump, introduce water heated to ∼ 90°C (194°F) at a pressure of 2 to 3 bar (29 to 43.5 psi). If there is any leakage from the cup plugs, replace them, using a suitable drift for their disassembly -assembly.

GRAPHIC SYMBOL

NOTE: Before fitting the plugs (3, fig. 144), apply a water--reactive sealant on their sealing surface. If you find any leakage from the cylinder head, it must be changed.

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SECTION 10 -- ENGINE -- CHAPTER 1

OIL FILTER -- Replacement

COOLANT THERMOMETER -- Testing

The oil filter (3, fig. 10) is the paper integral cartridge type.

If malfunction is suspected, immerse the bulb of the thermometer in water and check the readings against a test thermometer (repeat the test a number of times with different water temperature to be sure).

If the filter gets too clogged, the safety valve opens to enable the oil to by--pass the filter, keeping the engine lubricated, albeit with non--filtered oil. Replace the cartridge periodically (every 800 operating hours), remembering to: --

oil the outer part of the seal in contact with the mounting on the crankcase;

screw on the new cartridge until the seal is up against the mounting on the crankcase;

tighten the cartridge, by hand only, through a further 3/4 turn.

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THERMOSTAT VALVE -- Replacement The thermostat valve (5, Fig. 5) is fitted in the cylinder head coolant outlet union. The thermostat valve cannot be adjusted and therefore must be replaced if it does not meet the temperature specifications in the table on page 3.

SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 102 70

CRANKSHAFT FRONT SEAL Replacement

Disassembly Apply tool 380000665 (4) on the front shank (2) of the crankshaft. Perforate the inner seal (1) with a drill bit ∅ 3.5 mm (0.13 in) through the guide holes of tool (4), for a depth of 5 mm (0.19 in.). Secure the tool 380000665 (4) to the seal (1) by screwing down the screws (3) supplied. Extract the seal (1) by screwing down the screw (5).

MIF0916A

174 Fit the tie rod (3) of the tool to the outer seal (1) as shown in the figure and with the lever (4), extract it from the front cover (2).

MIF0917A

175 Assembly -- Fit part (4) of tool 380000666 on the front shank (3) of the crankshaft. Secure it with the screws (5) and spline the new seal (6) onto it. Position part (1) on part (4), screw down the nut (7) until the seal (6) is completely fitted in the front cover (2).

MIF1001A

176

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SECTION 10 -- ENGINE -- CHAPTER 1

84 Op. 10 102 74

CRANKSHAFT REAR SEAL Replacement

DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Check that no one is in the vicinity of the load to be lifted. 1. Apply tool 380000663 (3) on the rear shank (1) of the crankshaft. Perforate the inner seal (5) with a drill bit ∅ 3.5 mm (0.13 in) through the guide holes of tool 380000663 (3), for a depth of 5 mm (0.19 in.). Secure the tool 380000663 (3) to the seal (5) by screwing down the screws (2) supplied. Extract the seal (5) by screwing down the screw (4).

MIF0927A

177 2. Refit the flywheel casing (1) to the crankcase, screw down the fixing screws (2) in the position found upon disassembly and tighten them to the prescribed torque as shown on page 13.

MIF0929A

178 3. Fit part (4) of tool 380000664 on the rear shank (3) of the crankshaft. Secure it with the screws (5) and spline the new seal (6) onto it. Position part (1) on part (4), screw down the nut (2) until the seal (6) is completely fitted in the flywheel casing.

MIF0928A

179

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SECTION 10 -- ENGINE -- CHAPTER 1

Engine Component Access with engine installed in Telehandler It is not necessary to remove the engine hood to gain access to the top of the engine for routine service. However, some components will require removal to provide reasonable accessibility to the valve gear and injectors. Disconnect the battery negative lead before commencing any work on the engine.

180 Valve Tappet Clearance Adjustment 1. Remove the bolts (2) securing the coolant recovery bottle (3) to the air cleaner surround (1).

181 2. Tie the coolant recovery tank (1) to the radiator with the bottle upright. 3. Thoroughly clean the top of the engine

182 4. Remove the air inlet transfer pipe (1), by loosening the hose clip securing the pipe to the turbocharger hose and removing the four mounting bolts from the grid heater assembly. 5. Remove the blow--by valve (2) mounting screws and tie the valve back clear of the rocker covers.

183 604.55.181.00 - 10 - 2003

SECTION 10 -- ENGINE -- CHAPTER 1

6. Remove rocker covers (1 & 2) from the engine. 7. Discard the rubber seals fitted between the rocker covers and the cylinder head.

184 8. After taking off the covers, adjust the clearance between the rocker arms and valves using an Allen wrench (1), box wrench (2) and feeler gauge (3). The working clearance should be: -- inlet valves 0.30 ± 0.05 mm 0.0118 ± 0.0119 ins -- exhaust valves 0.55 ± 0.05 mm 0.0216 ± 0.0119 ins 9. Take the cylinder where the clearance is to be adjusted into the combustion phase; this cylinder’s valves are closed while they balance those of the symmetrical cylinder. The symmetrical cylinders are 1 -- 4 and 3 -- 2. -- FIRING ORDER 1 -- 3 -- 4 -- 2 Balancing valves of cylinder no.

Adjust valve clearance of cylinder no.

Reassembly is the reverse of the disassembly procedure. Fit new rocker cover seals Relocate the coolant recovery bottle and check coolant level. Reconnect the battery negative lead.

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MIF1016A

185

SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 218 30

ENGINE INJECTOR REMOVAL AND REPLACEMENT

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes.

CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 1. Disconnect the engine oil vapour recovery pipe (1) from the blow--by. 2. Remove the tappet cover (2). 3. Disconnect the fuel manifold pipes from the injectors (3).

MIF1082A

186 4. Remove the injectors (2) with tool 380000982 (1) and extract them from the cylinder head. 5. To refit, proceed as follows:

CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.

On the injector (1), mount a new seal (2) lubricated with Vaseline and a new washer (3).

Fit the injectors in the seats on the cylinder head and tighten them with a torque wrench to the torque prescribed on page 13. Fit the new seals on the fuel manifolds. Connect the manifolds to the injectors, tightening the fixing nuts. Fit the rocker cover back on with new seals. Reconnect the engine oil vapour recovery pipe to the blow--by. Tighten the injector leak--off pipe union. Tighten the high pressure fuel line union. Reconnect the battery negative lead.

--------

MIF1062A

187

MIF1063A

188

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SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 246 14 BOSCH INJECTION PUMP REMOVAL AND REPLACEMENT

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes.

CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. Proceed as follows: 1. Disconnect the battery negative cable. 2. Raise the engine hood.

189 3. Remove the throttle cable retaining spring (1) and extract the lever (2).

2 MDD2581A

190 4. Remove the clamp (1) and extract the hose (2) connected to the thermostarter device. 5. Disconnect the engine stop solenoid wire (1).

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SECTION 10 -- ENGINE -- CHAPTER 1

6. Unscrew the union (1) on the filter and the union (2) on the injection pump, remove the injection pump feed pipe. Remove the pipe (3) coming from the tank.

CAUTION Make the vehicle safe and put the gear into neutral.

MIF1066A

191 7. Remove the pipe (1) between the fuel filter and fuel pump.

MIF1067A

192 8. Unscrew the unions of the pipes (2) connecting the injection pump--injectors and the pipe (1) connected to the thermostarter device and the electrical connection (3).

MIF1068A

193 9. Turn the crankshaft to bring it into the condition of the No 1 cylinder at TDC in the combustion phase. 10. The condition of the No 1 cylinder at TDC at the end of the compression phase is obtained when the timing pin engages with the hole in the pump drive gear.

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SECTION 10 -- ENGINE -- CHAPTER 1

11. To set the injection pump correctly before removing it unscrew the locking bolt and remove the spacer. 12. Fully screw down the bolt on the pump casing. NOTE: Keep the spacer with the pump casing.

195 13. Remove the cover (1) from the gear casing (2) (part A). 14. Lock the crankshaft appropriately. 15. Remove the nut (4) fixing the injection pump gear (3) (part B).

MIF0921A

196 16. Remove the three nuts (2) (3) (5) securing the injection pump (1) to the flywheel casing (4) and extract it from its housing with tool 380000979 appropriately fitted to the gear (3, fig. 196) recovering the spacer/seal.

MIF0922A

197 17. Fit the injection pump back on, following the operations carried out for disassembly in reverse chronological order. Refer to page 13 for the tightening torques of the injector pump fixing screws.

CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 18. Reconnect the battery negative lead.

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SECTION 10 -- ENGINE -- CHAPTER 1

Checking injection pump timing -- Turn the crankshaft to bring it into the condition of the No 1 cylinder at TDC in the compression phase. The condition of the No 1 cylinder at the TDC in the compression phase is obtained when the timing p[in engages with the hole in the pump drive gear.

198 ----

With the injection pump in position but with the mounting bolts loose, remove the plug on the pump cover. Fit the dial gauge 380000228 (2) and the associated tool (1), pre--loading the shaft by 2.5 mm (0.098 in). Turn the crankshaft to move from the condition of 1° cylinder at TDC. Reset the dial gauges and turn the crankshaft in the opposite direction to bring it back into the condition of the 1° cylinder at TDC in the phase of the end of compression. In this position the dial gauge on the pump must read off a value of 1 mm (0.039 in.). Turn the pump anti--clockwise if the plunger has completed a stroke of less than 1 mm (0.039 in.), and clockwise if the stroke is greater than 1 mm (0.039 in.), repeating the test until the correct stroke is obtained. Verifying these conditions, lock the pump by tightening the relevant nuts to the torque shown on page 13.

MIF1070A

199

BOSCH INJECTION PUMP Fuel circuit air bleeding (fig. 200) 19. Take out the bleed screw (1) on the filter. 20. Operate the fuel pump lever (2) until fuel (without bubbles) comes out of the filter then put the screw (1) back in.

MIF1071A

200

21. Loosen the injector delivery union (1), start the engine and, after having checked that there are no air bubbles, tighten the union (1).

MIF1072A

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SECTION 10 -- ENGINE -- CHAPTER 1

Coolant Pump Removal 1. Remove the pressure cap (1) from the coolant recovery tank.

202 2. Unscrew the tap (3) and let the coolant drain from the radiator. 3. Disconnect the battery negative lead.

203 4. Slacken the alternator bolts (2 & 3) and move the alternator inwards to reduce the fan belt tension sufficiently to disengage the belt. 5. Disconnect the wiring connections from the alternator. 6. Remove the alternator.

204 7. Remove the coolant pump (1) retaining bolts and withdraw the pump from the engine.

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SECTION 10 -- ENGINE -- CHAPTER 1

Coolant Pump Installation 1. Fit a new pump (1) and gasket (2) and tighten retaining bolts to the specified torque.

MIF0997A

206 2. Install the alternator and fit the fan belt (1) 3. Reconnect wiring to the alternator 4. Adjust the fan belt tension and tighten the alternator bolts (2 & 3), figure 205.

207 5. Close the drain tap on the radiator and refill the system with 50% water and antifreeze mixture. 6. Add the coolant to the coolant recovery tank slowly until the coolant level is up to the mark in the tank. NOTE: A bleed screw is located on the radiator top hose on the left hand side of the engine. 7. Start the engine and run to warm up the coolant. Recheck coolant level and top up if required.

208

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SECTION 10 -- ENGINE -- CHAPTER 1

Engine Radiator Removal The radiator and cooler assemblies differ between models depending on model build. Engine Coolant Radiator (1) Air to Air Intercooler (2) (110 hp Engine only) Transmission Oil Cooler (3) Hydraulic Oil Cooler (4) (Flow Sharing System)

209 If cab air conditioning is fitted, the condenser (1) is mounted behind the transmission oil cooler.

If air conditioning is fitted it will be necessary to remove the condenser.

210

CAUTION DO NOT DISCONNECT THE AIR CONDITIONING SYSTEM HOSES AS THE ESCAPING PRESSURISED REFRIGERANT WILL CAUSE SEVERE INJURIES. 1. Remove the mounting screws (1 & 2) and carefully move the condenser and securely tie it to the right hand chassis member. A clean container will be required to collect the coolant when drained from the system. System capacity is approximately 14 litres. 211 2. Drain the cooling system by removing the pressure cap on the coolant recovery tank (1) and opening the drain tap (8), figure 214.

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SECTION 10 -- ENGINE -- CHAPTER 1

3. Remove the radiator--cooler connections. Intercooler Hoses (1 & 2) ** Coolant Hoses (3 & 9) Hydraulic Oil Cooler Hoses (4 & 7)* Transmission Oil Cooler Hoses (5 & 6) * Flow sharing Hydraulic System only ** Intercooled engine only 4. Also disconnect the radiator tie bar on the right hand side of the engine. 5. Use straps to secure the radiator to suitable hoist.

213

6. Remove the radiator mounting bolts and lift the radiator from the unit.

214 Radiator Installation 1. Installation of the radiator--cooler assembly and reconnection of hoses is the reverse of the removal procedure. 2. Tighten mounting bolts to 60 Nm (40 lbf,ft). 3. Refill the system with a mixture of 50% water and 50% antifreeze through the recovery tank to the correct level indicated on the tank. 4. To avoid trapping air in the system, release the bleed screw on the top radiator hose and fill the system as slowly as praticable. 5. Retighten the bleed screw and replace recovery tank cap. 6. Start the engine and run for 2--3 minutes to circulate the coolant and check for leaks. 7. Stop the engine and recheck the coolant level.

215

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SECTION 10 -- ENGINE -- CHAPTER 1

NOTES

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SECTION 10 -- ENGINE -- CHAPTER 2

SECTION 10 -- ENGINE Chapter 2 -- Engine Removal and Installation CONTENTS Section

Description

Page

10 001.54

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SPECIAL TOOLS Engine Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38001710

GENERAL EQUIPMENT Lifting Chains

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Approved for 1000 Kg

Hoist

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safe Working Load 1000 Kg

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SECTION 10 -- ENGINE -- CHAPTER 2

ENGINE REMOVAL AND INSTALLATION (Op 10 001 54)

CAUTION Ensure the telehandler is in a safe and secure position. Apply the park brake and chock the wheels. • Use only recommended tooling. • Handle all parts carefully. • Do not put your hands or fingers between parts. • Wear suitable safety clothing.

DISCONNECT THE BATTERY BEFORE COMMENCING WORK 1. Disconnect the battery negative lead (3). 2. Fully open the engine hood. 3. Disconnect the rear lighting loom connector (1) and securing clip (2).

2 4. Have an assistant hold the hood fully open while the two gas support struts are removed. 5. With an assistant, close the hood.

3 6. Remove the hood pivot support bolts (3 each side) and using suitable straps and lifting equipment, remove the hood from the unit. 7. Remove the engine compartment side panels adjacent to the starter motor and the fuel injection pump.

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SECTION 10 -- ENGINE -- CHAPTER 2

The heavy rear counter weight, fitted to LMA 435 & 445, must be removed to enable the engine to be removed The small counterweight, fitted to LMA 415 & 425, may be left in position.

WARNING The rear counter weight must be supported and balanced by suitable lifting equipment and straps before removing the mounting hardware.

5 8. With the counterweight securely supported, remove the counterweight rear mounting bolts (1 & 2). 9. Remove the mounting bolts (3) from the back of the weight and lift the counterweight clear of the unit.

6 A clean container will be required to collect the coolant when drained from the system. System capacity is approximately 14 litres. 10. Drain the cooling system by removing the pressure cap on the coolant recovery bottle (1) and opening the drain tap, (8) figure 10.

7 11. If an air conditioning system is fitted, the system refrigerant must be removed using approved specialist refrigerant recovery equipment. Air conditioning system servicing is covered in Section 50, Chapter 2. 12. Disconnect the condenser inlet and outlet hoses and mounting bolts and remove it from the back of the radiator.

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SECTION 10 -- ENGINE -- CHAPTER 2

There are two types of radiator--cooler assemblies. Figure 9 illustrates the assembly fitted with turbo charged and intercooled engine. 1. 2. 3. 4.

Coolant Radiator Air to Air Intercooler Transmission Oil Cooler .Hydraulic Oil Cooler ·(Flow Sharing Hydraulic System)

9 13. Remove the radiator--cooler connections. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Intercooler Hose R/H ** Intercooler Hose L/H** Coolant Hose L/H Hydraulic Oil Cooler Hose L/H* Transmission Oil Cooler Hose L/H Transmission Oil Cooler Hose R/H Hydraulic Oil Cooler Hose R/H* (Coolant Drain Tap) Coolant Hose R/H * Flow sharing Hydraulic System only ** Intercooled engine only

10 14. Also disconnect the radiator tie bar on the right hand side of the engine. 15. Use straps to secure the radiator to suitable hoist. 16. Remove the radiator mounting bolts and lift the radiator from the unit.

11 17. Remove engine air cleaner pre--cleaner assembly 18. Remove the coolant recovery tank mounting bolts (2). Disconnect the tank (3) and hose from the radiator hose, and remove from the engine. 19. Remove the bolts from the pre--cleaner surround (1) and lift clear from the top of the engine.

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SECTION 10 -- ENGINE -- CHAPTER 2

20. Remove the exhaust muffler mounting bolts (3) and tube clamp (4) and withdraw the muffler (2). 21. Remove the air cleaner and mounting plate (1), disconnect the hose clip (5) from the turbocharger inlet and remove the assembly.

13 22. On the left hand side of the engine disconnect the following:-• Alternator wiring connections • Coolant Temperature Sender

14 • •

Starter wiring (1) Earth Strap (2)

15 •

Heater hose connection (1) and also connection (2) on the right hand side of the engine.

604.55.181.00 09-- 2003

6 • •

SECTION 10 -- ENGINE -- CHAPTER 2 Disconnect transmission harness connector (2) from the forward -- reverse control valve solenoids. Carefully pull through the wiring harness from the engine compartment and tie up on the outside of the chassis.

17 On the left hand side of the engine:-23. Disconnect the fuel lines from the fuel injection pump and fuel lift pump. 24. Disconnect electrical wiring and throttle control cable from the fuel injection pump. 25. Disconnect the electrical supply harness from the cold start module above the fuel injection pump.

18 26. Disconnect the air conditioning hoses either side of the receiver--drier. 27. Remove the receiver -- drier from the chassis. 28. Disconnect the hoses from the air conditioning compressor. 29. On the right hand side of the engine disconnect the following electrical wiring connections:-• Air conditioning compressor • Fuel injection pump stop solenoid • Cold Start Module (2) • Oil pressure sender* • Cold start temperature sender* * Located behind the fuel filter 30. Remove the inlet hose from the hydraulic pump, plug the disconnected hose and tie up clear of the transmission. 31. Pull the wiring harness through from the engine compartment and tie outside the chassis. 32. If the power shift transmission is fitted disconnect the control solenoid harness connectors.

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SECTION 10 -- ENGINE -- CHAPTER 2 33. Before removal of the engine from the vehicle disconnect the following: -- Hydraulic pump (1) bolts x4 (from the rear of transmission) leave hoses attached to pump, Powershuttle shown. -- Transmission all electrical connections -- Transmission gear linkage (2) (Powershuttle) -- Reverse alarm switch (3) (to prevent damage)

3 1

1 22 34. Remove prop shaft coupling bolts at the rear of the transmission (1) Powershuttle shown. IMPORTANT: To prevent damage remove the trailer brake valve (where fitted) positioned above the transmission (2). NOTE: To access the transmission driveshaft coupling, the main driveshaft guard and the coupling access cover must be removed from under the chassis.

23 35. Ensure the cab heater, air conditioning and/or, hydraulic cooler hoses are tied back and will not prevent the engine being moved rearwards during removal. 36. Ensure the transmission cooler hoses are free to be removed attached to the transmission. 37. Check all electrical connections have been removed from the engine and transmission.

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SECTION 10 -- ENGINE -- CHAPTER 2

38. Attach the engine lifting bracket tool number 380001710 to the timing gear housing. The engine rear lifting bracket is already fitted to the engine 39. Attach lifting chains, capable of lifting 1000 kg, and take the weight of the engine. 40. Remove the engine and transmission mounting bolts and lift the engine & transmission clear of the chassis.

24 41. Attach the transmission to a suitable stand before attempting to disassemble the engine, from the transmission.

25 42. Remove the starter motor bolts and place to one side.

26 Using an allen key remove the 8 bolts (1) securing the torque converter to the flywheel. This allows the torque converter to remain with the transmission when the engine is removed.

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SECTION 10 -- ENGINE -- CHAPTER 2

43. Remove the engine to transmission securing bolts and position the engine on a suitable stand for disassembly.

28 44. After repair, the re--assembly of the transmission to engine is the reverse procedure.

29 IMPORTANT: In the rear of the flywheel are 6 counterbores, these must be aligned with the bolt heads on the torque converter when bolting up the assembly. If they are not aligned an interference fit between torque converter and flywheel will result in a lock up situation.

30 Engine Installation Engine installation follows the reverse procedure. 1. Install the engine--transmission unit using suitable lifting chains and hoist

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SECTION 10 -- ENGINE -- CHAPTER 2

2. After installation, ensure all hydraulic, electrical and mechanical components are reconnected correctly. 3. Check hydraulic and transmission oil levels, and top up with specified oil. 4. Refill the coolant system with mix of 50% water and 50% antifreeze. 5. If fitted, the air conditioning system must be evacuated and recharged with refrigerant by a specialist with approved equipment. 6. Bleed the fuel system. 7. Reconnect the battery, then start and run the engine for several minutes. 8. Stop the engine and check for any fluid leaks. 9. Recheck oil and coolant levels. 10. Replace engine side panels and hood and reconnect rear light wiring harness connector.

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

SECTION 21 -- TRANSMISSION Chapter 1 -- 4X4 Compact Shuttle CONTENTS Section

Description

Page

21 000

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 SPECIFICATIONS

Stall Speeds 95/110 PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2160 revs/min

Torque Convertor Diamater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 mm Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 : 1 Gear Ratios Synchronized 4x4 Transmission

Forward 1st 4.824:1 Forward 2nd 2.998:1 Forward 3rd 1.408:1 Forward 4th 0.792:1

Reverse 1st 4.824:1 Reverse 2nd 2.998:1 Reverse 3rd 1.408:1 Reverse 4th 0.792:1

Lubricant Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Litres Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATF DEXRON IID--LEVEL NH530A Sealant Gasket sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82995774 Thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82995768 Cold Start By--pass Valve Spring Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.4mm +/-- 0.96mm (2.10in +/-- 0.038in)

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

Clutch Piston Spring Free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.9mm (2.99in) Detent Spring Free length (Approximately)

. . . . . . . . . . . . . . . . . 42.06mm (1.656in)

End Float Input forward Primary Shaft . . . . . . . . . . . . . . . . . . . Input reverse Primary Shaft . . . . . . . . . . . . . . . . . . . Output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................................ ............................................ ............................................ Bearing End Floats . . . . . . . . . . . . . . . . . . . . . . . . . . Bearing End Float Shims available . . . . . . . . . . . . ............................................

0.0508--0.41mm (0.002--0.016in) 0.0508--0.41mm (0.002--0.016in) 1st Gear-- 0.33--0.508mm (0.013--0.020in) 2nd Gear-- 0.35--0.558mm (0.014--0.022in) 3rd Gear-- 0.38--0.838mm (0.015--0.033in) 4th Gear-- 0.20--0.558mm (0.008--0.022in) 0.025--0.076mm (0.001--0.003in) 0.050/0.076/0.127/0.177/0.381/0.508mm (0.002/0.003/0.005/0.007/0.015/0.020in)

Hydraulic Tests Tachometer Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 revs/min Test temperature, oil . . . . . . . . . . . . . . . . . . . . . . . . 80--85°C (176--185°F) Cold Start Valve (For reference only) . . . . . . . . . . . System Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 bar (377 lb/in2) 13.7--15.2 bar (198--220 lb/in2) 7--11 bar (101--159 lb/in2) 13.7--15.2 bar (198--220 lb/in2) 13.7--15.2 bar (198--220 lb/in2)

Cooler Flow Test Oil temperature 80--85°C (176--185°F)

Revs/min

Oil Flow Litres/min (gallons/min)

............................................ ............................................ ............................................ ............................................ ............................................

700 1000 1500 2000 2200

12.5 litres (2.7 gals) 18.2 litres (4.0 gals) 22.1 litres (4.8 gals) 24.0 litres (5.2 gals) 24.5 litres (5.4 gals)

TORQUE SPECIFICATIONS

Item Description

N·m

ft. lbs.

Cooler return pipe union Cooler return pipe elbow Stator support retaining bolt Flywheel to flex plate Flex plate to converter

49-78 49-78 26 43 43

36-58 36-58 19 32 32

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

SPECIAL TOOLS DESCRIPTION

APPLICATION

Bearing Cone Drift 40mm

Counter Shaft, Rear Main Shaft and 4WD Bearing

Bearing Cone Drift 35mm

Reverse Idler and Front Main Shaft Bearing

Bearing Cone Drift 40mm

Front Input Shaft Bearing

Bearing Cone Drift 50mm

Rear Input Shaft Bearing

Slide Hammer

Bearing cone removal

Bush Insertion Tool 22mm Welch Plug Drift

Pump rod Insertion Tool Shim Adjustment Cover

Oil Seal Drift

Pump Seal

*Spring Compressor

Main Clutches

Spring Compressor

Detent Ball Spring

Circlip Pliers Feeler Gauges

Where applicable Where applicable

*Dial Indicator Bolt

Shaft end float

NOTE: Tools identified * are available from SPX.

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Tool No 297409

Tool No 380000700

SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

DESCRIPTION AND OPERATION The transmission consists of a torque converter, an internal rotor-type hydraulic pump, an oil distributor, a solenoid control valve assembly, two hydraulically operated clutches, a 4-speed synchromesh geartrain, transmission case and oil cooler tubes. NOTE: A conventional clutch is not used with this transmission. The transmission case serves as an oil reservoir for the torque converter, hydraulic clutch assemblies and lubrication. 1 The gearbox receives power from the engine (1) by a fluid coupling in the torque converter (2) and hydraulic clutch assemblies in the transmission (3). TRANSMISSION CONTROL The front clutch provides power for forward travel and the rear clutch power for reverse travel. Engagement of the front and rear clutch is controlled by the operator through the movement of the hand operated power reversing lever (1). The gearshift lever (2) is used to select any one of four speeds through an ‘H’ pattern synchronized gear shift. 2 In any gear ratio the operator need only move the shuttle lever to change direction of travel, forward or reverse. However, as a clutch is not used between the engine and the transmission, the power flow from the engine to the transmission must be interrupted to shift from one gear ratio to another. This is accomplished by using a transmission disconnect switch on the gear lever. The console mounted switch must be in the off position. Transmission disconnect switches The transmission disconnect feature can be operated from 4 points by using the:

N R

2105001

3 — Gear shift lever (2). — Foot operated brake pedal (3). — Button (4) on the boom lever. — Parking brake switch (5). To select the operating choice depress the console mounted switch (1) for brake pedal control or select “off” at the switch which will return the operation to the gear lever this feature allows: Brake application without transmission disconnection. Brake application with transmission disconnection when speed is less than 5 km/h.

SMJ058A

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TORQUE CONVERTER NOTE: The torque converter is a sealed unit and can not be serviced as individual parts. The torque converter is the connection between the engine and the transmission. The main parts of the torque converter are the impeller, the turbine, the stator and the front and rear covers. The impeller is integral with the rear cover and is driven by the engine flywheel by means of a drive plate. The stator, is splined to a stationary shaft (stator support) through a one-way clutch that permits the stator to rotate only in the same direction as the impeller. All of the converter parts are enclosed in an oil-filled housing. The front and rear cover, being welded together, form the housing. The turbine (2), splined to the front input shaft, is splined to a stationary shaft (stator support) through a one-way clutch that permits the stator (3) to rotate only in the same direction as the impeller (1). All of the converter parts are enclosed in an oil-filled housing. The front and rear cover, welded together, form the housing. When the engine is running, the oil in the converter flows from the impeller (1) to the turbine (2) and back to the impeller through the stator (3). This flow produces a maximum torque increase. When enough oil flow is developed by the impeller, the turbine begins to rotate, driving the front input shaft. The torque multiplication gradually decreases as turbine speed approaches impeller speed, and becomes 1 to 1 when the turbine is being driven at nine tenths impeller speed. When the turbine is rotating at approximately nine tenths impeller speed, the converter stops multiplying torque because the oil is now acting on the rear face of the stator blades (3). The action of the oil on the rear face of the stator unlocks the one-way clutch, permitting the stator to rotate in the same direction as the turbine (2) and impeller (1). Through this action the converter becomes an efficient fluid coupling by transmitting engine torque from the impeller to the turbine.

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

When the turbine is rotating less than nine tenths impeller speed (1), the converter is multiplying torque through the action of the stator (3). This action, produced by oil acting on the front face of the stator blades, tends to rotate the stator in the opposite direction of the impeller (1) and turbine (2). However, the one-way clutch prevents this opposite rotation and allows the stator to direct oil back to the impeller, thereby producing torque multiplication. Maximum torque multiplication is achieved when the impeller is driven at stall speed and the turbine is stationary

6 To achieve optimum operation the engine performance, transmission ratios, hydraulic power delivery and converter torque multiplication are all ‘‘Matched’’ to provide the necessary vehicle drive torque when required. GEAR TRAIN The front and rear cases of the transmission sandwich a series of parallel shafts which support the helically cut gears, between tapered roller bearings.

7 A breather at the top of the filler transmission prevents pressure damage to the seals. GEAR SHIFT MECHANISM A mechanical arrangement of shift rails, forks and synchronisers allows static or rolling engagement of any of the 4 transmission ratios from a standard H gate pattern lever. The synchronisers prevent engagement of the selected gear until its shaft speed is synchronised with that of the output shaft. A detent interlock system prevents gear jumpout and the simultaneous engagement of 2 gears.

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CO--AXIAL DRIVE VEHICLE HYDRAULIC PUMP A solid shaft connects the flywheel (via the torque converter impeller) to the vehicle hydraulic pump input shaft. The pump drive shaft passes through the tubular input shaft and is supported at the rear by a bush. Accordingly, the main pump will run at engine speed regardless of the ratio or direction of the transmission.

9 The dipstick/oil filler tube (1) is used for monitoring and maintenance of the oil level, in the transmission.

TRANSMISSION HYDRAULIC PUMP OIL SUPPLY The transmission case serves as an oil reservoir for the torque converter and clutch assemblies. An integral hydraulic oil pump situated in the bell housing draws oil from the transmission sump to provide a pressurised flow which is continuously cooled by an external cooler. Oil is picked up from the sump, via an internal strainer, through the inlet section of the pump plate by the action of the rotors, and is forced through the outlet section of the pump plate through the spin on pressure filter to the oil distributor. A temperature sender provides a signal to the instrument panel warning light should the transmission oil become to hot.

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NOTES

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OPJ21034A

OIL FLOW AND SUPPLY IN NEUTRAL POSITION

Pump Pressure

Torque Convertor Flow

Return to Sump

Lubrication

Suction

1. Cold Start Pressure protection Valve -- Prevents system pressure exceeding 26 bar (377 lb/in2) at initial cold start.

4. Torque Convertor -- Receives low pressure circuit oil at maximum 10 bar (145 lb/in2) and returns oil to port (10).

2. Shuttle control solenoid valve oil 14 bar (203 lb/in2).

5. Oil Pump Port OUT, to oil filter assembly through internal drillings.

3. Pressure filter -- Mounted to the left of the transmission viewed looking forward.

6. Oil returned from the oil cooler lubricates shafts, gears and bearings and returns oil to reservoir.

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OIL FLOW AND SUPPLY IN FORWARD POSITION

OPJ21032A

Pump Pressure

Torque Convertor Flow

Return to Sump

Lubrication

7. Returned lubrication oil from the pump shaft bush to reservoir. 8. Torque Converter oil supply IN, received at maximum 10 bar (145 lb/in2). 9. Transmission Reservoir/System Capacity: 17 litres (2wd) 18 litres (4wd). 10. Oil Cooler -- Mounted below the engine coolant radiator.

Suction

12. Torque Converter oil OUT, to oil cooler 13.Torque Convertor pressure regulating valve, receives oil from the sequencing valve (16) and returns oil in excess of 10 bar (145 lb/in2) to reservoir. 14.System pressure sequencing valve -- Maintains circuit oil at 14 bar (203 lb/in2) and supplies a continuous oil feed to the torque convertor regulating valve.

11. Oil pump suction port IN, from the reservoir.

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TRANSMISSION OIL SUPPLY PORTS

Viewed From Front and Rear Housings

1. Oil supply port to Reverse clutch pack, rear casing. 2. Oil supply port to forward clutch pack, rear casing. 3. Oil supply port to pressure test reverse clutch pack. 4. Oil supply port too pressure test forward clutch pack. 5. System pressure test point, connected to test block. 6. Locating Dowel 7. Cold start oil pressure protection valve. 8. Torque convertor pressure test point.

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9. System pressure sequencing valve. 10.Torque convertor pressure regulating valve. 11.Oil supply from pump to solenoid valve pack. 12.Oil supply port to Reverse clutch pack, front casing. 13.Oil port to reservoir (dump) from solenoid. 14.Oil supply port to Reverse clutch pack, front casing. 15.Oil supply port to forward clutch pack, front casing. 16.Oil supply port to forward clutch pack, front casing. 17.Manufacturing drilling only.

SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

TRANSMISSION OIL FLOW THROUGH SOLENOID VALVE The solenoid valves forward (1) or reverse (2) fitted at the top of the transmission housing controls the oil flow to the forward/reverse clutch packs in the transmission, Figure 15.

15 On the underside of the solenoid valve are the 4 ports for directional oil flow to and from the solenoid. valve, Figure 16. 1. Oil supply from the valve to the forward clutch pack. 2. Return oil to reservoir 3. Oil supply from the valve to the reverse clutch pack. 4. Oil supply from the pump into the valve. 5. Locating Pin

16 When the shuttle lever in the cab is in neutral position the solenoid valve spool (1) will be static and oil (2) will not flow into either reverse (3) or forward (4) clutch pack oil gallery, Figure 17.

17 When forward direction is selected on the shuttle lever the solenoid valve spool (1) will move to the left (as shown) and the oil (2) will flow into the forward clutch pack oil gallery (4), Figure 18 When reverse direction is selected on the the shuttle lever the solenoid valve spool (1) will move to the right (not shown) and the oil (2) will flow into the reverse clutch pack oil gallery (3).

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OIL FLOW SOLENOID CONTROL VALVE OPERATION (Forward drive only shown) The solenoid valve when in neutral position dead heads the oil flow at the spool (1) from the supply port and no oil is allowed to pass through the valve. Therefore the oil in the galleries beyond the spool at the fill time metering valve (2) remains static.

19 Selection of the forward / reverse shuttle lever in the cab directs a current flow to the forward or reverse solenoid and the spool (1) will move in the direction selected, reverse shown. The oil then flows past the spool to the clutch pack and applies pressure to the fill time metering valve (3), a small bore allows oil to flow into the clutch feathering valve. When the metering valve (3) moves it partially uncovers a port to the reservoir and also opens the control orifice within the valve. Therefore a precisely metered flow of oil is fed to the pressure regulating (feathering) piston (2). As this piston is pushed back against its spring the pressure at the clutch builds up gradually to give a progressive clutch engagement.

When the piston reaches the end of its travel, clutch pressure quickly builds up to full system pressure either side of valve (3) so the the light spring pushes the valve covering the port to the reservoir. The oil is dead headed at system pressure at the clutch so ensuring full torque can be transmitted by the clutch.

21 NOTE: The control valve includes a pressure regulating (feathering) valve and a fill time metering valve for the both clutch packs.

= Pressure Oil = Regulated Pressure Oil = Return Oil

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TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS

22 NOTE: All pressure test ports are 9/16 in UNF thread size 1.Convertor pressure oil test port 7--11 bar (101--159 lb/in2) 2. Forward Solenoid valve 13.7--15.2 bar (198--220 lb/in2) 3. Test port for reverse clutch pack 13.7--15.2 bar (198--220 lb/in2) 4. Test port for forward clutch pack 13.7--15.2 bar (198--220 lb/in2) 5. System pressure sequencing valve 13.7--15.2 bar (198--220 lb/in2) 6. Oil flow OUT to cooler 7. Oil OUT to cooler, test port 6.5 bar (94 lb/in2)

8. Oil flow IN from cooler 9. Torque convertor pressure regulating valve 7--11 bar (101--159 lb/in2) 10.Oil in from cooler, test port 3.5 bar (50 lb/in2) 11.System Oil Filter 12.Reverse Solenoid valve 13.7--15.2 bar (198--2 lb/in2) 13.System pressure test point 13.7--15.2 bar (198--220 lb/in2) 14.Cold Start oil pressure relief valve 26 bar (377 lb/in2) reference only

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TRANSMISSION POWER FLOWS When neutral is selected on the shuttle lever (1), the transmission forward (3) and reverse hydraulic clutch packs or (4) are free to rotate and hence there is no drive in the transmission. With Forward or Reverse selected on the shuttle lever (1) power will be directed through the clutch packs (3) or (4) to the gear train and selection of gear on lever (2) will result in engagement of gears to the output shafts. Power for all four forward gear ratios is transmitted from the front hydraulic clutch (3) on the input shaft. The input shaft then transmits power to the countershaft forward gear and the countershaft in turn transmits power to the output shaft. Power flow for all four reverse gear ratios is the same as for all four forward gear ratios except that the rear clutch (4) is engaged to transmit power to the reverse idler gear. The reverse idler gear in turn transmits power to the gear on the countershaft and in turn transmits power to the output shaft . Because power is being transmitted through the reverse idler gear, the countershaft and output shaft will rotate in the opposite direction as for forward gear ratios. The rear input shaft will also rotate in the opposite direction.

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NOTES PAGE

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

TRANSMISSION POWER FLOWS

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

TRANSMISSION POWER FLOWS

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FAULT FINDING IMPORTANT: If a malfunction of the transmission is suspected, a systematic checking procedure should be followed in order to assist in determining the problem. The following table lists problems and their possible causes with recommended remedial action. To assist in the diagnosis of suspected hydraulic system failures, test ports have been included in the transmission housing. The locations Shown in figure 22. Each port accepts a 9/16 in UNF ‘O’ ring connection. A gauge is required that is capable of measuring to 20 bar (290 lbs in2).

Pressure checks are essential as a failure in the hydraulic system can be difficult to trace once the transmission is stripped down on a bench. All pressure checks should be carried out with the transmission in neutral gear, engine speed set at 2000 revs/min with oil temperature at 80--85°C (176--185°F). The temperature can be raised by working the machine or following the stall procedure as follows

STALL PROCEDURE With the transmission oil up to operating tempreture. Apply the brakes and block wheels. Place the transmission in 4th gear and select forward. With the engine running, gently increase speed to full throttle. Record engine speed. Repeat this test in reverse. Do not stall for more than 30 seconds. Select neutral for 15 seconds then repeat to reach the temperature range. STALL SPEEDS 95/110 PS

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2160 revs/min

SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

FAULT FINDING PROBLEM Low pump pressure reading

High pump pressure reading

Low converter inlet pressure reading

POSSIBLE CAUSES

CORRECTION

1. Low or no oil

1. Check on dipstick and top up

2. Pump or pump seal failure

2. Remove converter housing inspection plate and check for leaks. Dismantle and replace pump or seals.

3. Regulator valve stuck open

3. Inspect regulator cartridge

4. Blockage at strainer between filter and pump

4. Drain and flush the transmission, clean strainer, replace filter

5. Damaged convertor splines

5. Repair

6. Cold start valve stuck open

6. Remove and clean

1. Test performed at low oil temperature

1. Retest at 80--85°C

2. Sticking regulator valve

2. Inspect regulator cartridge

1. Converter relief valve failure

1. Inspect valve

2. Leak in converter, cooling or cooler hoses

High converter inlet pressure reading

Low or no clutch pressure reading -- Forward or Reverse

converter

relief

2. Remove converter housing inspection plate and check for leaks. Inspect the cooler

1. Relief valve sticking

1. Inspect valve

converter

relief

2. Low Oil Temperature

2. Raise Temperature

1. Wiring fault

1. Check voltage at directional valve. Check that the resistance across each coil is close to 5.0 ohms

2. Sticking directional valve

2. Inspect directional valve

3. Leakage at input shaft or clutch piston seals

3. Dismantle and examine

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FAULT FINDING PROBLEM High oil temperature (frequent warnings from temperature light)

Stall test inconclusive

POSSIBLE CAUSES

CORRECTION

1. Restrictions in cooler

1. Back flush cooler and clean hoses

2. Binding foot or parking brake

2. Inspect and adjust brakes

3. Excessive stall operation

3. Change work cycles to avoid stall for more than 30 seconds

4. Worn plates

slipping clutch

4. Dismantle and replace

5. Worn transmission bearings

5. Dismantle and replace

6. Temperature sensor

6. Check

7. Oil cooler air flow restricted

7. Clean

1. Low stall speed

Hydraulic clutch not releasing.

Stator support broken. Defective torque converter. Low engine power. 2. High stall speed

Hydraulic clutch not applying or is slipping. Low line pressure. Sealing rings on rear input shaft broken. Defective torque converter.

FAULT FINDING -- MECHANICAL SYSTEM CHECKS PROBLEM Noise in neutral

Noise in gear

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POSSIBLE CAUSES

CORRECTION

1. Worn or damaged primary or reverse idler gears

1. Dismantle and renew

2. Worn bearings

2. Dismantle and renew

1. Worn or damaged countershaft or drive gears

1. Dismantle and renew

2. Worn bearings

2. Dismantle and renew

SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

FAULT FINDING PROBLEM Gear selection -- Hard shifting

Gear jump out

Main vehicle pump no power

Erratic or noisy response from main pump

POSSIBLE CAUSES

CORRECTION

1. Worn or bent shift rods

1. Dismantle and renew

2. Worn or chipped dog teeth on drive gears

2. Dismantle and renew

3. Worn synchronizer cones or cups

3. Dismantle and renew

4. Broken or missing detent spring or ball

4. Dismantle and renew

5. Residual clutch pressure (clutch supply fault)

5. Dismantle and renew

6. Corrosion at stud lever (boot damaged)

6. Dismantle and renew

7. Clutch plates distorted

7.Replace

1. Worn detent notches on shift rail

1. Dismantle and renew

2. Worn or broken synchronizer cones or cups

2. Dismantle and renew

3. Worn or loose shift forks

3. Dismantle and renew

1. Main pump Failure

1. Dismantle and renew

2. Fractured drive rod

transmission

2. Dismantle and renew

3. Failed splines on converter, drive rod or pump

3. Dismantle and renew

1. Main pump Failure

1. Dismantle and renew

2. Out of balance transmission drive rod

2. Dismantle and renew

3. Worn drive rod support bush

3. Dismantle and renew

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FORWARD / REVERSE CONTROL SOLENOID VALVE

27 1. Solenoid Retainer 2. Dirt Seal 3. Solenoid 4. ’O’ Ring 5. Spool 6. Valve Housing 7. Clutch Fill Metering Valve* 8. Spring* 9. End Cap* 10. Guide

Shuttle Valve Disassembled 11. Spring 12. Solenoid Pin 13. Seal 14. Support Body Solenoid 15. Piston Clutch Fill 16. Spring 17. Retainer 18. Spring 19. Seal 20. End Plug

* NOTE: These items are not serviceable other than for cleaning Solenoid Valve -- Disassembly Mounted on the top of the transmission is the shuttle solenoid valve of which is controlled by the forward (2) and reverse (1) solenoids. Remove the 4 attaching bolts and remove from the transmission. Removal of the retaining ring and ‘O’ ring on the end of each of the coil blocks allows removal of the coils from the solenoid assembly. Anti clockwise rotation of the solenoid sleeve disassembles the sleeve from the body and allows removal of the plungers, springs, spool supports and spool. Clean and inspect parts for wear or scoring on the friction areas, replace if in doubt. Fit new ‘O’ rings before re--assembly.

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

Resistance Checking of Coils Condition of the coils (1) and (2) can be checked by the resistance of the coil field measured at the connector which in good condition should read 5 ohms. If the reading is zero then a short circuit in the coil has occurred and a new one will be required. Before re--assembly ensure the valve body is clean and new ‘O’ rings are placed on the transmission mounting face.

Re--assembly Re--assemble in reverse order but observe the following: The Coils must align with the pins on the body before tightening the coil retaining rings, ensure the ‘O’ rings are fitted. Assembly of the valve onto the transmission must align with the locating pin to ensure correct alignment of oil feed ports and correct forward / reverse shuttle operation. Re--assemble the attaching bolts and torque to 20--27 Nm (15--20 lbf ft)

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OIL PUMP DISASSEMBLY NOTE: The oil pump can only be removed when the transmission is separated from the engine. Disassembly of the oil pump is not generally recommended since individual components are matched and are non serviceable. However it may be dismantled for cleaning purposes and visual checks.

1. Place the transmission in an horizontal position and remove the 4 attaching bolts (1) from the oil pump body. 31 2.

The ‘O’ ring (1) behind the pump body must be replaced with new before re--assembly of the pump.

1 2

32 3. Carefully separate the oil pump components and clean, inspect the components for wear. If in any doubt replace the pump. IMPORTANT: A worn oil pump will reduce the efficiency of the transmission and the machine if not corrected. 4. A single lipped seal (1) is incorporated in the front oil pump housing and should be changed when ever a complete teardown has taken place. Push out the old seal and replace with new, grease outer seal and push in ensuring it is fully seated into the housing.

Re--assemble the pump in reverse order, fit new seals and copper washers under the bolt heads and torque the retaining bolts to 20--27 Nm (15--20 lbf ft)

33 IMPORTANT: Ensure the pump outer ring face with chamfer enters the pump body first.

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TRANSMISSION OVERVIEW IMPORTANT: Before commencing any dismantling procedure it is essential to thoroughly clean the transmission and work area.

TIJ21045A

34 4X4 POWER SHUTTLE (FWD VERSION SHOWN) 1. REVERSE IDLER SHAFT -- Gear Teeth = 24 and 27 2. INPUT OR PRIMARY SHAFT -- Gear Teeth = 24 and 27 3. COUNTER SHAFT -- Gear Teeth = 35 29 18 and 13 4. OUTPUT SHAFT -- Gear Teeth = 19 -- 4th ratio, 28 -- 3rd ratio, 37 -- 2nd ratio, 43 -- 1st ratio

= Number of Gear Teeth

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

TRANSMISSION OVERHAUL IMPORTANT: Before commencing any dismantling procedure it is essential to thoroughly clean the transmission and work area. If new clutch friction discs are to be installed it will be necessary to soak the discs in clean new oil for a minimum of 3 hours before fitting.

35 4X4 POWER SHUTTLE

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

Remove the transmission and engine as a complete unit from the vehicle and place on a suitable stand for disassembly.

NOTE: Prior to disassembly drain the oils into suitable containers for disposal.

Prior to separating the transmission from the engine Remove the starter motor (1) Engine timing tab (2) Torque convertor backplate attaching bolts through the starter motor aperture (1) Bell housing attachment bolts (3)

2 5 21029002

36 IMPORTANT: Prior to positioning the transmission vertically remove the vehicle system oil pump (4) and torque converter unit (5) from the transmission bell housing Using eye bolts (1), 1 per side capable of lifting a weight of 250 kgs (550 lbs) hoist the transmission vertically and place in a safe, clean and suitable workshop environment.

. Remove the transmission handbrake, loosen and withdraw the output coupling and disc (1). Remove the gear shift attaching bolts and withdraw the gear lever (2). Loosen and remove the control valve and oil filter assembly, gaskets and adapters (3) if required. Remove all pipes and connectors that may be easily damaged or interfere with the disassembly.

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Remove the rear cover bolts (1) and using a certified right angled bracket (2) attached to the center boss on the cover, lift the cover clear of the transmission. CAUTION: The bearing cup and cones may become dislodged when the rear cover is removed from the transmission. Ensure the the rear cover is shimmed correctly upon re--assembly.

GEAR TRAIN REMOVAL Disassemble the gear train in the following order: 1. Counter Shaft 2. Reverse Idler Shaft 3. Input Shaft 4. Output Shaft

39 1. Remove the gear shift detent retaining bolt and remove the outer spring and ball, replace bolt before remove rails.

40 NOTE: The inner rail detent balls and springs will no longer be captive in position when the rails are removed and may fly out with some force. 2. Using a right angled hexagonal key loosen the selector forks on the rail. Angle the output shaft and lift out the gear selector forks and rails. Place all of the springs and balls to one side.

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

3. With the shift rails removed lift out the output shaft and place on a clean bench for inspection

41 4. With the counter shaft and reverse idler shaft held to one side remove the input shaft and place on a bench for inspection.

42 5. Remove the counter shaft and reverse idler shaft and place on a bench for inspection

43 Before attempting any disassembly of the gear train ensure all the components are clean and inspect for signs of wear, scoring, or chipping of the gear teeth or wear on related components.

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

OUTPUT SHAFT -- DISASSEMBLY

44 OUTPUT SHAFT 1. 2nd GEAR 2. Ouput Shaft 3. Bearing 4. Spacer 5. 1st GEAR 6. Spacer 7. Bearing 2 places 8. Sleeve 9. Bulk Pin Synchronizer 2 places 10. Synchronizer Hub 2 places 11. Circlip

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12. 3rd GEAR 13. Gear Selection Fork ‘Lower’ 14. Gear Selection Fork ‘Upper’ 15. Fork Locking Allen Key 16. Detent Ball 17. Detent Spring 18. Gear Selection Rail 19. Gear Selection Rail 20. Bearing 21. Thrust Washer 22. 4th GEAR

SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

Output Shaft Support End)

Disassembly

(Front

IMPORTANT: When using a bearing puller be very careful to ensure it does not touch the tip of the gear teeth as they may become chipped or broken. 1. Place the shaft vertically and (hold in a soft jaw vice). Using a three legged puller (1) under the face of the front gear and pull the gear and bearing carefully from the shaft.

45 2. With the bearing, washer and 4th gear removed, withdraw the baulk ring synchroniser, circlip, hub sleeve and 3rd gear. Inspect all parts for scoring wear marks and discolouration, replace suspect parts as necessary. 3. The baulk pin synchronizer assembly can be disassembled for inspection for wear patterns or scoring and for cracking of the outer cones, if in any doubt replace with ‘new’.

46 The Baulk pin synchroniser assembly consists of a sliding clutch mounted on and splined to the appropriate transmission shaft, with a friction synchronising inner cone located on each side. The inner cones are mounted on three locking pins which pass through holes on the sliding clutch. 1.Outer Cone 2.Inner Friction Cone 3.Baulk Pin Assembly 4.Sliding Clutch 5.Locking Pin 6.Baulk Pin

47 The baulk pin synchroniser ensures the shaft speed and the gear speed is equal before allowing the sliding coupling to positively engage the shaft to the gear. 1.Gear 2.Locking Pins 3.Outer Cone

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As the sliding clutch moves, the inner friction cone comes into contact with the outer cone allowing the shaft speed and gear speed to become equal. The three locking pins prevent the sliding clutch from positively engaging the shaft to the gear. This is achieved by the notches around the locking pins contacting the edges of the three holes in the sliding clutch. 1.Sliding Clutch 2.Inner Friction Cone 3.Leaf Springs

49 When the gear and shaft speeds are equal the locking pins become free and move to the centre of the holes in the sliding clutch allowing the sliding clutch to move connecting the shaft to the gear selected. The three split sleeves are expanded by the inner leaf springs, positively locking the sliding clutch into position. 1.Locking Pin 2.Leaf Spring

Output Shaft Disassembly (Rear Output Shaft End) IMPORTANT: When using a bearing puller be very careful to ensure it does not touch the tip of the gear teeth as they may become chipped or broken. 1. Support the shaft vertically (front support end) in a soft jawed vice and attach a 3 legged puller to the underside of the 1st gear, Remove the bearing, output gear and 1st gear from the shaft.

51 2. With the 1st gear removed withdraw the needle bearing, spacer, 2nd needle bearing, sleeve, bulk ring synchronizer, hub sleeve and 2nd gear. Inspect for scoring wear marks and or discolouration, replace suspect parts as necessary.

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Output Shaft Support End)

Re-- assembly

(Front

With the shaft supported vertically re--assembly is in reverse order of disassembly, however ensure all parts are liberally coated in clean transmission oil before fitting.

53 1. Refit the 3rd gear to the shoulder, place the hubsleeve in position and refit the circlip. Ensure a minimum freeplay of 0.38--0.83 mm (0.015--0.033 in) is maintained to enable 3rd gear to rotate freely. Continue to refit the synchronizer, 4th gear, washer and bearing. 2. To refit the bearing use a 35 mm bearing tool and press the head of the tool until the bearing is seated onto the washer.

54 3. When the bearing is fully seated ensure the clearance between the 4th gear to washer is between 0.05--0.56 mm (0.008--022 in).

Output Shaft Re--assembly (Rear Output Shaft End) With the shaft supported vertically re--assembly is in reverse order of disassembly, ensure all parts are liberally coated in clean transmission oil before fitting. 1. Refit the 2nd gear to the shaft, along with the hub sleeve. Fit the spacer onto the shaft and using a sleeve tool press the sleeve down to the shoulder. 56 604.55.181.00 09-- 2003

SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

2. With the sleeve fully seated ensure the freeplay between the 2nd gear and hub sleeve is a minimum of 0.35--0.56 mm ( 0.014--0.022 in) to

57 3. Refit the needle bearing, spacer, 2nd needle bearing, synchronizer assembly, 1st gear, output gear and washer prior to fitting the bearing. allow free rotation of the 2nd gear.

58 4. Refit the bearing, when fully seated ensure the freeplay between the gears is at least 0.33--0.58 mm (0.013--0.020 in) to allow free rotation of the 1st and output gears.

59 COUNTERSHAFT -- DISASSEMBLY 1. The counter shaft support bearings can be removed by using a suitable puller. Inspect for scoring wear marks and or discolouration, replace suspect parts as necessary. 2. To refit the bearings use a 40 mm press tool

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

NOTES PAGE

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

INPUT SHAFT -- DISASSEMBLY

61 INPUT SHAFT 1. Clutch Pack Retaining Circlip 2. Clutch Pack Retaining Plate 3. Friction Disc (x6 Each Clutch) 4. Circlip 5. Spring Retainer 6. Sleeve Guide 7. Input Shaft / Housing Assembly 8. Bearing -- Oil pump drive shaft 9. Roller Bearing 10. Circlip 11. Thrust Washer 12. Thrust Bearing

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13. Gear / Clutch Hub 14. Bearing Spacer 15. Bearing 16. Thrust Washer 17. Clutch Plates (6 per clutch) 18. Spring 19. Sleeve Guide 20. Piston 21. Roller Bearing 22. Thrust Washer 23. Gear Hub

SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

Input Shaft Disassembly (Front Support End) IMPORTANT: When using a bearing puller be very careful to ensure it does not touch the tip of the gear teeth as they may become chipped or broken. 1. Support the shaft vertically (rear support end) in a soft jawed vice and remove the sealing ring. Attach a 3 legged puller (1), to the underside of the forward primary gear (2) and remove the gear hub, needle bearings and spacer, thrust washer, and bearing from the shaft.

2. Release the snap ring (1), retaining the clutch pack drive rings and remove from the clutch housing. The discs must be flat and not discoloured in any way, if in doubt renew the discs.

63 3. Using a press and tool 297409 (1), compress the clutch piston spring (2) to enable release of the circlip (3). Carefully release the press pressure on the spring. Remove the circlip, washer and spring.

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4. To remove the piston blank off the oil feed holes that are not required and carefully apply air pressure to the forward clutch oil feed hole (1) in the middle ring sufficiently to push the piston out against seal resistance.

65 5. The piston have integral moulded seals, therefore the pistons should be discarded and new pistons fitted on reassembly. Inspect all parts for scoring wear marks and or discolouration, replace suspect parts as necessary.

Input Shaft Disassembly (Rear Support End) 1. Support the shaft vertically (front support end) in a soft jawed vice and remove the sealing rings (1). Attach puller (2) to the underside of the bearing (3) and remove. Remove the circlip which allows the removal of the thrust washer, thrust bearing, gear/hub, needle bearings with spacer.

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2. Release the snap ring (1) retaining the clutch pack drive discs and remove from the clutch housing.

68 3. Using a press and tool 297409 compress the clutch piston spring to enable release of the circlip. Carefully release the press pressure on the spring. Remove the circlip, washer and spring.

69 IMPORTANT: When using compressed air always wear safety goggles. 4. To remove the piston blank off the oil feed holes that are not required and carefully apply air pressure to the forward clutch oil feed hole (1) in the third ring, sufficiently to push the piston out against seal resistance. The piston can also be removed by using a hooked tool applied carefully to the land at the rear of the piston

70 5. The piston have integral moulded seals, therefore the pistons should be discarded and new pistons fitted on reassembly. Inspect all parts for scoring wear marks and or discolouration, replace suspect parts as necessary.

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Input Shaft Re--assembly (Front Support End) With the shaft supported vertically (in a soft jawed vice), re--assembly is in reverse order of disassembly, ensure all metallic parts are liberally coated in clean transmission oil before fitting. 1. Lubricate the piston seals and carefully place the piston back into the clutch housing until fully seated. Re--assemble the piston spring, washer and compress using tool no 297409 sufficiently to allow refitting of the circlip and place the thrust washer in position.

72 IMPORTANT: Soak new clutch friction discs in clean new oil for a minimum of 3 hours 2. Continue to refit the clutch discs (6 thin steel with 1 thick retaining plate) and (6 friction plates) back into the hub, steel first, followed by friction and then repeat steel, friction. The final steel plate to be fitted is the thicker retaining plate that the snap ring seats onto. Refit the snap ring into the groove of the clutch hub.

73 3. Once the gear is assembled into the clutch plates the needle bearings and spacer can be assembled into the bore of the gear without removing it from the clutch drum.

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4. Place the thrust bearing (1) on the gear face with the thrust washer and refit the bearing using a press and cone drift (2).

75 5. With the bearing (1) fully seated ensure a freeplay of at least 0.0508--0.40 mm (0.002--0.016 in) exists between the thrust washer and gear (2).

76 6. Fit a new sealing ring onto the shaft above the bearing (1).

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Input Shaft Re-- assembly (Rear Support End) With the shaft supported vertically (in a soft jawed vice), re--assembly is in reverse order of disassembly, ensure all metallic parts are liberally coated in clean transmission oil before fitting. 1. Lubricate the piston seals and carefully place the piston back into the clutch housing until fully seated. Re--assemble the piston spring, washer and compress sufficiently using tool 297409 to allow refitting of the circlip and place the thrust washer in position.

78 IMPORTANT: Soak new clutch discs in clean new oil for a minimum of 3 hours 2. Continue to refit the clutch discs (6 thin steel with 1 thick pressure plate) and (6 friction plates) back into the hub, steel first, followed by friction and then repeat steel, friction. The final steel plate to be fitted is the thicker retaining plate that the snap ring seats onto. Refit the snap ring into the groove of the clutch hub.

79 3. Once the gear is assembled into the clutch plates the needle bearings and spacer can be assembled into the bore of the gear without removing it from the clutch drum.

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SECTION 21 -- POWERSHUTTLE -- CHAPTER 1

4. Refit the thrust bearing (1), thrust washer (2) and circlip (3).

81 5. With the circlip seated in position ensure that a freeplay of 0.05--0.40 mm (0.002--0.016 in) exists between the gear and thrust washer with the bearing fully seated.

82 6. Using a suitable press and 50 mm tool refit the bearing onto the shaft. NOTE: New seals must be fitted, however do not fit the seals until the rear cover shimming procedure is completed, as the seals may be damaged when the cover is fitted and removed during the shimming procedure.

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OIL PUMP DRIVE SHAFT SUPPORT BEARING 1. Remove the soft bearing from the bore of the shaft and discard. Ensure the bore is clean and free of all residues.

84 2. Fit a new bearing into the shaft using a small drift and tap gently into the bore until it is flush with the end face of the shaft.

85 REVERSE IDLER SHAFT-- DISASSEMBLY 1. The idler shaft support bearings can be removed by using a bearing puller. Inspect for scoring wear marks and or discolouration, replace suspect parts as necessary. 2. To refit the bearings use a press and 35 mm tool

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GEAR TRAIN RE-- ASSEMBLY

87 Gear Train Re--assembly

24. Reverse Idler Shaft 25. Counter Shaft 26. Input or Primary Shaft

27. Gear Selection Shafts and Forks 28. Output Gear Shaft

Transmission Re-- assembly IMPORTANT: Prior to re--assembly of the transmission ensure all parts are clean and oiled. Change the double lipped oil seal in the rear cover on the output shaft (2) while it is disassembled. Push out the old seal and push in a new seal to seat on the shoulder and fill the cavity between the seal double lips with a silicone grease.

88 1. Place in the front cover the inner detent spring and ball and retain by using a small piece of tube 18 mm (0.709 in) diameter by 23 mm (0.906 in) long, in lieu of the gear shift rail, Figure 89. 2. Re--assemble the gear train in the following order: D Counter Shaft D Reverse Idler Shaft D Input shaft (hold counter/idler shaft to one side) D Output Shaft D Gear Shift 1st rail and fork (push out tube). Fit intermediate ball, 2nd rail and fork, ball and spring and detent retaining plug, torque plug to 41 -- 54 Nm (30--40 lbf ft).

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With the detent spring and balls in position fit the retaining bolt and torque to 40--54 Nm (30--40 lbs ft) With the gear train set in neutral position torque the shift fork hexagonal head screws to 8 --16 Nm (6--12 lbf ft)

Gear Train End float Procedure

Shimming

The purpose of this procedure is to create an end float of 0.025--0.076 mm (0.001--0.003 in) on each of the gear shafts, this is achieved by adding or deleting the shims (1) between the shaft bearing cone (2) and spacer (3) in the rear cover on each shaft assembly. To determine end float the rear cover is seated on the transmission and securing with four bolts evenly spread around the cover, checking the end float of each shaft in turn. 91 IMPORTANT: The mating faces of the front and rear transmission cases must be scraped clean and free of dirt and gasket material. Any residue remaining on theses faces may affect the endfloat shimming procedure when the cases are bolted together. Before attempting to check the end float in any shaft assemblies they must be rotated several times to allow the taper bearing rollers to settle in tracks. Removal of the bearing cones is achieved by use of a removal tool (1). When a new bearing cone is to be fitted fit the spacer first (but less the shims) and then fit the cone (gently tapping the cone into the counter bore). 92 However if the old bearing and cone is to remain in the transmission, leave the old cones installed until the end float is checked and then remove and adjust shims between the spacer and cone as required. 1. REVERSE IDLER GEAR SHAFT -- Place Tool 380000700 in the end of the shaft through the rear cover and position a dial indicator onto the bolt head. Using a small block and lever gently lift the shaft up (do not use excessive force) and record the reading. If the result is not to the specification of 0.025--0.076 mm (0.001--0.003 in) it will be necessary to add or delete the shims accordingly beneath the bearing cone in the rear cover.

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2. INPUT SHAFT -- This shaft can raised by placing a lever and block below the transmission and levering the input end of the shaft where it protrudes into the bell housing. Alteratively it can be raised by placing the lever through the side casing access aperture and levering between the clutch housings. Position a dial indicator so the indicator rests on the rear face of the shaft and gently lift the shaft up (do not use excessive force) and record the reading. If the result is not to the specification of 0.025--0.076 mm (0.001--0.003 in) it will be necessary to add or delete the shims accordingly beneath the bearing cone in the rear cover. 94 3. COUNTER SHAFT -- Place Tool 380000700 in the end of the shaft through the rear cover and position a dial indicator onto the bolt head. Using a small block and lever gently lift the shaft up (do not use excessive force) and record the reading. If the result is not to the specification of 0.025--0.076 mm (0.001--0.003 in) it will be necessary to add or delete the shims accordingly beneath the bearing cone in the rear cover.

95 4. OUTPUT SHAFT -- Place Tool 380000700 in the end of the shaft through the rear cover and position a dial indicator onto the bolt head. Using a small block and lever gently lift the shaft up (do not use excessive force) and record the reading. If the result is not to the specification of 0.025--0.076 mm (0.001--0.003 in) it will be necessary to add or delete the shims accordingly beneath the bearing cone in the rear cover.

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Upon completion of recording the results lift the rear cover off and add or delete shims beneath the cones on the relative shafts to achieve the required end floats. Refit the rear cover with 4 bolts evenly spread around the cover and recheck end float through steps 1 to 4. When all correct end floats are achieved, proceed to rear cover attachment.

REAR COVER ATTACHMENT Lift the rear cover and fit new seals to the end of the input shaft.

98 Replace the ‘O’ rings on the oil feed supply ports

99 Apply a 2 mm wide band of sealer 82995770 to the mating face of the front cover and carefully lower the rear cover. Torque the cover bolts 45 -- 64 Nm (33--47 lbf ft), working out from the middle of the cover, alternating each side of the cover, to the top and bottom of the transmission.

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Replace the 2 shaft end bolts and torque to 45--64 Nm (33--47 lbf ft). Replace oil drain plug (1) and torque to 34--54 Nm (25--40 lbf ft)

101 Replace suction strainer ‘O’ ring washer and plate and torque screws to 18--31 Nm (13--23 lbf ft).

102 Control valve clean the mating faces and apply sealer to joint face on the transmission and torque bolts to 45--64 Nm (33--47 lbf ft).

103 GEAR SHIFT SELECTOR ASSEMBLY Refit the gear shift lever and spacer and torque the bolts to 16.2--24.4 Nm (12--18 lbs ft). SPIN ON OIL FILTER Replace the spin on filter with a new one and hand tighten the filter plus 3/4 of a turn or as instructed on the filter body.

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Install a new flexible drive plate (3) and back--up plate (1) to the torque converter (2). Install torque converter into location on the input and pump drive shafts in the transmission bell housing. The bolts retaining the torque converter to the flywheel are fitted through the starter motor aperture after the engine and transmission are coupled together.

105

Powershuttle Transmission Wiring Diagram Circuit Key 50 51 52 53 54

Forward drive relay Start--up safety Reverse drive relay Forward drive pressure relay Solenoid valve -- forward drive

55 56 57 58 59

Solenoid valve -- reverse drive Reversing light -- left hand Reversing light -- right hand Reversing warning buzzer (option) Transmission disconnect

S2 S7 S14 S24 S25 S26 Y2 Y3

Shuttle lever Handbrake Transmission disconnect on gear lever Transmission disconnect selection switch Transmission disconnect on pedal Transmission disconnect on joystick Forward drive Reverse drive

Cab Rear lighting

F H

Fuse panel/relays (7--pin socket) Fuse panel/relays (21--pin socket)

Transmission shuttle -- 13A

F23

Rotating beacon -- 7.5A

Component Key E20 E22 K0 K1 K2 K3 K4 K5 M10

Reversing light -- left hand Reversing light -- right hand Transmission disconnect on joystick Transmission disconnect Forward drive relay Reverse drive relay Safety start switch Forward drive pressure relay Reverse warning buzzer

Connector Key C D

Fuses F13

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106

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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NOTES PAGE

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SECTION 21 -- POWERSHIFT -- CHAPTER 2

SECTION 21 -- POWERSHIFT TRANSMISSION DRIVE CONTROL Chapter 2 -- Powershift Operating Lever CONTENTS Section

Description

Page

21 300

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Driving with Powershift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fault Finding

................................................................ 9

Powershift Microprocessor Test Modes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Electrical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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SECTION 21 -- POWERSHIFT -- CHAPTER 2

4X3 POWER SHIFT TRANSMISSION Transmission Control, Figure 1 The transmission fitted to this machine is designed to be able to powershift gear changes. Supplying drive to the vehicle wheels dependant upon the speed, gear and direction selected. The transmission is controlled by a microprocessor in the Power Shift Lever unit (1) which is mounted below and to the left of the steering column.

Power Shift Lever, Figure 1 NOTE: The powershift HANDGRIP (2) is the only moving part of the power shift assembly The power shift lever (2) with electronic speed selection actuates the powershift gearbox with four forward speeds, three reverse speeds. 1

Power Shift Lever Display - (LEDs) LEDs -- Numbered 1 through 4 : Indicate the direction of travel by the colour of the LED: Forward = Green Neutral = Red Reverse = Yellow

and also indicate the selected shift lever gear. 3 STEADY ILLUMINATED LED: Indicates selected transmission gear. LEDs -- Numbered 1 through 7: Used during test modes, 1

LED -- Number 8: illuminates green when the vehicle is at a standstill (in normal mode). 1

LED -- Letter T = Self-diagnostic Mode: T

Used in self-diagnostic test mode and will illuminate during self test. In the event of a fault, (the light will flash), Contact your Authorised dealer for assistance.

LED -- Letter N Indicates Neutral : N Illuminates red when the transmission is shifted to neutral.

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SECTION 21 -- POWERSHIFT -- CHAPTER 2

Power Shift Lever and Microprocessor Functions

that gear selection and range changes are always performed in a safe manner.

Power Up: Immediately after starting up (ignition on) LEDs T & N are switched on, in order to show they are operational. The microprocessor controls the transmission and self checks its own memory continuously to ensure N -- LED

T -- LED

CONDITION

Flashing

Currently shown on display will be the last fault

Flashing

Flashes Slower

Input Fault Detected

Flashing

Flashes in Phase

Non Critical Output Fault Detected

Flashing

Flashes Faster

Safety Critical Output Fault Detected

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DRIVING WITH POWERSHIFT Selecting Neutral At power up, ‘‘NEUTRAL and 2nd Gear’’ are automatically selected regardless of the power shift lever position (1). The LED 2 and the N--LED are illuminated RED.

3 4

7 8

N R

If forward or reverse are selected from neutral while the vehicle is moving then neutral remains selected and the warning lamp is illuminated. If the speed drops below 8.5 KPH the selected direction is engaged in 3rd gear. 3 Selecting Forward To select forward travel move the lever upwards and the LED will illuminate green. NOTE: When forward is selected you will not be given any indication of gear selected, only the maximum selected gear the transmission will shift too. The microprocessor is programmed to be an automatic speed based shift system.

3 4

7 8

N R

In addition whether forward actually engages at that time, depends on the status of the vehicle, for example if on the move, road speed and direction will be considered by the microprocessor before any shift changes take place.

4 Selecting Reverse To select reverse travel move the lever downwards and the reverse LED will illuminate yellow.

3 4

7 8

N R

NOTE: When reverse is selected you will not be given any indication of gear selected, only the maximum selected gear the transmission will shift too. The microprocessor is programmed to be an automatic speed based shift system. In addition whether reverse actually engages at that time, depends on the status of the vehicle, that is if on the move road speed and direction will be considered by the microprocessor. 5

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Up Shifting Up shifting to a desired gear from neutral is achieved by twisting the handgrip counter clockwise in single movements, If held in this position the processor will advance the shift selection from 2 though to 4 in 1.5 second intervals.

3 4

7 8

N R

NOTE: An upshift request after a downshift is delayed for 2 seconds. Should an error occur with the speed sensor the microprocessor will not allow up shifts above 2nd gear.

6 NOTE: If ascending up a steep inline select 2nd and proceed, if speed and power allow upshift onto 3rd and 4th Down Shifting

WARNING

If descending down a steep incline select 2nd and proceed, upshifting only when safe to do so. YOU CAN NOT DOWNSHIFT TO REDUCE SPEED IF THE VEHICLE SPEED IS ABOVE 15 km/h (9 mph)

3 4

7 8

N R

Downshifting to the desired gear is achieved by twisting the handgrip clockwise in single movements. NOTE: If the gear requested and the shift attainable are not the same because of torque convertor turbine RPM being too high, the gear position LED(e.g. LED 4) will flash and the shift lever position will illuminate, not flashing, (e.g. LED 2), until the requested gear is reached. When a gear position LED is flashing this indicates that the vehicle has to reduce speed to reach the requested gear.

