New Holland Telehandlers LM1340, LM1440, LM1740 Service Manual 6036701002 - PDF DOWNLOAD by www.heydownloads.com

LM1340 LM1440 LM1740 TELEHANDLERS Service Manual Print N. 603.67.010.02 (I -- 2004)

THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY. Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to safeguard your health and your safety. You will find this symbol in the text of this Manual referred to the following key words: WARNING -- Cautions directed to avoid improper repair interventions involving potential consequences for the operatorâ&#x20AC;&#x2122;s safety. DANGER -- These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved. IMPORTANT NOTICE All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service Organization of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the recommended specific tools. Whoever performs the operations reported without following exactly the precautions is responsible on his own, for the damages that may result. Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national, regional or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or merchandized by the Factory. In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or merchandized by the Factory, when failures are caused by the use of parts and/or components not approved by the Factory.

AVOID ACCIDENTS Most accidents and injuries occurring in industry, on the farm, at home or on the road, are caused by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason, MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and taking the necessary precautions, before the accident occurs. Regardless of the care used in design and construction of any type of equipment, there may be conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation. A careful operator is the best insurance against accidents. The complete observance of one simple rule would prevent many thousands serious injuries each year. This rule is: Never attempt to clean, lubricate or adjust a machine while it is in motion.

WARNING On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment.

MODEL CODES The complete range of telescopic handlers (Telehandler) described in this manual is identified in the text by reference to the maximum extension of the telescopic arm. The vehicles listed below may not be available in all countries or markets, therefore for the latest information consult your authorised dealer. Model

LM1340 not stab.

small stab.

large stab.

not stab.

88 kW (120 Cv) Turbo Aftercooler

Engine Max. lifting height (m)

LM1440

LM1740

small stab.

large stab.

88 kW (120 Cv) Turbo Aftercooler

not stab.

stab.

88 kW (120 Cv) Turbo Aftercooler

12.300

12.450

13.300

13.550

16.240

16.600

Max. capacity (kg) at 500 mm from fork stop

4000

Capacity at max. height (kg)

2600

3600

4000

2800

3000

3600

700

2500

Extension at max. height (m)

1.200

0.500

0.000

1.000

0.500

0.300

2.000

1.000

Max. longitudinal extension ( m) Capacity at max. extension (kg)

8.650 700

1700

9.330 1800

650

1400

12.540 1500

450

Weight (kg)

11050

11970

12340

Length (m)

5.850

6.070

6.135

Service manual LM1340 -- LM1440 -- LM1740 TELESCOPIC HANDLERS GENERAL LIST OF CONTENTS SECTION 00 -- GENERAL Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 10 -- ENGINE Description

Page

Coding of engines of origin

.................................................................... 3

Main engine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General engine specifications Generalities

.................................................................. 5

................................................................................. 7

Description of main mechanical components of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fuel and mechanical injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Injectionassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Removal of the engine transmission group from the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Engine overhaul on bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Replacing the injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Adjustment of valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Setting of timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Timing of the injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Data -- Mounting plays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 603.67.010.02 - 01 - 2004

GENERAL LIST OF CONTENTS

SECTION 21 -- POWERSHIFT GEARBOX Description

Page

Powershift Gearbox 4x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Driving with the powershift gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Idler gear case assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Gearbox operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Transmission and Hydraulic oil circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Modulation valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Torque converter and heat exchanger hydraulic oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Troubleshooting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Pressure testing clutch and high pressure circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Pressure testing torque converter and cooler circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Check points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

SECTION 25 -- FRONT AXLE Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front axle removal procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Front axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Axle drive pinion bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 How to install and adjust the axle drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Front drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

603.67.010.02 - 01 - 2004

GENERAL LIST OF CONTENTS

SECTION 27 -- REAR AXLE Description

Page

SECTION 33 -- BRAKES Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Power brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake disc adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Brakes disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 35 -- HYDRAULIC SYSTEM Description

Page

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering system hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Telescopic boom hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Component operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front loader controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power steering (OSPQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Telescopic boom distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Auxiliary control distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Working platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Procedure for the calibration of the personnel carrier platform electronic controller . . . . . . . . . . . . . . . . . . . . . 47 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

603.67.010.02 - 01 - 2004

GENERAL LIST OF CONTENTS

SECTION 55 -- ELECTRICAL SYSTEM Description

Page

Chapter 1 â&#x20AC;&#x201C; Electrical system general Electrical equipment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Electrical system and fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Use of the tip--over prevention system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Protecting the electrical systems during charging or welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Starting the machine using jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Temporary wiring repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical system--general fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Working platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Chapter 2 â&#x20AC;&#x201C; Circuit diagrams List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 How to use the circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Diagram 1: Starter/Recharge/Warning/Indicators lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Diagram 2: Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Diagram 3: Wheel alignment/Hydraulic solenoids/Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Diagram 4: Arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Diagram 5: Stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Diagram 6: Lights/Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Diagram 7: Work lamps/Roof beacon light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Diagram 8: Tilting prevention system/Roof wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Diagram 9: Heating/Sound system/Electric socket/Interior lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Diagram 10: Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Chapter 3 -- Wiring list Instrument panel wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Cab wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Front wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Rear wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair interventions listed in this Manual must be performed exclusively by the Service Network of the Manufacturer, complying strictly with the indications herein and using, when required, the prescribed special tools. Whoever performs service operations described herein without complying strictly with the instructions becomes solely responsible for any consequential damage that could occur. ADJUSTING SHIMS For each adjustment select the adjusting shims, measuring them one by one with a micrometer and adding to gether subsequently, the values measured. Do not rely on the measurement of the entire pack, that could be wrong, or the nominal value indicated on each ring. SEALS FOR ROTATING SHAFTS For correct installation of the seals for rotating shafts, please comply with the following precautions: ----

-----

prior to installation, keep the seals soaking for at least half an hour in the same oil they are going to seal; clean thoroughly the shaft and make sure that its working face is undamaged; direct the sealing lip toward the fluid; in the event the lip is of the hydro dynamic type, the grooves must be directed so that, in relation to the rotating direction of the shaft, they tend to return the fluid toward the inside of the sealing device; smear the sealing lip with a film of lubricant (oil to be preferred to grease) and fill with grease the gap between sealing lip and dust lip in twin lip seals; insert the seal in its seat, pressing it with a punch with a flat face; never strike it with a hammer or mallet; when pressing in the seal, make sure that it is inserted perpendicularly in relation to the seat and, once in position, make sure that, when required, it contacts the shoulder; to prevent the sealing lip of the seal being damaged by the shaft, insert appropriate protection during the installation of the two parts. “0--RING” TOROIDAL SEALS

Lubricate O--rings before inserting them in the relevant seats to prevent them becoming twisted and rolled during installation, thus jeopardising their sealing capacity. SELAING COMPOUNDS Mating surface marked X must be smeared with a sealing compound recommended by the Manufacturer or an adequate equivalent. Prior to applying the compound, prepare the surfaces in the following manner: ---

remove all possible scaling with a metal brush; degrease the surfaces thoroughly using the degreesing agent recommended by the Manufacturer or an adequate equivalent. BEARINGS

When installing bearings, it is recommended to: ---

warm them up to 80° – 90 °C (176 – 194 °F) before installing them on the relevant shafts; cool them down before inserting them in the relevant seats with an outer fitting. SPLIT PINS

When installing split pins, make sure that the cut is pointing in the direction of the load on the pin. On the other hand, spiral elastic pins do not require any installation orientation.

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NOTES ON SPARE PARTS Use genuine spare parts guaranteed by the Manufacturer only. Genuine spare parts are the only ones ensuring the same quality, the same life and the same safety as the originally mounted parts, since they are the same as the ones installed in production. Only genuine parts from the manufacturer ensure this guarantee. Orders for spare parts must include the following indications: ----

model of the vehicle (commercial designation) and serial number; type and number of the engine; part number for the item ordered, as provided by the “Microfiches” or the “Spare Part Catalogue”, on which the order is based. NOTES ON TOOLING

The tooling that the Manufacturer recommends and illustrates in this Manual is: --------

studied and designed specifically for servicing vehicles of this range; required to ensure a reliable repair; accurately developed and inspected to provide effective and long lasting working. You are also reminded that correct tooling allows you to: to operate under optimised technical conditions; to achieve the best results; to save time and effort; to work in safer conditions. WARNING

The wear limits provided for some items must be considered as recommended values, but not absolutely binding. The indications “front”, “rear, “right”, “left” refer to different parts as seen seating from in the operator’s seat oriented in the normal travel direction of the vehicle. HOW TO MOVE A VEHICLE WITHOUT BATTERIES The cables of the external power supply must be connected exclusively to the respective terminals of the positive and negative cables of the vehicle, using efficient clamps providing adequate and safe contact. In the event it is necessary to check the operation of the electrical system of the vehicle, do it exclusively with the power supply connected. At the end of the inspection, disconnect all actuators and deactivate the power supply before disconnecting the cables.

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SAFETY RULES PAY ATTENTION TO THIS SYMBOL This alert symbol announces important messages involving your safety. Read carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to safeguard your health and your safety. You will find this symbol in the text of this Manual with the following key words: WARNING -- Cautions intended to avoid improper repair interventions involving potential consequences for the safety of the personnel performing the repairs. DANGER -- These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved.

AVOID ACCIDENTS Most accidents, whether they occur in workshop, on the farm, at home or on the road, are caused by the failure of some individuals to follow simple and fundamental safety rules and precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs. Regardless of the care used in the design and construction of any type of equipment, there are many conditions that cannot be completely safeguarded against without hindering reasonable accessibility and efficient operation. A careful operator is the best insurance against an accident. The complete observance of one simple rule would prevent many serious accidents. DANGER. Never attempt to clean, lubricate or maintain a machine while it is in motion.

ator co--operating in the operation to be performed. ◊

Never attempt to operate the machine or its tools from any position other than seated in the operator’s seat.

◊

Never perform any intervention on the machine with engine running unless this is prescribed.

◊

Cut--off the engine and make sure that all pressures in the hydraulic systems are released before removing caps, covers, valves etc.

◊

All service interventions must be performed with the utmost care and attention.

◊

Shop and/or field service platforms or ladders must be constructed and maintained in accordance with local and national regulations.

◊

Disconnect the batteries and tag all controls to signal that an intervention is in progress. Block the machine and all equipment that must be lifted.

◊

Do not check nor refill fuel tanks, as well as batteries, nor use starting fluid while smoking or near open flames since these fluids are flammable.

◊

Brakes are inactive when manually released for service interventions. Under such circumstances it is necessary to maintain the control of the machine using appropriate blocks or similar devices.

◊

The fuel--filling nozzle must be kept constantly inside the filling neck. Keep this contact from the beginning to the end of the fuelling operation to avoid the possibility that sparks due to static electricity are generated.

◊

Use only designated towing or attaching points. Use care in making attachments. Make sure pins and/or locks are secure before pulling. Stay clear of drawbars, cables or chains under load.

◊

To move a disabled machine, use a trailer or a low--boy, if available.

SAFETY RULES SAFETY RULES ◊

Read and heed all safety rules before any intervention.

◊

Do not wear rings, wristwatches, jewellery, and loose or hanging apparels, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can catch on moving parts. Wear proper safety equipment as recommended for the job. Examples: hard hat, heavy gloves, ear protection, safety glasses or goggles, reflector vests, respirator. Consult your employer for specific safety equipment requirements.

◊

Do not perform any service operation on the machine with a person seated in the operator’s compartment, unless he is an authorised oper-

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SECTION 00 -- GENERAL

◊

To load/unload a machine from transporter, choose a level surface ensuring firm support to the wheels of truck or trailer. Anchor the machine securely to the bed of truck or trailer and block wheels or tracks with appropriate wedges.

◊

Use only approved grounded auxiliary power sources for heaters, chargers, pumps and similar equipment to reduce the hazards of electrical shocks.

◊

Lift and handle heavy parts with a lifting device of proper capacity.

◊

Beware of bystanders.

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

◊

Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, non--flammable, non--toxic commercial solvents.

◊

When using compressed air for cleaning parts, use safety glasses with side shields or goggles.

◊

Limit pressure to 2.1 bar, in accordance with local and national regulations.

◊

Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

Do not carry loose objects in pockets that might fall unnoticed into open compartments.

◊

Do not smoke or permit any open flames or spark near when re--fuelling or handling flammable materials.

Wear proper protective equipment such as safety goggles or safety glasses with side shields, hard hat, safety shoes, heavy gloves when metal or other particles are apt to fly or fall.

◊

Wear welders protective equipment such as dark safety glasses, helmets, protective clothing, gloves and safety shoes, when welding or burning. Wear dark safety glasses near welding zones. DO NOT LOOK AT ARC WITHOUT PROPER EYE PROTECTION.

◊

Steel cables are frayed after prolonged use; always wear appropriate protections (heavy gloves, goggles etc.).

◊

Handle all parts carefully. Keep hands and fingers away from structures, gears or moving parts. Use and wear always the appropriate protections, such as safety goggles, gloves and safety shoes.

◊

Do not use an open flame as a light source to look for leaks or for inspection anywhere on the machine.

◊

Move with extreme care when working under the machine, its attachments and or on or near them. Always wear protective safety equipment as required, such as hard hat, goggles, safety shoes, ear plugs.

◊

When performing operations requiring running of the engine, have a qualified operator in the operator’s seat at all times with the mechanic on sight. Place the transmission in neutral and set the brakes and safety lock.

◊

For field service, move machine to level ground, if possible, and block it. If work on an incline is absolutely necessary, first block machine and its attachments securely, than move it to level ground as soon as possible with a certain margin of safety.

603.67.010.02 - 01 - 2004

◊

Do not trust worn and /or kinked chains and cables: do not use them for lifting or pulling operations. To handle them, always use heavy gloves.

◊

Be sure chains and cables are anchored and the anchor points are strong enough to handle the expected load. Keep exposed personnel clear of anchor points and cables or chains. No bystanders are allowed near the hooking points, chains or cables.

◊

Keep the area where maintenance operations are performed CLEAN and DRY. Eliminate immediately all water and oil spillages.

◊

Do not pile up oily or greasy rags; they represent a fire hazard. Store in a closed metal container. Before starting machine, check, adjust and lock the operator’s seat for maximum comfort and control of the machine. Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Sound the horn.

SECTION 00 -- GENERAL

STARTING ◊

Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes.

◊

Do not place head, body, limbs, feet, hands or fingers, near rotating fans or belts. Be especially alert near pusher fans.

HYDRAULIC SYSTEM ◊

Fluid escaping under pressure from a very small hole can be almost invisible and can have sufficient force to penetrate the skin. Use a piece of cardboard or wood to search for suspected pressure leaks. DO NOT USE HANDS. If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately.

◊

In case pressures must be measured, use instruments of adequate capacity. Always follow the recommended procedures.

ENGINE ◊

Loosen the radiator cap very slowly, to release pressure from the system, before removing it. All coolant level top--ups must be performed with engine inoperative or at low idle, if warm

WHEELS AND TYRES

◊

Do not run engine when refuelling and use care if the engine is hot due to the increased possibility of a fire if fuel is spilled.

◊

Make sure that the inflation pressure of the tyres is according to the specifications issued by the Manufacturer and check it periodically.

◊

Never attempt to check or adjust fan belts when engine is running. Do not adjust engine fuel pump when machine is moving.

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Should the pressure be changed, stand on the side of the tyre at a safe distance.

◊

Never lubricate the machine with engine running.

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Pressure check operations must be performed with unloaded machine and cold tyres. Never use reconditioned tyre rims, since eventual weldings, heat--treatments or repairs not performed correctly can weaken the wheel, thus causing subsequent damages or dangers.

◊

Do not perform torch cutting or welding operations on rims with inflated tyres installed.

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Before operating on tyres, block all wheels, front and rear. After jacking the machine, block it with stands according to current safety rules and regulations.

◊

Before removing objects from the tyre tread, deflate it.

◊

Never inflate tyres with flammable gas; explosions and serious bodily injuries may result.

ELECTRICAL SYSTEM ◊

◊

Should booster batteries be used, remember to connect both ends of the booster cables in the proper manner (+) with (+) and (--) with (--). Avoid short--circuits of the terminals. Follow thoroughly the instructions of this Manual. Avoid short circuiting the terminals. BATTERY GAS IS HIGHLY FLAMMABLE. Leave battery box open to improve ventilation when recharging batteries. Never check charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near battery to guard against the possibility of causing an explosion. Before any intervention, make sure that there are no fuel or electrolyte leakages; eliminate them before proceeding with further work.

REMOVALS AND INSTALLATIONS

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When recharging batteries in closed ambient, make sure that there is appropriate ventilation to prevent possible accidental explosions due to the accumulation of gases generated during the recharge.

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Lift and handle all heavy parts with lifting devices of adequate capacity. Make sue that the parts are attached to lifting devices are properly slinged. Use the lifting eyes provided. Beware of persons in the vicinity.

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Before any intervention, make sure that the main switch is OFF.

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Handle all parts carefully. Keep hands and fingers away from structures, gears or moving parts. Use and wear always the appropriate protections, such s goggles, gloves and safety shoes.

◊

Prevent chains and cables from kinking. To handle them, always use heavy gloves.

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PRODUCT IDENTIFICATION The Telehandler and its main components are identified by various numbers and letters providing its identification by the Service network. The following information gives the location of the identification plates, of the numbers stamped on the machine and various examples of what can be found on the machine.

VEHICLE SERIAL NUMBER The serial number is stamped on the front part of the machine, on the upper side of the main frame, right side. NOTE: The serial number and the identification number of the components can be requested by the Dealer when Spare Parts are ordered or interventions are required. These numbers are also required as help in identifying the machine in the event of theft. Keep them in a safe place. TH100025

VEHICLE IDENTIFICATION PLATES The vehicle identification plate is located on the left side of the seat location. Record here below the data for your machine. TECHNICAL TYPE/MODEL SERIAL NO. OF VEHICLE YEAR TH001028

IDENTIFICATION OF ENGINE The identification data of the engine are on the left side of the engine cylinder block. Please record here below these data for easier consultation, when required. MODEL NO. SERIAL NO. DATE CODE TH100026

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IDENTIFICATION OF FRONT AXLE The serial number and the axle type are indicated on plate (1) located on the front side of the axle housing. Please record here below the data indicated for faster consultation when required. AXLE TYPE SERIAL NO. DATE CODE

IDENTIFICATION OF 4x3 POWER SHIFT TRANSMISSION The serial number and the model are indicated on plate (1) located on the lower side of the transmission. Please record here below the data indicated for faster consultation when required. MODEL NO. SERIAL NO. DATE CODE

1 TH001030

IDENTIFICATION OF REAR TRANSMSSION The serial number is indicated on plate (1) located on the lower side of the rear transmission. Please record here below the data indicated for faster consultation when required. AXLE TYPE SERIAL NO. DATE CODE

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IDENTIFICATION PLATES IN THE CAB The cab identification plate contains a series of further details and it is located on the left rear side of the seat. Please record here below the data indicated for faster consultation when required. SERIAL NO. DATE CODE The data relative to the engine are indicated on the conformity plates installed together with the Cab Plate. Please record here below the serial number indicated for faster consultation when required. SERIAL NO. DATE CODE

TH001058

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SECTION 00 -- GENERAL

ENVIRONMENTAL CONSIDERATIONS The following recommendations can be useful:

â&#x20AC;˘

Become familiar and make sure you have well understood the relevant legislation in effect in your country.

â&#x20AC;˘

In the event no regulations exist, ask for specific information with the suppliers of lubricants, antifreeze and detergents regarding their effects on humans and the environment and how to store, handle and dispose of these substances safely.

4. Avoid spillage when draining used coolant mixtures, engine oils, transmission and hydraulic fluids, brake fluid. After draining, do not mix brake fluid or fuel with lubricants. Store them in a risk free manner until when they can be disposed of in an adequate way, in accordance with local regulations and the resources available.

5. Modern cooling mixtures, such as antifreeze and other additives, must be changed every two years. Maximum attention must be paid to prevent that they spill over the ground. They must be collected and disposed of so that do not create any danger.

6. Do not unseal air conditioning system by yourselves, since they can contain gases that must not be released into the atmosphere. The personnel specialised in air conditioners uses special equipment to charge and discharge air conditioning systems.

Useful indications

7. Repair at once any leakage or defect of the engine cooling system or hydraulic system.

1. Do not fill tanks with inadequate canisters or dispensing pressurised systems that could cause considerable spillage.

8. Do not increase the pressure of any pressurised system, since this could cause serious problems to the components of the system.

2. In general, avoid the contact of the skin with any fuel, oil, acid, solvent etc. The majority of them contain substance dangerous for your health.

9. Protect hoses when performing any welding, since a splash of welding materials could penetrate and burn them, causing a hole or weakening the wall with subsequent leakages of oil, coolant etc.

3. Modern lubricants contain additives. Do not burn contaminated fuels and/or wed oils in normal heating burners.

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MAINTENANCE TECHNIQUES GENERAL NOTICES Clean the outside of all the components prior to performing any type of repair. Dirt and abrasive dust can reduce the efficient life expectancy of a component and result in expensive repairs. The time spent in preparing and cleaning working surfaces is giving results, making work easier and safer, and the components overhauled will be more reliable and operate better. Use cleaning fluids proven to be safe. Some types of fluid can cause serious problems to O--Rings and irritate the skin. It is necessary to check that the solvents are suitable to clean the components and that of they are free of risks for the health of workers. Replace O--Rings, sealing rings and seals every time they are moved. Never use old O--Rings or seals and new ones together, independently from their conditions. Always lubricate new O--Rings and seals with hydraulic oil before installing them. When replacing components, always use the tooling required by this type of work.

If a hose swells, this indicates that there is an internal leakage due to a structural failure. This condition deteriorates very quickly and causes the failure of the hose. Clogged, squeezed, excessively tensioned or deformed hoses are generally easily subject to flow reduction, decrement of the operational speed of the fluid and the final failure of the hose. Loose hoses move freely and must be prevented from touching each other and nearby surfaces. This causes a rubbing action shortening the useful life of the hose.

CONNECTIONS WITH FRONT SEALING O--RINGS When repairing connections with front sealing O--Rings, please comply with the following procedures.

HOSES AND STEEL PIPES Always replace hoses and steel pipes when the taper end or connections are damaged. When a new hose is installed, connect it without tightening the ends and make sure that it is routed in the correct manner, before tightening the ends. Fixtures must be tightened just enough to hold the hose without squeezing it, avoiding rubbing as well. After replacing a hose of moving components, make sure that the hose is not disturbed by the movement of the component in any position. Make sure that all hoses installed are not choked or bent. If hose connections are damaged, dented, choked or leaking, decrease the flow of oil and the productivity of the relevant actuators. Connections showing signs of displacement from their original pre-pressed position must be considered as already broken, since they are going to fail or separate soon. A hose with a ragged outer sleeve allows water to penetrate. Thus, hidden corrosion of the reinforcing wire will develop along the entire length of the hose, with the subsequent failure of the hose itself.

603.67.010.02 - 01 - 2004

WARNING: NEVER DISCONNECT, NOR TIGHTEN A HOSE OR A STEEL PIPE UNDER PRESSURE. IF IN DOUBT, MOVE THE CONTROL LVERS SEVERAL TIMES WITH THE ENGINE INOPERATIVE BEFORE DISCONNECTING A HOSE OR A STEEL PIPE. 1. Loosen the connections and separate the hose or steel pipe, then remove and eliminate the O--Rings from the connection. 2. Dip a new O--Ring in clean, hydraulic oil before installing it. Install the new O--Ring in the connection and, if necessary, hold it in its position with vaseline. 3. Install a new hose or steel pipe and tighten manually the connection holding, at the same time, the pipe still to prevent it from turning. 4. Use two wrenches to tighten the connection to the torque prescribed for its size. Please refer to the table to follow for the tightening torques. NOTE: to ensure that a joint does not leak, it is important that the connections are neither excessively tightened nor too little.

SECTION 00 -- GENERAL

SPECIFIC SEALING COMPOUNDS The following sealing compounds must be used, complying with the indications provided by the Manual: SEALANTS

COMMERCIAL NAME

Anaerobic sealant

LOCTITE 518 (liquid gasket)

RTV silicon sealant

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

Pipe sealant

PST 592 (pipe sealant with teflon)

Locking compound for threads

LOCTITE 271/RED (sealant/locking for threads)

TIGHTENING VALUES FOR FASTENERS Check periodically that the fasteners are properly tightened.

or tightening procedure for a specific application. The torque values are provided for general use only.

Based upon the tables to follow, determine the correct tightening torque when parts of the fastening components are checked, adjusted or replaced.

Make sure that the threads of the fasteners are clean and undamaged.

IMPORTANT: DO NOT use the values listed in the tables when the Manual indicates a different torque

NOTE: use a torque wrench to tighten fasteners correctly.

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MINIMUM TIGTENING TORQUES FOR FASTENERS IN NEWTON-- METRES (Nm) FOR NORMAL INSTALLATION APPLICATIONS METRIC BOLTS AND LOCK NUTS CLASS 8.8

CLASS 5.8

CLASS 10.9

LOCK NUT CL 8 with BOLT CL 8.8

NOT PLATED

PLATED Zn/Cr

NOT PLATED

PLATED Zn/Cr

NOT PLATED

PLATED Zn/Cr

1.7

2.2

2.6

3.4

3.7

4.8

1.8

5.8

7.6

8.9

6.3

M10

M12

107

138

M16

121

158

186

240

266

344

131

M20

237

307

375

485

519

671

265

M24

411

531

648

839

897

1160

458

NOMINAL DIMENSION

IDENTIFICATION HEX SCREWS (WITHOUT NUT) AND ROUND HEAD BOLTS CLASS 5.6 AND HIGHER IDENTIFICATION OF THE MANUFACTURER

COMMERCIAL CLASS

HEX NUTS AND TIGHTENING NUTS CLASS 05 AND HIGHER IDENTIFICATION OF THE MANUFACTURER

COMMERCIAL CLASS

603.67.010.02 - 01 - 2004

MARKING

SECTION 00 -- GENERAL

MINIMUM TIGTENING TORQUES FOR FASTENERS IN NEWTON-- METRES (Nm) FOR NORMAL INSTALLATION APPLICATIONS INCH MEASUREMENT SCREWS AND LOCK NUTS

GRADE SAE 2 NOMINAL DIMENSION

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

NOT PLATED OR SILVER PLATED

6.2 13 23 37 57 81 112 198 193 289

PLATED Zn/Cr GOLD

8.1 17 30 47 73 104 145 256 248 373

GRADE SAE 5

NOT PLATED OR SILVER PLATED

PLATED Zn/Cr

9.7 20 35 57 87 125 174 306 495 742

13 26 46 73 113 163 224 397 641 960

GOLD

GRADE SAE 8

NOT PLATED OR SILVER PLATED

PLATED Zn/Cr

14 28 50 80 123 176 244 432 698 1048

18 37 65 104 159 229 316 560 904 1356

GOLD

LOCK NUTS

NOT PLATED OR SILVER PLATED

PLATED Zn/Cr

6.9 14 26 41 61 88 122 217 350 523

9.8 20 35 57 88 125 172 306 494 739

NOMINAL DIMENSION

GOLD

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

IDENTIFICATION SCREWS (WITHOUT NUT) AND ROUND HEADED SCREWS

GRADE SAE 2

GRADE SAE 5

GRADE SAE 8 NORMAL NUTS

HEX NUTS GRADE SAE 5

HEX NUTS GRADE SAE 8

LOCK NUTS

GRADE IDENTIFICATION GRADE A: NEW MARK GRADE B: THREE MARKS GRADE C. SIX MARKS

GRADE IDENTIFICATION GRADE A: NO CUTS GRADE B: ONE PERIMETER CUT GRADE C: TWO PERIMETER CUTS

THE MARKS ARE NOT COMPULSORILY LOCATED IN THE CORNERS GRADE A. NO MARKS GRADE B: LETTER B GRADE C: LETTER C GRADE IDENTIFICATION

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

GENERAL NOTE: â&#x20AC;&#x153;The Manufacturerâ&#x20AC;? pursues a policy of constant improvements, thus reserves the right to modify at any moment technical and design data, without notice, and without any obligation to modify the machines previously manufactured. All the data provided in this Manual are subject to variations in production. Dimensions and weights are approximate and the illustrations do not necessarily show the machines in normal conditions. In order to have specific information about a determined machine, please consult an Authorised Dealer. Model

LM1340 not stab.

small stab.

large stab.

not stab.

88 kW (120 Cv) Turbo Aftercooler

Engine Max. lifting height (m)

LM1440

LM1740

small stab.

large stab.

88 kW (120 Cv) Turbo Aftercooler

not stab.

stab.

88 kW (120 Cv) Turbo Aftercooler

12.300

12.450

13.300

13.550

16.240

16.600

Max. capacity (kg) at 500 mm from fork stop

4000

Capacity at max. height (kg)

2600

3600

4000

2800

3000

3600

700

2500

Extension at max. height (m)

1.200

0.500

0.000

1.000

0.500

0.300

2.000

1.000

Max. longitudinal extension ( m) Capacity at max. extension (kg)

8.650 700

1700

9.330 1800

650

1400

12.540 1500

450

Weight (kg)

11050

11970

12340

Length (m)

5.850

6.070

6.135

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100027

LM1340 A

1200 mm

1260 mm

3120 mm

4396 mm

1617 mm

2730 mm

5850 mm

5204 mm

7050 mm

980 mm

2050 mm

3890 mm

402* mm

2445 mm

1100 mm

* Value measured with tyres 405/70x24

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100029

LM1340 without stabilisers or with stabilisers raised and with rear axle look

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100030

LM1340 without stabilisers and without rear axle look

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100031

LM1340 with large stabilisers lowered

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100032

LM1340 with small stabilisers lowered

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100027

LM1440 A

1200 mm

1260 mm

3120 mm

4552 mm

1837 mm

2730 mm

6070 mm

5390 mm

7270 mm

980 mm

2050 mm

3890 mm

402* mm

2445 mm

1100 mm

* Value measured with tyres 405/70x24

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100033

LM1440 without stabilisers or with stabilisers raised and with rear axle look

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100034

LM1440 without stabilisers and without rear axle look

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100035

LM1440 with large stabilisers lowered

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

ϒ TH100036

LM1440 with small stabilisers lowered

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100027

LM1740 A

1200 mm

1260 mm

3120 mm

4598 mm

1902 mm

2730 mm

6135 mm

5445 mm

7335 mm

980 mm

2050 mm

3890 mm

402* mm

2445 mm

1100 mm

* Value measured with tyres 405/70x24

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100037

LM1740 with stabilisers raised

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TH100038

LM1740 with stabilisers lowered

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

LM1740 (without stabilisers and without rear axle lock)

TH100039

NOTE: This diagram must be considered when the rear axle lock manual control is selected.