Direction Changes Changing driving direction is achieved simply by shuttling the power shift lever between forward and reverse and vice versa which is allowed at any time.

3 4

7 8

N R

The system response however depends on vehicle speed and currently engaged gear. When driving in 1st or 2nd gear direction changes are unrestricted and are granted immediately. Forward / Reverse shuttles are available only below 11 KPH

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Declutch Function When the brake pedal switch is switched to ground, the transmission is put in neutral when the vehicle speed drops below 5km/h. When the brake pedal is released, or when the vehicle speed increases and exceeds 5 km/h the direction indicated by the shift lever is re--engaged. When the transmission is placed in to neutral due to the declutch function, automatic shifting is not avaliable.

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9 Powershift Microprocessor Circuit 1.

Reverse Modulation Valve

S Solenoid

Forward Modulation Valve

Number 1 Solenoid

Reverse Solenoid

Number 2 Solenoid

Forward Solenoid

Manifold Plate

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COMMON CONNECTION BETWEEN MICROPROCESSOR AND CONTROL VALVES Wire

Function

Type

Comment

E01

Battery plus

Use 6A fuse

E02

Battery Ground

Direct to battery GND

E03

Solinoid

switch to ground

neutral stsrt solinoid

E04

Solenoid 1

switch to plus output

1/2 selection Solenoid

E05

Solenoid 2

switch to plus output

Forward Lo/Hi selection Solenoid

E06

Forward Solenoid

switch to plus output

Forward/Neutral selection Solenoid

E07

Reverse Solenoid

switch to plus output

Reverse/Neutral selection Solenoid

E08

not used

E09

not used

E10

speed sensor plus

Speed sensore input

E11

speed sensor ground

speed sensore input

E12

Not used

E13

S. solinoid

pull to ground input

splitter

E14

Declutch input

pull to ground input

Transmission dissconect request

E15

not used

E16

ground

Microprocessor

pull to ground input = PTG pull to plus input = PTP

+ PTP

STP Microprocessor

PTG

STG

switch to ground output = STG switch to plus output = STP

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FAULT FINDING Before attempting any fault finding ensure you have a suitable Multimeter for checking component continuity. When fault finding remember that with an electrical concern it is often a minor fault that may have occurred and could be as simple as: Poor continuity between connector pins Condensation in the connectors Disconnected cables It should also be remembered that mechanical problems could result in fault codes appearing on the LED display Damaged or broken wires all of which could result in a no drive situation but easily remedied when found and corrected.

Refer to pages 12 and 13 for the Transmission wiring diagram.

Indication of faults In case a fault is present during normal operation and is detected by the microproccesor, both the T--led and N--led may be blinking in some way as shown in the table below. NOTE: That on an open circuit or connection to battery plus on ON/OFF outputs can only be detected while the corresponding output is in the OFF position. Also a short to ground is only detected while the output is on.

T-- LED (Yellow)

N--LED (Red)

Condition

Situation

Off

Normal operation

Off

Normal operation -- N selected

Off

Blinks

Normal operation -- N selected / speed too high --

Off

Speed sensor test

Controller in Reset

Fault

Blinks

Last fault is currently shown on display

Fault

Blinks

Blinks slower

Input Fault detected

Fault

Blinks

Blinks in Phase

Non critical Output Fault detected

Fault

Blinks

Blinks Faster

Safety Critical Output Fault detected

Fault

Blinks Fast

Blinks out of phase

System Shutdown -- Neutral till Power Down

Fault

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SECTION 21 -- POWERSHIFT -- CHAPTER 2

INPUT TEST This test is used to verify operation of the shiftlever and its inputs. In this mode driving is not possible NOTE: The gear position indicators on the Microprocessor top cover are used to display the test information. INPUT TEST REQUIREMENTS: Powershift lever to be in forward position, twist to upshift (keep the shift lever in this position during power up) and turn the ignition on, this will place the microprocessor in the Input test mode. As shown in the table below placing the shift lever in different positions in this mode illuminates its respective LED (only 2 at the same time).

11 IMPORTANT: Selftest modes can only be started WHILE POWERING UP (ignition on). Leaving the selftest mode is done by switching OFF the power of the Microprocessor (ignition off).

POWERSHIFT LEVER POSITIONS -WITH UP AND DOWN SHIFT SELECTION

LED NUMBER

LED COLOUR -DISPLAYED = Okay

Neutral

RED

Neutral and Upshift

RED

Neutral and Downshift

RED

Forward

GREEN

Forward and Upshift

GREEN

Forward and Downshift

GREEN

Reverse

ORANGE

Reverse and Upshift

ORANGE

Reverse and Downshift

ORANGE

Operate Disconnect Button brake pedal

RED

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SECTION 21 -- POWERSHIFT -- CHAPTER 2

SPEED SENSOR TEST If a speed sensor fault is detected the microproccesor will modify its Behaviour in the following areas: • no up shifts will be allowed above 2nd gear • direction change while in F3 or F4: the actual reversal is preceded by a downshift sequence until 2nd gear is obtained. NOTE: That the system response in this case is identical to the response in case of a power supply overvoltage

Speed Sensor Test Using The Turbine Speed Display NOTE: A lamp test is performed prior to the speed sensor test and monitors all LEDs are operational SPEED SENSOR TEST REQUIREMENTS: Powershift lever to be in reverse position, twist to upshift (keep the shift lever in this position during power up) turn the ignition on and start the engine. With engine running return Powershift lever to neutral position and then place lever in forward and twist to upshift. Increase engine speed and compare with the table opposite.

Turbine Rev/Min

LED

1 blinks

0 -- 249

1 on

250 -- 499

2 on

500 -- 749

3 on

750 -- 999

4 on

1000 -- 1249

5 on

In this mode, driving is possible

1250 -- 1499

6 on

The LED corresponding with the table opposite illuminates to indicate the torque converter turbine speed and increases with engine revs.

1500 -- 1749

7 on

1750 -- 1999

8 on

above 2000

8 blinks

IMPORTANT: Selftest modes can only be started WHILE POWERING UP (ignition on). Leaving the selftest mode is done by switching OFF the power to the Microprocessor (ignition off).

NOTE: Application of the footbrakes during this test will reduce the turbine speed to zero.

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SECTION 21 -- POWERSHIFT -- CHAPTER 2

12 OUTPUT TEST

Output test - Fault by LED Number

OUTPUT TEST REQUIREMENTS: Powershift lever to be in forward position, twist clockwise to downshift and turn ignition on.

The LED numbers correspond to the connector output wires as follows:

In this mode, driving is not possible, since all Microprocessor outputs remain off until the test mode is left.

Example: LED 1 = Forward solenoid -- colour Yellow = (Output not connected or shorted to battery plus)

LED NUMBER

OUTPUT WIRE

The colour and number of the LED indicates its status:

E06

E07

COLOUR

STATUS

E04

GREEN

Output OK

E05

ORANGE

Output not connected or shorted to battery plus

E09 (NOT USED)

E13

E08 (NOT USED)

E03

RED

Output shorted to ground (or to another output)

Powershift Transmission Wiring Diagram Circuit Key 19 20 21 22 23 24 25

Transmission disconnect Rotating beacon Starter relay Reverse relay EGS (Electronic gearshift) First & second gear electro--valve First gear electro--valve

26 27 28 29 30 31 32

Fourth gear electro--valve Forward electro--valve Reverse electro--valve Left--hand reversing light Right--hand reversing light Reversing warning (optional) Not used

S25 S26 V2 Y2 Y3 Y9 Y10 Y11

Transmission disconnect on pedal Transmission disconnect selection switch Diode Forward solenoid valve Reverse solenoid valve Second gear solenoid valve First gear solenoid valve ’S’ solenoid valve

Cab Rear lighting Fuse/relay board (21--pin socket)

H N

Fuse/relay board (21--pin socket) EGS (15--pin socket)

Transmission shuttle -- 13A Rotating beacon -- 7.5A

F24

Not used

Component Key E19 E20 E22 K3 K4 M10 S2 S14 S19

Rotating beacon Reversing light -- left hand Reversing light -- right hand Reverse relay Safety start relay Reverse warning (optional) Forward / reverse direction lever/module Speed sensor Rotating beacon switch

Connector Key C D F

Fuses F13 F23

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SECTION 21 -- POWERSHIFT -- CHAPTER 2

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 21 -- POWERSHIFT -- CHAPTER 2

NOTES

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

SECTION 21 -- POWERSHIFT TRANSMISSION Chapter 3 -- Overhaul CONTENTS Section

Description

Page

21 200

Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal from vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

SPECIFICATIONS STALL SPEED 95/110 PS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2160rpm

TORQUE CONVERTER Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.84 : 1 GEAR SPEEDS (kph) Powershift 4x3 Transmission 1st forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

1st reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

2nd forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

2nd reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7

3rd forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.9

3rd reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

4th forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 GEAR RATIOS 1st forward . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 5.58

1st reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 5.58

2nd forward . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 2.55

2nd reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 2.55

3rd forward . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1.44

3rd reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1

4th forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1 LUBRICANT Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 litres Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AMBRA HYDRODEX (NH 530 A) Oil change period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hrs

SPECIAL TOOLS Pressure Regulator Sleeve Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000606 Clutch Spring Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380000711 Pressure Test Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297404 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

TORQUE SPECIFICATIONS

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

TORQUE SPECIFICATIONS

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION CONTROL The transmission is operated via a control lever mounted on the left hand side of the steering column. Directional changes are made by moving the lever forward and backward, gears are selected by twisting the lever anti clockwise for a higher gear , and clockwise for a lower gear. Transmission disconnect is operated by depressing the brake pedal.

1 NOTE: For full instructions on the operation of the powershift transmission refer to the Operators manual.

TORQUE CONVERTER NOTE: The torque converter is a sealed unit and can not be serviced as individual parts. The torque converter which is a fluid coupling transmits drive from the engine to the transmission. Attachment of the torque converter to the flywheel is through a flexi--plate using bolts (1) to converter and bolts (2) to flywheel. The main parts of the torque converter are the impeller, the turbine, the stator and the front and rear covers. The impeller is integrated with the rear cover which is driven by the engine flywheel by means of a drive plate. The torque converter must be full of oil to operate correctly. The oil must flow constantly throuogh the converter from the oil cooler to prevent overheating. When the engine is running the impeller pumps oil to the turbine. This oil acts on the turbine and flows on to the stator which is fixed. As the flow increases the turbine starts to rotate, at this point we get maximum torque increase. As the turbine speed increases the torque multiplication gradually decreases. When the turbine rotates at the same speed as the impeller oil now acts on the rear face of the stator blade. This unlocks the one--way clutch, permitting the stator to rotate in the same direction.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION HYDRAULIC SYSTEM The transmission case serves as an oil reservoir. The transmission hydraulic pump is mounted to the torque converter housing and is driven from the torque converter casing by a shaft and gears. The hydraulic pump draws oil through a strainer in the sump. Pump output is directed through the external pressure filter to a regulating valve, which maintains clutch operating pressure.

3 Surplus oil then enters the cooler circuit and is directed to the two external oil coolers connected in series. The rear oil cooler (3) is part of the engine cooling package.

4 The second oil cooler is located in the reservoir compartment and is cooled by a thermostatically controlled electric fan. The fan operates when transmission oil temperature rises above 70° C. 1. 2. 3. 4. 5.

Oil Cooler Radiator Inlet tube Electric Fan Outlet to Transmission Thermostatic Switch -- Cut in at 70° C

Oil returning from the coolers enters the transmission to fill the torque converter and provide transmission lubrication. 5 The additional electrical system for the cooler fan and thermostatic switch consists of a fuse and relay box mounted adjacent to the battery. The box contains: -F29. Line ceramic type master fuse 25A K19. Relay F28. Fuse 10A

6 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION ASSEMBLY The transmission is composed of four main assemblies

1. 2.

The converter The input shaft and directional clutches

The 6 transmission clutch packs are controlled by 5 solenoids, therefore combinations of between 1 and 3 activated solenoids are required for clutch engagement. These combinations are shown in the table below. The clutches are hydraulic pressure engaged and spring disengaged.

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3. 4.

The output shaft with C and D clutch assemblies The lower shaft with E and F clutch assemblies

The forward and reverse clutch packs are hydraulically modulated using a mechanical valve. The other four speed clutches are not modulated during engagement. Output is in the oposite direction direction to engine rotation.

SECTION 21 -- POWERSHIFT -- CHAPTER 3 SOLENOIDS GEAR

CLUTCHPACKS 1

F4 F3 F2 F1 N R1 R2 R3 8 Torque Converter Stall The torque converter stall test is carried out to determine the efficiency of the torque converter and to check for transmission clutch slippage. Torque converter stall speed is the stabilised engine speed when the torque converter turbine is held stationary. In the test, engaging gear and applying the brakes holds the turbine. Preliminary Checks 1. Ensure transmission oil temperature is 82 -93°C. 2. Check transmission oil level. 3. Check maximum engine no load speed is 2400 -- 2450 rpm (hydraulics & transmission in Neutral). 4. Switch off the brake pedal disconnect switch. Torque Converter Stall Test 1. Release the handbrake & apply fully apply the foot brake. 2. Start the engine. 3. Engage F2. 4. Press the accelerator pedal to the floor. 5. Stabilised engine speed should be 2160 rpm. 6. Repeat test in R2. Do not run in stall condition for more than 30 seconds.

Analysis 1. If the stall speed is within 50 rpm of specified speed and equal in F2 & R2, then the torque converter is performing to specification. 2. If the stall speed is more than 150 rpm below specified speed in both directions suspect the torque converter or low engine power. 3. If the stall is more then 150 rpm above specified speed, suspect clutch slippage. 4. Carry out stall test in following speeds to check clutches. Gear Clutch Tested R1 A&E R2 A&F R3 A&D F1 B&E F2 B&F F3 B&C Any test that indicates high stall speed identifies the suspect clutch. e.g. High stall speed in R1, R2, & R3 would indicate clutch A slippage.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

9 Operating Valves and Solenoids 1. 2. 3. 4.

Forward Feathering Valve Reverse Feathering Valve Solenoid (R) Solenoid (F)

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5. 6. 7. 8.

Solenoid (S) Solenoid (1) Solenoid (2) Housing

SECTION 21 -- POWERSHIFT -- CHAPTER 3

10 1. 2. 3. 4. 5. 6.

’O’ Ring Seal Valve Housing Springs Sleeve Accumulator Valve Stop Pin Regulator Valve Stop Pin

Modulating Valve Components 7. Spring Retainer 8. Shim 9. Regulating Valve Spring 10. Regulating Valve 11. Accumulator Valve 12. Regulating Valve Limiter Rod

NOTE: The regulating valve (10) and the accumulator valve (11) are not interchangeable as the regulating valve has an orifice.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

POWER FLOWS

11 1st Speed Forward

12 2nd Speed Forward

SHJ21069A

13 3rd Speed Forward

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14 4th Speed Forward

SECTION 21 -- POWERSHIFT -- CHAPTER 3

POWER FLOWS

15 1st Speed Reverse

16 2nd Speed Reverse

17 3rd Speed Reverse

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

HYDRAULIC OIL FLOWS Torque converter and cooler circuit Oil is drawn up from the sump, via an internal strainer, through the inlet port of the hydraulic pump. Oil is pumped out to the pressure filter. Across the oil filter is a filter by pass valve which will open if the pressure difference becomes higher than 4.3 bar (62.5 lb/in2). Oil flows to the pressure regulating valve, maintaining system pressure to the control valve and clutches at 16.5 -- 19 Bar (240 -- 280 PSI) Excess oil flow is bled off to the converter circuit which is protected by a 10 bar (145 lb/in2) safety valve. Oil then flows to the external oil coolers, which are connected in series. The rear cooler (12) is combined with the engine coolant radiator and is cooled by the engine fan air flow. The second oil cooler is located in the reservoir compartment and is cooled by a thermostatically controlled electric fan. The fan operates when oil temperature rises above 70° C. Oil enters the converter from the rear of the transmission through the centre of the input shaft. After leaving the converter the oil is directed to the C/D clutches and shaft and E/F clutches and shaft via a oil distributer ring in the front housing. Oil then drains back by gravity to the transmission sump.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

18 Suction Oil

Cooler & Torque Converter Oil (2 -- 7 bar)

Regulated Pressure Oil (16.5 -- 19.5 bar)

Reservoir Return Oil

Transmission Sump

System Regulating Valve (16.5 -- 19.5 bar)

Transmission Breather

10. Torque Converter Safety Valve (Max 10 bar)

Suction Filter

11. Oil Cooler ’IN’ Test Port

Transmission Hydraulic Pump

12. Rear Oil Cooler (Engine Fan Cooling)

Pressure Filter

13. Side Oil Cooler (Electric Fan Cooling +70_C)

Filter Bypass Valve

14. Torque Converter ’IN’ Pressure

Regulated Pressure Oil to Clutch Solenoid Valves

15. Torque Converter

Clutch pressure

16. Torque Converter ’OUT’ Temperature 17. Transmission Lubrication Galleries

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION OPERATION FORWARD, FIRST GEAR ENGAGED

Suction oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.5 bar)

Return to reservoir

Forward modulation valve

Pressure oil from the system regulating valve flows to the 1st solenoid and forward solenoid. The 1st solenoid is energised and allows system pressure to engage the E clutch. At this time the 2nd solenoid is energised allowing any pressure in clutches D or F to return to sump.

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Reverse modulation valve

The forward solenoid is energised allowing system pressure to flow through the splitter solenoid, to the forward B clutch. Modulation is controlled by the modulation valve in the circuit. As pressure increases in the forward clutch line drive is taken up giving a smooth modulation. Clutches A, C, D and F are open to reservoir.

SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION OPERATION FORWARD, SECOND GEAR ENGAGED

Suction oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.5 bar)

Return to reservoir

Forward modulation valve

Reverse modulation valve

Pressure oil from the system regulating valve flows to the 1st solenoid and forward solenoid.

As pressure increases in the forward clutch line drive is taken up giving a smooth modulation.

The 2nd solenoid is energised and allows system pressure to engage the F clutch.

Clutches A, C, D and E are open to reservoir.

The forward solenoid is energised allowing system pressure to flow through the splitter solenoid, to the forward B clutch. Modulation is controlled by the modulation valve in the circuit.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION OPERATION FORWARD, THIRD GEAR ENGAGED

Suction oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.5 bar)

Return to reservoir

Forward modulation valve

Pressure oil from the system regulating valve flows to the 1st solenoid and forward solenoid. The 2nd solenoid is energised and allows system pressure coming from the 1st solenoid to flow through and engage the F clutch.

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Reverse modulation valve

Oil flows through the energised forward F solenoid and then through the energised splitter S solenoid which engages the C clutch pack. Clutches A, B, D and E are open to reservoir.

SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION OPERATION FORWARD, FOURTH GEAR ENGAGED

Suction oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.5 bar)

Return to reservoir

Forward modulation valve

Pressure oil from the system regulating valve flows to the 1st solenoid and forward solenoid. The 1st and 2nd solenoids are de--energised allowing oil pressure to engage the D clutch.

Reverse modulation valve

The forward F solenoid is energised allowing oil to flow through the de--energised splitter S solenoid to the forward C clutch. Clutches A, C, E and F are open to reservoir.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION OPERATION REVERSE, FIRST GEAR ENGAGED

Suction oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.5 bar)

Return to reservoir

Forward modulation valve

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Reverse modulation valve

The forward solenoid is not energised allowing oil to flow through the reverse solenoid which is then energised. Oil flows to the reverse clutch. Modulation is controlled by the modulation valve in the circuit. Clutches B, C, D and F are open to reservoir.

SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION OPERATION REVERSE, SECOND GEAR ENGAGED

Suction oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.5 bar)

Return to reservoir

Forward modulation valve

Pressure oil from the system regulating valve flows to the 1st solenoid and forward solenoid. The 1st solenoid is not energised and allows system pressure to flow on to solenoid 2. At this time the 2nd solenoid is energised allowing oil to flow to the F clutch, and at the same time open clutch D to reservoir.

Reverse modulation valve

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION OPERATION REVERSE, THIRD GEAR ENGAGED

Suction oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.5 bar)

Return to reservoir

Forward modulation valve

Pressure oil from the system regulating valve flows to the 1st solenoid and forward solenoid. The 1st solenoid is not energised and allows system pressure to flow to solenoid 2. Solenoid 2 is not energised therefore oil flows to clutch D.

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Reverse modulation valve

SECTION 21 -- POWERSHIFT -- CHAPTER 3

TRANSMISSION OPERATION NEUTRAL

Suction oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.5 bar)

Return to reservoir

Forward modulation valve

Pressure oil from the system regulating valve flows to the 1st solenoid and forward solenoid.

Reverse modulation valve

Clutches E, F, C, B and A are open to reservoir.

None of the solenoids are engaged, allowing the oil to flow through to the clutch D only.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

MODULATION VALVE OPERATION The modulation valve shown on the pages opposite consists of the following components: 5. Modulation Valve Housing 6. Modulation Sleeve 7. Accumulator Valve 8. Regulator Valve 9. Stop Pin The graph (figure 27) shows how the pressure increases in the clutch pack from the moment of solenoid activation (A) until maximum clutch pressure is achieved (F). Diagram A (figure 28) Oil is just about to enter the modulation valves and both the accumulator and regulator valves are seated on the stop pins. Diagram B (figure 29) Oil initially flows in to the bottom of the regulator valve and unseats the regulator valve this momentarily sends a high pressure pulse to the clutch pack which takes up the freeplay between the clutch pack plates. Diagram C (figure 30) Oil starts to flow through the small orifice in the regulator valve and equalises the pressure on either side.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

Modulated pressure

Clutch presure

Time 27 Modulated Pressure

Clutch Pressure

Zero Pressure (Reservoir) 2123001 28

2123002

2123003 29

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

Diagram D (figure 31) When the top side of the regulator valve is full of pressure oil the spring pressure pushes the regulator valve back to its seat. Pressure then begins to act on the bottom of the accumulator valve. Diagram E (figure 32) The accumultor valve starts to move up the sleeve, as it does the oil pressure required to push it up becomes greater and greater as the opposing spring pressure increases. This gradual increase in pressure feathers the clutch plates into engagment. The pressure increase stops when the accunulator hits the limit rod at the top. Diagram F (figure 33) As the oil supply continues to the clutch pack excess flow is bled off via the regulator valve. Diagram G (figure 34) When the supply of oil to the clutch pack is cut off the regulator valve seats on the bottom pin allowing oil to flow out the top of the regulator valve allowing the modulation valve to become seated.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

2124001

2124002 32

2124003

2124004 33

34 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

PRESSURE TESTING CLUTCH AND HIGH PRESSURE CIRCUIT

35 Port 1 System pressure Engine set to idle. Minimum pressure 13 bar. Desired oil pressure 16 -- 19 bar.

Port 5 C Clutch Engine set to idle Pressure range clutch activated 16 -- 19 bar. Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).

Port 2 E Clutch Engine set to idle. Pressure range clutch activated 16 -- 19 bar. Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).

Port 6 B Clutch Engine set to idle. Pressure range clutch activated 16 -- 19 bar. Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).

Port 3 F Clutch Engine set to idle. Pressure range clutch activated 16 -- 19 bar. Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).

Port 7 A Clutch Engine set to idle. Pressure range clutch activated 16 -- 19 bar. Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).

Port 4 D Clutch Engine set to idle. Pressure range clutch activated 16 -- 19 bar. Clutch released 0 -- 0.2 bar (0 -- 3 lb/in2).

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

PRESSURE TESTING TORQUE CONVERTER AND COOLER CIRCUIT

36 All pressure and flow testing should be measured with an oil temperature of 82--93 degrees Celsius (180 -- 200 F). For operating speed refer to each test. Port 1 System pressure Engine set to 2000 revs/min. Minimum pressure 13 bar ( lb/in2). Desired pressure 16.5 -- 19.5 bar ( -- lb/in2). Port 2 Oil cooler in Engine set to 2000 revs/min. Pressure range 2 -- 7 bar ( -- lb/in2).

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

37 Left Hand Side View 1. 2.

Forward clutch pressure (B clutch) Reverse clutch pressure (A clutch)

C Clutch pack pressure

38 Top View 1. 2.

Regulated clutch pressure Oil temperature to cooler

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3. 4.

Pressure from cooler Pressure to cooler

SECTION 21 -- POWERSHIFT -- CHAPTER 3

39 Right Hand View 1. 2.

E clutch pack F clutch pack

D clutch pack

40 Rear View 1. 2.

Oil to cooler Oil from cooler

3. 4.

Forward (B) clutch test port Reverse (A) clutch test port

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

41 Transmission / Engine removal from Telehandler

Removal

WARNING Before performing any service or maintenance on the machine ensure the wheels are chocked/blocked to prevent the machine from moving. 1. Lower the boom to the ground release any pressure in the system as required. Apply the handbrake and chock the wheels. 2. Isolate battery 3. Remove all engine panels 4. Remove rear cast weight 5. Remove axle and driveshaft guards underneath the chassis 6. Drain engine coolant and remove hoses IMPORTANT: Air Conditioning where fitted -- Do not disconnect the air conditioning hoses from the compressor or condenser unless a refrigeranr reclaim system is to be used. Engine/Transmission removal from the machine does not require the system to be discharged. Remove the condenser from the front radiator and place the condenser to one side of the chassis.

604.55.181.01 09-- 2004

Disconnect the air conditioning compressor attaching hardware and place the compressor to one side of the chassis. Disconnect the expansion bottle connections from the radiator. 7. Pull main hydraulic cooler over radiator tabs 8. Remove all attaching bolts from radiator 9. Disconnect transmission cooler pipes 10. Remove radiator, taking care not to damage the fan or hydraulic oil cooler 11. Remove air cleaner asssembly 12. Disconnect all electrical connections 13. Disconnect hydraulic pipe clamps 14. Disconnect the fuel tank feed and return pipes 15. Disconnect the foot throttle cable at the fuel injection pump 16. Disconnect the connector from the transmission valve chest mounted to the left hand side of the transmission

SECTION 21 -- POWERSHIFT -- CHAPTER 3

17. Remove front drive shaft 18. Disconnect and pull back hydraulic pump (leaving all pipes attached). check that the oil pump drive shaft does not slide out with the pump 19. With the engine supported and using a hoist capable of supporting a total weight of 800 kgs, 1760 lbs loosen and remove the engine and transmission mounting bolts IMPORTANT: If the hydraulic oil pump is removed from the engine/transmission assembly the balance of the assembly when hoisted will be front end heavy 20. Using lifting tool very carefully raise the hoist and guide the engine/transmission assembly from the vehicle For a full description of the Transmission and Engine removal see section 10 -- Engine.

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

Separating Engine from Transmission with assembly removed from the vehicle 1. Place the engine/transmission assembly on a suitable splitting stand 2. Remove the starter motor assembly

42 3. Remove the torque converter attaching bolts accessed through the starter motor aperture (1) 4. Remove the engine timing tab (2) 5. Remove the bell housing bolts 6. Gently slide the transmission with the torque converter from the engine

43 Installation Place a stud in one tang of the flexi plate and as the transmission is offered up to the engine guide the stud through a bolt hole of the flywheel -- remove the stud and refit a bolt. Refit the attaching bolts transmission to engine. Turn the engine crankshaft using a torque bar to expose inturn each attaching bolt hole of the flywheel through the flexi plate and refit all of the bolts. Hoist the engine/transmission back into the vehicle and centralise in the machine using a measure between the chassis and centre line of the crankshaft pulley. This ensures the engine is centrally positioned before torque up of the engine/trans to chassis bolts. Reconnect all ancillary equipment as previously described. Ensure all attaching hardware is tightened to the correct torque value as detailed in the specifications. Ensure after installation that all fluid levels are correct prior to start up. Start and run the engine until correrct operating temperature is achieved to purge air from cooling system. stop engine, check for leaks, rectify as required and recheck all fluid levels.

45 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

NOTES

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

Overhaul Remove the capscrews and washers connecting the drive plate to the torque converter and remove the drive plates and backing ring.

46 Remove the torque converter plug retaining ring and then lever out the plug.

47 Remove the torque converter to turbine shaft retainer ring. Then pull off the torque converter.

48 Remove the torque converter to shaft locating ring.

49 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the filter assembly.

50 Remove the pressure regulator and regulator sleeve, using special tool 380000606.

51 Remove the pump mounting bolts and washers and remove the pump body.

52 Remove the pump transfer gear assembly.

53 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the converter housing to transmission case bolts and washers. NOTE: There is an allen bolt attaching the converter housing to the middle manifold plate, this is located at the top of the transmission on the other side and must also be removed

54 Remove the converter housing and gasket.

55 Remove the impeller hub gear.

56 Remove the solenoid cover retaining nuts (1) and the cover (2). Then remove the five solenoid valves (3) by firstly removing the retaining nuts, then the solenoid coils and finally unscrew the valve and remove.

57 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the manifold plate retaining bolts and washers. Position the transmission so the manifold plate is horizontal and lift the manifold plate upwards and away from the shafts and main transmission housing. The end of the gear shafts may need to be tapped with a rubber mallet to encourage them to remain in the transmission.

58 Remove the gear clusters in the order shown in the drawing. (1) E/F clutch and shaft (2) Input shaft and A/B clutches, and finally (3) C/D clutches and output shaft. Remove the roller bearing located behind the F clutch. NOTE: The D clutch gear must remain in the transmission.

59 Remove the baffle plate retaining screws and washers, and then remove the baffle plate.

60 Remove the oil supply tube ’O’ ring and remove the supply tube and screen assembly.

61 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

From inside the transmission remove the D clutch gear and the roller bearing in which it was located, also remove the bearing locating ring.

62 From outside the transmission loosen the snap ring on the output shaft.

63 Then using a suitable brass drift and hammer tap out the drive shaft, seal, ball bearing and snap ring, and remove the remaining snap ring from the casing.

64 Remove the inner case set screw plug. Remove the clutch shaft distributor sleeve set screw.

65 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Using a suitable puller remove the distributor sleeve and shaft pilot bearing.

66 Modulation Valve Removal Remove the modulation valve housing and ’O’ ring.

67 Remove modulation valve sleeve assembly and ’O’ ring.

68 1. 2. 3.

’O’ Ring Sleeve Assembly and Springs Modulating Valve Housing

69 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

To assist in removing the diverter valve use a 5/16--24 threaded rod.

604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Disassembly of the A and B clutches A clutch disassembly Remove the outer thrust washer, thrust bearing and inner thrust washer.

71 Remove the clutch hub and gear assembly and press out the 2 bearings and spacer.

72 Remove the outer thrust washer, thrust bearing and inner thrust washer.

73 Remove the end plate retainer ring.

74 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the end plate and also the 6 friction discs and 6 separator plates.

75 Compress the belleville washers and remove the snap ring, also remove the snap ring retainer, belleville washers and the clutch piston wear plate.

76 To remove the piston turn the clutch pack upside down and tap the shaft on a block of wood.

77 Disassembly of B clutch Remove the 3 oil slip rings.

78 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Slide off the clutch hub and gear assembly and press out the 2 bearings and spacer.

79 Remove the outer thrust washer, thrust bearing and inner thrust washer.

80 Lever out the end plate retainer ring.

81 Remove the end plate and the 6 friction discs and 6 steel sparator plates.

82 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Compress the belleville washers and remove the snap ring, then proceed to remove the snap ring retainer, belleville washers and the clutch piston wear plate.

83 Turn the clutch pack upside down and tap the shaft on a block of wood , this will dislodge the piston for removal.

84 A clutch reassembly Install the clutch piston into the clutch housing.

85 Install the clutch piston wear plate, followed by the five belleville washers starting with the first washer with the larger diameter towards the wear plate, then alternate the remaining four. Position the snap ring retainer on to the belleville washers and then fit the snap ring.

86 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Fit the 6 steel separator plates and the 6 friction discs and the the end pate.

87 Then fit the end plate retainer ring.

88 To check the A clutch pack disc clearance position the clutch pack upside down. Measure the distance between the clutch piston and the first steel sparator disc by inserting a feeler gauge (1). The required clearance is 1.22 -- 2.74 mm (0.48 -0.108 inches). If the clearance is greater than 2.74 mm (0.108 inches) add one steel disc under the end plate.

89 Position the inner thrust washer, thrust bearing and outer thrust washer.

90 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Press one bearing into the clutch hub and gear assembly then place the spacer and second bearing on top and press the second bearing flush to the top of the gear. Then install the hub assembly into the clutch pack.

91 Then place the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

92 Reassembly of the B clutch Install the piston into the clutch pack.

93 Place the piston wear plate over the shaft and then place the first belleville washer with the larger diameter towards the piston wear plate, then alternate the remaining 4 washers. Position the snap ring retainer, compress the belleville washers and fit the snap ring.

94 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Install the 6 steel separator plates and 6 friction discs, starting with a steel separator plate first, then fit the end plate.

95 Install the end plate retainer ring.

96 To check the clutch disc clearance place the clutch pack upside down and place a feeler gauge (1) between the clutch piston and the steel separator plate. The required clearance should be 1.22 -- 2.74 mm (0.048 -- 0.108 inches). If the clearance is greater than 2.74 mm (0.108 inches) add one steel disc under the end plate.

97 Then position the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

98 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Press one bearing flush to the top of the B clutch hub gear then place the spacer and bearing on top of the pressed bearing and press the second bearing flush to the gear face.

99 Install the inner thrust washer, thrust bearing and outer thrust washer.

100 Fit the 3 oil slip rings.

101

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

Disassembly of C and D clutches and shaft C clutch disassembly Remove clutch shaft oil slip rings.

102 Using a suitable puller, remove the clutch gear and front bearing.

103 Remove the clutch gear locating snap ring, thrust washer retaining snap ring and then the outer thrust washer, thrust bearing and inner thrust washer.

104 Remove the clutch gear and hub assembly and press the 2 bearings and spacer from the gear.

105 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the end plate retainer ring.

106 Remove the end plate and six friction discs and six separator plates.

107 Compress the belleville washers and remove the snap ring, then proceed to remove the snap ring retainer, belleville washers and clutch piston wear plate.

108 Remove the clutch piston by rturning the clutch pack upside down and tapping the shaft on a block of wood.

109 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

D clutch disassembly Remove the thrust washer retaining snap ring, then remove the outer thrust washer, thrust bearing and inner thrust washer.

110 Remove the end plate retainer ring.

111 Remove the end plate and the five friction discs and five steel separator plates.

112 Compress the belleville washers and remove the snap ring, snap ring retainer, belleville washers and the clutch piston wear plate.

113 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the clutch piston by turning the clutch pack upside down and tapping the shaft on a block of wood.

114 Reassembly of C clutch Install the clutch piston into the housing.

115 Install the clutch piston wear plate, then install the first belleville washer with the larger diameter toward the wear plate, then alternate the remaining 4 washers, place the snap ring retainer over the shaft, compress the belleville washers and fit the snap ring.

116 Install the 6 separator discs and friction discs. Install a steel separator first and then alternate the remaining discs and finish with the end plate.

117 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Fit the end plate retaining ring.

118 To check the clearances turn the clutch pack upside down and measure the distance between the clutch piston and steel separator plate. The desired clearance should be 1.22 -- 2.74 mm (0.048 -- 0.108 inches) if the clearance is greater than 2.74 mm (0.108 inches) then fit another steel disc under the end plate.

119 Position the thrust bearing inner washer, thrust bearing and thrust bearing outer washer over the shaft.

120 Press one bearing into the hub then place the spacer on top and press the next bearing flush to the face of the gear. Install into the clutch assembly.

121 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Position the inner thrust washer, thrust bearing and outer thrust washer over the shaft. Then fit the snap ring on top and end gear locating snap ring.

122 Install the end gear and then press on the bearing with the bearing shield upwards.

123 Refit the two oil slip rings and lubricate.

124 D clutch reassembly Refit the clutch piston.

125 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Install the clutch piston wear plate and then the belleville washers, place the first belleville washer with the larger diameter towards the wear plate, alternate the remaining four. Then position the snap ring retainer, compress the belleville washers and fit the snap ring.

126 Fit the 5 steel separator plates and 5 friction discs, start with a steel separator plate on the piston and then alternate between friction disc and steel separator plates. Lastly place on the thicker end plate.

127 Fit the end plate retainer ring.

128 Place the thrust bearing washer, thrust bearing and the outer thrust washer.

129 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

NOTES

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

DISASSEMBLY AND REASSEMBLY OF THE E/F CLUTCH PACKS. Disassembly of E Clutch Remove the clutch shaft oil slip rings.

130 Remove the front bearing using a suitable puller.

131 Remove the outer thrust washer, bearing and inner thrust washer.

132

604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the clutch gear and hub assembly and press out the two pilot bearings.

133 Remove the outer thrust washer, thrust bearing and inner thrust washer.

134 Remove the clutch disc end plate retaining ring.

135 Remove the clutch disc end plate, then remove the 10 friction and 10 steel separator discs.

136 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Compress the belleville washers and remove thesnap ring retainer, belleville washers and clutch piston wear plate.

137 To remove the clutch piston turn the clutch over and tap the shaft on a block of wood.

138 Disassembly of F Clutch Using a suitable puller, remove the gear and rear bearing inner race.

139 Remove the gear locating ring from the shaft.

140 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the thrust bearing and clutch gear snap ring, followed by the outer thrust washer, thrust bearing and inner thrust washer. Then remove the clutch gear and hub with the pilot bearings.

141 Remove the outer thrust washer, thrust bearing and inner thrust washer.

142 Remove the clutch disc end plate retainer ring.

143 Remove the end plate and 5 friction and 5 steel separator discs.

144 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Compress the belleville washers and remove the snap ring, followed by the snap ring retainer, belleville washers and the clutch piston wear plate.

145 Remove the clutch piston by turning the clutch pack over and tapping the shaft on a block of wood.

146 Clean and inspect all parts for damage. Where damage is evident replace parts and also all gaskets. NOTE: It is more economical to replace parts when the unit is disassembled than to carry out overhaul due to premature faliure. Reassembly of the E Clutch If new seal rings have been fitted to the piston make sure they have been sized. After sizing wipe the surfaces with a little transmission oil, the fit to the clutch housing.

147

604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Place the clutch piston wear plate onto the piston, then place the first belleville washer on top of the wear plate with the large diameter downwards, then alternate the remaining 6 washers followed by the snap ring retainer. Compress the washers and fit the snap ring.

148 Then fit the 10 steel separator discs and 10 friction discs. Fit a steel separator plate first and then alternate the friction and separator discs. Finish with the clutch disc end pate.

149 Then fit the end plate retainer ring.

150 To check the clutch disc clearance, place the clutch plate on end as shown so that the clutch discs are resting on the piston. Measure the distance between the end plate and the retainer ring using a set of feeler gauges. The measurement should be within the limits of 2.03 -- 3.43 mm (0.08 -- 0.135 inches). If the clearance is greater than 3.43 mm (0.135 inches) add one steel sepataror disc under the end plate.

151 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Position the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

152 Press the 2 pilot bearings into the clutch gear and hub. Press the bearings flush with the face of the gear. Place the clutch gear and hub on the shaft.

153 Position the inner thrust washer, thrust bearing and outer thrust washer over the shaft onto the top of the gear. Offer the side of the bearing up to the shaft on top of the thrust washer and visually check the snap ring will fit. If it does not, ensure the gear and hub assembly is fully seated on the discs.

154 With the bearing shield upwards press on the shaft bearing.

155 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Fit the snap ring.

156 Fit the oil slip rings. Use some vaseline to facilitate reassembly into the housing.

157 Reassembly of the F Clutch If new seal rings have been fitted to the piston make sure they have been sized. After sizing wipe the surfaces with a little transmission oil, then fit to the clutch housing.

158 Install the clutch piston wear plate onto the piston, then place the first belleville washer on top of the wear plate with the large diameter downwards. Then alternate the remaining 4 washers followed by the snap ring retainer.

159 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Fit the 5 steel and 5 friction discs. Fit a steel separator disc first and then alternate the friction and separator discs. Finish with the clutch disc end plate.

160 Install the end plate retainer ring.

161 Install the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

162 Press the pilot bearings onto the clutch gear and hub, ensuring the bearings are pressed flush with the gear face. Place the clutch gear and hub onto the shaft.

163 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Place the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

164 Using circlip pliers position the thrust washer retaining circlip and clutch shaft locating circlip. Then install the gear with the conical section downwards onto the snap ring.

165 Press the roller bearing inner race onto the clutch shaft with the bearing race shoulder down.

166

604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Regulator valve disassembly Using a suitable punch tap the valve retaining pin from the regulator valve sleeve. NOTE: The valve is under spring pressure.

167 Remove the regulator valve piston and spring.

168 Regulator valve reassembly is the reverse of the disassembly. Clean and inspect all parts.

604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Disassembly of the modulator valve Remove the inner, middle and outer springs and stop pin from the housing sleeve.

169 Remove the accumulator spool.

170 Remove the cross pin which is approximately 1/3 the way up the housing sleeve, it should also be the shorter of the two pins in the sleeve.

171 Remove the regulator spool, spring, spring retainer and spacer from the housing sleeve.

172 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the cross pin in the end of the sleeve, this will be the longer of the two pins.

173 Reassembly Refit the shortest pin 1/3 the way up the sleeve and fit the spring retainer, spacer, spring and regulator spool. Compress the regulator spool by hand and push in the end (larger) pin. NOTE: The regulator spool can bottom out on the spring retainer. Care shouold be taken to ensure the spring retainer slides inside the spool.

174 In the other end of the sleeve, place the accumulator spool as shown.

175 Then fit the outer, middle and inner springs and then install the stop pins.

176 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Disassembly of the manifold plate Remove the reverse idler gear retaining nut and washer.

177 Then remove the end plate with dowel pin, reverse idler gear, bearing and thrust washer.

178 If the reverse idler shaft is to be replaced, support the manifold plate around the idler shaft and press the idler shaft from the plate.

179 Using a suitable punch, tap out the pump drive idler shaft from the manifold plate and remove the shaft and thrust washer. In some instances this may come out with the converter housing plate, however for reassembly the idler shaft and gear must be fitted to the manifold plate.

180 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

The stator support is held in place by two retaining rings, remove the retaining ring from the converter side of the stator. Then push the support back into the transmission side to expose the second retaining ring and remove it.

181 Remove the stator support and thrust washer.

182 Remove the stator support oil sealing ring and expander ring.

183 If the bushing and/or bearing need to be removed, the bushing must be removed from the same end as the needle bearing.

184 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Compress the safety valve using a suitable hand tool and remove the retaining washer. Remove the spring, and from the other side of the manifold plate, remove the poppet valve.

185 Reassembly of the manifold plate Reassemble in the reverse order of disassembly.

604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Disassembly of the converter housing From the top of the housing remove the hexagonal drive plug. Then using a small screwdriver, lever out the check valve ball assembly and remove from the top of the housing.

186 Remove the torque converter bearing.

187 Remove the oil distributor and ’O’ rings.

188 Remove the converter oil seal.

189 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Remove the pressure test plug for the C clutch and then using a suitable hexagonal drive remove the distributor lock screw.

190 Using a suitable puller remove the C & D oil distributor sleeve.

191 Remove the F clutch pressure test plug and using a hexagonal drive remove the distributor locking screw. Then using a puller remove the E & F distributor sleeve.

192 Reassembly Reassembly of the converter housing is done in the reverse order of disassembly. Ensure the chamfered end of the distributers are upwards.

604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Reassembly of transmission Install the forward/reverse (A/B) distributor sleeve with the inside diameter chamfer out, and the notch in the distributor aligned upwards with the retaining screw hole in the housing.

193 Apply some thread lock to the lock screw and install in the housing. Then install the plug.

194 Install the forward/reverse shaft rear bearing.

195 Install the output flange shaft complete with seal, bearing and bearing to shaft snap ring.

196 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Install the C/D shaft rear bearing.

197 Position the D clutch gear and shaft through the bearing and onto the output flange.

198 Position the oil suction tube and screen in the transmission case. Push the suction tube through the opening in the case and install the ’O’ ring.

199 Position the oil baffle in the transmission case, fit the fixing bolts and tighten to the specified torque.

200 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Firstly position the C/D clutch pack. Align the splines of the D gear & hub already fitted with internal teeth of the friction disc.

201 Position the reverse/forward (A/B) clutch packs and shaft. Use caution so as not to damage the shaft oil slip rings.

202 Install the E/F clutch pack and shaft rear roller bearing into the casing and then fit the shaft and clutches.

203 Fit a new gasket to the transmission case using a light coat of grease to hold it in position.

204 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Install the manifold plate onto the main transmission housing. Use the dowel pins to locate the manifold plate correctly. Ensure the manifold plate is tight against the transmission case before installing the bolts. Do not use the bolts to pull the plate to the housing.

205 Install the manifold plate to transmission housing bolts and tighten to the correct torque. Remember the allen bolt on the other side of the manifold plate

206 Position the impeller hub gear onto the stator support.

207 Position the manifold plate to converter housing gasket using a light coat of grease to hold the gasket in place.

208 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Position the converter housing onto the manifold plate. To assist with this the transmission can be laid on its back so the manifold plate is horizontal. The converter housing to manifold plate bolts must not be fitted until the two faces are tight against each other.

209 Fit the housing bolts recommended torque.

and

tighten

the

210 Install the converter locating snap ring on the turbine shaft.

211 Slide on the torque converter and fit the torque converter retaining snap ring.

212 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

With a new ’O’ ring fitted, install the bore plug into the converter assembly and fit the plug retaining snap ring.

213 Fit the five solenoid valves, ’O’ rings solenoid coils and nuts.

214 Fit the modulation diverter to the housing.

215 Fit a new ’O’ ring to the bottom of the transmission valve sleeve, install the sleeve and spring assembly into the transmission housing.

216 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Fit the modulator valve housing, complete with new ’O’ ring, into the transmission housing and tighten to correct torque.

217 Install the regulator valve using the fabricated tool and tighten to the correct torque.

218 Refit the filter onto the regulator valve.

219 With a new gasket in place, install the transmission pump, and tighten to the correct torque.

220 604.55.181.01 09-- 2004

SECTION 21 -- POWERSHIFT -- CHAPTER 3

Install the drive plate onto the torque converter and tighten the bolts to the specified torques.

221 Transmission Oil Cooler The supplementary transmission oil cooler is mounted in the reservoir compartment. The oil cooler radiator (1), the electric fan assembly (3) and the thermostatic switch assembly (5) are serviced as individual assemblies, or as a complete unit. Replacing The Thermostatic Switch Before replacing the thermostatic switch, place a drain tray under the switch location and have the new switch available. Ensure the engine has been switched off for at least 10 minutes to relieve residual pressure. Also ensure that the oil has cooled sufficiently to prevent the risk of injury. Remove the switch connector and replace the switch (5). Reconnect the harness. The switch should activate the fan when the oil temperature reaches 70°C. Replacing The Electric Fan Assembly The fan (3) is mounted to the oil cooler radiator (1) with six screws. The fan wiring has harness connector.

604.55.181.01 09-- 2004

222

SECTION 21 -- POWERSHIFT -- CHAPTER 3 Replacing The Oil Cooler Radiator Assembly The radiator assembly (3) is bolted (4) to a mounting frame (2), which in turn is mounted to the compartment panel (1). Place a suitable drain train under the radiator location. Also ensure that the oil has cooled sufficiently to prevent the risk of injury. Disconnect the fan and switch harness connectors. Disconnect the inlet and outlet hoses and plug to prevent contamination. Remove the mounting frame bolts (6) and remove the radiator assembly and grill (5). Change over the mounting frame (2), fan, and thermostatic switch to the new radiator. Install the new assembly and grill and secure with the mounting bolts (6). Reconnect the hoses and electrical harness connectors. Transmission Oil Cooler Electrical System

1. 2. 3.

Fan Relay K19 Thermostatic Switch Fuse F28 -- 10 A In line Main Fuse F29 -- 25A

223

The oil cooler electrical system is an individual circuit connected directly to the battery.

4. 5. 6.

Battery Thermostatic Switch Fan

224

Wiring Colours j. Yellow j--vt. Yellow & Green r. Red

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SECTION 21 -- POWERSHIFT -- CHAPTER 3

NOTES

604.55.181.01 09-- 2004

SECTION 23 -- DRIVE LINES -- CHAPTER 1

SECTION 23 -- DRIVE LINES Chapter 1 -- Drive Lines CONTENTS Section

Description

Page

23 000

Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TIGHTENING TORQUE Lower Shaft Centre Drive Flange Bolts Centre Bearing Retaining Bolts Centre Bearing Hub Retaining Nut

100 Nm / 75 lbf.ft 100 Nm / 75 lbf.ft 406 Nm / 305 lbf.ft

604.55.181.00 09-- 2003

SECTION 23 -- DRIVE LINES -- CHAPTER 1

Description

1 Transmission and Axle Drive Line

Drive Line Power Flow Engine power is transmitted from the transmission to the front axle transfer box gearbox by the upper drive shaft. Within the transfer box, gears transfer power directly to the front axle pinion shaft and, by the lower drive shaft, to the rear axle pinion shaft. The lower shaft is a two piece shaft with a centre support bearing assembly. 1. 2. 3. 4. 5. 6.

Mounting Block Retaining Bolt Bearing Support Retaining Bolt Centre Universal Joint Rear Shaft Bearing & Bracket Assembly Front Shaft

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SECTION 23 -- DRIVE LINES -- CHAPTER 1

Drive Shaft Removal The front axle transfer box (1) must be removed for access to the front end of the drive shafts.

3 Rear Lower Driveshaft 1. Remove the lower driveshaft guard 2. Support the centre of the shaft with a stand. 3. Remove the four bolts (5) from the front universal joint flange (1). 4. Remove the rear universal joint (3) spider retaining bolts. 5. Lower the shaft and remove from under the chassis.

4 Upper Driveshaft 1. Remove the access plate above the rear lower driveshaft.(2, Figure 4) 2. Remove the upper shaft rear universal joint retaining bolts (1)

5 3. Remove the upper shaft front universal joint retaining bolts (1) The upper shaft universal joint spiders can be removed and replaced without removing the shaft from the unit. 4. The lower front driveshaft (3) must be disconnected from the transfer box (2) and the front axle removed to replace the upper driveshaft.

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SECTION 23 -- DRIVE LINES -- CHAPTER 1

Front Lower Driveshaft If not previously done:-1. Remove the lower driveshaft guards 2. Remove the four bolts from the drive flange (3) and separate the rear shaft.

7 3. If the bearing is to be replaced, slacken the hub (2) retaining nut in the centre of the hub.

8 4. Remove the four bolts from the front universal joint flange (3). 5. Support the front of the shaft with a stand. 6. Remove the bearing mounting bolts (1, fig 8). 7. Lower the shaft and remove from under the chassis.

9 Driveshaft Installation 1. Install upper shaft first. 2. Ensure the universal joint flange yokes are in line on the two section shafts 3. Tighten retaining bolts to specified torques.

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SECTION 23 -- DRIVE LINES -- CHAPTER 1

Centre Bearing Replacement Slacken the hub retaining nut (2) before removing the shaft from the unit. 1. 2. 3. 4.

Bearing Assembly Retaining Nut Tapered Bearing Hub Front Shaft Splines

1. Remove the nut (2), and slide the bearing and hub from the front shaft. 2. Use a hydraulic press to push the tapered hub through the bearing. 3. Press a new bearing onto the hub and locate the assembly onto the driveshaft splines. 4. Fit the retaining nut, tightening to specified torque should be done after the shaft has been installed into the unit.

11 1. 2. 3. 4. 5.

Front Shaft Assembly Bearing & Bracket Assembly Mounting Block Bearing Hub Retaining Nut

Lower Driveshaft Components 6. Rear Shaft Assembly 7. Threaded Collar 8. Drive Flange 9. Drive Flange 10. Universal Joint Spider & Bearings

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SECTION 23 -- DRIVE LINES -- CHAPTER 1

12 1. 2. 3.

Drive Flange Threaded Collar Shaft Assembly

Upper Driveshaft Components 4. Universal Joint Spider & Bearings 5. Transmission Output Shaft Universal Joint Spider & Bearings

The driveshaft components are available as service parts. Repair kits are available for the universal joints. Inspect the shafts for damage and wear. Ensure the drive flange and shaft slide freely on their splines. If suitable for further service, install new universal joint spiders and bearings.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

SECTION 25 -- FRONT AXLE Chapter 1 -- Front Axle CONTENTS Section

Description

Page

25100

Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer gearbox, centre drive (crown wheel and pinion) and integral steering cylinder. Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2110 mm Oil capacities Hubs/each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 litre (1.76 pints) Axle differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 litres (1.9 gallon) Transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 litres (1.0 pint) Oil change period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours Lubricants Hub and transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambra hypoid 90 (80W90) Axle differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambra Multi F (20W30)

CLEARANCES AND ADJUSTMENTS Front wheel toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 -- 2 Ncm Drive pinion bearing rolling resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 -- 170 Ncm Differential bearing rolling resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ncm Pinion to crown wheel backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 -- 0.23 mm .

SPECIAL TOOLS Pinion Nut Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297410 Hub Seal Installer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297409

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SECTION 25 -- FRONT AXLE -- CHAPTER 1 SEALANTS

Thread sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH 82995773 Dowel Fixative adhesive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH 82995772 Flange sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH 82995770

TORQUE SPECIFICATION

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

DESCRIPTION

The axle fitted to this unit incorporates: • Integral steering cylinder • Steering sensor • Central drive

• • •

Double reduction (crown wheel and pinion plus planetary hubs) Transfer gearbox Power brake and park brake

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

Engine power is transmitted from the engine through the transmission to the front axle via a drive shaft.

3 The transfer box transmits drive to the front axle and also to the rear axle to give constant four wheel drive.

4 Transfer gearbox ratio (E/F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1.125 Differential ratio (D/C) or (I/J) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2.82 . Planetary reduction ratio (B/A) or (K/L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:6 .

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

5 Front axle components -- Cut--away view 1. 2. 3. 4. 5. 6. 7. 8.

Differential casing Differential Crown wheel Brake discs Brake piston Hand brake actuator Drive shaft Shaft retaining nut

9. Hub pivot 10. Universal joint 11. Planet gear 12. Ring gear 13. Hub 14. Hub seal 15. Steering cylinder 16. Pinion

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

The data plate mounted on the axle, details the manufacturing code, axle model and serial number.

TAGAWS012

6 Steering stops (1) are incorporated onto the hubs at each end of the axle. The stops are adjustable to prevent the tyres contacting any part of the frame or cab when on full lock and held by the locknut.

7 When checking the tracking ensure the front wheels are straight ahead using the steering position indicator lamp in the cab. Measure the distance between the two front wheels at the front of the rim A. Then measure the distance between the front wheel at the rear of the rim B. The variance between A and B should be 0 -- 2 mm (0 -- 0.078 in) Toe--in. i.e. B--A = 0 -- 2 mm

8 Tracking Specification 0 -- 2 mm (0 -- 0.78 in) To adjust front wheel toe-in slacken both lock nuts and turn rims equally to correct toe-in measurement. Re-tighten both lock nuts. 1. 2.

Steering knuckle adjuster Lock nut

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

FRONT AXLE -- HOUSING Oil capacity -- 8.5 litres (1.9 imp gals) Check oil level every 50 hours, check using plug (2). Change oil every 1200 hours -- drain from plug (3). NOTE: There are two plugs, one located at the bottom of each trumpet housing. These should be removed to allow all oil to be drained.

TRANSFER GEAR BOX Oil capacity -- 0.6 litres (1.0 imp pints) Check oil level every 50 hours, check using plug (2). Change oil every 1200 hours, drain from plug (1).

HUBS Oil capacity -- 1.0 litres (1.76 imp pints) Check oil level every 50 hours, with hub level plug (1) in the middle position. Change oil every 1200 hours, with plug (1) at the lowest point.

COMPONENT OVERHAUL Axle in situ The following components can be overhauled with the axle mounted on the unit. • Steering cylinder • Planetary reduction hub assembly • Swivel casing • Swivel pin • Axle drive shafts, seals and bushes 13 604.55.181.00 09-- 2003

SECTION 25 -- FRONT AXLE -- CHAPTER 1

AXLE REMOVED The following components can be overhauled with the axle removed. • Transfer gear box • Brake assemblies • Differential assembly • Pinion assembly

AXLE REMOVAL PROCEDURE •

Extend boom and lower to the ground

• •

Chock rear wheels Chock rear axle

• •

Jack-up machine and secure on axle stands Remove axle and driveshaft guards from under the chassis Remove the upper and lower drive shafts

•

15 • • •

• • •

Remove wheels Disconnect park brake cable (1 & 5) Disconnect steering hoses NOTE: Ensure both pipes are plugged preventing constant oil leaking. Remove brake pipe (2 & 3) Disconnect steering angle sensor (4) Support axle and remove the eight fixing bolts.

16 NOTE: Some items which require servicing after axle removal may be more easily loosened while the axle is in-situ, i.e. steering tie rod ends.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

OVERHAUL Planetary Reduction Assembly and Wheel Hubs Drain hub oil.

17 Remove the two allen screws which secure the planetary carrier assembly to the hub assembly.

18 Gently tap the planetary carrier with a soft face mallet and using the slots provided, lever the carrier from the hub. Remove ‘O’ ring seal.

19 Remove the circlip and lever the planetary gear and bearing from the carrier.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

Check components for wear and replace worn or damaged components and then reassemble. 1. 2. 3.

Planetary carrier Planetary gear and needle roller bearings Circlip

Remove the eight hub bolts,and then remove the spacer plate.

21 Using a puller, remove the planetary ring gear.

22 Remove the conical hub bearing.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

Using a rubber mallet, tap the hub until loose. Then remove the hub by hand.

24 Steering rod end ball joint removal Remove the locking pin, loosen and remove the nut. Remove the tapered rod end ball joint using a puller or a copper hammer.

25 Swivel pin removal Remove the upper and lower swivel pins from the axle hubs. Remove the rubber grease rings.

26 Swivel housing removal Carefully remove the swivel housing from the axle.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

Handbrake lock NOTE: Before removal of the shaft retaining pin and drive shafts the handbrake actuator should be levered ‘ON’ using a wrench and a metal retainer placed behind the stop. This holds the brake discs in position and allows replacement of the shaft without trumpet housing removal.

28 Shaft retaining lock nuts Using a wrench, loosen the lock nuts. Then, using a suitable allen key, unscrew the pin. NOTE: This axle has retaining nuts top and bottom.

29 Axle shaft removal Withdraw the shaft from the axle housing.

30 Swivel hub seal removal Remove the seal from the swivel casing using a slide hammer and an internal puller.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

Swivel pin bearing removal Remove the swivel pin bearings using a puller and slide hammer.

32 Removal of lower swivel pin bearing cone Hold the swivel in a soft jawed vice and using a suitable drift carefully tap off the bearing cone from the swivel.

33 Removal of shaft bearing and seal housing To remove the bearing and seal housing remove the circlip and tap the seal housing with a rubber mallet. This will remove the bearing with the housing. 1. 2. 3.

Inner dust seal Outer ‘O’ ring seal Inner oil ring seal

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

Reduction hub, swivel housing and axle shaft reassemble

35 Hub oil seal fitment To fit the ‘cassette’ type oil seal use tool 297409 as this will place the seal accurately at the correct depth.

36 Swivel housing seal installation To install the seal use a suitable oil seal installer.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

Installation of swivel pin bearing cone Before assembly of a new cone, ensure the swivel area is thoroughly clean. Using a suitable installer, gently tap with a hammer until seated.

38 Installation of the lower swivel pin bearing cone Thoroughly clean the swivel shaft and check for damage or scoring. Carefully stone any imperfections away before fitting a new cone. Using a suitable spacer, press on the new cone until seated.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

STEERING CYLINDER REMOVAL Using an allen key, remove the fixing screws of the steering angle sensor and remove the sensor (1).

40 Remove the left side track rod end to accommodate removal of the cylinder through the differential housing.

41 Remove the hydraulic fittings left and right (1) and the snap ring (where fitted) on the left (2) from the ram cylinder. Then remove the four allen bolts.

42 Then, using a rubber mallet, hammer the ram cylinder on the end opposite to were the allen bolts were removed and pull out the complete ram assembly.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

44 1. 2. 3. 4. 5. 6. 7.

Circlip Snap ring Inner Dust seal Gland Outer Seal Gland Block Gland Inner Back up Seal Gland inner Seal

8. Piston Seal 9. Magnetic Ring 10. O Ring 11. Seal 12. Ram Rod 13. Ram Cylinder

DISASSEMBLY To disassemble the steering cylinder remove the circlip first then tap the end of the gland block back into the cylinder until the snap ring lines up with the small access hole on the cylinder wall. Using a suitable tool push through the access hole to extract the snap ring and then lever out using a small screwdriver. With the snap ring removed tap the steering rod end piston which will push out the gland block. To fit new seals place in warm water for 5 minutes for easy fitment and after fitment allow the seals to cool and shrink to fit. Lubricate all the new seals and reassemble the steering cylinder in reverse sequence to disassembly.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

TRANSFER GEARBOX DISASSEMBLY To assist in removal of the two couplings fabricate the tool in the diagram opposite.

46 Secure the tool to the coupling and, using a suitably sized socket, undo the coupling nut. Repeat the procedure on the lower drive coupling.

47 Remove the transfer gearbox front casing retaining bolts. Using a pry bar and the two lever points, separate the front casing and differential housing. Holding the top shaft remove the front casing complete with top shaft.

48 Disassemble the front casing and top shaft by firstly replacing the central locking nut onto the top shaft. Then, using a rubber mallet, tap the shaft and components away from the casing.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

Using a bearing puller remove the bearing on either side of the gear. Then remove the shim and the gear from the splined portion of the shaft.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

AXLE TRUMPET HOUSING REMOVAL Remove the right and left brake connecting pipe.

51 Take the weight of the trumpet housing using either a strap or chains, then remove all the fixing bolts.

52 Remove the axle at the same time as removing the brake discs. NOTE: Both side casings can be removed without disturbing the differential as this is held in by a side plate. The front brakes consist of four friction discs and five static plates each side.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

To remove the brake piston housing, firstly remove the three return springs (1) and the three piston guides (2). Then withdraw the piston (3) by hand.

54 To remove the handbrake assembly, firstly unscrew the handbrake actuator fixing screw.

55 Before removal of the actuator from the splined shaft mark across the shaft and actuator to assist in reassembly.

56 Remove the bush and seal and then the handbrake pivot.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

58 Front Axle Trumpet Housing Components 1. 2. 3. 4. 5. 6. 7. 8.

Fixed separator discs Brake piston Piston seals Handbrake actuator Bleed nipple Brake feed union Trumpet housing Bush and seal

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9. Actuator retaining screw 10. Drive shaft 11. Handbrake lever 12. ‘O’ ring seals 13. Screws 14. Piston return springs 15. Piston guides 16. Brake friction discs

SECTION 25 -- FRONT AXLE -- CHAPTER 1

8 59 Differential Components 1. 2. 3. 4. 5. 6. 7.

Planetary carrier Thrust washer Planetary gear Side gear plate End plate Friction discs Separator plates

8. ’O’ ring oil seal 9. Differential case 10. Crown wheel fixing bolts 11. Differential bearings 12. Side gear 13. Housing side plate

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

SHJ25056

60 Drive Pinion Components 1. 2. 3. 4. 5. 6.

Pinion lock nut Transfer gearbox cover Oil seal Output coupler Coupler retaining bolt Rear bearing

The differential housing consists of the pinion and the differential assembly with crown wheel. If for some reason either the pinion or crown wheel need replacing, both must be changed together as they are matched at manufacturing. Although the front and rear axles appear different due to the transfer box on the front axle, both set up procedures are the same for the pinion and crown wheel. The differential is not a serviceable item as the planetary carriers are pressed into position during manufacture and are held by an internal circlip which cannot be accessed after production.

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7. Front bearing 8. Pinion 9. Preload shims 10. Pinion height shims 11. Bearing spacer

The only purpose in removing the differential case bolts are 1. The crown wheel needs replacing. 2. The limited slip plates need inspection and measuring. 3. The side gears, planetary gears and thrust washers need inspection for damage.

SECTION 25 -- FRONT AXLE -- CHAPTER 1

DIFFERENTIAL ASSEMBLY REMOVAL Prior to disassembly of the differential the axle side casing must be removed and also the transfer front cover and top shaft. Loosen and remove the 4 Allen bolts and remove the side cover of the differential housing.

61 The differential can then be removed as a complete assembly.

DIFFERENTIAL DISASSEMBLY Remove the 12 bolts from the crown wheel and lift off the crown wheel. The side gears and limited slip plates can then be removed for inspection.

63 To judge the amount of limited slip plate wear measure the plates with a gauge. They should measure 18.2 mm +/-- 0.2 mm.

The planet gears cannot be removed, however, after removal of the side gear and slip plates, the planet gears, carriers and thrust washers can only be inspected for damage or wear. 64 604.55.181.00 09-- 2003

SECTION 25 -- FRONT AXLE -- CHAPTER 1

PINION DISASSEMBLY Fit tool number 297410 onto the pinion nut. Then slide the fabricated tool used to disassemble the transfer gearbox with the coupler attached onto the end of the pinion shaft. Fit a 3/4” drive bar to the tool and remove the nut. Using a rubber hammer drive the pinion gently into the casing and remove.

65 The pinion is inscribed with two numbers. 1. 2.

Pinion and crown wheel serial number Pinion height number

These two numbers should be the same on each component.

66 Pinion height adjustment is only neccessary when a new pinion is being fitted. The adjustment of the pinion height is achieved by the following calculations. 1. Note the pinion height measurement inscribed on the original pinion head. 2. Note the pinion height measurement inscribed on the new pinion head. 3. Original pinion height -- new pinion height = +/-- adjustment. If the value is positive (+) add this amount of shims to the shim pack. If the value is negative(--) remove this amount from the shims in the original shim pack. Important Whatever amount of pinion height shims are added or taken away, the same adjustment should be carried out on the smaller diameter preload shims.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

PINION BEARING PRELOAD Assemble the pinion into the housing with a new bearing spacer. To check the pinion preload use a torque meter capable of measuring Ncm. Preload = 120 -- 170 Ncm. Each 0.10 mm shim approximately equals 50 Ncm. Shim thickness Pinion height shims

Preload shims

0.10

0.15

0.20

0.30

0.40

0.50 Before installing the differential remove the top housing plug by tapping out from the inside of the housing, this facilitates backlash measurement later.

DIFFERENTIAL PRELOAD After setting the preload on the pinion the differential can be assembled into the housing and the side cover replaced.The preload measurment is taken via the pinion shatf as shown previously. The preload should increase by only 10 Ncm so for example if the pinion preload was 150 Ncm the pinion and differential combined preload should be 160 Ncm. If the preload needs to be increased rotate the two adjusters into the casing which compresses the bearings. Rotate the adjusters out of the casing to lessen the preload.

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SECTION 25 -- FRONT AXLE -- CHAPTER 1

CROWN WHEEL TO PINION BACKLASH To check the backlash use a dial gauge mounted on top of the housing and measure through the access hole as shown.

68 The backlash should be 0.15 -- 0.23 mm. To adjust the backlash firstly mark (2) the adjusters on both sides with relation to the housing. Then move the adjusters (3) so that the preload does not change. This is done by moving one adjuster into the casing and the other out from the casing or vice versa, pushing the crown wheel towards the pinion decreases the backlash, pulling the crown wheel away from the pinion increases the backlash. Use the housing mark to judge equal movement on each side so that the preload doesn’t change. Refit the allen screw (1) to lock the adjuster in position. 69

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SECTION 27 -- REAR AXLE -- CHAPTER 1

SECTION 27 -- REAR AXLE Chapter 1 -- Rear Axle CONTENTS Section

Description

Page

27100

Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Load Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centre drive (crown wheel and pinion) with integral steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . and planetary reduction hubs. Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2110 mm Oil capacities Hubs/each . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 litre (1.76 pints) Axle differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 litres (1.9 gallon) Oil change period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 hours Lubricants Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambra hypoid 90 (80W90) Axle differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambra Multi F (20W30)

CLEARANCES AND ADJUSTMENTS Wheel toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 -- 2 mm Drive pinion bearing rolling resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 -- 170 Ncm Differential bearing rolling resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ncm Pinion to crown wheel backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 -- 0.23 mm .

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SECTION 27 -- REAR AXLE -- CHAPTER 1 SEALANTS

TORQUE SPECIFICATION

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SECTION 27 -- REAR AXLE -- CHAPTER 1

DESCRIPTION

The axle fitted to this unit incorporates: • Integral steering cylinder • Steering sensor • Central drive

• •

Double reduction (crown wheel and pinion plus planetary hubs) Power brakes

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SECTION 27 -- REAR AXLE -- CHAPTER 1

Engine power is transmitted from the engine through the transmission to the front axle via a drive shaft.

3 The transfer box transmits drive to the front axle and also to the rear axle to give constant four wheel drive.

4 Transfer gearbox ratio (E/F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1.125 Differential ratio (I/J) or (C/D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2.82 . Planetary reduction ratio (K/L) or (A/B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:6 .

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SECTION 27 -- REAR AXLE -- CHAPTER 1

5 Front axle components -- Cut--away view 1. 2. 3. 4. 5. 6. 7. 8.

Differential casing Differential Crown wheel Brake discs Brake piston Drive shaft Shaft retaining nut Hub pivot

9. Universal joint 10. Planet gear 11. Ring gear 12. Hub 13. Hub seal 14. Steering cylinder 15. Pinion

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SECTION 27 -- REAR AXLE -- CHAPTER 1

LOAD SENSOR The load monitor strain gauge is located on the top of the axle shaft housing. The gauge measures the deflection of the axle in operation with differing loads and signals a load indictor panel in the dash to warn the operator of the load conditions and related stability.

6 An optional safety feature can be fitted to the loader hydraulics to neutralise the hydraulics if the safe working load is reached.

7 The load monitor system operation and fault finding are described in Section 55, Chapter 6.

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SECTION 27 -- REAR AXLE -- CHAPTER 1

COMPONENT OVERHAUL Axle in situ The following components can be overhauled with the axle mounted on the unit. • Planetary reduction hub assembly • Swivel housing • Swivel pin • Axle drive shafts, seals and bushes

8 Axle removed The following components can be overhauled with the axle removed. • Brake assemblies • Differential assembly • Pinion assembly

AXLE REMOVAL PROCEDURE • •

Chock front wheels Jack-up the rear of the machine and secure on axle stands • Remove the drive shaft • Remove the wheels • Remove the steering hoses left and right • Remove the brake pipes • Disconnect steering angle sensor • Remove the load monitor strain gauge retaining screws and separate from the axle. • Using a trolley jack support the weight of the axle in the middle • Loosen and remove the four axle retaining bolts • Using the trolley jack lower and pull the axle from under the machine NOTE: Some items which require servicing after axle removal may be more easily loosened while the axle is in-situ, i.e. steering tie rod ends.

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SECTION 27 -- REAR AXLE -- CHAPTER 1

OVERHAUL Pivot bushes Remove the front and rear pivot casing from the axle and lever the bushing from the casing. Inspect the bush and pivot for wear NOTE: The internal diameter of the bush is slightly ovalled, therefore the vertical distance is 0.8 mm larger than the horizontal dimension. This is for the operation of the axle load sensor. SHJ27006

10 The axle fitted to the rear of the Telescopic Handler is almost identical to that fitted to the front. Therefore when overhauling the following components refer to Section 25. • Axle hubs • Swivel housing • Axle shafts • Axle trumpet housing • Brake housing • Differential Crown wheel and Pinion • Steering cylinder

LOAD SENSOR INSTALLATION The load monitor strain gauge is located on the top of the axle shaft housing. 1. When replacing the strain gauge (3) ensure the machined pad is clean. 2. Locate the strain gauge on the axle and install the retaining screws (1) and tighten to 90 Nm (68 lbf.ft) DO NOT OVER TIGHTEN THE RETAINING SCREWS 3. Fit the cover and seal (2), then tighten retaining screws. 11

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SECTION 33 -- BRAKES -- CHAPTER 1

SECTION 33 -- BRAKES Chapter 1 -- Brake Overhaul CONTENTS Section

Description

Page

33 000

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Brake Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Brake Master Cylinder Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disc Brake Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SPECIFICATIONS Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powered Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet Disc, Piston operated Brake Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LHM Brake Discs

(Front Axle per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 (Rear Axle per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SPECIAL TOOLS Pressure Test Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380001667

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SECTION 33 -- BRAKES -- CHAPTER 1

Description and Operation The front and rear axles have inboard wet disc brakes with four discs per side. The front and rear brakes are hydraulically applied by a foot operated, servo assisted, master brake cylinder. The trailer brake valve is also applied simultaneously by the same circuit. LHM brake fluid is used in the brake circuit. The hand brake operates the front brakes mechanically.

The servo assistance is provided by the 40 bar servo circuit supplied from the pressure reducing valve. When the brake pedal is depressed, pressure in the load sensing line operates the pump flow divider valve to provide priority oil flow to the pressure reducing valve and steering motor. The accumulator is also charged by the servo circuit to provide a pressure reservoir for brake servo assistance with the engine off.

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SECTION 33 -- BRAKES -- CHAPTER 1

Braking System

System Pressure Oil

Suction Oil Reservoir Brake Fluid

Reservoir Return

Brake Pressure

Servo Pressure Oil

1. 2. 3. 4.

Front Axle Disc Brakes Load Sensing Line Shuttle Check Valve Pressure Reducing Valve & Accumulator Hydraulic Pump & Flow Divider

5. 6. 7. 8.

Rear Axle Disc Brakes Trailer brake Valve Brake Fluid Reservoir Servo Assisted Master Cylinder

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SECTION 33 -- BRAKES -- CHAPTER 1

2 1. 2. 3.

Braking System Circuit Diagram 4. Rear Disc Brakes Hydraulic Pump & Flow Divider Valve 5. Pressure Reducing Valve & Accumulator Front Disc Brakes Servo Assist Master Cylinder & Reservoir

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SECTION 33 -- BRAKES -- CHAPTER 1

Brake Master Cylinder The servo assisted brake master cylinder and the brake fluid reservoir are located under the instrument console. 1. 2. 3. 4. 5. 6. 7. 8.

Brake Fluid Reservoir Reservoir Hose Brake Fluid Pressure Line Mounting Bolts Servo Circuit Supply Line 40 bar Load Sensing Line to Pump Flow Divider Hydraulic Reservoir Return Line Brake Pressure Switch

4 1. 2. 3. 4.

Brake Servo Housing Brake Piston Assembly Brake Master Cylinder Housing ’O’ Ring Seal

Brake Master Cylinder Components 5. Return Spring & Feed Valve Assembly 6. Plunger Assembly 7. Circlip 8. Washer

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SECTION 33 -- BRAKES -- CHAPTER 1

5 Brake Master Cylinder Operation -- Brakes Released

Servo Pressure Oil

Brake Fluid Zero Pressure

Reservoir Return

Pressurised Brake Fluid

1. 2. 3. 4. 5. 6. 7. 8.

Brake Servo Housing Check Valve Spring Conical Valve Brake Piston Piston Brake Fluid Seal Return Spring Spring Guide Brake Master Cylinder Housing

P. L.

40 bar Servo Supply Load Sensing Line to Pump Flow Divider

9. Brake Fluid Feed Valve Seal 10. Brake Fluid Feed Valve 11. Actuator Pin 12. Spring Seat 13. Piston Oil Seal 14. Snap Ring 15. Check Valve 16. Pushrod Brake Master Cylinder Ports B. Brake Pressure Line R. Brake Fluid Reservoir

N. Return to Hydraulic Reservoir

Brakes Released When the brake pedal is released, the return spring (6) returns the brake piston (4) and the pushrod (16) to the left. In this position the 40 bar servo pressure oil at port P is blocked by the check valve (15). The load sensing line at port L is open to the hydraulic reservoir return port N through the conical valve (3) and drillings in the brake piston (4). The conical valve is restrained by a snap ring (14) which prevents it blocking the drilling in the brake piston.

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The return spring (6) and seat (12) pull the actuator (11) and the brake fluid feed valve (10) clear of the brake fluid reservoir gallery R. The brake cylinder is open to the brake fluid reservoir, allowing the cylinder to be fully charged with fluid.

SECTION 33 -- BRAKES -- CHAPTER 1

6 Brake Master Cylinder Operation -- Brakes Applying

Servo Pressure Oil

Brake Fluid Zero Pressure

Reservoir Return

Pressurised Brake Fluid

Brakes Applying As the brake pedal is depressed, the push rod moves to the right. Initially as the pushrod (16) contacts the brake piston (4), the conical valve (3) closes the central drilling in the brake piston closing off the reservoir return port N from the load sensing port L. The return spring (6) is also compressed allowing the brake fluid feed valve seal (9) to close and seal off the fluid reservoir gallery R from the brake cylinder. Further pushrod travel opens the check valve (15) allowing 40 bar servo pressure oil to apply pressure to the brake piston to provide servo assistance to the brake pedal effort. Brake cylinder fluid pressure increases as further pedal pressure is applied and pressurised fluid is forced out of port B to the brake lines to apply the front and rear axle disc brakes.

Brakes Applied When the brakes are applied sufficiently, the foot pedal pressure will be held constant. Momentarily the brake piston (4) will continue to travel to the right separating from the pushrod (16) allowing the conical valve (3) to close the check valve (15) to cut off the servo circuit pressure supply. However the conical valve (3) remains seated blocking the central drilling in the piston (4) and trapping servo oil between the pushrod and the brake piston. In this condition the brake fluid pressure applied to the brakes remains constant to keep the brakes applied.

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SECTION 33 -- BRAKES -- CHAPTER 1

FAULT FINDING CHART1 START " "

B Are the brakes functioning correctly?

YES

B Is the brake reservoir full?

Top up

YES

B Has the brake system been bled?

Bleed the system

YES

B Is the reservoir level dropping?

Go to chart 2

B Is the pressure from the accumulator valve 40 bar? YES B Are brake lights functioning as the pedal is moved? YES B Disassemble axle, replace seals and check for wear and damage B "

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FINISH

Adjust or repair the accumulator valve

Disassemble the servo, replace all seals and check for damaged components

SECTION 33 -- BRAKES -- CHAPTER 1

FAULT FINDING CHART2 START " "

B Is the brake fluid reservoir level dropping?

YES

B Are there any signs of leakage around the servo, brake pipes and connectors?

YES

Repair the fault

YES B During the 1 minute does the reservoir level drop?

B Remove the output pipe from the connection and fit a plug. Then press the brake pedal for 1 minute. Does the pedal gradually go down to the floor?

Disassemble axle brake assembly, replace the " piston seals and check for damage

Disassemble the servo and replace the brake piston seals

YES B Disassemble the servo and replace the piston guide seals and ’O’ rings which separate the primary and secondary bodies. B "

FINISH

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SECTION 33 -- BRAKES -- CHAPTER 1

Brake Bleeding Procedure The brake bleeding operation requires two people to carry out the procedure efficiently. A suitable collecting container and a 750 mm length of 5 mm I.D. clear hose are required. Always use LHM brake fluid. A pressure bleeder is recommended to ensure all the air is removed from the system. Machine Preparation 1. Remove the instrument access panel.

7 2. Remove the front axle access plate

8 3. Install Pressure Bleeder Top up the brake fluid reservoir and install the pressure bleeder kit. 1. 2. 3. 4. 5.

Air supply hose max 1.2 bar* Transfer hose Air tight adapter cap with non return valve** Brake fluid reservoir Kit Fluid Reservoir

*Ideally the air pressure should be supplied from a compact electric air pump with adjustable preset maximum pressure. ** The reservoir cap is 60mm diameter.

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SECTION 33 -- BRAKES -- CHAPTER 1

10 Brake Pipe and Component Layout An assistant will be required to operate the brake pedal while each bleed point is opened to expel the air from the system. 4. The pressure bleeder should be fitted to the brake reservoir and pressurised to 1.0 to 1.2 bar. 5. Ensure the reservoir is full before commencing the bleeding procedure. 6. Fit a transparent collector tube to each bleed screw in turn and feed the end into a clean container. 7. Loosen the screw while the pedal is slowly depressed and allow fluid and air to escape. When the fluid flow is free of air bubbles close the bleed screw. If the pedal is approaching the end of travel and air is evident in the escaping fluid, close the bleed screw and repeat the bleeding procedure for another stroke of the pedal.

The system should be bled in the following sequence: 1. Rear Axle Left Hand Side 2. Rear Axle Right Hand Side 3. Front Axle Right Hand Side 4. Front Axle Left Hand Side 5. Trailed Brake Valve (where fitted) Keep checking the fluid level during the bleeding operation and top up with specified fluid. NEVER reuse the fluid bled off from the system.

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SECTION 33 -- BRAKES -- CHAPTER 1

Servo Circuit Pressure Testing The pressure test checks the 40 bar servo hydraulic circuit used by the brake master cylinder. 1. Fully retract the telescopic boom. Raise the boom sufficiently to install the safety support 297451 on the lift cylinder.

DANGER DO NOT work under an unsupported boom.

11 2. Remove the control valve access panel from the outside of the cab. 3. Relieve residual servo circuit pressure by operating the brake pedal at least 40 times with the engine switched off. 4. Install test elbow (2) and adaptor (3), tool numbers 380001667 & 380000493, into ’U’ port line and connect a 60 bar gauge (1) and test hose long enough to reach inside the cab.

12 5. Start the engine and run at 2000 rpm. Apply the foot brake several times and observe gauge reading. 6. If maximum pressure is 40--45 bar, the pressure setting is to specification. 7. If the pressure is below 40 bar, remove the valve cap (1) add shims (2) to the spring and repeat pressure test procedure.

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SECTION 33 -- BRAKES -- CHAPTER 1

BRAKE MASTER CYLINDER OVERHAUL The brake master cylinder is located under the instrument panel cover. Remove the four securing screws and remove the panel.

WARNING Before disconnecting the servo connections, pump the brake at least 20 times to release residual line pressure.

14 Brake Master Cylinder Removal 1. Clamp the hose (2) from the reservoir to limit loss of brake fluid. 2. Disconnect wiring from the brake pressure switch (8) and release cable ties. 3. Disconnect the servo supply (5), load sensing (6) and hydraulic reservoir (7) return lines. 4. Disconnect the brake (3) and reservoir (7) return lines.

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SECTION 33 -- BRAKES -- CHAPTER 1

5. Disconnect the brake stop light switch wiring (4). 6. Remove the mounting bolts and (1) withdraw the assembly from above.

Master Cylinder Installation Installation is the reverse of the removal procedure. The pedal stop (3) is adjusted to limit the pedal height when released. The braking system must be bled to remove any air in the system. Use only the specified brake fluid in the system. 16 MASTER CYLINDER OVERHAUL Brake Master Cylinder Assembly 1. 2.

Brake Servo Housing Brake Master Cylinder Housing

Ports P. Pressure Supply from Pump L. Sensing Line N. Return to Hydraulic Reservoir B. Brakes R. Brake Reservoir 1. Remove the two screws and separate the two housings. 2. Disassemble the components following the sequence shown in figures 17 to 22.

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SECTION 33 -- BRAKES -- CHAPTER 1

18 1. 2. 3. 4.

Brake Servo Housing Brake Piston Assembly Brake Master Cylinder Housing ’O’ Ring Seal

Brake Master Cylinder Components 5. Return Spring & Feed Valve Assembly 6. Plunger Assembly 7. Circlip 8. Washer

Push Rod Components 1.

2. 3. 4. 5.

Push Rod Assembly Ball, spring and retainer located in the push rod are not removable in service. Spring Conical Valve Retaining Snap Ring Seal

19 Servo Housing 1. 2. 3. 4. 5.

Housing Bronze Bearing Ring Circlip Stepped Spacer ’O’ Ring Seal

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SECTION 33 -- BRAKES -- CHAPTER 1

Brake Piston 1. 2. 3.

’O’ Ring Seal Brake Fluid Seal Wear Rings

21 Return Spring & Feed Valve Assembly 1. 2. 3. 4. 5. 6.

Actuator Pin Spring Locator Fluid Feed Valve Valve Spring Spring Locator/ Feed Valve Housing Tie Rod

3. Inspect parts for any scoring or wear. 4. A seal kit is the only serviced item.

22 Replacing Fluid Feed Valve The return spring must be compressed to remove and replace the fluid feed valve. A suitable valve spring compressor (1) provides a safe method of this operation. A suitable washer (5) (OD 30 mm/ ID 18 mm) may be required to adapt the return spring to the spring compressor jaws. A clevis pin or bolt, 50 mm long, 8 mm diameter, must be located in the return spring (6) to hold the tie rod in position while installing the new valve (4).

DANGER Never attempt to compress the return spring in a vice or with hand tools. 5. If parts are suitable for further service, install seal kit parts and reassemble using brake grease as a lubricant on the seals. 6. Install the brake master cylinder and bleed the system as previously described.

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SECTION 33 -- BRAKES -- CHAPTER 1

Brake Disassembly Front Axle Remove hub and drive shaft assembly as listed in Section 25.

25 Brake Assembly Front Axle

Brake Piston Assembly Ensure brake piston seals are installed and lubricated with L.H.M. oil to prevent damage when installing. 1. 2. 3. 4. 5. 6.

Brake piston Piston guides Piston guide screws ‘O’ rings and back up seals Piston return springs Handbrake knuckles

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SECTION 33 -- BRAKES -- CHAPTER 1

Brake Disassembly Rear Axle Refer to Section 21 for hub disassembly.

Brake Piston Assembly Ensure brake piston seals are installed and lubricated with L.H.M. oil to prevent damage when installing. 1. 2. 3. 4. 5.

Brake piston Piston guides Piston guide screws ‘O’ rings and back up seals Piston return springs

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SECTION 33 -- BRAKES -- CHAPTER 1

PARKING BRAKE OPERATION The parking brake mechanically applies the brakes on the front axle only. The handbrake is pulled upward to apply the handbrake. This action tensions the handbrake cable which pulls the two actuator levers towards the centre of the axle.

Internally the actuators on each side push the brake piston against the brake discs. The action of the brake discs coming together locks the half shaft to the axle housing effectively locking the wheels.

SHJ33028

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SECTION 33 -- BRAKES -- CHAPTER 1

Handbrake Adjustment There are two adjustment points for the handbrake: 1. at the handbrake lever 2. at the front axle

31 1. At the handbrake lever This adjustment would be carried out by the operator and would be required when the cable stretches or brake discs wear slightly. Turn the end of the lever clockwise to tighten or anti-clockwise to loosen the cable tension. NOTE: Do not overtighten as this will only stretch the cable.

32 2. At the front axle The handbrake will need adjusting at the front axle if • The axle has been removed • Brake components have to be changed • No adjustment is left in the handbrake lever.

Adjustment procedure 1. Place the machine on axle stands so the front and rear wheels are free to rotate. 2. Place the handbrake lever ‘off’ and loosen the cable by rotating the end of the lever anti-clockwise. This facilitates adjustment from the cab after front axle adjustment is complete. 3. Remove the retaining bolts from the front axle cover and place the cover to one side.

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SECTION 33 -- BRAKES -- CHAPTER 1

4. Remove the actuator return spring from each side. 5. For easier access to the cable adjustment nuts loosen the horn bracket to chassis nut, unclip the horn electrical connector and rotate the horn and horn bracket forward. 6. During production or prebuild (see section 25) the actuator lever return stops should be set so that it holds the actuator to just touch the two brake piston knuckles. Then back off the stop nut half a turn. 33 At this position with the handbrake lever off, the cable at the front axle should just be taking up any slackness. Due to worn or changed components this stop position may change. Therefore actuator stops and cable needs to be adjusted. To adjust the actuator lever stops a) remove the cable end clamp (1) from the right hand actuator lever by firstly removing the small split pin and unscrewing the end of the clamp, lift the clamp off the right hand actuator lever ball joint. b) Loosen the two cable lock nuts (2) on the left hand actuator and lift the cable away from the actuator.

34 c) Back of the stop bolts (1) on both sides, then by hand move the levers in the direction of handbraking, the actuator lever should move under little resistance and then stop when the actuator hits the piston knuckles internally. d) Readjust the stops so they hold the actuator lever in the ‘just touching’ position.

35 d) Replace the cable onto the left and right actuator levers leaving the adjustment nuts loose.

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SECTION 33 -- BRAKES -- CHAPTER 1

7. With the actuator lever stops adjusted proceed to move the cable on the left actuator left or right so that the cable between the two actuator levers is just taking up any slackness. When the cable tightness is satisfactory, tighten both the adjustment nuts to lock the outer cable.

36 8. Replace the actuator return springs. 9. Rotate wheels and ensure the brakes are not binding with the handbrake off. 10. Return the horn to its original position, tighten the retaining nut and attach the electrical connection. 11. Replace the front cover and bolts. 12. Remove the axle stands and place the machine on the ground.

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SECTION 33 -- BRAKES -- CHAPTER 2

SECTION 33 -- BRAKES Chapter 2 -- Trailer Brakes CONTENTS Section

Description

Page

33 000

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Trailer Brake Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Trailer Brake Valve Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Trailer Brake Valve Coupling Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SPECIFICATIONS Trailer Brake Valve:

Maximum Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . 140 -- 150 bar Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 -- 80 l/min

Piston Housing Retaining Screw Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm

SPECIAL TOOLS Pressure Test Adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83918233 Complete Coupling Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83918234

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SECTION 33 -- BRAKES -- CHAPTER 2

Description and Operation The trailer braking system provides synchronised hydraulic braking for trailer brakes. A quick release coupling (1) is mounted at the rear of the telehandler.

1 The trailer brake valve is mounted above the transmission. The valve is actuated, simultaneously with the telehandler brakes, by brake master fluid pressure at port Y. The trailer brake valve has a hydraulic pump oil supply port P, reservoir return port T, and brake port B. Port P is connected to the trailer brake coupling and the hydraulic pump priority valve. The trailer brake valve connections into the braking system are illustrated in the braking system schematic, Chapter 1, figure 1. 2 Trailer Brake Valve & Circuit Y. CV. ST. P. T. B. C

Brake Fluid Supply To Loader Control Valve Priority to Steering & Brakes Pump Pressure Reservoir Return Trailer Brake & Sensing Quick Release Coupling

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SECTION 33 -- BRAKES -- CHAPTER 2

4 1. 2. 3. 4. 5. 6. 7.

Piston Relief Valve Spring Guide Orifice Valve Spool Spool Orifice Return Orifice End Cap

Trailer Brake Valve -- Brakes Released 8. Return Spring 9. Feed Back Valve 10. Feed Back Gallery 11. Guide & Seal Assembly 12. Relief Valve Plunger 13. Relief Valve Body 14. Brake Fluid Seal

Brakes Released -- figure 4 With the foot brake pedal released, the return spring (8) pushes the valve spool assembly (4), relief valve (13) and piston (1) fully to the left. The trailer brake port B is open to the reservoir return port T. The pump oil supply port, P, is cut off from the trailer brake port B. Brakes Applying -- figure 5 As the brake pedal is depressed, pressurised brake fluid acting on the piston (1) progressively moves the valve spool (4) to the right against the return spring. Port B now has a restricted opening to Port P, allowing pump oil to flow to the pump priority valve and trailer brake coupling. Pump priority oil will flow to port P, across the valve spool (4) to the trailer brake Port B. Trailer brake pressure oil will also flow through spool orifice (5), to the feed back valve (9). The feed back valve (9) flats allow trailer brake pressure oil to flow to the right hand end of the valve spool.

The feed back gallery (10) allows trailer brake pressure oil to flow to the left hand end of the valve spool. As the trailer brakes are being applied, the feed back oil provides a damping effect on the valve spool (4) to provide progressive trailer braking. Brakes Applied -- figure 6 Maximum trailer brake pressure is limited to 140 --150 bar by the relief valve element (Items 2, 12 & 13). When the trailer braking pressure builds up to 140 bar, the valve spool (4) will move to the left against the relief plunger (12) and compress the relief valve spring (2) The valve spool will restrict pump oil flow from port P to port B to maintain trailer brake pressure.

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SECTION 33 -- BRAKES -- CHAPTER 2

5 Brakes Applying

6 Brakes Applied -- Maximum Pressure

Brake Reservoir Fluid

Hydraulic Reservoir Return

Pressurised Brake Fluid

Reduced Pressure

Trapped Oil

Maximum Pressure

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SECTION 33 -- BRAKES -- CHAPTER 2

FAULT FINDING Ensure the telehandler braking system is functioning correctly before attempting any fault diagnostic procedures on the trailer brake system.

PROBLEM 1. Trailer Braking System Inoperative

POSSIBLE CAUSES Trailer brake hose Trailer brakes

Trailer brake valve

2. Trailer Braking System Erratic or Not Progressive

Trailer brakes Trailer brake valve reservoir return Telehandler brake fluid system Trailer brake valve

REMEDIAL ACTION Check hose is correctly attached to coupler. Check trailer brake drum area for oil leaks. Check trailer mechanical parking brake. Carry out pressure test. If trailer brake pressure is low and/or not progressive, replace trailer brake valve. As in 1 above. Check return hose is not twisted or restricted. Bleed trailer brake valve, refer to Chapter 1, pages 6 & 7. Carry out pressure test. If trailer brake pressure is low and/or not progressive, replace trailer brake valve.

PRESSURE TESTING Test equipment shown enables testing of the trailer brake valve only or the complete trailer brake circuit with a system connected. 1. 2. 3. 4. 5.

Pressure Gauge -- 300 bar Female Half Coupling Male Half Coupling Tee Adapter Hose & Adapters

1. Ensure hydraulic oil temperature is 60°C. 2. Install test equipment into trailer brake coupling. 3. Have an assistant start and run the engine at 2000 rpm and progressively depress the brake pedal. 4. The pressure gauge reading should increase in proportion to brake pedal effort. Maximum pressure should be 140--150 bar.

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SECTION 33 -- BRAKES -- CHAPTER 2

Trailer Brake Valve Removal 1. Thoroughly clean the brake valve and surrounding area. 2. Disconnect and cap the hoses and cap the valve port adapters. Figure 8: Left Hand Side Reservoir Return (1) Pump Supply (4) Brake Line (3)

8 Figure 9: Right Hand Side Sensing Line (4) Trailer Brake (5) 3. Remove adapters (1 & 2) and elbow (3).

9 4. Remove mounting bolts (3), and washers (4) and withdraw the trailer brake valve and spacers (2).

10 Trailer Brake Valve Installation 1. Remove hexagon plug (2) from the old trailer brake valve and install into port N of the new Valve (1). 2. Installation and connection of the replacement valve is the reverse of the removal procedure. 3. The braking system must be bleed to remove air from the brake fluid. 4. Bleeding procedures are covered in Chapter 1 on pages 10 & 11.

11 604.55.181.01 09-- 2004

SECTION 33 -- BRAKES -- CHAPTER 2

Trailer Brake Valve Disassembly Individual parts are not serviced, therefore disassembly is only carried out to inspect for contamination or wear to determine if the valve is suitable for further service. 1. Scribe an alignment reference mark between the two housings. 2. Remove the two screws (3) and separate the piston housing (1) from the valve housing (2).

12 1. 2. 3.

’O’ Ring Valve Spool Assembly Relief Valve Element

3. Disassemble the components in the sequence shown in figures 13 to 17.

13 1. 2. 3. 4. 5. 6. 7.

Piston Housing Piston Relief Valve Element End Plug Seal Valve Body Valve Spool Assembly & Spring

1. 2. 3. 4.

Valve Spool Return Spring Feed Back Valve Guide & Seal Assembly

NOTE: Two machined flats run the full length of the feed back valve.

15 604.55.181.01 09-- 2004

SECTION 33 -- BRAKES -- CHAPTER 2

WARNING Do NOT disassemble the relief valve element without compressing the relief valve spring as shown using a vice. 1. 2.

Relief Valve Element Bolt

1. 2. 3. 4. 5. 6.

Relief Valve Body Relief Valve Spring Snap Ring Relief Valve Plunger Shims Piston

Thoroughly clean all components with a suitable cleaning fluid. Check the piston, relief valve and valve spool and their respective bores for scoring. The components should move freely in the bores. 17 If the component parts are suitable for further service, assemble parts lubricating with clean hydraulic oil in reverse order. 1. 2. 3. 4. 5. 6. 7.

Piston Housing Piston Relief Valve Element End Plug Seal Valve Body Valve Spool Assembly & Spring

18 Align the two housing using the marks made prior to disassembly. Install retaining screws (3) and tighten to 20 Nm.

19 604.55.181.01 09-- 2004

SECTION 33 -- BRAKES -- CHAPTER 2

Trailer Brake Coupling Replacement 1. Remove the trailer brake hose (3) from the coupling (1). 2. Remove the retaining nut (2) and coupling assembly (1)from the mounting bracket 3. Install new coupling and secure to the mounting bracket with nut (2), 4. Connect the trailer brake hose (3)

20 Reservoir Return Connections Trailer brake valve return hose connection to main reservoir return.

21 Trailer brake valve return hose connection to main reservoir return with Smooth Ride Control.

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SECTION 33 -- BRAKES -- CHAPTER 2

NOTES PAGE

604.55.181.01 09-- 2004

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

SECTION 35 -- HYDRAULIC CIRCUIT AND COMPONENTS Chapter 1 -- Mechanical and Monoramp Hydraulic System Circuits and Components

CONTENTS Section

Description

Page

35 000

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Component Operation Hydraulic Pump and Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Accumulator and Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Hydraulic Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Circuit Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Monoramp Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Hydraulic System Flow and Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Circuit Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Servo Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Component Overhaul

35 701

Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

35 701

Accumulator and Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

35 701

Monoramp Solenoid Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

SPECIFICATIONS Hydraulic Oil Specification

Capacity Total System Hydraulic Oil Filter Change Hydraulic Oil Change

Ambra Hydrosystem 46 HV NH646H New Holland Specification NH 646 H International Specification ISO VG 46, DIN 51524 125 Litres 300 Hours 300 Hours

Hydraulic Pump Gear Pump with load sensing flow divider valve to provide priority flow to the steering, low pressure reducing valve and braking circuits. Capacity 46.34 cc/rev. Output 110 Litres/min Hydraulic Control Valves Open centre sectional valve with system relief valve and individual circuit relief valves. Refer to page 3 Pressure Reducing Valve Regulated Pressure Relief Valve Pressure

40 bar 50 bar (Max.)

Accumulator Pre--charge Pressure Capacity

13 bar 0.7 Litres

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

1 1. 2. 3. 4. 5. 6.

Hydraulic Control Valve Assembly Main Relief Valve @ 260 bar 7. Inlet End Cover Lift Cylinder Relief Valve @ 270 bar (Piston End) 8. Lift Control Valve Tilt Cylinder Relief Valve @ 190 bar (Rod End) 9. Tilt Control Valve End Cover 10. Telescopic Control Valve Telescopic Cylinder Relief Valve @ 200 bar (Piston 11. Auxiliary Control Valve (where fitted) End) 12. Pick--up Hitch/Auxiliary Control Valve (where fitted) Tilt Cylinder Relief Valve @ 270 bar (Piston End)

TORQUES Refer to figure 2 Hydraulic Valve Connections M27 x 150 Pipe Fittings M22 x 150 Pipe Fittings

150 Nm (110 lbf.ft.) 100 Nm ( 74 lbf.ft.)

SPECIAL TOOLS Boom Safety Support Tool 297451

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

DESCRIPTION AND OPERATION INTRODUCTION The hydraulic circuit comprises of the following: • Telescopic Telehandler Boom Circuit • Steering Circuit • Brake Circuit The hydraulic circuits shown in Figures 15 and 18 and the location and basic function of the principal components shown in the circuits are as follows. A more comprehensive description and operation of each component follows the circuit diagrams on Page 14 onwards. Gear Type Hydraulic Pump The pump is mounted on the rear of the transmission with an output of 110 L/min at 2200 engine rpm. The pump (2) incorporates a load sensing flow divider valve (3) which distributes pump flow to the hydraulic circuits with priority flow to the steeting and brakes. 3 Brake Circuit Accumulator and Pressure Reducing Valve The pressure reducing valve (1) is located beneath the right hand side of the cab and controls the operating pressure of the power brake circuit at 40 bar. The accumulator (2) provides sufficient pressure when the engine is turned OFF to operate the brakes. The manifold (3) contains a shuttle valve and directs load sense pressure to the flow divider valve on the hydraulic pump. 4

Hydraulic Control Valves The control valve consists of several spool operated sections and is located to the right hand side of the cab. Each section directs oil to the appropriate loader or auxiliary service whenever a spool is operated. The joystick control lever mechanically operates the lift and tilt spools. The telescopic and auxiliary spools are mechanically operated with the basic control system, but are electro--hydraulically operated with the Monoramp control system.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Telescopic Loader Controls The mechanical type controls position the control valve spools mechanically to direct oil to the specific circuit. 1. 2. 3. 4. 5.

Auxiliary Services Control Boom & Fork Control Lever In line movement controls boom lift & lower. Cross ways movement controls fork tilt. Boom Telescopic Control Optional Rear Auxiliary Control Button control selects change over to additional Auxiliary Service

6 The Monoramp type controls position the lift and tilt control valve spools mechanically to direct oil to the specific circuit. The telescopic and auxiliary spools are positioned hydraulically by servo pressure controlled by solenoid operated valves. 1/2 Boom Telescopic Control Buttons 3/4 Auxiliary Services Control Buttons 5. Boom & Fork Control Lever In line movement controls boom lift & lower. Cross ways movement controls fork tilt. 6. Control Button selects change over to additional Auxiliary Service 7.

Optional Rear Auxiliary Control

A mechanical lock out valve (8) is available with standard boom auxiliary and the Electro Change Over Valve (ECOV). The lock out valve enables the boom auxiliary service to operate a carrier lock or an external service for a remote cylinder.

8 An auxiliary control button isolator switch (9) is fitted to Monoramp systems when the lock out valve (8) is fitted.

9 604.55.181.00 09-- 2003

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

10 1. 2.

Hydraulic Cylinders 3. Tilt Cylinder with Counterbalance Valve Telescopic Cylinder with Double Counterbalance Valve (9 m Boom) 4. Lift Cylinder with Counterbalance Valve Telescopic Cylinder with Counterbalance Valve (all 5. Compensation Cylinder models)

The internal telescopic cylinder (2) is used to operate the telescopic boom on all models. On 9 metre 3 section booms, an additional external cylinder (1) is fitted to the boom. The two cylinders are connected hydraulically in series to provide synchronised travel to both cylinders.

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The compensating cylinder (5) is hydraulically linked to the tilt cylinder (3) and ensures self levelling of the forks during the boom lift and lower cycles.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Counterbalance Valves Counterbalance (load holding) valves are fitted to all cylinders as a safety feature to ensure that the cylinders remain locked in position if a hose should fail. The engine must be running to enable the cylinders to be operated. The valves incorporate overload relief valves to prevent damage to the cylinders due to mechanical overload. Description, operation and adjustment of the valves are covered in Chapter 4. The counter balance valves are mounted on their respective cylinders as illustrated. 1.

Lift Cylinder

Tilt Cylinder

Internal Telescopic Cylinder

External Telescopic Cylinder Three section, 9 meter boom only.

14 604.55.181.00 09-- 2003

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

HYDRAULIC CIRCUIT

Basic Circuit Operation The basic circuit operation is as follows. A more detailed explanation on the operation of the flow divider, pressure reducing valve, counterbalance valve and control valve is given from Page 15 onwards. The pump (1) draws oil through a 100 micron filter in the hydraulic reservoir and passes it through the load sensing flow divider at the rear of the pump. This ensures priority flow is given to the steering and

1. 2. 3. 4. 5. 6.

Hydraulic Pump & Flow Divider Loader Control Valve Pressure Reducing Valve Trailer Brake Valve Load Sensing Shuttle Valve Hydrostatic Steering Motor

braking circuits (priority circuit) while remaining flow is directed to the telescopic boom and auxiliary hydraulic circuits (secondary circuits). Flow from the priority port of the pump flow divider valve is directed to the steering motor, trailer brake valve (where fitted) and the pressure reducing valve. The pressure reducing valve maintains a 40 bar pressure servo circuit for operation of the braking system and the monoramp solenoid operated control valves.

Monoramp Hydraulic Circuit Schematic 7. Trailer Brake Coupling 8. Brake Master Cylinder 9. Mono Ramp Control Solenoids* 10. Hydraulic Reservoir & Filters 11. Load Sensing Shuttle Valve

* The mechanically controlled hydraulic system does not incorporate the control solenoids

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Monoramp Hydraulic Circuit Schematic

System Pressure

Suction Oil

Reduced Pressure @ 40 bar

Return to Reservoir

Load Sense Line

Pilot Line from the Brake Master Cylinder

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

An excess load anti tilt system is available as an optional safety feature. When fitted, the system is incorporated in the loader hydraulic system and operates in conjunction with the standard load monitor system. The system is activated by depressing switch ’B’ adjacent to the load monitor panel on the dash. The load being lifted is monitored by a strain gauge fitted to the rear axle. Coloured lights indicate the load as percentage of maximum safe load. When the load becomes equivalent to the maximum safe load, the dump valve solenoid is activated. 16 The dump valve (1) is fitted between the pump supply (2) and return lines and is located adjacent to the reservoir return filter (3). When activated, the dump valve opens to return pump supply oil back to the reservoir. Further operation of the boom is no longer possible until the boom is retracted and the solenoid valve de--energised.

Figure 18 Hydraulic System Circuit Diagram -- Mechanical Controls 1. Brake Master Cylinder 2. Lift Cylinder 3. Tilt Cylinder 4. Compensation Cylinder 5. Telescopic Cylinder (Internal Boom Cylinder all models) 6. Auxiliary Hydraulic Connections 7. Mechanical Controls 8. Control Valve Auxiliary Section 9. Control Valve Telescopic Section 10. Control Valve Fork Tilt Section 11. Control Valve Boom Lift Section 12. System Relief Valve 13. Pressure Test Point 14. Hydraulic Pump & Priority Valve 15. Pressure Reducing Valve 16. Load Sensing Line Shuttle Valve 17. Steering Motor 18. Steering Mode Control Valve 19. Lift Cylinder Counter Balance Valve 20. Tilt Cylinder Counter Balance Valve 21. Telescopic Cylinder Counter Balance Valve 22. Telescopic Cylinder (External Cylinder 9 metre /3 Section Boom)

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Mechanical Hydraulic System Circuit Diagram

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Figure 19 Hydraulic System Circuit Diagram -- Monoramp Controls 1. Brake Master Cylinder 2. Lift Cylinder 3. Tilt Cylinder 4. Compensation Cylinder 5. Telescopic Cylinder (Internal Boom Cylinder all models) 6. Auxiliary Hydraulic Connections 7. Monoramp Controls 8. Control Valve Auxiliary Section 9. Control Valve Telescopic Section 10. Control Valve Fork Tilt Section 11. Control Valve Boom Lift Section 12. System Relief Valve 13. Pressure Test Point 14. Hydraulic Pump & Priority Valve 15. Pressure Reducing Valve 16. Load Sensing Line Shuttle Valve 17. Steering Motor 18. Steering Mode Control Valve 19. Lift Cylinder Counter Balance Valve 20. Tilt Cylinder Counter Balance Valve 21. Telescopic Cylinder Counter Balance Valve 22. Monoramp Solenoid Valve 23. Auxiliary Solenoid Valve 24. Telescopic Solenoid Valve

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Monoramp Hydraulic System Circuit Diagram

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

NOTES PAGE

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

COMPONENT OPERATION Hydraulic Pump The hydraulic pump is a fixed displacement gear (2) with a capacity of 46.34 cc /revolution. A load sensing flow divider valve (3) is mounted on the pump, this provides priority oil flow to the steering and brake circuits. The pump is mounted on the back of the Powershuttle transmission and is driven directly from the flywheel by a drive shaft, which engages with the pump shaft (4). 20 The hydraulic pump is mounted on the side of the Powershift transmission and is driven through a gear train. The pump fitted has a different mounting flange.

21 Hydraulic pump connections on the Powershuttle transmission are:-1. 2. 3. 4.

Suction Hose Steering Circuit Loader Control Circuit Load Sensing Line

22 Hydraulic pump connections on the Powershift transmission are:-1. 2. 3. 4.

Loader Control Circuit Suction Hose Steering Circuit Load Sensing Line

23 604.55.181.00 09-- 2003

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Flow Divider Valve The flow divider consists of the parts illustrated 1. 2. 3. 4. 5. 6. 7. 8. 9.

Housing Steering Priority Valve Spring Seat Shim End Cap Spring Restrictor Filter & Restrictor Assembly Load Sensing Connector

Flow Divider Valve Operation -- Engine Off

Reservoir Return Oil 1. 2. 3. 4. 5.

Priority Valve Spool Restrictor Gauze Filter Restrictor Spring

CF. EF. LS. P.

Outlet to Steering & Braking Circuits Outlet to Loader Control Valve Sensing Line Gallery Pump Outlet Gallery

The load sensing flow divider valve provides priority oil flow on demand to the steering and braking circuits. The remaining flow is available to the loader hydraulic circuit. Restrictors are fitted to both ends of the hollow valve spool, the left hand restrictor incorporates a gauze filter. With the engine off, the priority valve spool is positioned to the left by the spring. The outlet ports (CF & EF) and pump gallery (P) are open to reservoir through the LS gallery and sensing line.

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1. 2. 3. 4. 5.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Flow Divider Valve Operation -- Loader Hydraulic Operation

Flow Divider Valve Operation -- Steering & Braking System Priority

System Pressure Oil

Load Sensing Oil

Reduced Pressure Oil

Reservoir Return Oil

Priority Valve Spool Restrictor Gauze Filter Restrictor Spring

When the engine is started, initial oil flow is directed through the CF port to the closed centre hydrostatic steering motor. Pressure build up through restrictor (2) on the left hand end of the priority valve spool (1) over comes spring pressure and moves valve to the right, figure 26. Pump output is now directed to the loader hydraulic circuit. The sensing line is open to the reservoir through the LS port and sensing line. The balancing restrictor (4) acts a damper to prevent erratic valve spool movement.

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CF. EF. LS. P.

Outlet to Steering & Braking Circuits Outlet to Loader Control Valve Sensing Line Gallery Pump Outlet Gallery

Operation of the steering motor or braking system creates a pressure in the sensing line which is sensed on the right end of the priority valve spool, figure 27. The combined sensing line pressure and spring pressure will move the spool to the left and increase pump flow to the steering and brake circuits. Because oil directed to the sensing line flows through control orifices in the steering motor and brake valve, load sense pressure is always proportional to demand. This ensures the right amount of pump flow is directed to the steering and brake circuits.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Pressure Reducing Valve and Accumulator The pressure reducing valve (1) provides servo pressure at 40 bar for the brake servo circuit and Monoramp control circuit. The accumulator (2) maintains a residual pressure in the brake servo circuit to enable the brakes to be applied several times after the engine is switched off.

29 1. 2. 3. 4. 5. 6. 7. 8. 9.

Check Valve Ball Adapter Valve Spool Spring Shim Seal End Cap Plug Seal

Pressure Reducing Valve 10. Spring 11. Relief Valve 12. Housing 13. Plug 14. Seal 15. Sleeve 16. Check Valve 17. Spring 18. Connector

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

604.55.181.00 09-- 2003

hand end of the pressure reducing valve spool moves the spool to the right restricting the supply of system pressure oil. When the pressure in the brake servo circuit falls to below 40 bar the pressure reducing valve moves toward the left allowing system pressure oil to once again re--supply and maintain the pressure reducing valve spool shuttles back and forth metering the supply of oil to maintain 40 bar pressure in the brake servo circuit. If the pressure reducing valve spool became faulty and sticks in the left hand end of the bore the pressure in the brake servo circuit would increase. In this instance the pressure will increase up to 50 bar at which time the relief valve would lift of its seat and vent the circuit to reservoir through Port T and protect the circuit.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Pressure Reducing Valve Operation

System Pressure Oil

Oil Pressure @ 40 bar

Oil Pressure @ 50 bar

Return to Reservoir

Oil Pressure less than 40 bar A. Brake Servo Circuit Pressure Less than 40 bar B. Brake Servo Circuit Pressure at 40 bar C. Brake Servo Circuit Pressure at 50 bar (Relief Valve Operating)

1. 2. 3. 4. 5.

Accumulator Check Valve Regulating Spool End Cap, Shims & Spring Relief Valve

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Hydraulic Control Valves

31 1. 2. 3. 4. 5. 6.

Hydraulic Control Valve Assembly--Mechanically Operated 7. Inlet End Cover Main Relief Valve @ 260 bar 8. Lift Control Valve Lift Cylinder Relief valve @ 270 bar (Piston End) 9. Tilt Control Valve Tilt Cylinder Relief Valve @ 190 bar (Rod End) 10. Telescopic Control valve End Cover 11. Auxiliary Control Valve (where fitted) Telescopic Cylinder Relief Valve @ 200 bar (Piston 12. Pick--up Hitch/Auxiliary Control Valve (where fitted) End) Tilt Cylinder Relief Valve @ 270 bar (Piston End)

The control valve assembly is made up of four or five open centre spool sections sandwiched between two end plates. Its function is to control the system pressure and direct oil flow to the appropriate cylinder in accordance with spool movement. The inlet plate houses the pressure test point and the main relief valve which limits system pressure to 260 bar. The lift valve section is equipped with a 270 bar circuit relief valve for the lifting function and protects the circuit from shock pressures. The telescopic valve section has a 200 bar circuit relief valve on the piston side of the cylinder.

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The tilt valve section is protected from shock pressures by the 190 and 270 bar circuit relief valves. These valves also provide protection for the compensating circuit, described later in this section. The front auxiliary valve section (11) and rear auxiliary valve section are optional and not fitted with separate relief valves. Auxiliary equipment connected to these valve sections can be operated in either single or double acting mode. Each valve section contains a spool which is non detended and sprung loaded back to the neutral position. The spool directs the flow of high pressure circuit oil to either the piston or rod end of the cylinder in the circuit it controls.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

32 1. Spool 2. ’O’ Ring 3. Wiper 4. Seal Plate 5. Spring Seat 6. Spring 7. Washer 8. Spring Seat 9. Retainer 10. Screw

Typical Control Valve Section – Manually Operated 11. Washer 12. Spool Cap 13. Load Check Valve 14. Spring 15. Sleeve/Retainer 16. Housing 17. ’O’ Ring 18. Wiper 19. Relief Valve 20. Seal Plate

The control valve assemblies are similar in operation for Telehandler machines installed with either the mechanical or monoramp joy--stick type controls.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

33 1. 2. 3. 4. 5.

Hydraulic Control Valve Assembly -- Monoramp Control 6. Tilt Cylinder Relief Valve 270 bar Main Relief Valve 260 bar Piston End Lift Cylinder Relief Valve 270 bar 7. Inlet End Cover Piston End 8. Lift Control Valve Tilt Cylinder Relief Valve 190 bar 9. Tilt Control Valve Rod End 10. Telescopic Control Valve End Cover 11. Auxiliary Control Valve Telescopic Cylinder Relief Valve 220 bar Piston End

The Monoramp hydraulic valve telescopic (10) and auxiliary (11) sections are hydraulically operated by servo pressure. The control buttons activate solenoid valves, to direct servo pressure oil to the spool end caps (12) to reposition the spool to operate the circuit required. The lift (8) and tilt (9) sections are mechanically operated by the joystick control.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

35 1. 2. 3. 4. 5. 6. 7. 8. 9.

Spool Wiper Seal Spring Seat Spring Spring Washer Spring Seat Retainer Screw

Control Valve Section -- Monoramp Servo Control 10. Washer 11. Spool Cap 12. ’O’ Ring 13. Check Valve Plug 14. Spring 15. Load Check Valve 16. Housing 17. Cylinder Relief Valve 18. Spool Cap

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Control Valve Oil Flow

Oil Flow through Control Valve Section

A. 1. 2. 3. 4. 5.

Pump Pressure Oil

Trapped Oil

Spool Positioning Oil (Hydraulic controls only)

Return to Reservoir

Neutral Relief Valve Cylinder Port Check Valve Cylinder Port Relief Valve

When the controls are in neutral pump oil flows through the open centre gallery at port P and returns to reservoir through port T, Figure 36. When a control spool is operated flow through the staggered open centre gallery is blocked and pump system pressure will rise in both the staggered open centred and parallel galleries.

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B. Operating 6. Spool Centring Spring 7. Exhaust Gallery 8. Staggered Open Centre Gallery 9. Parallel Gallery 10. Spool

The oil behind the check valve is no longer trapped and the rise in system pressure lifts the check valve of its seat enabling oil to flow through the valve and operate the circuit. Exhaust oil from the cylinder returns via the spool and back to reservoir.

1. 2. 3. 4.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Oil Flow through Control Valve Sections

Pump Pressure Oil

Trapped Oil

Spool Positioning Oil (Hydraulic controls only)

Return to Reservoir Oil

Lift Control Valve Tilt Control Valve Telescopic Control Valve Auxiliary Control Valve

5. 6. 7. 8.

Check Valve Parallel Gallery Open Centre Gallery Return To Reservoir Gallery

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Circuit Relief Valves

38 1. 2. 3. 4. 5.

Main Relief Valve @ 260 bar Lift Cylinder Relief Valve 260 bar Piston End Tilt Cylinder Relief Valve 190 bar Rod End End Cover Telescopic Cylinder Relief Valve 220 bar Piston End

Circuit Relief Valves 6. Tilt Cylinder Relief Valve 270 bar Piston End 7. Inlet End Cover 8. Lift Control Valve 9. Tilt Control Valve 10. Telescopic Control Valve 11. Auxiliary Control Valve

All circuit relief valves are double acting with an anti--cavitation feature. The main system relief valve is direct acting and protects the system from excessive pressure. The valve is set at 260 bar and calibrated at 80l/min. The pressure setting (1) and flow rate of each relief valve is stamped on the end of the valve.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

40 1. 2. 3.

Locknut Adjuster Spring

Direct Acting Circuit Relief Valve 4. Poppet 5. Body

41 1. 2. 3. 4. 5.

Seals Adjuster Spring Anti--cavitation Valve Body

Direct Acting Circuit Relief Valve with Anti--cavitation Feature 6. Poppet 7. Spring 8. Spring Seat 9. Retainer 10. Locknut

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

System Relief Valve--Direct Acting When the system is not subject to overload conditions hydraulic pressure acting against the face of the poppet is insufficient to force the poppet against the spring and off its seat.

42 When system pressure increases to 260 bar the pressure acting against the face of the poppet moves the poppet against the spring and allows the excess pressure to be vented to reservoir.

43 Circuit Relief Valves--Direct Acting with Anti--cavitation Feature The circuit relief valves located in each individual control valve section are direct acting with anti cavitation feature. Operation of the relief valve portion of these valves are similar to those for the direct acting relief valve is described above. When the circuit is not subject to overload conditions the spring holds the poppet on its seat preventing any loss of circuit pressure by venting to reservoir through the valve. 44 When circuit pressure increases or is subject to a shock loading above that which the relief valve is set the circuit pressure moves the poppet against the spring and off its seat. Excess pressure is then vented to reservoir through the control valve exhaust gallery. High Pressure Oil Exhaust Oil

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Operation of Cylinder Relief Valve and Anti--cavitation Valve

Exhaust Oil (Higher pressure than System Pressure)

Pump Pressure Oil 1. 2. 3.

Cylinder Rod Circuit Relief Valve (Operating) Control Valve Exhaust Gallery

The circuit relief valves will operate in the following conditions. 1. When there is a rapid extension of the cylinder due to gravity at low engine speed. The oil exhausted from the cylinder will create a void in the opposite end of the cylinder, which will be below reservoir back pressure. The anti--cavitation valve will open to allow reservoir oil to flow to the cylinder and supplement the pump oil flow to reduce anti--cavitation.

4. 5.

Spool Anti--cavitation Valve (Open)

2. When there is a mechanical overload with the control valve spool in neutral, as illustrated in Fig 46. One end of the cylinder is subject to pressure build up due to the external mechanical overload, for example the tilt cylinder when operating earth moving bucket. When cylinder pressure builds up to the circuit relief valve pressure, the valve (5) opens allowing the cylinder to extend. Cylinder extension creates a void in the opposite end causing the opposite circuit relief valve anti cavitation valve (2) to open to allow reservoir oil to fill the voiding end of the cylinder.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Monoramp Control System The function of the system is to control the acceleration and deceleration of the telescopic and auxiliary circuits. The Monoramp control system consists of the following components. 1. 2. 3. 4. 5. 6.

Joystick (with telescopic & auxiliary control buttons) Master Solenoid Valve Manifold Block Spool Operating Solenoid Valves Harness & Connectors Electronic Control Module

47 When a control button is operated the master solenoid (2) is progressively energised by PWM signal from the control module. The master solenoid valve provides a controlled servo pressure build up to the spool operating solenoid valves (4). These solenoids (4) are energised simultaneously to supply servo oil to reposition the selected control valve spool. When the buttons are released the pressure reduction is progressively controlled. This system provides a smooth operation of the two circuits. The electronic control module (2) is located behind the dash adjacent to the fuse and relay box (1). The solenoid valve functions are:-1. 2. 3. 4.

Auxiliary Circuit Solenoid Valve Progressive Solenoid Valve Manifold Telescopic Circuit Solenoid Valve

Each solenoid control valve has two solenoids mounted on the valve core. When energised, the solenoids will move the valve in the core either in or out depending on which control button is operated. The Master Solenoid Operation is illustrated in figure 51. 49 As the control button is depressed the solenoid is energised progressively as indicted in the graph. The resultant valve operation is shown in conditions A, B & C as pressure is increased. As the control button is released and the solenoid is de--energised progressively as shown in the graph. The resultant valve operation will be follow condition C to A as pressure is reduced. Control Buttons Released -- Master Solenoid De--energised The solenoid pushrod (2) is retracted allowing the regulating valve (5) to cut off the 40 b servo pressure supply and connect gallery (S) to the reservoir return gallery (T) as shown in condition A. 604.55.181.00 09-- 2003

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Monoramp Control System

40 bar Circuit 1. 2. 3. 4. 5.

Plunger Solenoid Pushrod Spring Valve Core Regulating Valve

Control Button Depressed --Master Solenoid Progressively Energised When the control button is depressed, the solenoid is progressively energised and the solenoid pushrod and plunger are extended to cut off port T and position the regulating valve to open gallery P to S.

Reduced Pressure P.

40 bar Servo Supply

Return to Reservoir

51 Reservoir Return

S. Gallery to Operating solenoids

The regulating valve will increase the pressure supplied to gallery S as the solenoid voltage determines the pressure at which the regulating valve will cut off port P (Condition B) With maximum voltage applied to the solenoid, the regulating valve will be completely open. (Condition C) and supply 40 bar pressure to gallery S.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

FAULT FINDING Before disassembling hydraulic components it is important to correctly identify the concern. Always flow and pressure test the machine to assist in reaching the correct diagnosis. PROBLEM Hydraulic system not working.

Lift, tilt or telescopic cylinders drop under load.*

Noisy Counterbalance valves.*

POSSIBLE CAUSES

REMEDY

Steering circuit not charged.

Turn steering wheel from lock to lock to charge system.

Insufficient oil in reservoir.

Check and add oil to correct Specification.

Counterbalance (load holding) valve seals leaking.

Inspect/replace check valve seat, seals and spool in appropriate counterbalance valve.

Counterbalance safety valve out of adjustment.

Replace counterbalance safety valve.

Hydraulic cylinder seals leaking.

Overhaul cylinder.

Air in system.

Operate hydraulic circuit to purge air from system.

Delayed response when operating Counterbalance valve pilot screw Telescopic boom.* incorrectly adjusted.

Adjust pilot screw to protrude 22--23 mm from end of valve housing.

Boom will not lift load.

Lighten load. Pressure test hydraulic system. Flow test/overhaul pump.

Load to heavy. Pressure relief valves set incorrectly. Hydraulic pump worn.

* Counterbalance valves are covered in Chapter 4 of this section. The Monoramp electrical control system fault finding is detailed in Section 55, Chapter 7. FLOW AND PRESSURE TESTING Preparation 1. Ensure you are familiar with the mechanical and mono ramp hydraulic system controls by referring to page 5. 2. Warm hydraulic oil as follows:-Fully curl in (dump) the tilt cylinder and hold control lever in this position to blow the relief valve for 30 seconds. Release tilt cylinder control for 15 seconds then repeat, blowing relief valve for 30 seconds. Repeat this procedure until oil temperature is 55--60_C.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

FLOW TESTING (Using auxiliary Test Hydraulic Ports) Most machines are supplied with auxiliary test ports and the following pump flow test procedure uses these as a suitable method of attaching a flowmeter to the pump circuit. If the auxiliary test ports are not fitted refer to, alternative flow test procedure on Page 36. 1. Install 400 bar pressure gauge into auxiliary test port. Set engine speed to idle and operate auxiliary controls.

53 2. Identify the direction of flow through the ports when the controls (1) or (3) are operated. IMPORTANT: Always establish the direction of flow, in relation to operation, of the controls before installing the flowmeter. If a control is incorrectly operated sending a reverse flow through the flowmeter damage to the instrument will occur.

54 3. Having identified the direction of flow install flowmeter. 4. Set engine speed to 1800 rpm. Maximum flow from couplers is 85 l/min, therefore all testing should be carried out at 1800 rpm. Operate the control buttons (1 or 3) established in step 2. Use an assistant to operate the flowmeter load valve and record readings. Before carrying out Pump Performance Test, check pump inlet flow with flow meter:-5. Pump Cavitation Test: At 900 erpm, check flow with no load: e g 40 l/min At 1800 erpm, check flow with no load: e g 80 l/min * Flow should double with erpm, if not suspect pump inlet flow.

55 6. Performance Test Flow at 1800 rpm -- No Load = (80) A. l/min Flow at 1800rpm -- 160 bar = (72). B. l/min Pump Efficiency = B/A x 100 = (72/80) x 100 = (90) % ( min 89 %) 7. If the pump flow is below minimum, the pump should be replaced.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

FLOW TESTING (Alternative method) If machine is not installed with auxiliary test ports perform flow test as follows. 1. Raise boom and install boom cylinder support 297451.

DANGER Do Not work under an unsupported boom.

56 2. Install flowmeter between input hose at control valve and return to reservoir hose on top of oil reservoir.

57 3. Set engine speed to 2200 rev/min 4. Use an assistant to slowly close flowmeter control valve and increase system pressure to 240 bar. Record pump flow. 5. If pump flow is less than 98 L/min the pump should be replaced as overhaul will not produce a satisfactory repair. 6. If pump output is greater than 98 L/min but there is evidence of external leakage the pump should be removed and inspected for wear.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

PRESSURE TESTING The following pressure test procedure assumes the vehicle is installed with auxiliary test ports and enables limited pressure testing of the machine without the need to have direct access to the control valve.

58 A pressure test port (1) is fitted to the end cover of the control valve assembly and should be used when further pressure testing or adjustment of circuit relief valves is require required. Full details on pressure testing and adjusting valves using this test port is described on Page 39.

59 PRESSURE TESTING (Using auxiliary Test Hydraulic Ports) 1. Install 400 bar pressure gauge into auxiliary test port.

60 System Pressure Test 1. Set engine speed to 2200 rev/min. 2. Operate auxiliary hydraulic control (1) or button (3). 3. Pressure reading should be 260 bar. Adjust valve as necessary.

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Telescopic Circuit Relief Valve Pressure Test 1. Set engine speed to 650 rpm. 2. Continually operate auxiliary control (1) or button (3) and at the same time fully extend telescopic cylinder with control (4) and button (1). 3. When cylinder reaches end of travel the pressure reading should be 200 bar. Adjust valve as necessary

62 Tilt Cylinder Pressure Test Rod End Circuit Relief Valve 1. Set engine speed to, 650 rpm 2. Continually operate auxiliary control (1) or button (3) and at the same time fully curl out the loader attachment by moving joystick to the right. 3. When cylinder reaches end of travel pressure reading should be 190 bar. Adjust valve as necessary

Piston End Circuit Relief Valve 1. Continually operate auxiliary control (1) or button (3) and at the same time fully curl in the loader attachment by moving joystick to the left. 2. If the pressure reading is 260 bar when the cylinder reaches end of travel it is an indication that the relief valve is correctly set. This test will blow the main system relief valve and determine that the tilt cylinder piston end relief valve has been set higher than 260 bar. 3. To determine the exact value of the relief valve setting refer to Page 41. 64

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 LIft Cylinder Circuit Relief Valves Pressure Test NOTE: This test requires that the loader arm is raised to full height. A long length of hose must therefore be fitted to the gauge in order that the gauge can be read when the loader arm is raised. 1. Continually operate auxiliary control (1) or button (3) and at the same time fully raise the boom by moving joystick rearwards. 2. If the pressure reading is 260 bar when the cylinder reaches end of travel it is an Indication that the relief valve is correctly set. This test will blow the main system relief valve and determine that the tilt cylinder piston end relief valve has been set higher than 260 bar. 3. To determine the exact value of the relief valve setting refer to Page 41.

PRESSURE TESTING (Using Control Valve Test Port) When pressure testing the system perform all tests listed below. Preparation 1. Raise boom arm and install boom cylinder support 297451.

DANGER Do Not work under an unsupported boom.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

2. Install 400 bar pressure gauge into test port using suitable adaptors. If the control valve is not fitted with quick release coupling remove plug and install suitable 1/4 BSPP fitting to attach pressure gauge.

67 System Pressure Test 1. Set engine speed to 2200 rev/min. 2. Operate auxiliary hydraulic control (1) or button (3). 3. Pressure reading should be 260 bar. Adjust valve as necessary .

68 Telescopic Circuit Relief Valve Pressure Test 1. Set engine speed to 650 rpm 2. Fully extend telescopic cylinder and hold lever (4) or button (1) in extend position. 3. Pressure reading should be 200 bar. Adjust valve as necessary.

69 Tilt Cylinder Pressure Test Rod End Circuit Relief Valve 1. Set engine speed to 650 rpm 2. Fully curl out (dump) the tilt cylinder and hold in this position with the joystick. 3. Pressure reading should be 190 bar. Adjust valve as necessary

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Piston End Circuit Relief Valve 1. Interchange the system relief (1) and tilt cylinder piston end circuit relief valve (2). NOTE: This procedure eliminates the need to adjust the system pressure circuit relief valve to a setting above its normal operating pressure of 260 bar to test those relief valves which are set higher than the system, relief valve setting.

71 2. Set engine speed to 650 rpm. 3. Fully curl in the tilt cylinder and hold in this position with the joystick while relief valve operates. 4. Pressure reading should be 270 bar. Adjust valve as necessary

72 Boom Lift Cylinder Circuit Relief Valve Pressure Test 1. Set engine speed to 650 rpm. 2. Fully raise the loader and hold lever in this position while the circuit relief valve operates. 3. Pressure reading should be 270 bar. Adjust valve as necessary.

73 IMPORTANT: Upon completion of ail pressure tests re--install the main system pressure relief valve (260 bar) into position (1) and tilt cylinder circuit relief valve (270 bar) into position (2).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

ADJUSTMENT OF CIRCUIT RELIEF VALVES 1. Loosen locknut and turn adjuster to obtain correct pressure. 1/6 of a turn (60°) on the adjuster will alter the setting of the relief valve by approximately 20 bar.

75 Servo Hydraulic Circuit Pressure Test The pressure test checks the servo 40 bar circuit used by the brake servo and Monoramp control systems. 1. Fully retract the telescopic boom. Raise the boom sufficiently to install the safety support 297451 on the lift cylinder.

DANGER DO NOT work under an unsupported boom.

76 2. Remove the control valve access panel from the cab. 3. Relieve residual servo circuit pressure by operating the brake pedal at least 40 times with the engine switched off. 4. Install test elbow (2) and adaptor (3), tool numbers 380001667 & 380000493, into ’U’ port line and connect a 60 bar gauge (1) and test hose long enough to reach inside the cab. 5. Sit in the cab, start the engine and run at 2000 rpm. Apply the foot brake several times and observe gauge reading. 77 6. If maximum pressure is 40--45 bar, the pressure setting is to specification. 7. If the pressure is below 40 bar, remove the valve cap (1) add shims (2) to the spring and repeat pressure.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

COMPONENT OVERHAUL HYDRAULIC CONTROL VALVE Removal and Installation (Op No 35 701) 1. Retract telescopic extension and raise boom. Install safety support 297451 to boom lift cylinder.

DANGER DO NOT work under an unsupported boom. Always relieve residual hydraulic line pressure by operating the controls with the engine switched off. With Monoramp type controls, turn the key switch to the ’RUN’ position and operate telescopic and auxiliary control buttons to relieve pressure in these circuits.

79 2. Remove panels on outside of cab to gain access to control valve. 3. Using a centre punch or paint identify position of each hose attached to the control valve and disconnect hoses.

80 4. Remove control lever cover.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

5. If the machine is installed with mono ramp hydraulic controls, use a punch to identify the hydraulic connections (1) & (3) on the hydraulically operated spools, and then disconnect the hoses. 6. Disconnect the two connectors on the joystick harness from the main harness. 7. Support the control valve, remove the mounting bolts (2) & (4) and remove the valve from the unit.

83 1. 2. 3. 4. 5. 6.

Hydraulic Control Valve Assembly--Mechanically Operated Main Relief Valve @ 260 bar 7. Inlet End Cover Lift Cylinder Relief Valve @ 270 bar (Piston End) 8. Lift Control Valve Tilt Cylinder Relief Valve @ 190 bar (Rod End) 9. Tilt Control Valve End Cover 10. Telescopic Control Valve Telescopic Cylinder Relief Valve @ 200 bar (Piston 11. Auxiliary Control Valve (where fitted) End) 12. Pick--up Hitch/Auxiliary Control Valve (where fitted) Tilt Cylinder Relief Valve @ 270 bar (Piston End)

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Disassembly 1. Paint an alignment mark along total length of valve assembly to aid re--assembly. 2. Wash all dirt from valve assembly using approved degreaser.

84 3. Remove end cover and separate each valve section. Take care to remove the four ’O’ rings (1) and single polythene washer (2) located between each valve section. 4. Separate each valve section and wash using an approved cleaning agent. 5. Men overhauling mechanically operated control valves it is not necessary to disassemble linkage in order to separate valve sections.

86 1. 2. 3.

Inlet End Cover Lift Control Valve Tilt Control Valve

Control Valve Sections 4. Telescopic Control Valve 5. Auxiliary Control Valve (where fitted) 6. Pick--up Hitch/Auxiliary Control Valve (where fitted)

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

87 1. Spool 2. ’O’ Ring 3. Wiper 4. Seal Plate 5. Spring Seat 6. Spring 7. Washer 8. Spring Seat 9. Retainer 10. Screw

Typical Control Valve Section--Manually Operated 11. Washer 12. Spool Cap 13. Load Check Valve 14. Spring 15. Sleeve/Retainer 16. Housing 17. ’O’ Ring 18. Wiper 19. Relief Valve 20. Seal Plate

6. Disassemble each control valve section with reference to Figures 85 and 86. Inspection 1. Wash components in an approved degreaser. 2. Inspect spool and bore for scoring and damage. If spool is badly scored or worn the valve assembly must be replaced.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

88 1. 2. 3. 4. 5. 6. 7. 8. 9.

Spool Wiper Spring Seat Spring Spring Washer Spring Seat Retainer Screw

Typical Control Valve Section -- Mono Ramp Control 10. Washer 11. Spool Cap 12. ’O’ Ring 13. Sleeve/Retainer 14. Spring 15. Load Check Valve 16. Housing 17. Relief Valve 18. Spool Cap

3. The circuit relief valves can be serviced as required but must be re--adjusted prior to use. 4. The relief valve pressure setting (1) and flow rate (2) in litres per minute at which the valve was set is stamped on the end cap. Refer to Flow and Pressure testing, Pages 36 -- 42 for adjustment of relief valves.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

90 1. 2. 3.

Locknut Adjuster Spring

Direct Acting Circuit Relief Valve 4. Poppet 5. Body

91 1. 2. 3. 4. 5.

Seals Adjuster Spring Anti--cavitation Valve Body

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Direct Acting Circuit Relief Valve With Anti--cavitation Feature 6. Poppet 7. Spring 8. Spring Seat 9. Retainer 10. Locknut

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Re--Assembly 1. Re--assembly follows the disassembly procedure in reverse. 2. When assembling control valve sections ensure the four ’O’ rings (1) and single polythene washer (2) are located between each valve section as shown.

92 3. Progressively tighten tie rod nuts to, a torque of 65 Nm.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Accumulator and Pressure Reducing Valve Before removing the pressure reducing valve pressure test and adjust valve as described on Page 42 to establish if the valve requires overhauling.

Removal and Installation 1. Retract telescopic extension and raise boom. Install safety support 297451 to boom lift cylinder.

DANGER DO NOT work under an unsupported boom.

94 2. Remove panels to gain access to the pressure reducing valve (1) and accumulator (2). 3. Identify and disconnect hoses to ensure correct re--assembly. 4. Remove pressure reducing valve assembly and disassemble, referring to figure 94. 5. Installation follows removal procedure in reverse. 6. Pressure test valve after installation as described on Page 42.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Disassembly

96 1. 2. 3. 4. 5. 6. 7. 8. 9.

Check Valve Ball Adapter Valve Spool Spring Shim Seal End Cap Plug Seal

Pressure Reducing Valve 10. Spring 11. Relief Valve 12. Housing 13. Plug 14. Seal 15. Sleeve 16. Check Valve 17. Spring 18. Connector

7. Disassemble and clean valve with reference to Figure 94. Inspection 1. Wash components in an approved degreaser. 2. Inspect spool, check valve and relief valve and seats for scoring and damage. If the spool or badly scored or worn the valve assembly must be replaced.

Re--Assembly 1. Re--assemble in reverse order to disassembly use new oil to lubricate the components. 2. Install the valve assembly and reconnect hoses. 3. Carry out pressure test and if required adjustment, referring to page 42.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

97 1. 2. 3. 4. 5. 6.

Mono Ramp Solenoid Control Valve and Connections Auxiliary Solenoid & Connectors P. Servo Pressure Supply Mounting Screw T. Reservoir Return Master Solenoid & Connector A1/B1. Auxiliary Spool Control Valve Manifold A2/B2 Telescopic Spool Mounting Screw Telescopic Solenoid & Connectors

Solenoid Control Valves The solenoid control valve assembly is mounted beneath the cab floor. The solenoids and valve cores may be replaced individually. Mark connectors before disconnecting from the solenoids to ensure correct assembly. Remove the plastic retaining nut and withdraw the solenoid. Remove the valve core from the manifold. Refer to figure 94 for ’O’ ring locations. When reassembling, tighten valve core to torque of 25 Nm (18 lbf.ft). The solenoid retaining nuts should be finger tight.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

98 1. 2. 3. 4. 5. 6.

Auxiliary Solenoid Valve Control Valve Manifold ’O’ Rings (4) Master Solenoid Retaining Nut ’O’ Rings

Mono Ramp Solenoid Control Valve 7. Valve Core 8. ’O’ Rings (4) 9. Telescopic Valve Core 10. ’O’ Ring 11. Retaining Nut 12. Telescopic Valve Solenoids

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

NOTES

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

SECTION 35 -- HYDRAULIC CIRCUIT AND COMPONENTS Chapter 2 -- Flow Sharing Hydraulic System Circuits and Components CONTENTS Section

Description

Page

35 000

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Component Operation Hydraulic Pump and Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Accumulator and Pressure Reduciing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Servo Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Circuit Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Hydraulic System Flow and Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Circuit Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Servo Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Proportioning Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Component Overhaul

35 701

Accumulator and Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

35 701

Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

35 701

Servo Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Solenoid Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Hydraulic Oil Specification

Ambra Hydrosystem 46 HV NH646H New Holland Specification NH 646 H International Specification ISO VG DIN 51524

Total System Capacity Hydraulic Oil Filter Change Hydraulic Oil Change

125 litres 300 Hours 600 Hours

Hydraulic Pump Gear pump with load sensing flow divider valve to provide priority flow to the steering, low pressure reducing valve and braking circuits. Capacity

46.34 cc/rev

Output

110 litres/min @2200 rev/min @240 bar (3480 lbf/in2)

Hydraulic Control Valve Closed centre sectional valve with system relief valve and individual circuit relief valves. Refer to page 3 Pressure Reducing Valve Regulated Pressure Relief Valve Pressure

40 bar 50 Bar (Max)

Accumulator Pre--charge Pressure Capacity

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13 bar 0.7 litres

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

1 1. 2. 3. 4. 5. 6. 7.

Hydraulic Control Valve Assembly 8. Proportioning Control Valve Auxiliary Control Valve 9. Main Relief Valve 260 bar Tilt Control Valve 10. Flow Regulating Valve Lift Control Valve 11. Balancing Valve Telescopic Control Valve 12. Lift Cylinder Relief Valve (Piston End) 270 bar Inlet End Cover 13. Tilt Cylinder Relief Valve (Rod End) 190 bar Tilt Cylinder Relief Valve (Piston End) 270 bar 14. End Cover Telescopic Cylinder Relief Valve (Piston End) 200 bar

TORQUES Refer to figure 2 Hydraulic Valve Connections M27 x 150 Pipe Fittings M22 x 150 Pipe Fittings

150 Nm (110 lbf.ft.) 100 Nm (74 lbf.ft.)

SPECIAL TOOLS Boom Safety Support Tool 297451

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

DESCRIPTION AND OPERATION INTRODUCTION The hydraulic circuit comprises of the following: • Telescopic Telehandler Boom Circuit • Steering Circuit • Brake Circuit The hydraulic circuits shown in Figures 14 and 18 and the location and basic function of the principal components shown in the circuits are as follows. A more comprehensive description and operation of each component follows the circuit diagrams on Page 14 onwards. Gear Type Hydraulic Pump The pump is mounted on the rear of the transmission with an output of 110 L/min at 2200 engine rpm. The pump (2) incorporates a load sensing flow divider valve (3) which distributes pump flow to the hydraulic circuits with priority flow to the steeting and brakes. 3 Brake Circuit Accumulator and Pressure Reducing Valve The pressure reducing valve (1) is located beneath the right hand side of the cab and controls the operating pressure of the power brake circuit at 40 bar. The accumulator (2) provides sufficient pressure when the engine is turned OFF to operate the brakes.

4 Hydraulic Control Valves The control valve consists of several spool operated sections and is located to the right hand side of the cab. Each section directs oil to the appropriate loader or auxiliary service whenever a spool is operated. The lift and tilt spools are servo operated by the joystick control valve. The auxiliary spools are operated by solenoid control valves and servo circuit pressure. A proportional control valve and servo circuit pressure controls the telescopic spool. 5

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Telescopic Loader Controls The flow sharing system controls position the lift and tilt control valve spools hydraulically to direct oil to the specific circuit. The telescopic and auxiliary spools are positioned hydraulically by servo pressure controlled by solenoid operated valves. 1/2 3 4

6. 7.