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

88 kW (120 CV)

ENGINE DATA

Turbo Aftercooler Model Number of cylinders Bore Stroke Displacement Total displacement Firing order

mm mm cm3

Diesel 4 in--line 102 120 3900 17 : 1 1.3.4.2

Low idle Max. idle

rpm rpm

800--900 2350--2450

Nominal speed Maximum torque

rpm

2200 450 Nm

COOLING SYSTEM Type Fan Fan belt deflection Drive belt deflection Air conditioner compressor Thermostat: Starts opening at Radiator cap

Pressurised, full--flow, w/ by--pass con camera di espansione 7 blades 10 -- 16 mm 16 mm 81 Â°C 1 bar

INTAKE SYSTEM Injection pump Type Cold start device Excess fuel device Fuel shut off Lift pump

Rotary Thermostart Automatic governor Solenoid Mechanical

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TRANSMISSION POWERSHIFT – T 12000 4x3 = 4 speeds forward and 3 reverse Speed

Ratio

Stall speed (RPM)

4.025

2349

2.048

2309

III

1.000

2248

0.662

2170

ELECTRICAL SYSTEM Alternator Type of battery Optional Battery cut--off by switch Regulator Ground Starter motor Light bulb Stop light/tail light Outer light bulb Flashing light bulb Work light bulb Instrument/indicator lights bulb Switch light bulb

65 amp. 12 Volt grounded negative 160 Amph on negative/frame cable Transistor Negative Positive engagement, electrically controlled (3.1 kW) 40/45W 5/21 W with bayonet socket 5 W (string) 10 W bayonet socket 21 W with bayonet socket 55W H3 halogen 1.2 W w/out socket 1.2 W w/out socket

BRAKES Type Disc diameter Type of parking brake

Oil--bath, multiple disc. 8 per axle 203.2mm Mechanical, disc on transmission

STEERING Steering type Pump type System pressure Wheel toe--in

Orbitrol Gear 175 bar 0 -- 2mm

FRONT AXLE Mounted on front frame Differential lock

Swinging with levelling cylinder No

REAR AXLE Mounted on frame

603.67.010.02 - 01 - 2004

Floating with swing and automatic locking when boom angle exceeds 10°

SECTION 00 -- GENERAL

HYDRAULIC SYSTEM Gear pump Hydraulic system pressure: Main system pressure Steering system pressure

Hydraulic and steering system 250 bar 175 bar

TORQUES

Wheel nuts Cab securing screws

540 380

RADIATOR COOLANT The antifreeze must be changed every 1000 hours or every 24 months NOTE: To reduce deposits and limit corrosion, the water used in the cooling system must not exceed the following limits: Total hardness 300 ppm

Chloride 100 ppm

Sulphates 100 ppm

TYRE COMBINATION FOR 4-- WHEEL DRIVE VEHICLES The tyres mounted on 4--wheel drive machines are selected so that they are compatible with the transmission and axle gears. When damaged or worn tyres are replaced, always mount tyres of brand, model and dimension equal to the previous ones. The installation of combined tyres can result in an excessive wear, loss of available power or serious damage to the transmission components. If in doubt, consult your Dealer.

MACHINE WEIGHT

Weight 13 metre= 11,050 kg 14 metre= 11,970 kg 17 metre= 12,340 kg TH100028

IMPORTANT: The data listed here above and below are general data provided as a guide to evaluate the weight of the machine and do not necessarily consider the tyres installed, the level of fluids or the pres-

15 ence of additional equipment. To establish precisely the weight of your machine, it is necessary to place it on an official weight bridge.

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TYRE PRESSURES The tables are provided for reference only. For specific information relative to inflation pressures and the load of the tyres used, please consult your Dealer.

Model

TYRE DIMENSION 13 00 -- 24 14 ply 13.00 405/70 -- 24 14 ply

LM1340

15 5 R25 15.5 15 R22.5 R22 5 400/80 -- 24 14 ply 13 00 -- 24 14 ply 13.00 405/70 -- 24 14 ply

LM1440

15 5 R25 15.5 15 R22.5 R22 5 400/80 -- 24 14 ply 13 00 -- 24 14 ply 13.00 405/70 -- 24 14 ply

LM1740

15 5 R25 15.5 15 R22.5 R22 5 400/80 -- 24 14 ply

FRONT REAR

PRESSURE [bar]*

AXLE WEIGHT (static, empty) [kg]

AXLE WEIGHT (Dynamic, nominal) [kg]

front

4.5

4650

6390

rear

4.5

6060

5321

front

4650

6390

rear

6060

5321

front

4.5

4650

6390

rear

4.5

6060

5321

front

4.5

4650

6390

rear

4.5

6060

5321

front

4.25

4650

6390

rear

4.25

6060

5321

front

4.5

5380

7300

rear

4.5

6000

5200

front

5380

7300

rear

6000

5200

front

4.5

5380

7300

rear

4.5

6000

5200

front

4.5

5380

7300

rear

4.5

6000

5200

front

4.25

5380

7300

rear

4.25

6000

5200

front

4.5

5730

7470

rear

4.5

6360

5620

front

5730

7470

rear

6360

5620

front

4.5

5730

7470

rear

4.5

6360

5620

front

4.5

5730

7470

rear

4.5

6360

5620

front

4.25

5730

7470

rear

4.25

6360

5620

* The pressures listed refer to inflation for site use. The data listed here above correspond to the â&#x20AC;&#x153;approximate weightâ&#x20AC;? of a standard machine, without equipment.

603.67.010.02 - 01 - 2004

SECTION 00 -- GENERAL

TELEHANDLER TELESCOPIC LIFTER LUBRICANTS AND COOLANTS Engine oil correct viscosity grade depends on ambient temperature. Refer to the table on the right for selecting engine oil for your machine. NOTE: In areas with long periods of extreme temperature, local lubrication procedures are admissible, such as using SAE 5W30 where there are extremely low temperatures or SAE 50 where there are extremely high temperatures. Sulphur contents in fuel. Engine oil replacement interval is shown in Section 3. Local fuel can however have a high sulphur content: in this case engine oil replacement interval must be changed as follows: Sulphur contents in % Oil replacement interval Below 0.5 Normal 05.5 to 1.0 Half the normal Over 1.0 One fourth the normal

--30 °C --25 °C

--15 °C

+20 °C

+40 °C

SAE 5W--30

SAE 10W--30

SAE 15W--40

--22 °F

--13 °F

+5 °F

+68 °F

+104 °F

NOTE: It is advised to use fuel with a sulphur content below 1.3% SUGGESTED FLUIDS AND THEIR APPLICATION

Oil – ENGINE Ambra Master Gold HSP 15W40 Ambra Master Gold HSP 10W30 Oil – POWERSHIFT TRANSMISSION Ambra Hydropower Oil – FRONT AND REAR AXLE FUCHS Titan Gear LS 85W90 Oil – DROP BOX Ambra Hypoide LS 90 80W90 OIL – FRONT/REAR AXLE HUB Ambra Hypoide LS 90 80W90 OIL – FRONT LOADER HYDRAULIC SYSTEM Ambra Hydrosystem 46 HV ENGINE RADIATOR Water Ambra Agriflu BRAKE CONTROL CIRCUIT – OIL Ambra Brake LHM CRANE ARM SHOES – GREASE Ambra Tutela GR9 GENERAL – GREASE Ambra GR 9 CONDITIONER COMPRESSOR Freon R134a FUEL Diesel Fuel

International Specification

Quantity

Ambient Temperature (°C)

API CH--4 ACEA -- E5

7,6 litres (including engine oil filter) 12,9 + 4 litres (lines and radiator)

From –10 to +50

7 litres

From --20 to +50

ATF Type A Suffix A ALLISON C4 API GL5 e API GL5 LS GO 90 LS ZF TE--ML 05 API GL5

0,75 litres

API GL5

0,65 litres

ISO VG 46 DIN 51524

180 litres

From --20 to +50

H2O

12 litres 12 litres

From --35 to +50

M6C 59--A

1 litre

NLGI 2

As required

From --40 to +50

NLGI 2

As required

From --40 to +50

135 litres

NOTE: Fluid and lubricant quantities are comprehensive. Drained quantities may be less, due to certain amonnts of fluid or lubricant remaining trapped inside the machine.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

SECTION 10 â&#x20AC;&#x201C; ENGINE TABLE OF CONTENTS Section 10 000

Description Page Coding of engines of origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main engine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General engine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Generalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description of main mechanical components of the engine . . . . . . . . . . . . . . . . . . . . . . . . 13 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Fuel and mechanical injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Injectionassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Removal of the engine transmission group from the vehicle . . . . . . . . . . . . . . . . . . . . . . . 43 Engine overhaul on bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Replacing the injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Adjustment of valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Setting of timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Timing of the injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Tooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Data -- Mounting plays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

ENGINE F4 BE 0484

TH110060

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

CODING OF ENGINES OF ORIGIN F

Level of emission Power of homologation Use Fuel/injection D = TIER 2

No. of cylinders Configuration of cylinders: 0 = 4 stroke vertical Engine Type of cylinder block: B = not structural

4 = 4 cylinders

Family of engines

8 = Diesel turbo-charging I.D. Intercooler

4 = Earth Moving Machinery

X = 6 Rotary 2--valves injection pump Y = Engine variant

Production progressive number

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

MAIN SPECIFICATIONS OF ENGINES F4BE0484 A

F*D601

G*D600

B 3900 cm3

C D

88 kW 2200 rpm

74 kW 2200 rpm

Direct injection

Rotary injection pump

T.C.A. (Turbocharged with aftercooler) A B C D E F G

603.67.010.02 - 01 - 2004

Engine type Number of cylinders Total displacement p Maximum power p reallyy available Type of injection Injection system Ai Air iintake k system

SECTION 10 -- ENGINE

GENERAL ENGINE SPECIFICATIONS F4BE0484 Type

F*D601

Cycle

Diesel 4--stroke

Fuel

Turbocharged w/aftercooler

Injection

Direct

Number of cylinders

4--in--line

Bore

102

Stroke

120

cu cm

3900

Total displacement

Compression ratio

17 : 1

Maximum power

kW (HP) rpm

88 120 2200

Maximum torque Nm

(kgf) rpm

---

Engine speed at low idle

rpm

800--900

Engine speed at high idle

rpm

2350--2450

TURBOCHARGING Turbocharger type:

W/ aftercooler HOLSET HX25W Forced by gear pump, pressure relief valve, oil filter

LUBRICATION Oil pressure with hot engin at low idle at maximum speed

bar bar

1,2 3,8

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

F4BE0484 Type

F*D601

COOLING

Liquid Water pump drive: Thermostat: Start of opening:

Ambra Super Gold 15W40 10W30 W

CAPACITIES Total 1st filling

Belt °C litres kg

-- engine sump

litres kg

-- engine sump + filter

litres kg

7,6

FUEL Injection pump type Bosch

VE4 / 12 F 1100 L

Pump setting

Beginning of delivery

0° ± 0°,5

Nozzles type

Injection pressure

DSLA 145 P603

Firing order

603.67.010.02 - 01 - 2004

81± 2

1 -- 3 -- 4 -- 2

bar

245 bar

SECTION 10 -- ENGINE

GENERALITIES

G F

B C D

E TH110001

A. Drive belt for: water pump â&#x20AC;&#x201C; alternator fan B. Alternator C. Water pump

D. E. F. G.

Oil pump Belt tensioner Rotary injection pump Air heater for cold starting

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Upper view

TH110002

A. B. C. D.

Alternator Injectors Turbocharger Blow--by

603.67.010.02 - 01 - 2004

E. Injection pump F. Intake manifold G. Fuel filter

SECTION 10 -- ENGINE

Front view A

I B H

D F

TH110003

A. B. C. D. E.

Blow--by Fuel filter Priming pump Idle pulley Oil filter

F. G. H. I.

Poly--V belt Water pump Alternator Thermostat

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Right side view

A B C L

D E H F

TH110004

A. B. C. D. E.

Blow--by Turbocharger Thermostat Alternator Water pump

603.67.010.02 - 01 - 2004

F. G. H. I. L.

Poly--V belt Oil filter connection Starter motor Oil unloading pipe from turbocharger Exhaust manifold

SECTION 10 -- ENGINE

Left side view L

A B

D TH110005

A. B. C. D. E.

Blow--by Injector fuel lines Injection pump Oil filter Priming pump

F. G. H. I. L.

Fuel filter Fuel heater Cinghia Poly -- V Air Heater Intake manifold

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Rear view O

TH110006

A. B. C. D. E. F. G.

Blow--by Injector fuel lines WASTGATE valve Turbocharger Oil unloading pipe from turbocharger Alternator Exhaust manifold

603.67.010.02 - 01 - 2004

H. I. L. M. N. O.

Starter motor Engine flywheel Oil filter Injection pump Air heater Intake manifold

SECTION 10 -- ENGINE

DESCRIPTION OF MAIN MECHANICAL COMPONENTS OF THE ENGINE Cylinder block The cylinder block is a cast iron structure containing cylinder sleeves (1) main journals (5) and the seats for: camshaft bushes (3) and tappets, water/oil heat exchanger (7), water pump (2) and oil pump (4).

Also, the ducts for the circulation of the coolant are realised as well as the lubrication oil ducts to the various organs. Plate (6) mounted on the lower side of the cylinder block, provides higher strength to stresses.

2 7

TH110008

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Crankshaft The steel crankshaft rests on 5 journals. They are induction hardened. Inside, the lube oil ducts are made. On the front nose the oil pump drive gear, the phonic wheel, the damper wheel and the auxiliary component drive pulley are installed. On the rear nose the camshaft drive gear and the engine flywheel mounting hub are installed.

The main journal half bearings are steel made with anti friction alloy lining. The last but one journal half bearings are equipped with thrust washers to contain the axial play of the crankshaft. Items (1, 2) are fitted with an interference on the rear end and are not replaceable.

TH110009

1. 2.

Timing drive gear Hub for flywheel mounting

Crankshaft sealing rings The front and rear sealing rings are of a box type, with radial sealing. They require tools 380000663 and 380000665 for their extraction, whereas for the installation, 380000664 and 380000666 are required.

603.67.010.02 - 01 - 2004

Oil pump drive gear

SECTION 10 -- ENGINE

Conrods Steel stamped, they are of an inclined cut type, with separation of the cap obtained by a new technology (fracture split) and not by machining.

The conrod half bearings are steel made with anti friction alloy lining.

TH110010

10 Each conrod is marked: â&#x20AC;˘ On the body and cap a number indicates the matching and the cylinder on which it is installed. â&#x20AC;˘ On the conrod body, a letter indicates the weight class of the conrod installed in production.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Pistons

TH110011

11 On the ceiling of each piston a combustion chamber is made. The ceiling of the piston is cooled by engine oil provided by the jet installed on the cylinder block. There are three piston ring seats: the 1st one is obtained by a trapezoidal shape cast iron insert. The piston rings have different functions and have different shapes.

The 1st trapezoidal shape piston ring with chromium ceramic lining. The 2nd rectangular taper torsional sealing ring. The 3rd with a dual skid with inner spring. The i.d. numbers and manufacturing data are provided in zone 1 of the piston ceiling.

TH110012

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Camshaft The camshaft is mounted inside the cylinder block on 5 journals. The front and rear journals are equipped with interference fitted steel bushes lined with anti friction material. Each cylinder has 2 cams.

A. Intake valve drive B. Exhaust valve drive The camshaft is driven directly by the crankshaft by straight gears.

TH110013

B A

TH110014

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Valve drive

3 5 4 6

TH110015

1. 2. 3. 4. 5.

Rocker arm Shaft Adjusting screw Rod Half cones

603.67.010.02 - 01 - 2004

6. 7. 8. 9.

Cup Spring Tappet Camshaft

SECTION 10 -- ENGINE

Cylinder head The cast iron cylinder head has the seats for the following items: • added valve seats (4); • injector (6); • hermostat (5);

Also, the heads have: • single block exhaust manifold (1); • intake manifold (2) with air heater seat (3) for cold starting.

6 3

4 5

TH110016

View of cylinder head with added valve seats

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Valves and valve seats

TH110017

1. 2.

Intake valve Exhaust valve

The added seats on the cylinder head have an angle of: • 45 ° for the exhaust valves • 60 ° for the intake valves

A. Intake side S. Exhaust side

Exhaust valves (2) are different from the intake valves for the presence of a single grove at the tip of the stem.

TH110018

Figure 17 shows the oil seals installed on the valve stems. 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Valve guides The valve guides are not inserted.

TH110188

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Engine flywheel Flywheel (1) does not require a fixed position on the crankshaft, since there are no references, notches nor reference holes on it for sensors or timing.

The equal distance of securing screws (2) ensures an indifferent installation in all positions.

TH110020

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Auxiliary organs drive A Poly--V belt (1) drive the motion from crankshaft (4) to water pump (3) and alternator (2).

The belt is tensioned through the elongated hole on the alternator bracket.

TH110021

1. 2. 3.

Poly--V belt Alternator Water pump

4. 5.

Crankshaft pulley Guide pulley

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

LUBRICATION The forced circulation lubrication is provided by the following components: • rotor oil pump, located in the front side of the cylinder block, driven by a straight gear mounted on the crankshaft nose;

• • • •

water/oil heater exchanger located in the engine cylinder block, with oil filter connection; oil pressure relief vale incorporated in the oil filter connection; by--pass valve cutting off the filter when clogged, incorporated in the oil filter connection; cartridge oil filter.

TH110022

21 Oil gravity return way Pressurised oil way

603.67.010.02 - 01 - 2004

Oil filling

SECTION 10 -- ENGINE

Heat exchanger

1 2

3 4

6 TH110023

22 1. 2. 3.

Heat exchanger body Inner gasket Water oil heat exchanger

4. 5. 6.

Gasket between heat exchanger group and engine cylinder block Oil return to filter Oil inlet to filter

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Oil pump

TH110024

TH110025

24 1.

Crankshaft (1) with oil pump drive gear

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Oil sump Oil sump (1) is secured elastically to the cylinder block by aluminium plate (3), figure 26. The â&#x20AC;&#x153;Câ&#x20AC;? section rubber gasket (2) is mounted on the oil sump mounting profile, besides providing the sealing, reduce the noise.

This type of gasket has to be replaced only in case of deterioration or failure and not necessarily at each removal.

TH110026

25 3 2 1

TH110027

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Oil fume re--circulation The re--circulation of oil fumes occurs through valve (1) located on rocker arm cover (2).

The condensed fumes, drop for the gravity under rocker arm cover (2) whereas the remaining ones are recovered by blow--by (3) and directed appropriately to the intake.

TH110028

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

COOLING The engine cooling system, of a forced circulation closed circuit type, is made of the following components: •

• •

a water pump of a centrifugal type located in the front side of the engine cylinder block; a thermostat regulating the flow of the coolant.

a heat exchanger cooling the lubrication oil;

TH110029

28 Water outlet from the thermostat

Water entering the pump

Water re--circulation in the engine

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Water pump The water pump, located in a seat in the cylinder block, is driven by a poly--V belt. The very limited quantity of external piping, sleeves and bands eliminates many connections, reducing the chance of leakages.

A thermostat regulates the temperature of the engine. The coolant circulates also in the oil heat exchanger.

TH110030

TH110031

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

FUEL AND MECHANICAL INJECTION Fuel filter In support (1) are located: fuel temperature sensor (5) heater resistance (2) water bleeding screw (3) and filter (4). Grade of filtration of cartridge: 6 micron. Maximum operating pressure: 5 bar. Operating temperature: from – 40 °C (--40 °F) through + 90 °C (+ 194 °F).

5 1 2

3 TH110034

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

MECHANICAL FUEL PUMP

Volumetric pump, installed on the left side of the engine, has the function of supplying the injection pump. It is driven by the camshaft. 1. 2. 3.

Fuel outlet to filter Drive lever Fuel inlet from tank

1 2

TH110035

3 32

1. 2. 3.

Pump Drive lever Camshaft

2 3

TH110036

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

INJECTIONASSEMBLY

3 4 2 5 1 6

7 8 9

TH110037

1. 2. 3. 4. 5.

Fuel line injector 1 Fuel line injector 2 Fuel line injector 3 Fuel line injector 4 Fuel unloading line from injectors

Manifold for pressure measuring pipe in intake manifold for LDA 7. Thermal bulb for KKSB 8. Injection pump 9. Solenoid valve 10. Injector 6.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Injection pump The pump is of a rotary type, driven by a gear matching the one on the camshaft.

IdentificazioneIdentification V = rotary distributor piston E = size of pump 4 = for 4--cylinder engine 12 = distributor piston in mm 1100 = pump rpm L = anticlockwise rotation direction

2 14 3 4

13 12

7 8 9 10

TH110038

Longitudinal section view of injection pump 1. 2. 3. 4. 5. 6. 7. 8.

Membrane Adjusting ring nut Feeling pin Drive lever Speed governor Transfer pump Drive shaft Cam disc

603.67.010.02 - 01 - 2004

9. 10. 11. 12. 13. 14. 15.

Advance variator Distributor piston Delivery connection Hydraulic head Drive plate Regulation pin Return spring

SECTION 10 -- ENGINE

Description of operation Supply phase

1 2

3 6 4 9

TH110039

1. 2. 3. 4. 5.

Fuel inlet duct Solenoid valve Axial groove Compression chamber Fuel duct between pumping element and injectors

Distributor piston (6) is at L.D.C. and slider (8) closes end of delivery hole (7).

6. 7. 8. 9.

Distributor piston End of delivery hole Slider Injector

The fuel is forwarded to compression chamber (4) through supply duct (1) that is kept open by solenoid vale (2).

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Delivery phase

TH110040

1. 2. 3.

Fuel inlet duct Compression chamber Distributor piston inner duct

Distributor piston (5) under the effect of the rotation of the cam disc, raises toward the T.D.C. and, at the same time, rotates on its axis. The combination of the two movements determines the closing of fuel inlet duct (1) and the simultaneous compression of the fuel in chamber (2).

603.67.010.02 - 01 - 2004

4. 5. 6.

Duct between pumping element and injectors Distributor piston Injector

Inner duct (3) of the distributor piston is connected to duct (4) providing the delivery to injectors (6).

SECTION 10 -- ENGINE

End of delivery phase

5 4

TH110041

1. 2. 3.

Fuel inlet duct Compression chamber Delivery duct

Distributor piston (6) during its stroke toward T.D.C. connects the high pressure inner chamber through duct (4) establishing an equilibrium between the inner chamber of the distributor piston, the injector delivery line and the inside of the pump.

4. 5. 6.

End of delivery duct Slider Distributor piston

Since such pressure is insufficient to actuate the injector, the delivery ends.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Engine cut--off 1 4 3 2 5

TH110042

1. 2. 3.

Fuel inlet duct Mobile plug Spring

4. 5.

The engine cut--off occurs when cutting--off the starting contact. The electric power energising solenoid valve (4) is cut--off.

Solenoid valve Compression chamber

The solenoid valve, under the effect of spring (3) pushes mobile plug (2) to full stroke, obstructing fuel inlet duct (1).

L.D.A. device (delivery adjustment as a function of the load)

1 2 3 4 5 6 7 8

TH110043

Operation of the L.D.A. device The L.D.A. device has the purpose of changing the delivery of fuel as a ratio of the air pressure in the intake manifold. This air pressure actuates membrane (1) connected to regulation pin (4). In the lower side of regulation pin (4) taper seat (5) is machined in which feeling pin (6) slides.

603.67.010.02 - 01 - 2004

40 The axial movement of regulation pin (4) causes the sliding of feeling pin (6) that in turn, actuates stop lever (7). Stop lever turns on its axis (8) and actuates the drive plate so that the fuel deliveries are adjusted to the quantity of air introduced into the cylinders.

SECTION 10 -- ENGINE

Starting

1 4 7

TH110044

1. 2. 4.

Starting lever Leaf spring Slider

5. 6. 7.

After energising solenoid valve (6) a passage of fuel is created into compression chamber (7). Under these conditions, regulation sleeve (5) is with the masses closed; thus leaf spring (2) pushes lever (1) and slider (4) into supplement position.

Regulation sleeve Solenoid valve Compression chamber

Thus, the entire stroke of the pumping element useful for the injection is exploited.

Starting device disengaged

3 6 5

1 7

2 4

TH110045

1. 2. 3. 4.

Starting lever Leaf spring Tensioner lever Slider

Once the engine starts, regulation sleeve (5) under the effect of the centrifugal force due to the expansion of masses (7) starts the axial movement, pushes starting lever (1) against tensioner lever (3) thus compresses leaf spring (2).

5. 6. 7.

Regulator sleeve Solenoid valve Masses

Under these conditions slider (4) moves determining maximum delivery.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Delivery start depending upon the load (L.F.B.)

8 5 6

TH110046

Structure of the regulator group with correction of the delivery start depending upon the load 1. 2. 3. 4.

Regulation spring Regulator spring Tensioner lever Starting lever

Description The correction of the beginning of the delivery as a function of the load (LFB) provides a smoother (more silent) operation of the engine. The operation of the LFB device is provided by modifying: •

The regulation sleeve with a supplementary hole to the “anti lunging” hole.

603.67.010.02 - 01 - 2004

5. 6. 7. 8.

Slider Distributor piston Governor shaft Centrifugal masses

•

The governor support shaft with a longitudinal hole and two and crossway ones. The pump body with one hole, closed externally by a ball communicating with the supply chamber.

•

SECTION 10 -- ENGINE

Positioning of governor sleeve in the LFB

TH110047

a b. c. 1. 2.

Sleeve in rest position Moving sleeve Sleeve under correction conditions, inner pressure drop Longitudinal hole in governor support shaft Governor shaft

Operation Not withstanding the position of the outer throttle lever, when the rpm of the governor masses increase, under the effect of the centrifugal force, move governor sleeve (4) a reduction of the delivery is determined. In order to obtain a smoother operation of the engine a reduction of the advance must correspond to a reduction of delivery. Since in the rotary pump the advance device operates hydraulically, to obtain a reduction it is necessary to reduce

3. 4. 5. 6. 7.

Cross--way hole in governor sleeve Governor sleeve Cross--way hole in governor shaft Edge from governor centre line Cross--way hole in governor shaft

the transfer pressure. This is obtained by the LFB device. When regulating sleeve (4) sliding on governor support shaft (2) connects hole (3) with groove (6) and hole (7) a portion of pressurised fuel is unloaded through duct (1 and 5) into the supply chamber, causing a reduction of the transfer pressure inside the pump thus reducing the advance.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Cold injection advance automatic device (KKSB)

TH110048

1 45

KKSB bulb

The KKSB device has the function of setting an appropriate injection advance when the engine is cold.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

REMOVAL OF ENGINE TRANSMISSION GROUP FROM THE VEHICLE Warnings

ATTENTION

Please comply with the following warnings prior to perform interventions on the engine involving or interesting components of the fuel system. • The utmost clean conditions of the parts must be ensured, during the handling and the installation of any part (starting from the simple replacement of filter and pre--filter), to prevent the entry of impurities or foreign bodies. For this purpose, the protection plugs of hydraulic parts and sensors must be removed just before positioning the components in their seats. • Care must be taken ensuring the correct polarity of electric connections. • All threaded connections must be tightened to the prescribed torque.

Quick release couplings for low pressure lines All connectors must be fully engaged and with stopper (1) in locking position (see Figure 47 – A). To disconnect the low pressure system pipes, press stopper (1) (as indicated in Figure 47 – B) to release the pipe connector from the socket. After disconnecting it, return stopper (1) in the locking position (Figure 47 – A) to prevent any possible deformation. When re--assembling the low pressure system, press stopper (1) as indicated in Figure 47 – B and connect the connector to the relevant socket. Return stopper (1) into locking position A to provide the connection of the pipe to the relevant component. Failing to comply with the pipe connection procedure can result in the sudden separation of the pipes, when starting or during the engine operation, under the effect of the operating pressures.

TH110064

1 47

A B

Connector properly locked Connector released for removal – installation

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Removal Remove the engine compartment guard.

ATTENTION Prior to performing any removal/installation operation, disconnect the battery cables and secure the machine under safe conditions.

• •

• • •

• • • • •

• • •

•

Remove the batteries; drain the engine coolant into an appropriate container, as a consequence of the separation of all the cooling system pipes; disconnect the air and exhaust fume pipes; disconnect all electric connections located on the engine deriving from the frame wiring; disconnect all the transmission group hydraulic pipes and drain the oil into an appropriate container; disconnect all the electric wires present in the engine compartment; disconnect the pipe to the after--cooler; disconnect the intake duct; disconnect the pipes from the air conditioner compressor; disconnect the fuel delivery pipes from the primer pump and return to the tank from the injection pump; separate from the frame the lower side of the engine compartment hood; remove the radiator group from the engine support beam (front side); remove the propeller shafts located under the telehandler frame from the transmission drive. Install lifting device 380000216 on the engine and using an appropriate lifting device, place the engine under pull; remove the securing screws, then, paying attention to the wiring on the frame, making sure that all components are free, lift the engine/transmission and remove it from the compartment; once the engine/transmission group is removed from the frame, proceed with the removal of the engine (please refer to the transmission section).

603.67.010.02 - 01 - 2004

Reinstallation To reinstall the engine, reverse the operations described for the removal, complying with the following warnings: • pay special attention to the manoeuvres required for the installation of the engine in the engine compartment; • check the conditions of the cooling system sleeves and pipes and the air conveyors; in the event they are damaged, replace them; • check the elastic supports of the engine and transmission groups; in the event they are damaged, replace them; • check the components of the exhaust piping that they are not deteriorated or near to deteriorate, as well as the elastic securing elements; • tighten screws and nuts to the prescribed torques; • check thoroughly that the connections of the fuel pipes and their relevant connections are correct, as specified in the notices 2main interventions on the engine installed on the vehicle”; • fill the cooling system with coolant and bleed the air as described in the relevant paragraphs;

ATTENTION Prior to reusing it, check that the coolant is free from impurities; otherwise filter it with appropriate screen filters. For any topping--up, please refer to the CAPACITIES table.

•

check the engine and the transmission oil levels. For any topping--up, please refer to the “CAPACITIES” table.

SECTION 10 -- ENGINE Checks and inspections Start the engine and let it operate at a speed just above low idle and wait for the temperature of the coolant to reach the thermostat opening value, then check that: • there is no leakage of coolant from the sleeves connecting the pipes of the engine cooling system and the cab heating, tightening the securing elements as required; • there are no oil leakages of oil between the cover and cylinder head, between sump and cylinder block, heat exchanger oil filter and relevant seats and the various pipes of the lubrication system; • there are no leakages of fuel from the fuel pipes; • make sure that the indicator lights on the instrument dashboard and the instruments that have been disconnected when removing the engine operate correctly.

Filling the engine cooling system General standards • The filling operations must be performed with engine cold. • To prevent the formation of air pockets in the system, the pouring of the liquid must occur slowly. • The percentage of antifreeze in the cooling liquid must not exceed 50%. • Proceed with the filling in compliance with the procedures previously described until the expansion tank is filled.

Air bleeding from the system • The air bleeding from the cooling system must be started immediately after the filling operation. • Start the engine letting it operate at low idle for at least five minutes. After this time, top--up as required. • Close carefully the expansion cap and run the engine at a high speed to facilitate the warming up of the coolant, until the thermostat opens. Note: to speed--up the operation, it is suggested that the radiator be screened placing a piece of cardboard between radiator and aftercooler. • Bring the temperature of the coolant to about 90 °C (195 °F) (to make sure the thermostat is open) checking the on--board temperature gauge. • From the time the coolant temperature is reached, it is necessary to keep the engine running at high idle rpm to let the complete evacuation of the air. This situation can be verified checking that no air bubbles or foam are present in the expansion tank. • The maximum time for a full elimination of the air is about 15 minutes, from the time the thermostat opens. Important notices • Do not open the expansion tank cap from the time it is closed and the engine warm--up operation starts until when the engine is fully cooled-off. Consequently, any topping--up of missing coolant must be done when the engine is for sure cooled--off. This is to prevent two possible consequences: – burns for the person performing the operation; – possible damages to the engine, since the system is pressurised only when the coolant warms--up from a cold engine.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

ENGINE OVERHAUL ON BENCH Engine disassembly Drain the engine oil by removing the sump plug and the filler cap on the cylinder head cover. Remove the fan group from the fan pulley. To install bracket 380000661 to the engine to secure it on the engine overhaul stand proceed on the left side of the engine: • remove oil filter (2) from support (3) using tool 380000670; • remove oil pipes (1) and (4) of filter support (3); • remove support (3); • remove electric harness (5).