Optional Auxiliary Control Buttons Boom Auxiliary Services Thumb Control Telescopic Boom Thumb Control Proportional operation, the more the control is rotated the faster the telescopic boom movement. Boom & Fork Control Lever In line movement controls boom lift & lower. Cross ways movement controls fork tilt. Control Button selects change over to additional Boom Auxiliary Service Transmission Disconnect Button

Operation of the mechanical control auxiliary lever button (5) or Monoramp button (6) energises the change over solenoid valve mounted on the boom. This changes the boom auxiliary oil flow over to the additional auxiliary service. (4th auxiliary service to 5th service) A mechanical lock out valve (8) is available with standard boom auxiliary and the Electro Change Over Valve (ECOV). The lock out valve enables the boom auxiliary service to operate a carrier lock or an external service for a remote cylinder. 7 An auxiliary thumb button isolator switch (9) is fitted to Flow Sharing systems when the lock out valve (8) is fitted.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

9 1. 2.

Hydraulic Cylinders Telescopic Cylinder with Counterbalance Valve 3. Lift Cylinder with Counterbalance Valve Tilt Cylinder with Counterbalance Valve 4. Compensation cylinder

The internal telescopic cylinder (2) is used to operate the telescopic boom.

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The compensating cylinder (4) is hydraulically linked to the tilt cylinder (2) and ensures self levelling of the forks during the boom lift and lower cycles.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Counterbalance Valves Counterbalance (load holding) valves are fitted to all cylinders as a safety feature to ensure that the cylinders remain locked in position if a hose should fail. The engine must be running to enable the cylinders to be operated. The valves incorporate overload relief valves to prevent damage to the cylinders due to mechanical overload. Description, operation and adjustment of the valves are covered in Chapter 4. 10 The counter balance valves are mounted on their respective cylinders as illustrated. 1. 2.

Lift Cylinder Tilt Cylinder

Internal Telescopic Cylinder

Lift Cylinder

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

HYDRAULIC CIRCUIT

1. 2. 3. 4. 5. 6. 7.

Hydraulic Pump & Flow Divider Loader Control Valve Pressure Reducing Valve Trailer Brake Valve Load Sensing Shuttle Valve Hydrostatic Steering Motor Trailer Brake Coupling

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is directed to the telescopic boom and auxiliary hydraulic circuits (secondary circuits). Flow from the priority port of the pump flow divider valve is directed to the steering motor, trailer brake valve (where fitted)and the pressure reducing valve. The pressure reducing valve maintains a 40 bar servo circuit for operation of the braking system and the loader control valve servo operated and solenoid operated control valves.

Flow Sharing Hydraulic System Schematic 8. Brake Master Cylinder 9. Auxiliary Control Solenoids 10. Joystick Servo Control Valve 11. Reservoir & Filters 12. Hydraulic Oil Cooler 13. Load Sensing Shuttle Valve

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Flow Sharing Hydraulic System Schematic System Pressure

Suction Oil

Reduced Pressure @ 40 bar

Return to Reservoir

Load Sense Line

Pilot Line from the Brake Master Cylinder

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

An excess load anti tilt system is available as an optional safety feature. When fitted, the system is incorporated in the loader hydraulic system and operates in conjunction with the standard load monitor system. The system is activated by depressing switch ’B’ adjacent to the load monitor panel on the dash. The load being lifted is monitored by a strain gauge fitted to the rear axle. Coloured lights indicate the load as percentage of maximum safe load. When the load becomes equivalent to the maximum safe load, the dump valve solenoid is activated. 15 The dump valve (1) is fitted between the pump supply (2) and return lines and is located adjacent to the reservoir return filter (3). When activated, the dump valve opens to return pump supply oil back to the reservoir. Further operation of the boom is no longer possible until the boom is retracted and the solenoid valve de--energised.

16 Figure 17 Flow Sharing Hydraulic System Circuit Diagram 1. Brake Master Cylinder 2. Telescopic Cylinder 3. Lift Cylinder 4. Tilt Cylinder Lift Cylinder 5. Compensation Cylinder 6. Boom Auxiliary Hydraulic Connections 7. Rear Auxiliary Hydraulic Connections 8. Flow Sharing System Hydraulic Controls 9. Rear Auxiliary Control Valve 10. Rear Auxiliary Solenoid Control Valve 11. Boom Auxiliary Section Control Valve 12. Boom Auxiliary Solenoid Control Valve 13. Fork Tilt Control Valve 14. Boom Lift Control Valve

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15. Telescopic Proportioning Control Valve 16. Joystick Servo Control Valve 17. Relief Valve Section 18. Pressure Test Point 19. Cooler & Bypass Valve 20. Hydraulic Pump & Flow Divider 21. Pressure Reducing Valve 22. Load Sensing Line Shuttle Valve 23. Steering Motor 24. Steering Mode Control Valve 25. Telescopic Cylinder Counter Balance Valve 26. Lift Cylinder Counter Balance Valve 27. Lift Cylinder Counter Balance Valve 28. Tilt Cylinder Counter Balance Valve

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Flow Sharing Hydraulic System Circuit Diagram

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Hydraulic Oil Cooler A hydraulic oil cooler (4) is fitted behind the main radiator (1) and below the transmission oil cooler assembly (3).

18 Cooler Bypass Valve The cooler bypass valve (1) is located in the return line from the main control valve adjacent to the reservoir return filter (3). The bypass valve ensures maximum oil flow through the cooler and opens at 2 bar differential pressure. Steering motor and brake valve return is hose (2). Servo control & solenoid operated valve return is hose (5). Pressure reducing valve, proportioning valve, and control valve load sense return is hose (4). 19 Hydraulic Oil Filters and Screen The hydraulic oil is protected by a filter and two screens:-1. 2. 3.

Screen below filler cap Replaceable element filter Suction Screen

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

COMPONENT OPERATION Hydraulic Pump The hydraulic pump is a fixed displacement gear (2) with a capacity of 46.34 cc /revolution. A load sensing flow divider valve (3) is mounted on the pump, this provides priority oil flow to the steering and brake circuits. The pump is mounted on the back of the Powershuttle transmission and is driven directly from the flywheel by a drive shaft, which engages with the pump shaft (4). 21 The hydraulic pump is mounted on the side of the Powershift transmission and is driven through a gear train. The pump fitted has a different mounting flange.

22 Hydraulic pump connections on the Powershuttle transmission are:-1. 2. 3. 4.

Suction Hose Steering Circuit Loader Control Circuit Load Sensing Line

23 Hydraulic pump connections on the Powershift transmission are:-1. 2. 3. 4.

Loader Control Circuit Suction Hose Steering Circuit Load Sensing Line

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Flow Divider Valve The flow divider consists of the parts illustrated 1. 2. 3. 4. 5. 6. 7. 8. 9.

Housing Steering Priority Valve Spring Seat Shim End Cap Spring Restrictor Filter & Restrictor Assembly Load Sensing Connector

Flow Divider Valve Operation -- Engine Off

Reservoir Return Oil 1. 2. 3. 4. 5.

Priority Valve Spool Restrictor Gauze Filter Restrictor Spring

CF. EF. LS. P.

Outlet to Steering & Braking Circuits Outlet to Loader Control Valve Sensing Line Gallery Pump Outlet Gallery

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1. 2. 3. 4. 5.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Flow Divider Valve Operation -- Loader Hydraulic Operation

Flow Divider Valve Operation -- Steering & Braking System Priority

System Pressure Oil

Load Sensing Oil

Reduced Pressure Oil

Reservoir Return Oil

Priority Valve Spool Restrictor Gauze Filter Restrictor Spring

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CF. EF. LS. P.

Outlet to Steering & Braking Circuits Outlet to Loader Control Valve Sensing Line Gallery Pump Outlet Gallery

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

30 1. 2. 3. 4. 5. 6. 7. 8. 9.

Check Valve Ball Adapter Valve Spool Spring Shim Seal End Cap Plug Seal

Pressure Reducing Valve 10. Spring 11. Relief Valve 12. Housing 13. Plug 14. Seal 15. Sleeve 16. Check Valve 17. Spring 18. Connector

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Pressure Reducing Valve Operation System pressure oil from the priority circuit outlet port of the flow dividing valve on the rear of the hydraulic pump is directed to both the steering circuit and the pressure reducing valve Port P1. Refer to Schematic on Page 21. If the pressure in the accumulator is less than 40 bar, system pressure oil flows through the centre of the pressure reducing valve spool (3), lifting the check valve (2) off its seat to charge the accumulator (1) and supply the brake servo circuit through port U. NOTE: If the engine has been switched off oil pressure in the priority circuit falls to zero. It may therefore be necessary on starting the engine to turn the steering wheel to create an initial pressure in the priority circuit and charge the accumulator and servo circuit to 40 bar. When oil pressure in the accumulator and servo circuit reaches 40 bar the pressure applied to the left hand end of the pressure reducing valve spool moves the spool to the right restricting the supply of system pressure oil. When the pressure in the brake servo circuit falls to below 40 bar the pressure reducing valve moves toward the left allowing system pressure oil to once again re--supply and maintain the pressure reducing valve spool shuttles back and forth metering the supply of oil to maintain 40 bar pressure in the brake servo circuit. If the pressure reducing valve spool became faulty and sticks in the left hand end of the bore the pressure in the brake servo circuit would increase. In this instance the pressure will increase up to 50 bar at which time the relief valve (5) would lift of its seat and vent the circuit to reservoir through Port T and protect the circuit.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Pressure Reducing Valve Operation

System Pressure Oil

Oil Pressure @ 40 bar

Oil Pressure @ 50 bar

Return to Reservoir

Oil Pressure less than 40 bar A. Brake Servo Circuit Pressure Less than 40 bar B. Brake Servo Circuit Pressure at 40 bar C. Brake Servo Circuit Pressure at 50 bar (Relief Valve Operating)

1. 2. 3. 4. 5.

Accumulator Check Valve Regulating Spool End Cap, Shims & Spring Relief Valve

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

33 Hydraulic Servo Control System Schematic

40 bar Circuit 1. 2. 3. 4.

Trapped Oil

Joystick Electrical Control Main Control Valve Proportioning Valve Pressure Reducing Valve

The pressure reducing valve supplies 40 bar servo pressure oil to the joystick control valve, the solenoid control valves and the telescopic section proportioning valve.

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5. 6. 7.

Reservoir Return Oil

Solenoid Control Valve Boom Auxiliary Solenoid Control Valve Rear Auxiliary Servo Control Valve

The pressure reducing valve is supplied with oil from the pump flow divider priority circuit.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

The 40 bar servo circuit pressure oil operate the control valve spools. The proportioning valve controls the telescopic valve section (1). The joystick servo control valve controls the lift (2) and tilt (3) sections. The auxiliary sections (4 & 5) are controlled by solenoid valve activated by lever mounted controls.

34 There are six servo hydraulic ports in the base of the servo control valve. The ports are identified as follows:-P. 40 bar Supply T. Return to reservoir 1 & 2 Controls the boom auxiliary circuit 3 & 4 Controls the fork tilt cylinder The servo control valve contains four operating elements operated by the joystick rocker plate. When operated by the control lever, the elements supply oil to the spools at a pressure proportional to control lever movement providing corresponding control valve spool travel. 35 The joystick control lever (1) and the servo control valve (2) are two separate assemblies. The joystick is threaded into the control valve rocker plate (3) and retained in position by a locknut (4). The electrical controls are connected to the main harness by a multipin connector.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

37 1. 2. 3. 4. 5. 6.

Dust Cover Rocker Plate Mounting Plate Control Valve Assembly Return Spring Piston

Joystick Servo Control Valve Components 7. Washer 8. Reaction Spring 9. Spring Seat 10. Retaining Clip (2) 11. Retainer & Seal Assembly 12. Plunger

Servo control symbol diagram

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

39 Joystick Servo Control Valve Operation

40 bar Servo Circuit 1. 2. 3. 4. 5. 6.

Plunger Reaction Spring Return Spring Piston Control Valve Spool Spool Centralising Spring

Proportion Pressure Oil 0--40 bar

Return Oil

A. Piston Activated B. Piston in Neutral P. Servo Circuit Pressure T. Return to Reservoir

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

With reference to the joystick control schematic on page 23:-When the joystick control lever is released, the return springs (3) hold the four pistons (4) in a neutral position. In this position each piston blocks the 40 bar servo circuit oil. Also in this position the control valve spools are centralised by the springs (6) as any pressure in either end of each spool is relieved to the reservoir through the pistons to port T. When the lever is moved, the rocker plate pushes on a plunger (1) which pushes down the piston (4) allowing oil from port P to flow to the outlet port of the piston being depressed. The oil pressure being applied to the end of the spool (5) in the control valve will overcome the force of the spool centralising spring (6) and move the spool to the correct position in the valve. Oil displaced from the opposite end of the control valve spool can return through the piston to port T. In operation the pressure required to continue moving the control valve spool will increase as the spool moves against its centralising spring. When the joystick control lever is operated, the amount of movement determines the pressure applied to control piston, which in turn determines the amount of spool travel. This travel is in proportion to the lever movement.

If the joystick control lever is only moved for half of its travel, the plunger (1), piston (4), reaction and return (2 & 3) springs are put under half of maximum force. As the spool moves the centralising spring force increases and, at approximately 20 bar the piston in the controller will be pushed up cutting off the servo circuit supply and trapping the 20 bar pressure to hold the control valve spool in position. Oil flow to the cylinder circuit will be approximately half of maximum. In this condition the system is in balance with both the joystick control and the control valve spool held at half travel. If the joystick control is moved further towards maximum travel, the pressure applied to the piston through the return and reaction springs will increase the pressure supplied to the end of the control valve spool and increase spool travel. Oil flow to the cylinder circuit will be increased in proportion. If the joystick control is moved back towards neutral, the pressure applied to the piston through the return and reaction springs will reduce the pressure supplied to the end of the control valve spool and the centralising springs will move the spool towards neutral. Oil flow to the cylinder circuit will be reduced.

SOLENOID CONTROL VALVES The solenoid operated control valves, which activate the boom auxiliary and rear auxiliary circuits, are operated by a joystick thumb control or button controls. When energised, the two solenoids (2 & 4) mounted on each valve core (6) move the valve spool in or out depending on which control is operated. Resultant solenoid control valve movement will direct the 40 bar servo circuit oil to the appropriate end of the spool to reposition the spool to direct pump oil flow to the cylinder circuit. 40

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

41 1. 2. 3. 4. 5. 6. 7.

Hydraulic Control Valve Assembly 8. Proportioning Control Valve Auxiliary Control Valve 9. Main Relief Valve 260 bar Tilt Control Valve 10. Flow Regulating Valve Lift Control Valve 11. Balancing Valve Telescopic Control Valve 12. Lift Cylinder Relief Valve (Piston End) 270 bar Inlet End Housing 13. Tilt Cylinder Relief Valve (Rod End) 190 bar Tilt Cylinder Relief Valve (Piston End) 270 bar 14. End Cover Telescopic Cylinder Relief Valve (Piston End) 200 bar

The control valve is a closed centre sectional valve. The valve sections are clamped between the inlet end housing and the end cover. An additional auxiliary section can be fitted to operate rear auxiliary circuits. The inlet end cover contains the main relieve valve, balancing valve and the flow regulator valve. The lift and tilt sections are servo operated by the joystick servo control valve. The auxiliary sections are operated by solenoid control valves and servo pressure. A proportioning valve using servo pressure operates the telescopic section.

The control valve spools direct pump oil flow to either the piston or rod end of the cylinder circuit it controls. The lift, tilt and telescopic cylinders are protect from shock load pressures by circuit relief valves fitted in these sections of the control valve.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Inlet End Housing 1. 2. 3. 4. 5. 6. 7.

Plug System Relief Valve Load Sensing Return Orifice End Housing Flow Balancing Valve Spring Shim

43 1. 2. 3. 4. 5.

Relief Valve Body Valve Spring Seat Spring Adjuster & Locknut Assembly

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Inlet End Housing Valves 6. Plug 7. Spring 8. Load Sensing Flow Regulator 9. Regulator Valve Body

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

44 1. 2. 3. 4. 5. 6. 7.

Spool Cap Centring Spring Spool Plug Spring Load Check Valve Spring Seat

Typical Control Valve Section 8. ’O’ Ring Seal 9. Plug 10. Pressure Compensation Spool 11. Pressure Compensation metering Element 12. Valve Section 13. Circuit Relief Valve (2 in Tilt Section)

Control Valve Galleries 1. 2. 3. 4.

Load Sensing Gallery Reservoir Gallery Closed Centre Gallery Reservoir Gallery

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Control Valve Components Component 1.

Pressure Compensating Valve

Control Valve Spool

3. 4. 5.

Closed Centre Gallery Load Sensing Line Flow Balancing Valve

6. 7.

Restriction Load Sensing Limiter

8. 9.

Load Sense Flow Regulator Load Check Valve

Function Allows operation of unevenly loaded cylinders to operate simultaneously Neutral, Raise & Lower positions Control Valve Spools Calibrated to Cylinder Capacity Pump Pressure Oil Supply to control valve spools Controls the balancing valve to provide required flow Dumps surplus pump flow and (Unload Valve) creates system standby pressure of 15 bar Dampens sensing line pressure variations Limits maximum system pressure to 260 bar (System Relief Valve) Vents Load Sensing line Prevents load dropping on initial lift

Oil Flow In Nuetral 1. Pump pressure oil flow enters the control valve at port P and enters the closed centre gallery (3). 2. All the control valve spools (2) are in neutral. 3. The load sensing line (4) is vented to the reservoir from port T1 through the load sense flow regulator (8). 4. Pump pressure oil flows through the flow balancing valve (5) and returns to reservoir from port T. 5. System standby pressure, created by the balancing valve spring, is 15 bar.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Flow Sharing Load Sensing System Schematic -- Oil Flow in Neutral

Pump Pressure Oil 1. 2. 3. 4. 5. 6. 7.

Pressure Compensating Valve Control Valve Spool Closed Centre Gallery Load Sensing Line Flow Balancing Valve & Spring Orifice Load Sensing Limiter (Relief Valve)

Trapped Oil

Reservoir Return Oil

8. 9.

Load Sensing Bleed Orifice Load Check Valve

P. LS. T1. T.

Pump Pressure Port Load Sensing Port Load Sensing Reservoir Return Port Main Reservoir Return

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

SINGLE CYLINDER OPERATION The maximum flow to each cylinder is determined by the machining of the individual control valve spool metering notches. The maximum flows are:-Lift Cylinder: Piston & Rod End: 100 l/min Tilt Cylinder: Piston & Rod End: 100 l/min Telescopic Cylinder Piston End: 90 l/min Telescopic Cylinder Rod End: 50 l/min Boom Auxiliary Both Ends: 100 /min Rear Accessory Both Ends: 100 l/min The schematic illustrates the valve oil flows for single cylinder operation. The control valve spool is moved to the right by servo pressure from the control system. The following oil flow sequence occurs:-1. Oil flows from the closed centre gallery (3) over the spool metering notches to the pressure compensating valve (1). 2. The pressure compensating valve metering element (1) lifts allowing oil to flow through a drilling in the inner spool (10) into the sensing line (4). 3. The pressure oil in the sensing line acts on the spring side of the flow balancing valve (5) which partially closes, raising pump pressure until the load check valve (9) opens. The load sensing line orifice (6) dampens variations in load sensing pressure. 4. The load check valve (9) will open when pump pressure exceeds the residual cylinder and spring pressure. Pump pressure oil will then flow through the check valve and past the control valve spool to the cylinder. 5. Metering notches on the control valve spool (2), between the cylinder and exhaust galleries, control the displaced oil flow from the exhaust end of the cylinder. This reduces cavitation of the hydraulic oil. 6. Load sensing line pressure is also sensed on the top of the other valve section pressure compensating elements.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Flow Sharing Load Sensing System Schematic -- Oil Flow with One Spool Operating

1. 2. 3. 4. 5. 6. 7.

Pump Pressure Oil

Sensing Line Pressure Oil

Trapped Oil

Reservoir Return Oil

Pressure Compensating Valve Control Valve Spool Closed Centre Gallery Load Sensing Line Flow Balancing Valve & Spring Orifice Load Sensing Limiter (Relief Valve)

Servo Pressure Oil

8. 9.

Load Sensing Bleed Orifice Load Check Valve

P. LS. T1. T.

Pump Pressure Port Load Sensing Port Load Sensing Reservoir Return Port Main Reservoir Return

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

MULTI--CYLINDER OPERATION The LMA flow sharing and pressure compensating hydraulic system allows two or more unevenly loaded cylinders to operate simultaneously. This feature allows operations such as boom lift and telescopic boom extension simultaneously With an open centre system, attempted operation of two or more unevenly loaded cylinders would result in oil flow operating the lighter loaded cylinder only without skilful use of the controls. 1. The oil flow sequence in the section operating the heavier loaded cylinder is the same as for single spool operation in figure xx. 2. The cylinder circuit with the highest provides the load sensing pressure to control the flow balancing valve (5). This also pressurises the top of the pressure compensating valve metering elements (1) in the other sections. 3. When the spool of the lighter loaded cylinder is operated, pump oil partially raises the metering element (1) against sensing pressure. This allows restricted pump oil flow to this cylinder. 4. The flow balancing valve (5) maintains the cylinder flows required, surplus pump oil is returned to the reservoir from port T.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Flow Sharing Load Sensing System Schematic -- Oil Flow with Two Spools Operating

1. 2. 3. 4. 5. 6. 7.

Pump Pressure Oil

Reduced Pressure Oil

Sensing Line Pressure Oil

Servo Pressure Oil

Trapped Oil

Reservoir Return Oil

Pressure Compensating Valve Control Valve Spool Closed Centre Gallery Load Sensing Line Flow Balancing Valve & Spring Orifice Load Sensing Limiter (Relief Valve)

8. 9.

Load Sensing Bleed Orifice Load Check Valve

P. LS. T1. T.

Pump Pressure Port Load Sensing Port Load Sensing Reservoir Return Port Main Reservoir Return

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

52 Component 1. Module & Solenoid Housing

Proportioning Valve Components Function Contains Solenoid Valves

2. 3. 4. 5. 6. 7. 8.

Extend Solenoid Valve Assembly Piston Housing Control Valve Section Control Valve Centring Spring Control Valve Spool Positioning Piston Retract Solenoid Valve Assembly

Controls servo operation to move control valve when energised Contains Piston & Oil Galleries Controls Telescopic Cylinders Returns Control Valve to Neutral when solenoids are de--energised Controls Oil Flow to Cylinders Servo Operation of Control Valve Controls servo operation to move control valve when energised

9. 10. 11. 12.

Linear Transducer (Magnet) Spring End Cover Electronic Module (Analogue Card)

Feed back of Control Valve Position Maintains Transducer against Control Valve Seals Electronic Module Modulates the Solenoid Current

Neutral -- Figure 53 In Neutral, the solenoids are not energised and the chambers on either side of the piston (7) are open to tank. The centring spring (5) positions the control valve (6) in Neutral. Telescopic Operation -- Figure 54 When the telescopic thumb control is rotated to either extend or retract the boom, a voltage signal is applied to the electronic module (12) in proportion to the thumb control rotation. A modulated signal is sent by the module to the selected solenoid valve (8) to control the pressure supplied to the control valve piston (7) to move the control valve in proportionally. The control valve position is measured and signalled to the module by the magnetic linear transducer. This has the effect of reducing the module signal voltage to the solenoid closing the valve to hold the control valve spool in a position proportional to the control thumb control rotation.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

53 Telescopic Section in Neutral

54 Telescopic Section Proportioning Valve Activated

40 bar Servo Pressure Oil

Return to Reservoir Oil

Further rotation of the thumb control will increase the voltage signal to the electronic module to repeat the cycle. This will have the effect of moving the control valve to increase the oil flow to the cylinder in proportion to the control rotation. The electronic control circuit description is covered in Section 55, Chapter 8.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Cylinder Overload

System Pressure Oil

Reservoir Return Oil

Trapped Oil 1. 2. 3.

Cylinder Rod End Circuit Relief Valve Exhaust Gallery

The circuit relief valves protect the cylinders from excessive pressure build up due to mechanical overload when the valve section spool is in neutral. In the cylinder overload condition shown, cylinder rod end pressure will increase until the circuit relief valve blows off. When the circuit relief valve opens, cylinder rod end oil flows through the valve into the exhaust gallery. This allows the cylinder to extend and prevent subsequent damage due to excessive pressure. The circuit relief valves are pilot operated and have a two stage action. Circuit relief valve operation is illustrated in figure 57.

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4. 5.

Control Valve Spool -- in Neutral Position Piston End Circuit Relief Valve

A. Valve Closed The valve remains closed whenever the cylinder circuit pressure remains below the pilot valve pressure setting. In this condition, the operating pressure, sensed through the piston gallery (4), acts on the larger inner face area of the relief valve (3) to hold the valve closed. B. Pilot Valve Operation When cylinder pressure overcomes the pilot valve spring, the valve (1) opens reducing the pressure acting on the larger inner face area of the relief valve (3). C. Pilot and Relief Valve Operation The high cylinder pressure opens the relief valve (3) allowing cylinder oil to flow into the exhaust gallery to limit cylinder pressure.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Circuit Relief Valve Components 1. Valve Body 2. Relief valve 3. Valve 4. Valve Return Spring 5. Spring 6. Pilot Valve Body 7. Pilot Valve Adjuster 8. Locknut & Seal 9. Pilot Valve Spring 10. Pilot Valve

56 A

57 Circuit Relief Valve Operation

A. Valve Closed

B. Pilot Valve Open

C. Pilot & Relief Valve Open

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Fault Finding Check out the operation and performance of all loader functions before attempting any fault diagnosis, testing, adjustment or repair. Also check the operation of related functions to identify the source of the problem. For example, if the joystick servo operated circuits are operating normally but the telescopic proportioning valve or auxiliary solenoid controlled circuits are problematic, then the fault could be in the associated electrical circuits rather than the servo circuit. Timing the loader lift cycle with a loaded fork can indicate the general condition of the hydraulic pump and system. Refer to the load lift performance charts, in Section 00 Chapter 1, applicable to your the telehandler to check maximum lift with the boom retracted. (eg LM425A 3300 kg ) Load forks to at least 80% of maximum safe load and carry out lift cycle time check:-Hydraulic oil temperature: 50 -- 60oC. Engine: 2200 rev/min Lift Cycle Time 7 seconds Ground level to full height with boom retracted Lower Cycle Time 6 seconds If the cycle time is greater than 9 seconds carry out flow and pressure test using a flowmeter to verify pump output and maximum circuit pressure. Fault Finding General PROBLEM

POSSIBLE CAUSES

REMEDIAL ACTION

All circuits fail to operate but steering OK.

Pressure reducing valve.

Pressure test/remove pressure reducing valve and investigate.

All circuits and steering inoperative.

Pump drive inoperative.

Investigate pump drive gears (Powershift) or driveshaft (Powershuttle). Check and top up if required. Check suction line and reservoir filters.

Low Oil Level. Restricted pump suction line. All circuits operate slowly or have loss of power.

Worn pump. Restricted pump suction line. Main pressure relief valve.

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Perform pump flow test and replace if required. Check suction line and reservoir filters. Perform pressure test

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Fault Finding Loader Servo Circuits PROBLEM

POSSIBLE CAUSES

REMEDIAL ACTION

Tilt and/or & lift cylinders do not function or function slowly.

40 bar circuit not available to joystick servo control valve or control valve spools.

Check pressure at port P on servo control valve. Check hose line from pressure reducing valve. Check pressure at servo. connections on control valve. Check for sticking spool/ broken return spring.

Telescopic cylinder does not function or functions slowly.

Electronic/electrical control circuit inoperative.

Refer to Section 55, Chapter 7 for description and fault finding of control circuit. Check pressure and gauze screen at pressure port of proportioning valve. Check hose line from pressure reducing valve. Check for sticking control valve spool/ broken return spring. Check neutral adjustment.

40 bar circuit not available to proportioning valve.

Auxiliary circuits do not function or Electrical control circuit function slowly. inoperative. 40 bar circuit pressure not available to the solenoid control valves.

Refer to Section 55, Chapter 7 for description and fault finding of control circuit. Check pressure at port 3 on solenoid servo control valve. Check hose line from pressure reducing valve. Check pressure at servo connections on control valve. Check for sticking control valve spool/ broken return spring.

Fault Finding Loader Cylinder Circuits PROBLEM

POSSIBLE CAUSES

REMEDIAL ACTION

Individual cylinder circuits do not operate.

Servo control system.

Refer to Loader Servo Circuit Fault Finding Chart.

Individual cylinder circuits operate slowly or erratically.

Low Oil Level. Counterbalance valve. Damaged cylinder, piston or rod.

Check and top up if required. Check adjustment Visually check externally. Remove cylinder and investigate. Refer to Servo Circuit Chart. Check operation of load status display and refer to lift chart in Section 00, specifications.

Control valve spool sticking. Cylinder overloaded.

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FLOW AND PRESSURE TESTING Preparation 1. Ensure Oil is visible in the sight glass (2). Add specified oil through the filler (1) as required. 2. Warm the hydraulic oil as follows:-Fully extend the tilt cylinder and hold the joystick in this position to blow off the relief valve for 30 seconds. Release the joystick for 15 seconds then repeat blowing off the relief valve for another 30 seconds. Repeat this procedure until the oil temperature is 55--60OC.

FLOW TESTING A. Using auxiliary boom hydraulic ports If boom auxiliary hydraulics are not fitted to the Telehandler, refer to flow test procedure B. 1. Install 400 bar pressure gauge into one auxiliary port, set engine speed at idle and operate the auxiliary thumb control to determine which direction of rotate of the control pressurises the upper coupler. 2. This determines the direction of flow before installing the flowmeter to ensure the correct oil flow direction through the test equipment.

3. Install the flowmeter, ensure the flowmeter load valve is fully open. 4. Set engine speed to 1800 rpm. Maximum flow from couplers is 85 l/min, therefore all testing should be carried out at 1800 rpm. Operate the thumb control in the direction established in step 1. Use an assistant to operate the flowmeter load valve and record readings. Before carrying out Pump Performance Test, check pump inlet flow with flow meter:-60 5. Pump Cavitation Test: At 900 erpm, check flow with no load: e g 40 l/min At 1800 erpm, check flow with no load: e g 80 l/min NB. Pump flow should double with erpm, if not suspect pump inlet for restriction. 6. Performance Test Flow at 1800 rpm -- No Load = (80) A. l/min Flow at 1800rpm -- 160 bar = (72). B. l/min Pump Efficiency = B/A x 100 = (72/80) x 100 = (90) % (min 89 %) 7. If pump flow is below minimum, the pump should be replaced. 604.55.181.01 09-- 2004

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

FLOW TESTING A. Alternative Procedure 1. Raise the boom sufficiently to install the boom safety support 297451.

DANGER Do Not work under an unsupported boom. 2. Ensure preparation steps 1 & 2 of previous flow test procedure are completed before conducting flow tests.

62 3. Install flowmeter between the pump output and the reservoir return on top of the reservoir. 4. ENSURE THE FLOWMETER LOAD VALVE IS FULLY OPEN BEFORE STARTING THE ENGINE 5. Set the engine at 2200 rev/min 6. Use an assistant to slowly close the flowmeter load valve to increase system pressure to 240 bar. 7. Record the indicated flow, and then open the flowmeter load valve before switching off the engine. 8. If the indicated pump flow is less than 98 litres/min, the pump should be replaced. 9. If pump flow is greater than 98 litres/min but there is evidence of leakage, the pump should be removed and overhauled. 10. Only seals are available as service parts.

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PRESSURE TESTING 1. Raise the boom sufficiently to install the boom safety support 297451.

DANGER Do Not work under an unsupported boom. 2. Ensure preparation steps 1 & 2 of flow test procedure are completed before conducting pressure testing.

64 3. Remove cab trim panel to gain access to the test port. 4. Install 400 bar pressure gauge into the pressure test port using quick release coupler.

65 The following valves are accessible from within the cab after the trim panel is removed:-Main relief valve (1) Tilt cylinder piston end relief valve (2) Telescopic cylinder piston end relief valve (3) The following valves are accessible from outside the cab after the control access panel has been removed:-Tilt cylinder rod end relief valve Lift cylinder piston end relief valve

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Relief Valve Locations 1. 2. 3. 4. 5.

Tilt Cylinder Piston End Telescopic Cylinder Piston End Main Relief Valve Lift Cylinder Piston End Tilt Cylinder Rod End

270 bar 200 bar 260 bar 270 bar 190 bar

67 System Pressure Test 1. Set engine speed to 2200 rev/min 2. Operate auxiliary hydraulic thumb control (3). 3. Indicated pressure should be 260 bar. Adjust Valve if required.

68 NOTE: If the tilt cylinder piston end or lift cylinder piston end relief valves are to be included in the pressure testing, then increase main relief valve to 280 bar at this stage. Locknut: 19 mm Adjuster: 5 mm internal

69 Telescopic Cylinder Relief Valve 1. Set engine speed to 1000 rev/min 2. Fully extend the telescopic cylinder and hold the thumb control (4) forward with the boom extended position. 3. Indicated pressure should be 200 bar. 4. Adjust valve if required.

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Circuit Relief Valve Adjustment Locknut: 17 mm Adjuster: 5 mm internal

71 Tilt Cylinder Relief Valves Rod End Relief Valve 1. Set engine speed to 1000 rev/min 2. Fully retract the tilt cylinder and hold the joystick in the dump position. 3. Indicated pressure should be 190 bar. 4. Adjust valve if required.

72 Piston End Relief Valve NOTE: The main relief valve must have been increased to 280 bar before this test. 1. Set engine speed to 1000 rev/min 2. Fully retract the tilt cylinder and hold the joystick in the dump position. 3. Indicated pressure should be 270 bar. 4. Adjust valve if required.

73 Boom Lift Cylinder Relief Valve NOTE: Ensure there is enough headroom to fully lift the boom. 1. Set engine speed to 1000 rev/min 2. Fully Lift the telescopic boom and hold the joystick in the lift position. 3. Indicated pressure should be 270 bar. 4. Adjust valve if required.

Reset the main relief valve to 260 bar 74

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Servo Hydraulic Circuit Pressure Test The pressure test checks the 40 bar servo circuit used by the brake servo, flow sharing joystick and solenoid controls, and the telescopic proportioning systems. 1. Fully retract the telescopic boom. Raise the boom sufficiently to install the safety support 297451 on the lift cylinder.

DANGER Do Not work under an unsupported boom.

75 2. Remove the control valve access panel from the cab. 3. Relieve residual servo circuit pressure by operating the brake pedal at least 40 times with the engine switched off. 4. Install test elbow (2) and adaptor (3), tool numbers 380001667 & 380000493, into ’U’ port line and connect a 60 bar gauge (1) and test hose long enough to reach inside the cab.

76 5. Start the engine and run at 2000 rpm. Apply the foot brake several times and observe gauge reading. 6. If maximum pressure is 40--45 bar, the pressure setting is to specification. 7. If the pressure is below 40 bar, remove the valve cap (1) add shims (2) to the spring and repeat pressure.

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Proportional Valve Adjustment A trimmer screw, accessible through an inspection hole in the cover, provides the adjustment. 1. Ensure the hydraulic oil temperature is at 50 -60o C. 2. Remove the plug from the module cover. 3. Start and run the engine at 1500 rev/min and extend the boom approximately 2 metres. 4. A small green LED, visible through the inspection hole, should be illuminated with the thumb control in neutral. 5. If the led is on the adjustment is correct. 6. If the LED is not illuminated, then adjust trimmer screw until the led remains on. 7. Replace the plug and valve access panel in the cab.

Valve Components 1. 2. 3. 4. 5.

End Cover Module Valve Housing Retaining Screw Valve Housing Plug

79 Proportioning Valve Module Replacement 1. Remove the control valve access panel in the cab. 2. Disconnect the module wiring connector. 3. Remove the four retaining screws and carefully withdraw the module. The solenoid valves and feed back rod may drop out of the module as it is removed. 4. Install the new module and reconnect the wiring connector. 5. Check neutral LED, and adjust if required. 80

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COMPONENT OVERHAUL The telescopic boom must be retracted and the safety support installed on the lift cylinder before attempting to remove or replace the pressure reducing valve or the main control valve.

DANGER Do Not work under an unsupported boom. Always relieve residual hydraulic line pressure by operating the controls with the engine switched off. Turn the key switch to the ’RUN’ position and operate telescopic and auxiliary thumb controls buttons to relieve pressure in these circuits. Operate the joystick to relieve pressure in the lift and tilt circuits.

81 Pressure Reducing Valve and Accumulator 1. With the engine switched off, operate the foot brake pedal at least 40 times to exhaust the accumulator residual pressure. 2. Remove the outer cab panel to gain access to the pressure reducing valve (1) and accumulator (2). 3. Identify and disconnect the hoses to ensure correct assembly. 4. Disconnect the hoses and remove the valve and accumulator as a unit. 5. Overhaul and inspect the components as described on page 47. 6. Installation follows the reverse of the removal procedure.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Disassembly

83 1. 2. 3. 4. 5. 6. 7. 8. 9.

Check Valve Ball Adapter Valve Spool Spring Shim Seal End Cap Plug Seal

Pressure Reducing Valve 10. Spring 11. Relief Valve 12. Housing 13. Plug 14. Seal 15. Sleeve 16. Check Valve 17. Spring 18. Connector

7. Disassemble and clean the valve with reference to figure above. Inspection 1. Wash components in an approved degreaser. 2. Inspect spool, check valve and relief valve and seats for scoring and damage. If the spool or badly scored or worn the valve assembly must be replaced.

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Re--assembly 1. Re--assemble in reverse order to disassembly use new oil to lubricate the components. 2. Install the valve assembly and reconnect hoses. 3. Carry out pressure test and if required adjustment, referring to page 45.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Main Control Valve The telescopic boom must be retracted and the safety support installed on the lift cylinder before attempting to remove or replace the pressure reducing valve or the main control valve.

84 1. Remove the outer cab panel (2) and the deck panel (1) on top of the chassis to gain access to the main control valve.

85 2. Identify the cylinder hose connections to the control valve to ensure correct reassembly. 3. Disconnect and plug the cylinder hoses (1), starting at the front of the valve, then remove load sensing return hose (2) main feed hose (3) and reservoir return hose (4).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

4. Remove the valve access panel from inside the cab. 5. Disconnect the proportional valve harness connector (2).

87 6. Disconnect and plug the pressure test hose 7. Identify and then disconnect and plug the two hose connected to the proportioning valve (1) and the upper servo control hoses (2) from inside the cab. 8. Identify and then disconnect and plug the lower servo control hoses (3) from inside the cab.

WARNING The control valve is heavy and there is limited access to remove it from the location on the side of the cab. Therefore an assistant will be required to take some of the weight of the valve using a suitable strap from within the cab while the 3 mounting bolts are removed.

9. Remove the 3 mounting bolts (4). 10. Allow the valve to rest on the chassis. 11. Lift the valve from the machine with the aid of an assistant. 12. Overhaul & inspection procedures are described in the following pages Valve Installation 1. Installation is the reverse of the removal procedure 2. Check hydraulic reservoir oil level and top up if required. 3. Carry out any pressure testing and adjustment referring to pages 42 --44.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Control Valve Disassembly 1. Make a diagonal mark across the back of the control valve assembly using a permanent marker pen. 2. Stand the valve assembly upright on the inlet end section. 3. Remove the tie rod nuts and lift off each section. 4. Disassemble each section while referring to the appropriate exploded view. Clean all the disassembled components.

91 1. 2. 3. 4.

Auxiliary Section Tilt Section Lift Section Telescopic Section

Control Valve Sections 5. Inlet End Section 6. Tie Rods 7. Nuts 8. End Cover

5. Inspect the spools and their bores for any scoring or excessive wear. The spool and valve body are not serviced separately. 6. Service kits are available for the check valves, pressure compensating valves, the relief valves and seals. 7. Always replace all seals and ’O’ rings.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Control Valve Section Seals 1. 2. 3. 4.

Load Sensing Gallery Reservoir Gallery Closed Centre Gallery Reservoir Gallery

93 1. 2. 3. 4. 5. 6. 7.

Spool Cap Centring Spring Spool Plug Spring Load Check Valve Spring Seat

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Typical Control Valve Section 8. ’O’ Ring Seal 9. Plug 10. Pressure Compensation Spool 11. Pressure Compensation metering Element 12. Valve Section 13. Circuit Relief Valve (2 in Tilt Section)

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

94 Proportioning Valve NOTE: The proportioning valve may be removed and replaced without removing the control valve from the unit 1. --Remove the four retaining screws from the cover plate (2) and carefully remove the module.

95 2. As the module (1) is removed be prepared for the solenoid valves (2) and feed back rod (3) separating from the module.

96 3. Remove the two retaining screws from the piston housing and withdraw the assembly (1) from the control valve spool piston (2).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Proportioning Valve Assemblies 1. 2. 3. 4. 5.

Manifold Block Piston Housing Module & Solenoid Assembly Transfer Tubes & ’O’ Rings Inlet Gauze Screen

99 1. 2. 3. 4. 5.

Proportioning Valve Components 6. Valve Sleeve Module & Solenoid Housing 7. Spacer Spring 8. Valve Linear Transducer (Magnet) & Feed Back Rod 9. Connector Adapter & ’O’ Rings 10. Solenoid Core Insert & ’O’ Rings

1. The module and solenoids are only available as a complete assembly. 2. ’O’ ring seal kits are available as service parts.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

100 1. 2. 3. 4. 5. 6. 7. 8. 9.

Telescopic Section with Proportioning Valve 10. Electronic Module & Solenoid Housing Pressure Compensation Metering Element 11. Control Piston Housing Plug 12. Transfer Pipes (2) Pressure Compensation Spool 13. Inlet Filter Plug 14. Manifold Spring 15. End Plate & Seals Load Check Valve 16. Centring Spring & Seats Control Valve Spool 17. End Cap Seal Control Piston & ’O’ Rings

Control Valve Reassembly 1. Reassemble the individual sections fitting new seals 2. Assemble the valve sections in the correct order fitting new ’O’ rings between each section. 3. Tighten hardware to the specified values. 4. Install the control valve into the Telehandler and carry out testing and adjustment as described earlier in this section.

101

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Servo Control Valve Removal 1. Remove the cab floor mat and replace with oil absorbent pads, as there will be some oil loss when disconnecting the servo hydraulic hoses. 2. Relieve residual servo circuit pressure by operating the brake pedal at least 40 times with the engine switched off. 3. Remove the three bolts securing the servo control console support (3) to the operator’s seat. 4. Disconnect the control harness connector (2) from the main wiring loom. Remove cable ties securing the main harness to the servo hoses (1).

102

5. Pull up the hose trunking (1) to expose the servo hose connections (2) in the cab floor. 6. Identify each of the six hoses and then disconnect and plug each hose. 7. Remove the complete assembly from the cab.

103 The console consists of:-Support (3) Console Cover (1) The servo control Valve (2) is mounted to the support (3).

8. Remove the screws holding the console cover (1) to the support and remove over the joystick lever. 9. Remove the four screws (4) securing the servo control valve (3) to the support (2) and slide the valve forward to withdraw from the support. 10. Identify and then remove the six hoses (item 1 figure 103) from the base of the servo control valve.

104

Servo Control Valve Installation 1. Installation is the reverse of removal procedure. 2. After installation, check all connections for leakage. 3. Check the function of all the servo controls. 105

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 Servo Control Valve Overhaul 1. Loosen the locknut (4) on the joystick shaft and unscrew the lever (1) from the control valve rocker plate (3). 2. Remove the rocker plate retaining screw from the base unit, the threads are loctited in production. 3. Remove the rocker plate that will release the four plungers and control elements. 4. Wash the components in suitable cleansing fluid and inspect plungers, pistons and their bores for wear and scoring. 5. Only seal are available in service, if the parts are not suitable for further service, then a new assembly must be fitted.

106

107 1. 2. 3. 4. 5. 6.

Dust Cover Rocker Plate Mounting Plate Control Valve Assembly Return Spring Piston

Joystick Servo Control Valve Components 7. Washer 8. Reaction Spring 9. Spring Seat 10. Retaining Clip (2) 11. Retainer & Seal Assembly 12. Plunger

If the parts are suitable for further service, reassemble as follows. 6. Reassemble the control elements (items 5--12) in each bore. 7. Apply a loctite to the rocker plate retaining screw threads.

8. Install the mounting plate and carefully push down to locate the pistons and plungers and hold while replacing the rocker plate screw. 9. Reconnect the six hoses to their original locations in the base of the valve and install into the console referring to page 56.

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10. Flow sharing joysticks with the optional rear hydraulic control buttons have a 12--pin connector to accommodate the additional wiring.

108 11. Flow sharing joysticks with the optional Electro Change Over Valve have an additional 2--pin connector in addition to either the 8--pin or 12--pin connector.

109 12. Two relays (3), operated by the boom auxiliary thumb control, are located on the control valve. The relays are part of an intermediate harness (4) between the main harness (1) and the joystick harness (2) on earlier machines, or part of the main harness on later machines.

110 13. When installing the joystick, ensure there is clearance between the steering wheel and joystick with the seat positioned fully forward. Adjust if required by slackening locknut (2). Turn the joystick handle with a spanner on the hexagon (1), and then retighten the locknut.

111

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Solenoid Control Valves

112 1. 2. 3. 4. 5.

Solenoid Retaining Nut Solenoid Valve Body retaining Nuts Valve Body

Solenoid Control Valves and Connections

An additional solenoid control valve is fitted above the boom auxiliary solenoid control valve if rear auxiliary option is fitted. Only the solenoids are available as service parts. If the complete valve is to be replaced, release residual servo circuit pressure as described on page 56.

Port Identification stamped on the valve 1. 2. 3. 4.

Return to Reservoir Boom Auxiliary Spool 40 bar pressure supply Boom Auxiliary Spool

1. Identify and then remove the servo connections from ports 1--4. 2. Disconnect the solenoid connectors. 3. Remove the retaining nuts and withdraw the valve assembly. Install the replacement valve assembly and reconnect the hose to ports 1--4.

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NOTES

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 3 -- Casappa Hydraulic Pump CONTENTS Section

Description

35 700

Hydraulic Pump

Page

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pump Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Flow Divider Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pump Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

HYDRAULIC PUMP ASSEMBLY The assembly consists of a gear type pump and load sensing flow divider. Pump output flows through the flow divider which provides priority oil flow to the steering and brake circuits. Hydraulic Pump Assembly 1. 2. 3. 4.

Flange Mounting Assembly Pump Body Flow Divider Valve Drive Shaft

1 Hydraulic Pump Ports 1. 2. 3. 4.

Pump Outlet to Telehandler Control Valve Pump Outlet to Steering Motor & Pressure Reducing Valve Pump Inlet Port Sensing Line Port

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

Flow Divider Valve The flow divider valve mounted on the side of the pump (1), consists of a housing (2) containing a load sensed steering priority valve. The housing is retained to the pump body by four allen screws, an ’O’ ring seal (3) is fitted between the pump body and the housing. The operation of the flow divider is described in chapters 1 & 2 of this section.

3 The flow divider assembly consists of the following parts, 1. 2. 3. 4. 5. 6. 7. 8. 9.

Housing Steering Priority Valve Spring Seat Shim End Cap Spring Restrictor Filter & Restrictor Assembly Adapter

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

FAULT FINDING -- HYDRAULIC PUMP PROBLEM System noisy.

Hyraulic oil exhausts from breather at the reservoir.

Oil heating.

POSSIBLE CAUSES

REMEDY

Worn or damaged pump gears or pressure plates. Aeration: Air entering the systems at: suction tube, pump shaft, fitings, or cylinder glands. Cavitation: Restrictions in the system at the suction line or at the suction screen in the reservoir. Water in the system. Tubing vibration. Cold hydraulic oil.

Hydraulic pump performance test.

Wrong type of oil being used.

Investigate/drain and refill.

Reservoir overfilled. Aeration: Air entering the systems at: suction tube, pump shaft, fitings, or cylinder glands. Cavitation: Restrictions in the system at the suction line or at the suction screen in the reservoir.

Check hydraulic oil level. Hydraulic pump performance test.

Oil supply low. Contaminated oil.

Fill reservoir. Drain reservoir and refill with clean oil. Drain reservoir and refill with clean oil. Test relief valves. Drain reservoir and refill with correct viscosity oil. Clean oil cooler.

Setting of relief valve too high or too low. Oil in system too light. Oil cooler fins blocked.

Hydraulic pump performance test.

Visual and/or hydraulic pump performance test. Visual Visual Check hydraulic oil operating temperature.

Visual and/or hydraulic pump performance test.

Shaft seal oil leakage.

Worn shaft seal.

Replace shaft seal and inspect pump.

Foaming oil.

Low oil level. Air drawn into suction line. Wrong oil grade.

Fill reservoir. Check/tighten suction line. Drain and refill with correct oil.

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

COMPONENT OVERHAUL Hydraulic Pump If the pump assembly is suspected of wear, carry out flowmeter performance tests to determine the condition of the pump prior to removal. The load sensing flow divider valve can be serviced without removing the pump. Pump Removal and Installation (Op No 35 700) 1. Retract the boom and lower the boom to the ground. 2. Position a suitable drain tray beneath the pump and disconnect the following connections,

Pump with Powershuttle Transmission 1. 2. 3. 4.

Suction Hose Steering Circuit Loader Control Circuit Load Sensing Line

Remove the mounting bolts and lower the pump from the machine.

6 Pump with Powershift Transmission 1. 2. 3. 4.

Loader Control Circuit Suction Hose Steering Circuit Load Sensing Line

Remove the mounting bolts and lower the pump from the machine.

7 Installation 1. Installation is the reverse of removal procedure. 2. Tighten retaining nuts to a torque of 80--100 Nm (60--74 lbf.ft)

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

3. Check oil level in reservoir in the sight glass (2). Add specified oil to bring up to the required level. 4. Operate the boom hydraulics and steering to check for correct operation and any oil leaks.

9 Flow Divider Valve Overhaul The flow divider valve can be serviced without removing the pump from the machine. Clean the area around the flow divider valve. 1. Disconnect the load sensing line (4).

10 2. Remove the four retaining screws and remove the flow divider assembly (2) from the pump (1). Discard the ’O’ ring (3).

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

3. Remove the end cap (5), shims (4), spring (6) and seat (3), and priority valve (2) from the housing (1). 4. Unscrew the restrictors (7 & 8) from either end of the priority valve. 5. Remove the adapter (9) from the housing. 6. Wash all parts in an approved degreaser and inspect as follows:-Restrictor (7) and adapter (9) for restriction or contamination. Restrictor and filter assembly (8) for restriction or contamination. Check the spool and bore for damage. The spool should slide freely in the bore in the housing. Provided the parts are suitable for further service, reassemble into the housing using clean oil to lubricate. Flow Divider Valve Reassembly 1. Install the restrictors (7 & 8) into their location in either end of the priority valve. 2. Install priority valve (2), spring (6) ,seat (3), and shims (4), into the housing (1) and fit the end cap (5). 3. Tighten end cap to a torque of 98--108 Nm (72--79 lbf.ft.) 4. Install the adapter (9) into the housing and tighten to 45 Nm (33 lbf.ft.).

13 5. Install a new ’O’ ring (3) on the pump body. 6. Locate the flow divider valve assembly and fit the allen screws. 7. Tighten the screws evenly to maximum of 46--51 Nm (34--38 lbf.ft.) 8. Check oil level in reservoir in the sight glass and add specified oil to bring up to the required level. 9. Operate the boom hydraulics and steering to check for correct operation and any oil leaks.

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

PUMP OVERHAUL Remove the pump from the transmission as described on page 3. Flow Divider Removal 1. Remove the flow divider assembly (2) from the pump body (1) 2. Discard the ’O’ ring located on the pump outlet port. Flow divider overhaul is described on page 4.

16 1. 2. 3. 4. 5.

Flange Mounting Pump Body ’O’ Ring Seal Plastic Back--up Seal Pressure Seal

Hydraulic Pump Components 6. Pump Gears 7. Bearing Block 8. Seal 9. Circlip 10. Seal

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

Pump Disassembly 1. Remove the four retaining screws and separate the flange (1) from the pump body. 2. Tilt the open end of the pump body downwards and slide the pump gears (6) and bearing blocks (7) out of the body as an assembly. 3. Separate the bearing blocks and gears, noting the position of the bearing blocks on the gear shafts and in relation to the inlet and pressure ports. Remove the seals (4/5) from the bearing blocks. NOTE: The open end of the bearing block seal and back up seal face towards the inlet port. 4. Remove the circlip (9) and seals (8/10) from the flange. Inspection 1. Wash all components in approved degreasant. 2. Inspect the wear track cut by the gears in the inlet side of the pump body. The body can be re--used if the track is bright and polished and does not exceed 0.15 mm in depth. 3. Examine bearing block faces for scoring. 4. Inspect PTFE coated bearings in body or flange for wear. If bearings are worn the bronze backing will be revealed. 5. Examine pump gears for scored or worn side faces, journals and damaged teeth. 6. Examine flange seal contact area on driveshaft. If pump block, gears, bearing blocks or drive shaft are worn the pump assembly must be replaced.

Re--assembly 1. Re--assemble using disassembly procedure in reverse whilst observing the following:-• Ensure all parts are perfectly clean and lubricate bushes and gears with clean hydraulic fluid. • Replace all seals and ‘O’ Rings.

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

2. Install bearing blocks (1) into the same positions from which they were removed. • Ensure back--up seals are correctly positioned in the seal.

19 3. Fit a new ’O’ ring into the groove in the body to flange mating surface. Install the flange (1) onto the pump body (2). 4. Install the pump retaining screws and tighten to specified toque. 5. Install flow divider valve assembly (4) with a new ’O’ ring (3). 6. Install retaining screws and tighten to specified torque.

20 7. Coat the seal lips with high melting point grease. Install inner seal (1) with the spring and lip facing into the pump. Install the outer seal (2) with the garter spring and lip facing outwards. 8. Refit the retaining circlip (3). NOTE: If the seal recess has been scored during seal removal, coat the outer diameter surface of the new seals with flexible gasket sealant 82995770 to prevent leakage.

21 9. Recheck screw tightening torques. 10. Install pump onto the transmission as described on page 3.

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SECTION 35 -- CASAPPA HYDRAULIC PUMP -- CHAPTER 3

NOTES PAGE

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 4 -- Hydraulic Cylinders and Counterbalance Valves CONTENT Section

Description

Page

35 000

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and Operation Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Counterbalance Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

35 730

Counterbalance Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cylinder Removal and Installation Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Compensating Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Internal Telescopic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 External Telescopic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

35 730

Cylinder Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Specifications Thread Sealant Grease Counterbalance Load Holding Valves Location Lift Cylinder Piston End Tilt Cylinder Piston End 2 Section Telescopic Boom Cylinder Piston End 3 Section Boom External Telescopic Cylinder Piston & Rod End Special Tools Adjustable Spanner Wrench

New Holland Thread Sealant 82995773 NH 720A, NLG12, MIC 75--B

315 bar 315 bar 320 bar

300 bar

65--115 mm 115--160 mm

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

DESCRIPTION AND OPERATION The hydraulic cylinders are double acting and are located in the boom to control the telescopic boom elements, as illustrated in figure 4. Counterbalance (load holding) valves are fitted to each cylinder as a safety feature to ensure the cylinders remain hydraulically locked should there be a hose failure.

1 Telescopic Boom Controls Mechanical Controls 1. 2. 3. 4. 5.

Auxiliary Services Control Boom & Fork Control Lever Boom Telescopic Control Optional Rear Auxiliary Control Button control selects change over to additional Auxiliary Service

2 Monoramp System Controls 1/2. 3/4. 5. 6. 7.

Boom Telescopic Control Buttons Auxiliary Services Control Buttons Boom & Fork Control Lever Control Button selects change over to additional Auxiliary Service Optional Rear Auxiliary Control

3 Flow Sharing System Controls 1/2. 3. 4. 5. 6.

Optional Auxiliary Control Buttons Auxiliary Control Roller Telescopic Control Roller Servo Cotrol Joystick -- Boom & Fork Auxiliary Change Over Button

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5 1. 2.

Hydraulic Cylinders Telescopic Cylinder with Double Counterbalance 3. Tilt Cylinder with Counterbalance Valve Valve (Double Telescopic Boom Section only) 4. Lift Cylinder with Counterbalance Valve Telescopic Cylinder 5. Compensation Cylinder

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6 1. 2. 3. 4. 5.

Lift and Telescopic Cylinder Circuit Components 6. Telescopic Cylinder Counterbalance Valve Internal Telescopic Cylinder -- 2 Section Boom 7. Telescopic Cylinder Counterbalance Valve Lift Cylinder 8. External Telescopic Cylinder -- 3 Section Boom Lift Cylinder Counterbalance Valve 9. Internal Telescopic Cylinder -- 3 Section Boom Telescopic Cylinder Counterbalance Valve Hydraulic Control Valve

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7 1. 2. 3. 4. 5.

Tilt and Auxiliary Cylinder Circuit Components Auxiliary Quick Release Couplings The compensating cylinder is mechanically Tilt Cylinder extended or retracted as the boom raises or lowers. Tilt Cylinder Counterbalance Valve The compensating cylinder is connected in parallel Compensation Cylinder with the tilt cylinder and has the same displacement. Hydraulic Control Valve

The cylinder provides hydraulic self levelling to the tilt cylinder as the boom raises or lowers.

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Counterbalance Valves The counter balance valves are mounted on their respective cylinders as illustrated. 1. Lift Cylinder

8 2. Tilt Cylinder

9 3. Internal Telescopic Cylinder

10 4. External Telescopic Cylinder

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12 1. 2. 3. 4. 5. 6. 7.

Safety Valve Body Spring Seat Spring Adjuster Seal Locknut Valve Spool

Single Cartridge Counterbalance Valve Components 8. Check Valve Sleeve 9. Spring 10. Spring Seat 11. Dashpot Relief Valve 12. Housing 13. Adjuster & Locknut

Single Cartridge Counterbalance Valve Schematic Diagram

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Counter Balance (Load Holding) Valve The counterbalance (load holding) valves are fitted to the lift, tilt and telescopic cylinders to ensure that the cylinder ram remains locked in position if a hose fails. With these ttype of load holding valves the cylinders cannot be retracted unless the engine is running and control valve spools are being operated. Where the double extension boom arm is fitted a double acting over centre counterbalance valve is fitted and prevents both the cylinder and rod end of the telescopic cylinder from being operated unless the engine is running. A. Extending the Cylinder When a cylinder fitted with a counterbalance valve is extended oil flows from the control valve to port V2 and through the check valve to Port C2. Return oil from the cylinder returns freely from Port C1 to Port V1 and back to reservoir through the control valve. B. Load Holding (Neutral) When the control valve is in neutral the back pressure generated in the circuit by the weight of the telescopic boom and load, holds the check valve onto its seat and prevents the cylinder retracting. C. Retracting the Cylinder When a cylinder is to be retracted oil flows from Port V1 to Port C1 but the pressure of oil exhausted from the cylinder into Port C2 is insufficient on its own to move the double pilot spool against the safety valve spring and allow the cylinder to retract. Pressure

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applied to the cylinder through Port V1/C1 is therefore also applied as a pilot pressure through the screw threads of the pilot screw to the end face of the spool. This pressure in combination with the back pressure applied to the spool through Port C2 moves the spool against the safety valve spring allowing oil exhausted from the cylinder to return to reservoir. D. Retracting Cylinder In certain conditions, the pilot spool opening creates aggressive cylinder operation due to the restriction created by the adjuster screw threads to the V1/C1 releasing pressure oil. The dashpot relief valve will open at 110 bar providing a bypass past the adjuster threads V1/C1 releasing pressure oil. This produces a smooth cylinder operation especially with lighter loads. E. Safety Valve Operation If a cylinder is subjected to shock loading, for example when driving with the telescopic boom extended and hitting the face of a wall, the shock load applied to the cylinder will be excessive. In this instance the pressure generated in the exhaust Port C2 is sufficient to move the spool against the safety valve spring and vent the excess pressure to reservoir through the circuit relief valve in the hydraulic control valve section. The moment the pressure has been relieved the safety valve will close and hold the cylinder.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

Counterbalance Valve Operation

A. B. C. D. E.

Pump Pressure Oil

Trapped Oil

Back Pressure Oil

Return to Reservoir Oil

Extending Load Holding Retracting -- Initial Condition Retracting -- Normal Condition Safety Valve Operation

1. 2. 3. 4. 5.

Pilot Screw Pilot Spool Check Valve Sleeve Relief Valve Dashpot Relief Valve

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15 1. 2. 3. 4.

Relief Valve Valve Housing Pilot Screw Relief Valve Adjuster

Double Cartridge Counterbalance Valve 5. Check Valve Sleeve & Spring 6. Pilot Spool 7. Pilot Screw

Double Cartridge Counterbalance Valve Schematic Diagram The double cartridge counterbalance valve provides load holding capability in both directions. This type of valve is used on the 3--section boom external telescopic cylinder.

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COUNTERBALANCE VALVES Removal and Installation Before any counterbalance or cylinder removal operations, refer to page 2 and check out the operation of the loader hydraulic controls. Always relieve residual hydraulic line pressure by operating the controls with the engine switched off. With mono ramp type controls, turn the key switch to the ’RUN’ position and operate telescopic and auxiliary control buttons to relieve pressure in these circuits. With flow sharing system controls, turn the key switch to the ’RUN’ position and operate telescopic and auxiliary control buttons to relieve pressure in these circuits, and also operate the joystick control to relieve pressure in the lift and tilt circuits. Lift Cylinder Counterbalance Valves

DANGER DO NOT remove the lift counterbalance valves with the boom raised unless the boom support is installed on the lift cylinder. 1. Fully retract the telescopic boom. Raise the boom sufficiently to install the safety support 297451 on the lift cylinder.

17 2. Clean the valve housing (1) before removing from the cylinder. 3. Identify each hose to ensure correct reassembly. 4. Disconnect the hoses (2 & 3) from the valve. 5. Remove the four mounting bolts and remove the assembly from the cylinder.

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Lift Cylinder Counterbalance Valve Flow Sharing System Only 1. Fully retract the telescopic boom. Raise the boom sufficiently to install the safety support 297451 on the lift cylinder. 2. Remove the panel covering the hoses on top of the chassis. 3. Clean the valve housing (2) before removing from the cylinder. 4. Identify each hose to ensure correct reassembly. 5. Disconnect the hoses (1, 3 & 4) from the valve. 6. Remove the four mounting bolts and remove the assembly from the cylinder.

Telescopic and Tilt Cylinder Counterbalance Valves Fully retract the telescopic boom and lower the boom to the ground. Relieve residual pressure using with the controls. DO NOT loosen the valve mounting bolts unless the boom is fully lowered to the ground. Beware of residual cylinder pressure when slackening the valve retaining bolts.

20 Telescopic Cylinder Counterbalance Valve Internal Cylinder 2 & 3 Section Booms 1. Fully retract the telescopic boom and lower loader to the ground. 2. Clean the valve housing (5) before removing from the cylinder. 3. Remove the hose clamps from the Auxiliary hoses (4) and tilt hoses (3) to provide easier access to the valve (5). 4. Identify each hose to ensure correct reassembly. 5. Disconnect the hoses (1 & 2) from the valve. 6. Remove the four mounting bolts and remove the assembly from the cylinder.

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Telescopic Cylinder Counterbalance Valve External Cylinder 3 Section Booms Only 1. Fully retract the telescopic boom and lower loader to the ground. Clean the valve housing (1) before removing from the cylinder. 2. Identify each hose to ensure correct reassembly. 3. Disconnect the hoses (2 &3) from the valve. 4. Remove the four mounting bolts and remove the assembly from the cylinder.

22 Tilt Cylinder Counterbalance Valve 1. Fully retract the telescopic boom and lower loader to the ground. 2. Clean the valve housing (1) before removing from the cylinder. 3. Identify each hose to ensure correct reassembly. 4. Disconnect the hoses (2 & 3) from the valve. 5. Remove the four mounting bolts and remove the assembly from the cylinder.

23 Installation 1. Installation of all counterbalance valves follows the removal procedure in reverse. 2. Ensure ’O’ rings (1) are replaced and correctly installed. 3. Reconnect hoses in the correct location and tighten the valve mounting bolts to the specified torque.

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Disassembly

25 1. 2. 3. 4. 5. 6. 7.

Safety Valve Body Spring Seat Spring Adjuster Seal Locknut Valve Spool

Single Cartridge Counterbalance Valve Components 8. Check Valve Sleeve 9. Spring 10. Spring Seat 11. Dashpot Relief Valve 12. Housing 13. Adjuster & Locknut

NOTE: Specialised equipment is required to adjust the safety cartridge in these valves. If operation of the valve is suspect restrict any overhaul to disassembly of items (1) to (5) and adjustment of pilot screw item (12). If the safety cartridge items (6) to (11) is suspected of being faulty replace the complete safety cartridge. Double Cartridge Counterbalance Valve Where the double cartridge counterbalance valve, Figure 26, used on the double extension telescopic booms is required the overhaul procedure is identical to that for the single valve. 26

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Adjustment 1. Adjusting screw (1) should protrude 22--23 mm (X). 2. Some fine adjustment may be necessary on the lift cylinder counterbalance valve to achieve smooth cylinder operation under load. 3. The safety relief valve and dashpot relief valve are both preset in manufacture, and should not be adjusted.

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CYLINDER REMOVAL AND INSTALLATION (Op No 35 730) NOTE: The threads of the cylinder gland are coated with sealant during manufacture. If the cylinder is to be disassembled after removal a high torque may be required to loosen the cylinder gland. It is therefore recommended that where possible the gland is loosened white the cylinder barrel is still connected to its fixing point on the machine. Do Not attempt to loosen the gland white the cylinder ’piston rod’ pivot pin is attached to the machine. If the gland cannot be loosened heat the threaded area of the gland to 250°C using a hot air gun. Tilt Cylinder Removal 1. Fully extend tilt cylinder and support fork attachment apron on axle stands.

28 2. Switch off engine and relieve residual pressure in circuit by operating controls.

29 3. Using suitable marker or tape identify the hoses connected to the cylinder. 4. Position drain tray under hose connections and disconnect hoses. 5. Remove circlip securing cylinder rod pivot pin to, apron and using brass drift remove pin.

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6. Support the cylinder using a suitable sling passing through the boom head greasing point (1).

31 7. Ensure the sling is securely attached around the cylinder before removing the top pivot pin.

32 8. Remove the circlip securing cylinder barrel pivot pin to boom and using brass drift remove pin. 9. Carefully lower cylinder from boom.

33 Installation 1. Install cylinder using removal procedure in reverse. 2. Grease pivot pins using grease to Specification NLG12, MIC 75--B or NH 720 A. 3. Reconnect hoses and check for leaks before using the machine.

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Compensation Cylinder Removal 1. Remove the battery tray covers. 2. Lower boom.

34 3. Switch off engine and relieve residual pressure in circuit by operating controls with engine Off. 4. Using suitable marker or tape identify the hoses (2) connected to the cylinder. 5. Position drain tray under hose connections then disconnect hoses. 6. Remove the circlip and using brass drift remove pin (3). 7. Remove retaining bolt securing cylinder barrel pivot pin (1) and using brass drift remove pin. 8. Carefully remove cylinder.

35 Installation 1. Install cylinder using removal procedure in reverse. 2. Grease pivot pins using grease to Specification NLG12, MIC 75--B or NH 720 A. 3. Reconnect hoses and check for leaks before using the machine.

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Lift Cylinder NOTE: Although, the lift cylinder can be removed while the boom is fitted to the machine difficulty may be experienced when re installing the cylinder barrel pivot pin. Overhaul of the cylinder piston seals and gland can however be be performed without completely removing the cylinder barrel provided the boom is safety supported. Removal 1. Remove the covers.

36 2. Retract telescope and raise boom to allow access to the cylinder rod end pivot pin. 3. Support boom using an overhead hoist (1) attached to the boom lifting eye or suitable stand positioned at front of boom. Ensure hoist is capable of lifting 1150 kg.

WARNING DO NOT work under an unsupported boom.

37 4. Support the cylinder using a hoist or stand (2). If a stand is used position suitable packing material between stand and cylinder rod to ensure the rod is not damaged. 5. Remove circlip from pivot pin and using brass drift drive out pin (1).

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6. Carefully lower cylinder and support on a block or stand in the horizontal position.

39 7. If cylinder piston and gland seals are to be replaced use adjustable spanner wrench (1) to loosen gland by turning it very slowly and evenly. The glands are locked in position using thread seal and if loosening the gland is difficult pull cylinder rod out of barrel by 200 mm and use a hot air gun to heat end of gland to 250°C and break the seal. 8. Completely unscrew gland and remove rod and piston from barrel. 9. Overhaul cylinder gland and seals with reference to overhaul procedure on Page 12. 40 10. If cylinder is to be completely removed from machine ensure cylinder hoses are not obstructing cylinder barrel pivot pin. 11. Remove circlip securing barrel end pivot pin and using brass drift and suitable mallet drive out drive out pin. 12. Carefully remove cylinder. Installation 1. Install cylinder using removal procedure in reverse. 2. Grease pivot pins using grease to Specification NLGI2, MIC 75--B or NH 720 A. 3. Reconnect hoses and check for leaks before using the machine.

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Internal Telescopic Cylinder Removal 1. Remove the battery tray covers. 2. Lower then slightly incline the boom and extend the telescopic boom 20 cm (8.0 in). 3. Support the boom on a suitable stand, switch off engine and relieve residual pressure in circuit by operating controls with engine Off.

42 4. To gain access to the end of the boom (1) remove the: -- Engine Hood -- Engine air cleaner assembly -- Boom back plate assembly -- Engine Exhaust Assembly (if required)

43 5. Remove the two hose clamps (4), (13 mm wrench) and disconnect the following: Tilt cylinder hoses (3). Accessories circuit hoses (1). Telescope cylinder hoses (2). 6. Cap the hose tubes and cylinder valve openings to prevent any dirt entering the system.

44 7. Support the cylinder using a hoist or stand (2). If a stand is used position suitable packing material between stand and cylinder rod to ensure the rod is not damaged. 8. Remove circlip from pivot pin and using brass drift drive out pin (1).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

9. Remove retaining bolt securing cylinder barrel pivot pin. 10. Using brass drift and suitable hammer drive out cylinder barrel securing pin.

46 11. Place a plank (about 4 cm thick) on the radiator and using a suitable lifting system (forklift truck), remove the cylinder by pulling it from the rear of the boom.

47 Installation 1. Install cylinder using removal procedure in reverse. When installing the cylinder check that the cylinder pivot point is correctly aligned. Withdrawing the rod slightly from the barrel will assist in aligning the pivot point. 2. Grease pivot pins using grease to Specification NLG12, MIC 75--B or NH 720 A. 3. Reconnect hoses and check for leaks before using the machine.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

External Telescopic Cylinder (3 Section Telescopic Boom)

49 Removal 1. Lower boom and disconnect hoses to cylinder. 2. Switch off engine and relieve residual pressure in circuit by operating controls. 3. Support cylinder using suitable hoist. 4. Identify and disconnect cylinder hoses (1) at front of cylinder. 5. Remove circlip on cylinder pivot pin and using brass drift and suitable hammer drive out pin. 6. Identify and disconnect hoses (4) from load holding valve. 7. Remove circlip on cylinder pivot pin and using brass drift and suitable hammer drive out pin. 8. Lift cylinder from boom. Installation 1. Install cylinder using removal procedure in reverse. 2. Grease pivot pins using grease to Specification NLG12, MIC 75--B or NH 720 A. 3. Reconnect hoses and check for leaks before using the machine.