5 4

1 3 2

TH110061

48 To install bracket 380000661 on the right side of the engine, remove: • starter motor (3); • oil return (1) securing bracket (2); • oil return pipe (1) relative to the turbine; • remove oil pipes (4) and (5) from heat exchanger group (6). Secure the engine to rotary stand 380000301 • disconnect turbine lubrication delivery pipe (7)

7 1 2

3 5

TH110062

49 • • • • • • • • • •

disconnect the engine oil fumes recovery pipe from blow--by (1); remove rocker arm cover (4); remove electric harness (8); remove fuel filter (9); remove intake manifold (3); remove heater (2); remove heater (5) controller; remove LDA system pipe (13); remove quick release pipes (7), (10), (11) and (12) following the notices provided in figure 51; remove fuel filter support (6).

603.67.010.02 - 01 - 2004

2 1 13

10 TH110063

9 50

SECTION 10 -- ENGINE Actuate fork (1) as indicated in the figure (item B) and remove the connector. To prevent deformations, once the connector is separated, return fork (1) into locking position (item A).

TH110064

51 •

•

Disconnect supply pipes (5) from injection pump injectors (6); remove the securing brackets of the pipe group (1), (2) and (3) on the cylinder head. Remove primer pump (4).

TH110065

6 52

• •

Remove the supply pipe group from injectors (1). Remove fuel unloading pipe (2) from the injectors removing screw (4) and gasket (3).

4 TH110066

603.67.010.02 - 01 - 2004

48 • •

SECTION 10 -- ENGINE Remove screws (3) and proceed with the removal of turbine (1). Remove exhaust manifold (2).

2 3

TH110067

54 • • • •

Remove auxiliary organs belt (5) moving alternator securing bracket (1). Remove alternator (2), water pump (4), fan pulley (7) and guide pulley (6). Remove the support from pulley (8). Remove connection (3) of the engine cooling system from the cylinder block.

1 2

8 7

6 3

TH110068

5 55

Install tool 380000990 (1) to the flywheel housing to prevent the rotation of the flywheel.

TH110069

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Remove securing screws (1) from pulley (2).

1 TH110070

57 Seal ring removal Install tool 380000665 (4) on the nose (2) of the crankshaft. Drill inner sealing ring (1) with a drill (3.5 mm diam.) through the guide holes of tool 380000665 (4) for a depth of 5 mm. Secure tool 380000665 (4) on ring (1) tightening the 6 screws (5) provided. Pullout ring (1) tightening screw (3).

1 2

3 4 5 6 TH110071

58 Install the appropriate puller (3) of tool 380000669 to outer sealing ring (2) as indicated in the figure and using lever (4) extract it from front cover (1). Remove the front cover.

1 2

3 4

TH110072

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Remove oil gear pump (1).

ATTENTION Oil pump (1) cannot be overhauled. 1

TH110073

60 Removal of the injection pump Prior to removing the injection pump remove the flywheel locking tool described in figure 48. Turn the crankshaft until it is in the TDC on the 1st cylinder. The TDC condition of the 1st cylinder is obtained when pushing pin (1) indicated by the arrow, it rests in its seat drilled on camshaft drive gear (2).

2 TH110074

61 To pre--set correctly the injection pump prior to removing it, loosen screw (2) and remove “L” spacer (1). Retighten screw (2) full stroke.

ATTENTION Store “L” spacer in an appropriate manner with the pump body.

1 TH110075

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE • • •

Remove cover (1) from gear cover (2). Lock the engine flywheel as described in figure 48. Remove nut (4) securing injection pump drive gear (3).

2 3

TH110076

63 Remove the three nuts (2) (4) (5) securing injection pump (1) to flywheel housing (3) and extract it from its seat using tool 380000322 properly installed on gear (3) of figure 63B.

4 TH110077

64 Install tool 380000990 (2) to loosen screws (1). Remove tool 380000990 (2). Remove screws (1) securing flywheel (4) on crankshaft (3).

TH110078

65 Install two pins (2) of appropriate length in the holes of crankshaft (3). Extract flywheel (1) so that it is possible to sling it with a lifter and rest it in a container.

1 2

3 TH110079

66 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Install tool 380000663 (3) on the rear (5) of the crankshaft. Drill inner sealing ring (1) with a drill (3.5 mm diam.) for a depth of 5 mm. Secure tool 380000663 (3) on ring (1) tightening the 6 screws (4) provided. Pullout ring (1) tightening screw (2). 1 5

3 4

TH110080

67 Install the appropriate puller (3) of tool 380000669 to outer sealing ring (2) as indicated in the figure and using lever (4) extract it from flywheel housing (1).

1 2

TH110072

68 Remove screws (2) and remove rear cover (1).

ATTENTION Record the mounting position of screws (2) since they have different dimensions.

1 2

TH110081

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Turn the engine upside down, remove screws (2), remove plate (3) and remove oil sump (1).

1 2

TH110082

70 Remove screws (1) and (4) and remove oil suction strainer (5). Remove screws (2) and remove stiffening plate (3).

5 1 2 4

3 TH110083

71 Remove screws (1) and gear (3) from camshaft(2).

1 2

3 TH110084

72 Removal of rocker arm group For each cylinder, remove rocker arm group (1) loosening adjustment nuts (3), adjusters (2) and removing screws (4).

3 4

TH110057

73 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Extract injectors (2) using tool (1) 380000671.

2 TH110053

74 Remove screws (1) securing the heat to the cylinder block.

1 TH110085

75 Attach to brackets (1) and (2) the steel cables and remove the cylinder head from the cylinder block.

TH110086

76 Remove screws (2) and remove timing gear housing (1).

ATTENTION Record the mounting position of screws (2) since they have different dimensions.

TH110087

77 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Remove screws (1) securing conrod caps (2) and remove them. Extract the pistons complete with conrods from the top of the cylinder block.

ATTENTION Keep the half bearings in the relevant seats. In the event they are reused, they must be installed in the same position found at the disassembly.

2 TH110088

78 Remove screws (1) and remove main journal caps (2). 1 2

TH110089

79 The last but one main journal (1) and relevant support have half--bearing (2) equipped with thrust washer.

ATTENTION Record the mounting positions of the upper and lower half bearings, since in the event they are reused, they must be installed in the same position found at the disassembly.

1 2

TH110090

80 Lift crankshaft (2) from the cylinder block using tool 380000262 (1).

TH110091

81 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Remove main journal half bearings (1). Remove screws (2) and remove oil jets (3). 1 2

3 TH110092

82 Remove screws (1) and plate (2) retaining camshaft (3).

ATTENTION Record the mounting position of plate (2).

1 3

TH110093

83 Extract carefully camshaft (1) from the cylinder block.

TH110094

84 Extract tappets (1) from the cylinder block. 1

TH110095

85 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

REAPIR INTERVENTIONS ON THE CYLINDER GROUP

Checks and measurements Once the disassembly of the engine is completed, proceed with an accurate cleaning of the cylinders--cylinder block group. Use the appropriate eyes to handle the cylinder group. Check accurately that the engine cylinder block is free from cracks. Check the conditions of the machining plugs. Replace them when showing signs of rusting or there are doubts about their sealing. Examine the surfaces of the cylinder sleeves; they must be free from any sign of seizing, scratches, out--of round, tapering or excessive wear. The check of the inner diameter of the cylinder sleeves, to verify the amount of out--of--round, tapering and wear is made using bore gauge 380000827 (1) equipped with dial previously zeroed on ring caliper (2) with the diameter of the cylinder sleeve.

TH110096

ATTENTION In the event the ring caliper is not available, use a micrometer for the zeroing.

The measurements must be made for each single cylinder, at three different heights of the sleeve and on two planes perpendicular between them: one parallel to the longitudinal axis of the engine (A) and the other perpendicular (B). On the latter and in correspondence with the first measurement, the maximum wear is generally found. When an out--of round, tapering or any wear is found, proceed with the re--boring and grinding of the cylinder sleeves. The re--boring of the cylinder sleeves must be performed in relation with the diameter of pistons provided as spare parts oversized 0.5 mm over the nominal value and with the prescribed mounting play. TH110097

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE ATTENTION

In case of re--boring, all the sleeves must have the same oversize.

Check the seats of the main journal bearings proceeding as follows: • install the main journal caps without the bearings; • tighten the securing screws to the prescribed torque; • using an appropriate bore dial gauge, check that the diameter of the seats is at the prescribed value. In the event a higher value is found, replace the cylinder block.

TH110098

88 Checking the head mounting face on the cylinder block Check that the head mounting face on the cylinder block is not deformed. This check can be made, after removing dowels (4) using a calibrated ruler (2) and feeler gauge (3). In the event deformations are found, grind the mounting face. The flatness error cannot exceed 0.075 mm.

ATTENTION The grinding of the cylinder block can be performed only after making sure that once the work is finished, the protrusion of the piston from the cylinder sleeve does exceed the prescribed value.

Check the conditions of machining plugs (1). Replace them when showing signs of rusting or there are doubts about their sealing. Once the grinding is completed rework the bevel of the cylinder sleeves as indicated in Figure 88.

603.67.010.02 - 01 - 2004

TH110099

SECTION 10 -- ENGINE

TIMING

Camshaft

TH110100

MAIN CAMSHAFT DATA The data listed refer to the normal diameter of the pins.

The surfaces of the main journals and those of the cams must be absolutely smooth. In the event they show signs of seizing or scratches, replace the camshaft and the relevant bushes. Check of the cam lifting and the journals alignment Place the camshaft on centres and using a dial gauge on the central main journal, check the alignment deviation does not exceed 0.04 mm, otherwise replace the camshaft. Also, check the cam lifting. It must measure 7.239 mm for the exhaust ones and 6.045 mm for the intake ones, otherwise replace the camshaft. Check the diameter of camshaft (2) main journals with micrometer (1) on two axis perpendicular between them.

1 2

TH110101

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

BUSHES Bushes (2) of the camshaft must be forced into the relevant seats. The inner surfaces must be free from any sign of seizing or wear. Measure with bore gauge (3) the diameter of front and rear bushes (2) and intermediate seats (1) of the camshaft. The measurements must be done on two axis perpendicular between them.

2 TH110102

TH110103

MAIN DATA OF CAMSHAFT BUSHES AND RELEVANT SEATS * dimension to be obtained after press fitting the bushes

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Replacing the bushes To replace front and rear bushes (1) use puncher 380000667 (2) and holder 380000668 (3) for the disassembly and reassembly.

ATTENTION

Bushes (1) to be reassembled must be directed so that the lubrication holes coincide with those on the seats on the cylinder block.

3 2 TH110104

94 Tappets

MAIN DATA OF TAPPETS AND RELEVANT SEATS ON THE CYLINDER BLOCK

TH110105

95 AInstalling the tappets â&#x20AC;&#x201C; Camshaft Lubricate tappets (1) and install them in the relevant seats on the cylinder block.

1 TH110106

96 Lubricate the camshaft main journal bushes and install camshaft (1) taking care that, during the operation, the bushes or the support seats are not damaged. 1

TH110094

97 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Position plate (1) retaining camshaft (3) with the groove toward the upper side of the cylinder block and the stamping directed toward the operator. Tighten screws (2) to the prescribed torque. 1 3 2 TH110107

98 Check the axial play of camshaft (1). It must measure 0.23 Âą 0.13 mm.

TH110108

99 Install jets (2) and tighten securing screws (1) to the prescribed torque. 1

2 TH110109

100

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

CRANKSHAFT

Measuring main and conrod journals In the event signs of seizing, scoring or excessive out--of round are found on the main and conrod journals, it is necessary to grind them. Prior to proceeding with the journal (2) grinding operation, measure with micrometer (1) the journals, so as to establish to what diameter the journals must be undersized.

1 2

ATTENTION It is suggested that the data measured be recorded on a table. See Figure 102.

TH110110

101

The undersize classes are 0.250, 0.500 mm.

ATTENTION The main and conrod journals must always be ground to the same undersize class. The undersize done on the main and conrod journals must be recorded by an appropriate stamping done on the side of the no. 1 crank. For undersized conrod journals digit M. For undersized main journals digit B. For undersized conrod and main journals digits MB.

TH110111

DATA ON WHICH TO RECORD THE VALUES RELATIVE TO THE MEASUREMENT OF CRANKSHAFT MAIN AND CONROD JOURNALS * Nominal value

102

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Measured on a radius exceeding 45.5 mm

between adjacent main journals

TH110112

103 TOLERANCES FORM ORIENTATION POSITION OSCILLATION

MAIN CRANKSHAFT TOLERANCES FAETURE OF THE SUBJECT OF TOLERANCE Roundness Taper Parallelism Perpendicularity Straightness Out--of--round or concentricity Circular oscillation Total oscillation Taper

CLASS OF IMPORTANCE GIVEN TO THE FEATURES OF THE PRODUCT

GRAPHIC SYMBOL ○ /○/ //

GRAPHIC SYMBOL

CRITICAL



IMPORTANT

⊕

SECONDARY

⊝

CAMSHAFT DRIVE SIDE MAIN JOURNAL

INTERMEDIATE JOURNALS

FIRST JOURNAL FRONT SIDE

TH110113

104

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Replacement of oil pump drive gears Check that the teeth of gear (1) are undamaged and not worn, otherwise extract it with an appropriate puller (2). To reinstall a new gear warm it up for 10 minutes in an oven at 180Â°C and install it on the crankshaft including the key.

2 TH110114

105 Installation of main journal bearings

ATTENTION In the event the replacement of the main journal bearings is not required, it is necessary to reinstall them in the same identical order and position found at the disassembly.

Main journal bearings (1) are provided as spare parts with an undersized inner diameter of 0.20 â&#x20AC;&#x201C; 0.500 mm.

TH110115

106

ATTENTION Do not adjust the fitting of the bearings.

Clean accurately main journal half bearings (1) with the lubrication hole and install them in the relevant seats. The last but one main half bearing (1) is equipped with thrust washers. Measuring the installation play of the main journals Install crankshaft (1). Check the play between crankshaft main bearings and the relevant bearings, operating as follows. 1

TH110091

107

603.67.010.02 - 01 - 2004

66 • • •

SECTION 10 -- ENGINE clean accurately the parts and eliminate all traces of oil; place a piece of calibration wire (3) on crankshaft main journals (4) parallel to the longitudinal axis; install caps (1) complete with half bearings (2) on the relevant journals.

1 2 3 4

TH110116

108 Tighten screws (1) pre--lubricated in subsequent phase. • 1st phase with torque wrench * • 2nd phase with torque wrench * * the value of the torque is not available.

three

1 TH110117

109

3rd

phase with tool 380000304 (1) installed as shown in the figure and tighten further screws (2) to an angle * * the value of the torque is not available.

•

TH110118

110 • remove the caps from the journals. The play between main journal bearings and the relevant journals is measured by comparing the with of calibration wire (2) in the point of largest deformation, with the scale printed on wrapping (1) of the wire. The numbers listed on the scale indicate the play in millimetres. When a play different from the prescribed value is found, replace the half bearings and re--measure. Once the correct value is obtained, lubricate the main journal bearings and install permanently the supports, tightening the securing screws as previously described. 603.67.010.02 - 01 - 2004

2 TH110119

111

SECTION 10 -- ENGINE

Checking the crankshaft end play The check of the end play is done using a magnetic base dial gauge (2) on crankshaft (3) as indicated in the figure. Normal end play is 0.068 รท 0.410 mm. In the event an excessive play is found, replace the half bearings of the last but one thrust rear main journal (1) and repeat the check of the play between crankshaft and main journal half bearings. 1

2 3

TH110120

112

CONROD--PISTON ASSEMBLY

1 2

7 5 8 1

TH110121

COMPONENTS OF THE CONROD PISTON ASSEMBLY 1. 2. 3. 4.

Circlips Pin Piston Piston rings

5. 6. 7. 8.

113

Screws Half bearings Conrod Bush

ATTENTION Spare pistons oversized 0.5 mm are provided.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Removal of piston rings (1) from piston (2) using tool 380000221 (3). 1 2

TH110122

114 Removal of piston pin (1) circlips (2) is done using a scribing point (3).

1 2 3

TH110123

115

TH110124

MAIN DATA OF PISTON PINS AND PISTON RINGS * The dimension is measured on a 99 mm diameter

603.67.010.02 - 01 - 2004

116

SECTION 10 -- ENGINE

Pistons Measurement of piston diameter Measure with micrometer (2) the diameter of piston (1) to determine the mounting play.

ATTENTION The diameter must be measured 12 mm from the base of the piston skirt.

TH110125

117 The play between piston and cylinder sleeve can also be measured using a calliper and feeler gauge (1) as indicated in the figure.

TH110126

118 Piston pins Measurement of piston pin (1) using micrometer (2).

TH110127

119 Conditions for a correct pin--piston installation Lubricate pin (1) and the relevant seats on the piston with engine oil. The pin must enter the piston with a slight finger pressure and must not come out under the effect of gravity.

TH110128

120 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Piston rings Check the thickness of piston rings (2) using micrometer (1). 1 2

TH110129

121

Check the play between piston rings (3) of the 2nd and 3rd seat and the relevant seats on piston (2) using feeler gauge (1).

1 2

TH110130

122 DIAGRAM FOR THE MEASUREMENT OF PLAY BETWEEN THE FIRST PISTON SEAT AND TRAPEZOIDAL RING

Due to the peculiar shape of the first trapezoidal section ring, the play between seat and ring must be measured in the following manner. Have piston (1) protruding from cylinder block so that ring (2) gets about half out cylinder sleeve (3). Under these conditions, use a feeler gauge to measure play (X) between ring and seat. This play must be within the prescribed limits.

3 2

TH110131

123 Measuring the gap between the tip of piston rings (2) installed in cylinder sleeve (3) using feeler gauge (1).

3 TH110132

124 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Conrods MAIN DATA FOR CONROD, PISTON PIN BUSH AND HALF BEARING * Inner diameter to be obtained after press fitting in the conrod small end and reboring. ** Dimension not measurable at free state.

ATTENTION The conrod--conrod cap mounting faces are grooved for a better fitting. Consequently, it is recommended not to remove the grooves.

TH110133

125

ATTENTION Each conrod is marked: • On the body and cap a number indicating the match and the cylinder in which it is installed. Thus, in case of replacement it is necessary to renumber the new conrod with the same marking of the previous one. • On the conrod body a letter indicating the weight class of the conrod installed in production: -- V, 1820 ÷ 1860 (marked by a yellow colour); -- W, 1861 ÷ 1900 (marked by a green sign; -- X, 1901 ÷ 1940 (marked by a blue sign). Spare conrods are provided for class W colour coded green *. No removal of material is allowed.

TH110134

126

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Bushes Check that the bush in the conrod small end is not loose and it it is free from scratches or signs of seizing, otherwise replace it. The removal and installation are done using an appropriate punch. When press fitting, make absolutely sure that the oil passage holes on the bush and conrod small coincide. Use a boring tool to obtain the prescribed diameter. Checking the conrods Check the parallelism of conrod (1) centre lines using fixture 3800001003 (5) operating as follows: • install conrod (1) on the mandrel of fixture 3800001003 (5) and lock it with bscrew (4); • arrange mandrel (3) on “V” blocks resting conrod (1) on stop bar (2). 1

2 3 4

TH110135

127 Checking the torsion Check the torsion of conrod (5) comparing two points (A and B) of pin (3) on the conrod centre line horizontal plane. Place support (1) of dial gauge (2) so that the latter is preloaded ∼ 0.5 mm on pin (3) in point A and zero dial gauge (2). Move mandrel (4) with conrod (5) and compare on the opposite side (B) of pin (3) any possible discrepancy. The difference between A and B must not exceed 0.08 mm.

1 2 B

3 5 4

TH110136

128

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Checking the flexion Check the flexion of conrod (5) comparing the two points C and D of pin (3) on the vertical centre line of the conrod. Place vertical support (1) of dial gauge (2) so that the latter rests on point C of pin (3) . Rock the conrod for and aft looking for the highest position of the pin and zero dial gauge (2) in this position. Move the mandrel with conrod (5) and repeat on opposite side D of pin (3) and check the highest point. The difference between point C and point D must not exceed 0.8 mm.

1 2 D

5 3 4

TH110137

129 Assembly of conrod--piston assembly Mating of conrods-- pistons The following references are stamped on the ceiling of the piston: 1. Spare part number and number of engineering modification; 2. Date of manufacturing; 3. Indication of the mounting direction in the cylinder sleeve. It must be directed toward the front side of the cylinder block.

1 2

TH110138

130 Connect piston (2) to conrod (4) with pin (3) so that installation reference wording (1) of piston (2) in the cylinder sleeve and digits (5) stamped on conrod (4) are seen as indicated in the figure.

1 2 3

4 5 TH110139

131

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Insert circlips (2) securing pin (1).

1 2

TH110140

132 Installing piston rings To install piston rings (1) on piston (2) use pliers 380000221 (3). The rings must be installed with the wording “TOP” upward. Also position the ring gaps so that they are placed at 120° .

1 2

ATTENTION The piston rings are supplied as spare parts with the following dimensions: -- standard, marked by yellow paint; -- oversized 0.5 mm marked by yellow/green paint.

TH110122

133 Install half bearings (1) on both conrod and cap.

ATTENTION When the conrod bearings do not required being replaced, they must be reinstalled in the same sequence and position found during the disassembly. Do not perform any adjusting operation on the half bearings.

TH110141

134 Installation of conrod piston in the cylinder sleeves Lubricate thoroughly the pistons, including the piston rings and the surface of the piston sleeves. Use band 38000020 (2) to help with the installation of conrod--piston assembly (1) into the cylinder sleeve, checking that: • the number of each conrod corresponds to the matcing number of the cap.

TH110142

135 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

• • •

DIAGRAM FOR THE INSTALLATION OF THE CONROD--PISTON ASSEMBLY INTO THE GALLERY the gap of the piston rings must be 120 ° offset among them; the conrod/piston assemblies must have the same weight; the wording stamped on the ceiling of the pistons must be directed toward the front side of the cylinder block or the recess machined on the skirt of the pistons corresponds to the position of the oil jets.

TH110143

136 Measuring the installation play of the conrod pins To measure the play operate as follows: • clean accurately the parts and eliminate all traces of oil; • place a piece of calibrating wire (2) on crankshaft journals (1); • install conrod caps (3) with the relevant half bearings (4).

1 2 3 4

TH110144

137 •

tighten screws (1) previously lubricated with engine oil with torque wrench (2) to the prescribed torque.

2 1

TH110145

138 •

install tool 380000304 (1) on the socket and tighten further screws (2) at the angle.

1 2

TH110146

139 603.67.010.02 - 01 - 2004

76 โ ข

SECTION 10 -- ENGINE remove the cap and determine the existing play comparing the width of calibrated wire (1) with the scale printed on envelope (2) containing the wire.

TH110147

140 In the event a play different from the prescribed value is found, replace the half bearings and repeat the check. Once the prescribed play is obtained, lubricate the conrod half bearings and install them permanently tightening the conrod cap securing screws as described. 2

ATTENTION Prior to the final installation of the conrod cap securing screws, check their diameter, measured at the centre of the length of the thread, is not 0.1 mm smaller than the diameter measured at about 10 mm from the tip of the screw.

1 TH110148

141

Check manually that conrods (1) slide axially on the crankshaft journals and that their axial play measured with feeler gauge (2) is 0.10 รท 0.33 mm. Checking the piston protrusion Once the installation of the conrod--piston assemblies is over, check with dial gauge 380000228 (1) equipped wih base 380000364 (2) the protrusion of pistons (3) at T.D.C., with respect to the upper face of the cylinder block. It must be 0.28 รท 0.52 mm.

TH110149

142

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Timing Timing gear housing DIAGRAM OF THE ZONE OF APPLICATION OF LOCTITE 5999 SEALANT Clean accurately timing gear housing (1) and the cylinder block. The cleaning of the face to be sealed is necessary and indispensable to achieve an effective sealing. Apply sealant LOCTITE 5999 on the housing so that it forms a strip of a few mm diameter. It must be uniform (no lumps), free from air bubbles, thin zones or discontinue. Any imperfection must be corrected in the shortest possible time. Prevent using material in excess to seal the joint. To much sealant would escape on both sides of the joint and clog oil passages. After the application of the sealant is completed, the joints require an immediate fitting (10 – 20 minutes). DIAGRAM FOR THE TIGHTENING OF THE REAR GEAR HOSING SECURING SCREWS Reinstall housing (1) on the engine cylinder block. Tighten the securing screws in the position found at the disassembly and torque the screws to the prescribed value.

TH110150

143

TH110151

144 Setting the timing Using a felt pen, show the drive gear tooth (1) installed on crankshaft (2) on the side face of which the timing sign (→) is stamped.

TH110152

145

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Set crankshaft (4) and camshaft (2) so that when installing on the latter driven gear (1) the marks stamped on gears (1 and 3) coincide.

1 3 4 2 TH110153

146 Tighten screws (1) securing gear (2) to camshaft (3) to the prescribed torque.

3 TH110154

147 Injection pump â&#x20AC;&#x201C; Phase 1 Timing Position the first piston to T.D.C. The condition occurs when pin (1) indicated by the arrow enters the seat on camshaft drive gear (2). 1

2 TH110074

148 Install injection pump (1) in the seat of gear housing (2) and secure it with screws (3).

2 TH110155

149 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Install injection pump (1) in the seat of gear housing (2) and secure it with screws. 1

TH110156

150 Flywheel housing DIAGRAM OF THE LOCTITE 5999 SEALANT APPLICATION ZONE Clean accurately the mounting faces of flywheel housing (1) and timing gear housing. The cleaning of the face to be sealed is necessary and indispensable to achieve an effective sealing. Apply sealant LOCTITE 5999 on housing (1) so that it forms a strip of a few mm diameter. It must be uniform (no lumps), free from air bubbles, thin zones or discontinue. Any imperfection must be corrected in the shortest possible time. Prevent using material in excess to seal the joint. To much sealant would escape on both sides of the joint and clog oil passages. After the application of the sealant is completed, the joints require an immediate fitting (10 â&#x20AC;&#x201C; 20 minutes). DIAGRAM FOR THE NTIGHTENING OF THE FLYWHEEL HOUSING SECURING SCREWS Reinstall housing (I) on the engine cylinder block, installing the securing screws in the position found during the disassembly and tighten them to the prescribed torque.

TH110157

151

TH110158

152

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Install item (5) of tool 380000666 on the rear tip (6) of the crankshaft securing it with screws (4) and install on it the new sealing ring (3). Install item (1) on item (5) tightening nut (2) until sealing ring (3) is fully mounted in flywheel housing (7).

1 2

3 4 6

5 TH110159

153 ENGINE FLYWHEEL Check that the clutch disc contact face is free from scratches, otherwise machine it.

ATTENTION The nominal thickness of the engine flywheel is 37.6 mm. Replacing the engine flywheel ring gear Check the conditions of the teeth of flywheel ring gear (2). When failures or excessive wear of the teeth are found, remove it from the flywheel (1, fig. 154) using a punch and install a new one, previously warmed--up to 150 Â°C for about 15 â&#x20AC;&#x201C; 20 minutes. The bevel on the inner diameter of the ring gear must be directed toward the flywheel. Install two studs (2) of suitable length into the shaft holes (3) and install the flywheel (1) by means of suitable lifting slings and tackle.

TH110160

154

1 2

3 TH110079

155

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Install tool 380000990 (2) on flywheel housing (1) to prevent the rotation of engine flywheel (4). Tighten screws (3) securing flywheel (4) on the crankshaft.

TH110161

156 Tighten screws (1) securing flywheel (2) in two phases: • 1st phase, tightening with torque wrench to the prescribed value; • 2nd phase, angle tightening to the prescribed value.

ATTENTION The angle tightening is done with tool 380000304.

2 TH110162

157 Injection pump – Phase II Installation of injection pump – Phase II Tighten nut (1) to torque using torque wrench (2).

1 2

TH110163

158 Apply sealant (1) as indicated in the figure and install cover (2).

TH110164

159 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Remove pin (1) from the seat of the timing gear figure 61. Remove pre--setting screw (2) and insert â&#x20AC;&#x153;Lâ&#x20AC;? spacer (1). Retighten screw (2) to stroke end.

TH110075

1 160

Installing oil and water pump Install oil pump (1). Install securing screws (2) and tighten them to the prescribed torque.

1 2

TH110165

161 Install a new sealing ring (2) on water pump (1). 1

TH110166

162 Install water pump (1). Install screws (2) and tighten them to the prescribed torque.

2 TH110167

163 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Remove sealing ring (2) from front cover (1). Clean accurately the joint face and apply LOCTITE 5999 sealant on it. 1 2

TH110168

164 Clean accurately the joint face on the cylinder block of front cover (2) and install it. Install screws (1) and tighten them to the prescribed torque. 1

2 TH110169

165 Install item (4) of tool 380000666 on the front nose (6) of the crankshaft and secure it with screws (5) and install on it a new sealing ring (7). Place item (2) on item (4), tighten nut (3) until sealing ring (7) is fully mounted into front cover (1).

1 5 2 3 4 1 2

3 4 5

TH110170

166

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Installation of the oil sump Install plate (1) strainer (2) install securing screws (3) and tighten them to the prescribed torque.

TH110171

167 Install gasket (1) on oil sump (2).

ATTENTION When the gasket is in good conditions it can be reused.

1 2

TH110172

168 Install sump pump (1) install plate (3) on it. Install screws (2) and tighten them to the prescribed torque.

1 2

TH110082

169 Install pulley (1) on the crankshaft equipped with spacer (2) and tighten the screws to torque and angle using tool 3800000304. Secure idle pulley (4) to front cover (3) with screw (3).

3 1 2

TH110173

170 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Installation of water/oil heat exchanger Install a new seal (1) on the cylinder block, heat exchanger (2) a new seal (3) and oil filter support (4). Install screws (5) and tighten them to the prescribed torque.

1 2 3 4 5

TH110174

171 Lubricate sealing ring (1) with engine oil and install it on oil pipe connection (2). Install oil pipe connector (2) on support (4) Install a new sealing ring (3) in the cylinder block.

4 1

TH110175

172 Install alternator support (1) so that pins (3 and 4) are against the engine cylinder block. Install screws (2) and tighten them to the prescribed torque.

2 4

TH110176

173 Reinstall alternator (1) on alternator support (3). Tighten screws (2) not to torque.

3 TH110177

174 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Cylinder head Removal of valves The removal of the valves is performed with tools 380000302 (1) pressing plate (3) so that, by pressing springs (4) it is possible to remove half--cones (2). Then, remove plate (3) and springs (4). Repeat the operations on all valves.

2 3

TH110178

175 Extract oil seals (1) installed on the valve stems. To remove the valves, turn the head upside down.

ATTENTION Mark the exhaust and intake valves prior to their removal.

TH110179

176 Besides the dimensions of the head, the exhaust valves differ from the intake valves for the presence of additional groove (1) on the intake valve stem.

TH110180

177 Remove thermostat group (2) and brackets (1) and (3).

2 TH110181

178 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE Checking the cylinder head joint face The check of cylinder head (1) mounting face to the cylinder block is done with ruler (2) and feeler gauge (3). The deformation measured on the entire length of the head cylinder must not exceed 0.20 mm. When excessive values are found, grind the cylinder head in accordance with the values and instructions indicated in the figure to follow.

TH110182

179 Checking the sealing of the cylinder head Check the hydraulic sealing using the appropriate tooling. Inject, using a pump, heated water at ∼ 90 °C and a pressure of 2 ÷ 3 bar. In the event leakages from plugs or cups replace them using an appropriate tool for the removal--installation.

ATTENTION Prior to the installation of plugs, apply water repelling sealant on the joint faces.

In the event leakages are found the cylinder head must be replaced. The nominal thickness A of the cylinder head is 95 ± 0.25 mm. The maximum amount of metal that can be removed must not exceed thickness B equivalent to 0.13 mm.

ATTENTION After the grinding check the recess of the valves and regrind the valve seats as required, to provide the prescribed recess of the valves.

TH110183

180

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

VALVES INTAKE AND EXHAUST VALVE MAIN DATA

TH110184

181 De--scaling inspection and re--grinding of valves Remove the carbon deposits from the valves using an appropriate metal brush. Check that the valves do not show signs of seizing, cracks or burns. Re--grind, if required, the valve seats with grinder 380000828 removing the least possible amount of material.

TH110185

182 Use micrometer (2) to measure the stem of valves (1): it must result 7.96 รท 7.98 mm.

TH110186

183 Checking the play between valve stem and valve guide and valve centring The inspections are done with magnetic base dial gauge (1) positioned as illustrated; the mounting play is 0.039 รท 0.079 mm. Turning valve (2) check that the centring error does not exceed 0.03 mm.

1 2

TH110187

184 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

VALVE GUIDES Use a bore gauge to measure the inner diameter of the valve guides. The value must be as indicated in the figure.

TH110188

185 VALVE SEATS Re--grinding â&#x20AC;&#x201C; replacing the valve seats Check valve seats (2). When light scoring or burns are found, re--grind with tool 380000828 (1) in accordance with the bangle values indicated in Figure 187.

1 2

TH110189

186

TH110190

187

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

TH110191

188 MAIN DATA OF CYLINDER HEADS In the event the valve seats are not re--workable with a single re--grinding, it is possible to replace them with spare parts. Use the same tool 380000828 (1, Figure 186) and taking care to prevent grinding the cylinder head, remove as much material from the valve seats as possible, until it is possible to extract them from the cylinder head with a punch. Warm--up the cylinder head to 80 Ăˇ 100 Â°C and, using an appropriate punch, install into it the new valve seats previously cooled. Then, using tool 380000828, regrind the valve seats in accordance with the values shown in Figure 187. After the regrinding operations, with base 380000364 (2) and dial gauge 380000228 (1) check that the recess of valves (3) is at the prescribed value.

1 2 3

TH110192

189

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

VALVE SPRINGS MAIN DATA FOR THE INSPECTION OF THE INTAKE AND EXHAUST VALVE SPRINGS Prior to the re--installation, check the flexing of the valve springs using tool 380000976. Compare the load and elastic deformation data with the ones indicated in the table here below. Height

Under a load of

H (free)

63.50

no load

49.02

329

38.20

641

TH110193

190

ASSEMBLY OF CYLINDER HEAD Lubricate the valve stems and insert them in the relevant valveguides in accordance with the position marked at the disassembly. Install sealing rings (1) on the valve guides. 1

TH110179

191 Install on the cylinder head: spring (4) and upper plate (3). Using toll 380000302 (1) pressing spring (4) and secure the parts to valve (5) using half cones (2).

2 1

4 5 TH110178

192

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Reinstallation of cylinder head Check that the mounting face of the cylinder head and the cylinder block are clean. Do not dirt the cylinder head gasket.

ATTENTION Prior to re--using the screws securing the cylinder head check that they do not show signs of deterioration or deformation, otherwise replace them.

TH110194

193 Install the cylinder head on the cylinder block tightening screws (1) without torquing them. 1

TH110085

194 Before inserting the push rods check their conservation conditions. The ball contact seats with the rocker arm adjusting screws and the tappets (arrows) must not show signs of seizing or wear, otherwise replace them. The intake and exhaust valve push rods are identical, thus they are interchangeable.

TH110195

195 Rocker arm group ITEMS COMPOSING THE ROCKER ARM GROUP: 1. Support 2. Rocker arm 3. Shaft 4. Screws

3 TH110196

196 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

MAIN DATA FOR SHAFT--ROCKER ARM Check that the shaft/rocker arm mounting face do not show signs of excessive wear or damages.

TH110197

197 Check that the tappet adjusters are loosen to prevent the forcing them on the push rods when installing the rocker arm group (1). Then, install the rocker arm group made of rocker arm support and shafts and secure them to the head without tightening screws (2) and (3) to torque.

1 2

TH110198

198 Secure the head screws in accordance with the prescriptions indicated in Figure 200.

TH110199

199 Diagram of the tightening sequence of the screws securing the cylinder head *. • 1st phase pre--tightening with torque wrench * • 2nd phase, angle tightening * • 3rd phase, angle tightening * * The values of the torques and angle tightening and the diagram are not available.

DIAGRAM NOT AVAILABLE

TH110059

200 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Adjust the valve clearance using Allen wrench (1), ex wrench (2) and feeler gauge (3). The operating valve clearance is: -- intake valve 0.25 ± 0.05 mm -- exhaust valve 0.50 ± 0.05 mm.

ATTENTION In order to speed--up the adjustment of the valve clearance, proceed as follows: -- turn the crankshaft; balance the valves of no. 1 cylinder and adjust the valves marked by an axterix as indicated in the tables: cylinder no.

intake

–

exhaust

–

TH110056

201

Turn the crankshaft; balance the valves of no. 4 cylinder and adjust the valves marked by the axterisc as indicated in the diagram: cylinder no.

intake

–

exhaust

–

Installation of injectors Install a new sealing ring (2) lubricated with vaseline and a new sealing washer (3) on injector (1). Install the injectors in the seats on the cylinder head and tighten them with a torque wrench.

3 TH110054

202

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Install the injector fuel lines group (1). Install fuel unloading lines (2) from the injectors, using gaskets (3) and tightening screws (4).

4 TH110066

203 Install injector fuel lines (5) of injection pump (6), secure lines group (1), (2) and (3) brackets on the cylinder head. Install primer pump (4).

2 1

TH110065

5 204

• • • • • • •

• • •

Install rocker arm cover (4) Install heater (2) Install the elbow of intake manifold (3) Install heater controller (5) Install fuel filter support (6) Install fuel filter (9) Connect the lines with quick release couplings (7), (10), (11) and (12) following the recommendations listed in Figure 206. Install electric harness (8) Install the line of the LDA system (13) Connect the engine oil fumes recovery line to blow--by (1).

1 13

7 11

10 9

TH110063

205

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Press stop (1) in the direction of the arrow (item B) and connect the line. Return the stop in the initial locking position (item A).

TH110064

206 The intake manifold group is made of manifold (6) on the cylinder head, cover (5) gaskets (2) and (4) cold starting heater (3) and elbow (1). Apply LOCTITE 5999 sealant between cover (5) and manifold (6) and tighten the screws to the prescribed torque.

1 2 3 4 5

TH110019

207 • • • •

Install oil filter support (3) on the cylinder block Install oil filter (2) on support (3) Connect oil lines (1) and (4) on filter (2) Install electric harness (5) 5 4

3 TH110061

2 208

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE • •

Install exhaust manifold (3) Install turbine (1) using screws (2).

2 3 TH110067

209 • • •

Install starting motor (3) Install turbine lubrication oil return line (1) with the relevant securing screws (2) Install turbine oil lubrication delivery pipe (7) and engine oil pipes (4) and (5) to water/oil heat exchanger group (6).

7 1 6

2 3

5 4

TH110062

210 • • •

Install thermostat group (1) on cylinder head (3) tightening screws (2) to torque. Install coolant temperature sensor (6) tightening it with a torque wrench Install fan pulley support (5) on head (3) using screws (4) tightened to torque.

6 1

2 5

3 TH110031

4 211

Install fan pulley (2) on support (1) using screws (3) tightened to torque.

TH110032

212 603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

Install Poly--V belt (5) on the crankshaft pulley(7), on idle pulley (6), on water pump (4) and alternator (2); stretch the belt moving bracket (1) on alternator (2).

1 2

6 4

TH110068

5 213

REPLACING THE INJECTORS Removal Place the vehicle under safe conditions. Lift the engine compartment hood, disconnect the battery cables and proceed as follows: • disconnect engine oil fumes recovery line (2) from the blow--by; • remove rocker arm cover (1); • disconnect the lines of the fuel manifolds from injectors (3).

TH110052

214 Remove injectors (2) with tool 380000671 (1) and extract them from the cylinder head.

1 2 TH110053

215

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SECTION 10 -- ENGINE

Reinstallation Install a new sealing ring (2) lubricated with Vaseline on injector (3) and a new sealing washer (1). Install the injectors in the seats on the cylinder head using a torque wrench. 2

1 TH110054

216 Install new sealing rings (1) on fuel manifolds (2). Connect the manifolds to the injectors, tightening the securing nuts to a torque of 50 Nm. Reinstall the rocker arm cover. Reconnect the engine oil fumes recovery pipe to the blow--by. 2

TH110055

217

603.67.010.02 - 01 - 2004

100

SECTION 10 -- ENGINE

ADJUSTMENT OF VALVE CLEARANCE Adjust the valve clearance using Allen wrench (1) poly wrench (2) and feeler gauge (3). The operating valve clearance is: -- ± 0.05 mm -- intake valve 0.25 ± 0.05 mm -- exhaust valve 0.50 ± 0.05 mm.

1 2

ATTENTION

In order to speed--up the adjustment of the valve clearance, proceed as follows: -- turn the crankshaft; balance the valves of no. 1 cylinder and adjust the valves marked by an asterix as indicated in the tables: cylinder no.

intake

–

exhaust

–

TH110056

218

Turn the crankshaft; balance the valves of no. 4 cylinder and adjust the valves marked by the axterisc as indicated in the diagram: cylinder no.

intake

–

exhaust

–

REMOVAL/REINSTALLATION OF ROCKER ARMS Removal Loosen nuts (3) securing valve clearance adjuster and remove adjusters (2). Remove screws (4) and remove rocker arm group (1) made of rocker arm support and shafts and remove the valves.

TH110057

219 Reinstallation Check that the valve adjusters are loosen to prevent forcing them on the pushing rods during the reinstallation of the rocker arm group. Then, install the rocker arm groups made of rocker arm support and shafts and secure them to the cylinder head tightening the securing screws to a torque of 36 Nm. Proceed with the adjustment of the valve clearance as previously described.

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE SETTING OF TIMING

The timing drive is provided by a straight teeth gear mounted on the rear nose of the crankshaft engaging with the one mounted on the camshaft.

101

The timing setting is provided by matching the signs (â&#x2021;?) stamped on them.

TH110049

220

603.67.010.02 - 01 - 2004

102

SECTION 10 -- ENGINE

TIMING OF THE INJECTION PUMP Once the timing of the crankshaft with the camshaft is obtained, move the first piston to T.D.C. This condition is obtained by turning the crankshaft until the pin installed on the gear housing near the pump enters the relevant seat on the timing gear. When an injection pump is provided as spare part, it is already pre--set, thus it is sufficient to install it on the camshaft, secure it to the gear housing and remove appropriately the seal ensuring the pre--setting of the pump blocking its shaft. To check the correct timing, install dial gauge 380000228 (2) and adapter 380000229 (1) on the pump as indicated by the figure here below. Turn appropriately the crankshaft to eliminate the gear backlash and return the engine under the condition of T.D.C. on the first piston.

The dial gauge must read a value of 1 mm, equivalent to the stroke done by the pump distributor piston with respect to the B.D.C. in the event the prescribed value is not achieved, loosen the screws securing the pump to the gear housing and through the elongated holes, turn the pump body until the pre--load value is obtained. In the event the injection pump has been overhauled, when it is installed on the engine it must be pre-loaded to 1 mm with respect to the B.D.C. of the distributor piston. Install dial gauge 380000228 with its support 380000229 as in the figure here below and turn the pump body in the securing elongated holes until a 1 mm value is measured by the dial gauge. Secure the pump on the gear housing and check as previously described.

TH110050

221

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SECTION 10 -- ENGINE ELECTRICAL COMPONENTS

103

Pre--post heating controller Controller 1 defines the time of intervention of the heater (pre--post heater) as a function of temperature 2 of the engine coolant.

Pre--post heating kit (for engines P4BE0484 G*D600 – F4BE0484 F*D601) (*). • Coolant sensor KKSB, on injection pump. • Oil pressure sensor piloting the oil pressure indicator light on the dashboard. (*) Controller, engine coolant temperature sensor, heater. •

Diagram of principle 1 5

TH110051

1. 2. 3.

Pre--post heating controller Coolant temperature sensor Heater solenoid switch

4. 5.

Heater Pre--heating indicator light on dashboard

222

603.67.010.02 - 01 - 2004

104

SECTION 10 -- ENGINE

TROUBLESHOOTING The engine fails to start Cause 1. Batteries partially exhausted. 2. Battery terminal connections corroded or loosen. 3. Wrong timing of injection pump on the engine. 4. Accumulation of dirt or water in fuel lines.

Remedy 1. Check; recharge batteries and replace, if required. 2. Clean; check, tighten nuts and, if required, replace excessively corroded terminals and nuts 3. Set correct timing of injection pump on engine.

5. Empty fuel tank.

4. Disconnect lines and injection pump and clean accurately. If necessary, clean and dry fuel tank. 5. Refuel.

6. Presence of air in fuel lines.

6. Check fuel pump and replace if required.

7. No fuel supply to injection pump.

8. Starter motor damaged.

7. Check lines, connections, fuel pump, filters and injection pump to ascertain presence of air, the bleed the system. 8. Repair or replace starter motor.

9. Cold starting system inefficient.

9. Check or replace cold starter.

The engine stalls Cause 1. Low idle too low. 2. Irregular deliveries by injection pump. 3. Accumulation of dirt and water in fuel lines. 4. Clogged fuel filters. 5. Abnormal valve clearance. 6. Burnt or cracked valves. 7. Presence of air in fuel lines.

8. Injection pump drive damaged.

Rimedio 1. Adjust low idle. 2. Check calibration of deliveries on bench. 3. Disconnect lines and injection pump and clean accurately. If necessary, clean and dry fuel tank. 4. Replace filter integral cartridges. 5. Adjust valve clearance. 6. Replace valves. 7. Check lines, connections, fuel pump, filters and injection pump to ascertain presence of air, the bleed the system. 8. Replace damaged parts.

The engine is overheating Cause 1. Inefficient cooling system pump.

Remedy 1. Overhaul pump and replace, if necessary.

2. Inefficient thermostat

2. Replace thermostat.

3. Radiator partially inefficient.

3. Eliminate possible scaling by flushing, check and repair possible leakages from pipes.

4. Scaling in the coolant passages in cylinder head and cylinder block.

4. Flush accurately

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

105

The engine overheats (cont.ed) Cause 5. Insufficient tension of centrifugal and fan drive pump. 6. Coolant (insufficient quantity). 7. Wrong timing. 8. Injection pump out of calibration both in excess and defect 9. Clogged air cleaner.

Remedy 5. Check and adjust the belt tension. 6. Top--up level in expansion tank using the prescribed liquid. 7. Check and adjust timing correctly. 8. Calibrate the injection pump on bench complying with the calibration tables. 9. Clean the group and replace filtering element as required.

The engine lacks power and operates irregularly Cause 1. Wrong timing of injection pump on engine.

Remedy 1. Set correct timing of injection pump on engine.

2. Advance automatic variator in injection pump damaged.

2. Overhaul injection pump and calibrate it on test bench complying with relevant calibration table.

3. Worn distributor pumping element.

3. Overhaul injection pump and calibrate it on test bench complying with relevant calibration table.

4. Irregular deliveries by injection pump.

4. Overhaul injection pump and calibrate it on test bench complying with relevant calibration table. 5. Overhaul injection pump and calibrate it on test bench complying with relevant calibration table. 6. Clean, overhaul and calibrate the injectors.

5. All--speed governor damaged. 6. Partially clogged or damaged injectors. 7. Accumulation of dirt or water in fuel lines.

8. Damaged fuel supply pump.

7. Disconnect pipes, injection pump and clean accurately, if required, clean and dry the fuel tank; 8. Replace fuel pump.

9. Abnormal valve clearance.

9. Adjust valve clearance.

10. Insufficient cylinder compression.

10. Check compression and overhaul engine, if required. 11. Clean the group and replace filtering element, if required. 12. Adjust length of rod.

11. Clogged air cleaner. 12. Length of rod between throttle and injection pump out of adjustment. 13. Injection pump with max. speed stroke end screw out of adjustment.

13. Adjust maximum idle screw.

603.67.010.02 - 01 - 2004

106

SECTION 10 -- ENGINE

The engine has abnormal knocks Cause 1. Injectors partially clogged or damaged. 2. Accumulation of dirt in fuel lines. 3. Wrong timing of injection pump on engine. 4. Knocks in the engine caused by excessive play of one or more main or conrod journals or excessive end--play. 5. Unbalanced crankshaft. 6. Loosen flywheel securing screws. 7. Conrods with non parallel axis. 8. Knocking piston due to abnormal wear. 9. Noisy piston pins for excessive play in the piston seats and conrod bush. Free bushes in conrod seat. 10. Ticking due to noisy timing.

Remedy 1. Clean, overhaul and calibrate correctly the injectors. 2. Clean pipes and replace the ones showing dents or markings; clean injection pump, if required. 3. Provide correct timing of injection pump on engine. 4. Grind crankshaft journals; install oversized bearings and thrust bearings. 5. Check alignment and balance of crankshaft; replace if required. 6. Replace loosen screws and tighten all of them to prescribed torque + angle. 7. Straighten conrods; check parallelism of axes and replace conrods if required. 8. Re--bore cylinder sleeves and install oversized pistons. 9. Replace piston pin with oversized one; re--bore seats on piston and conrod bushes. Replace bushes with new ones. 10. Check that there are no broken springs, excessive play between stems and guides, tappets and seats. Adjust valve clearance.

The engine smokes in abnormal way: black or grey smoke Cause 1. Excessive maximum delivery by injection pump. 2. Injectors pump is excessively retarded or the automatic advance variator is damaged. 3. The injection pump is excessively advanced. 4. Injectors partially and/or totally clogged or out of calibration. 5. Clogged air cleaner. 6. Loss of compression by the engine due to: -- Sticky piston rings -- Wear of cylinder sleeves -- Valves deteriorated or out of adjustment. 7. Damaged injection lines.

603.67.010.02 - 01 - 2004

Remedy 1. Calibrate injection pump on test bench complying with relevant calibration table. 2. Perform the correct timing of the injection pump on engine or check advance automatic variator. 3. Perform correct timing of injection pump on engine. 4. Clean, overhaul and calibrate correctly the injectors. Replace them, if required. 5. Clean the group and replace filtering element, if required. 6. Replace damaged parts and overhaul engine, if required.

7. Check the conditions of the lines and replace them, if required.

SECTION 10 -- ENGINE

107

Blue, grey-- blue or grey tending to white smoke Cause 1. The injection pump is excessively retarded or automatic advanced variator is damaged. 2. Seized or defective injectors. 3. Passage of oil through piston rings caused by sticky rings or wear of cylinder sleeves. 4. Passage of oil through intake valve guides due to wear of guides or valve stems. 5. The engine does not reach the operating temperature (damaged thermostat).

Remedy 1. Perform the correct timing of the injection pump on engine or check advance automatic variator. 2. Clean, overhaul and correctly calibrate the injectors. Replace them, if necessary. 3. Replace damaged parts or overhaul the engine, if required. 4. Overhaul cylinder head. 5. Replace thermostat.

The engine does not cut--off Cause 1. Damaged cut--off solenoid. 2. Damaged all--speed governor.

Remedy 1. Replace the solenoid. 2. Overhaul the injection pump and calibrate it on the test bench, complying with the relevant calibration tables.

603.67.010.02 - 01 - 2004

108

SECTION 10 -- ENGINE

TOOLING TOOL no.

DESIGNATION

380000216

Balanced rig for engine removal and installation

380000220

Band for piston insertion into cylinder sleeves (60--125 mm)

380000221

Pliers for piston rings removal and installation (65--110 mm)

380000228

Dial gauge (0--5 mm)

380000229

Dial gauge holder tool for rotary injection pump timing (use w/ 380000228)

380000362

Engine crankshaft lifting tool

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

109

TOOL no.

DESIGNATION

380000301

Rotary stand for group overhauls (capacity 1000 daN, torque 120 daN/m)

380000302

Engine valves removal and installation tool

380000304

Set of measuring tools for angle tightening w/ 1/2’’ and 3/4’’square

380000322

Puller for gear connecting injection pump to engine

380000661

Brackets securing engine to rotary stand 380000301

603.67.010.02 - 01 - 2004

110

SECTION 10 -- ENGINE

TOOL no.

DESIGNATION

380000663

Puller tool for crankshaft rear seal extraction

380000664

Mounting tool for crankshaft rear seal

380000665

Puller tool for crankshaft front seal extraction

380000666

Mounting tool for crankshaft front seal

380000667

Punch for removal and installation of camshaft bushes (w/ 380000668)

380000668

Handle for interchangeable punches

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

TOOL no.

DESIGNATION

380000669

Seal extraction tool

380000670

Cartridge filter removal tool

380000671

Injector puller tool

111

603.67.010.02 - 01 - 2004

112

SECTION 10 -- ENGINE

DATA – MOUNTING PLAYS F4BE0484 Type CYLINDER AND CRANK ORGANS GROUP

Cylinder sleeves

∅1

Pistons: supplied as spare parts type tipo Measuring dimension X Outer diameter ∅1 Pin set ∅2 Piston – cylinder sleeve Piston diameter

Location of pistons in cylinder block

Piston pin

102.01 ÷ 102.03

61 101.777 ÷ 101.795 40.006 ÷ 40.012 0.215 ÷ 0.253

∅1

∅3

Piston pin – pin seat Type of piston Piston ring seats

F*D601

G*D600

0.5

0.28 ÷ 0.52

39.9968 ÷ 40.0032 0.0028 ÷ 0.0152

X1* X2 X3

2.69 2.425 ÷ 2.445 4.04 ÷ 4.06

S1* S2 S3

2.560 ÷ 2.605 2.310 ÷ 2.340 3.075 ÷ 4.000

1 2 3

0.245 ÷ 0.265 0.085 ÷ 0.135 0.040 ÷ 0.985

* measured on ∅ di 99 mm Piston rings * measured on ∅ 99 mm Piston rings -- seats

Piston rings

603.67.010.02 - 01 - 2004

0.5

SECTION 10 -- ENGINE

113

F4BE0484 Type

F*D601

G*D600

CYLINDER AND CRANK ORGANS GROUP

Gap of piston rings in cylinder sleeves: X1 X2 X3

0.40 ÷ 0.70 0.25 ÷ 0.55 0.25 ÷ 0.55

Seat of bush in conrod small end ∅1 Conrod bearing seat ∅2

42.987 ÷ 43.013 77.075 ÷ 78.25

Conrod bearing seat Outer Inner

43.279 ÷ 43.553 40.019 ÷ 40.033

∅4 ∅3

Conrod small end--seat bush

0.266 ÷ 0.566

Piston pin – bush pin

0.0158 ÷ 0.0362

Measurement dimension

Maximum error on parallelism axes of conrod

Main journal Conrod journal Main journal half bearings Conrod journal half bearings * provided as spare parts Main journal nos.: no. 1--5 no. 2--3--4

∅1 ∅2 S1* S2*

82.99 ÷ 83.01 68.987 ÷ 69.013 2.456 ÷ 2.464 1.955 ÷ 1.968

∅3

87.982 ÷ 88.008 87.977 ÷ 88.013

603.67.010.02 - 01 - 2004

114

SECTION 10 -- ENGINE

F4BE0484 Type CYLINDER AND CRANK ORGANS GROUP

Half bearings – main journals: no. 1--5 no. 2--3--4

0.041 ÷ 0.119 0.041 ÷ 0.103

Half bearings – conrod journals

0.033 ÷ 0.041

Main journal half bearings Conrod half bearings

+ 0.250; + 0.500

Thrust main journal

Thrust main journal support

Thrust half rings

Cranckshaft thrust

603.67.010.02 - 01 - 2004

F*D601

G*D600

37.475 ÷ 37.545

25.98 ÷ 26.48

37.28 ÷ 37.38

0.068 ÷ 0.410

SECTION 10 -- ENGINE

115

F4BE0484 Type CYLINDER AND CRANK ORGANS GROUP Valve guide seats on cylinder head

F*D601

G*D600 mm

∅1

8.019 ÷ 8.039

∅4 α ∅4 α

7.96 ÷ 7.98 60° 7.96 ÷ 7.98 45°

Valves:

Valve stem and relevant guide

0.052 ÷ 0.092

Seat on head for valve seat: ∅1

46.987 ÷ 47.013

∅1

43.637 ÷ 43.663

Outer diameter of valve seat; angle of valve seat on cylinder head: ∅2 α ∅2 α Recess

Between valve seat and head

47.063 ÷ 47.089 60° 43.713 ÷ 43.739 45°

0.356 ÷ 1.102

0.104 ÷ 0.840 0.050 ÷ 0.102 0.050 ÷ 0.102

Valve seats

603.67.010.02 - 01 - 2004

116

SECTION 10 -- ENGINE

F4BE0484 Type CYLINDER AND CRANK ORGANS GROUP Valve spring height: free length: under a load of: 329 N 641 N

F*D601

G*D600 mm H

63.5

H1 H2

49.02 38.20

not adjustable

Injector protrusion

Seats for camshaft bushes no. 1--5 Camshaft seats no. 2--3--4

---

Camshaft journals: 1⇒5

∅

53.995 ÷ 54.045

Outer diameter of camshaft bushes:

∅

Bush inner diameter

∅

54.083 ÷ 54.147

Bushes and seats in cylinder block Bushes and main journals

-0.038 ÷ 0.162

Cam lift: 6.045 7.239

603.67.010.02 - 01 - 2004

SECTION 10 -- ENGINE

117

F4BE0484 Type CYLINDER AND CRANK ORGANS GROUP

∅1

∅2 ∅3

Tappet plate seat in cylinder block

F*D601

G*D600 mm

∅1

16.000 ÷ 16.030

Outer diameter of tappet plate: ∅2 ∅3

∅2 Between tappets and seats

15.929 ÷ 15.959 15.965 ÷ 15.980 0.020 ÷ 0.065

Tappets

∅1

Rocker arm shaft

∅1

18.963 ÷ 18.975

Rocker arms

∅2

19.000 ÷ 19.026

∅2

Between rocker arm and shaft

0.025 ÷ 0.063

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

SECTION 21 -- POWERSHIFT GEARBOX CONTENT Section 21 000

Description

Page

Powershift Gearbox 4x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Driving with the powershift gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gearbox assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Idler gear case assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Gearbox operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Transmission and Hydraulic oil circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Modulation valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Torque converter and heat exchanger hydraulic oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Troubleshooting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Pressure testing clutch and high pressure circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Pressure testing torque converter and cooler circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Check points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

POWERSHIFT GEARBOX 4 X 3 Gearbox control The microprocessor--controlled gearbox assembled on this machine is called Powershift. The Powershift gearbox lever is assembled on the left side of the steering column and it enables the electronic selection of four forward gears and three reverse gears.

TH121230

DRIVING WITH THE POWERSHIFT GEARBOX

Neutral position N

Select the neutral position by shifting the gearbox level to the centre.

Selecting the forward gear To select the forward gear, pull the lever towards the steering wheel and push it upwards. NOTE: Actual forward gear selection at this time depends upon vehicle conditions; if it is moving, the microprocessor will take into consideration speed on road and running direction before any gear shift can take place. Selecting the reverse gear To select the reverse gear pull the lever towards the steering wheel and push it downwards. NOTE: Actual reverse gear selection at this time depends upon vehicle conditions; if it is moving, the microprocessor will take into consideration speed on road and running direction before any gear shift can take place.

603.67.010.02 - 01 - 2004

TH121231

SECTION 21 -- POWERSHIFT

Automatic gear increase Automatic increase from the 1st gear position to the required gear is achieved by turning the handgrip anticlockwise by single movements. If the lever is kept on this position, the processor will make the gear selection advance from the 2nd gear to the 4th gear by intervals of 1.8 seconds. NOTES: The request for automatic increase, after a decrease, is delayed by 2 seconds. In the case of a speed sensor error, the microprocessor will not authorize increases over the 2 nd gear.

TH121230

NOTES: Should a steep slope be driven up, select the 2 nd gear speed and proceed, if enabled by speed and power, to the 3 rd and 4 th gear speed. Automatic gear decrease

s s s

ATTENTION

To drive down a steep slope, select the 2nd speed gear and proceed by increasing it only when this is possible in full safety. As a matter of fact IT IS NOT POSSIBLE TO SHIFT DOWN A GEAR TO REDUCE VEHICLE SPEED IF THIS IS OVER 15 Km/h. Automatic gear decrease down to the required speed gear is obtained by turning the handgrip clockwise by single movements. Changing direction Running direction is simply inverted by moving the Powershift lever to the reverse gear and the other way round, and this operation is allowed at any time. System response in any case depends upon vehicle speed and upon the speed gear used at the moment. When driving in 1st or 2nd speed gear, changes in direction have no limits and they are performed immediately.

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

When driving in 3rd or 4th forward speed gear, two responses are possible, depending on vehicle speed. RESPONSE 1: If vehicle forward speed is over 15 km/h and a reverse gear is selected, automatic down shift is activated, but inertia however remains until speed is reduced sufficiently to enable performing inversion in 2nd speed gear. RESPONSE 2: If vehicle forward speed is below 15 km/h, the reverse gear is immediately obteined in 2nd speed gear.

Shown speed ranges refer to a Powershift gearbox with 13.00 â&#x20AC;&#x201C; 24 wheels corresponding to a wheel diameter of 1200 mm. * Except different specifications of foreign Countries

TH121229

4 DISCONNECTING THE GEARBOX

Gearbox disconnection can be performed in two different ways: 1. Powershift speed gear lever 2. Push button on manipulator

Gearbox disconnection is a consequence of applying the parking brake. Normal gearbox operation is restored as soon as the brake is released.

2 TH121232

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

GEARBOX ASSEMBLY The gearbox comprises five main assemblies

TH121001

1. The converter 2. The input shaft and directional clutches: A – Reverse B – Forward

3. The output shaft with C (4th speed) and D (3rd speed) clutch assemblies

4. The lower shaft with E (1st speed) and F (2nd speed) clutch assemblies 5. The output shaft to the idler gear case

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

GEAR AND CLUTCH POSITION F E

TH121002

7 Reverse (A)/Forward (B)

4th speed (C)/3rd speed (D)

1st speed (E)/2nd speed (F)

Output shaft with gear

Idler gear

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

IDLER GEAR CASE ASSEMBLY The idler gear case is mounted directly on the transmission. The sleeve (3) connects the transmission output shaft directly to the idler gear case input shaft (1). The front and rear axles are set in motion by the output shaft (2) via the drive shafts.