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Cylinder Overhaul (Op No 35 730) NOTE: The gland and piston seal arrangements within the cylinders differs according to the application of the cylinder The following instructions apply generally to the overhaul of cylinders and reference must be made to Figures 59 to 63 for the various piston and seal arrangements which may be found within the cylinders. Adjustable spanner wrenches 65--115 mm or 115--160 mm are necessary to overhaul these cylinders. 50 Disassembly 1. Thoroughly drain oil from cylinder. Cap the ports and clean the exterior so that the internal parts will not become contaminated. 2. Place the pivot point of the barrel in a vice fitted with soft jaws and support cylinder barrel on a suitable stand. 3. Flatten the gland locking tab.

51 4. Using correct size adjustable spanner wrench loosen and remove the cylinder gland by turning it very slowly and evenly. The glands are locked in position using thread seal and If loosening of gland is difficult pull cylinder rod out of barrel by 200 mm and use a hot air gun to heat end of gland to 250°C and break the seal. IMPORTANT: Never force the gland as this may cause it to seize.

52 5. Withdraw the piston and rod from the barrel. 6. Secure the cylinder rod trunnion in a vice with soft jaws and support rod on a suitable stand. 7. Remove locking screw. Note the locking screw has been installed using thread seal and staked in position during manufacture.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

8. Unscrew piston using 65--115 mm adjustable spanner wrench.

54 Seal Replacement Refer to Figures 59 to 63 for specific details on piston and gland seal arrangements for each type of cylinder. IMPORTANT: Never use screwdrivers or knives when removing seals and ensure work area is clean. 1. Remove seals taking care not to damage the locating grooves in the piston and gland. 2. Degrease and clean piston and gland using an approved cleaner. 3. Check that the grooves are clean, smooth and not damaged with scratches. 4. Examine the cylinder rod and check that it is straight over its entire length using a dial indicator. 5. Check that the rod surface finish is not damaged. 6. Slide the gland onto the cylinder rod and move it up and down the length of the rod. The gland should slide freely but not have an excessive gap between rod and gland bore diameters. 7. Fit new ’O’ ring and seals. When fitting piston seals open them sufficiently to slip into the grooves in the piston while ensuring they do not break. 8. When fitting new seals and ’O’ rings onto the gland ensure the lip on the stem seal faces towards the pressure side.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

9. To fit the stem seal, first position the edge of the seal into the groove holding it back with your thumb. 10. Gently push the seal into the groove with the other hand. If the seal is a tight fit dip the seal into hydraulic oil heated to 50°C.

56 Re--Assembly 1. Slide gland onto cylinder rod and then install piston. NOTE: On pistons where a bush is fitted the groove on the face of the bush must be positioned towards the piston.

57 2. Tighten piston onto rod until the position where the locking screw ’bites’ into the rod is the same as before the piston was removed in step 4 page 2. 3. Apply New Holland thread sealant 82995773 to locking screw and install. Tighten screw to a torque of 20 Nm and strike with a chisel to drive screw into the metal. 4. Using a brush, coat the piston seals with oil. 5. Carefully assemble piston and rod into cylinder barrel ensuring that the seals are not damaged by the thread inside the top of the cylinder. 6. Apply New Holland sealant 8A95773 to gland and tighten gland. NOTE: Take care not to cross threads when threading gland into barrel. When threads are correctly aligned only a little effort is required to tighten the gland. 7. Deform locking tab to prevent gland from moving.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

59 1. 2. 3. 4. 5. 6. 7.

Bush (4 off) Cylinder Barrel Piston Rod Scraper Ring Rod Seal ’O’ Ring Back--up Ring

Tilt Cylinder -- Typical 8. ’O’ Ring 9. ’O’ Ring 10. Piston Seal 11. Locking Screw 12. Piston 13. Sleeve 14. Sleeve

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60 1. 2. 3. 4. 5. 6.

Bush (2 off) Cylinder Barrel Piston Rod Scraper Ring Rod Seal Back--up Ring

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Compensation Cylinder -- Typical 7. ’O’ Ring (2 oft) 8. ’O’ Ring 9. Piston Seal 10. Locking Screw 11. Piston 12. Gland

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

61 1. 2. 3. 4. 5. 6. 7. 8. 9.

Bush (4 off) Cylinder Barrel Piston Rod Scraper Ring Rod Seal (2 oft) Sleeve (2 off) Back--up Ring ’O’ Ring (3 off) ’O’ Ring

Lift Cylinder -- Typical 10. Support Sleeve 11. Back--up Ring 12. Support Sleeve 13. Back--up Ring 14. Piston Seal 15. Locking Screw 16. Piston 17. Bush 18. Gland

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

1. 2. 3. 4. 5. 6. 7.

Telescopic Cylinder -- 2 Section Telescopic Boom -- Typical 8. Gland 9. Piston Rod 10. Cylinder Barrel 11. Scraper Ring 12. Rod Seal 13. ’O’ Ring (2 off) 14. Piston seal

62 Circlip Bush Piston Locking Screw Spacer Bush Ring

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

63 Telescopic Cylinders -- 3 Section Telescopic Boom -- Typical 11. Ball 1. Cylinder Barrel (Typical) 12. Bush 2. Piston Rod 13. Circlip 3. Scraper Ring 14. Pin 4. Seal 15. ’O’ Ring (2 off) 5. ’O’ Ring 16. Seal (2 off) 6. Bush 17. Piston Seal 7. Locking Ring 18. ’O’ Ring 8. Locking Screw 19. Back--up Ring 9. Piston 20. Gland 10. Bush

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 4

NOTES PAGE

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 5 -- Smooth Ride Control CONTENTS Section

Description

Page

35 000

Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System Oil Flows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Flow Divider Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Specifications Smooth Ride Control Valve Pressure Settings Counterbalance Valve Relief Valve Dashpot Relief Valve Accumulator Capacity Tightening Torques Solenoid Valve Cartridge Counterbalance Valve Dashpot Relief Valve Safety Valve

320--335 bar 55--60 bar 1.5 litres @ 30 bar

54--66 Nm 60--70 Nm 27--30 Nm 2--6 Nm

Adjustments Safety Valve Disc Clearance Counterbalance Valve Adjuster Protrusion* * Adjustment under load conditions

1.8 mm 20 --23 mm

The Smooth Ride Control electrical system is covered in Section 55, Chapter 9.

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Description and Operation The Smooth Ride Control provides a boom cylinder suspension system to improve the Telehandler ride when travelling across fields or on the highway. The Smooth Ride Control system operates from ground level to 3 metres above the ground, equivalent to boom elevation angle of 35° on LM 415/425A and 31° on LM 435/445A. The system consists of a control valve, accumulator, dash mounted control switch and electrical system.

1 The Smooth Ride control valve is mounted on the lift cylinder and incorporates the cylinder counterbalance (load holding) valve. The control valve is operated by two solenoids (1 & 3) and a pressure switch (2).

2 The accumulator (2) is mounted above the fuel tank and connected to the Smooth Ride Control valve by a hose (1). The control switch activates or de--activates the system. The 3--position switch is self centring. To activate the system:-1. Start the engine 2. Fully lower the boom* 3. Depress switch at A 4. Green LED (A) will illuminated to indicate the system is activated. * This relieves residual pressure on the pressure switch to allow the switch to close.

To de--activate the system:-1. Depress switch at B 2. Turn off the key switch The Smooth Ride control valve solenoids are temporarily de--energised when the joystick is used to:-1. Extend or retract the tilt cylinder* 2. Lower the boom* 3. Raise the boom more than 3m above the ground. * LED temporarily turned off

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

5 1. 2.

Lift Cylinder Smooth Ride Control Valve

Smooth Ride Control System Component Layout 3. Accummulator 4. Reservoir

V1. Loader Control Valve Lower Port V2. Loader Control Valve Lift Port

C1. Cylinder Rod End C2. Cylinder Piston End

Smooth Ride Valve Component Location 1. 2. 3. 4. 5. 6. 7.

Solenoid valve (Y22) Pressure Switch (S39) Check Valve Solenoid Valve (Y21) Relief Valve Cartridge Dashpot Relief Valve Adjuster

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

7 1. 2. 3. 4.

Smooth Ride Control Valve Components 5. Overload Relief Valve Cartridge 6. Check Valve & Unload Valve Spool 7. Check Valve & Unload Valve Spool 8. Adjuster

Solenoid Valve Check Valve Safety Cut Off Valve Solenoid Valve

Smooth Ride Valve Operation -- Reference Figures 8 -- 12

1. 2.

Component Solenoid Valve (Y22) Pressure Switch (S 39)

3. 4. 5.

Safety Cut Off Valve Check Valve Solenoid Valve (Y21)

6. 7. 8. 9. 10. 11.

Relief Valve Cartridge Overload Relief Valve Load Check Valve Unload Valve Spool Dashpot Relief Valve Adjuster

604.55.181.01 09-- 2004

Function Connects lift cylinder rod end to reservoir when energised Normally Closed (no pressure): Opened with pressure Must be closed to activate the system Prevents boom cylinder collapse if hose to the accumulator fails Allows initial oil fill Connects lift cylinder piston end to the accumulator when energised to provide boom suspension Contains overload relief valve Protects the lift cylinder from excess pressure Prevents cylinder creep down under load Releases cylinder piston end oil for lowering cycle Provides smooth initial lowering with cold oil Varies operation of unload valve spool

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

8 Smooth Ride Control Valve Oil Flow in Neutral with System Deactivated

Loaded Cylinder Pressure

Reservoir Return

Trapped Oil 1. 2. 3. 4. 5. 6.

Solenoid Valve (Y22) Pressure Switch (S 39) Safety Cut Off Valve Check Valve Solenoid Valve (Y21) Relief Valve Cartridge

7. Relief Valve 8. Load Check Valve 9. Unload Valve Spool 10. Dashpot Relief Valve 11. Adjuster

V1. Loader Control Valve Lower Port V2. Loader Control Valve Lift Port Acc Accumulator Port

C1. Cylinder Rod End C2. Cylinder Piston End T. Reservoir Port

With the Smooth Ride System deactivated, both solenoids are de--energised and the valves are closed. The accumulator is isolated from the lift cylinder piston end port C2 and cylinder rod end is isolated from the reservoir port T. The Smooth Ride control valve functions as a counter--balance (load holding) valve. With the lift valve section in neutral, the load check valve (8) is closed to hold the cylinder in position. Cylinder Overload in Neutral If the cylinder is subjected to a mechanical shock loading, the excess pressure generated through port

C2 acts on the tapered portion of the unload valve spool (9). When the generated pressure exceeds the relief valve spring pressure, the spool will move against the overload relief valve (7) and compress the spring. The tapered portion of the spool will now be clear of the check valve (8) to relieve the excess cylinder pressure through port V2 to the control valve section. The relief valve will close when the cylinder pressure is relieved.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

9 Smooth Ride Control Valve Oil Flow in Neutral with System Activated

Suspension Cylinder Pressure

Reservoir Return

Trapped Oil 1. 2. 3. 4. 5. 6.

Solenoid Valve (Y22) Pressure Switch (S 39) Safety Cut Off Valve Check Valve Solenoid Valve (Y21) Relief Valve Cartridge

7. Relief Valve 8. Load Check Valve 9. Unload Valve Spool 10. Dashpot Relief Valve 11. Adjuster

V1. Loader Control Valve Lower Port V2. Loader Control Valve Lift Port Acc Accumulator Port

C1. Cylinder Rod End C2. Cylinder Piston End T. Reservoir Port

With the system activated, both solenoids are energised and the valves are opened. Solenoid valve (5) is opened to connect the accumulator to the lift cylinder piston end port C2. Solenoid valve (1) is opened to connect the cylinder rod end port C1 to the reservoir port T. The boom cylinder is now free to ’float’ on the suspension provided by the accumulator connected to the piston end. The rod end of the cylinder is open to the reservoir to allow free cylinder movement.

When the joystick is moved to operate the forks or lower the boom, or the boom is raised more than 3 metres above the ground, the solenoids are temporarily de--energised and the valves closed. The reservoir port T is now isolated from ports V1 & C1 and oil in the lift cylinder rod end is trapped. This temporarily cancels the suspension system. When the joystick is returned to neutral, the solenoids are re--energised to reconnect the boom suspension system.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

10 Smooth Ride Control Valve Oil Flow in Lifting with System Deactivated

Cylinder Pressure

Reservoir Return

Trapped Oil 1. 2. 3. 4. 5. 6.

Solenoid Valve (Y22) Pressure Switch (S 39) Safety Cut Off Valve Check Valve Solenoid Valve (Y21) Relief Valve Cartridge

7. Relief Valve 8. Load Check Valve 9. Unload Valve Spool 10. Dashpot Relief Valve 11. Adjuster

V1. Loader Control Valve Lower Port V2. Loader Control Valve Lift Port Acc Accumulator Port

C1. Cylinder Rod End C2. Cylinder Piston End T. Reservoir Port

With the control valve lift section in the raise position, pump oil enters the Smooth Ride valve through port V2. The load check valve (8) opens when pump pressure exceeds the combined residual cylinder and spring pressures. Pump oil now flows to the lift cylinder piston end through port V2 to port C2.

Displaced oil from the cylinder rod end flows through port C1 to port V1 to return to the control valve. With the Smooth Ride control system activated, the solenoids (Y21/22) will be energised and the valves open. The accumulator will be connected to the piston end of the lift cylinder during the raising cycle.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

11 Smooth Ride Control Valve Oil Flow in Lowering with System Deactivated

1. 2. 3. 4. 5. 6.

Cylinder Pressure C1

Trapped Oil

Cylinder Pressure C2

Reservoir Return

Solenoid Valve (Y22) Pressure Switch (S 39) Safety Cut Off Valve Check Valve Solenoid Valve (Y21) Relief Valve Cartridge

7. Relief Valve 8. Load Check Valve 9. Unload Valve Spool 10. Dashpot Relief Valve 11. Adjuster

V1. Loader Control Valve Lower Port V2. Loader Control Valve Lift Port Acc Accumulator Port

C1. Cylinder Rod End C2. Cylinder Piston End T. Reservoir Port

With the control valve lift section in the lowering position, pump oil enters the Smooth Ride valve through port V1 and flows to the cylinder rod end out of port C1. The load check valve (8) is initially closed and therefore the cylinder is hydraulically locked causing pump pressure to rise. The oil trapped in the lift cylinder piston end is released by the unload valve moving to the right so that the tapered portion is clear of the check valve.

This occurs when pump pressure oil acting on the left hand end of the unload valve spool (9) exceeds the overload relief valve spring pressure. Pump pressure oil in V1 gallery reaches the unload valve spool along the adjuster threads. At low oil temperatures, the dashpot relief valve (10) will open if pump pressure exceeds 55--60 bar. This allows oil to flow to the end of the unload valve as well as along the adjuster threads providing smoother initial operation.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

12 1. 2. 3. 4.

Smooth Ride Valve Circuit Diagram 5. Solenoid Valve (Y21) 6. Overload Relief Valve 7. Load Check Valve 8. Dashpot Relief Valve

Solenoid Valve (Y22) Pressure Switch (S 39) Safety Valve Solenoid Valve (Y21)

FAULT FINDING PROBLEM

POSSIBLE CAUSES

REMEDIAL ACTION

Smooth Ride system does not activate when correctly selected.

Smooth Ride Electrical System

Refer to Section 55, Chapter 9 for electrical fault finding.

Smooth Ride System does not provide boom floatation when activated correctly.

Smooth Ride Electrical System

Refer to Section 55, Chapter 9 for electrical fault finding.

Accumulator discharged

Change Accumulator.

Lift Cylinder Leak Down.

Check cylinder seals.

Check lift cylinder seal leakage by pressurising rod end with piston end hose removed. Remove cylinder and replace seal if required.

Load Check Valve (8) or Unload Valve (9) Check Valve (4).

Remove Smooth Ride control valve and check components for contamination or damage. Only complete valve available.

Lift Cylinder Collapses Under Load.

Overload Relief Valve.

Carry out Pressure Test If not to correct specification, adjust as required.

Initial Lowering Aggressive

Load Check Valve Release Pressure Unload Valve Spool

Check and adjust valve adjuster referring to page 11.

Dashpot Relief Valve

Sealed unit, replace if required.

(Hot or Cold).

(Cold)

Remove Smooth Ride control valve and check components.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

Counterbalance Valve Adjustment The adjusting screw should protrude 20--23 mm (X). Some fine adjustment may be necessary to achieve smooth cylinder operation under load. The dashpot relief valve is preset and sealed in manufacture and should not be adjusted.

13 Accumulator Replacement Ensure the boom is fully lowered and residual pressure in the lift circuit has been relieved. Disconnect hose connection (1) and remove adapter (5). Remove the clamp screws and plate (2) and slide the accumulator rearwards from the mounting bracket (4). Install the new accumulator and replace the clamp. Locate the adapter (5) into the accumulator and tighten. Reconnect hose (1). 14

CAUTION Handle the accumulator carefully. Keep away from excessive heat. Do NOT attempt to remove the valve from front end. Do NOT weld the accumulator. Smooth Ride Valve & Component Replacement Always install safety support onto the lift cylinder when working on the Smooth Ride Valve. The telescopic boom must be retracted and the safety support installed on the lift cylinder before working on the machine.

DANGER Do not work under an unsupported boom. Always relieve residual circuit pressure by operating the manual controls, joystick and the joystick thumb or button controls immediately after the engine has been shut down but with the key switch in the ’RUN’ position.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

Smooth Ride Valve Electrical Component Replacement Disconnect required harness connector and replace the suspect solenoid or switch component, then reconnect the harness. 1. 2. 3. 4.

Pressure Switch (S39) Solenoid (Y22) Solenoid (Y21) Connectors (C1/C2/C3)

16 C1. Pressure Switch Connector C2. Solenoid (Y22) Connector C3. Solenoid (Y21) Connector

17 The solenoid valve assemblies can also be replaced without removing the Smooth Ride valve from the lift cylinder. Tighten replacement valves to the specified torque.

Smooth Ride Valve Replacement 1. Ensure the lift cylinder safety support is fitted. 2. Relieve lift cylinder circuit residual pressure. 3. Identify and remove the four hoses from the valve and plug. 4. Disconnect the three electrical connectors. 5. Support the valve while removing the four socket headed retaining screws. 6. Remove the hose adapters if the valve is being replaced. 7. Install the hose connectors if a new valve is being fitted. Locate the valve onto the cylinder mounting with new ’O’ rings. Install and tighten the retaining screws. 8. Reconnect hoses and harness connectors.

19 604.55.181.01 09-- 2004

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

20 1. 2. 3. 4.

Solenoid Valve Check Valve Safety Cut Off Valve Solenoid Valve

Smooth Ride Control Valve Components 5. Relief Valve Cartridge 6. Check Valve & Unload Valve Spool 7. Dashpot Relief Valve 8. Adjuster

Smooth Ride Control Valve Component Inspection Thoroughly clean the valve assembly with a suitable cleaning fluid. Remove and layout the component parts as shown in figure 20 on a clean workbench. Use snap ring pliers engaged into holes in the safety valve to remove and replace the valve. The safety valve disc clearance is set to 1.8 mm.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

Counterbalance and Load Check Valve 1. 2. 3. 4. 5. 6. 7.

Valve Body Relief Valve & Spring Relief valve Adjuster Locking Cap Unload Valve Spool Load Check Valve, Spring and Seat Adjuster

Wash all components with suitable cleaning fluid, dry and inspect for wear or damage. Reassemble components, lubricating with specified oil, if suitable for further service. Tighten the valves to the specified torque.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

NOTES PAGE

604.55.181.01 09-- 2004

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 6 -- Auxiliary Hydraulic Systems CONTENT Section

Description

35 000

Description and Operation

Page

Auxiliary Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Attachment Hydraulic Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electro Change Over Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Boom Auxiliary Return . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rear Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Component Replacement Electro Change Over Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cable Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Flow Sharing Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Flow Sharing Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ... ...

BOOM AUXILIARY SERVICE The standard boom auxiliary service consists of a double acting system with quick release couplings mounted on the left hand side of the jib.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

HYDRAULIC SYSTEM CONTROLS Mechanical Lever System 1. 2. 3. 4. 5.

Boom Auxiliary Services Boom & Fork Joystick Control Boom Telescopic Control Rear Auxiliary Services Control Boom Auxiliary Services Change Over Control

2 Monoramp System 1/ 2. Boom Telescopic Controls 3/ 4. Boom Auxiliary Service Controls 5. Boom & Fork Joystick Control 6. Auxiliary Services Change Over Control 7. Rear Auxiliary Services Control

3 Flow Sharing System

1/ 2. Rear Auxiliary Service Controls 3. Boom Auxiliary Service Control 4. Boom Telescopic Control 5. Boom & Fork Joystick Control 6. Auxiliary Services Change Over Control

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

Hydraulic Lock for New Holland and Manitou Carriers

Hydraulic Lock The hydraulic lock consists of a shut off valve and additional hoses fitted to the boom auxiliary service. With the valve open (position A), the boom auxiliary control can actuate the attachment lock. With the valve closed (position B), the attachment lock is isolated and the boom auxiliary control can actuate an external hydraulic cylinder connected to the two couplers.

6 An isolator switch is fitted to Monoramp and Flow Sharing Systems whenever the hydraulic lock is fitted. When switched ’OFF’, (A depressed) the boom auxiliary control is inoperative and should be used to prevent operation of the boom auxiliary service when using the machine on the road. When switched ’ON’, (B depressed) the red LCD will be illuminated and the auxiliary control will be operational.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

8 Electro Change Over--Valve -- 6 & 7 m Boom

Electro Change--Over Valve The Electro Change--Over Valve (ECOV) consists of a solenoid valve fitted into the boom auxiliary service and mounted on the jib. The valve provides an alternative additional service for an attachment with two hydraulic cylinders. A cable reel mounted on the boom allows the cable to extend and retract with the jib. Note. The standard auxiliary is the 4th service, the additional service is the 5th service.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

The valve is actuated by an additional control (B) mounted on the auxiliary control lever or joystick. Operating the boom auxiliary control (A) operates the rear (4th ) service A. Depressing and holding the change--over valve control (B) actuates the valve, and the boom auxiliary control will now operate the 5th service (A+ B).

10 Mechanical Controls

11 Monoramp Controls

12 Flow Sharing Controls

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

14 Electro Change Over--Valve with Hydraulic Lock Installation -- 9 m Boom

Electro Change--Over Valve & Hydraulic Lock The combined installation provides a shut off valve connected into the 4th service. The auxiliary control isolator switch is fitted with the Monoramp and Flow Sharing systems.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

16 Boom Auxiliary Return Installation -- 6 & 7 Metre Booms

17 Boom Auxiliary Return Installation -- 9 Metre Boom

The installation provides a higher capacity return direct to the reservoir return filter for hydraulic motors or similar attachments.

The hose reel mounted on the outer end of the boom allows the hose to extend and retract with the jib.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

18 Rear Auxiliary Hydraulic Installation -- Mechanical & Monoramp Systems

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

20 Rear Auxiliary Hydraulic Installation -- Flow Sharing System

Rear Auxiliary Hydraulic Service The installation provides a rear double acting service (single acting available) through rear mounted quick release couplings. The installation consists of an additional control valve section, solenoid control valve and connections, hoses and quick release couplings. The joystick and wiring harness differs from the standard as the joystick has additional control buttons for the rear auxiliary service and a 12--pin connector. The standard joystick has a 8--pin connector. 21

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

COMPONENT REPLACEMENT Electro Change Over Valve The solenoid is serviced separately. The valve is only available as a complete assembly.

22 Relieve the residual pressure in the boom auxiliary circuit. Follow the steps in figures 23 -- 25 to replace the valve 1. Remove the 4th service couplers and adapters (1).

23 2. Remove the 5th service couplers, pipes and adapters (2).

24 3. Remove the valve retaining screws (3), disconnect the valve adapters (4) from the boom elbows and remove the valve assembly (5). 4. Install the new valve in the reverse order to removal. Reconnect the solenoid harness connector. 5. Test the valve change over using a pressure gauge as shown on page 5.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

Cable Reel The cable reel is only available as a complete assembly Follow the steps in figures 26 -- 29 to remove and replace the reel. 1. Disconnect the solenoid connector and remove the wires from the connector.

26 2. Remove the jib cable clamp screws (4), plate (3) and outer half clamp (2). 3. Pull the cable (5) through the jib guide tube (1).

27 4. Slacken jib cable clamps (1 & 2) and pull the cable through the clamps. 5. Remove boom cable ties (3). 6. Remove cable reel mounting bolts (4) and lower reel to the ground

28 7. Remove the rear cover from the reel assembly. Disconnect the wires (1 & 3) noting the wiring colours and location. Remove cable clamp (2). 8. Connect the boom wires to the new cable reel and install the cover. 9. Install the cable reel onto the boom. Feed the solenoid feed cable through the jib cable clamps and jib guide. Tighten the clamp screws. 10. Reconnect the wiring to the solenoid connector and secure to the valve solenoid.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

Flow Sharing Joystick 1. Flow sharing joysticks with the optional rear hydraulic control buttons have a 12--pin connector to accommodate the additional wiring.

30 2. Flow sharing joysticks with the optional Electro Change Over Valve have an additional 2--pin connector in addition to either the 8--pin or 12--pin connector.

31 3. Two relays (3), operated by the boom auxiliary thumb control, are located on the control valve. The relays are part of an intermediate harness (4) between the main harness (1) and the joystick harness (2) on earlier machines, or part of the main harness on later machines.

32 4. When installing the joystick, ensure there is clearance between the steering wheel and joystick with the seat positioned fully forward. Adjust if required by slackening locknut (2). Turn the joystick handle with a spanner on the hexagon (1), and then retighten the locknut.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

Flow Sharing Solenoid Valves The rear auxiliary solenoid control valve is mounted above the boom auxiliary solenoid valve located under the cab floor. The harness cables connectors to each solenoid are identified by colour bands as shown. K. Black R. Red U. Blue W. White The solenoids and their valve assemblies can be replaced with the assemblies in situ. 34 Solenoid Valve Component Parts 1. 2. 3. 4. 5. 6.

Nut Solenoid Seal Solenoid Valve Block Valve Assembly

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 6

NOTES PAGE

604.55.181.01 09-- 2004

SECTION 39 -- CHASSIS -- CHAPTER 1

SECTION 39 -- VEHICLE CHASSIS Chapter 1 -- Frame, Chassis and Attachments CONTENTS Section

Description

Page

39 000

Specifications are listed for the individual components at the beginning of each section of the Repair Manual for your guidance. TORQUES Torque figures for individual components are listed at the beginning of each section of the Repair Manual. This section specifies the torques of the attachment of components to the vehicle and interlinking parts hoses and tubes. General Torque Values are given on pages 2 and 3. SPECIAL TOOLS Special Tools are listed in the Repair Manual introduction and at the beginning of each section of the Repair Manual for your guidance.

604.55.181.00 09-2003

SECTION 39 -- CHASSIS -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS - LBF. FT (NEWTON-METRES -- Nm) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC HARDWARE AND LOCKNUTS CLASS 5.8

CLASS 8.8

CLASS 10.9

UNPLATED

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL 8 CL.8 W/CL8.8 BOLT

15* (1.7)

19* (2.2)

23* (2.6)

30* (3.4)

33* (3.7)

42* (4.8)

16* (1.8)

51* (5.8)

67* (7.6)

79* (8.9)

102* (12)

115* (13)

150* (17)

56* (6.3)

124* (14)

159* (18)

195* (22)

248* (28)

274* (31)

354* (40)

133* (15)

M10

21* (28)

27* (36)

32* (43)

41* (56)

45* (61)

58* (79)

22* (30)

M12

36* (49)

46* (63)

55* (75)

72* (97)

79* (107)

102* (138)

39* (53)

M16

89* (121)

117* (158)

137* (186)

177* (240)

196* (266)

254* (344)

97* (131)

M20

175* (237)

226* (307)

277* (375)

358* (485)

383* (519)

495* (671)

195* (265)

M24

303* (411)

392* (531)

478* (648)

619* (839)

662* (897)

855* (1160)

338* (458)

NOMINAL SIZE

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

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CLOCK MARKING

SECTION 39 -- CHASSIS -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS - LBF. FT (NEWTON-METRES -- Nm) FOR NORMAL ASSEMBLY APPLICATIONS

INCH HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL SIZE

UNPLATED or PLATED SILVER

PLATED W/ZnCr GOLD

SEA GRADE 5 UNPLATED or PLATED SILVER

SEA GRADE 8

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

LOCKNUTS GR.B w/GR5 BOLT

GR.C w/GR8 BOLT

NOMINAL SIZE

GOLD

1/4

55* (6.2)

72* (8.1)

86* (9.7)

112* (13)

121* (14)

157* (18)

61* (6.9)

86* (9.8)

1/4

5/16

115* (13)

149* (17)

178* (20)

229* (26)

250* (28)

324* (37)

125* (14)

176* (20)

5/16

3/8

17 (23)

22 (30)

26 (35)

34 (46)

37 (50)

48 (65)

19 (26)

26 (35)

3/8

7/16

27 (37)

35 (47)

42 (57)

54 (73)

59 (80)

77 (104)

30 (41)

42 (57)

7/16

1/2

42 (57)

54 (73)

64 (87)

83 (113)

91 (123)

117 (159)

45 (61)

64 (88)

1/2

9/16

60 (81)

77 (104)

92 (125)

120 (163)

130 (176)

169 (229)

65 (88)

92 (125)

9/16

5/8

83 (112)

107 (145)

128 174)

165 (224)

180 (244)

233 (316)

90 (122)

127 (172)

5/8

3/4

146 (198)

189 (256)

226 (306)

293 (397)

319 (432)

413 (560)

160 (217)

226 (306)

3/4

7/8

142 (193)

183 (248)

365 (495)

473 (641)

515 (698)

667 (904)

258 (350)

364 (494)

7/8

773 (1048)

1000 (1356)

386 (523)

545 (739)

213 (289)

275 (373)

547 (742)

708 (960)

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS

SEA GRADE 2

SEA GRADE 5

SEA GRADE 8 REGULAR

SEA GRADE 5

SEA GRADE 8

NUTS

HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION

GRADE A NO NOTCHES GRADE B ONE CIRCUMFERENTIAL NOTCHE

GRADE A NO MARKS GRADE B THREE MARKS

GRADE C TWO CIRCUMFERENTIAL NOTCHES

GRADE C SIX MARKS MARKS NEED NOT BE GRADE A NO MARKS

LOCATED AT CORNERS

GRADE B THREE MARKS GRADE C SIX MARKS GRADE IDENTIFICATION

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SECTION 39 -- CHASSIS -- CHAPTER 1 SEALANTS

Description THREAD LOCK & SEAL 24ml

SUPER GLUE GEL 20gm

FLEXIBLE 50ml GASKET SEALANT 300ml

THREAD SEAL 50ml CLEAR ADHESIVE 50ml AND SEALANT 310ml

GASKET DRESSING 60ml

STUD & BEARING LOCK 24ml

Part No. NH 82995773

82995778

82995770

• General locking and sealing of metallic threads--medium strength • Oil tolerant • Resists vibration, seals against corrosion and leakage • Can be dismantled with standard tools • General purpose instant non drip gel adhesive Ideal for repair of cab trim, mats, external trim etc. • Bonds most materials including wood, rubber, metals, most plastics • Not absorbed by porous materials

82995771

• Replaces pre cut gasket materials • Use on hydraulic lift cover joint, transmission to axle joint and all rigid machined faces • Anaerobic sealant cures on assembly • Will not cure and block oil ways etc.

82995768

• General purpose metallic thread and pipe sealant • Use on fuel system, hydraulics, air lines etc. • Replaces pastes, hemp, pipe tape etc.

82995775 82995776

82995774

82995772

SOLVENT CLEANER & DEGREASER 400ml 82995779

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Typical Applications

• Clear, flexible adhesive and sealant • Suitable for glass, metal, wood etc., seals and bonds gaps to 6mm • Use to seal glazing and windscreens, vehicle lamps, electrical boxes, sump joints etc. • Non hardening sealant--enhances sealing of all types of pre cut gaskets • Holds gasket in place--assists assembly • Dries slowly, sets to pliable film for easy dismantling • General high strength metallic locking and sealing of all threaded fasteners and studs • Retains cylindrical parts, e.g. bushes, bearings, gears to shafts etc. • Resists severe vibration loosening. Seals against corrosion • All purpose cleaner & degreaser • Specially designed for parts to be lubricated, bonded or sealed leaving no film or residue • Removes grease, oil and dirt from electrical parts, tools etc. FLAMMABLE. Do not smoke, use only in well ventilated areas

SECTION 39 -- CHASSIS -- CHAPTER 1 MISCELLANEOUS

Part No. NH

Typical Applications

STRIPPED THREAD REPAIR KIT

82995777

• Use for fast repair of most stripped or damaged threaded metallic parts (see pack) • Complete kit, no additional special tools required Withstands temperature to 150°C

GASKET REMOVER 300ml

82995782

Description

CITRUS HAND CLEANER 400ml

82995780

3 litre

82995781

PENETRATING OIL 330ml

82995769

• Spray on fast action foaming gasket remover • Removes old heat hardened gasket residue without damaging metal surfaces • Removes all Loctite gaskets and gasket residue. • Removes carbon deposits from cylinder heads etc. • Natural hand cleaner made from citrus oil • Removes ground in dirt, grease, grime, paint, glue oil and tar • Contains premium skin conditioners • Use with or without water • General purpose penetrating lubricant • Frees corroded fasteners, mechanisms etc. • Lubricates cables, locks, linkages etc. • Cleans, displaces moisture, prevents corrosion

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DESCRIPTION AND OPERATION This section can be used as a quick reference for general disassembly of the machine and its components.

Where disassembly of a specific component is required refer to, the relevant Repair Manual Section.

REPAIR MANUAL BY SECTION 10 Engine 17 Toque Convertor 21 Power Shuttle Transmission 21 Power Shift Transmission 25 Front Axle 27 Rear Axle 33 Brake System 35 Hydraulic System 39 Frame And Chassis 41 Steering System Overhaul 50 Cab Heat And Air Conditioning 55 Electrical System 82 Loader Telescopic Boom 90 Cab

VEHICLE CHASSIS TYPE The chassis of the Loader is manufactured as a one piece unit on which all of the major assemblies are attached or supported from.

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10 000 Engine, 17 000 Torque Convertor and 21 000 Transmission ENGINE 10 000 -- Supported by 2 rubber bushes held in position by 2 support brackets. The brackets, are attached to, the frame one either side of the engine.

WARNING The engine and transmission bolted together act as a one piece unit. If separated in the machine they are not self supporting, and will collapse which could cause personal injury or damage to the machine. TORQUE CONVERTOR 17 000 -- Fitted between the engine and transmission and can only be removed when the engine/transmission assembly are separated. TRANSMISSION 21 000 -- Attached to the rear of the engine, dampened by rubber bushes, in fixed brackets held within the frame.

the following: REMOVE: Air Cleaner bowl Engine hood panel Radiator and related hoses Rear Counter Weight (if required) DISCONNECT: (cap all exposed ports and hoses) Fuel pump throttle cable and electric shut off Engine harness Fuel tank connection and leak off return pipes Hydraulic Pump and related pipework NOTE: The hydraulic pump if not being overhauled can be removed from the transmission but remain in the machine with its pipe work and connections intact. Transmission Lever Transmission harness connectors Engine supports (with engine supported by hoist) Transmission supports

To make repairs that require disassembly of the transmission or engine it is advisable to remove the engine/transmission as a complete unit from the chassis. To remove the engine/transmission from the machine it will be necessary to remove or disconnect COMPONENTS

IMPORTANT: Combined weight of Engine and transmission is 800 kgs (1764 Ibs). TORQUES

ENGINE Engine to transmission retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Nm (28 lbf ft) Engine coolant expansion tank retaining bolts . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lbf ft) Engine to Frame mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.8 Nm (48 lbf ft) Engine Mounting Damping Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Nm (88 lbf ft) Transmission to Frame mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Nm (77 lbf ft) Engine panel support bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Nm (59 lbf ft) Air cleaner retaining bolts to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lbf ft) Air cleaner bowl to pipe clamp connection . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.6 lbf ft) Coolant radiator bolts to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Nm (70 lbf ft) Radiator hose connections (small) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.6 lbf ft) Radiator hose connections (large) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.6 lbf ft) Radiator retaining bolts to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Nm (70 lbf ft) Fuel tank connecting hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (3.6 lbf ft) TRANSMISSION Transmission (Power Shuttle) gear lever clamp bolt . . . . . . . . . . . . . . . . . . 90 Nm (66 lbf ft) Flywheel to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lbf ft) Torque Convertor to Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.7 Nm (15 lbf ft) Spicer universal couplings rear and front . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Nm (28 lbf ft) 604.55.181.00 09-2003

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25 000 Front Axle and 27 000 Rear Axle FRONT AXLE -- 25 000: Attached to the frame at the front of the machine by 4 through bolts on each half axle. To remove the Front axle it will be necessary to disconnect or remove the following with the vehicle suitably supported: REMOVE: Front Wheels DISCONNECT: Brake piston hoses (cap all exposed ports) Steering piston hoses Cardan coupling’s Parking Brake Cable Axle Retaining Bolts COMPONENTS

REAR AXLE -- 27 000: Mounted below the rear of the chassis and held in position by the swivel pin trunnion supports. The axle support is attached to the underside of the chassis by 4 through bolts. To remove the Rear axle it will be necessary to disconnect or remove the following with the vehicle suitably supported: REMOVE: Rear Wheels DISCONNECT: (cap all exposed ports and hoses) Brake piston hoses Steering piston hoses Cardan coupling Swivel Trunnion Bolts TORQUES

FRONT AXLE Axle to frame retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Nm (210 lbf ft) Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630 Nm (464 lbf ft) Cardan coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm (34 lbf ft) REAR AXLE Axle Swivel retaining bolts to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607 Nm (447 lbf ft) Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630 Nm (464 lbf ft) Cardan Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Nm (34 lbf ft)

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33 000 Hydraulic Brake BRAKES 33 000 -- The master brake cylinder and reservoir are situated behind the instrument console. The brake system is interconnected by hoses and tubing between the foot pedal, trailer brake valve, gear pump, accumulator, and axles. IMPORTANT: Before disconnecting any brake hoses relieve ail pressure in the hydraulic system and have ready suitable clean containers to drain the oil into. Ensure all ports and hoses are plugged or capped to prevent dirt ingress during overhaul. To overhaul, it will be necessary to disconnect or remove the following with the vehicle suitably chocked and supported: REMOVE: Instrument Console Cover Steering Column Cover DISCONNECT: Hoses and tubes as required

COMPONENTS

TORQUES

Pipes to hydraulic services (M22X1 50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (7.3 lbf ft) Pipes to hydraulic services (M27X150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 lbf ft) Pump hose to Trailer Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft) Brake Tube connections to Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 lbf ft) Brake Reservoir to support Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 lbf ft) Trailer Brake Hose to Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft) Oil Pump to transmission bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80--100 Nm (60--74 lbf ft)

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35 000 Hydraulic Loader Valve Pack -- Mechanical & Monoramp Controls LOADER VALVE BLOCK 35 000 -- Situated inboard of the right hand side of the cab is the hydraulic valve slice block which is interconnected by pipes and tubing to the pump and reservoir for operation of the Loader cylinders, and related components. IMPORTANT: Before disconnecting any hoses relieve ail pressure in the hydraulic system, with loader supported and have ready a suitable clean container to drain the oil into. Ensure ail ports and hoses are plugged or capped to prevent dirt ingress during overhaul

To overhaul, it will be necessary to disconnect or remove the following with the vehicle suitably chocked and boom supported:

REMOVE: Cab Side Panel Control Levers and Boots DISCONNECT: Hydraulic Valve Block Hoses and tubes as required Control Lever Harness Connector -- Monoramp Only

COMPONENTS

TORQUES

Pipes to hydraulic valves (M22X150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm (74 lbf ft) Pipes to hydraulic valves (M27X150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lbf ft) Loader control pipe clamp to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lbf ft) Valve Slice Pack Retaining Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Nm (48 lbf ft)

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35 000 Hydraulic Telescopic Boom Controls HYDRAULIC CONTROLS 35 000 -- Situated inboard to the right of the cab are the hydraulic valve controls mounted above the valve slice block IMPORTANT: Before removing any parts from the hydraulic system ensure ail pressure in the system is at zero and components are mechanically supported which would normally be hydraulically supported. Have ready suitable clean containers to drain the oil into.

Ensure all ports and hoses are plugged or capped to prevent dirt ingress during overhaul

To overhaul, it will be necessary to disconnect or remove the following with the vehicle suitably chocked and supported:

REMOVE: Cab Side Panel Instrument Console Cover Steering Column Cover Control Levers and Boots DISCONNECT: Hydraulic Valve Block Hoses and tubes as required

COMPONENTS

TORQUES

Pipes to hydraulic valves (M22X150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm (74 lbf ft) Pipes to hydraulic valves (M27X150) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Nm (110 lbf ft) Loader control pipes clamp to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lbf ft)

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39 000 Frame Attachments RESERVOIR TANK’S -- Attached to the right hand chassis is the tank for the Hydraulic system and the fuel. Both tanks (are housed in a one piece unit) and when drained of their contents can be removed from the machine by removal of the attaching pipe work and supporting bolts. IMPORTANT: Ensure all ports and pipes are plugged or blanked off to prevent dirt ingress. To overhaul, it will be necessary tc, disconnect or remove the following with the vehicle suitably chocked and supported: REMOVE: Drain the fluids into suitable clean containers

REAR WEIGHT PACK -- The rear weight pack is attached by x4 bolts into the frame. The large weight pack (with nudge bar) may require removal if the engine is to be rernoved. IMPORTANT: When lifting the counter weight ensure the lifting equipment to be used is capable of lifting the weight of the weight as for the different models: Weight of small counter weight, less the nudge bar = 530 kgs (1146 Ibs) Weight of large counter weight, with the nudge bar = 1230 kgs (2700 Ibs)

WARNING Never operate the machine without the rear counter weight being fitted as the machine will be unstable.

DISCONNECT: Hose connections Harness connections Attaching Bolts COMPONENTS

TORQUES

OIL RESERVOIR (1) Attaching bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm (63 lbf ft) Filter retaining plate to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm (8.8 lbf ft) Drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (40 lbf ft) Hoses heat exchanger to oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Nm (118 lbf ft) Filler tube plate retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm (8.8 lbf ft) Power steering outlet to reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (40 lbf ft) FUEL TANK (2) Holding bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm (63 lbf ft) Fuel sender to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Nm (15 lbf in) Fuel drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm (8.8 lbf ft) Hose connections to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm (8.8 lbf ft) BALLAST Rear counter weight Attaching Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Nm (369 lbf ft)

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SHJ39005

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41 000 Hydraulic Steering Control STEERING CONTROL 41 000 -- The steering column is fixed to the cab frame and connected by hoses between the steering motor, pump, tank and steering cylinders. IMPORTANT: Before disconnecting any hoses relieve ail pressure in the hydraulic system and have ready suitable clean containers to drain the oil into. Ensure all ports and hoses are plugged or capped to prevent dirt ingress during overhaul.

To overhaul the steering motor, it will be necessary to, disconnect or remove the following with the vehicle suitably chocked and supported:

REMOVE: Steering Console

DISCONNECT: Hose connections

COMPONENTS

TORQUES

Steering hoses to support frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft) Steering outlet to tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft) Steering Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft) Steering Motor to Steering Column Bracket . . . . . . . . . . . . . . . . . . . . . . . . . 23 Nm (17 lbf ft) Steering Motor End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lbf ft) Steering Motor Pipe Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (35 lbf ft) Steering Motor Pipe Adaptors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (40 lbf ft) Steering Cylinder Ball--joint Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Nm (32 lbf ft) Steering Cylinder Ball--joint Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Nm (130 lbf ft) Steering Cylinder Extension Tube to Cylinder . . . . . . . . . . . . . . . . . . . . . . . 271 Nm (200 lbf ft) Steering Pump Body Through Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Nm (26 lbf ft) Steering Pump Drive Gear Nut

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 lbf ft)

Steering Pump to Front Cover Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Nm (23 lbf ft) Steering Pump Reservoir Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Nm (12 lbf ft) Steering Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 lbf ft) Check Valve Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 lbf ft) 604.55.181.00 09-2003

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82 000 Loader LOADER 82 000 -- Attached in position by pivot pins, retained by bolts/circlips the loader boom can be removed as an assembly from the machine. Removal of the loader is achieved by disconnection or removal of the following with the loader boom fully supported: IMPORTANT: Before disconnecting any hoses or cylinders relieve ail pressure in the hydraulic system, and have ready suitable clean containers to drain the oil into. Ensure ail ports and hoses are plugged or capped to prevent dirt ingress during overhaul. DISCONNECT: Balance Cylinder Pivot Pins Lift cylinder Cylinder hoses REMOVE: Boom Pivot Pin IMPORTANT: When lifting the boom ensure the lifting equipment to be used is capable of lifting the weight of the boom for the different models: 6 metre = 1150 kgs (2500 lbs) 9 metre = 2000 kgs (4409 lbs)

COMPONENTS

TORQUES

LOADER HOSES AND CONNECTIONS Loader control pipe bracket to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (18 lbf ft) Loader lifting cylinders elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft) Loader bucket cylinder elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft) Hoses loader valve to pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Nm (63 lbf ft) Loader Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Nm (41 lbf ft)

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90 000 Chassis / Cab CAB 90 000 -- The cab frame is a one piece unit mounted to left of the chassis. The cab is retained by 5 fixing bolts between the cab mounts to the chassis through rubber dampening blocks. Removal of the cab requires disconnection or removal of the following with the cab fully supported by a hoist: Parking Brake Cable Steering Control Valve Throttle cable to Fuel Pump Hydraulic Brake Pipes Loader Lever linkage/Servo, Hose Connections Auxiliary Lever Connections Transmission Lever Connections Harness connections Cab attaching bolts IMPORTANT: When lifting the cab ensure the lifting equipment to be used is capable of lifting at least 600 kgs (1322 lbs) COMPONENTS

TORQUES

CAB Cab Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 Nm (265 lbf ft)

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11 Major Components attached above the chassis

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NOTES

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SECTION 41 -- STEERING -- CHAPTER 1

SECTION 41 -- STEERING Chapter 1 -- System Overhaul CONTENTS Section

Description

Page

41 000

SPECIFICATIONS Steering Motor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambra Hydrosystem Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic Closed Centre Load Sensing Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 cm3/rev Steering Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 bar (2030 psi) Standby Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 bar (101.5 psi) Shock Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 bar (2900 psi)

TIGHTENING TORQUES Nm 55 23 30 45 42 30

Steering Wheel Nut Steering Motor to Steering Bracket Steering Motor End Cover Steering Motor Pipe Connections Steering Pump Relief Valve Check Valve Bolt

ft.lbs 41 17 20 35 31 22

SPECIAL TOOLS Pressure Test Adaptor

380001668

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Steering Hydraulic System System Pressure

Suction oil

Reduced Pressure @ 40 bar

Return to Reservoir

Load Sense Line 1. 2. 3. 4.

Front Axle Steering Cylinder Load Sensing Line Shuttle Valve Connection to Pressure Reducing Valve Hydraulic Pump & Flow Divider Assembly

The schematic is shown with the steering inoperative. Priority steering oil flow is provided on demand by the load sensing pump flow divider valve (4). 604.55.181.00 09-- 2003

5. 6. 7.

Rear Axle Steering Cylinder 2 & 4 Wheel Steer Control Valve Hydrostatic Steering Motor

The steering control valve (6) selects 2--wheel steer, 4--wheel steer and crab steer modes.

SECTION 41 -- STEERING -- CHAPTER 1

2 1. 2. 3.

Hydraulic Pump & Flow Divider Load Sensing Line Shuttle Valve Front Axle Steering Cylinder

Steering Systen Schematic 4. Hydrostatic Steering Motor 5. Steering Control Valve 6. Rear Axle Steering Cylinder

The steering cylinders are fitted with sensors which operate indictor lights to show when the wheels are in the straight ahead position. Switch B must be ’ON’ for the lights to operate. Changing between steering modes must be done with the wheels in the straight ahead position. If the front and rear steering becomes out of phase, correct the condition by positioning the rear wheels in the straight ahead position, indicated by lamp A2. Select 2--wheel steer, position front wheels in straight ahead position, indicated by lamp A1. The system is now synchronised. 3 604.55.181.00 09-- 2003

SECTION 41 -- STEERING -- CHAPTER 1

COMPONENT OPERATION Hydraulic Pump The hydraulic pump is a fixed displacement gear (2) with a capacity of 46.34 cc /revolution. A load sensing flow divider valve (3) is mounted on the pump, this provides priority oil flow to the steering and brake circuits. The pump is mounted on the back of the Powershuttle transmission and is driven directly from the flywheel by a drive shaft, which engages with the pump shaft (4). 4 The hydraulic pump is mounted on the side of the Powershift transmission and is driven through a gear train. The pump fitted has a different mounting flange and a drive gear is fitted to the pump shaft.

5 Hydraulic pump connections on the Powershuttle transmission are:-1. 2. 3. 4.

Suction Hose Steering Circuit Loader Control Circuit Load Sensing Line

6 Hydraulic pump connections on the Powershift transmission are:-1. 2. 3. 4.

Loader Control Circuit Suction Hose Steering Circuit Load Sensing Line

7 604.55.181.00 09-- 2003

SECTION 41 -- STEERING -- CHAPTER 1 The flow divider consists of the parts illustrated 1. 2. 3. 4. 5. 6. 7. 8. 9.

Housing Steering Priority Valve Spring Seat Shim End Cap Spring Restrictor Filter & Restrictor Assembly Load Sensing Connector

Flow Divider Valve Operation -- Engine Off

Reservoir Return Oil 1. 2. 3. 4. 5.

Priority Valve Spool Restrictor Gauze Filter Restrictor Spring

CF. EF LS P

Outlet to Steering & Braking Circuits Outlet To loader Control Valve Sensing Line Gallery Pump Outlet Gallery

The load sensing flow divider valve provides priority oil flow on demand to the steering and braking circuits. The remaining flow is available to the loader hydraulic circuit. Restrictors are fitted to both ends of the hollow valve spool, the left hand filter incorporates a gauze filter. With the engine off, the priority valve spool is positioned to the left by the spring. The outlet ports (CF & EF) and pump gallery (P) are open to reservoir through the LS gallery and sensing line.

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1. 2. 3. 4. 5.

SECTION 41 -- STEERING -- CHAPTER 1

Flow Divider Valve Operation -- Loader Hydraulic Operation

Flow Divider Valve Operation -- Steering & Braking System Priority

System Pressure Oil

Load Sensing Oil

Reduced Pressure Oil

Reservoir Return Oil

Priority Valve Spool Restrictor Gauze Filter Restrictor Spring

When the engine is started, initial oil flow is directed through the CF port to the closed centre hydrostatic steering motor. Pressure build up through restrictor (2) on the left hand end of the priority valve spool (1) over comes spring pressure and moves valve to the right, figure 10. Pump output is now directed to the loader hydraulic circuit. The sensing line is open to the reservoir through the LS port and sensing line. The balancing restrictor (4) acts as a damper to prevent erratic spool movement. 604.55.181.00 09-- 2003

CF. EF. LS. P.

Outlet to Steering & Braking Circuits Outlet to Loader Control Valve Sensing Line Gallery Pump Outlet Gallery

Operation of the steering motor or braking system creates a pressure in the sensing line which is sensed on the right end of the priority valve spool, figure 11. The combined sensing line pressure and spring pressure will move the spool to the left and increase pump flow to the steering and brake circuits. Because oil directed to the sensing line flows through control orifices in the steering motor and brake valve, load sense pressure is always proportional to demand. This ensures the right amount of pump flow is directed to the steering and brake circuits.

SECTION 41 -- STEERING -- CHAPTER 1

Flow Divider Valve Operation -- Steering Overload

Reduced Sensing Line Pressure

System Pressure Oil Reduced Pressure Oil 1. 2. 3. 4. 5.

Priority Valve Spool Restrictor Gauze Filter Restrictor Spring

CF. EF LS P

Outlet to Steering & Braking Circuits Outlet To loader Control Valve Sensing Line Gallery Pump Outlet Gallery

When the steering circuit becomes overloaded, the steering motor relief valve blows off. This creates a reduction in sensing line pressure acting the right hand end of the priority valve spool. The higher pressure acting on the left hand end of the spool moves the spool to the right to allow increased pump flow to be directed to the loader hydraulic circuit. When the steering load reverts to normal, the valve spool and oil flow returns to the condition shown in figure 11.

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SECTION 41 -- STEERING -- CHAPTER 1

PRESSURE TESTING Preparation Ensure oil is visible in the reservoir sight glass, add specified oil as required Warm up the oil as follows:-Fully curl the tilt cylinder and hold the joystick in this position to blow off the relief valve for 30 seconds. Release the joystick for 15 seconds, then repeat the relief valve blowing off for 30 seconds. Repeat this procedure until the oil temperature is 55--60 oC. 13 Ensure the front and rear wheels are in the straight ahead position and then select 2--wheel steer. Pressure Test 1. Install test elbow (1) and adaptor (2), tool numbers 380001668 & 380000493, into the steering control valve under the cab floor. Connect a 400 bar gauge and test hose (2) long enough to reach inside the cab.

14 2. Sit in the cab, start the engine and run at 2000 rpm. Turn the wheels to full left hand lock and hold the steering wheel. 3. Pressure gauge reading should by 140 -- 150 bar. If the pressure is below 140 bar, the steering motor relief valve must be adjusted.

15 The steering motor relief valve adjuster is not accessible with the motor in situ. The steering motor must be removed from the steering column and reconnected to the system to enable any adjustment to be made. Identify the four hose connections (2) before disconnecting and plugging the hoses. Remove the four mounting bolts (1) and withdraw the motor from the column.

16 604.55.181.00 09-- 2003

SECTION 41 -- STEERING -- CHAPTER 1

The relief valve adjuster (1) is located on top of the steering motor. With the motor removed and reconnected to the system, repeat pressure test procedure, adjusting pressure as required. Reinstall the steering motor into the steering column and reconnect the hoses.

17 Steering Motor Shock Relief Valves The shock relief valves protect the cylinders from mechanical shock loads and do not normally need adjustment. If the valve settings are suspect, the motor must be removed and the pressures checked using a hand pump connected to the left turn or right turn port. Shock valves are set at 200 bar. Steering Control Valve Removal 1. Place a drain tray under the valve. 2. Remove and plug the four hose connections. 3. Remove the nuts (2) from the guide studs and remove the valve (1).

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SECTION 41 -- STEERING -- CHAPTER 1

19 1. 2. 3. 4.

End Cap Seal Retainer Body Control Lever Support

Steering Control Valve 5. Control Valve Spool 6. Plug 7. Detent

Overhaul 1. Inspect the spool and housing bore for wear and scoring. If these parts are not fit for further service, replace the complete assembly. 2. If spool and housing are serviceable, reassemble and install new seals.

3. Install the reassembled valve onto the unit in the reverse order to removal. 4. Check steering operation and synchronise the front and rear wheels, referring to page 3.

Steering Motor Removal 1. Identify the four hose connections (2) before disconnecting and plugging the hoses. 2. Remove the four mounting bolts (1) and withdraw the motor from the steering column.

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SECTION 41 -- STEERING -- CHAPTER 1

Supply line non return valve. 1.

Non return valve

21 End plate removal NOTE: The position of the pin bolt must remain the same upon re--assembly of the end cap. 1. 2.

End plate Pump body

22 Metering unit removal 1. 2. 3. 4.

Steering motor Driving link Stator Rotor

23 Drive link removal 1. 2.

Steering motor body Drive link

24 604.55.181.00 09-- 2003

SECTION 41 -- STEERING -- CHAPTER 1

Valve plate removal 1. 2.

Body Valve plate

25 Check valve removal 1. 2.

Retainer cap Check valve

26 Suction and check valves 1. 2. 3. 4.

Suction valve balls Suction valve rods Retainer cap Check valve

27 Cylinder relief valves IMPORTANT: Before removal of the cylinder relief for cleaning valves if necessary remove the end plug and seal. Measure at, (x) using a depth gauge, the distance from the outer body to the head of the adjuster (5) and record the results. Upon re--assembly reset the adjuster to the exact depth previously recorded. 1. 2. 3. 4. 5. 6.

Ball Seat End Plug Seal Adjuster Spring

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3 4 x

4108001

SECTION 41 -- STEERING -- CHAPTER 1

Control valve removal 1. 2.

Control valve Housing

NOTE: When removing the control valve spool and sleeve, ensure drive pin is in a horizontal position so that it cannot fall into an integral gallery and make removal difficult.

29 Control valve 1. 2. 3. 4. 5. 6. 7.

Control valve sleeve Washer Thrust bearing Washer Spool Centring springs retainer Centring springs

NOTE: The thick washer must be reinstated with internal diameter chamfer toward the valve sleeve.

30 Drive pin and centring springs 1. 2. 3. 4.

Control valve Drive pin Spool Centring springs

31 Oil seal location 1. 2.

Seal seat Seal

32 604.55.181.00 09-- 2003

SECTION 41 -- STEERING -- CHAPTER 1

1. 2. 3. 4. 5. 6. 7. 8.

Hydrostatic Steering Motor 9. ‘O’ Ring 10. End Plate 11. Metering Unit 12. Distributor Port 13. Non Return Valve 14. Check Valve Port 15. System Relief Valve 16. Cylinder Relief Valve

33 Valve Thrust Washers and Bearings Drive Pin Spring Retaining Ring Valve Spool Suction Valves Retaining Bolts Valve Sleeve Drive Link

Component Inspection Check for signs of wear in the following areas: • Rotor and stator of metering unit move freely

•

Ensure thrust washers are not warped or cracked

•

Ensure check valve ball is free to move

•

Check the drive pin is not cracked or bent

•

Check the rollers in thrust bearing are free to rotate

Check control valve, spool and sleeve for wear or scoring

•

Replace all seals and ‘O’ rings

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SECTION 41 -- STEERING -- CHAPTER 1 Re--assembly NOTE: Great care should be taken during re--assembly. Coat all components in hydraulic oil. •

Ensure drive pin is horizontal before installation.

•

Ensure thick thrust washer internal diameter chamfer is towards the valve sleeve.

•

Do not over torque end plate.

•

This motor does not have to be timed due to a master spline.

•

Finally, check motor turns freely.

Replace the end cover 4

Refit the bolts and torque up in sequence to an initial setting of 10.8 Nm (8 lbf ft).

Torque up the bolts in sequence to a second setting of 30.0 Nm (21 lbf ft).

1 7

3 5 4111001

35 Pressure Testing To pressure test the steering system use a ’T’ Connector and T into the circuit where the steering pipe joins the steering cylinder on the front axle. Attach a pressure gauge capable of reading 200 bar to the T connector. Start the engine and run at 1000 rpm, turn the steering wheel to full lock and read the pressure gauge. A maximum reading of 140 bar should be seen.

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SECTION 41 -- STEERING -- CHAPTER 1

NOTES

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 1

SECTION 50 -- CAB ENVIRONMENT Chapter 1 -- Heating System CONTENTS Section

Description

Page

50 100

SPECIFICATIONS Engine Radiator Coolant: Antifreeze -- Ambra Agriflu Water System Type Fan Belt Deflection: Turbo/Turbo Intercooled Thermostat: Start to Open at Coolant Tank Cap

13.6 Litres (3.6 U.S. gals) 13.6 Litres (3.6 U.S. gals) Pressurized Full Flow By--pass with Expansion Chamber 10 -- 13 mm (0.38 -- 0.52 in) 79°C (180°F) 0.50 bar (7 lb in2)

TORQUE VALUES Coolant/Hot water hose connections Air hose ducting connections

5 Nm (3.6 lbf ft) 5 Nm (3.6 lbf ft)

SEALANTS Code Number 82995768 82995776 82995774 82995773

Name Sealer--Anaerobic Low strength Sealer--Silicone Sealer--Polyester Urethane Sealer--Anaerobic

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 1

CAB CLIMATE CONTROLS Heater Blower Control A two speed blower is installed for the heat movement around the cab and is controlled by switch (1) mounted in the instrument console to your right. Press the switch to the first position for slow speed and further for fast speeds. NOTE: With the window and door closed, the blower may be used to pressurise the cab to exclude dust. 1

Heater Temperature Control The temperature of the air from the heater is adjusted using the control knob (1). Turn the control clockwise to increase the temperature of air from the heater and counter clockwise to reduce the temperature. The Air Conditioning (2) where fitted, should be OFF if trying to heat the cab.

WARNING The cab air filters are designed to remove dust from the air but may not exclude chemical vapour. When working in an enclosed area ensure there is adequate ventilation as exhaust fumes can suffocate you. 2

Air Flow Vents Air flow vents are conveniently positioned in the cab and may be independently adjusted, as required, to direct warm or cold air into the cab interior as required. To open a vent, press one side of the disc and turn it, as required, to direct the air flow.

Windscreen Demisting Air flow to the windscreen is through fixed air ducts and continuous as long as the blower motor is running.

4 604.55.181.00 09-- 2003

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 1

HEATER RADIATOR The heater radiator (1) for cab heating is fitted behind the roof lining in a self contained housing. Hot water is directed up to the radiator by a hose from the water pump housing. The heater radiator dissipates the heat into the roof space and by the action of the heater blower warm air is forced through the open air vents. The water is then returned from the radiator to the engine system through tubing into the radiator return line behind the oil filter cooler.

CAB AIR FILTER Unscrew the filter retaining cover (1) and remove the filter to clean. Clean the chamber with a damp, cloth and re--assemble the pod filter element (2) with the seal facing the inside of the cover.

6 IMPORTANT: The filter (2) as above should be cleaned more frequently when operating in extremely dusty conditions reassemble as previously described.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 1

1 1. 2. 3.

Heater Control Valve Blower Motor Switch Water return to system

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Schematic -- Heater system 4. Engine Radiator 5. Hot Water Hose to Cab Heater Matrix 6. Blower Motor 7. Heater Matrix

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 1 FAULT FINDING -- GENERAL Items that may cause a concern are suggested in the fault finding chart but as a general rule apply the following steps: Ensure water flow to the heater radiator is steady and all air has been removed from the system.

Hoses are unrestricted and not leaking. Check the electrical connections are good and the blower motor is operational. The operating cable to the heater valve and valve is operational.

FAULT FINDING PROBLEM Dust enters the cab

POSSIBLE CAUSE

CORRECTION

Improper seal around filter element Check seal condition Blocked filter

Clean or replace filter

Defective filter

Replace filter

Excessive air leak (s) around doors Repair and Seal air leak (s) and windows Blower motor air flow low

Blocked filter or recirculation filter

Clean or replace filter(s)

Heater radiator core blocked

Clean radiator core thoroughly

Blower motor not working

Fuse blown

Replace fuse

Cab does not heat up

Engine not reaching operating Replace thermostat temperature. Thermostat stuck open

Heater hose from engine to cab Ensure water flow to heater radiator is adequate and not restricted radiator, kinked or blocked Cab does not cool

Heater control turned on

Turn temperature control knob fully counterclockwise for maximum cooling

Heater control valve stuck in open Free up valve or change as position required Temperature not stable

Low engine coolant

Top up coolant recovery tank

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 1

OVERHAUL IMPORTANT: when overhauling the heating system remember that with the engine running or shortly after it is turned off that the system will be at engine temperature and therefore the water will be hot and under pressure. To effect repairs to the heater core or blower motor, it will be necessary to remove the roof lining and heater pod fixtures. 7

Draining the System Too drain the cooling system down disconnect either hose at the ’T’ junction found at the rear of the engine oil filter mounted to the right hand side of the engine.

Heater Radiator With the system drained remove the heater core hose connections, attaching bolts and remove from the vehicle. Inspect the Heater Core: Check water flow through the heater pipe which should be free running, if not clear any blockage. Fins should be free of all debris and not damaged clean and or repair. Clean the heater radiator using compressed air not exceeding 7 bar (100 lbs in2) taking care not to damage the radiator fins. Ensure the radiator is not leaking under pressure, repair or replace as required. Clean the chamber with a damp, cloth and re--assemble the housing with the seal facing the inside of the cover.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 1

Blower Motor With the roof lining removed the blower motor can be serviced by removal of the attaching hardware and disconnection of the wiring connector. Check the blower and if not working check the fuse, if okay check the continuity of the blower motor. If defective replace the blower unit as an assembly.

Heater Control Valve To service the control valve disconnect the hoses and remove the attaching screws. Check the operation of the valve and if tight or worn replace.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 1

NOTES

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

SECTION 50 -- CAB ENVIRONMENT Chapter 2 -- Air Conditioning CONTENTS Section

Description

Page

50 200

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fault Finding and System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Leak Testing, Charging, Discharging and System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . 32 Component Overhaul (excluding compressor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Compressor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

Refrigerant Specification

50 000 SPECIFICATIONS New Holland Specification 82000810 (R134a)

Refrigerant Charge

850 grammes (1.87 lbs)

Compressor Oil Specifications

New Holland Specification 82008750 (PAG Type) (ISO 46 Viscosity) Sanden SP10

Refrigerant Oil Capacity (Compressor and system)

186 cc -- 228 cc

Cooling capacity @ 22oC -- 49oC (75oF -- 120oF) ambient. 4.5 kW Typical (Actual capacity dependent on system control operator settings) Pressure Cut Out Switch (Mounted in the body of the receiver dryer) High Pressure 10 bar (145 lb/in2) Low Pressure 1 bar (14.5 lb/in2) Temperature Cycling Control Switch (Mounted in the heater pod behind the roof lining Switch Setting On Off 10° C Minimum Cooling 14 +/ -- 2 ° C 1 +/ -- 1° C Maximum Cooling 4 +/ -- 1° C COMPRESSOR Manufacturer and Type Compressor Clutch and Pulley Air Gap Drive Belt Tension

Sanden SD7H15 0.4--0.8 mm (0.016--0.031”) 10 mm (0.4 in) deflection with 1 kg (2.2 lb) force applied midway between the pulleys

TORQUES Compressor Cylinder Head Bolts 24.5--26.5 Nm (18--19.5 lbf.ft) Compressor Clutch Front Plate Retaining Bolt 11.0--14.0 Nm (8--10 lbf.ft) Self--sealing Couplings small 40--54 Nm (29--40 lbf.ft) large 54--68 Nm (40--50 lbf.ft) Compressor Mounting Bolts 20.5--25.5 Nm (15--19 lbf.ft) SPECIAL TOOLS Certified Refrigerant Recovery, Recycling and Recharge Equipment suitable for the type of refrigerant gas used on tractors are required when servicing air conditioning systems. This special equipment is available through recognised suppliers of air conditioning equipment. Refer to the Tool supplier for details on the latest equipment available for servicing the air conditioning system. Vacuum/charge Portable system

New Holland Tool No. 294030

Recovery/recharge Portable System

New Holland Tool No. 294161

Evaporator and Condenser Cleaner

New Holland Tool No. 293831

Electronic Gas Leak Detector

New Holland Tool No. 294036

Manifold Gauge Set (where required)

New Holland Tool No. 292744

COMPRESSOR TOOLS: Sanden SD7H15 Kit

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SPX

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

SAFETY PRECAUTIONS

WARNING Before overhauling an air conditioning system read and observe the following Safety Precautions If a repair or replacement becomes necessary, ensure that only certified Air Conditioning technicians are employed, using approved equipment to effect repairs. Do not attempt to disassemble the air conditioning system, It is possible to be severely frostbitten or injured by escaping refrigerant.

•

The oil and refrigerant mixture inside the air conditioning system is pressurized. Consequently, never loosen fittings or tamper with lines unless the system has been properly discharged.

•

Before loosening any connection, cover the fitting in question with a cloth and wear gloves and goggles in order to prevent refrigerant from reaching the skin or eyes.

•

In the event of an accident, proceed as follows:--

IMPORTANT: Do not allow refrigerant to escape into the atmosphere. Refrigerant must be handled with care in order to AVOID HAZARDS. Undue direct contact with liquid refrigerant can produce freezing of skin and eyes.

Keep the refrigerant container and air conditioning system away from flame or heat sources, the resulting pressure increase can cause the container or system to explode.

If in direct contact with open flames or heated metal surfaces, the refrigerant will decompose and produce products that are toxic and acidic.

Make sure to comply with the following indications and simple precautions to avoid any risk of injury:

•

Never discharge refrigerant into the atmosphere. When servicing air conditioning units a certified refrigerant recovery unit operated by a certified technician must be used.

•

When discharging the refrigerant in the system make sure you are operating in well--ventilated premises with good air circulation and far away from open flames.

•

When charging and discharging the system always wear goggles and take suitable precautions to protect the face in general and the eyes in particular, from accidental spillage of the refrigerant fluid.

If the refrigerant has reached the eyes, wash them immediately with copious amounts of sterilised water or mains pressure tap water and transfer to hospital for immediate medical help.

If the refrigerant has touched the skin, wash with cold water and transfer to hospital for immediate medical help.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

AIR CONDITIONING SYSTEM Heat reduction is controlled by circulating the air through the cooling unit (evaporator). This unit also serves to reduce the moisture and dirt content of the air, as the wet surface of the evaporator collects dust and pollen particles which drain off the condensed moisture.

The system consists of two heat exchangers and a compressor inter--connected by tubing. The cooling unit, evaporator (1), is located in the cab with the second heat exchanger (condenser), mounted in front of the engine radiator. A special refrigerant R--134A that is easily heated and cooled, is circulated through the two heat exchangers by the pump (compressor). This is mounted to the right hand side of the the engine, and driven by a ‘V’ belt from the crankshaft pulley. IMPORTANT: R--134A is the only refrigerant acceptable for your machine Air Conditioning system. Prior to seasonal operation of the air conditioner it is essential you close the heater knob fully OFF.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 Operation To operate depress button (1), which will engage the air conditioning compressor

A two speed blower is used for the air circulation and operates by operating the switch (2). To ensure optimum cooling make sure the heater knob (3) is turned off. The air--conditioner filter is located in the roof and should be serviced as outlined in the Section 3.

WARNING The air filter is designed to remove dust from the air but may not exclude chemical vapour. Refer to chemical manufacturers directions regarding protection from dangerous chemicals.

Air Recirculation Air recirculation is recommended in conditions of high ambient temperature or humidity to reduce the load on the air conditioning system by passing already cooled and dehumidified air over the evaporator.

2 4

REFRIGERANT R-- 134A WARNING

IMPORTANT: The air--conditioning can be operated with the cab heater on to eliminate moisture on a damp morning, but this action will not cool the cab. Too cool the cab on a hot day ensure the cab heater is turned off.

R--134A can be dangerous if improperly handled. Therefore it is important the following warning and directions are adhered to.

If the machine has been parked in the sun, quicken the cooling by operating the air--conditioning for 2--3 minutes at its coldest setting. Set maximum blower speed with a window left partially open to force most of the warm air from the cab.

Never expose any part of the air--conditioner system to flame or excessive heat because of risk of fire or explosion, and the production of phosgene gas.