TH121228

1. The input shaft

3. The connecting sleeve

2. The output shaft

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

GEARBOX OPERATION Through the converter, the thermal engine transmits motion to the gearbox input shaft, on which the advance/reverse motion clutches are assembled. Depending on the gearbox control lever selection, solenoid valves are energised/de--energised to enable oil

under pressure to engage the clutch packages corresponding to the selected direction and speed. NOTE: For details, see the following pages.

TH121004

Control pump converter and pressure adjusting valve

Output shaft

Input shaft and direction clutches (forward/reverse)

Speed clutches

Speed gears

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Converter, pump control section and pressure adjustment valve Engine power is transmitted from the engine flywheel to the impeller through the impeller cover. This element is the pump portion of the hydraulic torque converter and is the primary component which starts the oil flowing to the other components which results in torque multiplication. This element can be compared to a centrifugal pump, that picks up fluid at its centre and discharges it at the outer diameter. The torque converter turbine is mounted opposite the impeller and is connected to the turbine shaft of the torque converter. This element receives fluid at its outer diameter and discharges it at its centre. The reaction member of the torque converter is located between and at the centre of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element. This recirculation will make the converter multiply torque.

The torque multiplication is function of the blading (impeller, turbine and reaction member) and the converter output speed (turbine speed). The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM (stall). Therefore we can say that as the turbine shaft is decreasing in speed, the torque multiplication is increasing. The hydraulic pump is connected to the pump mechanism. The compressor hub gear drives this mechanism. Since the compressor hub gear is connected to the compressor cover, pump speed is directly related to engine speed. NOTE: The pressure regulator valve is mounted behind the filter, in the filter adapter housing.

A B C

TH121005

10 Converter, pump control section and pressure adjustment valve.

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Input shaft and directional clutches The turbine shaft, driven by the turbine, transmits power to forward gear, at 4th speed or at reverse speed. These clutches consist of a drum with internal splines and a bore to receive a hydraulically actuated piston. The piston is kept oil tight by the use of sealing rings. The steel discs with external splines, and friction discs with internal splines, are alternated until the required total is achieved. A back--up plate is then inserted and secured with a retainer ring. A hub with outer diameter splines is inserted into the splines of discs with teeth on the inner diameter. The discs and hub are free to increase in speed or rotate in the opposite direction as long as no pressure is present in that specific clutch. To engage the clutch, the solenoid will direct oil under pressure through tubes and passages to the selected clutch shafts. Oil sealing rings are located on the clutch shafts. These rings direct the oil through a drilled passage in the shaft to the desired clutch.

Pressure of the oil forces the piston and discs against the back--up plate. The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and allows them to drive as one unit. When the clutch is released, a return spring will push the piston back and oil will drain back via the solenoid, the bleed valve or holes in the clutch piston into the transmission sump. These bleed valves will only allow quick escape of oil when the pressure to the piston is released. The transmission is equipped with a reverse gear and two forward gears (forward and 4th gear): These speeds combined with a 3--speed clutch, produces a type of transmission with 4--forward gears and 3--reverse gears at different speeds. The engagement of the directional clutches (forward and reverse) are modulated. This means that clutch pressure is built up gradually. This will enable the unit to make forward, reverse shifts while the vehicle is still moving and will allow smooth engagement of drive. The modulation is done hydraulically.

A B C

TH121006

11 The input shaft and directional clutches

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

The range clutches

The output section

Once a directional clutch is engaged power is transmitted to the range clutches (1st, 2nd or 3rd). Operation and actuation of the range clutches is similar to the directional clutches. The engagement of the range clutches is not modulated.

With a range clutch engaged, power is finally transmitted to the output shaft. Output rotation is same as the engine rotation when the forward clutch is engaged. A front axle disconnect is optional and is located on the output shaft. The drive to the front axle can be disconnected or connected by manual shifting.

C D

E F

TH121007

TH121008

12 The range clutches

13 The output section

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

The transmission controls (refer to hydraulic diagram) The transmission is controlled by the direction and range solenoids. The solenoids are mounted on the left side of the transmission case. When the selected direction and range solenoids are energised, oil under pressure will flow through tubes and passages to the selected clutch shafts.

Oil sealing rings are located on the clutch shafts. These rings direct oil under pressure through a drilled passage in the shaft to the desired clutch.

TH121009

14 The transmission controls R. Reverse gear solenoid valve T. Forward gear solenoid valve S. Splitter solenoid valve

603.67.010.02 - 01 - 2004

1. 2.

Solenoid valve (1) Solenoid valve (2)

SECTION 21 -- POWERSHIFT

SOLENOID/CLUTCH COMBINATION 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. SOLENOIDS GEAR

CLUTCHPACKS 1

A4 A3 A2 A1 N R1 R2 R3 15 The clutches are engaged by hydraulic pressure and disengaged by spring. 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 to engine rotation.

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

2 1

3 4 8 5 6 7

TH121010

Operating Valves and Solenoids 1. Forward Feathering Valve

5. Solenoid (S)

2. Reverse Feathering Valve

6. Solenoid (1)

3. Solenoid (R)

7. Solenoid (2)

4. Solenoid (T)

8. Housing

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TRANSMISSION AND HYDRAULIC OIL CIRCUIT DIAGRAMS NEUTRAL GEAR ENGAGED

A – Reverse clutch B – Forward clutch C – 4th speed clutch D – 3th speed clutch E – 1st speed clutch F – 2nd speed clutch

Operating solenoids: none TH121011

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TH121012

18 Aspirated oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.5 bar)

Return to reservoir

VT Forward modulation valve

Pressure oil from the system regulating valve flows to the 1 solenoid and forward solenoid T. None of the solenoids are engaged, allowing the oil to flow through to the clutch D only.

603.67.010.02 - 01 - 2004

VR Reverse modulation valve

Clutches A, B, C, D, E and F are open to reservoir.

SECTION 21 -- POWERSHIFT

TRANSMISSION OPERATION FIRST GEAR ENGAGED

A – Reverse clutch B – Forward clutch C – 4th speed clutch D – 3th speed clutch E – 1st speed clutch F – 2nd speed clutch

Operating solenoids: T, 1 and 2 TH121013

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TH121014

20 Aspirated oil High pressure oil (16.5 -- 19.3 bar)

VT Forward modulation valve

Pressurised oil coming from the system regulation valve arrives at solenoid valve 1 and at the forward gear solenoid valve. Solenoid valve 1 is energised and it enables system pressure to engage clutch E. At this point solenoid valve 2 is energised enabling pressurised oil possibly present in clutches D or F to be discharged into the sump.

603.67.010.02 - 01 - 2004

Torque converter and lubrication oil (2 -- 7 bar) Return to reservoir VR 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 increases with smooth modulation. Clutches A, C, D and F are open to the reservoir.

SECTION 21 -- POWERSHIFT

TRANSMISSION OPERATION SECOND GEAR ENGAGED

A – Reverse clutch B – Forward clutch C – 4th speed clutch D – 3th speed clutch E – 1st speed clutch F – 2nd speed clutch

Operating solenoids: T and 2 TH121015

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TH121016

22 Aspirated oil High pressure oil (16.5 -- 19.3 bar)

VT Forward modulation valve

Pressurised oil coming from the system regulation valve arrives at solenoid valve 1 and at the forward gear solenoid valve. Solenoid valve 2 is energised enabling system pressure to engage clutch F. The forward solenoid is energised allowing system pressure to flow through the splitter solenoid, to the forward B clutch.

603.67.010.02 - 01 - 2004

Torque converter and lubrication oil (2 -- 7 bar) Return to reservoir VR Reverse modulation valve

Modulation is controlled by the modulation valve in the circuit. As pressure increases in the forward clutch line, drive increases with smooth modulation. Clutches A, C, D and E are open to the reservoir.

SECTION 21 -- POWERSHIFT

TRANSMISSION OPERATION THIRD GEAR ENGAGED

A – Reverse clutch B – Forward clutch C – 4th speed clutch D – 3th speed clutch E – 1st speed clutch F – 2nd speed clutch

Operating solenoids: T TH121017

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TH121018

24 Aspirated oil High pressure oil (16.5 -- 19.3 bar)

VT Forward modulation valve

Pressurised oil coming from the system regulation valve arrives at solenoid valve 1 and at the forward gear solenoid valve. Since neither solenoid valve 1, nor solenoid valve 2 are energised, pressurised oil can engage clutch D.

603.67.010.02 - 01 - 2004

Torque converter and lubrication oil (2 -- 7 bar) Return to reservoir VR Reverse modulation valve

Forward gear T solenoid valve is energised and it enables oil to flow through the separation solenoid valve S. which is not energised, and from there to clutch B. Clutches A, C, E and F are open to the reservoir.

SECTION 21 -- POWERSHIFT

TRANSMISSION OPERATION FOURTH GEAR ENGAGED*

A – Reverse clutch B – Forward clutch C – 4th speed clutch D – 3th speed clutch E – 1st speed clutch F – 2nd speed clutch

Operating solenoids: T and S TH121019

* Except different specifications of foreign Countries

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TH121020

26 Aspirated oil High pressure oil (16.5 -- 19.3 bar)

VT Forward modulation valve

Pressurised oil coming from the system regulation valve arrives at solenoid valve 1 and at the forward gear solenoid valve. Oil flows through solenoid valve 2 and engages the multi--disk clutch D.

603.67.010.02 - 01 - 2004

Torque converter and lubrication oil (2 -- 7 bar) Return to reservoir VR Reverse modulation valve

Oil flows through forward gear T solenoid valve which is energised, then through separation solenoid valve S which is also energised, and which engages multi--disk C clutch. Clutches A, B, E and F are open to the reservoir.

SECTION 21 -- POWERSHIFT

TRANSMISSION OPERATION REVERSE FIRST GEAR ENGAGED

A – Reverse clutch B – Forward clutch C – 4th speed clutch D – 3th speed clutch E – 1st speed clutch F – 2nd speed clutch

Operating solenoids: R, 1 and 2 TH121021

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TH121022

28 Aspirated oil High pressure oil (16.5 -- 19.3 bar)

VT Forward modulation valve

Pressurised oil coming from the system regulation valve arrives at solenoid valve 1 and at the forward gear solenoid valve. Solenoid valve 1 is energised and enables system pressure to engage clutch E. At this point solenoid valve 2 is energised enabling pressurised oil possibly existing in clutches F and D to be discharged into the sump.

603.67.010.02 - 01 - 2004

Torque converter and lubrication oil (2 -- 7 bar) Return to reservoir VR 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 the reservoir.

SECTION 21 -- POWERSHIFT

TRANSMISSION OPERATION REVERSE SECOND GEAR ENGAGED

A – Reverse clutch B – Forward clutch C – 4th speed clutch D – 3th speed clutch E – 1st speed clutch F – 2nd speed clutch

Operating solenoids: R and 2 TH121023

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TH121024

30 Aspirated oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.3 bar)

Return to reservoir

VT Forward modulation valve

Pressurised oil coming from the system regulation valve arrives at solenoid valve 1 and at the forward gear solenoid valve. Solenoid valve 1 is not energised and it enables oil at system pressure to continue towards solenoid valve 2. At this point solenoid valve 2 is energised enabling oil to flow towards clutch F and opening clutch D at the same time towards the tank.

603.67.010.02 - 01 - 2004

VR Reverse modulation valve

SECTION 21 -- POWERSHIFT

TRANSMISSION OPERATION REVERSE THIRD GEAR ENGAGED

A – Reverse clutch B – Forward clutch C – 4th speed clutch D – 3th speed clutch E – 1st speed clutch F – 2nd speed clutch

Operating solenoids: R TH121025

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TH121026

32 Aspirated oil High pressure oil (16.5 -- 19.3 bar)

VT Forward modulation valve

Pressurised oil coming from the system regulation valve arrives at solenoid valve 1 and at the forward gear solenoid valve. Solenoid valve 1 is not energised and it enables oil at system pressure to flow towards solenoid valve 2. Solenoid valve 2 is not energised and hence oil flows towards clutch D.

603.67.010.02 - 01 - 2004

Torque converter and lubrication oil (2 -- 7 bar) Return to reservoir VR Revese modulation valve

SECTION 21 -- POWERSHIFT

MODULATION VALVE OPERATION The modulation valve shown on the pages opposite consists of the following components: 1. Modulation Valve Housing 2. Modulation Sleeve 3. Accumulator Valve 4. Regulator Valve 5. Stop Pin The graph 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 Oil is just about to enter the modulation valves and both the accumulator and regulator valves are seated on the stop pins. Diagram B 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

Diagram D When the top side of the regulator valve is full of pressurized 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 The accumulator valve starts to move up the sleeve and 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 accumulator hits the limit rod at the top. Diagram F As the oil supply continues to the clutch pack excess flow is bled off via the regulator valve. Diagram G 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.

Oil starts to flow through the small orifice in the regulator valve and equalises the pressure on either side.

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

E Modulated pressure Pressure

Clutch pressure 2

3 A

Time

TH121229

Modulated pressure

Clutch pressure

Zero Pressure (Reservoir) TH121230

TH121231

603.67.010.02 - 01 - 2004

TH121232

SECTION 21 -- POWERSHIFT

TH121235

TH121233

TH121234

TH121236

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TORQUE CONVERTER AND HEAT EXCHANGER HYDRAULIC OIL CIRCUIT 12

14 13

8 16 7

5 4

3 1

TH121027

33 Aspirated oil

Torque converter and lubrication oil (2 -- 7 bar)

High pressure oil (16.5 -- 19.3 bar)

Return to reservoir

1. Transmission sump

9. System pressure regulating valve

2. Transmission breather

10. Safety valve (10 bar)

3. Suction filter

11. Oil cooler test port

4. Oil pump

12. Torque converter pressure

5. Pressure filter

13. Torque converter

6. Filter by pass valve

14. Torque converter temperature

7. To clutch pack solenoids

15. Lubrication galleries

8. Clutch pressure (240 -- 280 psi) (16.5 -- 19.5 bar)

16. Forward and reverse clutch lubrication

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

TROUBLESHOOTING GUIDE

TROUBLESHOOTING PROCEDURES

The following information is presented as an aid to isolating and determining the specific problem area in a transmission that is not functioning correctly. When troubleshooting a “transmission” problem, it should be kept in mind that the transmission is only the central unit of a group of related powertrain components. Proper operation of the transmission depends on the condition and correct functioning of the other components of the group. Therefore, to properly diagnose a suspected problem in the transmission, it is necessary to consider the transmission fluid, charging pump, torque converter, transmission assembly, oil cooler, filter, connecting lines, and controls, including the engine, as a complete system. By analysing the principles of operation together with the information in this section, it should be possible to identify and correct any malfunction which may occur in the system. The transmission (power shift with torque converter transmission) troubles fall into three general categories: 1. Mechanical problems. 2. Hydraulic problems. 3. Electrical problems. In addition to the mechanical and electrical components, all of which must be in the proper condition and functioning correctly, the correct functioning of the hydraulic circuit is most important. Transmission fluid is the “life blood” of the transmission. It mus be supplied in an adequate quantity and delivered to the system at the correct pressures to ensure converter operation, to engage and hold the clutches from slipping, and to cool and lubricate the working components.

Stall test A stall test to identifies transmission, converter, or engine problems. Use following procedure: 1. Put the vehicle against a solid barrier, such as a wall, and/or apply the parking brake and block the wheels. 2. Put the directional control lever in FORWARD (or REVERSE, as applicable). 3. Select the highest speed. With the engine running, slowly increase engine speed to approximately one--half throttle and hold until transmission (converter outlet) oil temperature reaches the operating range.

ATTENTION Do not operate the converter at stall condition longer than 30 seconds at one time, shift to neutral for 15 seconds and repeat the procedure until desired temperature is reached. Excesssive temperature 120 °C (250 F) maximum will cause damage to transmission clutches, fluid, converter, and seals.

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Transmission pressure checks

Hydraulic checks

Transmission problems can be isolated by the use of pressure tests. When the stall test indicates slipping clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure. In addition, converter charging pressure and transmission lubrication pressure can also be measured.

Also, before checking the transmission clutches, torque converter, charging pump, and hydraulic circuit for pressure and rate of oil flow, it is important to make the following transmission fluid check. Check oil level in the transmission. The transmission fluid must be at the correct (full level). All clutches and the converter and its fluid circuit lines must be fully charged (filled) at all times..

Mechanical and electrical checks Prior to checking any part of the system for hydraulic function (pressure testing), the following mechanical and electrical checks should be made: • •

• •

•

Check the parking brake and inching pedal for correct adjustment. Be sure all lever linkage is properly connected and adjusted in each segment and at all connecting points. The controls are actuated electrically. Check the wiring and electrical components. Be sure that all components of the cooling system are in good condition and operating correctly. The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission. Air clean the radiator, if necessary. The engine must be operating correctly. Be sure that it is correctly tuned and adjusted to the correct idle and maximum no--load governed speed specifications..

603.67.010.02 - 01 - 2004

NOTE: The transmission fluid must be at operating temperature of 82--93 °C (180--200 °F) to obtain correct fluid level and pressure readings. Do not attempt to make these checks with cold oil. To raise the oil temperature to this specification it is necessary to either operate (work) the vehicle or run the engine with converter at “stall” (Refer to “Stall test”).

ATTENTION Be careful that the vehicle does not move unexpectedly when operating the engine and converter at stall rpm.

SECTION 21 -- POWERSHIFT

TROUBLESHOOTING Refer to the following troubleshooting guide for the diagnosis of typical transmission troubles. Low clutch pressure Cause

Remedy

1. Low oil level. 2. Clutch pressure regulating valve stuck open. 3. Faulty charging pump. 4. Broken or worn clutch shaft or piston sealing rings. 5. Valvola di spurgo pistone della frizione aperta.

1. Fill to proper level. 2. Clean valve spool and housing. 3. Replace pump. 4. Replace sealing rings. 5. Clean bleed valves thoroughly.

Low charging pump output Cause

Remedy

1. Low oil level. 2. Suction screen plugged. 3. Defective charging pump.

1. Fill to proper level. 2. Clean suction pump. 3. Replace pump.

Overheating Cause

Remedy

1. Worn oil sealing rings.

1. Remove, disassemble, and rebuild converter assembly. 2. Replace charging pump. 3. Fill to proper level. 4. Clean cooler. 5. Change cooler lines.

2. Worn charging pump. 3. Low oil level. 4. Dirty oil cooler. 5. Restriction in cooler lines. Noisy converter Cause

Remedy

1. Worn charging pump. 2. Worn of damaged bearings.

1. Replace charging pump. 2. A complete disassembly will be necessary to determine which bearing is faulty.

Lack of power Cause

Remedy

1. Low engine RPM at converter stall. 2. See “Overheating” and make same checks.

1. Tune engine check governor. 2. Make corrections as explained in “Overheating”.

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

PRESSURE TESTING CLUTCH AND HIGH PRESSURE CIRCUIT

2 E

3 F

5 B

TH121028

Port 1 System pressure

Port 5 C Clutch

Engine set to idle. Minimum pressure 13 bar. Desired oil pressure 16 -- 19 bar.

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

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

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).

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

PRESSURE TESTING TORQUE CONVERTER AND COOLER CIRCUIT 8

TH121029

All pressure and flow testing should be measured with an oil temperature of 82--93 °C (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 8 Oil cooler in Engine set to 2000 revs/min. Pressure range 2 -- 7 bar ( -- lb/in2). Port 9 Heat exchanger (output)

Port 10 Converter output temperature

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

CHECK POINTS

1 2

TH121030

Left hand side view 1. Forward clutch pressure oil (B clutch)

3. Clutch circuit pressurised oil

2. Reverse clutch pressure oil (A clutch)

4. Heat exchanger pressure oil

2 3

TH121031

Top view 1. Regulated clutch pressure 2. Oil temperature to cooler 603.67.010.02 - 01 - 2004

3. Pressure from cooler

SECTION 21 -- POWERSHIFT

3 4

TH121032

Right hand side view 1. E multi--disc clutch pressure oil

4. D multi--disc clutch pressure oil

2. F multi--disc clutch pressure oil

5. C multi--disc clutch pressure oil

3. Converter output temperature

5 4

TH121033

2 39

Rear view 1. Visual oil indicator on idler gear case

4. Transmission oil level check bar

2. Magnetic plug for oil draining from idle gear case

5. Transmission oil breather

3. Transmission oil draining magnetic plug

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

ASSEMBLY INSTRUCTIONS

13 T

K 10

H 4 6

7 4 11 3 6 8

R 10 5

2 7

TH121034

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

19 TH121036

TH121035

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Use Permatex and Loctite only where specified. All lead in chamfers for oil seals, piston rings, and “O”--rings must be smooth and free from burrs. Inspect before assembly. Lubricate all piston ring grooves and “O”--rings with oil before assembly. Apply a thin coat of grease between seal lips on lip type seals prior to assembly. Apply a thin coat of Permatex No. 2 or Loctite No. 641 to O.D. of all oil seals before assembly. Apply a thin coat of Loctite No. 592 or 506 Dryseal to all pipe plugs. After assembly of parts using Loctite or Permatex, there must not be any free or excess material which might enter the oil circuit.

1. Assemble oil filter and tighten to 27--34 Nm. 2. Teflon seals must be sized prior to assembly. 3. 10 outer steel plates, 10 inner plates, alternately assemble, starting with outer steel plate. 4. 6 outer steel plates, 6 inner plates, alternately assemble, starting with outer steel plate. 5. 5 outer steel plates, 5 inner plates, alternately assemble, starting with outer steel plate. 6. Shield bearing, assembly with shield as shown Add a coating of Loctite 641 to outer diameter of bearings. 7. Fwd., Rev., 2nd and 3rd clutch return disc springs. Concave side of first disc spring to be placed against clutch piston wear sleeve. Remaining four springs to be stacked alternately as shown.

603.67.010.02 - 01 - 2004

8. Lower clutch disc return spring concave side is to be placed against clutch piston wear sleeve. Remaining six springs to be stacked alternately as shown.

10. Clearance between clutch piston and steel separator plate to be 1.22--2.74 mm. If over 2.74 mm clearance, add one steel outer disc under end plate. 11. Clearance between clutch piston and steel separator plate to be 2.03--3.43 mm. If over 3.43 mm clearance, add one steel outer disc under end plate. 13. Tighten regulator sleeve to 61--68 Nm. 14. Use solenoid bore plug in middle position for 3--speed version only. 15. Solenoid cartridge to be assembled and tightened to 22--27 Nm. 16. Tighten nut to 339--407 Nm. 17. Tighten all cartridge nuts to 5--7 Nm. 18. Tighten modulation valve and inching valve to 81--88 Nm. 19. M10 x 30. 20. M10 x 60. 21. Use 5/16 – 18 screw. 22. Use 5/16 – 18 screw. 23. Use 3/8 – 16 screw.

SECTION 21 -- POWERSHIFT

OVERHAUL Remove the capscrews and washers connecting the drive plate to the torque converter and remove the drive plates and backing ring.

TH121037

42 Support the idler gear case appropriately and remove the lock screws and their washers.

TH121038

43 Use a lever to remove the idler gear case.

TH121039

44 Remove the torque converter plug snap ring and then lever out the plug.

TH121040

45 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the torque converter to turbine shaft snap ring. Then pull off the torque converter.

TH121041

46 Remove the torque converter to shaft locating ring.

TH121042

47 Remove the filter assembly.

TH121043

48 Remove the pump mounting bolts and washers and detach them from the pump body with the relative gasket.

TH121044

49 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the pressure adjuster and its housing where the filter is screwed in with the tool shown in the following figure.

TH121045

50 Tool diagram to remove the pressure adjuster and its housing.

TH121046

51 Remove the converter housing to transmission case bolts and washers. NOTE: There is a hex head screw 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.

TH121047

52 Remove the converter housing and gasket.

TH121048

53 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove impeller hub gear.

TH121049

54 Remove pump drive gear washer.

TH121050

55 Remove pump drive gear and bearing.

TH121051

56 Remove pump drive shaft and washer. NOTE: In some cases the pump drive shaft can be removed with the converter case plate, but when subsequently reassembling it, the countershaft and the gear must be mounted on the manifold plate.

TH121052

57 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Remove the solenoid cover retaining nuts and the cover (1). Then remove the five solenoid valves (2) by firstly removing the retaining nuts, then the solenoid coils and finally unscrew the valve and remove.

2 TH121053

58 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 keep them in the transmission.

TH121054

59 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.

3 TH121055

60 Remove the oil supply tube (1) O--ring (2) and remove the supply tube and screen assembly.

TH121056

61 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

From inside the transmission remove the D clutch gear and the roller bearing in which it was located, also remove the bearing locating ring.

TH121057

62 Then using a suitable brass drift and hammer tap out the drive shaft, seal, ball bearing and snap ring, and remove the remaining retaining ring from the casing.

TH121058

63 Remove the inner case set screw plug. Remove the clutch shaft distributor sleeve set screw.

TH121059

64 Using a suitable puller, remove the distributor sleeve and shaft pilot bearing.

TH121060

65 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the coupling sleeve.

TH121061

66 Remove the output shaft front bearing snap ring.

TH121062

67 Remove the output gear snap ring

TH121063

68 From the rear, remove the output shaft bore plug.

TH121064

69 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

From the front tap the output shaft and rear bearing from the housing.

TH121065

70 Output shaft and rear bearing removed.

TH121066

71 Remove the output shaft gear and snap ring.

TH121067

72 Remove the output shaft front bearing.

TH121068

73 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the output shaft front bearing snap ring.

TH121069

74 Remove the clutch shaft rear bearing outer races.

TH121070

75 From the rear, remove the rear bearing snap ring.

TH121071

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Modulation Valve Removal Remove the modulation valve housing and O--ring.

TH121072

77 Remove the inner, middle and outer valve springs, the valve stop pin and the accumulator spool.

TH121073

78 Remove the modulation housing sleeve and O--ring.

TH121074

79 To assist in removing the diverter, use a 5/16--24 threaded rod.

TH121075

80 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Disassembly of the A and B clutches

55 A

A clutch disassembly (Reverse) Remove the outer thrust washer, thrust bearing and inner thrust washer.

TH121076

81 Remove the clutch hub and gear assembly and press out the 2 bearings and spacer.

TH121077

82 Remove the outer thrust washer, thrust bearing and inner thrust washer.

TH121078

83 Remove the end plate retaining ring.

TH121079

84 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the end plate and also the 6 friction discs and 6 separator plates.

TH121080

85 Compress the belleville washers and remove the snap ring, also remove the snap ring retainer, belleville washers and the clutch piston wear plate.

TH121081

86 To remove the piston turn the clutch pack upside down and tap the shaft on a block of wood.

TH121082

87 Disassembly of B clutch (Forward)

Remove the 3 oil slip rings.

TH121083

88 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Remove the external thrust washer, the thrust bearing and the internal thrust washer.

57 B

TH121084

89 Slide off the clutch hub and gear assembly and press out the 2 bearings and spacer.

TH121085

90 Remove the outer thrust washer, thrust bearing and inner thrust washer.

TH121086

91 Lever out the end plate retaining ring.

TH121087

92 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the end plate and the 6 friction discs and 6 steel sparator plates.

TH121088

93 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.

TH121089

94 Turn the clutch pack upside down and tap the shaft on a block of wood, this will dislodge the piston for removal.

TH121090

95 A clutch reassembly (Reverse)

Install the clutch piston in the clutch housing.

TH121082

96 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

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.

TH121081

97 Fit the 6 steel separator plates and the 6 friction discs and the the end pate.

TH121080

98 Then fit the end plate retaining ring.

TH121091

99 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.

A A

B 1 TH121092

100 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Position the inner thrust washer, thrust bearing and outer thrust washer.

TH121078

101 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.

TH121077

102 Then place the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

TH121076

103 Reassembly of the B clutch (Forward)

Install the piston into the clutch pack.

TH121090

104 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

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.

TH121089

105 Install the 6 steel separator plates and 6 friction discs, starting with a steel separator plate first, then fit the end plate.

TH121088

106 Install the end plate retaining ring.

TH121093

107 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.

TH121094

108 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Then position the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

TH121086

109 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.

TH121085

110 Install the inner thrust washer, thrust bearing and outer thrust washer.

TH121084

111 Fit the 3 oil slip rings.

TH121083

112 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Disassembly of C and D clutches and shaft

63 C

C clutch disassembly (4th speed) Remove clutch shaft oil slip rings.

TH121095

113 Using a suitable puller, remove the clutch gear and front bearing.

TH121096

114 Remove the clutch gear locating snap ring, thrust washer retaining ring and then the outer thrust washer, thrust bearing and inner thrust washer.

TH121097

115 Remove the clutch gear and hub assembly and press the 2 bearings and spacer from the gear.

TH121098

116 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the end plate retaining ring.

TH121099

117 Remove the end plate and six friction discs and six separator plates.

TH121100

118 Compress the belleville washers and remove the snap ring, then proceed to remove the snap ring retainer, belleville washers and clutch piston wear plate.

TH121101

119 Remove the clutch piston by turning the clutch pack upside down and tapping the shaft on a block of wood.

TH121102

120 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Disassembly of D clutch (3rd speed)

65 D

Use an extractor to remove the clutch pack gear.

TH121107

121 Remove also the shaft bearing inner race, the thrust bearing with its inner and outer washers and the two gear bearings.

TH121108

122 Remove the thrust washer retaining ring, then remove the outer thrust washer, thrust bearing and inner thrust washer.

TH121103

123 Remove the end plate retaining ring.

TH121104

124 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the end plate and the five friction discs and five steel separator plates.

TH121105

125 Compress the belleville washers and remove the snap ring, snap ring retainer, belleville washers and the clutch piston wear plate.

TH121106

126 Remove the clutch piston by turning the clutch pack upside down and tapping the shaft on a block of wood.

TH121109

127

Reassembly of C clutch (4th speed)

Install the clutch piston into the housing.

TH121102

128 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Assemble the clutch piston wear plate. First enter the Belleville washer by setting it with the larger diameter turned towards the wear plate, and then add, by alternating them the other four springs. Position the elastic ring check device over the shaft, compress the Belleville washers, then assemble the elastic ring. Check that the elastic ring is correctly fitted in its own channel.

TH121101

129 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.

TH121100

130 Fit the end plate retaining ring.

TH121099

131 To check clearance, position the disk package upside down and use a thickness gauge (1) to measure the distance between clutch piston and the steel separation disk. 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.

1 TH121110

132 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Position the thrust bearing inner washer, thrust bearing and thrust bearing outer washer over the shaft.

TH121111

133 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.

TH121098

134 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.

TH121112

135 Install the end gear and then press on the bearing with the bearing shield upwards.

TH121113

136 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Refit the two oil slip rings and lubricate.

TH121095

137

Disassembly of D clutch (3rd speed)

Refit the clutch piston.

TH121109

138 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.

TH121106

139 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. Finally install the plate with the thickes section.

TH121105

140 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Fit the end plate retaining ring.

TH121104

141 Install the thrust bearing washer, thrust bearing and the outer thrust washer.

TH121103

142 Install the first the gear with its two bearings, the inner washer, the thrust bearing, the outer washer and the shaft bearing inner race.

TH121108

143

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Disassembly and reassembly of the E/F clutch packs

71 E

Disassembly of E Clutch (1st speed) Remove the clutch shaft oil slip rings.

TH121114

144 Remove the front bearing using a suitable puller.

TH121115

145 Remove the outer thrust washer, bearing and inner thrust washer.

TH121116

146 Remove the clutch gear and hub assembly and press out the two pilot bearings.

TH121117

147 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the outer thrust washer, thrust bearing and inner thrust washer.

TH121118

148 Remove the clutch disc end plate retaining ring.

TH121119

149 Remove the clutch disc end plate, then remove the 10 friction and 10 steel separator discs.

TH121120

150 Compress the belleville washers and remove the snap ring, the belleville washers and the clutch piston wear plate.

TH121121

151 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT To remove the clutch piston turn the clutch over and tap the shaft on a block of wood.

TH121122

152

Disassembly of F Clutch (2nd speed)

Using a suitable puller, remove the gear and rear bearing inner race.

TH121123

153 Remove the gear locating ring from the shaft.

TH121124

154 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.

TH121125

155 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the outer thrust washer, thrust bearing and inner thrust washer.

TH121126

156 Remove the clutch disc end plate retaining ring.

TH121127

157 Remove the end plate and 5 friction and 5 steel separator discs.

TH121128

158 Compress the belleville washers and remove the snap ring, followed by the snap ring retainer, belleville washers and the clutch piston wear plate.

TH121129

159 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Remove the clutch piston by turning the clutch pack over and tapping the shaft on a block of wood.

TH121130

160 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 (1st speed)

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.

TH121131

161 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.

TH121132

162

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

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.

TH121133

163 Then fit the end plate retaining ring.

TH121134

164 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 -- 3.43mm (0.08 -- 0.135 inches). If the clearance is greater than 3.43mm (0.135 inches) add one steel sepataror disc under the end plate.

E 1

F TH121135

165 Position the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

TH121136

166 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT 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.

TH121137

167 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.

TH121138

168 With the bearing shield upwards press on the shaft bearing.

TH121139

169 Fit the oil slip rings. Use some vaseline to facilitate reassembly into the housing.

TH121140

170 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Reassembly of the F Clutch (2nd speed)

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.

TH121141

171 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.

TH121142

172 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.

TH121143

173 Install the end plate retaining ring.

TH121144

174 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Install the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

TH121145

175 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.

TH121146

176 Place the inner thrust washer, thrust bearing and outer thrust washer over the shaft.

TH121147

177 Using snap ring pliers, position the thrust washer retaining snap ring and clutch shaft locating snap ring. Then install the gear with the conical section downwards onto the snap ring.

TH121148

178 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Press the roller bearing inner race onto the clutch shaft with the bearing race shoulder down.

TH121149

179 Regulator valve disassembly Using a suitable punch tap the valve retaining pin from the regulator valve sleeve. NOTE: The valve is under spring pressure.

TH121150

180 Remove the regulator valve piston and spring.

TH121151

181 Reassembly Regulator valve reassembly is in reverse order of disassembly. Clean and inspect all parts.

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Disassembly of the modulator valve Remove the inner, middle and outer springs and stop pin from the housing sleeve.

TH121237

182 Remove the accumulator spool.

TH121152

183 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.

TH121153

184 Remove the regulator spool, spring retainer, spring and spacer from the sleeve housing.

TH121154

185 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the cross pin in the end of the sleeve, this will be the longest of the two pins.

TH121155

186 Reassembly IMPORTANT: Make sure the neck on the regulator spool is not clogged. 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 should be taken to ensure the spring retainer slides inside the spool. TH121156

187 In the other end of the sleeve, place the accumulator spool as shown.

TH121157

188 Then fit the outer, middle and inner springs and then install the stop pins.

TH121158

189 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Disassembly of the manifold plate Remove the reverse idler gear retaining nut and washer.

TH121159

190 Then remove the end plate with dowel pin, reverse idler gear, bearing and thrust washer.

TH121160

191 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.

TH121162

192 The stator support is kept in position by means of two bull rings, remove the bull ring on the stator converter side.

TH121163

193 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Push down the support into the transmission to expose the retaining ring and make it possible to remove it.

TH121164

194 Remove the stator support and thrust washer.

TH121165

195 Remove the stator support oil sealing ring and expander ring.

TH121166

196 If the bushing and/or bearing need to be removed, the bushing must be removed from the same end as the needle bearing.

TH121167

197 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

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.

TH121168

198 Reassembly of the manifold plate Reassemble in the reverse order of disassembly.

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Disassembly of the converter housing From the top of the housing remove the hexagonal head plug. Then using a small screwdriver, lever out the check valve ball assembly and remove it from the top of the housing.

TH121169

199 Remove the torque converter bearing.

TH121170

200 Remove the oil distributor.

TH121171

201 Remove the converter oil seal.

TH121172

202 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Remove the pressure test plug for the C clutch and then using a suitable hexagonal wrench remove the distributor lock screw.

TH121173

203 Using a suitable puller remove the C and D oil distributor sleeve.

TH121174

204 Remove the F clutch pressure test point plug and using a hexagonal wrench remove the distributor locking screw. Then using a puller remove the E and F distributor sleeve.

TH121175

205 Reassembly Reassembly of the converter housing is carried out in the reverse order of disassembly. Ensure the chamfered end of the distributors are upwards.

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Disassembling the transmission idler gear case Use a percussion wrench to remove the retainer nut, washer, O--ring and the front output flange.

TH121176

206 Remove sleeve outer O--ring.

TH121177

207 Use an extractor to remove the outer sleeve and inner O--ring.

TH121178

208 Remove the coupling sleeve snap ring.

TH121179

209 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Use a percussion wrench to remove the retainer nut, washer, O--ring and the front output flange.

TH121180

210 Remove the idler gear case cover screws and washers.

TH121181

211 Hook the (front) cover and fasten it to a hoist. Use a lever to separate the two covers and then remove the front one.

TH121182

212 Remove the idler gears and the shafts.

TH121183

213 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Pry the input asssembly from cover.

TH121184

214 Remove the output shaft assembly.

TH121185

215 If the bearing outer races have to be replaced, remove the outer races.

TH121186

216 Remove the seal sleeve snap ring.

TH121187

217 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Use an appropriate driver to remove the sleeve gasket.

TH121188

218

Transfer case assembly Reverse the disassembly procedure to carry out the assembly. At the end of assembly, lock the output flanges and tighten the nuts at 339 â&#x20AC;&#x201C; 407 Nm.

TH121189

219

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Transmission assembly From the rear, install the rear bearing snap ring.

TH121071

220 Install the clutch shaft rear bearing outer races.

TH121070

221 Install the output shaft front bearing snap ring.

TH121069

222 From the front of transmission case, position the output gear with the long hub of the gear towards the front.

TH121190

223 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Install the output shaft rear bearing in case against the locating ring.

TH121191

224 Put the output shaft in position. Align the splines on the shaft with the splines in the output gear. Tap the shaft into position.

TH121192

225 Install a new bore plug.

TH121193

226 Install the output shaft gear snap ring.

TH121194

227 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Install the output shaft front bearing in the case against the locating ring.

TH121195

228 Install the front bearing snap ring.

TH121196

229 Install the coupling sleeve.

TH121061

230

603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

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.

TH121197

231 Apply some thread lock to the lock screw and install it in the housing. Then install the plug.

TH121198

232 Install the modulation diverter in the housing.

TH121075

233 Install a new O--ring on the transmission valve body bottom and then install the valves and the spring in the transmission case.

TH121074

234 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Install the modulation valve case with the new O--ring in the transmission case and tighten to the correct torque.

TH121072

235 Install the forward/reverse shaft rear bearing.

TH121199

236 Install the C/D shaft rear bearing.

TH121200

237 Position the D clutch gear and shaft through the bearing and onto the output flange.

TH121201

238 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT Replace the O--ring gasket (2) of the oil delivery tube (1) and install the delivery tube together with the net filter.

TH121056

239 Firstly position the C/D clutch pack. Align the splines of the D gear & hub already fitted with internal teeth of the friction disc.

TH121202

240 Position the reverse/forward (A/B) clutch packs and shaft. Use caution so as not to damage the shaft oil slip rings.

TH121203

241 Install the E/F clutch pack and shaft rear roller bearing into the casing and then fit the shaft and clutches.

TH121204

242 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Fit a new gasket to the transmission case using a light coat of grease to hold it in position.

TH121205

243 Install the thrust washer and the pump control shaft on the manifold plate. 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. NOTE: Be careful not to damage the oil seals.

TH121206

244 Install the manifold plate to transmission housing bolts and tighten to the correct torque. Remember the hex head bolt on the other side of the manifold plate.

TH121207

245 Position the swivel hub gear on the stator support.

TH121208

246 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

Install the pump idler gear bearing on idler shaft.

TH121210

247 Install the pump idler gear on bearing.

TH121211

248 Install the idler gear thrust washer, aligning the hole with the roll pin.

TH121212

249 With the O--ring in position, install the solenoid cartridges.

TH121213

250 603.67.010.02 - 01 - 2004

100

SECTION 21 -- POWERSHIFT

Tighten the cartridges to the specified torque.

TH121214

251 With cartridge to coil O--ring in place, position the solenoid coils on the cartridges.

TH121215

252 WIth new O--ring in position, install the coil to cartridge nuts. Tighten the cartridge nuts to specified torque.

TH121216

253 Install solenoid protection cover and mounting screws. Tighten the screws to the specified torque.

TH121217

254 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

101

Position the manifold plate to converter housing gasket using a light coat of grease to hold the gasket in place.

TH121209

255 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.

TH121218

256 Fit the housing bolts and tighten to the recommended torque.

TH121219

257 Install the converter locating snap ring on the turbine shaft.

TH121220

258 603.67.010.02 - 01 - 2004

102

SECTION 21 -- POWERSHIFT

Slide on the torque converter and fit the torque converter snap ring.

TH121221

259 With a new O--ring fitted, install the bore plug into the converter assembly and fit the plug snap ring.

TH121222

260 Install the regulator valve using the fabricated tool and tighten to the correct torque.

TH121223

261 Refit the filter onto the regulator valve.

TH121224

262 603.67.010.02 - 01 - 2004

SECTION 21 -- POWERSHIFT

103

With a new gasket in place, install the transmission pump and tighten to the correct torque.

TH121225

263 Install the transfer case assembly.

TH121227

264 Install the transfer case washers and lock screws. Tighten the screws to the correct torque.

TH121228

265 Install the drive plate onto the torque converter and tighten the bolts to the specified torques.

TH121226

266 603.67.010.02 - 01 - 2004

104

SECTION 21 -- POWERSHIFT

SPECIAL TOOLS POWERSHIFT TRANSMISSION Q.TY

NUMBER

380000606

380000607

SKETCH

DESCRIPTION Sleeve wrench for power-shift oil delivery control valve

For oil delivery control valve

RECOMMENDED

ALL

Hydraulic clutch springs com- To press the hydraulic clutch pression adapter springs 1,2,3,4 FW REV RECOMMENDED

380000430

380000258

603.67.010.02 - 01 - 2004

HOW TO USE/MODEL

ALL

Tool for installation of power-- For the installation of new shift FW REV hydraulic clutch bearings (use with shaft needle bearing 380000258) COMPULSORY

ALL

Striker handle

ALL

SECTION 25 -- FRONT AXLE

SECTION 25 -- FRONT AXLE CONTENT Section

Description

Page

25 100

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wheel toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Component overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front axle removal procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Front axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Axle drive pinion bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 How to install and adjust the axle drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Front drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering differential with final epicycloids reductions Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2050 mm (flange--to--flange) Crown wheel and pinion ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 : 34 Final reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 6 (4 satellites) Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 degrees Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Without lock Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet disc with 8 discs + parking brake with inner negative control Steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With position sensor NOTE: As to replacement intervals, oil and lubricant quantity and type for the front axle, refer to the OPERATORâ&#x20AC;&#x2122;S MANUAL.

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SECTION 25 -- FRONT AXLE

DESCRIPTION

Front view

Top view

TH125160

1 The axle fitted to this unit incorporates: • Integral steering cylinder • Steering sensor • Central drive

603.67.010.02 - 01 - 2004

• •

Double reduction (crown wheel and pinion plus planetary hubs) Service brakes and park brake with inner negative control

SECTION 25 -- FRONT AXLE

OPERATION Engine power (1) is transmitted from the engine through the powershift transmission (2) and the drop box (3) to the front axle (4) via the drive shaft (5).

3 4

TH125188

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SECTION 25 -- FRONT AXLE

TROUBLESHOOTING PROBLEM

CAUSE

REMEDY

Same noise for engagement and 1. Hub bearings damaged release

Replace damaged elements

Higher noise during engagement 2. Low oil level rather than release

Top up oil

3. Crown wheel and pinion worn

Check through the upper cover. Replace worn crown wheel and pinion

4. Crown wheel and pinion bear- Replace damaged elements ings worn 5. Epicycloids planetary hub or Replace damaged elements bearing worn

Noise under steering

6. Pinion ring nut loose

Check the crown wheel and pinion and respective bearings. If they are not damaged, tighten the ring nut

7. Only one pinion bearing worn

See remedy No. 4

8. Differential satellites and/or plan- Replace damaged elements etary hubs damaged

â&#x20AC;&#x153;Stick slipâ&#x20AC;? noise when changing 9. Universal joint damaged direction of travel. 10. Wheel loose

Check and replace the joint as shown in the vehicle handbook Check possible wheel hub disc and stud bolt damages. If needed, repla-ce damaged elements and tighten the nuts to prescribed torque

11. Steering pin seals, axle shafts Check and or steering pivots damaged elements 12. Differential case satellites free

replace

Check through the upper cover. Replace damaged elements

13. Differential adjusting bushes See remedy No. 8 worn

603.67.010.02 - 01 - 2004

damaged

SECTION 25 -- FRONT AXLE

WHEEL TOE--IN CHECK When checking the toe--in, ensure the front wheels are pointing straight ahead using the steering position indicator lamp in the cabin. Measure the distance between the two front wheels at the front of the rim (A). Then measure the distance between the front wheels 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 To adjust front wheel toe--in, slacken both lock nuts (2) and turn rims equally (1) in the same way. Re--tighten both lock nuts (2).

1 TH125162

The steering stops (1) are incorporated in 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.

1 TH125163

COMPONENT OVERHAUL Axle in situ The following components can be overhauled with the axle mounted on the unit. • Planetary reduction hub assembly • Steering knuckle • Tie rod pins • Axle drive shafts, seals and bushes Axle removed The following components can be overhauled with the axle removed. • Brake assemblies • Differential assembly • Pinion assembly

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SECTION 25 -- FRONT AXLE

FRONT AXLE REMOVAL PROCEDURE • • •

• •

Extend the boom and lower to the ground. Chock the rear wheels. Place wooden wedges between the axles and the frame to prevent the Telescopic Handler from swinging. Jack--up the machine upper part and secure it on suitable stands. Remove the front drive shaft.

TH125164

5 • Remove the wheels. • Disconnect the steering hoses (1). NOTE: Ensure both pipes are plugged to prevent constant oil leaking. • Disconnect the steering angle sensor (2).

1 TH125165

6 •

Remove service brake pipe (3).

TH125186

7 Remove the four axle levelling cylinder fixing screws (5). • Support the axle and remove the four fixing screws (6). NOTE: Tightening torque screws (6) M20x1,5x200 600 Nm. • Lower and remove the axle from the vehicle bottom with a wheeled jack. 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. •

TH125167

8 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

FRONT AXLE OVERHAUL

STEERING CASE REMOVAL

Support the axle (1) or leave it mounted and remove the steering tie rod pins (2). Sling the whole assembly (7) and hook it to the hoist, slightly pulling the tie rod.

1 TH125001

9 Unloose and remove the fitting screws (3) from the bottom pivot pin (4). NOTE: Screws cannot be re--used.

4 3 TH125002

10 Remove the bottom pivot pin (4) complete with the front sealing ring (11). Remove the front sealing rings (11).

NOTE: Note down the side for assembly. If the ball cover needs replacing, remove it from the bottom pivot pin.

TH125003

4 11

Unloose and remove the fitting screws (3) from the top pivot pin (6).

3 6

TH125004

12 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Using two levers, remove the top pivot pin (6) complete with front seal (5). Pay attention not to damage the surfaces. Remove the front sealing rings (5). NOTE: Note down the side for assembly. If the ball cover needs replacing, remove it from the bottom pivot pin.

5 6

TH125005

13 Remove the complete steering knuckle (7). 7

TH125006

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SECTION 25 -- FRONT AXLE

HOW TO ASSEMBLE THE COMPLETE STEERING KNUCKLE Apply a thin coat of clean oil to the splined end of the universal joint yoke (10) and install the trunnion housing (7). Be careful to prevent any damages to dust seals and oil seals. Prepare a shims pack of 0.85 mm to fit under the top trunnion.

TH125006

15 Install a new seal (5) on the top trunnion (6); apply a thin coat of clean oil and fit the trunnions into their seats in the housing. Install the screws (3) and tighten to a torque of 140 Nm. Check if the oil seal (5) is installed in the correct way. 5 6

TH125005

16 Fit a new seal (11) onto the bottom pivot pin (4). Lubricate and fit the unit in the steering case. Position the screws (3) and lightly tighten. Check for the correct assembly side of the seal (11).

4 TH125003

17 Tighten the new fittinig screws (3) of top and bottom pivot pins in sequence using the cross tightening method. Torque wrench setting: 140 Nm. 3

3 TH125010

18 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Use a pry to confirm there is no vertical play. If there is some play, take the measurement of the play and remove shims suitably.

TH125183

19 Verify the torque reaction of the trunnions, 30 ÷ 60 Nm. If it is higher, add shims adequately.

TH125184

20 Connect the steering tie rod (2) (See “STEERING CYLINDER INSTALLATION”).

NOTE: Lubricate joints with Molikote.

TH125001

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

DOUBLE UNIVERSAL JOINT REMOVAL Loosen and remove upper and lower dowel (3) lock nuts (2). Remove upper and lower bush retaining dowels (3).

TH125012

22 Remove the entire u--joint (4). NOTE: To remove the u--joint use, if necessary, a plastic hammer or a lever.

TH125013

23 Remove the snap ring (5) from the bushing unit (9).

5 TH125014

24 Position the entire u--joint (4) under a press and remove the complete bush (9). 4 9

TH125015

25 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Remove the snap ring (6) from the bearing (7). Use a puller to remove the bearing (7) the sealing ring (8) and the O--ring. NOTE: Note down the assembly side of the ring (8).

TH125016

2 5 6 7 2 3

4 8

TH125017

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SECTION 25 -- FRONT AXLE

INSTALLATION OF U--JOINT Using tool (T5) P.N. 380000582 insert sealing ring (8) into bush (9) and insert bearing (7) using a striker. NOTE: Carefully check the assembly side of the seal (8).

9 TH125189

28 Fit the snap ring (6) on the bearing (7).

6 7

TH125019

29 Heat the bearing in oil at an approx. temperature of 100 Â°C and fit the entire bush (9) on the u--joint (4).

TH125020

30 Fit the snap ring (5) on the bushing unit (9); also install the O--ring (10). 10

5 9 TH125014

31 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Insert the u--joint and tighten the top and bottom dowels (2). Torque wrench setting: Max. 15 Nm.

NOTE: For u--joint coming with a bush, centre the point of the check dowels in the slot.

TH125022

32 Apply Loctite 242 to the jutting parts of the dowels (2). Screw the check nuts (3) of the dowels (2) and lock them using a torque wrench. Torque wrench setting: 122 Nm.

TH125023

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE HOW TO DISASSEMBLE THE PLANETARY REDUCTION GEAR

Disconnect the tie rod from the steering knuckle. For details, see “HOW TO REMOVE THE COMPLETE STEERING KNUCKLE”. Remove the securing screws (1) from the planetary carrier cover (2). 1 2 TH125024

34 Loosen the planetary carrier cover (2) from the steering knuckle (3) by alternatively forcing a screwdriver into the appropriate slots.

3 2 TH125025

35 Remove the complete planetary carrier cover (2). 2

TH125026

36 Unloose and remove the tightening nuts (4) from the crown flange (5). 5

TH125027

37 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Remove the safety flange (6).

TH125028

38 Using a puller, remove the complete crown flange (5) by acting on the stud bolts. 5

TH125029

39 Partially extract the hub using a plastic hammer. 8

NOTE: Alternately hammer on several equidistant points. Remove the external bearing (8).

TH125030

40 Remove the complete hub (7) by hand. 7

TH125031

41 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE Remove the pivot pins and remove the steering knuckle (3). For details, see “HOW TO REMOVE THE COMPLETE STEERING CASE”.

TH125032

42 Remove the snap rings (9). 9

TH125033

43 With the help of a puller, remove the planetary gears (10).

NOTE: Note down the correct assembly position of the planetary gears.

TH125034

44 Remove the snap ring (12) from the crown (13).

12 13

TH125035

45 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Remove the crown flange (5). 5

TH125036

46 Remove the sealing ring from the hub (14).

TH125037

47 Remove the internal bearing (15).

TH125038

48 Remove the external thrust blocks from the bearings (8) and (15) forcing a pin--driver into the appropriate slots on the hub (7). NOTE: Hammer in an alternate way so as to avoid seizure or deformation of the thrust blocks. 7

TH125039

49 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE Use a puller to remove the centring ring (16), the sealing ring (17) and the bearing (18) from the steering knuckle (3). NOTE: Note down the orientation of both centring ring (16) and sealing ring (17).

16 16 17 18 17

18 3 TH125040

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SECTION 25 -- FRONT AXLE

ASSEMBLING THE PLANETARY REDUCTION GEAR

Lubricate the bushing (18) and the seat of the steering knuckle (3). Install the bushing (18), using tool (T7) P.N. 380000583.

18 TH125041

51 Lubricate the outer surface of the sealing ring (17) and centring ring (16); fit them into their seat using tool (T8) P.N. 380000584.

16 17

TH125042

52 Install the outer and inner races (8--15) of the bearings on sprocket hub (7) after lubricating the seats. For this operation, use appropriate strikers.

TH125208

53 Fit the bearing (15) into the internal thrust block. 15

TH125209

54 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE Apply a jointing compound for repositionable fixtures to the outer surface of the sealing ring (14). Position the sealing ring (14) in the hub (7).

14 7

NOTE: Check that the ring (14) is correctly oriented.

TH125210

55 Position tool (T10) P.N. 380000585 and press the sealing ring (14) into its seat.

T10 14

TH125211

56 Insert the flange (5) in the crown (13).

TH125036

57 Insert the snap ring (12) in order to fix the flange (5) in the crown (13). NOTE: Carefully check that ring (12) is properly inserted in the slot of the crown (13).

13 5

TH125156

58 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Using an appropriate striker (T11) insert planetary gears (10) into cover (2). Accurately check the orientation.

T11

10 TH125050

59 Lock the gears (10) into position by fitting the snap rings (9).

TH125033

10 60

Fit the steering knuckle (3) onto the U--joint (19) and install the articulation pins. For pin assembly details, see “HOW TO ASSEMBLE THE COMPLETE STEERING CASE”.

TH125032

19 61

Install the hub (7).

TH125031

62 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Install the external bearing (8).

NOTE: Using a plastic hammer, drive the bearing to the limit stop by lightly hammering around the edge.

TH125030

63 Fit the complete crown flange (5). 5

NOTE: In order to fasten the flange (5), use a plastic hammer and alternately hammer on several equidistant points. Apply Tecnolube Seal 101 grease to the surface of the safety flange (6) which touches the crown flange (5). Fit the safety flange (6).

TH125028

64 Apply Loctite 242 to the studs and fit in the nuts (4). Cross tighten the nuts (4) in two stages. Initial torque wrench setting: 120 Nm Final torque wrench setting: 255รท285 Nm

TH125053

65 Fit the planetary carrier cover (2) onto the hub (3). 20

ATTENTION

Check that the O--ring (20) is in good condition and in position.

TH125026

2 66 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Lock the planetary carrier cover (2) by tightening the screws (1). Torque wrench setting for screws: 40รท50 Nm

1 2 TH125055

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

HOW TO REMOVE THE STEERING CYLINDER Remove the centring sensor (1) of the steering piston, if supplied.

TH125217

68 Remove the safety cotter pins (3) from the articulation pins (4) of the tie rod bars (5).

ATTENTION

Dispose of used cotter pins. 6 Remove the castellated nuts (6) that lock the articulation pins (4).

TH125057

69 Disconnect the tapered pins of the articulation (4) from the steering knuckle (7) by means of a puller.

TH125058

70 If the connection of the steering bars includes a safety collar (13), raise the border. 13

TH125059

71 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Disconnect left and right tie rods from the piston (2).

TH125060

72 Remove the securing screws (8) from the steering cylinder (9). Extract the cylinder (9) using a plastic hammer.

NOTE: For cylinder disassembly, refer to “HOW TO DISASSEMBLE THE STEERING CYLINDER”.

8 TH125061

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

HOW TO INSTALL THE STEERING CYLINDER Check that the O--rings of the axle unit are in good condition; lubricate the seats of the seals and fit the steering cylinder (9) into its seat. Lock the cylinder by cross--tightening the screws (8). Torque wrench setting: 116 รท 128 Nm

8 TH125063

74 Apply Loctite 242 to the thread and connect the tie rods by screwing the terminals onto the piston stem. Torque wrench setting: 240 รท 270 Nm

NOTE: Versions with coupling require than the rim of the articulation (13) is riveted onto the surface of the piston stem.

TH125064

75 Insert the pins (4) in the steering knuckle (7) and lock them in that position by tightening the nuts to 260รท290 Nm. Find the notch position on the basis of the split pin hole and tighten the nuts further.

ATTENTION Check rubber guard integrity (A). Insert split pins and bend safety stems.

ATTENTION Use new split pins.

TH125065

If fitted, insert the proximity sensor (1) to check the piston location and tighten the screws (10). Tightening torque: 5 รท 6 Nm. 10

TH125212

77 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE ATTENTION

T12

Eliminate the action of the negative braken if fitted. Install tow drilled bars (T12) on the sprocket holder hubs and lock them. Using a level â&#x20AC;&#x153;Bâ&#x20AC;?, check that tools are perfectly flat and parallel to each other. B

T12

TH125067

78 Connect the sensor (1) to the inspection device according to either diagram. 1

TH125213

79 Sensor connection card, STANDARD version.

TH125069

80 Sensor connection card, OPTIONAL version.

TH125070

81 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Centre the piston by slowly moving it first in one direction then in the other and position it half way on the stroke, which is determined by the switching on and off of the signal lamp of the inspection device in the reversal stage.

TH125214

82 Inspect jut “C” on one side of the piston and note down the size for checking later adjustments.

NOTE: If cylinders come without a sensorm the centring of the piston must be carried out on the basis of the maximum stroke.

TH125072

83 Without moving the piston, check the front and rear measurement at the end of bars (T12). Max. difference: 0.6 ÷ 0.7 mm NOTE: To check the rear measurement, turn the bevel pinion and check the planarity and parallelism of bars (T12).

T12

TH125073

T12 84

If necessary, adjust convergency without moving the centring of the piston and adjust the length of the tie rods (5). NOTE: With a half turn of screw, the front size is reduced by about 3 mm, whereas the rear one is increased by about 3 mm.

TH125074

85 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Loosen the nuts (11) and screw them onto the ball-and--socket joints. Hold the steering knuckles still and rotate the ball-and--socket joints. Once the convergency has been adjusted, lock the nuts (11). Torque wrench setting for nuts: 298 รท 328 Nm

TH125075

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

ADJUSTMENT OF STEERING ANGLE NOTE: Perform the same operations on both sides. Loosen the locknut of one of the stop adjusting screws on the cylinder side. Steer completely until the stop screw touches the axle stop.

TH125180

87 On the opposite side, adjust the stop screw so as to bring it exactly in contact, without stress, with the relevant axle stop. Tighten the locknuts. Steer completely to the opposite direction and repeat the same procedure for the other stop screws.

Sul

TH125181

88 IMPORTANT: At steering lock position, the stop screws must touch simultaneously the axle stops.

TH125182

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SECTION 25 -- FRONT AXLE

HOW TO DISASSEMBLE THE STEERING CYLINDER

Remove the snap ring (1) from the cylinder head (2).

TH125077

90 With the help of a plastic hammer, push the head (2) inside the cylinder (3). NOTE: The head should line up with the edge of the cylinder.

3 2

TH125078

91 With the help of a drift, apply pressure to the stop ring (4) that is placed inside the cylinder (3) and extract the ring using a screwdriver.

TH125079

92 Hammer the piston (5) up to the rear of the head (2) using a plastic hammer. Continue hammering until the head (2) is ejected from the cylinder (3). 2 5 3 TH125080

93 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE Disassemble the cylinder unit (3) by extracting first the head (2), then the piston (5).

5 A

ATTENTION Note down the assembly side of the piston. The bevelled part â&#x20AC;&#x153;Aâ&#x20AC;? of the piston is oriented towards the head (2).

Remove all seals, anti--extrusion rings and scraper rings from head (2), cylinder (3) and piston (5). NOTE: 1 -- All seals must be replaced every time the unit is disassembled. 2 -- Particular attention must be paid not to damage the seats of both seals and piston slide.

TH125081

9 2 6 10

5 8

TH125082

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

HOW TO ASSEMBLE THE STEERING CYLINDER

After applying grease, install the sealing ring (6) of the shaft, the anti--extrusion ring (7) and the scraper ring (8) inside the cylinder (3).

ATTENTION Thoroughly check thet positioning of the anti--extrusion (7). 6 TH125083

96 After applying grease, install the sealing ring (6) of the shaft, the anti--extrusion ring (7) and the scraper ring (8) in the head (2).

ATTENTION Thoroughly check that positioning of the anti--extrusion (7) ring is correct.

TH125084

97 Fit the seal (9) onto the outside of the head (2).

ATTENTION 1 -- In order to facilitate assembly, apply grease to the outer surface of the piston. 2 -- Do not roll the seal (9) up.

TH125085

98 Prepare the piston (5) by fitting it with the guide ring (10), the magnetic ring (11), the O--ring (12) and the seal (13).

ATTENTION

12 5

1 -- In order to facilitate assembly, apply grease. 2 -- If a centring sensor is not fitted, then the magnetic ring (11) should be replaced by guide ring (10).

TH125086

99 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Apply tool (T18) P.N. 380001186 to the shaft on the opposite side of the head and centre it on the cylinder (3) so that it fits into the piston (5). NOTE: Apply a little grease to seals and cylinder.

T18

TH125087

100 Push the piston (5) into the cylinder for 100 mm using a plastic hammer.

TH125088

101 Remove tool (T18) P.N. 380001186 and apply it to the opposite side of the piston (5). Apply grease to head (2) seals, fit the head onto the piston and push it into the cylinder (3) using a plastic hammer. NOTE: Insert the head as to line it up with the edge of the cylinder.

2 T18

5 TH125089

102 Insert the stop ring (4) ensuring that it fits into the seat of the cylinder (3).

3 TH125090

103 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Apply pressure to the head using two screwdrivers or levers until the head is fastened onto the stop ring (4).

TH125091

104 Fit the snap ring (1) on the head (2). 2

ATTENTION Make sure that the snap ring (1) is securely fastened in its seat. If necessary, force it into its seat using a drift and a hammer. 1

TH125077

105

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SECTION 25 -- FRONT AXLE

HOW TO REMOVE AND DISASSAMBLE THE DIFFERENTIAL UNIT Remove the complete arms. For details, see “CHECKING WEAR AND REPLACING THE BRAKING DISKS”.

TH125092

106 Mark the position of the ring nuts (1). Remove the fitting screws (3) from the ring nuts (1).

1 TH125093

107 Uniformly heat the ring nuts (1) up to a temperature of 80°C. Apply tool (T13) P.N. 380000586 and remove the ring nuts.

T13

NOTE: Accurately clean the threaded portions of ring nuts, body and cover.

TH125094

108 Remove the fitting screws (4) from the middle cover (5).

4 TH125095

109 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Insert a screw--driver in the opposing slots then force and remove the middle cover (5) and the complete differential unit (6).