With the air cooled sufficiently, close the window and adjust the controls to the desired temperature. To ensure proper operation of the system be sure the cab filter is regularly serviced. Refer to maintenance Section 3 of the Operator’s Manual. It is the normal function of the air--conditioner to extract water from the air. As such it is possible pools of water will collect beneath the drain hose outlets under the cab when the machine is stationary.

R--134A has a boiling point of 10°F (--12°C)

Never disconnect or disassemble any part of the air--conditioning system as escaping refrigerant can cause frostbite. If refrigerant should contact the skin use the same treatment as for frostbite. Warm the area with your hand or lukewarm water 90°F (32°C), cover the area loosely with a bandage to protect affected area against infection and consult a doctor immediately. If refrigerant should contact the eyes wash immediately in cold clean water for at least 5 minutes and consult a doctor immediately.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

Air Flow Vents, Figure 5. Air flow vents are conveniently positioned in the cab and may be independently adjusted, as required, to direct warm or cold air into the cab interior as required.

To open a vent, press one side of the disc and turn it, as required, to direct the air flow. 5

Windscreen Demisting Air flow to the windscreen is through fixed air ducts and continuous as long as the blower motor is running.

COOLING EVAPORATOR The evaporator for cab cooling is fitted in the roof. To gain access it is necessary to remove the roof lining. Clean the heater and cooler using compressed air not exceeding 7 bar (100 lbs in2) taking care not to damage the radiator fins.

CAB AIR FILTER Unscrew the filter retaining cover and remove the filter to clean. Clean the chamber with a damp, cloth and re--assemble the pod filter element with the seal facing the inside of the cover.

IMPORTANT: The filter should be cleaned more frequently when operating in extremely dusty conditions reassemble as previously described. 8 604.55.181.00 09-- 2003

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 PRINCIPALS OF AIR CONDITIONING

The function of the air conditioning system is to improve the operator’s comfort by cooling the air temperature inside the cab and reducing the humidity level. In order to achieve this heat transfer the following principals of heat generation and transfer are applied within the air conditioning system.

60--50--001

9 1. When two bodies of different temperature come together heat is transferred from one to another. On air conditioning systems an evaporator is used to hold the low temperature refrigerant which absorbs the heat from the air within the cab.

2. When a gas is pressurised the temperature of the gas will rise. In air conditioning systems the increase in pressure is achieved using a compressor.

60--50--002

10 3. When a gas is cooled it will condense into a liquid. In the air conditioning system a condenser is used to cool the gas and the resulting liquid is stored in a receiver dryer.

60--50--003

11 4. When a liquid is atomized through an orifice, the temperature of the resultant vapour will drop. The low temperature of the atomized liquid will then absorb heat from its surroundings. On air conditioning systems the refrigerant is atomized using an expansion valve. C°

60--50--004

12 604.55.181.00 09-- 2003

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

13 1. 2. 3. 4. 5. 6. 7.

Air Conditioning Principle of Operation Expansion Valve -- Atomizes Liquid Refrigerant Before Passing to Evaporator Evaporator-- Absorbs Heat From Air In Cab Compressor -- Compresses and Raises Temperature Of Refrigerant Gas Condenser and Receiver Dryer -- Converts Refrigerant from Gas to a Liquid Blower Motor Temperature Control Switch Blower Motor Switch

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

LOW PRESSURE SIDE

HIGH PRESSURE SIDE

EXPANSION VALVE LOW TEMPERATURE HIGH PRESSURE LIQUID FILTERED AND MOISTURE REMOVED

LOWER TEMPERATURE LOW PRESSURE ATOMIZED LIQUID

RECEIVER DRYER

LOWER TEMPERATURE HIGH PRESSURE LIQUID

EVAPORATOR

CONDENSER WARM LOW PRESSURE VAPOUR HIGH TEMPERATURE HIGH PRESSURE VAPOUR

COMPRESSOR HEAT FROM INSIDE CAB MOVES TO REFRIGERANT

HEAT MOVES TO OUTSIDE AIR FROM REFRIGERANT

5009001

14 Air Conditioning Flow Diagram

It can now be seen that the principal components of an air conditioning system are:-• Refrigerant • Evaporator • Compressor • Condenser • Receiver Dryer • Expansion Valve Figure 13, uses the examples above to illustrate the air conditioning cycle. Figure 14, shows in schematic form the flow of refrigerant through the five major components of an air conditioning system. Refrigerant is drawn into the compressor as a cool, low pressure vapour which is compressed and then pumped out as a hot, high pressure vapour to the condenser. As the hot, high pressure vapour passes through the condenser core it gives off heat to the cooler outside air, being drawn past the fins by the engine cooling fan.

By giving off heat to the outside air, the vapour is condensed to a liquid which moves under high pressure to the receiver dryer where it is stored until released to the evaporator by the temperature sensing expansion valve. As liquid refrigerant passes through the metered orifice in the expansion valve the refrigerant changes from a high pressure liquid to a low pressure atomized liquid with a lower temperature. This low pressure, low temperature, atomized liquid enters the evaporator coils and absorbs heat from the cab warm air blown across the coils and fins by the cab blower motor. The refrigerant now changes from a cold low pressure atomized liquid to a warm low pressure vapour and leaves the evaporator outlet, moving to the suction (low pressure) side of the compressor to repeat the cycle. As this heat loss is taking place, moisture (humidity) in the cab air will condense on the outside of the evaporator and drain off as water through the drain hoses attached to the evaporator drain pan, thereby reducing the humidity level of the cab.

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SYSTEM DESCRIPTION AND OPERATION Refrigerant To achieve the absorption and the release of heat which is, in essence, the function of an air conditioning system, requires the use of a suitable “refrigerant” - a liquid that has a relatively low temperature boiling point, plus certain desirable safety and stability features. The refrigerant used in the air conditioning system is refrigerant R134a. NOTE: To help protect the environment legislation has been introduced in most territories banning the release into the atmosphere of refrigerants, including R134a. All service procedures contained in this manual can be carried out without the need to release refrigerant into the atmosphere. In order to prevent the incorrect type of refrigerant being charged to the system the service valves fitted to the machine and necessary to connect up to the refrigerant recovery, evacuation and recycling/recharging equipment will be of two different sizes. As recognised and specified by the air conditioning industry.

WARNING R134a refrigerant is not compatible with R--12 refrigerant. Do not attempt to replace R134a refrigerant with R--12 refrigerant or test the system using gauges or equipment previously used with R12 as damage to the system will result. R-134a refrigerant is stable at all operating temperatures and able to absorb great quantities of heat. The boiling point of R-134a is -22° C (-15° F) at atmospheric pressure. If the pressure is increased, R-134a will readily vaporize to absorb heat at temperatures between -11.7° C (11° F) at 1.9 bar (27.5 lb/in2) and 0°C (32° F) at 2.9 bar (42 lb/in2) in the evaporator. At higher pressures, R-134a will condense and give off heat at temperatures between 48° C (118° F) at 12.4 bar (180 lb/in2) and 58° C (136° F) at 15.85 bar (230 lb/in2) in the condenser.

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9 1 8

6 TA6050007

3 15

Air Conditioning Refrigerant Compressor 1. 2. 3. 4. 5.

Electro--magnetic Clutch Clutch Bearing Cam Rotor Wobble Plate Piston

Compressor Pump The tractor air conditioning unit compressor pump is mounted on the left hand side of the engine and is belt driven by the crankshaft pulley. The compressor separates the low and high pressure sides of the system and is basically a pump which has two functions: (1) To raise the refrigerant temperature by compression to a higher degree of temperature than the ambient (outside air) temperature. (2) To circulate the required volume of refrigerant through the system. The refrigerant compressor is a seven cylinder wobble plate unit housed in a die cast aluminium housing. Drive to the wobble plate is from the pulley, through the electro magnetic clutch to the main driveshaft. Attached to the driveshaft is a cam rotor which oscillates the wobble plate. The wobble plate is prevented from rotating by a static gear engaging with teeth formed in the face of the plate. The seven pistons are connected to the wobble plate by rods located in ball sockets.

6. 7. 8. 9.

Suction Chamber Discharge Chamber Cylinder Head Static Gear

Refrigerant is drawn in on the downward stroke of a piston through the reed valves located either end of the cylinder assembly. Refrigerant enters the cylinder assembly through a gallery in the outer circumference of the cylinder assembly. The upwards stroke of the piston compresses the refrigerant and expels it through another reed valve into an inner gallery in the cylinder assembly and out into the refrigerant circuit. The compressor is lubricated with a Polyalklene Glycol (PAG) oil. This oil is totally miscible with the refrigerant and is carried around the refrigerant circuit. The compressor is activated by an electro-magnetic clutch which functions to engage or disengage the compressor as required in the operation of the air conditioning system. The clutch is primarily activated by the:-• Temperature cycling control switch • Combined high/low pressure cut--out switch • Low pressure cut--out switch

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Temperature Control Switch

The air conditioner temperature control switch (1) is mounted in the roof pod. The switch is a device which turns the compressor clutch on and off to maintain a constant average evaporator temperature and senses the evaporator temperature using a thermistor (2) positioned within the evaporator fins.

SMJ50004B

The temperature control switch compares the voltage of the thermistor, which is dependent on the temperature of the evaporator, with the voltage across the potentiometer of the ‘in cab’ temperature control switch. The switch upon comparing the two voltages determines whether the compressor clutch should be switched ‘on’ or ‘off’ in order to maintain the desired in cab temperature control.

SMJ50004C

Low Pressure Cut-out Switch

The low pressure switch (1) is mounted in the body of the receiver dryer. The purpose of the switch is to shut off the compressor pump in the event of low pressure in the refrigerant system. Low refrigerant pressure may occur due to a faulty expansion valve, icing up of the expansion valve orifice or refrigerant loss. Low refrigerant pressure may result in damage to the compressor pump.

The low pressure switch is factory set and cannot be adjusted.

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Condenser The condenser, (1) located at the front of the engine radiator, consists of a number of turns of continuous coil mounted in a series of thin cooling fins to provide a maximum of heat transfer in a minimum amount of space. NOTE: The condenser after removal of the attaching bolts can be slid out for cleaning. The condenser receives the hot, high pressure refrigerant vapour from the compressor. The hot vapour passes through the condenser coils and outside air is drawn through the condenser by the engine cooling fan.

Heat moves from the hot refrigerant vapour into the cooler outside air flowing across the condenser coils and fins. When the refrigerant vapour reaches the pressure and temperature that will induce a change of state, a large quantity of heat is transferred to the outside air and the refrigerant changes to a high pressure warm liquid. The warm liquid refrigerant continues onto the receiver/drier where it is filtered and desiccated, to remove any moisture, before passing through an outlet line to the thermostatic expansion valve. Receiver Dryer The receiver/dryer (1) situated to the left of the engine stores the liquid refrigerant to be sure a steady flow to the thermostatic expansion valve is maintened under widely different operating conditions. The drier section contains a desiccant (Molecular sieve) to absorb any moisture within the system and a filter prevents the entry of foreign particles. NOTE: Any moisture in the air conditioning system is extremely harmful. Moisture not absorbed by the dehydrator will circulate with the refrigerant and droplets may collect and freeze in the thermostatic expansion valve orifice. This action will block the refrigerant flow and stop the cooling action. Moisture will also react with refrigerant R-134a and the lubricant to form a corrosive acid.

The desiccant can only absorb a limited amount of moisture before reaching saturation point. Because of this, after any system component replacement or repairs requiring entry into the system, the receiver/dryer should be replaced.

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Expansion Valve The expansion valve is located underneath the evaporator in the pressure line leading from the receiver/dryer and performs the following functions: 1. METERING ACTION A metered orifice changes the liquid refrigerant from a high pressure low temperature liquid to a low pressure, lower temperature atomized liquid. 2. MODULATING ACTION A thermostatically controlled valve within the expansion valve body controls the volume of liquid refrigerant passing through the orifice and makes sure the refrigerant is fully vaporized within the evaporator. Liquid refrigerant would damage the compressor reed valves or freeze the pistons. 3. CONTROLLING ACTION The valve responds to changes in the cooling requirements. When increased cooling is required, the valve opens to increase the refrigerant flow and when less cooling is required the valve closes and decreases the refrigerant flow.

Expansion Valve - Operation All of the needed temperature sensing and pressure sensing functions are consolidated into this basic unit and no external tubes are required for these purposes. The refrigerant from the condenser and receiver dryer enters the thermostatic expansion valve as a high pressure warm liquid. Upon passing through the ball and spring controlled metering orifice, the pressure and temperature of the refrigerant is reduced and the refrigerant leaves the thermostatic expansion valve as a low pressure, lower temperature atomized liquid. The atomized liquid now passes through the evaporator where it absorbs heat before returning via the expansion valve to the compressor as a warm low pressure vapour. 60--50--014

There are two refrigerant passages in the valve. One passage is in the refrigerant line from the condenser to the evaporator and contains the ball and spring type orifice valve. The other passage is in the refrigerant line from the evaporator to the compressor and contains the valve’s temperature sensing element.

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Liquid refrigerant flow from the condenser and receiver dryer is controlled by a push-rod forcing the orifice valve ball off its seat and the spring exerting pressure on the ball to keep it on its seat. During stabilized (vehicle shutdown) conditions, the pressure on the bottom of the expansion valve diaphragm rises above the pressure on the top of the diaphragm allowing the valve spring to close the orifice. When the system is started, the pressure on the bottom of the diaphragm drops rapidly, allowing the orifice to open and meter atomized liquid refrigerant to the evaporator where it begins to vaporize. Suction from the compressor draws the vaporized refrigerant out of the evaporator and back through a gallery in the top of the valve which passes the temperature sensor. The temperature sensor reacts to variations in refrigerant gas pressure returning from the evaporator. When heat from the passenger compartment is absorbed by the refrigerant the pressure of the gas increases causing a differential pressure above and below the temperature sensor diaphragm. The diaphragm reacts to this pressure differential and a push rod forces the ball in the expansion valve orifice further off its seat. This reaction allows an increase in the atomized refrigerant to flow through the valve, to the evaporator, so that more heat can be absorbed by the air conditioning system. Similarly when the temperature of the gas returning from the evaporator decreases the pressure of the gas decreases. This causes the diaphragm to react accordingly and allow the ball in the orifice to move closer towards its seat thus reducing the flow of refrigerant through the valve to the evaporator. Evaporator The evaporator is located beneath the cab seat and consists of a number of turns of continuous coils mounted in a series of thin cooling fins to provide a maximum of heat transfer in a minimum amount of space. Low temperature refrigerant in the evaporator absorbs heat from the hotter air in the operator’s compartment, thereby cooling the air. 23

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FAULT FINDING AND TESTING THE AIR CONDITIONING SYSTEM

Overhaul of the air conditioning system should only be undertaken by a certified specialist refrigeration engineer using a comprehensive air conditioning test kit, including a gas leak detector, suitable for R134a refrigerant gas.

WARNING Before dismantling an air conditioning system for repair the gas within the system must be discharged and recovered using a certified recovery unit designed for the type of refrigerant gas used in the system.

Preliminary Fault Finding

Always conduct the preliminary fault finding checks before performance testing the system.

1. Run the engine at 1000-1200 rev/min for 10 minutes with the air conditioner set at maximum cooling and the blower on high speed.

2. Check that the heater temperature control is switched OFF.

3. Check that the blower fan is operating at all speeds.

NEVER release refrigerant gas into the atmosphere. ALWAYS wear safety goggles and gloves when servicing any part of the air conditioning system.

To prevent the entry of any foreign material, observe the following points:

4. Check that the compressor clutch engages when the temperature control switch is turned from “OFF” to “ON” position. A clicking sound indicates the clutch is engaging. If the clutch fails to operate it may indicate an electrical problem in the high low pressure cut out switches or malfunction of the electric drive clutch on the compressor.

5. Check the engine cooling fan is drawing cool air through the condenser.

6. Check the compressor drive belt tension. •

•

Ensure all tools, gauges, hoses and replacement parts are kept clean and dry and are suitable for the type of refrigerant gas used in the system.

Clean all hoses and fittings before disconnecting. Cap or plug all openings when disconnected.

When adding lubricating oil to the system always uncap and re-cap the oil container immediately before and after use. Always ensure the oil remains free of moisture.

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7. Check the condenser core and grid is clean and free of obstruction.

8. Check the cab air filter is clean and free of obstruction.

9. Check the evaporator fins are not plugged or excessively dirty.

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

24 1. 2. 3. 4. 5.

Attaching Manifold Gauge Set to the Telehandler 6. Test Hose to Low Side Service Connector Low Side Gauge 7. Shut-off Valve High Side Gauge 8. Low Pressure Side Service Valve Shut-off Valve 9. High Pressure Side Service Valve Test Hose to High Side Service Connector Centre Hose (Not Used)

Performance Testing The Air Conditioning System The manifold gauge set is the most important tool used in testing and servicing the air conditioning system. NOTE: For Dealers who posses the latest design level of refrigerant recovery, recycling and recharging station, these gauges are an integral part of the machine. The following instructions for performance testing the air conditioning system is based on the use of the gauge set shown. The principal of operation is however similar when testing the system using a recovery and recharging station with integral gauges. When using this type of equipment always consult the manufacturers operating instructions. Operating Precautions IMPORTANT: Always ensure the shut--off valves are closed (turn clockwise until seated) during all test operations.

In the closed position, refrigerant circulates around the valve stems to the gauges. Therefore, when the manifold gauge set is connected into a system, pressure is registered on both gauges. • NEVER open the HIGH SIDE shut off valve when the system is operating. • ALWAYS open the LOW SIDE shutoff valve when adding refrigerant. Attaching The Gauge Set To The Telehandler

WARNING To avoid personal injury, stop the Telehandler engine during connection of the manifold gauge set. 1. Check that the gauge set shut off valves are closed (turned fully clockwise). 2. Connect the high side gauge hose (normally red) to the high pressure side service valve and the

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low side gauge hose (normally blue) to the low pressure side service valve on the Telehandler. Ensure the hose connections are fully tightened. IMPORTANT: Prior to connection of the manifold gauge set, identify the suction (low pressure) and discharge (high pressure) service gauge ports. The high pressure service valve is always in the line from the compressor to the condenser. The high and low pressure service valves on the Telehandler are spring loaded valve and will be automatically opened when the test hose is connected.

6. Check the manifold low pressure gauge reading is within the specified range of approximately 4.36 lb/in2 (0.28-2.48 bar) (0.28--2.53 kgf/cm2). 7. Check the manifold high pressure gauge reading and compare the reading to the pressure indicated on the pressure temperature chart below. 8. Measure and compare the temperature of conditioned air entering the cab through the louvered air vents with the ambient air at the air intake filters on the outside of the cab.

NOTE: The test hose must incorporate a valve depressor to actuate this type of valve.

If the system is operating correctly the conditioned air entering the cab should be 6--9° C (10--15° F) cooler than the ambient temperature of the outside air.

The service valves have a protective cap. This cap must be removed for test gauge connections and replaced when service operations are completed. Test Procedure After the manifold gauge set has been connected and before pressure tests can be made, the system must be stabilized as follows:

9. If it is confirmed that the system is not operating correctly refer to the fault diagnostic charts and performance test gauge reading examples on the following pages for possible corrective action.

1. Apply the parking brake, check the gear shift levers are in neutral and close the cab windows and doors. 2. Re--check that both the high and low side shut off valves on the manifold gauge set are fully closed. 3. Run the engine at 1600 rev/min.

WARNING A significant amount of refrigerant vapour may have condensed to a liquid at the service fitting at the high side of the compressor. Use a cloth or other protective material when disconnecting the manifold hose from this fitting to prevent personal injury to hands and face.

4. Turn the heater temperature control ‘off’ 5. Operate the system at maximum cooling, with the blower fan at high speed for 10 minutes to stabilize all components. APPROXIMATE HIGH PRESSURE GAUGE READINGS

Ambient Air Temperature Degrees F Degrees C 80 85 90 95 100 105 110

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27 29 32 35 38 41 43

High Pressure Gauge Reading bar kgf/cm2 lb/in2 10.0/11.6 11.2/12.7 12.3/13.8 13.3/15.2 14.5/16.7 16.0/18.3 17.3/20.0

10.3/11.8 11.4/12.9 12.5/14.0 13.6/15.5 14.8/17.0 16.3/18.6 17.7/20.3

147/168 162/184 179/200 194/221 210/242 231/265 252/289

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 PERFORMANCE TEST DIAGNOSIS Gauge Readings:--

Low Pressure - Low High Pressure - Low

PROBLEM Evaporator air not cold

POSSIBLE CAUSES 1. Low refrigerant charge.

CORRECTION 1. Perform leak tests and repair Evacuate system Charge system

Evaporator air warm

1. Extremely charge.

low

system,

re--test

refrigerant 1. Perform leak tests and repair Evacuate system Charge system

system,

re--test

Evaporator air cool but not Expansion valve not permitting Check expansion valve as follows: sufficiently cold . sufficient flow. Set a for maximum cooling Low pressure switch cutting out Stuck valve Low pressure gauge should drop Expansion valve to evaporator slowly tube shows considerable If expansion valve is defective: condensation or frost. Too cold to touch

Discharge system Replace expansion valve Evacuate system Charge system Re--test

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PERFORMANCE TEST DIAGNOSIS CHART Gauge Readings:--

Low Pressure - High High Pressure - High

PROBLEM Evaporator air warm Liquid line hot (condenser outlet to expansion valve tube)

POSSIBLE CAUSES 1. mproper condenser

operation

CORRECTION of 1. Inspect for dirty condenser restricting air flow and cooling Check operation of condenser cooling fans. Repair or replace as needed.

High pressure switch cutting out

Overcharged with refrigerant Air in system

Evaporator air not cold

Check for overcharge as follows: Stop the engine. Recover and recycle the charge using correct recovery equipment. Recharge the the system with the correct quantity of refrigerant, replacing any lost lubricant. Recheck performance of air conditioning system.

1. Expansion valve allowing too 1. Check expansion valve as much refrigerant to flow follows: through the evaporator Set for maximum cooling. Low pressure gauge should drop slowly If expansion valve is defective: Discharge System Replace Expansion Valve Evacuate System Charge System Re--test

PERFORMANCE TEST DIAGNOSIS CHART Gauge Readings:--

Low Pressure - Low High Pressure - High

PROBLEM Insufficient cooling

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POSSIBLE CAUSES 1. Restriction in liquid line

CORRECTION 1. Discharge the system Replace the receiver/drier. Inspect all lines and tubing from compressor outlet to expansion valve. Replace if needed. Evacuate the system Charge the system Re--test

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 PERFORMANCE TEST DIAGNOSIS CHART Gauge Readings:--

Low Pressure - High High Pressure - Low

PROBLEM Evaporator air not cold

POSSIBLE CAUSES

CORRECTION

1. Internal leak in compressor. 1. Discharge the system (reed valves, gasket, worn or Replace the compressor scored piston rings or cylinder) Evacuate the system Charge the system Re--test

PERFORMANCE TEST DIAGNOSIS CHART Gauge Readings:--

Low Pressure - Normal High Pressure - Normal

PROBLEM Insufficient cooling Low pressure reading does not fluctuate with changes in temperature control switch (pressure should drop until compressor cycles) Evaporator air not cold.

POSSIBLE CAUSES

CORRECTION

1. System low on charge. Air or 1. Perform leak test moisture present in system Discharge system Repair leaks Replace receiver/drier Check oil level Evacuate system Charge the system Re--test

PERFORMANCE TEST DIAGNOSIS CHART Gauge Readings:--

Low Pressure - High High Pressure - Normal

PROBLEM Compressor cycles “on” and “off” too frequently

POSSIBLE CAUSES

CORRECTION

1. Defective temperature control 1. Stop engine and shut off A/C (thermostatic) switch Replace temperature control switch Re--test system and check compressor cycling

EXAMPLES OF MANIFOLD GAUGE READINGS AND INTERPRETATIONS The following examples show typical low and high pressure gauge readings obtained when performance testing the air conditioning system with an ambient temperature of 35° C (95° F). The recommended corrective action is based on a similar fault as identified in the performance test diagnosis charts.

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PERFORMANCE TEST EXAMPLE 1

60--50--019

25 Performance Test Example 1 1. 2. 3. 4.

High Side Low High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

PROBLEM: Little or no cooling.

5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side Low

2. Repair leaks. (Discharge and recover the refrigerant from the system; replace lines or components).

CAUSE:

3. Check compressor oil to ensure no loss.

Refrigerant slightly low.

4. Evacuate the system.

CONDITIONS* Low side pressure too low. Gauge should read 1--2 bar (15-30 lbf/in2). High side pressure too low. Gauge should read 13.3--14.8 bar (194--215 lbf/in2). Evaporator air not cold. CORRECTIVE PROCEDURES 1. Leak test the system.

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5. Charge the system. 6. Performance test the system. DIAGNOSIS: System refrigerant is low. May be caused by a small leak. NOTE: * Test procedure based upon ambient temperature of 35°C (95° F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 PERFORMANCE TEST EXAMPLE 2 7

60--50--020

26 Performance Test Example 2 1. 2. 3. 4.

High Side Low High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

PROBLEM:

5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side Very low

2. Discharge and recover the refrigerant from the system.

Insufficient cooling. 3. Repair leaks. CAUSE: Refrigerant excessively low. CONDITIONS* Low side pressure very low. Gauge should read 1--2 bar (15-30 lbf/in2) High side pressure too low. Gauge should read 13.3--14.8 bar (194--215 lbf/in2). Evaporator air warm. Low pressure switch cutting out CORRECTIVE PROCEDURES

4. Check compressor oil to ensure no loss. 5. Evacuate the system. 6. Charge the system. 7. Performance test the system. DIAGNOSIS: System refrigerant is extremely low. A serious leak is indicated. NOTE: * Test procedure based upon ambient temperature of 95° F. For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

1. Leak test the system.

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PERFORMANCE TEST EXAMPLE 3

60--50--021

27 Performance Test Example 3 1. 2. 3. 4.

High Side Normal High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

PROBLEM: Insufficient cooling.

5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side Low

2. Discharge and recover the refrigerant from the system. 3. Repair leaks.

CAUSE: Air in system.

4. Replace the receiver/dryer. 5. Check compressor oil to ensure no loss.

CONDITIONS*

6. Evacuate the system.

Low side pressure reading does not change when compressor cycles “on” and “off”.

7. Charge the system. 8. Performance test the system

High side pressure slightly high or slightly low. Gauge should read 13.3--14.8 bar (194--215 lbf/in2).

DIAGNOSIS: Air or moisture in system. System not fully charged.

Evaporator air not cold. CORRECTIVE PROCEDURES 1. Leak test the system. Give special attention to the compressor seal area.

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NOTE: * Test procedure based upon ambient temperature of 35°C (95° F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 PERFORMANCE TEST EXAMPLE 4

60--50--022

28 Performance Test Example 4 1. 2. 3. 4.

High Side Low High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

PROBLEM: Insufficient cooling. CAUSE: Compressor malfunction. CONDITIONS* Low side pressure too high. Gauge should read 1--2 bar (15-30 lbf/in2). High side pressure too low. Gauge should read 13.3--14.8 bar (194--215 lbf/in2).

5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side High

Evaporator air not cold. CORRECTIVE PROCEDURES 1. Replace the compressor. DIAGNOSIS: Internal leak in compressor caused by worn or scored pistons, rings, or cylinders. NOTE: * Test procedure based upon ambient temperature of 35°C (95° F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

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PERFORMANCE TEST EXAMPLE 5 7

60--50--023

29 Performance Test Example 5 1. 2. 3. 4.

High Side High High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

PROBLEM: Insufficient or no cooling. Engine overheats in some cases. CAUSE: Condenser not functioning properly. CONDITIONS* Low side pressure too high. Gauge should read 1--2 bar (15-30 lbf/in2). High side pressure too high. Gauge should read 13.3--14.8 bar (194--215 lbf/in2). Liquid line hot. Evaporator air warm. High pressure switch cutting out. CORRECTIVE PROCEDURES 1. Check belt. Loose or worn drive belts could cause excessive pressures in the compressor head. 2. Look for clogged passages between the condenser fins and coil, or other obstructions that could reduce condenser airflow.

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5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side High

3. If engine is overheating replace engine thermostat and radiator pressure cap. At this point, operate the system and check its performance. If still unsatisfactory, proceed as follows:-4. Discharge and recover the refrigerant from the system. 5. Remove the condenser and clean and flush it to ensure a free flow of refrigerant. Or, if the condenser appears to be unduly dirty or plugged, replace it. 6. Replace the receiver/dryer. 7. Evacuate the system, and recharge it with the correct quantity of refrigerant. 8. Performance test the system. DIAGNOSIS: Lack of cooling caused by pressure that is too high on the high side, resulting from improper operation of condenser. (Refrigerant charge may be normal or excessive). NOTE: * Test procedure based upon ambient temperature of 35°C (95° F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 PERFORMANCE TEST EXAMPLE 6

60--50--024

30 Performance Test Example 6 1. 2. 3. 4.

High Side Normal High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

PROBLEM: Insufficient or no cooling. CAUSE:

5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side Normal

2. Replace the receiver/dryer. 3. Evacuate the system. 4. Charge the system.

Large amount of air in system. 5. Performance test the system. CONDITIONS* Low side pressure too high. Gauge should read 1--2 bar (15-30 lbf/in2). High side pressure too high. Gauge should read 13.3--14.8 bar (194--215 lbf/in2). Evaporator air not cool. CORRECTIVE PROCEDURES 1. Discharge and recover the refrigerant from the system.

DIAGNOSIS: Air in system. This, and the moisture in the air, is contaminating the refrigerant, causing the system to operate improperly.

NOTE: * Test procedure based upon ambient temperature of 35°C (95° F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

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PERFORMANCE TEST EXAMPLE 7

60--50--025

31 Performance Test Example 7 1. 2. 3. 4.

High Side High High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side Hide

PROBLEM:

Operate the system at maximum cooling.

Insufficient or no cooling.

Check the low side gauge. The pressure should drop slowly.

CAUSE: Improper operation of thermostatic expansion valve (stuck open)

2. If the test indicates that the expansion valve is defective, proceed as follows: Discharge and recover the refrigerant from the system.

CONDITIONS*

Replace the expansion valve.

Low side pressure too high. gauge should read 1--2 bar (15-30 lbf/in2).

Evacuate the system.

High side pressure too high. Gauge should read 13.3--14.8 bar (194--215 lbf/in2).

Performance test the system.

Evaporator air warm. Evaporator and suction hose (to compressor) surfaces show considerable moisture. CORRECTIVE PROCEDURES 1. Check for sticking expansion valve as follows:--

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Charge the system.

DIAGNOSIS: Thermostatic expansion valve is allowing too much refrigerant to flow through the evaporator coils. Valve may be stuck open. NOTE: * Test procedure based upon ambient temperature of 35°C (95° F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 PERFORMANCE TEST EXAMPLE 8

60--50--026

32 Performance Test Example 8 1. 2. 3. 4.

High Side Low High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

PROBLEM: Insufficient cooling. CAUSE: Improper operation of thermostatic expansion valve (stuck closed).

5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side Low

Check the low side gauge. The pressure should drop slowly. 2. If the procedure outlined in Step 1 shows that the expansion valve is defective, proceed as follows: Discharge system

CONDITIONS*

Replace expansion valve

Low side pressure too low (zero or vacuum). Gauge should read 1--2 bar (15-30 lbf/in2). High side pressure low. Gauge should read 13.3--14.8 bar (194--215 lbf/in2). Evaporator air cool, but not sufficiently cold. Evaporator inlet pipe surface shows considerable moisture or frost. Low pressure switch cutting out.

Evacuate the system. Charge the system. Performance test the system. DIAGNOSIS: Expansion valve is not permitting a sufficient flow of refrigerant. May be caused by valve stuck in restricted or closed position.

CORRECTIVE PROCEDURES 1. Place finger on expansion valve to evaporator tube. If too cold to touch, proceed as follows: Operate the system at maximum cooling.

NOTE: * Test procedure based upon ambient temperature of 35°C (95° F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

PERFORMANCE TEST EXAMPLE 9

60--50--027

33 Performance Test Example 9 1. 2. 3. 4.

High Side Low High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

PROBLEM: Insufficient cooling. CAUSE: Restriction in high side of system. CONDITIONS* Low side pressure too low. Gauge should read 1--2 bar (15-30 lbf/in2). High side pressure too low. Gauge should read 13.3--14.8 bar (194--215 lbf/in2). NOTE: A normal or high reading of the high side pressure gauge under these conditions indicates the system is overcharged or the condenser or receiver/dryer is too small. Evaporator only slightly cool. Liquid line and receiver/dryer are cool to touch and show frost or considerable moisture.

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5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side Low

CORRECTIVE PROCEDURES 1. Discharge and recover the refrigerant from the system. 2. Replace the liquid lines, receiver/dryer, or other obstructed components. 3. Evacuate the system. 4. Charge the system. 5. Performance test the system. DIAGNOSIS: Restriction in the liquid line and/or receiver/dryer resulting in a “starved” evaporator (compressor moving refrigerant from the evaporator faster than it can enter). NOTE: * Test procedure based upon ambient temperature of 95° F. For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 PERFORMANCE TEST EXAMPLE 10

60--50--028

34 Performance Test Example 10 1. 2. 3. 4.

High Side Normal High Side Hand Valve Closed High Side Hose Connected to High Side Service Connector Not Used

PROBLEM: Compressor cycles (cuts in and out) too rapidly. CAUSE: Thermostatic switch defective. CONDITIONS* Low side pressure readings too high during both “on” and “off” compressor cycles and between cycles. Readings should be:

5. 6. 7.

Low Side Hose Connected to Low Side Service Connector Low Side Hand Valve Closed Low Side Gauge Compressor Cycles on at 34 lbf/in2 (2.3 bar) Compressor Cycles off at 28 lbf/in2 (1.9 bar )

CORRECTIVE PROCEDURES 1. Stop the engine and shut off A/C system. 2. Replace thermostatic switch with switch of same type. 3. Make sure the switch’s temperature sensor is installed in the same position and depth (in evaporator core) as previous. 4. Performance test the system.

0.8--1.0 bar (12-15 lbf/in2) - cycle “off”

DIAGNOSIS: Defective thermostatic switch.

2.5--2.7 bar (36-39 lbf/in2) - cycle “on”

NOTE: * Test procedure based upon ambient temperature of 35°C (95° F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

1.7--1.9 bar (24-27 lbf/in2) - between cycles High side pressure normal. Gauge should read 13.3--14.8 bar (194--215 lbf/in2).

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

LEAK TESTING, DISCHARGING AND CHARGING THE AIR CONDITIONING SYSTEM Leak Testing To perform a leak test if refrigerant leakage is suspected, use a leak detector following the manufacturer’s instructions. Leak detectors use light or sound dependant upon the type used to alert the operator of a leak. If the leak detector’s sensitivity is adjustable, be sure you calibrate the detector according to the manufacturer’s instructions before use. When using a leak detector, keep in mind that a very slight amount of leakage in the compressor pulley area is normal and does not necessarily indicate a repair is required.

60--50--029

When a leak is located, follow these steps. •

Discharge the system using refrigerant recovery system.

•

Repair the leak.

•

Evacuate the system.

•

Partially charge system with 400 grammes (14 ozs) of refrigerant.

•

Check system for leaks.

•

Fully charge the system.

certified

Always check the system for leaks as a final test after evacuating and before recharging. Refer to Evacuating the system. Discharging The System Legislation has been introduced banning the release of refrigerant into the atmosphere. Whenever overhauling the air conditioning system or performing other tasks which require the air conditioning system to be dismantled it is necessary to discharge the refrigerant gas before commencing repair. Before you can dismantle an air conditioning system for repairs, you must discharge and recover the refrigerant using a certified recovery unit in accordance with the manufacturers instructions. Shown is a combined refrigerant recovery, evacuation and recycling/charging station. This equipment removes R--134a refrigerant from the air conditioning system, recycles and recharges all in one hook up. The unit is designed to be used with the manifold gauge set built into the control panel.

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60--50--030

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

37 1. 2. 3. 4.

Connecting Recovery Evacuation and Recycling/Charging Station to the Telehandler Built In Manifold Gauge Set Recovery/Recharging Unit Low Side Service Valve (Blue Hose) High Side Service Valve (Red Hose)

Other recovery systems are available where the manifold gauges are not an integral part of the machine. When this type of equipment is used a separate manifold gauge set must be used. The following is a summary of the steps for discharging the system using a recovery/recycling unit

WARNING Never discharge refrigerant gas into the atmosphere. Always wear safety goggles and gloves when working with refrigerant. Only use authorised refrigerant tanks.

2. Set up the recovery unit following manufacturer’s instructions. Ensure that the units red (high side) hose is connected to the high side fitting and the blue (low side) hose to the low side fitting. NOTE: If a unit requiring the manifold gauge set is being used, the low and high sides of the manifold set are connected to the low and high sides of the Telehandler air conditioning system. The hose from the recovery unit is then connected to the manifold centre port. . 3. To recover refrigerant, open both high and low side valves on the control panel or the valves on the manifold gauge set if being used. 4. Open the valves labelled “gas” and “liquid” on the recovery unit refrigerant tank. 5. Plug in the unit’s power cord.

IMPORTANT: Always follow the manufactures instructions when operating recovery equipment.

6. Operate the recovery system in accordance with the manufacturers instructions.

1. Run the vehicle’s air conditioning system for a few minutes.

The compressor will shut off automatically when the recovery is complete.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

FLUSHING THE SYSTEM

7 Air conditioning systems may occasionally become contaminated with solid particles. This contamination may be the result of allowing dirt to enter the system while it was open, from aluminium corrosion or sludge, or from disintegrated compressor reed plates. Contamination of this nature can result in plugged evaporators, condensers and expansion valves. Flush System with dry nitrogen

6 2 5

4 60--50--032

3 TI

Each individual component must be flushed after disconnecting every hose fitting. The compressor and expansion valve can not be flushed, therefore, the compressor should be disassembled and cleaned or replaced and the expansion valve should be replaced. When flushing the system always replace the receiver/drier.

1. 2. 3. 4. 5. 6. 7.

Manifold Gauge Set High Side Gauge High Side Shut--off Valve High Side Hose Centre Service Hose Low Side Hose Low Side Shut--off Valve Low Side Gauge

NOTE: Never use any solvent for flushing an air conditioning system other than a special flush solvent made specifically for air conditioning systems. Always follow the manufacturer’s recommendations and directions for using the flushing equipment and solvent. Re--assemble and evacuate the system to remove air and moisture as described in “Evacuating the System”.

60--50--033

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 EVACUATING THE SYSTEM IMPORTANT: A system in which the refrigerant has been recovered to facilitate repairs, must be evacuated before new refrigerant is installed. Air and moisture are removed by evacuating the system using a vacuum pump. The automatic recycling, recharge and evacuation stations or evacuating and charging stations available throughout the air conditioning industry incorporate a vacuum pump within the assembly. If this type of equipment is not available a separate vacuum pump and manifold gauge set must be used. As the system is evacuated the boiling point of any moisture within the system is similarly lowered. As the vacuum increases the boiling reduces to below that of the ambient temperate and the moisture is subsequently boiled away. The relationship of system vacuum to the boiling temperature at which the water vapour is removed from the system is as follows:

System Vacuum In Cm. of Mercury Mercury 28.0 71.0 28.9 73.4 29.4 74.6 29.7 75.4 29.8 75.7 29.9 75.9

Temperature °F

°C

100 80 60 40 20 0

38 27 16 5 -7 -18

NOTE: For every 1000 feet (305 m) above sea level, the vacuum gauge reading must be corrected by adding 1″ (2.54 cm) of mercury to compensate for the change in atmospheric pressure. IMPORTANT: Be sure the system is completely discharged as refrigerant will damage the vacuum pump. 1. If the manifold gauge set FNH00172 is being used connect the low and high sides of the manifold to the low and high sides of the vehicle air conditioning system as described for discharging the system.

Connect the manifold centre hose to the vacuum pump suction port as per the manufacturers instructions. Fully open both the low and high side gauge shutoff valves. 2. If a combined recovery/evacuation unit is to be used attach the unit to the air conditioning system in accordance with the manufacturers instructions. Be sure to read all installation and operating instructions carefully before starting the unit. 3. After starting the evacuation cycle, note the low side gauge to be sure the system pulls down into a vacuum. 4. Time the evacuation for a minimum of 30 minutes from the point when lowest vacuum is attained. 5. Thirty minutes later when the low side gauge attains the lowest steady vacuum, stop the evacuation process. NOTE: The vacuum pump achieves ultimate vacuum with the vented exhaust valve closed. Do not evacuate too quickly as oil may be drawn from the system. 6. Check the system by closing the gauge shut--off valves, turning the vacuum pump off and noting the low side gauge reading. A loss of more than 2″ (5 cm) of vacuum in 5 minutes indicates either a leak or moisture in the system. 7. If the gauge needle remains stationary and the vacuum is maintained for 3-5 minutes, close both the high and low side manifold hand valves, turn off and disconnect the center hose from the pump. The system is now ready for charging. 8. If a leak is detected, charge the system with approximately 14 ozs (400 g) of refrigerant, see charging the system and locate the leak using a leak detector. 9. Once the leak is located discharge and recover the refrigerant in the system, repair the leak, then repeat the evacuation procedure.

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CHARGING THE SYSTEM IMPORTANT: Be sure there are no leaks in the system and the system has been fully evacuated. Observe all safety recommendations when handling refrigerant R-134a, see “Precautions when Handling Refrigerant R-134a” in this Section. 1. Ensure the charging unit is correctly connected to the Telehandler air conditioning system in accordance with the manufacturers instructions. 2. If a charging unit, in conjunction with the manifold gauge set is used, open the high and low side hand valves on the manifold. 3. Charge the system with 0.75 kg (1.65 lbs) of refrigerant as per the manufacturers instructions. 4. If the charging rate becomes very slow close the high side valve carefully, start the Telehandler and set engine speed to idle. Turn ‘ON’ the air conditioning so that the compressor can pull the remainder of the refrigerant into the system.

5. If the refrigerant charge will not completely transfer to the air conditioning system, recover and recharge the system. 6. Close the high and low side valves on the units control panel, or manifold gauge set if being used and test the air conditioning as detailed in Performance Testing The Air Conditioning System on Page 17. NOTE: After charging a system use the following start up procedure to ensure the lubricating oil is properly dispersed around the system: •

Ensure air conditioning is switched OFF.

•

Start the engine and bring speed down to idle.

•

Turn the air conditioning ON and allow system to operate for at least one minute before increasing engine speed.

40 1. 2.

Connecting Recovery Evacuation and Recycling/Charging Station to the Telehandler Built In Manifold Gauge Set 3. Low Side Service Valve (Blue Hose) Recovery/Recharging Unit 4. High Side Service Valve (Red Hose)

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

COMPONENT OVERHAUL (EXCLUDING COMPRESSOR)

WARNING Before disconnecting components in the air conditioning system the refrigerant gas must be discharged and recovered using a certified recovery system. Refer to Discharging the system on Page 32. Do Not discharge the gas into the atmosphere. If an air conditioning component is to be replaced during a system overhaul it is necessary to drain any refrigerant oil that has collected in the component being replaced into a clean calibrated container. A volume of clean refrigerant oil equivalent to that removed from the replaced component must then be added to the new item before being installed onto the Telehandler. Upon completion of the repair evacuate, recharge, leak test and performance test the system to ensure correct operation. EXPANSION VALVE The expansion valve is not a serviceable item and must be replaced if defective. 1. Fully discharge the air conditioning system. 2. Remove the roof lining to gain access to the valve. 3. Remove the inlet and outlet connections to the valve and pull valve from tubing. 4. Replace the ‘O’ ring seals and lubricate with refrigerant oil prior to installing the valve using disassembly procedure in reverse.

5037001

5. Evacuate, leak test and recharge the system. EVAPORATOR 1. Discharge and reclaim refrigerant gas using certified recovery systems. Remove roof lining and access the heater pod. 2. Remove temperature thermocouple.

cycling

control

3. Disconnect tubing to expansion valve. 4. Remove evaporator. 5. Check the evaporator assembly fins for damage. Straighten fins if necessary.

SMJ50004A

6. Clean the evaporator core of all foreign material to be sure it is free of obstructions.

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7. Check the evaporator assembly for indications of refrigerant leakage. If damage or leaks are evident, replace the evaporator core. 8. If a new evaporator is to be installed drain the refrigerant oil in the evaporator into a clean calibrated container. Measure the quantity of oil obtained and add the same quantity of new refrigerant oil directly into the replacement evaporator core. 9. Install evaporator using disassembly procedure in reverse. 10. Evacuate, leak test and recharge the system. AIR CONDITIONER TEMPERATURE CYCLING CONTROL SWITCH 1. Mounted in the heater pod is the heater control switch. This switch which is not serviceable and must be replaced if defective.

SMJ50004B

43 LOW PRESSURE CUT--OUT SWITCH 1. With the engine ‘Off’ check continuity across the switch contacts. If the switch shows ‘Open Circuit’ replace as detailed below. IMPORTANT: The pressure switch can not be replaced without discharging the system. 2. Remove switch by unscrewing from self sealing schrader valve. 3. Replace with new switch and connect to harness.

BLOWER MOTOR ASSEMBLY The blower motor can if required be removed without discharging the system as follows:-1. Remove the roof lining and access the heater pod. From the rear of the pod the blower motor can be removed for repair or replacement. NOTE: Take care not to damage hoses during this operation. If the cab heater hoses restrict movement of the housing drain the heater assembly and disconnect the hoses. 45

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

2. Disconnect the motor wiring connector block. 3. Remove the remaining motor securing screws and withdraw motor. 4. Re--assembly follows procedure in reverse.

the

disassembly

RECEIVER DRYER The receiver/dryer (1) cannot be overhauled and must be replaced as an assembly. The receiver/dryer assembly should be replaced if it is suspected that moisture is in the system. The receiver dryer must also be replaced if the system has been discharged and the air conditioning joints disconnected. 1. Discharge and reclaim refrigerant gas using certified recovery systems. 2. Disconnect the hoses and switch and remove the dryer from the Telehandler.

3. Drain the refrigerant oil from the receiver dryer into a clean calibrated container. Measure the quantity of oil obtained and add the same quantity of new refrigerant oil directly into the new item. 4. Cap and plug all fittings to prevent any dirt entering the system. 5. Install a new receiver dryer. CONDENSER 1. Disconnect the connections to the condenser. 2. Remove condenser from machine. 3. Inspect the condenser assembly fins for damage and be sure they are not plugged. 4. Check the condenser for signs of leakage. If the condenser is damaged or leaking, install a new condenser assembly.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

5. If the condenser is to be replaced, drain the refrigerant oil from the condenser into a clean calibrated container. Measure the quantity of oil obtained and add the same quantity of new refrigerant oil directly into the new condenser.

6. Soak new tubing connector ‘O’ rings in clean refrigerant lubrication oil and install onto tubing.

7. Evacuate, leak test and recharge the system. CAB AIR FILTER 1. Before servicing the filters, switch off the blower and close all windows and one door. Slam the final door closed and the resulting back pressure will dislodge most of the loose dirt from the underside of the filters.

2. Remove filter element(s) and clean by blowing with compressed air not exceeding 2 bar (30 lbf/in2).

Blow the dust from the upper surface through the element to the underside. Hold the nozzle at least 12 in (300 mm) from the element to prevent damage to the paper pleats.

3. Clean both filter chambers with a damp, lint free cloth.

4. Replace the filter elements with the rubber seal uppermost and re--install the covers.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

COMPRESSOR -- OVERHAUL Compressor Removal 1. Discharge and reclaim refrigerant gas using certified recovery systems. Record the amount of oil discharged as (X). 2. Disconnect tubing to compressor. 3. Disconnect wiring connector to compressor clutch. 4. Disconnect drive belt, remove the four mounting bolts and remove compressor (1) from tractor. 48 5. Drain the refrigerant oil from the old compressor into a clean calibrated container. Measure and record the quantity of oil as (Y). This information is required during installation of the new or overhauled unit. NOTE: It is necessary to rotate the compressor drive shaft several times to completely expel all the oil. Compressor Installation 1. Installation is the reversal of the removal but the following points should be noted:-• Torque the mounting bolts to 40--51Nm (29--38lbf.ft). NOTE: It is recommended that a new receiver / drier assembly is installed after any system component replacement or any repair that requires entry into the system. • Drain the oil from the new compressor to be fitted into a clean container, or if the old compressor is to be refitted, obtain a new can of refrigerant oil. • Calculate the amount of oil to be installed as, (x)+(y). Add this quantity of the new oil into the fill port on top of the compressor. NOTE: Refer to the following page regarding Oil Level Measurement to determine if the system oil quantity is correct. After charging a system use the following start up procedure to ensure the lubricating oil is properly dispersed around the system: • Ensure air conditioning is switched OFF. • Start the engine and bring speed down to idle. • Turn the air conditioning ON and allow system to operate for at least five minutes before increasing engine speed.

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

Oil Level measurement (on vehicle) Oil level in the compressor should be checked when a system component is removed or replaced or when an oil leak is suspected. Use the following procedure to determine if the oil quantity is correct. 1. Start the engine and allow to idle. Switch on air conditioning and run the compressor for 10 minutes. 2. Recover the refrigerant from the system, very slowly so as not to lose any oil. 3. Carefully remove the oil filler plug. Turn the armature retaining nut to allow full insertion of the oil dipstick (1) Figure 51, supplied with kit NH.50--100. 4. Remove the dipstick and count the notches covered by the oil. An acceptable level of oil is when 5--7 notches are covered. 5. Add or subtract oil through the filler plug to obtain the correct level. 6. Ensure the filler hole seat and filler plug seal are clean and not damaged and Install the oil plug. Tighten to 15--25Nm (11--18lbf.ft).

51 Oil Retained in System Components After replacement of individual system components it will be necessary to add some oil to the system to make up the amount lost in the removed component. The table, on the right, shows some typical volumes for the components. It is, however, still recommended that the on vehicle oil level measurement procedure, described above, is carried out after a new component has been installed to establish correct oil quantity.

52 Component

604.55.181.00 09-- 2003

Typical oil amount fl.oz.

Evaporator

2.0

Condenser

1.0

Receiver / drier

0.5

Hoses

0.3

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2 Preliminary Inspection 1. Rotate the compressor shaft. Use a suitable socket on the hub centre bolt or by hand using the rubber dampers. If severe roughness is felt while rotating the hub, the compressor should be disassembled. 2. Using a 12 volt battery check current drawn by the field coil which should be between 3.6-- 4.2 Amps.

TA605057

53 Very high current readings indicate a short circuit in the field coil and no current reading indicate an open circuit. Replace coil with either fault. Resistance of the coil using an ohmmeter should be approximately 3.0Ω at 20°C. A poor earth (ground) connection of the field coil will result in a low voltage. 3. Ensure clutch is disengaged and rotate pulley by hand. If roughness in the bearing is felt, it will be necessary to replace the pulley and bearing as an assembly. TA605058

54 Clutch Disassembly Removal All clutch servicing should be done with the compressor removed from the vehicle: 1. Support the compressor. If using a vice, do not hold on to the housing. 2. Remove the cover on the front of the clutch plate. 3. Using the front plate tool hold the clutch plate stationary and remove the retaining nut from the end of the shaft. Figure 55. 6050092TAG

55 4. Place a thread protector over the end of the driveshaft and using a puller remove the clutch front plate, Figure 56.

6050093TAG

56 604.55.181.00 09-- 2003

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

5. Carefully remove the bearing dust cover, if fitted.

TA605088

57 6. Remove the clutch shims

TA605062

58 7. Remove the shaft key

TA605063

59 8. Remove the pulley bearing external snap ring

TA605064

60 604.55.181.00 09-- 2003

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

9. With a shaft protector over the exposed shaft, use a suitable puller to remove the clutch pulley.

6050094TAG

61 10. Inspect the pulley bearing for wear and replace where necessary.

TA605066

62 11. Remove the field coil wire retaining clip.

TA605067

63 12. Remove the field coil retaining snap ring and lift the coil from the housing.

TA605068

64 604.55.181.00 09-- 2003

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

Clutch Reassembly 1. Install the field coil, ensuring that the lug on the compressor housing locates in the cut out on the back of the coil housing, secure with the snap ring.

TA605071

65 2. Position the pulley on the housing hub.

TA605069

66 3. Using a suitable adaptor that rests firmly on the inner race of the pulley bearing, tap the pulley onto the front hub of the compressor.

TA605070

67 4. Install the bearing snap ring. 5. Replace the original shims, key and a new bearing dust cover.

TA605064

68 604.55.181.00 09-- 2003

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

6. Install the clutch front plate and using a suitable adaptor, tap into position.

TA605073

69 7. Replace the retaining nut and tighten to a torque of 18Nm (13lbf.ft).

6050092TAG

70 8. Check the clearance between the clutch front plate and pulley. This should be consistent around the circumference and be between 0.4--0.8mm (0.016--0.031in.) 9. If the air gap is not consistent, lightly pry up on the counter weighted front plate at the low spots or lightly tap down at the high spots.

TA605074

71 10. If the clearance is not within specification the shims under the front plate, Figure 72, should be added to or subtracted from until the correct clearance is obtained. NOTE: New shims are available in sizes 1.00, 0.50 and 0.13 mm, (0.040, 0.020 and 0.005 in.).

TA605062

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

Shaft Seal Replacement The refrigerant must be discharged from the system and the compressor removed from the vehicle prior to replacing the shaft seal. Removal 1. Remove the clutch front plate, as detailed in steps 1 to 7 of clutch disassembly. 2. Using a suitable lever or pair of snap ring pliers, remove the felt ring. TA605076

73 3. Remove the shaft seal retaining snap ring.

TA605075

74 4. Insert the seal remover/installer tool. Twist the tool to engage the slots in the seal. Pull up to remove. Discard the seal. NOTE: If seal remover tool is not available, insert a suitable piece of hooked wire into the seal slot and pull out seal.

6050095TAG

75 Installation 1. Thoroughly clean the seal cavity in the hub. Use ‘lint free’ cloth only. 2. Position the seal protector over the driveshaft.

TA605077

76 604.55.181.00 09-- 2003

SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

3. Ensure the shaft seal ‘O’ ring is installed onto the seal assembly.

TA605079

77 4. Dip the new seal assembly in clean refrigerant oil and attach to the seal remover/installer tool. 5. Insert the new seal fully into the hub. NOTE: If remover/installer tool is not available, position the seal squarely in the hub and tap gently until fully seated.

TA605080

78 6. Install the seal snap ring. If the snap ring has a beveled edge this should face outwards.

TA605082

79 7. Install a new felt seal and gently tap into position. 8. Remove the shaft protector and position the shims over the shaft. 9. Reinstall the clutch front plate as described in clutch reassembly.

TA605083

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SECTION 50 -- CAB ENVIRONMENT -- CHAPTER 2

CYLINDER HEAD SERVICING Disassembly 1. Drain the refrigerant oil from the compressor into a clean calibrated container. Measure and record the quantity of oil obtained. This information is required during installation of the new or overhauled unit.

TA605084

81 2. Remove the six cylinder head bolts and using a hide mallet, gently tap the cylinder head free. The use of a gasket scraper may also be required to free cylinder the cylinder head from the compressor body. 3. If the valve plate and/or cylinder head are to be reused, carefully remove the gasket using a suitable scraper.

TA605085

82 4. Gently pry the valve plate free from the cylinder block and remove the gasket. 5. Inspect the valve plate for damage.

TA605086

83 Reassembly 1. Coat the top of the valve plate with clean refrigerant oil and reassemble the cylinder head using the reverse of the disassembly procedure. 2. When installing the gaskets and valve plate ensure they are correctly positioned over the locating pins in the cylinder block. 3. Install the cylinder head bolts and tighten using the sequence shown in Figure 84. Torque initially to 20Nm (14lbf.ft) then finally to 32Nm (24 lbf.ft). 4. When the overhaul is complete add to the compressor a volume of oil equivalent to that drained prior to disassembly. 604.55.181.00 09-- 2003

TA605087

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SECTION 55 -- ELECTRICAL SYSTEM Chapter 1 -- Electrical System General CONTENTS Section

Description

Page

55 000 55 100 55 512 55 514 55 000 55 000 55 100 55 000

Electrical Equipment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Electrical System and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controls and Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 System Precautions For Battery Charging and Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Starting the Machine Using Jump Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Temporary Wiring Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Electrical System General Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

55 000 ELECTRICAL EQUIPMENT SPECIFICATIONS ELECTRICAL SYSTEM

95 hp / 110 hp

90 amp 12 volt 165 Ah on Negative / chassis cable Transistorised Negative Positive Engagement, Solenoid Operated (3.5 kw) 40/45W H4 Halogen 5/21W Bayonet Cap 5W Festoon and 10W Bayonet Cap 21W Bayonet Cap 55W H3 Halogen 1.2W Capless 1.2W Capless

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

55100 ELECTRICAL SYSTEM AND FUSES The electrical system of all models consists of various wiring harnesses, instrument clusters, and switches. A micro--processor is also used to control the powershift transmission. The instrument console and information lamps are mounted in front of the operator, behind the steering wheel.

1 The Key start switch has five positions: I

Accessories On

Off

III Ignition ‘ON’ IV Thermostart (Engine Pre--Heat) V

Engine Start (cranking)

The battery is located behind the right hand side panel, Figure 3. The battery type is 12 volt , 165 ah.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

The alternator is a 90 amp. unit for all models.

4 The Starting motor is a Bosch 3.0Kw unit.

5 Fuses and Relays

Fuses and Relays

The machine fuse and relay board is located beneath the front console cover behind the steering wheel. The fuses are numbered and reference to Figure NO TAG & 8, will permit rapid identification of the circuits they protect. NOTE: Certain optional items of equipment may not be installed on your machine. However, the fuses are still installed and may be used as spares.

IMPORTANT: Do not replace a blown fuse with another of a different rating.

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POWERSHUTTLE FUSES & RELAYS FUSES Fuse No.

F1 F2

Rating Colour Circuit 15A Blue Blower Fan 5A Orange Wheel Align Indicator, Hydraulic Control System

F3 F4 F5 F6 F7 F8*

10A 10A 7.5A 7.5A 7.5A 10A

Red Red Brown Brown Brown Black

F9 F10 F11 F12 F13 F14 F15

10A 15A 7.5A 7.5A 15A 10A 5A

Red Blue Brown Brown Blue Red

F16 10A F17* 10A F18 F19 F20 F21 F22 F23 F24 F25 F26 F27

15A 7.5A 15A 15A 25A 7.5A 15A 3A 80A 80A

Horn Optional Equipment Left Hand Indicators Ritght Hand Side Lights Left Hand Side Lights Rear and Roof Windscreen Wash

Road Lights Rear Road Lights Front Optional Equipment Optional Equipment Transmission Load Monitor Indicator Orange Tachometer and Hour Gauge Red Hazard Flashers Black Front Windscreen Wash and Wipe Blue Front Lights Brown Right Hand Indicators Blue Reversing Lights Blue Warning Switch Neutral Auxiliary Socket Brown Rotating Beacon Blue Optional Equipment Purple Grid Heater Clear Grid Heater Clear Grid Heater

RELAYS K0 Transmission Disconnect - MR-- FS Joystick K1 Transmission Disconnect K2 Transmission Selection -- Forward K3 Transmission Selection -- Reverse K4 Starter Motor Circuit K5 Transmission Oil Pressure K6 Turn Indicators K7 Load Status Console K8 Cold Start Relay -- Option K10 Monoramp Control K11 Smooth Ride Control K12 K13 Air Conditioning K15 MR/FS Aux Cut Off / ECO Valve K16 Low Brake Pressure -- Option K17 Auxiliary Thumb Control -- FS Hyd prior to K18 update to K22 K20 K21 K22 K23 M7

Starting Joystick Disconnect -- FS Hyd Hydraulic Cut Out Valve -- Option Auxiliary Thumb Control -- updated FS Hyd Warning Module -- USA only Buzzer

Relay locations effective Ser. No: 041810657

* F8/17 Circuit Breaker Type Fuse 7

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POWERSHIFT FUSES & RELAYS FUSES Fuse No.

Rating Colour Circuit F1 15A Blue Blower Fan F2 5A Orange Wheel Align Indicator, Hydraulic Control System F3 10A Red Horn F4 10A Red Optional Equipment F5 7.5A Brown Left Hand Indicators F6 7.5A Brown Right Hand Side Lights F7 7.5A Brown Left Hand Side Lights F8* 10A Black Rear and Roof Windscreen Wash F9 10A Red Road Lights Rear F10 15A Blue Road Lights Front F11 7.5A Brown Optional Equipment F12 7.5A Brown Optional Equipment F13 15A Blue Transmission F14 10A Red Load Monitor Indicator F15 5A Orange Tachometer and Hour Gauge F16 10A Red Hazard Flashers F17* 10A Black Front Windscreen Wash and Wipe F18 15A Blue Front Lights F19 7.5A Brown Right Hand Indicators F20 15A Blue Reversing Lights F21 15A Blue Warning Switch F22 25A Neutral Auxiliary Socket F23 7.5A Brown Rotating Beacon F24 15A Blue Optional Equipment F25 3A Purple Grid Heater F26 80A Clear Grid Heater F27 F28 10A Red Cooler Thermostat Switch F29 25A In Line Cooler Fan

RELAYS K0 Transmission Disconnect - MR-- FS Joystick K1/2 If fitted prior to 041810657 -- no function K3 Transmission Selection -- Reverse K4 Starter Motor Circuit K5 If fitted prior to 041810657 -- no function K6 Turn Indicators K7 Load Status Console K8 Cold Start Relay -- Option K10 Rear Hydraulic FS only -- Option K11 Smooth Ride Control K12 K13 Air Conditioning K15 MR/FS Aux Cut Off / ECO Valve K16 Low Brake Pressure -- Option K17 Auxiliary Thumb Control -- FS Hyd prior to K18 update to K22 K19 Powershift Oil Cooler Fan K20 Starting Joystick Disconnect -- FS Hyd K21 Hydraulic Cut Out Valve -- Option K22 Auxiliary Thumb Control -- updated FS Hyd K23 Warning Module -- USA only M7 Buzzer Relay locations effective Ser. No: 041810657

* F8/17 Circuit Breaker Type Fuse 12

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55 512 CONTROLS AND INSTRUMENTS HAND AND FOOT OPERATING CONTROLS

Shown in Figure 17, is the cabin layout of a typical machine with a Powershuttle Transmission and Mechanical Controls for the Telescopic Arm. NOTE:The layout of controls in the diagram may vary between machines dependant upon options fitted and to meet Legislation in different Countries. 1. Steering Control: IMPORTANT: Prior to driving the vehicle always turn the steering wheel side to side at engine start up, to circulate the hydraulic oil. 2. Wheel Alignment Indicator Switch 3. Instrument Console and Switches 4. Direction Indicator and Road Lights 5. Vehicle Hazard Lighting Switches 6. Load Handling Monitor Indicator 7. Optional Automatic Load Handling Hydraulic Lock

13. Loader Lever which controls: -- Loader Boom Lift and Drop, -- Attachment Curl In and Out -- Transmission Disconnect IMPORTANT: At engine start up always fully retract all loader boom sections until the relief valve is actioned and hold for 10 seconds. This ensures all boom sections and hoses become fully synchronised, if not synchronised hose failure may result . 14. Heater Control Knob 15. Gear Lever With Transmission Disconnect Button 16. Foot Throttle 17. Safety Lockout for the Axle Steering Control Lever (Fitted Subject to Local Legislation) 18. Axle Steering Control Lever Two Wheel Steer, Four Wheel Steer and Crab Steer:, Select fully all steering modes at least once a day to ensure correct operation.

8. Switch Panel for miscellaneous services

19. Overcentre Parkbrake

9. Storage Bin (optional Radio Placement)

20. Windscreen Washer Reservoir

10. Auxiliary Hydraulic Movement (Bucket Clam etc.)

21. Foot Brake Pedal / Transmission Cut Off Pedal

Available also with an optional 5th hydraulic service switch 11. Telescopic Extend / Retract Lever 12. Auxiliary Hydraulic Equipment Lever (Pickup Hitch / Trailer Tipping)

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22. Key Start 23. Smooth Ride Control System Switch (when fitted). Plus two optional switch locations 24. Transmission Direction Lever (Power Shuttle)

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Operating Controls -- Mechanical

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HAND AND FOOT OPERATING CONTROLS

Shown in Figure 18, is the cabin layout of a typical machine with a Powershuttle Transmission and Mono Ramp Controls for the Telescopic Arm. NOTE:The layout of controls in the diagram may vary between machines dependant upon options fitted and to meet Legislation in different Countries. 1. Steering Control: IMPORTANT: Prior to driving the vehicle always turn the steering wheel side to side at engine start up, to circulate the hydraulic oil. 2. Wheel Alignment Indicator Switch 3. Instrument Console and Switches 4. Direction Indicator and Road Lights 5. Vehicle Hazard Lighting Switches

IMPORTANT: At engine start up always fully retract all loader boom sections until the relief valve is actioned and hold for 10 seconds. This ensures all boom sections and hoses become fully synchronised, if not synchronised hose failure may result . 12. Heater Control Knob 13. Gear Lever With Transmission Disconnect Button 14. Foot Throttle 15. Safety Lockout for the Axle Steering Control Lever (Fitted Subject to Local Legislation) 16. Axle Steering Control Lever Two Wheel Steer, Four Wheel Steer and Crab Steer:, Select fully all steering modes at least once a day to ensure correct operation.

6. Load Handling Monitor Indicator

17. Overcentre Parkbrake

7. Optional Automatic Load Handling Hydraulic Lock

18. Windscreen Washer Reservoir

8. Switch Panel for miscellaneous services 9. Storage Bin (optional Radio Placement) 10. Auxiliary Hydraulic Equipment Lever (Pickup Hitch / Trailer Tipping) 11. Loader Lever which controls: -- Loader Boom Lift and Drop, -- Attachment Curl In and Out -- Boom Extend and Retract -- Transmission Disconnect Available also with an optional 5th hydraulic service switch

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19. Foot Brake Pedal / Transmission Cut Off Pedal 20. Key Start 21. Boom auxiliary control button cut out switch (fitted with hydraulic lock option) is used to isolate the boom auxiliaries when the machine is driven on public roads. Smooth Ride Control System Switch (when fitted). Plus an optional switch location 22. Transmission Direction Lever (Power Shuttle)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Operating Controls -- Mono Ramp

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HAND AND FOOT OPERATING CONTROLS

Shown in Figure 19, is the cabin layout of a typical machine with a Powershift Transmission and Flow Sharing Controls for the Telescopic Arm. NOTE:The layout of controls in the diagram may vary between machines dependant upon options fitted to meet Legislation in different Countries. 1. Steering Control: IMPORTANT: Prior to driving the vehicle always turn the steering wheel side to side at engine start up. 2. Wheel Indicator Alignment Switch 3. Instrument Console and gauges 4. Direction Indicator and Road Lights

IMPORTANT: At engine start up always fully retract all loader boom sections until the relief valve is actioned and hold for 10 seconds. This ensures all boom sections and hoses become fully synchronised, if not synchronised hose failure may result . 12. Heater Control Knob 13. Loader Lever Isolator LEVER (when fitted) is used when the vehicle is driven on public roads to stop accidental movement of the loader. 14. Foot Throttle 15. Safety Lockout for the Axle Steering Control Lever (Fitted Subject to Local Legislation)

5. Vehicle Hazard Lighting Switches

16. Axle Steering Control Lever Two Wheel Steer, Four Wheel Steer and Crab Steer:,

6. Load Handling Monitor Indicator

Select fully all steering modes at least once a day to ensure correct operation.

7. Optional Automatic Load Handling Hydraulic Lock 8. Switch Panel for miscellaneous services 9. Storage Bin (optional Radio Placement) 10. Rear Auxiliary Hydraulic Equipment Control Buttons (Pickup Hitch / Trailer Tipping) 11. Loader Lever which controls: -- Boom Lift, Drop, -- Bucket / Fork -- Curl In/Out Lever -- Telescopic Extend Lever -- Transmission disconnect button Available also with an optional 5th hydraulic service switch

17. Overcentre Parkbrake 18. Windscreen Washer Reservoir 19. Foot Brake Pedal / Transmission Cut Off Pedal 20. Key Start 21. Boom auxiliary thumb control cut out switch (fitted with hydraulic lock option) is used to isolate the boom auxiliaries when the machine is driven on public roads. Smooth Ride Control System Switch (when fitted). Plus an optional switch location 22. Transmission Direction Lever and Power Shift Gear Selection

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Operating Controls -- Flow Sharing

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CAB INSTRUMENTS AND CONTROLS

20 1. Wheel Alignment Indicator

9. Storage Facility / Optional Radio Mounting

2. Fuel Gauge

10. Multi Function switch: Turn Indicators and Road Lights

3. Tachometer and Hour Gauge 4. Engine Temperature Gauge 5. Vehicle Hazard Lighting Switch Panel 6. Load Monitor Display 7. Load Monitor Sensitivity Switch (optional) 8. Auxiliary Switch Panel This section details the location and function of the instruments and related switches on your machine. Before attempting to drive or operate the machine, study this section carefully.

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11. Key Start Switch 12. Warning Lamp Panel 1 13. Warning Lamp Panel 2 14. Warning Lamp Panel 3 15. Optional Equipment Switch Panel 16. Transmission Control lever IMPORTANT: Switch and gauge positions may vary slightly from that shown: they are dependant upon options fitted and the local market requirements.

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LAMPS AND OPERATING LEVER FOR ALIGNMENT OF THE WHEELS LAMP INDICATOR PANEL

WARNING Before driving on the highway it is essential to check the alignment of the wheels and to drive with only two wheels steering. Unless otherwise stated two wheel steering is by the front wheels only. To establish current wheel alignment depress switch ‘B’ to ‘ON’ and slowly turn the steering wheel. The ‘A’ lamps will illuminate to indicate the alignment of the wheels when they are in the straight ahead position. The upper lamp Al illuminates when the front wheels are aligned and the lower lamp A2 illuminates when the rear wheels are aligned. IMPORTANT: The Indicator switch assembly only serves to indicate wheel position and does not have any influence on actual wheel position. See alignment of wheels below.

When not required switch ‘B’ can be turned off to prevent the ‘A’ lamps illuminating during normal operation. ALIGNMENT OF THE WHEELS IMPORTANT: Before selecting one of the three possible steering positions, bring the 4 wheels into alignment, that is in the straight ahead position, as previously described. A -- TWO WHEEL STEERING -- Shift the distributor control lever for steering selection to position ‘A’ for Highway Use (two wheel steer), turn the steering wheel to ensure engagement and monitor the illumination of lamps ‘A2’ (Rear Wheels Aligned). B -- ALL WHEEL STEER -- Shift the distributor control lever to position B for steering selection (4 wheel steer). C -- CRAB STEER -- Shift the distributor control lever to position C for steering selection (crab steer).

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INSTRUMENT CONSOLE IMPORTANT: Gauge’s and switches mounted in the Instrument panel may vary in position from that shown in this manual. This is dependent upon model and options fitted. Ensure you are familiar with all the functions before operation. Engine Coolant Temperature Warning Gauge with Warning Buzzer,

The engine coolant temperature indicator responds to a sensor fitted in the engine. During normal operations the indicator will tend to rise from the low point of the green segment to the centre of the gauge. When operating under heavy load conditions the indicator may continue to rise to just below the red segment and return to a lower position when normal machine operation is resumed. Should the indicator rise into the red segment a warning buzzer will sound. Stop the engine immediately and investigate the cause. Normal operations can be resumed once the engine has cooled sufficiently or the cause corrected.