6 5

NOTE: Support the pieces using a rod.

TH125096

110 If the bearings need replacing, extract the external thrust blocks of the bearings (7) and (8) from middle cover (5) and central body (2).

NOTE: Accurately check the O--ring (9). 7

TH125097

111 Remove the fitting screws (11) from the crown (12).

11 12

TH125099

112 If the bearing need replacing, extract the bearing (7) and remove the crown (12).

TH125100

113 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Remove the shim washer (13) and the planetary gear (14). 13 14

TH125101

114 If the bearing need replacing, extract the bearing (8) from the differential carrier (15). 8

TH125102

115 Remove the snap rings (16) from the two pins (17) of the planet wheel gears (18).

17 16

TH125103

116 Insert tool (T14) P.N. 380000587 between the planet wheel gears (18). T14

TH125104

117 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Force tool (T14) P.N. 380000587 in--between the planet wheel gears (18) using two pin--drivers.

ATTENTION Make sure that tool (T14) P.N. 380000587 is perfectly lined up with the pins (17) when locked.

17 TH125105

118 Place differential body (15) under a press position bush (T15) P.N. 380000588 and insert pin (T16B). Press pin (T16B) of kit T16 (T16A + T16B + T16C) P.N. 380000589 full stroke.

T16B

T15

T16B

17 15

TH125106

119 Remove gudgeon (T16B) and bush (T15) P.N. 380000588. NOTE: In this condition the tool (T14) P.N. 380000587 contains pin (17).

T16A

T15

TH125107

120 Remove tool (T14) P.N. 380000587 together with the pin (17) of the planet wheel.

17 TH125105

121 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE Leave the released planetary gear in position and again lock tool (T14) P.N. 380000587. Repeat the operations for the extraction of the pin of the 2nd planet wheel. Repeat the operations for all other pins.

T14

TH125104

122 Remove tool (T14) P.N. 380000587 and remove the last two planet wheel gears (18), the 2nd differential unit gear (14) and the relative shim washer (13) from the differential carrier.

14 13 15

TH125108

123 4

16 20

17 19 17 18 19

13 12

16 6

17 19 19 17 20 16

TH125109

124 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

ASSEMBLING Insert the shim washer (13), and the planetary gear (14) in the differential carrier (15).

14 13 15

TH125108

125 Position the shim washer (19) and the first planet wheel gear (18). Hold them in position using bar (T16C).

18 19 T16C

TH125111

126 With the help of gudgeon (T16A), position the second planet wheel gear (18) and the relative shim washer (19).

18 T16A

T16C 19

TH125110

127 Insert tool (T14) P.N. 380000587 between the two planetary gears (18). Line up the entire unit by pushing bar (T16C) all the way down until gudgeon (T16A) is ejected.

T14

T16C

TH125112

128 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Lock tool (T14) P.N. 380000587 behind the planet wheel gears (18). After locking, remove bar T16C.

T14

TH125104

129 Fit the snap rings (20) onto the pins (17). 20

TH125113

130 Place the differential carrier (15) under the press, position bush (T15) P.N. 380000588 and insert the planet wheel pin (17). Put gudgeon (T16B) on top of the planet wheel pin (17).

T16B

17 T15

T16B

TH125114

131 Press (T16B) pin all the way down.

T16B T15 T16B

TH125106

132 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Remove gudgeon (T16B), bush (T15) P.N. 380000588 and fit the snap ring (16) on the pin (17).

ATTENTION Make sure that the snap ring centres the seat and that it rests on the surface on the differential carrier. Repeat the operations on the other planet wheel pin or planet wheel axle.

16 17

TH125115

133 Position the second planetary gear (14) in the differential carrier (15). 14

TH125116

134 Position the shim washer (13) on the crown (12). NOTE: In order to hold the shim washer (13) in position, apply grease to it.

TH125117

135 Position the crown (12) on the differential carrier (15) and lock it with screws (11) applied with Loctite 242. Torque wrench setting for screws: 128รท142 Nm.

NOTE: Secure the screws using the cross--tightening method.

TH125118

136 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Using an appropriate striker (T17) install bearings (7) and (8).

T17

TH125119

137 If the bearings are replaced, insert the external thrust blocks in the middle cover (5) and in the central body (2).

TH125120

138 Position the differential unit (6) in the central body (2) with the help of a bar and fit the middle cover (5).

NOTE: Thoroughly check the state of the O--ring (9) and make sure that the cover is fitted with the oil discharge in the lower position.

TH125121

139 Lock the middle cover (5) with screws (4). Torque wrench setting for screw: 23.8รท26.2 Nm.

4 5

TH125122

140 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

NOTE: If the ring nuts (1) are removed, spread them with Loctite 242. Tighten ring nuts on the crown side until clearance between pinion are crown is zero, then lock the crown; go back 1/4÷1/2 turn.

TH125200

141 Pre--set the bearings by means of the ring nut situated on the opposite side of the crown, so as to increase pinion torque up to 140÷210 Ncm.

ATTENTION If bearings are not new, check the static torque; if bearings are new, check the continuous torque.

TH125201

142 Introduce a dial gauge with adjustable pointer “A” through the top plug hole. Position the did sense with adjustable pointer on the centre of one of the teeth of the crown (12), pre--load to 1 mm and then reset it to zero.

TH125125

143 Manually move the crown (12) in both directions in order to check the existing backlash between the pinion and the crown.

TH125126

144 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Adjust the backlash between the pinion and the crown by loosening one of the ring nuts (1) and tightening the opposite to compensate. Normal backlash: 0.18--0.23. Difference between MIN and MAX clearance for whole circumference should not exceed 0.09 mm.

TH125202

145 Apply Loctite 242 to the screws (3), fit them into one of the two holes and tighten. Torque wrench setting: 23.8÷26.2 Nm. Fit the top plug after applying repositionable jointing compound for seals to the rims.

TH125127

146 Re--install the complete arms. For details, see “CHECKING WEAR AND REPLACING THE BRAKING DISKS”.

TH125092

147

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SECTION 25 -- FRONT AXLE

HOW TO REMOVE THE AXLE DRIVE PINION Remove the complete arms and the differential unit. For details, see “CHECKING WEAR AND REPLACING THE BRAKING DISKS” and “REMOVING THE DIFFERENTIAL UNIT”.

TH125092

148 If disassembly is awkward, heat the check nut (1) of the flange (2) at 80°C. NOTE: Heating is meant to loosen the setting of Loctite on the nut (1).

2 1

TH125128

149 Prevent the rotation of the pinion using a bar (T20A) as indicated in the figure. Unloose and remove the nut (1); also remove the O--ring (3).

T20A

TH125215

150 Remove the flange (2) complete with guard (4) by means of a puller.

4 2 TH125130

151 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE Remove the swinging support (5).

TH125131

152 Remove the sealing ring (6).

TH125132

153 Position wrench (T22) P.N. 380000591 onto the ring nut (7) and apply bar hold (T21) P.N. 380000590 to the pinion. Stop wrench (T22) and rotate the pinion so as to release and remove the ring nut (7).

NOTE: If disassembly proves awkward, heat the ring nut to approx. 80 Â° C.

T21

T22

TH125133

154 Apply blocks (T23) P.N. 380000592 and, with the help of a puller, extract the pinion (8) complete with the internal bearing, the distance piece and shims.

T23 8

NOTE: The thrust blocks of the bearings remain in the central body (12).

TH125134

155 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Remove the pinion (8), shims (11) and spacer (10).

10 8

11 TH125135

156 Using a puller and a press, remove the inner bearing (9) from the pinion (8).

8 9

TH125136

157 Remove the external bearing (13) thrust block.

TH125137

158 Insert a drift in the appropriate holes and remove the internal bearing (9) thrust block as well as the shim washers (14).

14 9 TH125138

159 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

8 14

9 13 5

11 3

4 2

TH125139

160

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

AXLE DRIVE PINION BEARING ADJUSTMENT

Use the specific tool. Tighten the tool in a vice and insert the bearing (1) from above, the spacer (2) and the other bearing (3).

2 1

TH125140

161 Insert the other tool elements and tighten the nut (4) until the bearing/spacer unit is packed.

TH125141

162 Use a depth gauge (range 0--15 mm) to measure the Q value between the tool upper surface and the push rod.

TH125142

163 Mount the bearing outer housing on the differential case. Install the bearings and the spacer in the differential case with the tool. Tighten the nut tool so that the bearing/ spacer unit is packed.

TH125143

164 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Use a depth gauge(range 0--15 mm) to measure the Q1 value between the tool upper surface and the push rod (as it was done in the vice). S1 = Q1--Q corresponds to the shim to be inserted between the spacer and the bearing inner race.

TH125144

165 Check the nominal value (X) indicated on the pinion (5) and add to it or subtract from it the Y variation indicated on the pinion head in order to obtain measurement Z. E.g. X=118 mm Y=0.1 mm Z= 118--0.1=117.9 mm Install tool on the differential case and measure the Q2 value between the flange and the bearing inner housing. If Q2 is added to the fixed value Q3=50mm (value from the theoretical starting point of the pinion primitive generating line to the surface measured by the tool) the W value is obtained.

5 118

X (+0.1)

Y TH125146

166

E.g.: Q2=68.7 mm W=68.7+50=118.7 mm The S2 value is obtained also from W--Z corresponding to the shim to be inserted between the bearing and the pinion head. E.g.: S2=118.7--117.9=0.8 mm

TH125145

167

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

HOW TO INSTALL AND ADJUST THE AXLE DRIVE PINION Place the inner bearing (9), the shim “S2” previously defined (if needed), and the pinion (8) under a press. Force the bearing against the pinion. 8 9

TH125147

168 Fit the pinion (8), shim “S1” (11) and spacer (10) in the main body. NOTE: The finer shims must be placed between the thicker ones.

11 TH125135

169 Insert the external bearing (13) in the central body in order to complete the pack arranged as in the figure.

TH125148

170 Apply Loctite 242 to the thread of the ring nut (7) and screw the nut onto the pinion (8). 7 8

TH125150

171 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE Apply special wrench (T22) P.N. 380000591 to the ring nut (7) and bar--hold (T21) P.N. 380000590 to the pinion (8). Stop wrench (T22) P.N. 380000591 and tighten the pack using a torque wrench until the bearings are fully seated. Then tighten the opinion to the maximum required torque of 500 Nm.

T21

T22 TH125151

172 Install a torque meter on pinion (8) and check the rolling torque of the pinion. Torque: 120--170 Ncm. T19

ATTENTION If torque exceeds the maximum value, then the size of shim “S1” (11) between the bearing (13) and the spacer (10) needs to be increased. If torque does not reach the set value, increase the torque setting of the ring nut (7) in different stages to obtain a maximum value of 570 Nm. TH125124

173

ATTENTION If torque does not reach the minimum value, then the size of shim “S1” (11) needs to be reduced.

ATTENTION When calculating the increase or decrease in size of shim “S1”, bear in mind that a variation of shim (11) of 0.01 mm, corresponds to a variation of 60 Ncm in the rotation torque of the pinion (8). Lubricate the outer surface of the new sealing ring (6) and fit it onto the central body (12) using tool (T27) P.N. 380000594.

T27

TH125152

174

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Install the swinging support (5). 5

NOTE: Check that it is properly oriented.

TH125131

175 Fit the flange (2) complete with the guard (4) and fasten it. For seating the flange (2), use a plastic hammer if necessary. NOTE: Make sure that the guard (4) is securely fastened onto the flange and that it is not deformed.

TH125153

176 Apply Loctite 242 to the threaded part of the pinion. Prevent the rotation of the pinion using a bar (T20A) as indicated in the figure. Install O--Ring (3) and nut (1); tighten with a torque wrench. Torque wrench setting: 280÷310 Nm.

T20A TH125216

177 Remove blocks (T23) P.N. 380000592 (used for extracting the pinion) and re--install the differential unit and the arms. For details, see “HOW TO ASSEMBLE AND INSTALL THE DIFFERENTIAL UNIT” and “CHECKING WEAR AND REPLACING THE BRAKING DISKS”. T23

TH125155

178 603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

FRONT DRIVE SHAFT Specifications Length (A) closed: . . . . . . . . . . . . . . . . . . . . 662 mm Extension (B): . . . . . . . . . . . . . . . . . . . . . . . . 72 mm

TH125168

179

FRONT DRIVE SHAFT REMOVAL 1

ATTENTION Support the drive shaft with suitable instruments during removal. Slacken the locking stud bolt (2) screws (1) to disconnect the drive shaft (3) front part. Carry out the same operation for the drop box side and remove the drive shaft (3).

TH125169

180

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Spider removal 1. Clean the assembly components thoroughly after removing the drive shaft. NOTE: Since the drive shaft is a sliding assembly, it is recommended to mark the fork and the shaft both sides with a piece ot chalk.

TH125170

181 2. Remove the lubricator from the spider and install a flanged fork (1) on the vice shoes to make it possible to extract the drive shaft spider (5).

3. Remove safety snap rings and hit the shaft upper side with a hammer. Remove the bearings (3) and the shaft.

1 TH125171

3 182

4. Place the spider pins on the vice shoes and beat the flanged fork to remove the bearings. 5. Repeat the same operations on the opposite side (only for front shaft).

TH125172

183

603.67.010.02 - 01 - 2004

SECTION 25 -- FRONT AXLE

Spider installation 1. Lock the flanged fork. Insert the spider in the flanged fork following the lubricator hole direction.

Lubricator hole

TH125173

184 2. It is recommended to use a locating punch to position the bearing correctly. In this way the bearing can be inserted over the spider pin in the right way. 3. Remove the locating punch and insert the second bearing on the opposite side. Then insert snap rings.

Punch Bearing

4. Repeat operations 2 and 3 to match the spider and the shaft. 5. Fit again the lubricator.

Locating pin TH125174

185

6. Repeat the above mentioned operations on the universal joint opposite side (only for front shaft). 7. Apply grease with the lubricators until it is visible next to each bearing gasket.

603.67.010.02 - 01 - 2004

SECTION 27 -- REAR AXLE

SECTION 27 -- REAR AXLE CONTENT Section

Description

Page

27 100

SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering differential with final epicycloids reductions Overall width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2050 mm (flange--to--flange) Crown wheel and pinion ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 : 34 Final reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 6 (4 satellites) Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 degrees Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Without lock Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet disc with 8 discs Steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With position sensor NOTE: For replacement intervals, oil and lubricant quantity and type for the rear axle, refer to the OPERATORâ&#x20AC;&#x2122;S MANUAL.

603.67.010.02 - 01 - 2004

SECTION 27 -- REAR AXLE

DESCRIPTION

Front view TH127001

Top view TH127002

1 The axle fitted to this unit incorporates: • Integral steering cylinder • Steering sensor • Central drive

603.67.010.02 - 01 - 2004

• •

Double reduction (crown wheel and pinion plus planetary hubs) Power brakes

SECTION 27 -- REAR AXLE

OPERATION DIAGRAM Engine power (1) is transmitted from the engine through the transmission (2) and the drop box (3) to the rear axle (4) via the drive shaft (5).

5 3

TH127011

603.67.010.02 - 01 - 2004

SECTION 27 -- REAR AXLE

REAR DRIVE SHAFT Specifications Length (A) closed: . . . . . . . . . . . . . . . . . . . 1347 mm Extension (B): . . . . . . . . . . . . . . . . . . . . . . . . 72 mm

TH127005

ATTENTION

Support the drive shaft with suitable instruments during removal. Slacken the locking stud bolt (2) screws (1) to disconnect the drive shaft (3) front part. Make the same operation on the rear side and remove the drive shaft (3).

NOTE: Refer to Section 25 “FRONT AXLE” for drive shaft spider removal. TH127004

603.67.010.02 - 01 - 2004

SECTION 27 -- REAR AXLE

REAR AXLE REMOVAL PROCEDURE Chock the front wheels. Place wooden wedges between the axles and the frame to prevent the Telescopic Handler from swinging. • Jack--up the machine upper part and secure it on suitable stands. • Remove the rear drive shaft. • Remove the wheels. • Disconnect the steering hoses (1). NOTE: Ensure both pipes are plugged to prevent constant oil leaking. • Disconnect the steering angle sensor (2). • Remove the power and park brake pipes. • Remove the four axle levelling cylinder fixing screws. • Support the axle and remove the four fixing screws. • Lower and remove the axle from the vehicle bottom with a wheeled jack. 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. • •

TH127006

5 1

TH127007

603.67.010.02 - 01 - 2004

SECTION 27 -- REAR AXLE

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.

TH127008

7 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 • Steering knuckle • Axle shafts • Axle trumpet housing • Brake housing • Differential crown wheel and pinion • Steering cylinder

603.67.010.02 - 01 - 2004

SECTION 27 -- REAR AXLE

SPECIAL TOOLS FRONT AND REAR AXLES Q.TY

NUMBER

380000581

380000582

380000583

380000584

380000585

380000586

380000587

SKETCH

DESCRIPTION

HOW TO USE/MODEL

Device for the inspection of the axle brake clutch disc wear

To check the wear of brake discs

COMPULSORY

ALL

Tool for the installation of axle To install a new bush to be housing universal joint seal used with (380000258)

Tool for the installation of the swing axle housing universal joint seal

To install a new bush to be used with (380000258)

RECOMMENDED

ALL

Tool for the installation of axle To install a new seal to be housing u--joint shaft spindle used w/ (380000258) seal COMPULSORY

ALL

Tool for installation of axle wheel hub seal

To install a new seal to be used w/ (380000258)

COMPULSORY

ALL

Wrench for axle differential ring gear

To adjust the play of the bevel gear set

COMPULSORY

ALL

Retainer for axle differential planetary gear

To hold the planetary gears for removal of pins

COMPULSORY

ALL

603.67.010.02 - 01 - 2004

SECTION 27 -- REAR AXLE Q.TY

NUMBER

380000588

380000589

380000590

380000591

380000592

380000463

380000593

SKETCH

DESCRIPTION Guide for axle differential gear pin

To guide the pins

COMPULSORY

ALL

Set of pins for disassembly/ assembly of axle differential planetary gear pins

To remove/install the pins.

COMPULSORY

ALL

Retainer for axle bevel pinion slotted key

To hold the bevel pinion (to be used w/ 380000591

COMPULSORY

ALL

Wrench for axle bevel pinion ringnut

For bevel pinion ringnut

COMPULSORY

ALL

Set of brackets for disassem- To disassemble the bevel bly of axle bevel pinion pinion with a general puller RECOMMENDED

ALL

Adjuster for axle bevel pinion bearings

To adjust the bearings

COMPULSORY

ALL

Spacer (to be used w/ 380000463) COMPULSORY

380000594

380000609

603.67.010.02 - 01 - 2004

HOW TO USE/MODEL

ALL

Tool for the installation of axle To install a new seal bevel pinion seal COMPULSORY

ALL

Adapter for the arrangement of axle bevel pinion

To adjust the pinion.

COMPULSORY

ALL

SECTION 27 -- REAR AXLE Q.TY 2

NUMBER 380000281

380000306

380000210

SKETCH

DESCRIPTION

9 HOW TO USE/MODEL

Tool for the installation of Roto--Glyd DANFOSS seal

To install a new seal

COMPULSORY

ALL

Tool for the installation of DANFOSS rotor springs

To install the springs

RECOMMENDED

ALL

Tool for the installation of DANFOSS dust seal

To install a new seal

COMPULSORY

ALL

603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

SECTION 33 -- BRAKES CONTENT Section 33 000

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Power brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Brake disc adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Brakes disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SPECIFICATIONS Brake operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powered hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet discs, piston operated Brake discs

(front axle, per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 (rear axle, per side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

NOTE: For replacement intervals, oil and lubricant quantity and type for the brake system, refer to the OPERATORâ&#x20AC;&#x2122;S MANUAL.

603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

POWER BRAKES

1. Brake pedal 2. Brake pump

3. Oil sump 4. Front axle 5. Rear axle

TH133043

Description and operation The vehicle brakes on the front and rear axles. All front and rear axles are equipped with 4 + 4 discs (4 for each side).

603.67.010.02 - 01 - 2004

The footbrake operates the pump which actuates the front and rear assemblies hydraulically.

SECTION 33 -- BRAKES

PARKING BRAKE

PARKING BRAKE LEVER INSTALLED IN CAB

TRANSMISSION REAR VIEW

TH133056

Description and operation When parking brake lever (1) is actuate, the brake caliper closes on the disc mounted on the output of the transmission shaft, blocking the movements of the transmission itself. NOTE: When the parking brake lever is actuated, the transmission is cut--off.

TH133053

603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

BRAKE BLEEDING PROCEDURE NECESSARY CONDITIONS • Engine off. • Two operators required: -- 1 in the cabin to press the brake pedal and top up the reservoir -- 1 outside, on the axle, to open and close bleed screws EQUIPMENT • Transparent flex hose (L=500 mm ∅i = 5mm) • Oil recovery container. BLEEDING STEPS • Remove the upper cab instrument panel (1) (to access the pump reservoir) • Remove the chassis guard (upper side above front axle)

TH133054

603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES •

•

Loosen the front and rear axle (3) bleed screw (2). Usually start with rear axle and then proceed as follows: -- rear right--hand side axle -- rear left--hand side axle -- front right--hand side axle -- front left--hand side axle Attach the rubber hose to the end of the bleed screw. Place the other end of the hose in the collection container.

TH133047

TH133057

6 • • • •

• •

•

Remove the brake pump reservoir cap (4) and fill the reservoir with oil. Push the pedal repeatedly, down and up, so oil circulates through the system and the air out. As the reservoir level drops, top up. When the oil starts to flow down the transparent hose, tighten the bleed screw with the pedal still pushed down. Repeat steps for each of the bleed screws in the above mentioned order. Test the brakes with the engine off and the pedal should become hard before reaching half its downward stroke. If the pedal can be pressed further or to the floor, repeat the bleeding procedure. Re--install front axle cover and instrument panel inside the cabin.

TH133049

603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

BRAKE DISC ADJUSTMENT Perform operations on both axle arms. Remove the oil level cap (1). Operate the brakes and keep them pressed to check thickness “S” between the discs with a thickness gauge (minimum value of “S” = 4.5 mm)

ATTENTION Replace brake discs and intermediate discs on both sides, if needed.

1 TH133055

S 8

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SECTION 33 -- BRAKES

TROUBLESHOOTING Insufficient braking Cause

Remedy

1. Wrong adjustment

Check the brake disc thickness. If the brake discs can be re--used, adjust them as described in the vehicle manual. Check the brake disc thickness and replace them, if needed. Replace all axle and main cylinder seal rings which came into contact with the wrong fluid. Replace also the hoses. Check and repair all outside and main circuit leakages. If the cause is the wrong fluid, see remedy no. 3. If the leakage goes outwards, replace O--rings between the central case and the intermediate cover. If the leakage goes inwards, replace the above mentioned O--rings and those of the brake piston. See problem: Overheating.

2. Brake discs worn 3. Wrong fluid in the circuit

4. Fluid leak from brake circuit

5. Axle overheating with fluid evaporation (brakes return when axle cools down) Brake pedal does not react Cause

Remedy

6. Air in braking circuit

Bleed the braking circuit as described for the vehicle manual bleeding.

Parking brake inefficient Cause

Remedy

7. Incorrect adjustment

Check the thickness of the parking brake disc and brake pads to define whether they can be reused and adjust them in accordance with the instructions provided in the manual. Check the thickness of the parking brake disc and replace it when required.

8. Brake disc/brake pads worn--out Overheating Cause

Remedy

9. Wrong oil level 10. Little clearance between brake discs 11. Wrong fluid in the circuit 12. Brake circuit choked 13. Wrong lubricant

Discharge, wash and fill until level is reached. Adjust the brake as described for the vehicle manual. See remedy no. 3. Check and repair damaged pipes. Replace the brake system and pump seal rings.

Oil coming out Cause

Remedy

14. Hydraulic fluid leakage from braking system 15. Hydraulic fluid leakage from differential circuit

See remedy no. 2 and no. 3. See remedy no. 3.

603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

BRAKES DISASSEMBLY Remove the swivel support (2). NOTE: If the bush (1) is worn and needs to be replaced, take note of the fitting “A” notch assembly side.

A TH133028

9 Remove the steering tie rod pins from the steering knuckle (see “STEERING CYLINDER REMOVAL”). Sling the axle shaft to be removed (3) with a hoist and tension the hoist a little. Slacken and remove the screws (4) and the washers (5) fastening the axle shaft (3) to the central unit (6).

4 5

3 TH133029

10 Remove the axle shaft (3) and the brake disc unit (7). Set the axle shaft on a bench. 7

3 TH133030

11 Remove the brake discs (7) and write down the assembly order. NOTE: 1 – If the discs do not have be replaced, ensure their original position is maintained. 2 – Remove the double universal joint (18).

TH133031

12 603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

Remove the piston (9) return springs (8). NOTE: If the springs (8) are distorted, replace them.

8 TH133032

13 Remove the piston drive pin screws (10).

ATTENTION If the screws need to be replaced, write down colours for brake clearances (See “BRAKING UNIT ASSEMBLY”).

10 TH133033

14 Slowly blow compressed air through the braking circuit attachment in order to remove the whole piston (9).

ATTENTION Hold the piston because it might be ejected suddenly and get damaged.

9 TH133034

603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

1 2

10 15

9 8

3 13 12 18 TH133035

603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

Brakes assembly Clean the piston (9) and the sliding/seal housings thoroughly. Replace the O--rings (11) and (12) and the anti--extrusion rings (13) and (14). Respect assembly direction.

14 12 11 13

ATTENTION Make sure anti--extrusion rings (13) and (14) are positioned correctly.

3 9 TH133036

17 Insert the springs (15) on the piston (9) circumference for travel compensation.

15 9

15 TH133037

18 Lubricate the seals and install the piston (9) in the arm (3). A

ATTENTION Make sure the piston housing matches with the stop (A) inside the arm. 9

TH133038

19 Insert the piston (9) by lightly beating the circumference with a plastic hammer.

9 TH133039

20 603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

Insert the pin screws (10) and ensure they all have the same colour. White: clearance 1 mm Yellow: clearance 0.75 mm Blue: clearance 0.5 mm Apply Loctite 270 on the threading Tightening torque: 5 ÷ 7 Nm

TH133033

21 Insert the piston (9) return springs (8). 8

ATTENTION Be careful not to damage spring attachments.

8 TH133032

22 Slightly lubricate the brake discs (7) and install them on the arm in the correct order. They should be positioned so that the oil circulation holes align with marks “B”. NOTE: When steel discs are fitted, ensure the slot next to the oil plug is free.

7 TH133040

23 Check the arm seal ring (16) integrity and location. Install the whole arm. Fasten it with two opposite screws.

16 TH133041

24 603.67.010.02 - 01 - 2004

SECTION 33 -- BRAKES

Check the arm flatness and fasten them with the screws (4) and the washers (5) in a crosswise, alternate tightening fashion. Tightening torque: 298 Nm.

4 5

TH133042

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SECTION 35 -- HYDRAULIC SYSTEM

LIST OF CONTENTS Section 35 000

Description

Page

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering system hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Telescopic boom hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Component operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Delivery side divider valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Pressure reduction valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Front loader controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power steering (OSPQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Telescopic boom distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Auxiliary control distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Working platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Procedure for the calibration of the personnel carrier platform electronic controller . . . . 47 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

2 TECHNICAL DATA Hydraulic oil Specification

Total system capacity Hydraulic oil filter change interval Hydraulic oil change interval Checking interval

Ambra Hydrosystem 46 HV NH646H International specification ISO VG 46, DIN 51524 185 litres 250 hours 500 hours 10 hours

Hydraulic pump Gear pump with built--in flow divider valve sensitive to the load and delivering priority flow to the steering circuit. Delivery New pump 130 lt./min @ 2500 rpm @ 230 bar Worn pump 110 lt./min @ 2500 rpm @ 230 bar Pressure reducing valve Control pressure Relief valve pressure

35 bar 45 bar

Balancing and load checking valves Location Lifting cylinder, piston side Tilting cylinder, piston side Telescopic cylinder(s), piston side Safety valve against load peaks

350 bar

Hydraulic distributor Multi--element distributor with open centre and individual circuit relief valves. Pressure relief valve 230--240 bar Power steering Main safety valve Secondary safety valve

603.67.010.02 - 01 - 2004

175 bar 240 bar

SECTION 35 -- HYDRAULIC SYSTEM DESCRIPTION AND OPERATION INTRODUCTION The hydraulic circuit includes: • (primary) steering circuit • (secondary) telescopic boom circuit The latter also includes the system components responsible for the selection of the stabilisers, frame levelling and rear axle lock--up. The operating diagrams of the above--mentioned circuits and the relative descriptions are given below; the diagramsgive an overall view of the hydraulics and include some indications on the electrics, as needed to provide an understanding of the system’s operating logic.

STEERING SYSTEM HYDRAULIC CIRCUIT

Basic circuit operation Pump (3) takes in the oil through a 100 micron filter located in the hydraulic reservoir and delivers it through the load sensing divider valve (2) at the back of the pump. In this manner, the oil reaches first the steering system circuit (primary circuit) and the rest of the oil is transferred to the telescopic boom and the auxiliary hydraulic circuits (secondary circuits) (Ref. A). The flow of oil goes through the priority hole of the divider valve and reaches the steering system motor (1) and then the selection valve (7) for three steering modes: — Two steering wheels — Four concentric or discordant wheels — Four concordant or unilateral crab wheels. (see fig. TH135003, page 4)

Steering system hydraulic circuit diagram

TH135002

1. 2. 3. 4. 5. 6.

Power steering Priority flow divider valv Hydraulic pump Tank with intake filter Plug with inlet and outlet side overpressure valve Rear axle control cylinder

7. 8. A. B. C.

Steering mode selection valve Front axle control cylinder Delivery line to telescopic boom circuit Heat exchanger discharge line Discharge line from telescopic boom distributor

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

With the steering wheel stationary, the power steering distributor is in neutral and the oil can flow to the return path (from inlet P to outlet T). In these conditions, in the event of collisions against the wheels, the latter are dampened by the shock--proofing valves and are not transmitted to the steering wheel. Moreover, two anticavitation valves prevent cavitation phenomena from occurring in the steering cylinders chambers. When the steering wheel is turned, the movement is transferred to the distributor which gradually opens the conduits to the cylinder ways, while neutral contacts close. Following wheel rotation (and the ensuing distributor rotation) the volume of oil that goes through is directly proportional to the angular movement of the steering wheel and produces the angular movement of the drive wheels.

STEERING VALVE The machine is equipped with two steering axles and the related steering cylinders which provide for three different steering modes as a function of solenoid valve position: 1. 2. 3.

two steering wheels four concentric (or discordant) steering wheels four unilateral (or concordant) steering wheels (crab)

If the solenoid valve (5) is not activated, steering is achieved by means of the front axle (7) and the oil contained in the steering cylinder chamber, which is not pressurised, is controlled by the same distributor that conveys the oil to the discharge line (T) and hence to the reservoir simultaneously with the oil pressurisation command. If the solenoid valve (5) is activated in either direction the two steering cylinders are connected in series and the delivery oil enters the chamber of a rear axle cylinder (6) to return to the chamber of the other cylinder.

P TH135004

TH135003

3 4. 5. 6. 7. A. T. B. P. R.