NOTE: When the key--start/stop switch is turned off the gauge needle assumes a random position. Tachometer and Hour Meter The Tachometer (1) graduated to 3000 rev/min is driven from the alternator and reflects true engine speed. The hourmeter (2) situated in the lower half of the tachometer reflects hours of engine operation and is driven from the alternator when running. 24 Fuel Level Gauge This gauge indicates the level of fuel in the tank on a continuous basis but is only operative with the key--start/stop switch in the ‘‘ON’’ position. NOTE: When the key--start/stop switch is turned off the gauge needle may assume a random position.

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WARNING LIGHTS 1st Segment Figure 26 1. Transmission Oil Temperature Warning Light. Should the transmission oil temperature exceed a predetermined level the warning light will illuminate.

WARNING If the light stays ‘‘on’’ stop the engine as soon as possible and investigate the cause. Do not continue to drive the machine as failure of the transmission could occur and result in serious injury to you or bystanders. 2. Transmission Oil Pressure Warning Light with Buzzer: Should the transmission oil pressure drop to a predetermined level the warning light will illuminate and the buzzer will sound. If the warning light illuminates, place the transmission in neutral and stop the engine immediately. Check that the oil level is correct and adjust as required. If the transmission oil is lost or extremely low DO NOT ATTEMPT TO DRIVE THE MACHINE. Investigate the cause and consult the manual as for towing the machine as necessary. 26 3. Park Brake Warning Light: The warning light is illuminated when the parking brake is applied and the ignition is switched ON. A ‘BUZZER’ will sound when the ignition is ON and the parking brake applied.

WARNING Do not attempt to disconnect the warning apparatus in any way. Do not attempt to drive the machine with the parking brake applied, as serious damage to the machine brakes with possible failure will occur. This could result in serious injury to you and other people.

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4. Brake Reservoir Oil Low Level Indicator Lamp Figure 27. This warning lamp illuminates when the oil level in the reservoir is at a LOW LEVEL. If the lamp illuminates at any time stop the machine immediately and investigate the cause, correct and or top up with new oil to the level specified. To test the warning light refer to the maintenance section of the manual.

WARNING Corrective action must be taken immediately when this lamp illuminates. If not failure of the brake system could occur, resulting in serious injury to yourself and others.

WARNING LIGHTS 2nd Segment Figure 28 1. Turn Indicator Warning lamp 2. Spare Lamp: (used for optional equipment) 3. Lights on Warning Lamp 4. Main Beam Warning Lamp

WARNING LIGHTS 3rd Segment Figure 29 1. Alternator Charge Warning Light: The alternator charge warning light illuminates when the key start is turned on and will remain on until the engine is started. Once started the battery is being charged by the alternator and the lamp will be extinguished.

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2. Engine Oil Pressure Warning Light with Warning Buzzer: Indicates low oil pressure and should extinguish immediately after the engine starts. Should the oil pressure drop below the predetermined level the warning light will illuminate and an audible alarm will sound. 3. Air Filter Restriction Light: When illuminated the engine must be stopped as soon as possible and the filter serviced. IMPORTANT: If the machine is left to run with the warning light ‘on’ engine performance and fuel consumption will suffer. 4. Thermostart Heater Light: With the key start ‘ON’ this light is illuminated during the warm up period, of the thermostart heater element. And is extinguished once the temperature is achieved, when the engine can then be started.

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LOAD STATUS INDICATOR PANEL The load status indicator warns the operator when the machine reaches the limits of longitudinal stability.

WARNING

Any attempt to lift loads beyond the recommended limit will result in the machine becoming unstable.

LED’s (VISUAL ALARM) 1. 4 green LED’s. With 4 green warning lights displayed, the telehandler is operating well within its load capability. As the number of lights increase, the stability of the machine is reduced. 2. 2 yellow LED’s. The machine is approaching the limit of longitudinal stability. Use extreme caution when operating with two yellow LED’s illuminated. 3. 1 red LED. The telehandler has reached the limit of longitudinal stability. The audible alarm will sound a slow intermittent signal, stop all hydraulic movements which would aggravate the situation. Operate the machine carefully and reduce the load as soon as possible. 2 red LED’s. The telehandler is overloaded, do not travel the machine. The alarm will sound a fast intermittent signal. To recover stability first retract the jib and then raise it, observe the warning lights until optimum stability has been achieved. Reduce the load before continuing operation.

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SOUND ALARM SWITCH The sound alarm switch (1) allows the alarm to be used or switched OFF. When not in use, the red signal light (2) shows that the sound alarm has been de--activated and only the visual alarm is operating. NOTE:It is recommended the alarm be switched off when operating with loading or earth moving buckets. The alarm must be switched on at all other times. TEST SWITCH Operation of this switch (3) tests the alarm and illuminates the warning lamp to ensure all is working correctly. Check each day before commencing work and if either are not functioning correctly, in the interests of yours and bystander safety do not attempt to use the machine as a loader until a repair has been performed.

Correct Operation. All LED’s and the sound alarm function continuously while the button is depressed. Faulty Operation. All LED’s and the sound alarm function intermittently while the button is depressed. Do not use the telehandler, consult your authorised dealer.

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HYDRAULIC LOAD AUTOMATIC CUT OFF (where fitted) LIFTING FROM GROUND LEVEL When using the Handler for ground work such as earth moving the LOAD STATUS panel can be set as required: Switch in Position ‘A’, Lamp ON = NO CUT -- OFF. Only the red signal light (1) indicates that the handler reaches 100% of the maximum authorised load. There will be no ‘CUT OFF‘ when performing hydraulic operations. The sound alarm is disconnected

33 Switch in position ‘B’, Lamp OFF = CUT -- OFF. The red signal light (1) indicates that the handler reaches 100% of the maximum authorised load and the hydraulic movement will be stopped. The sound alarm goes off at the same time as the red signal light illuminates. To reset the hydraulic system to normal operating conditions, place switch in: Position ‘A’ - Retract and lower the Arm fully As required reselect switch position ‘B’ NOTE:When the telescope is fully retracted the cut--off for simple hydraulic movement is disconnected

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HYDRAULIC LOAD AUTOMATIC CUT OFF (where fitted) LOWERING FROM A HIGH POSITION When using the Handler for ground work such as earth moving the LOAD STATUS panel can be set as required: Switch in Position ‘A’, Lamp ON = NO CUT -- OFF. Only the red signal light (1) indicates that the handler reaches 100% of the maximum authorised load. There will be no ‘CUT OFF‘ when performing heavier hydraulic operations. The sound alarm is disconnected.

35 HYDRAULIC LOAD CUT OFF (in a worsening situation) Switch in position ‘B’, Lamp OFF = CUT-- OFF. The red signal light (1) indicates that the handler reaches 100% of the maximum authorised load and the hydraulic movement will be stopped. The sound alarm goes off at the same time as the red signal light. To reset the hydraulic system to normal - Retract and lift the Arm fully

NOTE:When the telescope is fully retracted the cut--off for worsening hydraulic movements is disconnected

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MULTI -- FUNCTION LEVER Direction Indicator Stalk, The direction (turn) indicators are operated (with the key start on) by the stalk switch (1) mounted to the right of the steering wheel. --

When pushed FORWARD: the LEFT HAND INDICATORS FLASH -- When Pulled REARWARD: from the neutral position the RIGHT HAND INDICATORS WILL FLASH. The warning lamp will flash when the direction indicators are flashing.

When the front lights are switched ‘ON’ and the stalk (1) is pushed down from the neutral position the head lamp main beam is switched ‘ON’ and the warning light on the instrument panel will illuminate.

Road Light Control The Road Lights are operated by Counter Clockwise rotation of the twist grip on the stalk (1). 0 = off I = Side Lights 2 = Main Dipped Beam Lights To operate the High Beam push the lever forward to flash the lights pull the lever toward you

Horn Push By pushing the end of the multifunction lever the horn can be activated

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SWITCHES (Upper bank) IMPORTANT: The rocker switch positions may vary slightly or may not be all available from that shown. They are dependant upon the model and options fitted to your machine. Thoroughly familiarise yourself with the layout of your machine. All switches are internally illuminated with ignition ‘On’ and will become brighter when each individual function switch is selected 1. Hazard flasher switch -- Selected when required to warn of a hazard. 2. Slow moving warning beacon -- Depressing this switch operates the function of the Roof beacon.

40 SWITCHES (Lower bank) IMPORTANT: The rocker switch positions may vary slightly or may not be all available from that shown. They are dependant upon the model and options fitted to your machine. Thoroughly familiarise yourself with the layout of your machine. 1. Front Windscreen Wash and Wipe (2 position switch) -- As required depress switch to operate. 2. Roof Window wash and wipe (2 position switch) -- As required depress switch to operate. 3. Blower Motor fan switch -- Depressing this switch from the off position selects the different motor speeds. 4. Transmission disconnect selection (1 position) switch -- This switch determines on whether the transmission disconnect can be operated by the brake pedal or disconnected by operation of the button on the loader lever. 5. Front Work Lamp and Loader Boom Light switch -- When operated the front lights are illuminated 6. Rear Work Lamp (1 position) switch -- When operated the rear lights are illuminated

7. Boom work light switch (option)

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8. Boom auxiliary control cut out switch (fitted with hydraulic lock option on Monoramp & Flow Sharing Systems) is used to isolate the boom auxiliaries when the machine is driven on public roads. 9. Smooth Ride Control System Switch (when fitted).

42 INTERIOR LIGHT, The roof mounted interior light (1) illuminates by sliding the switch forwards from the neutral position, or rearward from the neutral position,to illuminate the map reading light.

AGAWS014

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 BULB REPLACEMENT Work lamp Bulb Replacement, Front. To gain access to the bulb, extract the securing screws (1) gently remove the lens cover and remove the bulb. Replacement of the bulb follows the removal procedure in reverse. NOTE: Modern headlights and worklamps tend to have halogen bulbs fitted. Never touch a halogen bulb with the fingers. Natural moisture in the skin will cause the bulb to burn out when the lamp is switched on. Always use a clean cloth or tissue when handling halogen bulbs.

Headlight and Indicator Bulb Replacement To gain access to the headlight bulbs, extract the four securing screws (1) gently remove the lens cover and remove the plug from the rear of the bulb, release the retaining spring and extract the bulb. The sidelight bulb is removed by pulling the bulb carrier out of the reflector assembly. Replacement of the bulbs follow the removal procedure in reverse. The headlight beam may be adjusted vertically and laterally by adjustment of the recessed slotted screws (3).

3 45

The indicator bulb can be accessed by removal of the lens cover retaining screw (2)

Loader Mounted Work Lights To gain access to the bulb, extract the securing screws (1) gently remove the lens cover and remove the bulb. Replacement of the bulb follows the removal procedure in reverse.

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Interior Lamp Bulb Replacement The interior lamp bulb is accessible after removal of the moulded plastic lens cover (2). The bulb (1) may be removed by exerting outward pressure on one of the retaining tangs and sliding the opposite end of the bulb from its retaining tang. Installation of the bulb and lens cover follow the removal procedure in reverse.

47 Rear Work lamps All bulbs are accessible after the moulded plastic lens assembly screw’s (1) have been removed. The bulbs have a bayonet cap fitting with offset pins for the brake light bulb and parallel pins for the flasher bulb. Both bulbs may be removed by depressing slightly and rotating approximately 20° anti--clockwise.

48 Rear, Stop and Indicator All bulbs are accessible after the moulded plastic lens assembly screw’s have been removed. The bulbs have a bayonet cap fitting with offset pins for the brake light bulb and parallel pins for the flasher bulb. Both bulbs may be removed by depressing slightly and rotating approximately 20° anti--clockwise. Replacement of the bulbs follows the removal procedure in reverse, however ensure the brake light offset pins align with the socket correctly. The lens can be replaced after the electrics have been tested.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 Reversing Lamps Where fitted the lamps can be removed after removal of the lens cover (1), and are the twist bayonet type.

50 Rocker Switch Bulb Replacement The rocker switches are internally illuminated by a bulb which can be removed from the rear of the switch assembly (1).

To gain access to the switch remove the console attaching screws and rotate the console. The bulb is of the capless type, rated at 1.2w and is a push fit in the retainer. After changing the bulb, push the retainer into the back of switch. 5524001

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55 000 PROTECTING THE ELECTRICAL SYSTEMS DURING CHARGING OR WELDING

• Never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress.

To avoid damage to the electronic/electrical systems, always observe the following:

1. Never make or break any of the charging circuit connections, including the battery connections, when the engine is running.

6. Always disconnect the negative cable from the batteries when charging the batteries in the machine with a battery charger.

2. Never short any of the charging components to earth (ground).

3. Do not use a slave battery of higher than 12 volts nominal voltage.

4. Always observe correct polarity when installing the batteries or using a slave battery to jump start the engine. Follow the instructions in the operator’s manual when jump starting the machine. Connect positive to positive and negative to negative.

WARNING Batteries contain sulphuric acid. In case of contact with skin, flush the affected area with water for five minutes. Seek medical attention immediately. Avoid contact with the skin, eyes or clothing. Wear eye protection when working near batteries.

5. Always disconnect the negative cable from the batteries before carrying out arc welding on the machine or on any implement attached to the machine.

• Position the welder ground cable clamp as close to the welding area as possible. • If welding is to be carried out in close proximity to a computer module, then the module should be removed from the machine. It is recommended that this procedure be carried out by an authorised dealer.

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IMPORTANT: Failure to disconnect the two earth cable connections at the battery prior to charging the batteries or welding on the machine or attached implement will result in damage to the electronic and electrical systems.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 55 000 STARTING THE MACHINE WITH JUMP LEADS

WARNING

D Connect one end of the second jump lead to the auxiliary 12 volt battery negative (--) terminal and the other end to the machine engine block, following this procedure will prevent sparks occurring near the batteries. Follow the starting procedure previously described.

Operate the starting motor only from the operator’s seat. If the neutral start switch is by--passed the engine may be started inadvertently with the transmission in gear. Wear eye protection when charging the battery or starting the machine engine with a slave battery.

If it is necessary to use jump leads from an external battery to start the machine, proceed as follows:

D Connect one end of the jump lead to the machine 12 volt battery positive (+) terminal and the other to the auxiliary 12 volt battery positive (+) terminal.

NOTE: When using a slave battery to start the engine ensure that the polarity is correct otherwise the alternator may be damaged.

D When the engine starts allow it to run at idle speed, turn on all electrical equipment (lights, etc.) then disconnect the jump leads in reverse order to the connecting procedure. This will help protect the alternator from damage due to extreme load changes.

NOTE: Your machine has an electro--magnetic fuel shut--off, it is therefore not possible to operate the machine without a battery installed. The machine will shut down when the power supply to the fuel shut--off solenoid is disconnected (battery removed).

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Temporary Wiring Harness Repair (Op No 55 100) The following method to repair wiring is a temporary expedient only. Wiring should be replaced as soon as possible. Replacement of temporary repaired cables with new is particularly important if the tractor is to be used for spraying as chemicals can enter the repaired area, travel up the cable and damage electrical components. Do not attempt to repair the wire on any system sensors as these are sealed and should only be replaced with a new component. NOTE: When conducting a cable repair it is important that only RESIN CORED SOLDER is used. Use of other types of solder may result in further cable damage. To carry out a temporary repair, proceed as follows:--

5527001

1. Locate damaged portion of cable then cut away outer protective cover on both sides of the damaged area, Figure 52.

2. Peel back the cable from both ends of the dam-

aged area and carefully cut away the inner cable cover at the damaged area and strip about 13 mm (1/2 inch) of insulation from the wires. Do not cut away any wire strands.

5527002

3. Using a suitable solvent, clean about 2 inches

(50 mm) from each cover end. Clean the grey cable cover and the individual leads.

4. Twist two bare leads together for each damaged lead, being careful to match wire colours, then solder the leads using resin cored solder. Tape each repaired lead with vinyl insulation tape, Figure 53.

5. Wind a layer of vinyl insulation tape up to the grey

cable cover at each end of the repair section. Make a paper trough, Figure 54, then apply silicon rubber compound (non hardening sealant) over the repaired section up to the cover ends. Sufficient sealant must be used to fill the ends of the cut away area.

5527003

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

6. Allow the compound to cure then cover the area with insulating tape taking the tape well over each end of the repair. An overlap of at least 2 inches (50 mm) of tape at each end is necessary, Figure 55.

7. Check to ensure the repair is satisfactory and se-

cure the repaired cable so that repeat damage is avoided.

5528001

55 NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 55 000 ELECTRICAL SYSTEM -- GENERAL FAULT FINDING PROBLEM

POSSIBLE CAUSE

Electrical system is inoperative

Loose or connections

corroded

CORRECTION battery Clean and tighten connections

Sulphated batteries

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity.

Battery Isolator switch turned ‘off’ Re--instate isolator switch Main machine fuse link blown Starter speed low and engine Loose or corroded connections cranks slowly

Starter inoperative

Charge indicating voltage

indicator excessive

604.55.181.01 09-- 2004

Clean and connections

tighten

loose

Low battery output

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity.

Incorrect viscosity engine oil

Use correct viscosity temperature conditions

Transmission shift lever in gear

Place shift lever in neutral

Loose or corroded connections

Clean and connections

Dead batteries

Charge or replace batteries.

Charge indicator lamp stays on Low engine idle speed with engine running

Batteries will not charge

Establish reason of failure and replace fuse link

oil

tighten

for

loose

Increase idle speed

Loose belt

Check belt tension

Malfunctioning battery

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity.

Malfunctioning alternator

Check alternator

Loose or connections

corroded

terminal Clean and tighten connections

sulphated batteries

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity.

Loose or worn belt

Check automatic belt tensioner. Replace belt if required.

flashing Malfunctioning alternator charging

Check alternator

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

SECTION 55 -- ELECTRICAL CIRCUITS Chapter 2 -- Wiring Diagrams CONTENTS Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page How to use the wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wiring Diagrams A -- Powershift Transmission Models with Flow Sharing Hydraulic System Circuit location key -- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Circuit 1 -- Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Circuit 2 -- Charging / Warning / Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Circuit 3 -- Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Circuit 4 -- Wheel Alignment / Flow Sharing Control / Brake System . . . . . . . . . . . . . . . . 10 Circuit 5 -- Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Circuit 6 -- Load Status Alarm / Turn Indicators / Hazard warning . . . . . . . . . . . . . . . . . . 14 Circuit 7 -- Rear Wipers / Cab Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Power Shift Models with Monoramp Hydraulics System -- Use the Powershift Wiring Diagrams A. Disregard circuits for Flow Sharing Hydraulic System control circuits, diagram 4, circuits 35 -- 39 and refer to Powershuttle Wiring Diagrams B, diagram 3, circuits 22 -- 26A for the Monoramp control system electrical circuits. Wiring Diagrams B -- Powershuttle Transmission Models with Mechanical or Monoramp Hydraulic System Circuit location key -- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Circuit 1 -- Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Circuit 2 -- Charging / Warning / Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Circuit 3 -- Wheel Alignment / Monoramp Control / Brakes . . . . . . . . . . . . . . . . . . . . . . . . 24 Circuit 4 -- Gauges / Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Circuit 5 -- Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Circuit 6 -- Load Status / Front Wiper -- Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Circuit 7 -- Indicators / Hazard Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Circuit 8 -- Cab Environment / Rear Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Power Shuttle Models with Mechanical Controlled Hydraulics System -- Use Wiring Diagrams B Disregard circuits for Monoramp Hydraulic System control circuits, diagram 3 circuits 22 -- 26A. Power Shuttle Models with Flow Sharing Hydraulics System -- Use Wiring Diagrams B Disregard circuits for Monoramp Hydraulic System control circuits, diagram 3 circuits 22 -- 26A and refer to Wiring Diagrams A, diagram 4, circuits 35 -- 39 for the Flow Sharing control system electrical circuits.

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

HOW TO USE THE WIRING DIAGRAMS

The wiring diagrams have been drawn in a linear format, meaning that the complete vehicle system is drawn over a number of pages, with references to link the pages, where applicable. The flow of power is generally speaking, from top, positive, to bottom, negative. Here are a number of explanations to the layout and references contained within the diagrams:-8. All diagrams are located on the right hand pages. The left hand pages will identify the circuits involved using the reference number at the bottom of the diagram (1). 1 9. Within the diagram there are a number of references, Figure 2: 1. Letter within a box indicates a connector reference 2. Positive feed lines 3. Line continues on another diagram. In this instance, diagram 2 at line reference 15 4. Component identification reference 5. Wire colour (refer to colour code table) 6. Diagram circuit reference number 7. Return to Ground (negative) lines 8. Lamp symbol

10. Each component and connector appears only once in a set of wiring diagrams. 11. The wiring diagrams are broken up into sections, however where a single component is used in a number of circuits, such as a processor or multi--function switch, it is drawn either on its own or in the circuit which it influences the most. 12. Component Keys Connectors Modules Lights Fuses Battery/Charging Warning Lights Relays Motors/Buzzers Switches Diodes Solenoids

604.55.181.00 09-- 2003

A -- Z A1 -- A2 E1 -- E22 F1 -- F26 G1 -- G2 H1 -- H18 K0 -- K10 M1 -- M10 S1 -- S33 V1 -- V3 Y1 -- Y10

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

WIRING DIAGRAMS POWERSHIFT MODELS ONLY CIRCUIT LOCATION KEY 1. 2. 3. 4. 5.

Battery Starter Pre--heater (optional) Pre--heater warning light (optional) Coolant temperature sensor -- Pre--heater (optional) 6. Cold start 7. Engine shut--off solenoid 8. Coolant temperature 9. Fuel level 10. Alternator 11. Odometer/Tachometer 12. Engine oil pressure 13. Brake fluid level 14. Air cleaner restriction 15. Not used 16. Transmission oil temperature 17. Not used 18. Hand brake 19. Transmission disconnect 20. Rotating beacon 21. Start--up safety 22. Reverse drive relay 23. EGS 24. Solenoid valve -- 1st/2nd gear 25. Solenoid valve -- 1st gear 26. Solenoid valve -- 4th gear 27. Solenoid valve -- Forward drive 28. Solenoid valve -- Reverse drive 29. Reversing light -- left hand 30. Reversing light -- right hand 31. Reversing warning buzzer (optional) 32. Not used 33. Wheel alignment sensor -- front axle 34. Wheel alignment sensor -- rear axle 35. Joy stick disconnect 36. Boom head solenoid valve control 37. Transmission disconnect on joy stick 38. Accessory control 39. Proportional telescope control

40. Horn 41. Brake light -- left hand 42. Brake light -- Right hand 43. Radio (optional) 44. Not used 45. Coolant temperature gauge back--lighting 46. Fuel level gauge back--lighting 47. Odometer/Tachometer back--lighting 48. Side light warning light 49. Side light -- rear right hand 50. Side light -- front right hand 51. Side light -- rear left hand 52. Side light -- Front left hand 53. Dipped headlight -- left hand 54. Dipped headlight -- Right hand 55. Main headlight -- left hand 56. Main headlight -- right hand 57. Headlight warning light 58. Work light -- front left hand (optional) 59. Work light -- front right hand (optional) 60. Work light -- rear right hand (optional) 61. Work light -- rear left hand (optional) 62. Not used 63. Load safety system 64. Windscreen washer -- Front 65. Windscreen wiper -- front 66. Turn indicator control module 67. Turn indicator warning light 68. Indicator -- rear right hand 69. Indicator -- front right hand 70. Indicator -- rear left hand 71. Indicator -- front left hand 72. Turn indicator switch 73. Courtesy light 74. Wiper -- rear window 75. Wiper -- cab roof 76. Air conditioning (optional) 77. Ventilation fan 78. Not used

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershift Transmission Models with Flow Sharing Hydraulic System

STARTING Diagram 1 Circuit Key 1 2 3 4

Battery Starter Pre--heat Pre--heat indicator light

5 6 7

Pre--heater coolant temperature sensor Cold start Fuel shut off solenoid

R4 R5 S1 S23 Y1 Y4

Cold start temperature sensor Pre--heat temperature sensor Key start switch Battery cut--off (optional) Engine shut off Cold start solenoid

Fuse / relay board (4--point socket + 1--point socket)

G L

Fuse / relay board (11--point socket) Engine indicator lights module

Pre--heater control module -- 3A (optional)

F26

Pre--heater fuse -- 80A x 2 (optional)

Component Key A1 G1 H18 K4 K8 M1 R1

Pre--heater control module Battery Pre--heat indicator light Safety starter relay Pre--heater module (optional) Starter Pre--heat resistance

Connector Key A

Fuses F25

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Starting

Diagram 1

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershift Transmission Models with Flow Sharing Hydraulic System

CHARGING / WARNING / INDICATOR LIGHTS Diagram 2 Circuit Key 8 9 10 11 12 13

Coolant temperature Fuel level Alternator Hourmeter / revolution counter Engine oil pressure Brake fluid

14 15 16 17 18

Air filter blockage Not used Transmission oil temperature Not used Handbrake

P2 P3 R2 R3 S3 S4 S5 S7 S17 V1

Fuel level Engine coolant temperature Fuel sensor Engine coolant temperature sensor Engine oil pressure switch Brake fluid level switch Air filter restricted Hand brake switch Transmission oil temperature Fault alarm diode

J L

Transmission/brakes warning lights module Engine warning lights module

Component Key G2 H1 H2 H3 H4 H5 H8 H12 H13 M7 P1

Alternator Battery charge indicator light Engine oil pressure indicator light Brake fluid indicator light Air filter restriction indicator light Not used Transmission oil temperature warning light Not used Brake warning light Machine fault warning buzzer Hourmeter / revolution counter

Connector Key G K

Fuse / relay board (11--pin socket) Road lighting indicator lights module

Fuses F15

Indicator light / warning light -- 5 A

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Charging / Warning / Indicator lights

Diagram 2

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershift Transmission Models with Flow Sharing Hydraulic System

TRANSMISSION Diagram 3 Circuit Key 19 20 21 22 23 24 25

Transmission disconnect Rotating beacon Starter relay Reverse relay EGS (Electronic gearshift) First & second gear electro--valve First gear electro--valve

26 27 28 29 30 31 32

Fourth gear electro--valve Forward electro--valve Reverse electro--valve Left--hand reversing light Right--hand reversing light Reversing warning (optional) Not used

S25 S26 V2 Y2 Y3 Y9 Y10 Y11

Cab Rear lighting Fuse/relay board (21--pin socket)

H N

Fuse/relay board (21--pin socket) EGS (15--pin socket)

Transmission shuttle -- 13A Rotating beacon -- 7.5A

F24

Not used

Component Key E19 E20 E22 K3 K4 M10 S2 S14 S19

Connector Key C D F

Fuses F13 F23

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Transmission

Diagram 3

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershift Transmission Models with Flow Sharing Hydraulic System

WHEEL ALIGNMENT / FLOW SHARING CONTROL / BRAKE SYSTEM Diagram 4 Circuit Key 33 34 35 36 37 38

Front wheel alignment sensor Rear wheel alignment sensor Extend telescopic section Boom aux changeover Transmission disconnect Accessory control (optional)

39 40 41 42 43 44

Proportioning telescope control Horn Left--hand brake light Right--hand brake light Vehicle radio (optional) Not used

S9 S10 S16 S24 S27 S30 S33 Y6 Y7 Y8

Horn button Wheel alignment switch Brake light switch Joystick transmission cut off Rear wheels alignment sensor Retract and extend auxiliaries Boom head auxiliary change over solenoid valve Telescopic proportioning valve module Retract auxiliary solenoid valve Extend auxiliary solenoid valve

Fuse/relay board (4--pin socket + 1--pin socket) Rear lighting Fuse / relay board (11--pin socket)

H X Z

Fuse / relay board (21--pin socket) Joystick flow sharing controls Proportional valve module

Joystick controls/wheel alignment -- 5A Horn/brake lights -- 10A

Radio (where fitted) -- 10A

Component Key A2 E5 E6 H11 H14 K18 K19 K20 M5 R7 S6

Flow sharing joystick controls Left--hand stop light Right--hand stop light Front wheel alignment indicator light Rear wheel alignment indicator light Auxiliary Control Relay Auxiliary Control Relay Joystick cut off Horn Telescopic control potentiometer Front wheel alignment sensor

Connector Key A D G

Fuses F2 F3

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Wheel Alignment / Flow Sharing Control / Brake System

Diagram 4

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershift Transmission Models with Flow Sharing Hydraulic System

LIGHTING Diagram 5 Circuit Key 45 46 47 48 49 50 51 52

Water temperature gauge lighting Fuel level gauge lighting Hourmeter / revolution counter module lighting Sidelights indicator light Rear right--hand parking light Front right--hand parking light Rear left--hand parking light Front left--hand parking light

53 54 55 56 57 58 59 60 61

Front left--hand dipped beam Front right--hand dipped beam Front left--hand headlight Front right--hand headlight Headlights indicator light Work light -- front left hand (option) Work light -- front right hand (option) Work light -- rear right hand (option) Work light -- rear left hand (option)

E18 H7 H9 H15 H16 H17 S13a S13b S15 S18 V3

Worklight -- front right hand Sidelight warning light Headlights indicator light Revolution counter indicator light Water temperature warning light Fuel level warning light Sidelights Dipped beams / headlights Rear work lights (optional) Front work lights (optional) Diode

Fuse / relay board (4--pin socket + 1--pin socket) Cab Rear lighting

E F I K

Fuse / board table (13--pin socket) Fuse panel/relays (7--pin socket) Right hand multi function lever Road lighting indicator lights module

Right--hand sidelight / dashboard -- 7.5 A Left--hand sidelight / dashboard -- 7.5 A Rear work lights -- 10A Front work lights -- 15A

F18 F20 F22

Headlights -- 15 A Dipped beams -- 15 A Auxiliary socket -- 25 A

Component Key E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 E17

Rear right--hand side light Front right--hand side light Rear left--hand side light Front left--hand side light Front left--hand dipped beam Front right--hand dipped beam Front left--hand headlight Front right--hand headlight Worklight -- rear right hand Worklight -- rear left hand Worklight -- front left hand

Connector Key A C D

Fuses F6 F7 F9 F10

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Lighting

Diagram 5

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershift Transmission Models with Flow Sharing Hydraulic System

LOAD STATUS ALARM / TURN INDICATORS / HAZARD WARNING Diagram 6 Circuit Key 62 63 64 65 66 67

Not used Load status alarm and cut out Windscreen washer -- front Windscreen wiper -- front Turn indicator control module Turn indicator warning light

68 69 70 71 72 73

Indicator -- rear right hand Indicator -- front right hand Indicator -- rear left hand Indicator -- front left hand Turn indicator switch Cab interior light

K7 M2 M3 S8 S11 S13c S22

Load status module Front wiper Windscreen washer Front wiper/washer Hazard warning Indicator switch -- indicators Load status strain gauge

Front wiper Cab Rear lighting Fuse/relay board (13--pin socket)

F H I U

Fuse / relay board (7--pin socket) Fuse / relay board (21--pin socket) Turn indicator switch Load status strain gauge

Turn indicator -- left hand -- 7.5 A Not used -- 7.5 A Load status system -- 10 A Turn indicators -- 10A

F17 F19 F21

Front wiper -- washer -- 10A Turn indicator -- right hand -- 7.5A Hazard warning indicator / cab interior light -15A

Component Key E1 E2 E3 E4 E21 H6 H10 K6

Indicator -- rear right hand Indicator -- front right hand Indicator -- rear left hand Indicator -- front left hand Cab interior light Indicator warning light Hazard warning light Turn indicator/hazard module

Connector Key B C D E

Fuses F5 F12 F14 F16

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Load Status Alarm / Turn Indicators / Hazard Warning

Diagram 6

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershift Transmission Models with Flow Sharing Hydraulic System

REAR WIPERS / INDICATORS Diagram 7 Circuit Key 74 75 76

Cab rear screen wiper Cab roof screen wiper (option) Air conditioning (option)

77 78

Blower fan Not used

M8 M9 S20 S21

Cab rear screen wiper Air conditioning compressor clutch Rear screen / roof screen wiper Cab blower switch

Cab Fuse / relay board (7--pin scoket)

G H

Fuse / relay board (11--pin socket) Fuse/relay board (21--pin socket)

Cab blower fan -- 15A Rear wiper/roof light -- 10A

F11

Air conditioning -- 7.5A

Component Key K0 M4

Not used Roof screen wiper (option)

Cab blower motor

Connector Key C F

Fuses F1 F8

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Rear Wipers / Indicators

Diagram 7

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

NOTES

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

WIRING DIAGRAMS POWERSHUTTLE MODELS WITH MECHANICAL OR MONORAMP

HYDRAULIC SYSTEM CIRCUIT LOCATION KEY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26A 27 28 29 30 31 32 33 34 35 36 37

Battery Starter Pre--heater (optional) Pre--heater warning light (optional) Coolant temperature sensor -- Pre--heater (optional) Cold start Engine shut--off solenoid Coolant temperature Fuel level Alternator Odometer/Tachometer Engine oil pressure Brake fluid level Air cleaner restriction Not used Transmission oil temperature Transmission oil pressure Hand brake Not used Wheel alignment sensor -- front axle Wheel alignment sensor -- rear axle Joy stick feathering control Telescope extend Telescope retract Accessory extend Accessory retract Transmission disconnect on joy stick Horn Brake light -- left hand Brake light -- Right hand Not used Radio Coolant temperature gauge back--lighting Fuel level gauge back--lighting Odometer/Tachometer back--lighting Side light warning light Side light -- rear right hand Side light -- front right hand

38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75

Side light -- rear left hand Side light -- Front left hand Dipped headlight -- left hand Dipped headlight -- Right hand Main headlight -- left hand Main headlight -- right hand Headlight warning light Work light -- front left hand (optional) Work light -- front right hand (optional) Work light -- rear right hand (optional) Work light -- rear left hand (optional) Not used Forward drive relay Start--up safety Reverse drive relay Forward drive pressure relay Solenoid valve -- Forward drive Solenoid valve -- Reverse drive Reversing light -- left hand Reversing light -- right hand Reversing warning buzzer (optional) Transmission disconnect Rotating beacon Load safety system Windscreen washer -- Front Windscreen wiper -- front Turn indicator control module Turn indicator warning light Indicator -- rear right hand Indicator -- front right hand Indicator -- rear left hand Indicator -- front left hand Turn indicator switch Courtesy light Wiper -- rear window Wiper -- cab roof Air conditioning (optional) Ventilation fan

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershuttle Transmission Models with Mechanical or Monoramp Hydraulic System

STARTING Diagram 1 Circuit Key 1 2 3 4

Battery Starter Pre--heat (option) Pre--heat indicator light (option)

5 6 7

Coolant temperature sensor pre--heater Cold start Engine shut off solenoid

R4 R5 S1 S23 Y1 Y4

Pre--heater temperature sensor Cold start temperature sensor Key start switch Battery cut--off (option) Engine shut off solenoid Cold start solenoid

Fuse / relay board (4--pin socket + 1--pin socket)

G L

Fuse / relay board (11--pin socket) Engine indicator lights module

Pre--heater control module -- 3A (option)

F26

Pre--heater fuse -- 80A x 2 (option)

Component Key A1 G1 H18 K4 K8 M1 R1

Pre--heater module Battery Pre--heat indicator light Safety start relay Pre--heater module (option) Starter Pre--heat resistance

Connector Key A

Fuses F25

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Starting

Diagram 1

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershuttle Transmission Models with Mechanical or Monoramp Hydraulic System

CHARGING / WARNING / INDICATOR LIGHTS Diagram 2 Circuit Key 8 9 10 11 12 13

Coolant temperature Fuel level Alternator Hourmeter / revolution counter Engine oil pressure Brake fluid

14 15 16 17 18

Air filter blockage Free Transmission oil temperature Transmission oil pressure Handbrake

P1 P2 P3 R2 R3 S3 S4 S5 S7 S12 S17 V1

Hourmeter / revolution counter Fuel level gauge Engine water temperature gauge Fuel level sensor Coolant temperature sensor Engine oil pressure switch Brake fluid level Air filter restriction Hand brake switch Transmission oil pressure Transmission oil temperature Diode test fault

K L

Road lighting indicator lights module Engine indicator lights module

Component Key G2 H1 H2 H3 H4 H5 H8 H12 H13 K5 K9 M7

Alternator Battery charge warning light Engine oil pressure warning light Brake fluid warnnig light Air filter restriction warning light Not used Transmission oil temperature Transmission oil pressure Brake indicator light Forward pressure relay Delay relay -- 3.5 seconds Fault warning buzzer

Connector Key G H J

Fuse / relay board (11--point socket) Fuse / relay board (21--point socket) Transmission / brake indicator lights module

Fuses F15

Indicator light / fault warning light (5 A)

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Charging / Warning / Indicator lights

Diagram 2

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershuttle Transmission Models with Mechanical or Monoramp Hydraulic System

WHEEL ALIGNMENT / MONORAMP CONTROL / BRAKES Diagram 3 Circuit Key 19 20 21 22 23 24

Not used Wheel alignment sensor -- front axle Wheel alignment sensor -- rear axle Joystick feathering control Telescope extend Telescope retract

25 26 26A 27 28 29

Auxiliary extend Auxiliary retract Transmission disconnect on joystick Horn Brake light -- left hand Brake light -- right hand

S26 S27 S28 S29 S30 S31 Y5 Y6 Y7 Y8 Y9

Transmission disconnect Wheel alignment sensor -- rear wheels Telescope -- extend Telescope -- retract Auxiliary -- extend Auxiliary -- retract Telescope extend solenoid Telescope retract solenoid Auxiliary extend solenoid Auxiliary retract solenoid Monoramp master solenoid

Rear lighting Fuse/relay board (7 pin socket) Fuse/relay board (11 pin socket)

H V X

Fuse/relay board (21--pin socket) Joystick module Joystick to main harness

Wheel alignment/monoramp controls -- 5A Horn/brake lights -- 10A

F24

Not used -- 10A

Component Key E5 E6 H11 H14 K0 K10 M5 S6 S9 S10 S16

Brake light -- left hand Brake light -- right hand Wheel alignment warning light -- front Wheel alignment warning light -- rear Transmission disconnect relay Monoramp control module Horn Wheel alignment sensor -- front wheels Horn button Wheel alignment switch Brake light switch

Connector Key D F G

Fuses F2 F3

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Wheel Alignment / Monoramp Control / Brakes

Diagram 3

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershuttle Transmission Models with Mechanical or Monoramp Hydraulic System

GAUGES / LIGHTING Diagram 4 Circuit Key 30 31 32 33 34 35 36 37 38 39

Not used Radio Coolant temperature gauge back--lighting Fuel level gauge back--lighting Odometer/tachometer back--lighting Side light warning light Side light -- rear right hand Side light -- front right hand Side light -- rear left hand Side light -- front left hand

40 41 42 43 44 45 46 47 48 49

Dipped headlight -- left hand Dipped headlight -- right hand Main headlight -- left hand Main headlight -- right hand Headlight warning light Worklight -- front left hand (option) Worklight -- front right hand (option) Worklight -- rear right hand (option) Worklight -- rear left hand (option) Not used

E18 H7 H9 H15 H16 H17 S13a S13b S15 S18 V2

Worklight -- front right hand Sidelight warning light Headlight warning light Tachometer warning light Coolant temperature warning light Fuel level warning light Indicator switch -- sidelights Indicator switch -- headlights Rear work lights Front worklights Diode

Fuse/relay board (4--pin socket + 1--pin socket) Cab Fuse/relay board (13--pin socket)

F G I

Fuse/relay board (7--pin socket) Fuse/relay board (11--pin socket) Turn indicator switch

Not used -- 10 A Sidelights right hand/instrument panel -7.5A Sidelights left hand/instrument panel -- 7.5A Roof wiper / light -- 7.5A

F9 F10 F12 F20 F22

Rear worklights -- 10A Front worklights -- 15A Not used -- 7.5A Headlights -- 15A Indicator switch --

Component Key E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 E17

Side light -- rear right hand Side light -- front right hand Side light -- rear left hand Side light -- front left hand Dipped headlight -- left hand Dipped headlight -- right hand Headlight main beam -- left hand Headlight main beam -- right hand Worklight -- rear right hand Worklight -- rear left hand Worklight -- front left hand

Connector Key A C E

Fuses F4 F6 F7 F8

NOTE: HC = Hydraulic Control

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Gauges / Lighting

Diagram 4

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershuttle Transmission Models with Mechanical or Monoramp Hydraulic System

TRANSMISSION Diagram 5 Circuit Key 50 51 52 53 54 55

Forward drive relay Start--up safety Reverse drive relay Forward drive pressure relay Solenoid valve -- forward drive Solenoid valve -- reverse drive

56 57 58 59 60

Reversing light -- left hand Reversing light -- right hand Reversing warning buzzer (option) Transmission disconnect Rotating beacon

S2 S7 S14 S19 S24 S25 S26 Y2 Y3

Shuttle lever Handbrake Transmission disconnect on gear lever Rotating beacon Transmission disconnect selection switch Transmission disconnect on pedal Transmission disconnect on joystick Forward drive Reverse drive

Cab Rear lighting

F H

Fuse panel/relays (7--pin socket) Fuse panel/relays (21--pin socket)

Transmission shuttle -- 13A

F23

Rotating beacon -- 7.5A

Component Key E19 E20 E22 K0 K1 K2 K3 K4 K5 M10

Rotating beacon Reversing light -- left hand Reversing light -- right hand Transmission disconnect on joystick Transmission disconnect Forward drive relay Reverse drive relay Safety start switch Forward drive pressure relay Reverse warning buzzer

Connector Key C D

Fuses F13

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Transmission

Diagram 5

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershuttle Transmission Models with Mechanical or Monoramp Hydraulic System

LOAD STATUS / REAR WIPER -- WASHER Diagram 6 Circuit Key 61 62

Load status system Windscreen washer -- front

Windscreen wiper -- front

S8 S22

Front wiper/washer Load status strain gauge

Front wiper Fuse/relay board (11--pin socket)

H U

Fuse/relay board (21--pin socket) Load status strain gauge

Load status system -- 10A

F17

Front wash/wipe -- 10A

Component Key K7 M2 M3

Load status module Front wiper Windscreen washer

Connector Key B G

Fuses F14

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Load Status / Front Wiper -- Washer

Diagram 6

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershuttle Transmission Models with Mechanical or Monoramp Hydraulic System

INDICATORS / HAZARD WARNING Diagram 7 Circuit Key 64 65 66 67

Turn indicator module Turn indicator warning light Indicator -- rear right hand Indicator -- front right hand

68 69 70 71

Indicator -- rear left hand Indicator -- front left hand Turn indicator switch Cab interior light

H6 H10 K6 S11 S13c

Indicator/hazard warning light Hazard warning light Turn indicator/hazard module Hazard warning Indicator switch -- indicators

Cab Rear lighting Fuse/relay board (13--pin socket)

F I

Fuse/relay board (7--pin socket) Turn indicator switch

Turn indicator -- left hand -- 7.5A Turn indicators -- 10A Turn indicator -- right hand -- 7.5A

F21

Hazard warning indicators/cab interior light -- 15A

Component Key E1 E2 E3 E4 E21

Indicator -- rear right hand Indicator -- front right hand Indicator -- rear left hand Indicator -- front left hand Cab interior light

Connector Key C D E

Fuses F5 F16 F19

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Indicators / Hazard Warning

Diagram 7

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Powershuttle Transmission Models with Mechanical or Monoramp Hydraulic System

CAB ENVIRONMENT / REAR WIPER Diagram 8 Circuit Key 72 73

Wiper -- rear window Wiper -- cab roof

74 75

Air conditioning compressor clutch Cab blower fan

M9 S20 S21

Air conditioning Wiper switch Blower fan

Cab

Fuse/relay board (7--pin socket)

Blower fan -- 15A Wiper -- roof and rear -- 7.5A

F11

Air conditioning -- 7.5 A

Component Key M4 M6 M8

Roof wiper Blower fan Rear wiper

Connector Key C

Fuses F1 F8

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

Cab Environment / Rear Wiper

Diagram 8

Wire Colours bc: bl: g: j: jvt: m:

White Blue Grey Yellow Yellow/green Brown

n: o: r: ro: vt: v:

Black Orange Red Pink Green Violet

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

NOTES

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 -- ELECTRICAL SYSTEM Chapter 3 -- Starting System CONTENT Section

Description

Page

55 000

55 201

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Bench Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

55 000 SPECIFICATIONS Starter Type Bosch 3 Kw Gear Starter Maximum No Load Current Draw at 11.5 volts and 4000 rev/min.

120 amps

Minimum Brush Length

12 mm

Minimum Commutator Diameter

34.2 mm

TORQUE SPECIFICATIONS lbf.ft.

Starting Motor to Engine Block Retaining Bolts

Solenoid Cable Nuts

Starting Motor End Housing Bolts

4.8

6.8

Solenoid Retaining Screws

3.5

4.1

Brush Gear Plate Screws

3.5

4.1

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

DESCRIPTION AND OPERATION All starting systems consist of an ignition key switch (1), heavy--duty wiring, a starter motor with solenoid, a safety start switch and a start--up relay. These are the basic circuit components which ensure the engine can be started only under the proper conditions. The starter motor is rated at 3.0Kw for all models.

40 The safety start switch is incorporated in the powershift or powershuttle control levers (1). The solenoid consists of two coils connected in parallel. The low resistance pull--in coil is grounded via the engine, while the high resistance hold--in coil is grounded via the solenoid body. When the ignition switch is closed, the coils are energised and the plunger is magnetically drawn inside the solenoid. This movement, transmitted by means of an orientable joint mechanism, makes the driving pinion engage the flywheel ring gear. The moment the pinion touches the ring gear, the plunger closes a series of contacts and powers all four field windings directly from the battery, thus giving full power to the starter motor. At this stage, one end of the pull--in coil is connected to the positive battery pole through the starter switch, while the other end in connected to the positive pole through the solenoid valve contacts. The pull--in coil is thus bypassed, without absorbing power, and the hold--in coil alone keeps the plunger in position.

The starter motor includes a series of contacts and a two--part solenoid plunger which completely closes the contacts even if the pinion teeth are not perfectly in line with the ring gear. When this happens, a clutch spring compresses the pinion, forcing it to connect completely as soon as the starter motor starts turning. When the key ignition switch is released, power is taken from both the solenoid and the motor. The solenoid return spring, acting on the orientable joint mechanism, frees the driving pinion from the gear and opens the solenoid valve contacts again. A roller type clutch is incorporated to the driving pinion group. This prevents the pinion from overspeeding if it stays engaged with the flywheel ring gear after the engine has been started.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

2 Starting circuit R4 Cold start Temperature sender R5 Pre--heat temperature sensor S1 Key start switch S23 Battery isolator switch (option) Y1 Fuel shut off solenoid Y4 Cold start solenoid

A1 Pre--heater control module G1 Battery H18 Pre--heater Indicator lamp K4 Start relay K8 Pre--heater Module M1 Starter motor R1 Pre--heater resistance

3 Fuses and relay box

Starter motor

1. Start Relay -- K4

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

TROUBLE--SHOOTING The engine does not run when ignition key is turned and gear is in neutral. Is the battery fully charged?

Charge or change the battery. Are all the connections fastened correctly? Is the engine running correctly?

NO YES

Check the starting circuit wiring. Is the battery correctly grounded? Are there any broken or frayed wires which could cause a short circuit?

Repair the wiring accordingly.

YES

Has the engine YES seized? NO

Find the reason for engine failure.

Turn the ignition key. Are there +12V on the ignition solenoid input wire (violet wire)?

Can you hear the solenoid click?

YES

Possibly inefficient coils or brushes, or mechanical failure.

Probably an inefficient starter solenoid. Remove the starter motor and check. Check the starting relay. Can you hear the relay work when you turn the ignition key?

Change the relay.

YES

Remove the relay from the connector. Is there +12V at the Violet wire with the ignition key on? YES NO

Check the forward/reverse lever. Are the wires connected?

YES

Does the instrument display light up when ignition key is turned? YES

Check ignition key switch: if the wire leading to the switch is in good condition, change the switch.

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Change the relay. Reconnect the wire to the switch.

Check that main battery power reaches ignition key switch (ignition key connector pin 1).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

STARTER SYSTEM TESTING ON TELEHANDLER For easier and rapid diagnosis and for most conclusive test results, it is recommended that a battery--starter tester (high rate discharge tester) incorporating a 0--20 volt voltmeter and a 0--1000 amp ammeter be used to diagnose starting system problems. When using test equipment follow the manufacturers recommended test procedures. If test equipment is not available the following test procedure, using a standard 0--20 volt voltmeter and 0--1000 amp ammeter can be used to determine the correct operation of the starter without removing it from the engine. Before testing: • Check that the battery is fully charged. • Check the complete starting system wiring circuit for frayed or broken wires or loose terminal connections. • Check the engine is not seized.

Starter Motor Circuit Current Draw 79. Attach a suitable clamp meter, (1), with a 0--1000amp range, over the battery positive cable. 80. Connect the voltmeter(2) positive lead to the battery positive terminal and the voltmeter negative lead to the battery negative terminal. 81. Disconnect the wire from the fuel injection pump shut off solenoid. 82. Crank the engine while observing the voltmeter and ammeter readings. The voltage should remain steady at around 10--12 volts with between 250--400 amps being drawn. • If the current draw is within specification the starting motor (4) is functioning correctly. If the voltage drops during the test proceed to ‘Starting System Circuit Resistance’. • If the current draw is greater than specified, check the circuit as outlined below. If the starting system circuit tests are satisfactory the starting motor is defective and must be disassembled to determine the cause. • If the current draw is less than specified, the starting motor is defective and must be disassembled to determine the cause.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

STARTING SYSTEM CIRCUIT RESISTANCE (VOLTAGE DROP) If there is an excessive current draw the circuit should be checked by recording voltage drops across the individual components in the circuit IMPORTANT: Disconnect the fuel injection pump fuel shut off solenoid wire. Battery Positive Cable: 1. Connect the voltmeter positive lead to the battery positive terminal. 2. Connect the voltmeter negative lead to the starting motor solenoid battery terminal. 3. Crank the engine while observing the voltmeter reading. If the voltage exceeds 0.2 volts, check and tighten the cable connections. Recheck the voltage, if still excessive install a new cable.

60-- 55-- 002 mm

6 Starting Motor Ground Connections: 1. Connect the voltmeter positive lead to the starting motor frame. 2. Connect the voltmeter negative lead to the engine block. 3. Crank the engine while observing the voltmeter reading. If the voltmeter reading exceeds 0.2 volts check the ground connections between the starting motor flange and the rear engine plate.

60-- 55-- 003 mm

7 Battery Ground Cable: 1. Connect the voltmeter positive lead to the engine block. 2. Connect the voltmeter negative lead to the battery negative terminal. 3. Crank the engine while observing the voltmeter reading. If the reading exceeds 0.2 volts, check and tighten the ground cable connections. Recheck the voltage, if it is still excessive install a new ground cable.

60-- 55-- 004 mm

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

10 201 STARTER MOTOR REMOVAL AND INSTALLATION 1. Disconnect the battery ground (negative) cable from the battery. 2. Remove the protective cover from the solenoid assembly and disconnect the positive cables to the solenoid and the solenoid coil feed wire. 3. Remove the three starting motor mounting bolts and remove the starting motor. 4. Installation is the reverse of the removal procedure. 9

10 1. Front housing 2. Solenoid screws 3. Plunger 4. Spring 5. Solenoid 6. Engagement lever 7. Circlip 8. Reduction gear unit 9. Screws 10. End housing

Starter Motor -- Exploded View 11. Brush plate 12. Armature housing bolts 13. Motor casing 14. Armature 15. Snap ring and collar 16. Spring 17. Spring cap 18. Engagement lever plate 19. Washer

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

DISASSEMBLY With reference to Figure 10. 1. Support the starting motor in a soft jawed vice. 2. Disconnect the thick braided wire from the field coil housing to the solenoid assembly. 3. Remove the three screws from the front housing assembly and withdraw the solenoid assembly. The plunger may be left behind. In this case, pull the plunger from the front housing. • Mark the starter casing at each end prior to disassembly to ensure correct alignment of components during reassembly. 4. Remove the two armature housing bolts and the two screws retaining the end cap and brush plate to the end housing, withdraw the end housing, leaving the brush gear on the commutator. 5. At this stage of disassembly inspect the brushes and commutator. Check for sticking brushes. If necessary, clean brushes and brush channels using a suitable cleaning solvent. Check brushes for wear. If worn below the minimum length specified, of 7.00mm, it will be necessary to replace the complete starter motor. NOTE: The brushes are not serviced separately. They are spot welded into position and not intended to be replaced during the starter motors service life. 6. Withdraw the brush box and the motor casing from the armature and drive end housing.

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7. Withdraw the drive engagement lever pivot pin from the drive end housing. 8. Withdraw the drive assembly and lever together from the front housing. 9. Remove the drive assembly and reduction unit retaining snap ring from the armature shaft by driving the securing thrust collar squarely off the snap ring with a suitable diameter tube and then levering the snap ring from the groove. 10. Separate the reduction unit from the drive assembly. 11. The drive assembly can be further dismantled to replace the pinion gear. Remove the circlip from the drive assembly, relieving the pressure of the spring and disassemble the drive assembly. RE--ASSEMBLY 1. Re--assembly of the starting motor follows the disassembly procedure in reverse, observing the folloiwng points: • Ensure the marks made before disassembly are aligned before final tightening of the two armature housing bolts. • To aid brush installation over the commutator, insert a thin blade screwdriver under the brush spring to allow the brushes to move freely in their holders. Prior to installation the starting motor no load function must be tested.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Starting Motor No--Load Test: NOTE: A fully charged battery and a battery starter tester (high rate discharge tester) with a carbon pile (variable load resistor) should be used to perform this test. 1. Secure the starting motor in a vice equipped with soft jaws. 2. Connect the battery negative cable (4) to the starting motor mounting flange. 3. Connect a voltmeter (3) positive lead to the battery positive terminal, the voltmeter negative lead to the battery negative terminal. 4. Connect the battery positive cable to the starting motor terminal and attach a suitable clamp meter (1), over the cable. 5. Connect a short jumper lead (6) between the solenoid battery and solenoid switch terminals. NOTE: Connecting the jumper lead will cause the starter to operate. 6. Hold a hand tachometer (5) on the end of the armature shaft. Set the starting motor by adjusting the carbon pile (2) to give 11.7 volts. When the armature rotates above 4000 rev/min. the maximum current draw should not exceed 150 amperes. 7. If the starting motor does not perform to specification, check for grounded field coils, a rubbing armature or a distorted armature shaft.

BENCH TESTS Armature 1. The commutator face should be clean and free from burnt spots. If necessary remove any burnt spots using fine glass paper, not emery cloth. Finally clean the commutator with an alcohol moistened cloth. 2. If it is necessary to skim the commutator ensure the diameter is not reduced below the minimum specified diameter of 42.5mm. Following skimming the commutator should be polished with a fine glass paper and then wiped clean with an alcohol moistened cloth. NOTE: Do not cut into the commutator metal when recutting insulation slots.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

3. Armature insulation can be checked by connecting an ohmmeter between the commutator segments and the armature shaft. There should be an infinity reading, i.e, no continuity. Also, If there are black or burned points this will be an indication that the insulation has cracked. 4. To test the armature for short circuits it is necessary to use suitable armature testing equipment, the only alternative is to check the armature by substitution. 5. If there is evidence that the armature circumference has been in contact with the pole pieces, then the armature bearings are probably excessively worn. First check that the pole pieces are tight and that the armature runs true in a lathe, then if necessary renew the armature bearings. Field Coils 1. To test the insulation of the field coils connect an ohmmeter in turn between each of the field winding brushes and a clean unpainted part of the housing. There should be no reading, i.e, no continuity. 2. To test the field winding continuity connect an ohmmeter in turn between each of the field winding brushes and the main feed terminal (thick braided wire). A reading of 1 MΩ should be indicated. 3. If a fault is indicated in the field windings it will be necessary to replace the complete field coils and housing assembly. Bearing Bushes 1. Inspect the bushes in the brush end plate assembly and pinion drive end housing for wear. Install the armature shaft and observe the free play, replace bushes where free play appears excessive. Inspect the field poles for signs of rubbing by the armature which may also have been caused by worn bushes. Drive Pinion Assembly 1. Check the operation of the roller clutch. The pinion should rotate clockwise only. If the pinion is stuck or rotates in both directions, or if the pinion teeth are damaged install a new drive assembly. If damaged pinion teeth are evident, check the flywheel ring gear teeth as described in Section 10, Engine Systems.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

SECTION 55 -- ELECTRICAL SYSTEM Chapter 4 -- CHARGING SYSTEM CONTENTS Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 000

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System testing and trouble--shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal, re--installation and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

55 301

55 000 SPECIFICATIONS DESCRIPTION Alternator type Polarity Nominal voltage Max. rotation speed Maximun output Regulated controlled voltage

Bosch 14V -- 90A Negative earth 14 V 15,000 rpm 90 A 13.6 -- 14.4 V

TIGHTENING TORQUES Alternator fastening bolts Pulley fastening nut

5.5 Nm 70 Nm

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

DESCRIPTION AND OPERATION ALTERNATOR DESCRIPTION A Bosch, 90 A, external cooling fan alternator is fitted on all models. Stator winding is ventilated with an air conducting diaphragm in the support on rectifier bridge side and peripheral openings in the support on the control side. The alternator, installed on the left side of the engine, is operated by a pulley and a V--type driving belt. Alternators are fitted with a built--in regulator. 1. 2. 3.

Tachometer terminal ’W’ (brown wire) Output terminal ’B’ (white wires) Warning light terminal ’L’ (blue wire)

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

2 Alternator Charging Circuit 1. 2. 3. 4. 5. 6.

Ignition switch Alternator charge warning light Alternator electronic voltage regulation circuit Alternator Battery Electrical system circuits

B+

Battery Connection

L W

Alternator charge indicator Tachometer connection

ALTERNATOR OPERATION When the ignition key is turned, a small current passes from the battery through the rotor field winding wiring. The circuit closes powering the charge warning light, the alternator L terminal, the rotor field winding, the alternator regulator and ground. At this stage, the warning light comes on and the rotor is partially magnetised. When the engine starts and the rotor, partially magnetised, turns inside the stator windings and generates three--phase alternating current. A constant quantity of this current is transformed into direct current by three field diodes built into the rectifier.

This action causes a constant increase in the rotor magnetic field and a fast increase of current and voltage output. As the generated voltage output (reflected by L terminal) increases, the warning light intensity decreases and when the voltage at the L terminal equals that on the battery side of the warning light, the light goes out. Voltage increases until it reaches the pre--set regulated voltage level. If the driving belt breaks, there will be no voltage accumulation in the alternator. The charge warning light will stay on, thus showing there is a fault.

The direct current is then reintroduced into the circuit to increase current flow through the rotor field winding.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

SYSTEM TESTING AND TROUBLE--SHOOTING PRECAUTIONS To avoid damaging alternator charging system components, take the following precautions: •

DO NOT MAKE OR INTERRUPT any charging circuit connection, including battery, while the engine is running.

•

NEVER SHORT--CIRCUIT the alternator positive terminal to check if it is working.

•

ALWAYS DISCONNECT battery cables when recharging the battery on the vehicle with a battery charger.

•

ALWAYS CHECK battery polarity when installing a battery or using a supplementary battery to start the engine.

•

DO NOT SHORT--CIRCUIT regulator input/ output terminals when the alternator is working.

•

CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE.

PRELIMINARY CHECKS Before carrying out these electrical tests, carefully inspect the charging system and the electrical system in general. Check continuity in all conductors and connections. Check they are all well fastened. 1. CHECKING THE BATTERY Check all battery elements with a hydrometer. The battery must be at least 70% charged and efficient. 2. CHECKING THE DRIVING BELT Inspect the alternator driving belt and pulley, checking that they are both clean, with no traces of oil or lubricant and in good condition. Check the alternator driving belt tension regularly. Check condition of the drive belt, ensure the belt is not frayed and is free of nicks and tears. A correctly tensioned belt can be deflected 10--13mm when hand pressure is applied midway between the alternator and water pump pulley. To adjust the belt tension loosen the alternator mounting bolt (3) and the lock bolt (2). Screw in the adjusting bolt (1) until the correct tension has been achieved. Re--tighten the bolts (2) and (3). IMPORTANT: When prying the alternator away from the engine, apply pressure at the front housing only. Do not pry on the rear housing as damage may result. Also, adhere to the alternator precautions in this Section.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

3. CHECKING THE WARNING LIGHT

PRELIMINARY TESTS

Turn the ignition key and check the light is completely lit.

These preliminary tests can be carried out without removing any components from the tractor charging circuit. These tests check:

If the warning light does not light completely, check the light bulb. If the light bulb has not blown, carry out the alternator wiring connection tests as described in the paragraph “PRELIMINARY TESTS” in this section.

•

the alternator wire connections

•

alternator charging current and controlled voltage

•

voltage drop in the alternator charging circuit

•

maximum alternator output

If the light is on, start the engine and run it above minimum speed. The warning light should go out.

The following testing devices are required: If the warning light does not go out, stop the engine and disconnect the L terminal wire. If the warning light goes out now, one of the alternator components is malfunctioning and the alternator should be replaced. If the warning light stays on, check there is no grounded short circuit between L wire ending and warning light.

•

0--30V moving coil voltmeter

•

0--1V millivoltmeter

•

0--110 A moving coil ammeter

•

1.5 ohm, 110 A varying load resistance

NOTE: most testing devices on the market today include several devices in the same case. When using these devices, follow the manufacturer’s instructions.

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6 1.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 ALTERNATOR WIRE CONNECTIONS TEST

See figure 4. 1. Disconnect the battery. 2. Disconnect B+ (2) and L (3) alternator wires. 3. Reconnect the battery and turn the ignition key into position ON but without starting the engine. Connect a voltmeter (1) between each disconnected wire and ground (4). There must be voltage at the battery. If there is no voltage at the battery, track down and repair a continuity malfunctioning in the external wiring circuit. See circuit diagram in figure 2.

4. Disconnect L terminal, warning light wire (blue) and ground. The warning light should come on. 5. Disconnect the battery and reconnect the connection previously disconnected to the alternator. NOTE: if the warning light does not light up when the wire is connected to the alternator, this means that there is a fault either in the alternator regulator circuit or in the rotor circuit. Check L terminal is clean and retry. If still no light, replace the alternator.

CHARGING CURRENT VOLTAGE TESTS

AND

REGULATED

See figure 5. 1. Check that all tractor electrical devices are switched off and the ignition key is in OFF position. 2. Disconnect the negative battery terminal and the B+ alternator terminal (4). 3. Connect an ammeter (1) between the disconnected wires (white) (4) and the B+ alternator terminal (2). 4. Connect a voltmeter (3) between the B+ alternator terminal (2) and ground. 5. Reconnect the battery. Start the engine and run it at 2000 rpm. Note the readings on the voltmeter and the ammeter. The voltmeter reading should be higher than the battery voltage and when the ammeter reading falls below 10 A, the voltmeter reading should stabilise at 13.6 -- 14.4 V.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

If the voltmeter reading is higher than 14.4 V, the alternator regulator must be removed and repaired by an authorised repair agent. If the voltmeter reading is less than 13.6 V, there is either a faulty component in the alternator or a failure due to excessive resistance in external charging system connections. If the ammeter reads zero A. then one of the alternator components is malfunctioning. The alternator must be removed and repaired by an authorised repair agent.

CHARGING CIRCUIT VOLTAGE DROP TESTS

(a) Insulated side voltage drop test See figure 6. Check the ignition key is in OFF position. 1. Disconnect the negative battery cable and the B+ alternator wire (4). 2. Connect a millivoltmeter (1) between the positive battery terminal and B+ wire (4). 3. Connect a ammeter (3) between the B+ alternator terminal and the B+ wire. 4. Reconnect the negative battery cable and connect a varying load resistance (5) with cursor in minimum current absorption position (maximum resistance) through the battery terminal clamps. 5. Start the engine and increase speed to 2000 rpm. 6. Decrease resistance charging load (decreasing resistance) slowly until the ammeter reads 90 A. according to the type of alternator. 7. Note the reading on the millivoltmeter. This must not be higher than 400 millivolt.

A reading higher than 400 millivolt indicates malfunctioning due to excessive resistance on external circuits. If the alternator does not output required power and the millivoltmeter reading is less than 400 millivolt, there is a malfunctioning component in the alternator. 8. Stop the engine. Remove the alternator for authorised agent repair.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

(b) Ground side voltage drop test See figure 7. 1. Check the ignition key is in OFF position. 2. The circuit is the same as that described in the previous test, except that the millivoltmeter (4) is now connected between the negative battery terminal and the alternator casing. NOTE: check the varying load resistance (3) is in minimum current absorption position (maximum resistance). 3. Start the engine and increase speed to 2000 rpm.

4. Increase resistance current load (decreasing resistance itself) slowly until the ammeter (2) reads 90 A. 5. Note the reading on the voltmeter. This must not be higher than 200 millivolt. A reading higher than 200 millivolt indicates malfunctioning due to excessive resistance on external circuits. If the alternator does not output required power and the millivoltmeter reading is less than 200 millivolt, there is a malfunctioning component in the alternator. Remove the alternator for authorised agent repair. 4.

MAXIMUM ALTERNATOR OUTPUT TEST

See figure 8. 1. Check the ignition key is in OFF position. 2. Disconnect the negative battery cable and the B+ alternator wire (3). 3. Connect an ammeter (2) between B+ alternator terminal (1) and disconnected wire (3). 4. Connect a voltmeter (4) between the B+ alternator terminal and the disconnected wire (3). 5. Reconnect the negative battery cable. Start the engine and increase speed to 2000 rpm. 6. Increase resistance current load (5) (decreasing resistance) slowly until the ammeter reads 90 A. 7. Note the reading on the voltmeter. This must not be less than 13.6 V. A reading lower than 13.6 V. shows there is a malfunctioning component in the alternator. Remove the alternator for authorised agent repair.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

SECTION 55 -- ELECTRICAL SYSTEM Chapter 5 -- BATTERY CONTENTS Section

Description

55 000

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Causes of Battery Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 300

Page 1 1 2 3 4 7

55 000 SPECIFICATIONS

Standard Capacity -- Ah

165

Voltage

Cells

Ground Terminal

55 000 DESCRIPTION AND OPERATION

All models feature one 12 volt, negative ground, ‘maintenance free’ lead calcium (Pb--Ca) type battery, of six cell construction. NOTE: ‘Maintenance Free’ means that under normal charging conditions the battery does not lose water from the electrolyte. Conditions that may cause water loss include prolonged charging above 14.4volts where gassing occurs as it approaches full charge. This can be caused by a faulty charging system or boost/recovery charging equipment. The battery is mounted behind the right hand side panel of the unit. The battery has four major functions: •

To provide a source of current for starting, lighting and instrumentation.

•

To help control the voltage in the electrical system.

Negative

•

To furnish current when the electrical demands exceed the alternator output.

•

To support quiescent loads from radio and micro processor memory.

The battery is constructed in such a manner that each cell contains positive and negative plates placed alternatively next to each other. Each positive plate is separated from a negative plate by a non--conducting porous envelope separator. If any of the positive plates should make contact with negative plates within a cell, the cell will short circuit and suffer irreparable damage. All of the positive plates are welded to a bus--bar, forming a positive terminal and all of the negative plates are welded to a similar bus--bar forming a negative terminal. Each positive plate is composed of a lead grid with lead peroxide pasted into the grid openings. The negative plates are composed of a lead grid with spongy lead pasted into the grid openings. The plates are submerged in a liquid electrolyte solution of diluted sulphuric acid.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

REMOVAL AND INSTALLATION OP. 55 300 Removal 1. Tilt the side panel up on its support gas struts. 2. Remove the negative lead (3) and then the positive lead (1) from the battery. 3. Remove battery securing bracket (2). 4. Using the lifting handles, remove the battery.

Installation 1. Installation of the battery, (1), is the removal procedure in reverse, observing the following points: •

Ensure that the battery is clean and dry and that the vent caps are fully installed. Smear the terminals with petroleum jelly (vaseline or equivalent), do not use conventional lubricating greases as these can promote electrolytic corrosion. 2

•

Ensure the battery tray and clamps are clean and free from stones or small objects which may puncture the battery casing.

•

Ensure that the battery terminal polarity is correct and that the terminal connections are sufficiently tight, but not overtightened.

•

The radio, if fitted, will lose its stored information and will require re--programming.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 BATTERY MAINTENANCE AND TESTS

Table 1

Specific Gravity The specific gravity of the battery electrolyte indicates the state of charge. Fully charged the specific gravity of the electrolyte is 1.280 minimum at 25°C. Alternatively the approximate state of charge can be measured by using an accurate digital volt meter (+/-0.01V) as follows:-Less than 10.5V Battery un--serviceable* Less than 11.8V Battery discharged Less than 12.3V Battery 1/2 charged Better than 12.6V Battery fully charged * See note under tests for possible recovery of a mildly sulphated battery. Battery voltage to be taken with the battery unloaded and:-A) After the battery has rested unloaded for at least 4 hours. B) If the vehicle has recently run or battery has recently been charged, switch on headlamps for 2 minutes.

When a battery discharges, sulphuric acid in the electrolyte combines chemically with the plates and this action lowers the specific gravity of the solution.

A battery hydrometer will determine the specific gravity of the electrolyte in a cell and the amount of unused sulphuric acid in the solution is a measure of the degree of charge of that cell.

The lower the temperature at which a battery is required to operate, the more necessary it is that the battery is maintained in a fully charged condition. For example a battery with a low specific gravity of 1.225 at 27°C (80°F) will operate the starting motor at warm ambient temperatures but may not, due to lower battery efficiency at a low temperature.

Table 1 shows the effect of temperature on the efficiency of a typical battery.

Temperature

Efficiency of a Fully Charged Battery

25.0°C (77.0°F) --4.5°C (23.9°F) --24.0°C (--11.2°F) --27.5°C (--17.5°F) --31.0°C (--23.8°C) --34.5°C (--30.1°C) --37.5°C (--35.5°C)

100% 82% 64% 58% 50% 40% 33%

Maximum battery life will be obtained if the correct care and periodic inspection is given. It is important that output capacity should not be exceeded by constant and excessive overloading and that charging requirements are maintained. Servicing The Battery

WARNING Batteries contain sulphuric acid and during charging generate a highly explosive mixture of hydrogen and oxygen gases. • Never use equipment that generates flames or sparks in order to control electrolyte level •

Do not remove the battery cover plugs without protection for eyes and hands.

When servicing a battery the following steps should be observed: 1. Maintain the electrolyte to the recommended level of 6 mm (0.25 in.) above the plates. If this is not observed the acid will reach a high concentration that will damage the separators and impair the performance of the plates. 2. Use only distilled or de--mineralised water, do not overfill and never use tap water or water from a rain barrel or other source. 3. Always keep the battery at least 75% charged otherwise the plates will become sulphated and loss of efficiency will result with possible damage from freezing at low temperatures. 4. Avoid overcharging the battery as excessive charging will create high internal heat that will cause plate grid deterioration and produce water loss. 5. When fast charging ensure the temperature does not exceed 50°C.

battery

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

6. Do not add sulphuric acid to a cell unless the electrolyte has been lost through spilling. Before replenishing ensure the solution is at the correct specific gravity. A slow charge is the only method to be employed to fully charge a battery. A high rate charger can be used to quickly boost the battery capacity but this must be followed by a slow charge rate to bring the battery to full capacity. 7. When using a fast or high rate of charge carefully follow the manufacturers instructions. High rate charging raises the temperature of the electrolyte and unless the charger is equipped with an automatic time or temperature device, the electrolyte temperature could exceed 50°C , which may cause violent battery gassing and damage to internal components. 8. Re--check the level of electrolyte in each cell and add distilled water as necessary. Dry Charged Batteries 1. Remove the battery cell vent plugs. 2. Fill each cell to the recommended level with electrolyte of 1.260 specific gravity. Dry charged batteries must be prepared for service as follows: NOTE: The electrolyte must be diluted sulphuric acid preferably at a temperature of 21° --32°C (70° --90°F). 3. After filling, allow the battery to stand for 15 minutes then re--check the electrolyte level and top up if necessary. 4. Charge the battery for 4 hours at a rate of 5--8 amperes and check that all cells are gassing freely. 5. Install the battery cell vent plugs. Charging The Battery Before charging a battery: 1. Thoroughly clean the battery casing and cell covers with dilute ammonia or hot water and clean the terminals.

Normal (Top--up) Charging 1. With a slow charger use a rate of 3 to 6 amperes for the time necessary to bring the battery to full charge. This may take 36 hours or more if the battery is heavily discharged. A severely sulphated battery might not accept a charge. When the battery is fully charged the cells will gas freely and the specific gravity will remain constant. Remove the charger after three consecutive hydrometer readings taken at hourly intervals indicate that the specific gravity has stopped rising.

WARNING When a battery is being charged an explosive gas is produced. Do not smoke or use an exposed flame when checking the electrolyte level and ensure the charger is switched off before connecting or disconnecting to avoid sparks which could ignite the gas. Recharging Deeply Discharged Batteries The recommended method to recharge a maintenance free Pb--Ca battery is to use a constant voltage charger. For deeply discharged batteries a 48 hours charging period at 16volts is recommended, with current limitation, (47.5A for 105Ah and 150Ah). This system is self regulating: high current is delivered at the beginning (when battery voltage is low), lower and lower current is then absorbed when battery reaches full charge (and its voltage is high). If only constant current chargers are available it is recommended to use the current levels and times shown Table 2 below. The figures are intended for deeply discharged batteries. If the battery is only 50% discharged use one half of the time listed (slow charge programs). For other states of discharge reduce proportionally the time of charge. Whenever possible use the slowest charge program to increase the battery’s life. If when charging the battery, violent gassing or spewing of electrolyte occurs, or the battery case feels hot (50°C or greater), reduce or temporarily halt charging to avoid damaging the battery. Table 2 Battery Type

2. Check the level of the electrolyte in each cell and, if below plates, add distilled water to bring above plate level.

165Ah Slow Charge Programs

25hrs at 5A 12.5hrs at 10A

Fast charge Program (emergencies only)

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7hrs at 18A

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 Tests Before commencing battery tests check the battery for clogged vents, corrosion, raised vent plugs or a cracked case. Test equipment required: •

Hydrometer

•

Battery starter tester (High rate discharge tester)

•

Thermometer

•

Battery Charger

Specific Gravity: This test will determine the state of battery charge. 1. With the float in the vertical position take the reading. 2. Adjust the hydrometer reading for electrolyte temperature variations by subtracting 4 points (0.004 specific gravity) for every 5.5°C (10°F) below the temperature at which the hydrometer is calibrated and by adding 4 points (0.004 specific gravity) for every 5.5°C (10°F) above this temperature. The following examples are calculated using a hydrometer calibrated at 30°C (86°F). Example 1: Temperature below 30°C (86°F) Electrolyte temperature 19°C (66°F) Hydrometer reading 1.270 Subtract 11.0 x 0.004 0.008 5.5 Corrected specific gravity = 1.262 Example 2: Temperature above 30°C (86°F) Electrolyte temperature 40°C (104°F) Hydrometer reading 1.220 Add 10.0 x 0.004 0.007 5.5 Corrected specific gravity = 1.227 3. Use the following table to determine the state of charge.

Corrected

State of

Specific

Charge

Gravity

@15°C

@25°C

100%

1.295

1.287

12.76

75%

1.253

1.246

12.52

50%

1.217

1.210

12.30

25%

1.177

1.170

12.06

Discharged

1.137

1.130

11.84

Average Battery Voltage

NOTE: Specific gravity should not vary more than 0.025 points between cells. 4. If the specific gravity is 1.280 or more the battery is fully charged and in good operating condition. 5. Should the corrected specific gravity be below 1.280, charge the battery and inspect the charging system to determine the cause of the low battery charge. NOTE: If distilled water has recently been added the battery should be recharged for a short period otherwise accurate hydrometer readings will not be obtained. If the battery has been charged under static conditions, denser electrolyte will accumulate at the bottom of the cells. The battery should be shaken periodically to mix the electrolyte, this will improve the charge rate and provide a more accurate hydrometer reading when tested. Performance Test: The performance test is to determine if the battery has adequate capacity to turn the engine. The voltage reading obtained is used to determine the battery condition. Prior to testing, ensure the electrolyte level is correct and the open circuit voltage is 12.5V or more. The battery may be tested on or off the tractor. 1. Set the current control switch of the battery starter tester (high rate discharge tester) to the ‘off’ position and the voltage selector switch equal to, or slightly higher than, the rated battery voltage. Connect the tester positive leads to the battery positive terminal and the negative leads to the negative battery terminal. 2. Turn the current control knob until the ammeter reading is half the CCA rating of the battery and take the voltage reading.

•

If the reading is 9.6 volts or more after 15 seconds, the battery has an acceptable output capacity and will readily accept a normal charge.

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6 •

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 If however the reading is below 9.6 volts, the battery is considered unsatisfactory for service and should be test charged as described below.

CAUTION: Do not leave the high discharge load on the battery for periods longer than 15 seconds.

Test Charging: This test is designed only for batteries that have failed the previous capacity test.

1. Attach the battery starter (high rate discharge tester) positive leads to the battery positive terminal and the negative leads to the battery negative terminal.

2. Connect the battery charger positive lead to the battery positive terminal and the negative lead to the battery negative terminal.

3. Turn the charger timer past a ‘3 minutes’ charge indication and then back to the ‘3 minutes’ mark.

•

If the total voltage is over 15.5 volts the battery is unsatisfactory and is probably sulphated or worn out and should be replaced.

NOTE: A mildly sulphated battery can be recovered by using a multiple battery type charger, with an open circuit upper voltage limit of 50 volts. Owing to the high resistance of a sulphated battery, it will primarily require a high voltage setting to overcome the resistance of the sulphation. initially there may be no visible acceptance of the charge. After a few minutes of inactivity a small charge will be apparent, followed by a rapid increase in the charge rate. The charge rate must not exceed 14.0 amperes or the electrolyte temperature 50°C. When the ampere rate has stabilised, reset the volts until the charge rate is a steady 5 amperes. Continue at this rate until the electrolyte specific gravity stops rising at approximately 1.275--1.280 at 20°C (68°F), this can take up to 48 hours of charging. Stand the battery for 24 hours and then conduct the capacity test detailed previously.

•

If the total voltage is under 15.5 volts, test the specific gravity of each cell and re--charge the battery to the following scale:

Specific Gravity

Fast charge up to:

1.150 or less

60 minutes

1.151 to 1.175

45 minutes

1.176 to 1.200

30 minutes

1.201 to 1.225

15 minutes (Slow charge only)

4. Set the charging rate as close as possible to 40 amperes.

5. After 3 minutes at this fast charge take the voltmeter reading.

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NOTE: When battery problems are experienced the fan belt tension and the complete charging system should be checked.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 Common Causes of Battery Failures 1 Internal open circuit. 2 Internal short circuit. 3 Loss of electrolyte. 4 Separation of active materials from grids. 5 Accumulation of sulphate crystals too large to disperse. These failures are normally caused by the following: 1 Failure of inter cell components.

5 Crystal growth occurs whenever batteries are left discharged. High temperatures and extended discharged periods increase this condition. At room temperature after one week the battery is unlikely to recover on the vehicle. Recharge will require a higher constant voltage. After 3 weeks the battery will have suffered permanent degradation and the procedure detailed previously for charging a ‘Deeply Discharged’ battery should be followed.

When fully charged, batteries have a long shelf life. The lead calcium type battery self discharges at 3% per month. This means that it will take 16 months to drop to 50% charged. On the tractor the quiescent load is about 50mA. To predict rundown on a static vehicle this should be added as approximately 8Ah per week.

2 Excessive crystal growth may puncture the separators and cause short circuits. 3 Excessive over charging (charging system malfunction, boost/recovery techniques with high voltage, operation in very high temperatures.

It is worth stressing that when cranking, if a battery starts to fade, it is beneficial to stop and allow two minutes for the battery to recover. The recovery time should be increased as the temperature decreases.

4 Freezing of electrolyte. A fully charged battery does not freeze until --65°C. A 50% charged battery freezes between --17°C and --27°C. Fully discharged electrolyte freezes at --3°C to --11°C. Excessively high boost charging and gassing will also cause separation of active materials from the grids. Separation destroys the chemical function of the battery.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

NOTES

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

SECTION 55 -- ELECTRICAL SYSTEM Chapter 6 -- Load Status System CONTENTS Section

Description

55 000

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Description The Load Status safety system consists of strain gauge mounted on the rear axle and a dash mounted module. The coloured LED readout on the module indicates the percentage of safe working load on the telehandler forks or attachment. An alarm is activated on 95% load to warn of decreasing longitudinal stability. An optional solenoid operated hydraulic cut out valve may be fitted and operates in conjunction with the Load Status alarm. The strain gauge (3) measures the axle deflection created by differing axle loading. The strain gauge is mounted on the right hand side of the rear axle and is retained by two bolts (1). The gauge has a cover (2). The module display has colour LED display. 1. 4 Green LED’s (1) indicate safe working load conditions, each LED represents about 15% of maximum safe working load. 2. 2 Yellow LED’s (2) indicate that the load is approaching the limit of longitudinal stability, each LED represents about 15% of maximum safe working load. 3. 1 Red LED (3) indicates the telehandler has reached the limit of longitudinal stability. The audible alarm will sound a slow intermittent signal. 4. 2 LED’s (3) indicate the telehandler is overloaded and unstable. The audible alarm will sound a fast intermittent signal. When the 2 red LED’s are illuminated, the telehandler boom must be retracted until the red LED’s are extinguished.

Page

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Alarm and Test Switches The Sound Alarm Switch (1) enables the alarm to be switched off. The alarm must be switched on at all times except when operating with earth moving buckets. When the alarm is switched off, the red LED (2) illuminates indicating the sound alarm has been switched off. The Test Switch tests the alarm and LED’s to ensure the system is working. All LED’s and the sound alarm functioning continuously while the button is depressed, indicates correct system operation.

All LED’s and the sound alarm functioning intermittently while the button is depressed, indicates a faulty system operation.

Rear axle deflection is greatest when the telehandler loader is not loaded.

4 As the boom load increases, the weight on and the deflection of the rear axle decreases.

5 The strain gauge senses the reduced axle deflection and signals the module to change the indicated display.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Hydraulic Load Automatic Cut Off An excess load anti tilt system is available as an optional safety feature. When fitted, the system is incorporated in the loader hydraulic system and operates in conjunction with the standard load status system. The cut off system is activated by depressing switch ’B’ adjacent to the load monitor panel on the dash.

7 When the load becomes equivalent to the maximum safe load the following occurs: -1. First red LED illuminates. 2. Alarm sounds and red alarm LED illuminates. 3. The dump valve solenoid is activated. The dump valve (1) is fitted between the pump supply (2) and return lines and is located adjacent to the reservoir return filter (3). When activated, the dump valve opens to return pump supply oil back to the reservoir. Further operation of the boom is no longer possible until the boom is retracted and the solenoid valve de--energised.

The cut out system is turned off by depressing switch A. The load status system now operates as previously described.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

10 Load Status System Wiring Diagram

Circuit Key 61. Load Status System Component Key F14. Fuse 10A Joystick Controls K7. Load Status Module S22. Load Status Strain Gauge Connector Key H. Fuse/relay Board (21 pin Socket) U. Load Status Strain Gauge

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Wiring Colour Key bc. White bl. Blue g. Grey j. Yellow m. Brown n. Black r. Red vt. Green v. Violet

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Load Status System Calibration Preparation Before calibrating the telehandler load status system ensure a suitable weight or loaded pallet is available. Refer to Section 00, Chapter 2, specifications, for the load lifting performance diagram for the telehandler to be calibrated. In the example shown, a load of 2000 kg will be sufficient for the calibration. When correctly calibrated, it should be possible to extend the boom approximately 2.7 meters before the Load Status alarm operates. IMPORTANT: The exact weight of the test load must be known. A suitable test load could be made up of tractor front end weights.

11 Park the machine on a firm level surface with the hand brake applied.

12 Remove the panel behind the instrument panel to gain access to the back of the load status module (1). Peel back the sticker (2) covering the reset switch. Press the reset switch lightly for 2 seconds with a screwdriver to commence the calibration sequence.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

To confirm the memory has been erased, the LEDs will display:-1 & 2 ’ON’ 3 & 4/5 & 6 will flash alternately. Remove the forks and carriage from the carrier.

14 Establishing Zero Load Condition 1. Ensure the telehandler is standing on firm level surface with the handbrake applied and the wheels in a straight ahead position 2. Start the engine, run at 1200 rev/min. 3. Fully retract and fully raise the boom. 4. Register ’Zero Condition’ by pressing the sound alarm switch on the module display. Audible beeps indicate confirmation and the LED’s will display:-7 & 8 ’ON’ 3 & 4/5 & 6 will flash alternately 15 Recording Maximum Load Condition 1. Fit the forks and carriage to the carrier and then pick up the test load pallet or weight (X = selected from lifting performance diagram) and fully retract the boom with the load. 2. With the boom parallel to the ground, extend the boom slowly distance Y (dimension Y is taken from lifting performance chart for test load X) IMPORTANT: For calibration purposes ONLY, Y is measured from the front wheel to the rear of the forks as illustrated. 16 3. Register the ’Maximum Condition’ by pressing the test button on the module display. Audible beeps indicate confirmation and all the LED’s will be ’ON’. Checking System Operation With the test load on the forks, extend the boom by the amount specified on the load performance diagram. If the calibration is correct, 7 LED’s should be illuminated. If either 6 or all 8 LED’s are illuminated, repeat the calibration procedure. 17 604.55.181.00 09-- 2003

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Fault Finding Check out a functional check of the load status system. 1. If the module display LED’s do not illuminate check the power supply to the module referring to the electrical wiring diagram on page 4.

18 2. If the module LED’s illuminate but depressing the test button indicates a system fault, carry out a load test using a suitable load for the telehandler being diagnosed referring to page 5, Load Status System calibration preparation.

19 3. Carry out visual check of the strain gauge. Loosen the retaining bolts and clean the contact areas between the gauge and the rear axle housing. Reinstall the strain gauge, tighten the bolts to 67 Nm (50 lbf.ft). Check operation of the system. If the module display is operating, recalibrate the system. 4. If the system is still not operative, carry out resistance checks on the strain gauge.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Checking the Strain Gauge 1. Remove the instrument panel cover. 2. Disconnect the 6--pin connector (2) between the module (1) and the wiring harness.

20 The female half of the connector is part of the strain gauge wiring harness. The pin numbers are indicated on the back of the connector.

21 Use a multimeter to carry out the following checks on the strain gauge. 3. Resistance between pins 1 & 2 should be 300--400 ohms

22 4. Resistance between pins 3 & 4 should be 300--400 ohms. If the resistance in steps 3 & 4 is less than 300 ohms or more than 400 ohms, the strain gauge should be replaced.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

5. Measure the resistance between pins 2 & 5. The indicated value should be:-101 ohms + ( 0.39 x strain gauge temperature) Example: Temperature =20O C Indicated Resistance = 101 x (20 x 0.39) 109 Ohm If more than 10% below or above the value for the recorded temperature the strain gauge must be replaced.

24 6. The resistance between pins 1 & 6 should be infinite, that is open circuit.

25 7. The resistance between pin 1 and earth should be infinite, that is open circuit.

If the strain gauge is found to be suspect it must be replaced. The strain gauge wiring harness is an integral part of the assembly.

26 8. To remove the strain gauge, the harness connector (2, fig 20) must be disconnected and the harness removed with the strain gauge. 9. When replacing the strain gauge ensure the machined pad is clean and free of paint or rust. 10. Locate the strain gauge on the axle and install the retaining screws and tighten to 90 Nm (68 lbf.ft) DO NOT OVER TIGHTEN THE RETAINING SCREWS 11. Fit the cover and seal, then tighten retaining screws. 12. Install the harness and connect to the module. 27 604.55.181.00 09-- 2003

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

13. After installing a new strain gauge, the system must be calibrated as previously described. 14. Test the system after calibration to verify the calibration.

29 Module Replacement If the power supply, wiring and strain gauge check out correctly, then the module may be suspect and should be changed. 1. Remove the panel behind the dash. 2. Disconnect the 6--pin connector (2) and 3--pin connector (3) between the module (1) and the wiring harness. 3. Replace the module and reconnect the connectors. 4. Replace the instrument panel cover. 30 5. After installing a module, the system must be calibrated as previously described. 6. Test the system after calibration to verify the calibration.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

SECTION 55 -- ELECTRICAL SYSTEM Chapter 7 -- Monoramp Control System CONTENTS Section

Description

Page

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description The function of the system is to control the acceleration and deceleration of the telescopic and auxiliary circuits. The monoramp control system consists of the following components. 1. 2. 3. 4. 5. 6.

Joystick (with telescopic & auxiliary control buttons) Progressive Master Solenoid Manifold Block Main Control Valve Operating Solenoids Harness & Connectors Electronic Control Module

1 When a control button is operated the master solenoid (2) is progressively energised by a PWM signal from the control module. The master solenoid provides a controlled servo pressure build up to the spool operating solenoids (4). These solenoids are energised simultaneously to supply servo oil to reposition the selected main control valve spool. When the buttons are released the pressure reduction is also progressively controlled. This system provides a smooth operation of the two circuits. 2 The graph illustrates the voltage profile produced by the control module.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

4 Monoramp Control System Wiring Diagram

Circuit Key 22. Joystick feathering control 23 Telescope Extend 24. Telescope Retract Disconnect 25. Auxiliary Extend 26. Auxiliary Retract 26A. Joystick transmission Disconnect Connector Key G. Fuse/relay board (11 pin Socket) V. Joystick--Module X. Joystick--Main Harness Wiring Colour Key bc. White bl. Blue n. Black j. Yellow ro. Pink

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Component Key F2. 5 A K0. Joystick Transmission Relay K10. Monoramp Control Module S26. Transmission Disconnect S28. Telescope Extend S29. Telescope Retract S30. Auxiliary Extend S31. Auxiliary Retract Y5. Telescope Extend Solenoid Y6. Telescope Retract Solenoid Y7. Auxiliary Extend Solenoid Y8. Auxiliary Retract Solenoid Y9. Monoramp Master Solenoid

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Fault Finding Check out a functional check of the monoramp control buttons. 1. If none of the control buttons operate their circuits, check out the power supply to the monoramp control module referring to the electrical wiring diagram on page 2. 2. If one or more of the buttons operate their circuits, carry out button control electrical tests. Cable Functions 1. 2. 3. 4. 5. 6. 7. 8.

Green Button Signal -- Auxiliary Yellow Button Signal -- Telescope Telescope Button Supply + Transmission Cut Off Button signal Transmission Cut off Button Supply + Auxiliary Button Supply Green Button Signal -- Telescope Yellow Button Signal -- Auxiliary

5 Joystick Button Control Switch Checks If available, disconnect the joystick 8--pin connector and install Monoramp test harness tool number 380001665. With the ignition switched on, use a multimeter to check out the button controls. 1. 2. 3. 4.

Test Harness Tool 380001665 Monoramp Joystick Connector Harness and Female Connector Harness and Male Connector

6 1. Telescopic Boom Extend Check voltage between pin 2 and earth. Voltage should be 12 v with the button depressed and zero with the button released.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

2. Telescopic Boom Retract Check voltage between pin 7 and earth. Voltage should be 12 v with the button depressed and zero with the button released.

8 3. Auxiliary Extend Check voltage between pin 8 and earth. Voltage should be 12 v with the button depressed and zero with the button released.

9 4. Auxiliary Retract Check voltage between pin 1 and earth. Voltage should be 12 v with the button depressed and zero with the button released. If any of the the tests indicate a faulty switch, remove the joystick and install a new switch.

Serviced Parts 1. Screw 2. Green Buttons 3. Yellow Buttons 4. Gasket Seal 5. Button Switches (5) 6. Switch Support 7. Gasket Seal 8. Transmission Disconnect Button --White 9. Joystick Handle Casing 10. Connector Pin 11. Connector Assembly 12. 12 v Supply Wires (2) 13. Output Wires (6) 14. Rubber Boot

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

Monoramp Control Module Output Check 1. Install solenoid test adapter, tool number 380001660 onto the master solenoid and connect a multimeter to the voltage contacts. 1. 2. 3. 4.

Master Solenoid Voltmeter Probes Connector Test Adaptor Tool No 380001660

12 2. Switch on the ignition and hold down any of the joystick control buttons and observe the progressive voltage build up. 3. Release the button and observe the progressive voltage reduction. 4. The voltage characteristics should follow the profile of the chart illustrated. NOTE: Maximum voltage should be 45% of battery voltage. Voltage build up when the control button is depressed and voltage reduction when the button is released should be approximately 3 seconds. 13 If the voltage pattern observed is not within specifications the control module must be replaced. The Monoramp control module is located behind the instrument panel adjacent to the Fuse/relay box.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 7

NOTES

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

SECTION 55 -- ELECTRICAL SYSTEM Chapter 8 -- Flow Sharing Control System CONTENTS Section

Description

Page

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description The flow sharing system joystick control positions the lift and tilt control valve spools hydraulically to direct oil to the specific circuit. The telescopic and auxiliary spools are positioned hydraulically by servo pressure controlled by solenoid operated valves. 1/2 3. 4.

5. 6.

Optional Auxiliary Control Buttons On -- Off Switches Boom Auxiliary Services Thumb Control 3--way switch; Extend -- Neutral -- Retract Telescopic Boom Thumb Control Proportional operation, the more the control is rotated the faster the telescopic boom movement. Boom & Fork Joystick Control Lever Operates servo control valve Control Button selects change over to additional boom Auxiliary Service

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

2 Flow Sharing Control System Wiring Diagram

Circuit Key 35. Joystick Cut Off 36 Boom Auxiliary Change Over 37. Joystick Transmission Disconnect 38. Auxiliary Extend & Retract 39. Telescopic Proportioning Connector Key G. Fuse/relay Board (11 pin Socket) X. Joystick--Main Harness Z. Proportioning Valve Module Wiring Colour Key bc. White bl. Blue j. Yellow j/vt. Yellow/Green n. Black ro. Pink

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Component Key A2. Joystick Controls F2. Fuse 5 A K17 Auxiliary Control Switch Relay K18 Auxiliary Control Switch Relay K20. Joystick Cut Off Relay R7. Joystick Control Potentiometer S24. Joystick Transmission Cut Off S30. Auxiliary Extend & Retract S33. Boom Auxiliary Change Over Y6. Telescopic Proportioning Module Y7. Auxiliary Retract Solenoid Y8. Auxiliary Extend Solenoid

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

The proportioning valve assembly is located on the telescopic section of the main control valve. Valve Components 1. 2. 3. 4. 5.

End Cover Module Piston Hosing Retaining Screw (2) Piston Housing Plug (Access to Adjusting Trimmer)

3 Valve Cross Sectional View 1. 2. 3. 4. 5. 6. 7. 8. 9.

Module & Solenoid Housing Extend Solenoid Valve Piston Housing Valve Positioning Piston Retract Solenoid Valve Assembly Feed Back Transducer Spring End Cover Electronic Module (Analogue Card)

The analogue card (9) modulates the signal sent to the solenoid valves (2 or 8) so that the position of the control valve and piston (7), measured by the linear transducer (6), is proportional to the rotation of the operator’s thumb control. Each solenoid valve is connected to opposing sides of the positioning piston (7). When either valve is activated, the amount of oil sent by to the respective side of the piston moves the control valve in proportion to the command signal. The positioning piston and control valve assembly is returned to the neutral position by the centring spring. The graph illustrates the relationship between the control signal voltage and the control valve movement.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

6 1. 2. 3. 4. 5.

Solenoid Retaining Nut Solenoid Valve Body retaining Nuts Valve Body

Solenoid Control Valves and Connections

An additional solenoid control valve is fitted above the boom auxiliary solenoid control valve if rear auxiliary option is fitted.

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Port Identification stamped on the valve 1. 2. 3. 4.

Return to Reservoir Boom Auxiliary Spool 40 bar pressure supply Boom Auxiliary Spool

Two solenoids are mounted on the valve core. When energised, the solenoid will move the valve in or out depending on which control is operated.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

The rear auxiliary solenoid control valve is mounted above the boom auxiliary solenoid valve located under the cab floor. The harness cables connectors to each solenoid are identified by colour bands as shown. K. Black R. Red U. Blue W. White

7 Flow Sharing Joystick Flow sharing joysticks with the optional rear auxiliary hydraulic control buttons have a 12--pin connector to accommodate the additional wiring.

8 Flow sharing joysticks with the optional Electro Change--Over Valve have an additional 2--pin connector in addition to either the 8--pin or 12--pin connector.

9 Two relays (3), operated by the boom auxiliary thumb control, are located on the control valve. The relays are part of an intermediate harness (4) between the main harness (1) and the joystick harness (2) on earlier machines, or part of the main harness on later machines.

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Fault Finding Check out a functional check of the control buttons. A. If none of the thumb or button controls operate their circuits, check out the power supply to the control module referring to the electrical wiring diagram on page 2. B. If one or more of the buttons operate their circuits, carry out button control electrical tests. C. If controls operate correctly check voltages at module connector or solenoid valves A.

Checking Joystick Controls

Pin Functions & Wire Colours -- 8--pin 1. 2. 3. 4. 5. 6. 7. 8.

Auxiliary Thumb Control Retract Signal (White) Auxiliary Thumb Control Extend Signal (Red) Auxiliary Thumb Control Supply + (Black) Transmission Cut Off & Rear Auxiliary Controls Supply + (Blue) Transmission Cut Off Button Signal + (Blue) Earth Return from Telescopic Control Potentiometer (Black) Telescopic Control Supply + (Red) Telescopic Control Feed Back Signal (White)

11 Pin Functions & Wire Colours -- 12--pin Auxiliary Thumb Control Retract Signal (White) Auxiliary Thumb Control Extend Signal (Red) Auxiliary Thumb Control Supply+ (Black) Transmission Cut Off & Rear Auxiliary Controls Supply+ (Blue) 5. Rear Auxiliary Retract Signal (Blue) 6. Rear Auxiliary Extend Signal (Blue) 7. Not Used 8. Not Used 9. Transmission Cut Off Button Signal + (Blue) 10. Earth Return from Telescopic Control Potentiometer (Black) 11. Telescopic Control Supply + (Red) 12. Telescopic Control Feed Back Signal (White) 1. 2. 3. 4.

An additional 2--pin connector is fitted to Joysticks with Electronic Change--Over Valve Control Button.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

B. Control Button Tests Make up test harness to connect the pins and sockets of the separated joystick harness connector. Test harness tool number 380001665 is available for the standard 8--pin joystick Connector. 1. 2. 3. 4.

Test Harness Lead Female Connector Joystick 8--pin Connector Test Harness Lead Male Connector Test Box

With the key switch in the run position, use a multimeter to check the control functions. Measure the voltage between earth and the following while operating the controls. Pin Number Control Position Volts 8 pin/12 pin 3/3 Auxiliary Neutral 12 2/2 Auxiliary Up 12 1/1 Auxiliary Down 12 7/11 Telescopic N/Up/Down 4.85 8/12 telescopic Neutral 2.40 Retract 0.58 Extend 4.35

Alternatively check continuity between pins: -3 --1 Auxiliary Control Up 3 -- 2 Auxiliary Control Down 4 -- 5 Transmission Disconnect Button In (8-- pin) 4 -- 9 4 -- 5 4 -- 6

Transmission Disconnect Button In (12--pin) Rear Auxiliary Retract Button In (12--pin) Rear Auxiliary Extend Button In (12--pin)

Switches 1. 2. 3.

Auxiliary & Transmission Disconnect Auxiliary Change Over Telescopic Potentiometer

If any of the controls malfunction then they must be replaced. The auxiliary control is a 3--way switch, however the telescopic control is a potentiometer.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

C. Module Control Voltages 1. Check voltages at module connector Pin 1: Module Supply Voltage 12v Pin 4: Joystick Supply Voltage 5v Pin 2: Earth Return Pin 3: Potentiometer Feed Back Voltage 2.4v N If the joystick supply voltage is not to specification, it must be replaced. If the joystick feed back voltages are incorrect, but the joystick checks were correct, then check the wiring between the joystick and the module. 15 Auxiliary Circuit Solenoid Valves Check the auxiliary solenoid operation with a screwdriver while an assistant operates the auxiliary controls Or if available install test adapter tool number 380001660 onto each solenoid and check control voltages. If the solenoid control voltages are incorrect, but the joystick checks were correct, then check the wiring between the joystick and the individual solenoid.

16 The rear auxiliary solenoid control valve is mounted above the boom auxiliary solenoid valve located under the cab floor. The harness cables connectors to each solenoid are identified by colour bands as shown. K. Black R. Red U. Blue W. White

17 The solenoids and their valve assemblies can be replaced with the assemblies in situ. Solenoid Valve Component Parts 1. 2. 3. 4. 5. 6.

Nut Solenoid Seal Solenoid Valve Block Valve Assembly

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

Proportioning Valve Module Replacement Valve Components 1. 2. 3. 4. 5.

End Cover Module Piston Hosing Retaining Screw (2) Piston Housing Plug

19 1. Remove the control valve access panel in the cab. 2. Disconnect the module wiring connector. 3. Remove the four retaining screws and carefully withdraw the module. The solenoid valves and feed back rod may drop out of the module as it is removed. 4. Install the new module and reconnect the wiring connector. 5. Check neutral LED, and adjust if required.

20 Proportioning Valve Module Adjustment A trimmer screw, accessible through an inspection hole in the cover, provides the adjustment. 1. Ensure the hydraulic oil temperature is at 50 -- 60o C. 2. Remove the plug from the module cover. 3. Start and run the engine at 1500 rev/min and extend the boom approximately 2 metres. 4. A small green LED, visible through the inspection hole, should be illuminated with the thumb control in neutral. 5. If the led is on the adjustment is correct. 6. If the LED is not illuminated, then adjust trimmer screw until the led remains on. 7. Replace the plug and valve access panel in the cab.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 8

NOTES

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

SECTION 55 -- ELECTRICAL SYSTEM Chapter 9 -- Smooth Ride Control CONTENTS Section

Description

Page

35 000

Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Component Layout Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPECIFICATIONS Solenoid Resistance (Y21 & Y22) Timer Delay (T1)

8.5 ohms 0.5 sec

ADJUSTMENTS Boom Position Switch

Adjust to de--energise suspension system when the fork pivot point is more than 3 metres above the ground.

Monoramp & Mechanical Joystick Control Switches

Adjust to de--energise system when joystick moved towards boom lowering or fork tilting position.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Description and Operation The Smooth Ride Control provides a boom cylinder suspension system to improve the Telehandler ride when travelling across fields or on the highway. The system operates from ground level to 3 metres above the ground, equivalent to boom elevation angle of 35° on LM 415/425A and 31° on LM 435/445A.

1 The Smooth Ride control valve is mounted on the lift cylinder and is operated by two solenoids (1 & 3) and a pressure switch (2). The control switch activates or de--activates the system. The 3--position switch is self centring. To activate the system:-1. Start the engine-2. Fully lower the boom*. 3. Depress switch at A. 4. Green LED (A) will illuminated to indicate the system is activated. * This relieves residual pressure on the pressure switch to allow the switch to close. To de--activate the system:-1. 1. Depress switch at B. 2. 2. Turn off the key switch The solenoids are temporarily de--energised when the joystick is used to:-1. Raise the boom more than 3m above the ground. 2. Extend or retract the tilt cylinder.* 3. Lower the boom.* * LED temporarily goes out

3 When the fork is raised more than 3 metres above the ground, the system solenoids are temporarily de--energised by the cam (1) allowing the boom position switch (2) to open.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Mechanical and Monoramp control hydraulic systems have joystick actuated cams and switches to de--energise the Smooth Ride control valve solenoids when the joystick is moved from neutral towards the lower or fork tilt or roll back positions . Switch 1 (S36/37) is actuated by cam (2) when the joystick is moved towards fork tilt back or roll out positions. Switch 3 (S35) is actuated by cam (5) when the joystick is moved towards the lower position. Both switches are normally closed with the joystick in neutral. 5 Flow Sharing hydraulic systems have three pressure switches fitted into the servo control hoses between the joystick control valve and loader control valve. When the joystick is moved towards lower, tilt back or roll out positions, the switch in the related pressurised servo line is opened to de--energise the Smooth Ride control valve solenoids.

6 The pressure switches (S35/36/37) are normally closed. Each switch (1) is installed into a tee adapter (2).

7 The three switches are connected in series with the boom position switch, therefore if any one of the switches is opened the circuit is broken and the system de--energised.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

1. 2. 3. 4. 5.

Smooth Ride Electrical Component & Wiring Layout -- Mechanical & Monoramp Control Diode Links (1a : D1/ 1b :D2) 6. Loader Control Valve Relays (2a : K11 / 2b : K12 7. Lower & Tilt Deactivation Switches S35 & S36/37 Fuse F4 : 10A 8. Smooth Ride Control Valve Assembly Timer T1 (0.5 Sec) 9. Boom Position Switch (S38) System Selection Switch

C1. Pressure Switch (S39) Connector C2. Solenoid (Y21) Connector

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C3. Solenoid (Y22) Connector Wiring Colour Codes -- page 6

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

9 1. 2. 3. 4. 5.

Smooth Ride Electrical Component & Wiring Layout -- Flow Sharing Control Diode Links (1a : D1/ 1b :D2) 6. Flow Sharing Joystick Relays (2a : K11 / 2b : K12 7. Lower & Tilt Deactivation Switches S35 & S36/37 Fuse F4 : 10A 8. Smooth Ride Control Valve Assembly Timer T1 (0.5 Sec) 9. Boom Position Switch (S38) System Selection Switch

C1. Pressure Switch (S39) Connector C2. Solenoid (Y21) Connector

C3. Solenoid (Y22) Connector Wiring Colour Codes -- page 6

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

10 Smooth Ride Control Wiring Diagram Symbol

Description

Location

S34

Smooth Ride Control Switch

S35

Lowering Switch (ME/MR)

Pressure Switch (FS)

Joystick (ME/MR) Servo Hose (FS)

S36

Fork Tilt Back Switch (ME/MR)

Pressure Switch (FS)

Joystick (ME/MR) Servo Hose (FS)

S37

Fork Roll Out Switch (ME/MR)

Pressure Switch (FS)

Joystick (ME/MR) Servo Hose (FS)

S38

Boom Position Switch -- normally open

Boom Support

S39

Pressure Switch -- normally closed (with no pressure)

Smooth Ride Control Valve

D1 & D2

Diode Link Wire

Adjacent to Relay/Fuse Box

K11

System Cut Off Relay

Attached to Relay/Fuse Box

K12

System Supply Relay

Attached to Relay/Fuse Box

Y21

System Solenoid Valve (EV--S1) Accumulator On/Off

Smooth Ride Control Valve

Y22

System Solenoid Valve (EV--S2) Reservoir Open/Shut

Smooth Ride Control Valve

Timer (0.5 sec): Timed initial solenoid energising

Adjacent to Relay/Fuse Box

Dash Board

* ME--MR Hydraulic System: S36 & S37 are combiined : Switches S35--S37 normally closed Wiring Colour Codes

bl: blue

j: yellow

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r: red o: orange ro: pink v: violet

vt: green j--vt: yellow--green

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

ELECTRICAL SYSTEM OPERATION Key Switch ’ON’ with Engine Running 1. When the key start switch is turned on and the boom is lowered, the circuit through the joystick switches S35/36/37 and boom position switch S39 to relay K11 (pin 1) is completed. 2. As relay K11 is energised, the relay contacts are closed. The circuit to solenoids Y21 & Y22 is completed through the closed contacts of K11 (pins 3--5), diode link D2 & timer T1. However the circuit is not energised, as relay K12 contacts are open. System Activation 1. To activate the system, the boom is fully lowered to close the pressure switch S39 and then the control switch is momentarily held in position 1. 2. The circuit to relay K12 (pin 1) is completed and the relay is energised by battery voltage from switch S34, pin 3. 3. As relay K12 is energised the contacts are closed (pin 3--5) to complete the circuits to: a. K12 relay (pin 1) to maintain the relay coil energised. (through diode D1) b. Solenoids Y21 & Y22 through K11 contacts (pin3--5) and diode D2 c. Switch S34 LED. 4. With the 3-- way switch S34 in the centre position ’O’, battery voltage is available to the circuits and the system is activated. System De--activation 5. The system can be de--activated by a. Turning key switch ’OFF’ b. Depressing switch 34 to position 2, to cut off battery voltage to relay K12, opening the contacts and breaking the circuit to solenoids Y21 & Y22.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9 In condition a or b, relay K11 is de--energised, opening the contacts (pin 3--5) to break the circuit to solenoids Y21 & Y22 and the switch LED. The system remains activated as relay K12 is energised by voltage from switch S34 pin 6 through diode D1. When the boom is lowered or the joystick is returned to neutral, the solenoids will be re--energised. The switch LED will be illuminated to indicate the system is reactivated. Fault Finding Reference Smooth Ride Control Wiring and key on page 6 Before attempting any fault diagnoses, check Fuse 4, and power supply to Switch 34, terminal 1.

Telehandler Operation The Smooth Ride solenoids are temporarily de--energised to cancel the boom suspension during operation when: -a. The boom is raised above 3 metres, opening switch 38. b. Operating joystick for tilt or lowering, opening switches S35, S36 or S37.

PROBLEM Smooth Ride system does not activate when correctly selected.

POSSIBLE CAUSES

REMEDIAL ACTION

Fuse 4 (10A) blown

Replace fuse.

K11 Power--up circuit open circuit

Check circuit continuity from fuse 4 through S35/36/37 & S38 to relay K11 pin 1. If circuit OK, relay K1 should close (pins 3--5) when the key switch is turned on.If circuit OK but relay inoperative, replace relay K11.

K11 Relay Power--up circuit and relay OK but Smooth Ride System does not activate when correctly selected.

K12 Power--up circuit open circuit

Hold switch S34 in position 1 to check circuit:-Check voltage at switch pin 3. If no voltage, replace switch S34. If voltage at pin 3 is OK, check voltage at relay K12 pin 1. If no voltage, check pressure switch (n/c) and continuity of circuit. If voltage at K12 pin 1, check continuity between pins 3 & 5. If no continuity, replace relay K12. If continuity OK, check and, if required, replace D1.

K11 & K12 relay circuits OK, system Solenoid Circuit & can be activated, but suspension Components system not operating.

Check Diode D2 and, if open or short circuit, replace. Check Solenoid (Y21/Y22) resistance = 8.5 ohms. Check wiring continuity from diode D2 connector to the respective solenoid connectors. If OK replace timer T1.

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Joystick Switches & Connectors Monoramp & Mechanical Controls Connections between the harness and switches located behind the loader control valve. 1. 2. 3.

Lower Switch S35 Tilt Switch S36/37 Switch Connectors

14 Joystick Switches & Connectors Flow Sharing Controls The switches are located under the cab in the servo control lines. 1. 2. 3.

Link wires (3) Harness Wires (2) Pressure switches (3) S35/36/37

15 Boom Position Switch Connectors Position switch connector (1) is located under the boom. Always have the safety support installed on the lift cylinder when working under the boom.

16 Smooth Ride Control Valve Connectors C1. Pressure Switch S 39 C2. Solenoid Y 21 C3. Solenoid Y 22

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

Adjustments Check operation of the boom position switch and the joystick switches. Activate the Smooth Ride control system by fully lowering the boom and depressing part A of the switch. The green LED (A) should illuminate to indicate the system is activated. Raise the boom until the green LED goes out, the forks should be 3 metres above the ground. Lower the boom until the LED illuminates. Move the joystick in turn towards tilt roll out and roll back and lower positions. In each case the green LED should go out to indicate the system is temporarily de--energised. If any of the switches do not operate correctly, adjust as required.

19 Boom Position Switch Adjustment The telescopic boom must be retracted and the safety support installed on the lift cylinder before working on the machine.

DANGER Do not work under an unsupported boom. If the New Holland cylinder support (Tool No 297451) is used, the boom will be at the right height to adjust the switch.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

With the boom raised to position the fork pivot pin 3 metres above the ground, the cam (1) should be in contact with the switch arm (2). The switch LED should not be illuminated. If the LED is illuminated, adjust the switch to extinguish the LED.

21 The switch (4) is adjusted by loosening the bracket retaining screws (5) and moving the bracket (1) to obtain the correct switch operating position. The switch can also be moved in relation to the cam by loosening the screws (2) and repositioning the switch.

22 Joystick Switch Adjustment Mechanical & Monoramp Controls Remove the hydraulic control lever console (1). Both switches should be closed with the joystick in neutral. Disconnect the switches from the harness connector and check continuity through the switches with a multimeter. Move the joystick towards tilt and then lower positions. The switches should open immediately. If required adjust switch (1) to correct tilt operation and switch (3) to correct lower operation.

Flow Sharing Controls The joystick switches are non--adjustable and in the event of failure, must be replaced.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 9

NOTES PAGE

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

SECTION 82 -- LOADER Chapter 1 -- Loader Boom CONTENTS Section

Description

Page

82 000

General Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Overhaul, Checks, dimensions and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Model

Engine

Lift Height

Lift Capacity

Transmission Type

Hydraulic Controls(1)

Counterweight

LM 415A

95 hp *T

2.9 tonne

Powershuttle

Mechanical

Standard

LM 415A

110 hp *Ti

2.9 tonne

Powershuttle

Mono Ramp

Standard

LM 425A

110 hp *Ti

3.3 tonne

Powershuttle

Flow Sharing

Standard

LM 435A

95 hp *T

3.1 tonne

Powershuttle

Mechanical

Heavy

LM 435A

110 hp *Ti

3.1 tonne

Powershuttle

Flow Sharing

Heavy

LM 435A

110 hp *Ti

3.1 tonne

Powershift

Flow Sharing

Heavy

LM 445A

95 hp *T

3.0 tonne

Powershuttle

Mechanical

Heavy

* T = Turbocharged, Ti = Turbocharged and Intercooled (1) Standard Equipment

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN FOOT POUNDS - LBF. FT (NEWTON-METRES -- Nm) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC HARDWARE AND LOCKNUTS CLASS 5.8

CLASS 8.8

CLASS 10.9

UNPLATED

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL 8 CL.8 W/CL8.8 BOLT

15* (1.7)

19* (2.2)

23* (2.6)

30* (3.4)

33* (3.7)

42* (4.8)

16* (1.8)

51* (5.8)

67* (7.6)

79* (8.9)

102* (12)

115* (13)

150* (17)

56* (6.3)

124* (14)

159* (18)

195* (22)

248* (28)

274* (31)

354* (40)

133* (15)

M10

21* (28)

27* (36)

32* (43)

41* (56)

45* (61)

58* (79)

22* (30)

M12

36* (49)

46* (63)

55* (75)

72* (97)

79* (107)

102* (138)

39* (53)

M16

89* (121)

117* (158)

137* (186)

177* (240)

196* (266)

254* (344)

97* (131)

M20

175* (237)

226* (307)

277* (375)

358* (485)

383* (519)

495* (671)

195* (265)

M24

303* (411)

392* (531)

478* (648)

619* (839)

662* (897)

855* (1160)

338* (458)

NOMINAL SIZE

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

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CLOCK MARKING

SECTION 82 -- LOADER BOOM -- CHAPTER 1

TORQUES GENERAL Wear pad tightening torques: 92.6 Nm (68 lb ft) ± 25%.

TELESCOPIC LOADER CONTROLS

Wear Pad Insertion Tool

WARNING Study the safety precautions before operating the loader controls. Ensure you are thoroughly familiar with the loader operating techniques before attempting to operate the machine. Mechanical Controls 1. 2. 3. 4. 5.

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

Mono Ramp System Controls 1/2 3/4

Boom Telescopic Control Buttons Auxiliary Services Control Buttons

Boom & Fork Control Lever In line movement controls boom lift & lower. Cross ways movement controls fork tilt. Control Button selects change over to additional Auxiliary Service Optional Rear Auxiliary Control

6. 7.

3 Flow Sharing System Controls 1/2 3

Optional Auxiliary Control Buttons Boom Auxiliary Services Thumb Control

Telescopic Boom Thumb Control Proportional operation, the more the control is rotated the faster the telescopic boom movement. Boom & Fork Control Lever In line movement controls boom lift & lower. Cross ways movement controls fork tilt. Control Button selects change over to additional Boom Auxiliary Service

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

OVERHAUL OF THE LOADER BOOM

SHJ82037

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

6 2 Section Loader Boom

7 3 Section Loader Boom

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

8 Hydraulic Cylinders 1. 2.

Telescopic Cylinder with Double Counterbalance Valve (9 metre telescopic boom section only) Telescopic Cylinder

3. 4. 5.

Tilt Cylinder with Counterbalance Valve Lift Cylinder with Counterbalance Valve Compensation Cylinder

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

LOADER BOOM WEAR PADS Wear pads are fitted to the front and the rear of the telescopic boom to enable smooth leader telescoping operations. After a total disassembly of the boom the wear pads if having been removed must be refitted in the following order: 5B, 4A, 5A, 3B, 4B, 1B, 2B, 2A, 3A, 6A and 7A.

9 REMOVING THE WEAR PADS AT THE BASE OF THE LOADER BOOM To gain access to the end of the boom remove the: --

Engine Hood

Engine air cleaner assembly and boom back plate assembly (1) Engine Exhaust Assembly (if required) (2)

10 IMPORTANT: Ensure all shims and spacer are identified for re-assembly if being removed and refitted. Using a 6 mm hexagonal socket wrench and 19 mm single end wrench, remove the wear pad fastening screws and remove the Upper wear pads.

11 Remove the - Side wear pads

IMPORTANT: The telescopic boom must be removed in order to change the telescopic wear pad.

12 604.55.181.00 09-- 2003

SECTION 82 -- LOADER BOOM -- CHAPTER 1

INSTALLING THE WEAR PADS When fitting new wear pads at the rear of the telescope apply thread lock to the nut (1), stud (2) and insert (3).

13 Completely tighten the HC (headless) screw into the insert until a resistance is felt. NOTE: The insert has a tapered thread preventing the screw going through the insert and onto the boom surface. At minimum there should be a 0.5 mm (0.01968 in) gap between the insert and boom face and 3 mm (0.118 in) of thread above the nut.

14 Using the prefabricated tool install the side wear pads.

15 Clamp the side wear pads in position, there should be 0.8 to 1 mm (0.031 -- 0.039 in) of play and tighten the nuts to 92.6 Nm ± 25% (68 lbf.ft).

16 604.55.181.00 09-- 2003

SECTION 82 -- LOADER BOOM -- CHAPTER 1

REPLACING TILT CYLINDER AND AUXILIARY HOSES The hoses supplying the tilt cylinder and auxiliary couplers are routed through the telescopic boom in channels. The following procedure is recommended when replacing these hoses. The 2 section boom has double hoses, the 3 section has separate hoses. 1. Position the boom (1) level and extend by approximately 100 mm. 2. Remove the engine bonnet, disconnecting the telescopic bonnet stays and the rear lighting loom connector adjacent to the starter motor.

17 3. Remove the bolts securing the coolant expansion tank (1), and place the tank on top of the engine. 4. Disconnect the air cleaner hoses and warning light sender wires. Remove the boom rear access panel and air cleaner.

18 5. Fully extend the tilt cylinder and lower the boom onto a support to prevent the tilt cylinder retracting when the hoses are disconnected. 6. Switch off the engine and relieve any residual pressure by operating the mechanical controls and with the ignition ’ON’, operate any control buttons.

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

20 1. 2. 3. 4.

Tilt Cylinder and Auxiliary Boom Hose Connections -- 2 Section Boom Auxiliary Hose Connections 5. Connections to Control Valve Hoses Tilt Cylinder Hose Connections 6. Auxiliary Double Hose Tilt Cylinder Hose to Tube Connections 7. Auxiliary Hose to Tube Connections Tilt Cylinder Double Hose Assembly 8. Tilt Cylinder

2 Section Boom 7. Disconnect hoses from the tilt cylinder (1) and auxiliary ports (2). 8. Remove the connecting elbows from the hoses.

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

9. Attach a strong cord around the hose ends of both pairs of hoses ensuring the hose ends are tightly bound together. The cord must be long enough to reach from the cylinder connections to the hose tube connections around the back of the boom, that is slightly longer than the hoses to be replaced. 10. Remove the hose clamp (1) inside the boom. 11. Remove the tube clamp (2) from the underside of the boom.

22 Two people are required to remove and replace the hoses in the boom. 12. One person should pull the hoses through the rear of the boom and feed them forward through the boom, while the other pulls the hoses out of the front of the boom.

23 13. Disconnect the cord and discard the hoses.

24 14. Installation of the new hoses follows removal procedures in reverse. The new hose is attached to the cord and should be fed through the hole in the bottom of the boom to rear, then forward again to the front, again 2 people are required. The hoses must be routed through the channels (1) in the telescopic boom.

25 604.55.181.00 09-- 2003

SECTION 82 -- LOADER BOOM -- CHAPTER 1

15. To ensure the auxiliary hoses are correctly installed and prevent them being trapped in the boom head past the tilt cylinder, the cord should be fed through the hole in the boom head as illustrated. 16. Reconnect the tilt cylinder and auxiliary hoses at both ends. 17. Fully retract the boom and then cycle several times and check the hose connections for any leaks.

26 3-- Section Boom Tilt cylinder and auxiliary boom hose replacement follows the same procedure as for the 2--section boom, however the following items are different. 1. The hoses are not joined in pairs and must be removed and replaced individually. 2. There are two hoses clamps under the boom front and rear, which must be removed. 3. When installing the new hoses ensure they are not crossed or twisted in the boom. It may be necessary to loosen the hose connections and turn the hose to rectify any problem. 4. Fully retract the telescopic boom and then cycle several times. 5. Check the hoses in the boom, and then refit the front and rear hose clamps below the boom.

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

TILT CYLINDER REMOVAL Support the attachment plate. IMPORTANT: Ensure all pressure in the hydraulic system is relieved by using the distributor lever.

28 Mark and disconnect the tilt cylinders double hose (30 and 24 mm wrench). Collect the excess oil in a suitable container.

29 Remove the circlips and expel the cylinder head pivot.

30 Using a suitable lifting system sling the cylinder with a strap or a rope going through the boom head greasing aperture.

SHJ82020

31 604.55.181.00 09-- 2003

SECTION 82 -- LOADER BOOM -- CHAPTER 1

Securely attach the sling around the cylinder before removing the top pivot pin.

32 Remove the circlips from the upper pivot, expel the pivot and remove the cylinder (9 metre version shown). For the (6 metre version) undo th epin retaining bolt and remove pin. Re--assemble in reverse order.

SHJ2021A

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

REMOVING THE TELESCOPIC BOOM CYLINDER The boom should be slightly inclined and extend the telescopic boom 20 cm (8.0 in). IMPORTANT: Ensure all pressure in the hydraulic system is relieved by using the distributor lever. Remove the two hose clamps (1), (13 mm wrench) and disconnect the following: 2, Tilt cylinder (30 and 36, 24 and 30 mm). 3, Accessories circuit (24 and 30 mm). 4, Telescope cylinder (36 and 46 mm). Using caps, block the hose tubes and cylinder valve apertures.

Remove the 2 hose clamps under the boom for the tilt tubes and accessories.

SHJ2023A

35 Remove the circlips for the telescope cylinder’s head pivot and expel the pivot.

36 Remove the circlips for the telescope cylinder base pivot, and expel the pivot.

37 604.55.181.00 09-- 2003

SECTION 82 -- LOADER BOOM -- CHAPTER 1

Place a plank (about 4 cm thick) on the radiator and using a suitable lifting system (forklift truck), remove the cylinder by pulling it from the rear of the boom. Re--assemble in reverse order.

38 Verify the position of the telescope cylinder head in order to replace the pivot at the head of the telescope.

39 REMOVING THE TELESCOPIC BOOM Carry out the operation for the removal of the double hoses for the tilt and accessory cylinder, as well as removing the telescopic boom cylinder. 1, Upper wear pads 2, Side wear pads 3, Boom head wear pads

40 With all items deteched support the attachment plate with a suitable lifting device and support boom with a hoist. Slowly withdraw the boom from the machine. NOTE: The telescopic Boom weighs approximately 650 kgs. Re--assemble in reverse order.

41 604.55.181.00 09-- 2003

SECTION 82 -- LOADER BOOM -- CHAPTER 1

REMOVING THE LOADER BOOM ASSEMBLY Place the jib in the horizontal position, sufficient high enough to allow the lift cylinder pin (cab side) to be removed. Retract the telescope. IMPORTANT: Ensure all pressure in the hydraulic system is relived by using the distributor lever. Remove the two pipe clamps 1, (13 mm wrench). Disconnect the following hoses: 2, Tilt cylinder (30 and 36, 24 and 30 mm wrench).

3, Accessories circuit (24 and 30 mm wrench). 4, Telescopic boom cylinder (36 and 46 mm wrench). Using caps, block the hose tubes and cylinder valve apertures and the hoses to one side. Using a suitable support system sling the boom jib using the anchor points (this is the equilibrium point of the whole jib). IMPORTANT: The loader boom weights are: 6 metre = 1150 kgs. 9 metre = 2000 kgs.

43 Unscrew the compensating cylinder’s head pivot.

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

Block the lift cylinder securely before attempting to remove pivot pins.

45 Remove the circlips for the lift cylinder’s pivot and remove.

SHJ82034A

46 Unscrew the boom pivot and expel the pivot.

47 Remove the boom, taking care not to damage the cabin.

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SECTION 82 -- LOADER BOOM -- CHAPTER 1

NOTES

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SECTION 90 -- CAB -- CHAPTER 1

SECTION 90 -- CAB Chapter 1 -- Overhaul CONTENTS Section

Description

Page

90 100

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Hand & Foot Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overhaul -- Cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Overhaul -- Cab Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Overhaul -- Cab Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 .

TORQUES Torque figures for individual components are listed at the beginning of each section of the Repair Manual and can also be found in Section 39 Chapter 1. Front cab retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Nm (158 lbf ft) Rear cab retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Nm (133 lbf ft) Below are general torque figures for hydraulic hoses, tubes and ORS Connections that you may find on your machine. Thread Size:

9/ 16 in -- 18 . . . . . . . . . . . . . . . 11/ in -- 16 . . . . . . . . . . . . . . . 16 13/ in -- 16 . . . . . . . . . . . . . . . 16

1 in -- 14 . . . . . . . . . . . . . . . 13/16 in -- 12 . . . . . . . . . . . . . . . 17/16 in -- 12 . . . . . . . . . . . . . . . 111/16 in -- 12 . . . . . . . . . . . . . . . 2 in -- 12 . . . . . . . . . . . . . . .

13.5 -- 16.5 Nm . . . . . . . . . . . . . (10 -- 12 lbf ft) 23 -- 28 Nm . . . . . . . . . . . . . . . . . (17 -- 20 lbf ft) 45 -- 53 Nm . . . . . . . . . . . . . . . . . (32 -- 39 lbf ft) 62 -- 77 Nm . . . . . . . . . . . . . . . . . (46 -- 57 lbf ft) 86 -- 107 Nm . . . . . . . . . . . . . . . . (63 -- 79 lbf ft) 125 -- 142 Nm . . . . . . . . . . . . . . . (93 -- 105 lbf ft) 169 -- 190 Nm . . . . . . . . . . . . . . . (125 -- 140 lbf ft) 203 -- 246 Nm . . . . . . . . . . . . . . . (150 -- 182 lbf ft)

SPECIAL TOOLS

Special Tools are listed in the Repair Manual introduction and at the beginning of each section of the Repair Manual for your guidance.

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SECTION 90 -- CAB -- CHAPTER 1 HAND AND FOOT OPERATING CONTROLS

Shown in Figure 1, is the cabin layout of a typical machine with a Powershuttle Transmission and Mechanical Controls for the Telescopic Arm. NOTE: The layout of controls in the diagram may vary between machines dependant upon options fitted and to meet Legislation in different Countries. 1. Steering Control: IMPORTANT: Prior to driving the vehicle always turn the steering wheel side to side at engine start up, to circulate the hydraulic oil. 2. Wheel Alignment Indicator Switch 3. Instrument Console and Switches 4. Direction Indicator and Road Lights 5. Vehicle Hazard Lighting Switches 6. Load Handling Monitor Indicator 7. Optional Automatic Load Handling Hydraulic Lock

8. Switch Panel for miscellaneous services

19. Overcentre Parkbrake

9. Storage Bin (optional Radio Placement)

20. Windscreen Washer Reservoir

10. Auxiliary Hydraulic Movement (Bucket Clam etc.)

21. Foot Brake Pedal / Transmission Cut Off Pedal

Available also with an optional 5th hydraulic service switch

22. Key Start

11. Telescopic Extend / Retract Lever

23. Smooth Ride Control System Switch (when fitted).

12. Auxiliary Hydraulic Equipment Lever (Pickup Hitch / Trailer Tipping)

24. Transmission Direction Lever (Power Shuttle)

604.55.181.01 09-- 2004

Plus two optional switch locations

SECTION 90 -- CAB -- CHAPTER 1

Operating Controls -- Mechanical

604.55.181.01 09-- 2004

SECTION 90 -- CAB -- CHAPTER 1 HAND AND FOOT OPERATING CONTROLS

Shown in Figure 2, is the cabin layout of a typical machine with a Powershuttle Transmission and Mono Ramp Controls for the Telescopic Arm. NOTE: The layout of controls in the diagram may vary between machines dependant upon options fitted and to meet Legislation in different Countries. 1. Steering Control: IMPORTANT: Prior to driving the vehicle always turn the steering wheel side to side at engine start up, to circulate the hydraulic oil. 2. Wheel Alignment Indicator Switch 3. Instrument Console and Switches 4. Direction Indicator and Road Lights 5. Vehicle Hazard Lighting Switches

6. Load Handling Monitor Indicator

17. Overcentre Parkbrake

7. Optional Automatic Load Handling Hydraulic Lock

18. Windscreen Washer Reservoir

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SECTION 90 -- CAB -- CHAPTER 1

Operating Controls -- Mono Ramp

604.55.181.01 09-- 2004

SECTION 90 -- CAB -- CHAPTER 1 HAND AND FOOT OPERATING CONTROLS

Shown in Figure 3, is the cabin layout of a typical machine with a Powershift Transmission and Flow Sharing Controls for the Telescopic Arm. NOTE: The layout of controls in the diagram may vary between machines dependant upon options fitted to meet Legislation in different Countries. 1. Steering Control: IMPORTANT: Prior to driving the vehicle always turn the steering wheel side to side at engine start up. 2. Wheel Indicator Alignment Switch 3. Instrument Console and gauges 4. Direction Indicator and Road Lights

IMPORTANT: At engine start up always fully retract all loader boom sections until the relief valve is actioned and hold for 10 seconds. This ensures all boom sections and hoses become fully synchronised, if not synchronised hose failure may result . 12. Heater Control Knob 13. Loader Lever Isolator LEVER (when fitted) is used when the vehicle is driven on public roads to stop accidental movement of the loader. 14. Foot Throttle 15. Safety Lockout for the Axle Steering Control Lever (Fitted Subject to Local Legislation)

5. Vehicle Hazard Lighting Switches

16. Axle Steering Control Lever Two Wheel Steer, Four Wheel Steer and Crab Steer:,

6. Load Handling Monitor Indicator

Select fully all steering modes at least once a day to ensure correct operation.

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SECTION 90 -- CAB -- CHAPTER 1

Operating Controls -- Flow Sharing

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SECTION 90 -- CAB -- CHAPTER 1

DESCRIPTION AND OPERATION NOTE: Description of the disassembly procedure is ‘‘general’’ for most models. Disassembly therefore may vary slightly dependent upon model and options fitted.

Safety Cabs are of a steel monocoque construction, with an integral roll over protective structure.

4 The side and rear windows of the cab can be opened and locked in position to suit operator requirements.

Roll Over Protective Structure (ROPS) is the same as for cab but with weather protection.

The cab and ROPS are isolated from the tractor by rubber bushes, mounted towards the front and rear of the structure. The bushes are designed to absorb vibration and noise and improve the ride characteristics and operator comfort. Various access panels are provided in the floor to access below the floor pan and steering console to allow servicing of the brake reservoirs. An anti slip steps and hand grips are provided for ease of cab or platform entry and exit.

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SECTION 90 -- CAB -- CHAPTER 1

* *

6 Major Components attached above the chassis

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SECTION 90 -- CAB -- CHAPTER 1

CAB DISASSEMBLY

WARNING It will be necessary to raise the boom sufficiently to gain access to the brake valve connections. Ensure that the boom is supported. Choch all wheels to prevent movement. Disconnect the battery SMJ160

7 Remove the cab side panel to access the brake hoses and remove the brake hose connections (1).

INSIDE THE CAB Remove or detach the Following: ------

Gear Shift Lever boot (1) -- Power Shuttle Loader lever grip and boot as required (non servo) Rear auxiliary lever Valve chest cover plate (2) Detach foot throttle cable under valve block (3)

9 IMPORTANT: To minimise leakage, plug all open pipes and ports to prevent leaks and dirt ingress. Remove the Lower steering console cover --

Detach Power steering hoses

10 604.55.181.00 09-- 2003

SECTION 90 -- CAB -- CHAPTER 1

UNDERSIDE OF THE CAB IMPORTANT: To minimise leakage, plug all open pipes and ports to prevent leaks and dirt ingress. Remove or detach the Following: ----

Park brake cable and electrical connections (1) Steering control valve hose and electrical harness connections (2) Washer bottle harness connections (3) 11

Detach the Loader control hoses (servo type) and solenoid connections (1)

CAB HEATER HOSES It will be necessary too drain the cooling system down before cab removal. Disconnect the heater hoses from the engine weater pump outlet (1) and cylinder head (2).

AIR CONDITIONING (Where Fitted)

WARNING Prior to removing the cab the refrigerant in the Air Conditioning System (if fitted) must be evacuated into an Air Conditioning reclaim/recharge unit, refer to Section 50 Chapter 2. Do not attempt to disassemble the air conditioning system. It is possible to be severely frostbitten or injured by escaping refrigerant. Do not allow refrigerant to escape into the atmosphere.

14 604.55.181.00 09-- 2003

SECTION 90 -- CAB -- CHAPTER 1

ELECTRICAL/HARNESS CONNECTIONS

9010001

15 The vehicle harness from instruments to components is mainly a one piece harness with sub harnesses attached. Prior to cab removal it will be necessary to disconnect the chassis harness at all points shown in the sketch above and during cab lifting ease the harness through the left hand side aperture.

16 The initial harness connectors can be found under the engine hood to the left of the engine.

9010002

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SECTION 90 -- CAB -- CHAPTER 1

LIFTING THE CAB The cab can be lifted by using the attaching points in the roof using eye bolts and a spreader bar capable of lifting upto 600 kgs.

IMPORTANT: The spreader bar must be used to ensure even weight distribution on the cab, if this procedure is not adhered to injury to personnel or damage to the cab may occur. 9011001

18 Slowly raise the hoist sufficiently to take out any slack in the lifting chains and stop the hoist.

Rear Mounting -- With the nuts removed, the cab through bolts can remain in position as the cab is lifted.

Front Mounting Bolts -- With the nuts removed, the cab through bolts can remain in position as the cab is lifted.

NOTE: When lifting the cab ensure the hydraulic brake hoses are not caught and damaged.

Slowly raise the cab from the chassis ensuring that all cables, rods and hoses etc, are free moving.

With the cab safety clear of the chassis the vehicle can be repaired as required.

Re--assembly Of Cab To Chassis.

After completion of repairs re--assemble in reverse order or disassembly, ensuring all torque values are to specification, refer to relevant repair manual chapters.

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SECTION 90 -- CAB -- CHAPTER 1

OVERHAUL -- CAB INTERNAL PARTS SEATS Seats -- Retained to the cab floor with through bolts. 1. Seat Assembly Type 1 -- As depicted many parts are serviceable and assembled with standard hardware. Serviceable parts include rails, sliders, supports and levers. IMPORTANT: Be very careful when dissembling sprung seats (when fitted), releasing hardware without releasing spring pressure could result in sudden movement of the mechanism injuring yourself or others. Parts in General 1. Seat Type 1 2. Seat Frame 3. Aduster Arm 4. Fixture Plate 5. Gaitor 6. Tensioner 7. Piston 8. Height Frame 9. Seat Type 2 10. Adjusting Arm 11. Aduster Knob Seat Assembly Type 2 -- As shown many parts are serviceable and assembled with standard hardware. Serviceable parts include rails, sliders, supports, levers and gaitor. IMPORTANT: Be very careful when disassembling sprung seats, releasing hardware without releasing spring pressure could result in sudden movement of the mechanism injuring yourself or others.

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SECTION 90 -- CAB -- CHAPTER 1

STEERING COLUMN The steering column is bolted to the cab frame and connected by hoses and tubes to the various system components. It can be assessed by removal of the steering covers: 1. Front Upper 2. Rear Upper 3. Lower

20 Steering Column Removed: 1. 2. 3. 4. 5. 6. 7. 8.

Upper

Components

Steering Wheel Steering Wheel Cap Steering Wheel Nut Column Clamp Front Column Clamp Plate Attaching Nuts Column Clamp Rear Attaching Bolts 21

Steering Column Removed:

Lower

Components

1. Steering Column 2. Steering Motor Hoses 3. Steering Motor Attaching Bolts With all attachments and hoses removed the column can be removed from the cab.

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SECTION 90 -- CAB -- CHAPTER 1

INSTRUMENT PANEL

Housed within the Instrument Panel are the gauges and switches all of which are easily removed for repair. To gain access to the rear of the console remove the upper console cover above the steering wheel.

INNER ROOF PANEL The inner roof panel is a moulded one piece unit that is easily removed by removal of the attaching hardware.

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SECTION 90 -- CAB -- CHAPTER 1

WINDSCREEN WIPERS The front windscreen wiper motor is accessible from the front instrument console. To remove the unit the following will have to disassembled. 1. 2. 3. 4.

Wiper Arms (1) Upper Instrument Console Electrical Connections Motor (2) Attaching Hardware 25

The rear windscreen wiper motor is accessible from the inside of the cab. To remove the unit the following will have to disassembled. 1. Wiper Arm 2. Electrical Connections 3. Motor Attaching Hardware

26 The roof windscreen wiper motor (when fitted) is accessible from the inside of the cab roof panel (1). To remove the unit the following will have to disassembled. 1. Wiper Arm 2. Electrical Connections 3. Motor Attaching Hardware

OPJ90013A

ROOF PANEL The outer roof panel is a moulded one piece unit that is easily removed by removal of the attaching hardware.

28 604.55.181.00 09-- 2003

SECTION 90 -- CAB -- CHAPTER 1

CAB (BONDED) GLASS REPLACEMENT

The following instructions detail the procedure for the replacement of any direct glazed (bonded) glass.

The bonding kit, Figure 34, available from most reputable auto glazing companies can be used to perform repairs.

REMOVAL -- GLASS INTACT

WARNING Always wear gloves and eye protectors to avoid injury from small fragments of glass. 9016001

29 1. Remove exterior trim mouldings -- as required. 2. Remove interior trim mouldings -- as required. 3. Where possible remove glass support blocks as they can restrict the action of the cutting wire. Insert the cutting wire into the inner end of the tool and secure. 4. From inside the cab use a pair of pliers to push the wire (1) through the adhesive (2) between glass and frame, Figure 30.

TA6090018

30 5. Secure cutting wire (1) in external handle (2), see Figure 31.

TA6090019

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SECTION 90 -- CAB -- CHAPTER 1

6. Anchor end of tool in adhesive and pull handle, see Figure 32 (A), guiding wire close to glass edge. Pull end of tool (1) from the adhesive bead (2) and reposition further along the bead, Figure 32 (B). Use long cutting strokes on straight edges to reduce risk of wire breakage and short cutting strokes at corners to avoid breaking glass (two man operation).

7. Using suction cups, lift out glass. Place outer surface of glass face down on a protected surface.

TA6090020

32 8. Taking care not to damage the frame, cut away adhesive (1) to leave a smooth bevel of approximately 2.0 mm, see Figure 33.

NOTE: It is not necessary to remove all residual material from the frame.

9. Repeat Number 8, above, for glass clean up procedure.

REMOVAL -- GLASS BROKEN

1. Remove exterior trim mouldings -- as required.

2. Remove interior trim mouldings -- as required.

3. Where possible remove glass support blocks as they can restrict the action of the cutting knife.

4. Taking care not to damage frame cut away adhesive to leave a smooth bevel of approximately 2.0 mm, see Figure 33.

TA6090021

33 NOTE: It is not necessary to remove all residual material from the frame.

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SECTION 90 -- CAB -- CHAPTER 1

REPLACEMENT -- NEW GLASS Kit Contents (Figure 34) 1. 2. 3. 4. 5. 6. 7. 8.

Applicator Nozzle Adhesive Tissue Felt Pad Applicator Activator Primer Applicator Bottle TA6090022

34 1. Apply the activator to the edge of the glass (adhesive contact area) with the clean tissue provided. Allow to dry.

2. Shake the bottle of glass primer for 60 seconds. Pour into applicator bottle.

3. Trim the applicator to dimension ’C’ in Figure 35, and insert the felt pad.

TA6090023

4. Screw the applicator to the applicator bottle.

5. Apply the primer (2) to the previously prepared area of glass (1), Figure 36.

6. Allow 15 mins to dry.

TA6090024

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SECTION 90 -- CAB -- CHAPTER 1 7. Using a sharp knife, cut off the end of the adhesive applicator (1) and cut a ’V’ (2) in the end of the nozzle, as shown in Figure 37. All dimensions shown in millimetres.

8. Apply a smooth continuous bead of adhesive to the glass (or Frame).

7.0

NOTE: It is difficult to fill in spaces to the correct profile. Ensure that joints are formed correctly to avoid water leaks.

3.0

TA6090025

37 9. Fit glass support blocks in position. 10. Lift glass into position with suction cups. 11. Fit lower glass support blocks. 12. Press glass into frame to ensure good contact of adhesive bead. 13. Replace exterior trim mouldings -- as required. 14. Replace interior trim mouldings -- as required.

REPLACEMENT -- EXISTING GLASS 1. Using a sharp knife, cut off the end of the adhesive applicator (1) and cut a ’V’ (2) in the end of the nozzle, as shown in Figure 37. All dimensions shown in millimetres. 2. Apply a smooth, continuous bead of adhesive to glass (or frame). NOTE: It is difficult to fill in spaces to the correct profile. Ensure that joints are formed correctly to avoid water leaks. 3. Fit glass support blocks in position. 4. Lift glass into position with suction cups. 5. Fit lower glass support blocks. 6. Press glass into frame to ensure good contact of adhesive bead. 7. Replace exterior trim mouldings -- as required. 8. Replace interior trim mouldings -- as required.

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SECTION 90 -- CAB -- CHAPTER 1

NOTES

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