Front axle solenoid valve Rear axle solenoid valve Rear axle cylinder Front axle cylinder Connection to cylinder (6) Connection to cylinder (7) Connection to cylinder (6) Steering system delivery line Steering system delivery line

5 6 7

TH135006

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

STEERING SYSTEM HYDRAULIC CIRCUIT

TH135085

1. 2. 3.

Hydraulic pump Steering cylinder on front axle Reservoir

4. 5. 6.

Power steering Steering mode selection valve Steering cylinder on rear axle

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SECTION 35 -- HYDRAULIC SYSTEM

TELESCOPIC BOOM HYDRAULIC CIRCUIT

Basic circuit operation The pump (1) takes in the oil through a 100 micron filter situated in the hydraulic tank and sends it on to the steering circuit through line (a) in priority mode, and hence to the distributors (11) and (22) supply lines (secondary circuit). Taken as a whole, the circuit is mainly controlled by the operation of the control unit (14) and the push buttons (13) situated on the panel to the left of the driver. The pump delivery hydraulic oil flows to the distributors that control the various hydraulic functions by managing the flow--rate to the various actuators: the hydraulic oil coming back from the actuators through the distributors is transmitted to the oil cooler, where it is cooled and hence returns to the hydraulic reservoir via the total capacity filter, which holds back any impurities as may be contained in the oil returning from the actuators. When the oil temperature is low, oil viscosity increases and so does the resistance to the passage of the oil through the cooler. If the oil pressure exceeds 5 bar, whether because of the high viscosity of the oil (thermostatic valve function) or due to radiator clogging, the oil returns directly to the tank, by-passing the radiator. Tool distributor Stem lifting is achieved by working on the hand lever (14), which distributes the pressure load to the two central hydraulic (slide) valves of the distributor (22), which supply both the lifting cylinder (30) and the compensation cylinder (17). The circuit of the latter is connected to the lifting cylinder (30) and makes its possible to keep the tool (fork, bucket, etc.) in horizontal position during cylinder (30) lifting.

603.67.010.02 - 01 - 2004

The telescopic boom is extracted by means of an unstable cursor type switch located on the front of the unit’s control levet handle (14). The operation is electrically controlled by means of a trimmer (35), which activates electrically the proportional solenoid valve of the distributor (22). The latter distributes the load to the lifting cylinders (27) and (28) (if fixed). The front part of the handle houses two switches (34) for the operation of the solenoid valve equipping the distributor (28) that supplies the cylinder (6) (OPT.). The distributor (22) also contains, for each slide valve, load sensing valves, connected to the load sensing line G. Rear axle lock The rear axle locking cylinder uses the system’s discharge line which has a pressure of 3--4 bar. Its activation takes place automatically during the boom lifting stage: at ca 15°, the sensor fitted to the boom itself sends a signal to the control unit which activates the valve (20). Auxiliary control distributor The pump (1) supplies, in parallel with the distributor (22), the stabiliser and levelling control assembly (11). These controls are operated by means of push buttons (13) which activate the distributor’s solenoid valves and hence control the output pressures in the circuit itself, balanced by the load sensing line (G).

SECTION 35 -- HYDRAULIC SYSTEM

TH135008

6 Telescopic boom circuit

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

32 20

Arrangement of hydraulic system components, complete with: -- steering -- telescopic boom

33 20

29 30 31

21 20

16 15 14 13

6 C 7 8

12 11 35 14 37

TH135086

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

COMPONENT OPERATION 2 Hydraulic pump The hydraulic pump (1) is a constant flow gear pump with a built--in divider valve (2) that divides the load sensing line delivery flow. The pump moves at the speed of the engine and has a rated delivery flow of 130 lt./min at an engine speed of 2500 rpm, at 230 bar. It can work at temperatures ranging from -- 25Â°C to + 80Â°C. The pump input control (3) is direct type, without idle gears.

3 1

TH135011

Hydraulic scheme

TH135012

9 The hydraulic connections to the pump and flow divider valve are: 1. 2. 3. 4.

to the hydraulic distributor pump intake line load sensing line to power assisted circuit of steering system with reducing valve

TH135013

10 Delivery side divider valve The flow divider valve (2) mounted at the back of the hydraulic pump (1) ensures that a priority flow corresponding to the demand is always delivered to the steering circuit (priority circuit), while the remaining flow is transmitted to the telescopic boom activated by the distributor and to the auxiliary circuits (secondary circuit). 1. 2. 3. 4. 5. 6.

Housing Load sensing line connector Shim Spring Pin Plug

2 4

3 5 TH135014

6 11 603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

TH135015

12 Operation of the delivery side flow divider valve

To steering circuit

Steering circuit load sensing signal

To tool circuit 1. 2. 3. 4. 5. 6.

Pin To loader arm circuit Hydraulic pump intake hole Steering/braking circuit Hole Load sensing connector

The load sensing divider valve ensures that a priority flow corresponding to the demand is always delivered to the steering circuit (priority circuit), while the remaining flow is transmitted to the tool circuit (secondary circuit). At key--on, the pin in the load sensing valve is pushed to the left by a spring (8) enabling the pump flow to enter the valve through a hole (3) which ensures the delivery of the priority flow to the steering and braking system circuits. The pressure of the pump is also applied to the centre of the pin and transmitted to the left hand side of the pin through hole (10). The balancing hole (9) senses the pressure but works as a damper to prevent the pin from moving in an irregular manner. Assuming that during engine starting the braking and steering circuits are not used, the load sensing line opens towards the reservoir and the pump pressure applied to the left hand side of the pin moves the pin to the right, thereby conveying the delivery flow to the loader arm circuit. 603.67.010.02 - 01 - 2004

7. 8. 9. 10. 11.

Shim (if fitted) Spring Balancing hole Hole Plug

As soon as the steering wheel is rotated, the pressure generated in these circuits is sensed in the load sensing line and applied to the right hand side of the pin. When the combined effects of the load sensed and the force of the spring against the right hand side of the pin exceeds the pressure applied to the left hand side of the pin, the pin moves to the left, thereby increasing the flow delivered to the steering circuit. Since the oil in the load sensing line flows through the steering motor adjustment holes before reaching the divider valve, the load sensing pressure is always proportional to the demand. This ensures that the valve transmits only the quantity of oil necessary to the steering circuit, while the rest of the pumpâ&#x20AC;&#x2122;s output flow is routed to the loader arm circuit.

SECTION 35 -- HYDRAULIC SYSTEM

Pressure reduction valve Pressure reduction valve regulates the pressure at 35 bar in the part of the circuit that supplies oil to the piloted hydraulic controls and the joystick.

TH135088

13 1. 2. 3. 4.

Hydraulic diagram Piloting pressure pick--up Connection to PST of main control valve Powering for joystick Discharge to reservoir

TH135087

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

TH135089

15 Detail of ports of pressure reduction valve

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SECTION 35 -- HYDRAULIC SYSTEM

FRONT LOADER CONTROLS To lift, lower, retract and tilt the parts, move the lever (1) as follows: -- forward, to lower the arm -- back, to lift the arm -- to the left, to retract the front loader/tool -- to the right, to tip the front loader/tool.

1 2 3 4

1 TH135080

16 Upper control plate

This consists of an unstable cursor type three--position switch (2) and two buttons (3) and (4). The cursor (2) makes it possible to pull out the telescopic boom (when pushed forward) or retract its (when pulled back). The two buttons, buttons (3) and (4), are available for auxiliary functions. Under the load handling lever there are two unstable buttons that have been assigned the following functions: 5. Optional function 6. Transmission disengagement (neutral)

1 17

Hydraulic scheme 1--2 Cylinder lifting lines 3--4 Front loader training lines P -- Supply line T -- Discharge line

Being unstable, button (6) keeps the transmission disengaged until it is released.

The bottom part of the power assisted control unit includes six hydraulic connections that go to the joystick as follows: • Return to reservoir orifice (T) • Four outlet holes (1--2--3 and 4) for proportional pressure, each of which is connected to each end of the slide valves of the lifting and tilting control distributor. • An inlet orifice for the oil supply at a pressure of 35 bar (P). Each of the four outlet holes is equipped with small pistons with plungers that make it possible to apply a pilot pressure proportional to the movement of the joystick at the end of a pin and hence to move it by the extent necessary to activate it. The joystick is connected to a tilting plate; both the joystick and the plate are movable above the control unit body. When the joystick is used, the tilting plate moves over one of the piston and plunger assemblies to transfer the oil to the hydraulic distributor spools.

4 TH135021

TH135090

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

1 2 9 3

8 7

6 5

TH135091

19 Hydraulic cylinders 1. 2. 3. 4.

Telescopic cylinder with double balancing valve (only for telescopic boom in two sections) Telescopic cylinder Rear axle blocking cylinder Left stabiliser cylinder

The hydraulic cylinders employed to operate the telescopic boom are shown in the figure. The telescopic cylinder (2) is housed in the boom structure; however, when the telescopic boom is fitted with the three sections option, an additional cylinder (1) is mounted directly on the boom. The compensation cylinder (8) is connected hydraulically to the tilt cylinder (9) and ensures the 603.67.010.02 - 01 - 2004

5. 6. 7. 8. 9.

Right stabiliser cylinder Frame levelling cylinder (front axle) Lifting cylinder with balancing valve Compensation cylinder Tilt cylinder with balancing valve.

self--levelling of the load forks during the boom lifting cycle. A safety feature characterising the boom cylinders is the presence of balancing valves that ensure that the cylinder stays locked in its position even in the event of hydraulic pipe failure. The cylinders fitted with these valves cannot be retracted if the engine is not running.

SECTION 35 -- HYDRAULIC SYSTEM

The balancing and load holding valves are mounted on the piston side of the lifting, tilting and telescopic extension cylinders. Operation of balancing (load holding) valves -See next page The balancing (load holding) valves are mounted on the lifting, tilting and telescopic cylinders to ensure that the cylinder stem stays locked in its position even in the event of hydraulic pipe failure. With this type of load holding valves the cylinders cannot be retracted if the engine is not running and without operating the control valve spools. When the two--section telescopic boom is used, a centralised double--acting balancing valve is also provided to prevent the activation of the telescopic cylinder, on both the piston and the stem sides, if the engine is off. A. Extending the cylinder When a cylinder with a balancing valve is extended, the oil flows from the control valve spool to orifice V2 and through the check valve up to orifice C2. The oil from the cylinder returns freely from orifice C1 to orifice V1 and then to the reseervoir through the control valve spool. B. Load holding (in neutral) When the control pin is in neutral, the back pressure generated in the circuit by the weight of the telescopic boom and the load keeps the lock holding valve in its seat and prevents cylinder retraction. C. Cylinder retraction When a cylinder has to be retracted, the oil flows from orifice V1 to orifice C1, but the pressure of the oil discharged from the cylinder into orifice C2 is not sufficient by itself to move the double pilot spool against the force of the safety valve spring and bring about cylinder retraction. The pressure applied to the cylinder through orifices V1/C1 is therefore applied as pilot pressure also to the end surface of the pin through the threading of the pilot screw. This pressure, together with the back pressure applied to the spool via orifice C2, moves the spool against the action of the safety valve spring enabling the oil discharged from the cylinder to flow back into the reservoir.

TH1350070

20 Since it takes both the load sensing pressure applied to the end of the double pilot spool and the cylinder discharge pressure through orifice C2 to move the orifice and enable the oil discharged from the cylinder to flow back into the reservoir, in the event of cylinder hose failure, the balancing valve would close due to the action of the spring, thereby preventing cylinder retraction. Similarly, if the engine is not running, but the in--cab controls are moved, there will be no pressure at orifice V1/C1 to supplement the back pressure applied to orifice C2, move the pin and let the oil flow back into the reservoir. D. Operation of circuit relief (shock) valve If a cylinder is subjected to a sudden load variation, as may be caused, for instance, by a collision against a wall while driving with the telescopic boom extended, the sudden load variation applied to the cylinder is too high. In such circumstances, the pressure generated at discharge orifice C2 is sufficient to move the spool against the force of the safety valve spring and discharge the excess pressure into the reservoir via the circuit relief valve in the hydraulic distributor element. As soon as the pressure has been relieved, the circuit relief valve closes again and holds the cylinder in its position.

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

B 1

2 V1

TH135028

21 Operation of balancing valve

A. B. C. D.

Oil at pump pressure

Static oil

Counter--pressure oil

Return to reservoir

Extension Load holding Retracting Circuit relief function

603.67.010.02 - 01 - 2004

1. 2. 3. 4.

Pilot screw Double pilot spool Check valve Circuit relief valve

SECTION 35 -- HYDRAULIC SYSTEM POWER STEERING (OSPQ) The main components of the OSPQ are the control valve and the rotor assembly. The control valve is a revolving valve that modifies the alignment of the oil passages as it revolves, thereby activating the steering cylinders. The rotor assembly is under the control valve. Its normal function is to work as a hydraulic motor to perform metering operations. In an emergency, without fluid power, it is only possible to perform short steering manoeuvres while the vehicle continues moving over a short distance. 1. 2. 3. L R P T LS

Pipe fitting flange Flange to fasten the power steering Housing for steering column

2 LS L

TH135025

Cylinder supply line, for rear axle Cylinder supply line, for front axle From pump Discharge line to reservoir Load sensing line

The action generated by the steering wheel transmits pressure through the LS line to the divider valve on the pump, which, in its turn, gives priority to the power steering P line. The delivery flow to the motor assembly is controlled by valve (B). Steering lock is controlled by an anti--collision valve (A) which redirects the oil flow to the discharge line T.

TH135026

23 1. 2. 3.

Pilot and flow amplification valve Flow amplification circuit Flow pilot circuit

TH135027

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

20 20

5 25 2

12 11

26 15 13

17 24

18 21 22 23 TH135029

25 Power steering components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Dust guard Power steering body Check ball valve Threaded bushing Seals Steering lock parts Rings Rotary valve Sleeve return springs (11) Sleeve (11) driving pin and shaft (12) Valve seat sleeve (8) Rotor (17) drive shaft O--ring

603.67.010.02 - 01 - 2004

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Overpressure valve O--ring Distribution plate Rotor O--ring Fixed ring for rotor (17) Anti--collision valve Cover Washers Screw with pin Cover (21) fastening screws Pilot valve Spacer

SECTION 35 -- HYDRAULIC SYSTEM TELESCOPIC BOOM DISTRIBUTOR The main distributor is a ”compensated load sensing” type distributor that controls the lifting of the boom and the travel and compensation effects for tool training. Its main components include: • an input plate (1) • four sections (slide valves) (2) to distribute the flow • a closing plate (3). The task of each distributor section is to transfer the hydraulic oil flow to the various user devices as a function of the demand communicated by the operator using the hand lever. When the hand lever is set on neutral, the hydraulic oil from the pump reaches the distributor and is cut-off by the position of the four slide valves, after going through the circuit of the tool to be moved. Working in conjunction with the pump and the auxiliary control distributor, the distributor ensures that the hydraulic supply is distributed independently of the load applied. This system -- called ”Load Sensing” -works to ensure that the pump delivers only the output demanded. As long as the hand lever is not activated and the user devices require no flow, the Load Sensing line, and hence the ”LS” inlet of the distributor, is not pressurised. In these conditions, the pump flow is routed to the discharge line (T) by valve (9) (quick discharge valve). In these conditions, the main pump delivers exactly the amount of oil needed to compensate losses from the system; the pressure in the pump delivery line, called ”stand--by pressure”, is ca 25 bar.

TH1350071

26 When a distributor slide valve is opened by the action of the hand lever, the path of the hydraulic oil from the pump to the user device is opened up. In actual practice, the cross--sectional area of the opening, which is produced by the movement of the distributor slide valve, behaves like a calibrated restriction. Any variation in oil flow (user device movement speed) required by the operator is reflected in pump output through the Load Sensing signal. When a single distributor slide valve is activated, pump pressure is supplied to the user device and, through the Load Sensing line, is applied to the spring side of the Load Sensing valve (3) slide valve. The position of the pump plate will vary so as to increase flow--rate as a function of demand. When the pump’s delivery pressure exceeds the load pressure, the user device begins to move and the flow of oil delivered by the pump causes a pressure drop through the slide valve restriction. When this pressure drop corresponds to the load of the Load Sensing valve calibration spring, a balance is established.

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

TH135030

27 Distributor hydraulic circuit scheme 1. Input side valve -- 2. Auxiliary cylinder control On--Off solenoid valve (OPT) -- 3. Compensation valves (load sensing) -- 4. Hydraulic (slide) valve for tool (forks) tilt cylinder control -- 5. Hydraulic (slide) valve for boom lifting cylinder control -- 6. Telescopic boom (12 or 16 m) extension proportional solenoid valve -- 7. Distributor closing slide valve -- 8. Max. pressure control valves -- 9. Quick discharge for flow discharge with all user devices in neutral (stand--by) -- 10. Flow regulator -- P. Pump delivery line -- LS. Load sensing line -- T. Discharge line -- A1--B1. To compensation and tilt cylinders -- A2--B2. To telescopic boom lifting cylinders -- A3--B3. To auxiliary cylinder -- A4--B4. To telescopic boom extraction cylinders.

9 8

TH135092

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

MAIN COMPONENTS OF TELESCOPIC BOOM DISTRIBUTOR

3 7 3

1 10

TH135032

29 N.B.: For the definition of the components shown in this diagram, see legend to Figure 28.

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

AUXILIARY CONTROL DISTRIBUTOR This is a compensated type distributor, like the main distributor of the telescopic boom. It controls the right and left front stabilisers and frame levelling by means of the cylinder fitted to the front axle. It is located in the front part of the frame, near the front axle itself, and is connected to the main distributor of the load sensing line and the flow discharge line (T). It receives the flow directly from the pump and hence from the flow divider valve. It is managed by the operator by means of unstable switches (1) located on the control panel in front of the driverâ&#x20AC;&#x2122;s compartment.

TH135093

1. Control switches A1--B1. Connection to the right stabiliser cylinder A2--B2. Connection to the left stabiliser cylinder A3--B3. Connection to frame levelling cylinder on front axle P. Pump output flow T. Discharge line to reservoir LS. Load sensing line

1 TH135094

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

CYLINDERS

1 2 9 3

8 7

6 5

TH135091

32 1. 2. 3. 4. 5.

Outer telescopic cylinder (16 m model only) Inner telescopic cylinder Rear axle lock--up cylinder Left stabiliser cylinder Right stabiliser cylinder

6. 7. 8. 9.

Frame levelling cylinder Compensation cylinder (mated to lifting cylinder) Lifting cylinder (mated to compensation cylinder) Tilt cylinder

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

INNER TELESCOPIC CYLINDER

10 11

22 17

23 26 8 5

12 3

14 13

21 2 7 19

15 16

11 10

12 24

TH135051

Calibration of circuit relief valve on stem side (V1) = 260 bar Calibration of circuit relief valve on plunger side (V2) = 160 bar

Model

Stroke (C)

Stroke (D)

LM1340

3400 mm

3350 mm

LM1440

3800 mm

LM1740

3650 mm

Tightening torque 480-- 530 Nm

1070--1120 Nm

20--

25 Nm

380-- 430 Nm

3750 mm

1070--1120 Nm

3600 mm

120-- 125 Nm

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Complete cylinder liner Complete cylinder liner Complete rod Complete rod Front bottom Front bottom Plunger Plunger Guide ring Wiper ring Gasket Dowel O--ring Anti--extrusion ring O--ring Anti--extrusion ring

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

O--ring Plunger ring Plunger ring Plunger guide ring Plunger guide ring O--ring Plug O--ring Anti--extrusion ring O--ring Rod eye Valve Screw Valve Piston ring

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

OUTER TELESCOPIC CYLINDER (only 17 m model)

15 11 13

12 13 14

TH135050

Stroke (B): 3450 mm Operating pressure: 260 bar 7

Tightening torque: 550-- 600 Nm

Tightening torque: 1300--1350 Nm

Tightening torque:

1. 2. 3. 4. 5. 6. 7. 8. 9.

Complete cylinder liner Complete rod Front bottom Plunger Guide bush Wiper ring Gasket O--ring Anti--extrusion ring

603.67.010.02 - 01 - 2004

20--

Calibration of circuit relief valve on rod side (V1) = 260 bar Calibration of circuit relief valve on plunger side (V2) = 160 bar

25 Nm s

10. 11. 12. 13. 14. 15. 16. 17.

O--ring O--ring Plunger ring Plunger guide ring Dowel Spacer Valve Screw

SECTION 35 -- HYDRAULIC SYSTEM

FRAME LEVELLING AND REAR AXLE LOCKING CYLINDER

TH135096

Tightening torque

Stroke (A): 135 mm Max. retraction pressure: 180 bar Max. operating pressure: 260 bar

500-- 600 Nm

2100--2150 Nm

1. 2. 3. 4. 5. 6. 7.

Complete cylinder liner Complete rod Front bottom Plunger Guide bush Wiper ring Rod ring

20--

25 Nm

PS 1521--A

PS 1521--P

PS 1521--K

8. 9. 10. 11. 12. 13. 14.

O--ring Anti--extrusion ring O--ring O--ring Plunger ring Plunger guide ring Dowel

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

SMALL STABILISER CYLINDER (13 m and 14 m models only)

1 4

3 12

TH135053

Tightening torque

Stroke (A): 200 mm Max. operating pressure: 310 bar Circuit relief valve max. pressure: 330 bar (*) pay attention to direction of assembly

1. 2. 3. 4. 5. 6.

Complete rod Complete cylinder liner Rod gasket Front bottom O--ring O--ring

603.67.010.02 - 01 - 2004

530 Nm

1538.6 Nm

31.5 Nm

7. 8. 9. 10. 11. 12.

Anti--extrusion ring Plunger ring Plunger Guide ring Grease nipple Dowel

SECTION 35 -- HYDRAULIC SYSTEM

LARGE STABILISER CYLINDER (standard on 17 m model, available on 13 m and 14 m models)

TH135095

Stroke (A): 475 mm Max. operating pressure: 260 bar

Tightening torque 1

775-- 835 Nm

2400--2500 Nm

3 1. 2. 3. 4. 5. 6. 7.

Complete cylinder liner Complete rod Front bottom Plunger Guide ring Wiper ring Rod ring

8. 9. 10. 11. 12. 13. 14.

20--

25 Nm

O--ring Anti--extrusion ring O--ring O--ring Plunger ring Plunger guide ring Dowel

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

32 COMPENSATION CYLINDER

7 10

1 1 11

TH135055

Stroke (A): 1224 mm Max. Operating pressure: 260 bar

1. 2. 3. 4. 5. 6. 7.

Complete cylinder liner Complete rod Front bottom Plunger Guide ring Wiper ring Rod ring

603.67.010.02 - 01 - 2004

Tightening torque

300--350 Nm

700--750 Nm

20-- 25 Nm

8. 9. 10. 11. 12. 13. 14.

O--ring Anti--extrusion ring O--ring O--ring Plunger ring Plunger guide ring Dowel

SECTION 35 -- HYDRAULIC SYSTEM

LIFTING CYLINDER

1 6

2 10

3 13

TH135056

Stroke(A): 1220 mm Max. operating pressure: 260 bar

Tightening torque 1

1500--1500 Nm

5500--6000 Nm

3 1. 2. 3. 4. 5. 6. 7.

Complete cylinder liner Complete rod Front bottom Plunger Guide ring Wiper ring Rod ring

8. 9. 10. 11. 12. 13. 14.

20--

25 Nm

O--ring Anti--extrusion ring O--ring O--ring Plunger ring Plunger guide ring Dowel

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

34 TILT CYLINDER

1 6

2 5

3 12

TH135057

Stroke(A): 442 mm Max. operating pressure: 260 bar

Tightening torque 1

775-- 825 Nm

2500--2600 Nm

3 1. 2. 3. 4. 5. 6. 7.

Complete cylinder liner Complete rod Front bottom Plunger Guide ring Wiper ring Rod ring

603.67.010.02 - 01 - 2004

8. 9. 10. 11. 12. 13. 14.

20--

25 Nm

O--ring Anti--extrusion ring O--ring O--ring Plunger ring Plunger guide ring Dowel

SECTION 35 -- HYDRAULIC SYSTEM

ARMS BOOM REMOVAL Description of steps • Lift the boom to make the rod (1) of the lifting and compensation cylinders accessible and removable (top of engine bonnet) • Turn off the engine • Harness the boom (to prevent it from slipping out or falling off) with chains or ”bands” (use the two connecting plates equipping the boom).

TH135058

41 •

Place a support under the lifting + compensation cylinders so as to prevent them from falling and keep them in the required position for re--assembly.

TH135059

42 s

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

36 •

To remove the pin (1) from the lifting + compensation cylinders, remove the static ring (2) from the cab side and pull out the pin from the opposite side with the aid of an extrector.

2 1

TH135060

43 •

•

To remove the boom rear fastening pin (1), unscrew screw (2) and drive out the pin with the aid of a rubber mallet. Disconnect the hydraulic system pipes: -- outer telescopic cylinder pipes (16 m version) -- pipes on the boom (cab side) Remove the boom.

TH135082

44 s

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

BOOM INSTALLATION Description of steps • Harness the boom, then lift it and place it on the machine in the correct position •

Fit the boom fastening pin (to rear part of the machine)

•

Fit the lifting + compensation cylinders pin and remove the support

•

Connect the hydraulic system pipes: -- outer telescopic cylinder connection pipes (16 m version) -- pipes on boom

•

Remove che chains/bands

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

38 BOOM DISASSEMBLY

General conditions A. If you have to work on the machine, instead of the inner part of the boom, or have to work on the inner part but it is not possible to use an on--board pump to activate the cylinders, proceed as follows:

Take down the boom assembly (see Boom Removal and Installation procedure)

B. If you have to work on the inner part of the boom and the engine is ON, proceed as follows:

We recommend that you remove the boom sections from the machine one at a time. C. If you have to work on the inner part of the boom and the engine is OFF, or it there is no on--board pump, proceed as follows:

Take down all the boom sections simultaneously with the aid of a crane or a hoist and do not forget to deactivate the locking valve before removing the individual boom sections (by fastening the 1st on the pin side and pulling out the boom sections from the opposite side with the aid of an overhead crane or a lift truck).

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

Description of boom disassembly procedure (13 m + 14 m) 6

4 3

TH135097

1. 2. 3.

First boom Second boom Third boom

â&#x20AC;˘

Pull out the third boom by ca 500 mm to make it possible to remove pin (1) (take down the split ring and pull out the pin).

4. 5. 6.

Lifting + comp. cylinder Outer telescopic cylinder Tilt cylinder

s s s s

TH135062

46 â&#x20AC;˘

Unscrew and remove all the mounting hardware that fasten the shoes so as to release them (you can unscrew these on all the sections).

TH135063

47 603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

40 •

• •

Disconnect the hydraulic pipes of the ”tilt” cylinder and the hydraulic pipes of the auxiliary tool system. Pull out the third boom section; together with this, pull out the relative shoes. Unscrew the mounting hardware (1) for the supports (2) of the inner telescopic cylinder pin ar the rear and pull out the pin.

TH135064

1 48

•

• •

Take down the inner hydraulic pipes (if the hydraulic system is not active, these pipes can be removed at the beginning of the procedure) Pull out the inner telescopic cylinder from the back of the first boom. Remove (pull it out from the front) the second boom section (and together with this, remove the accompanying shoes, the mounting hardware of which has been removed previously).

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

Description of boom disassembly procedure (17 m) 5 8

TH135098

1. 2. 3. 4.

â&#x20AC;˘

First section Second section Third section Fourth section

Pull out the fourth section by ca 500 mm to make it possible to take out the pin (remove the split ring and pull out the pin).

5. 6. 7. 8.

Outer telescopic cylinder Lifting + compensation cylinder Inner telescopic cylinder Tilt cylinder

s s s s s s s s

TH135062

50 s

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

42 •

Unscrew and remove all the mounting hadware fastening the shoes so as to release them (you can unscrew this on all the sections).

TH135063

51 •

• •

Disconnect the hydraulic pipes of the ”tilt” cylinder and the hydraulic pipes of the auxiliary system tool. Pull out the fourth section; together with this the accompanying shoes are also removed. To take out the pin (1) of the outer telescopic cylinder, remove the central screw (2) and then pull out the pin (1).

1 TH135065

52 • •

•

• •

Disconnect the inner telescopic cylinder pipes. Remove the third and second sections (still connected together) and pull out simultaneously the shoes of the second section. Remove the screws (1) of the supports (2) of the inner telescopic cylinder pin on the back of the second section and pull out the pin. Pull out the inner telescopic cylinder from the back of the second section. Remove the third section (by pulling it out from the front end) from the second section (and the accompanying shoes).

1 TH135064

BOOM ASSEMBLY PROCEDURE Fit back the boom sections by repeating the same steps in reverse order.

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

WORKING PLATFORM The use of the working platform requires the hydraulic system to be equipped with an hydraulic block with proportional solenoid valve.

TH135074

54 Such proportional valve, indicated in the illustration, checks the pilot oil pressure for boom lifting/telescoping, allowing this manoeuvre by radio control from the working platform.

TH135075

55 The electrical components of the working platform are illustrated in SECTION 55 â&#x20AC;&#x201C; ELECTRIC SYSTEM, in this manual.

603.67.010.02 - 01 - 2004

CODE CNH--MT: 76091086

PROPORTIONAL SOLENOID VALVES PILOTING BLOCK

TH135077

5. SHUTTLE VALVE LG 6--S--2X (40 Nm) 6. PRESSURE REDUCTION PROPORTIONAL VALVES 4 K1X/30AG12C4V (12 Nm + 5 Nm) 7. VALVE BLOCK

44 SECTION 35 -- HYDRAULIC SYSTEM

SECTION 35 -- HYDRAULIC SYSTEM

TELEHANDLER HYDRAULIC SYSTEM WITH WORKING PLATFORM TH135076

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

PROCEDURE FOR THE CALIBRATION OF THE PERSONNEL CARRIER PLATFORM ELECTRONIC CONTROLLER Memorisation of the parameters of the controller 1. Connect BB3 to the 12--way connector located in the rear side of the machine. The connector is located in the harness connected to the Rexroth controller

TH135099

58 2. Starting conditions: • Starter key in ON. • Key on radio control in position “1” • Press button START on the radio control

3. Select F1 (Config/Cal) to enter the change menu

TH135100

59 s

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

48 4. Select 1 (prop + Adj)

TH135101

60 5. Scroll the display using the buttons with symbol

TH135102

61 6. Select 5 (Poti Adjust)

TH135103

62 7. Reading 2.2 V with the joystick in NEUTRAL

TH135104

63 603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM 8. Reading 4.0 V with the joystick full stroke in lowering Press ENTER

TH135105

64 9. Reading 0.4 V with the joystick full stroke in lifting Press ENTER

TH135106

65 10. Press button Menu until the previous display reading returns.

Select 8 (Potiadjust)

TH135103

66 s

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

11. Reading 2.2 V with the joystick in neutral

TH135107

67 12. Reading 4.0 V with the joystick full stroke (rightward) in extension Press ENTER 13. Reading 0.4 V with the joystick full stroke (leftward) in retract Press ENTER

TH135108

68 14. Press button Menu until the previous display reading returns.

Select 2 (settings)

TH135101

69 s

15. Scroll the display using the buttons with

TH135102

70 603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM 16. Select 3 (Poti Mid)

TH135103

71 17. Reading 2.2 V with the joystick in NEUTRAL Press ENTER

TH135109

72 s

18. Select 4 (Poti mid)

19. Reading 2.2 V with the joystick in NEUTRAL Press ENTER

TH135110

73 s

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

20. Press button Menu until the home display returns. Press TEACH Storage to enter the memorisation menu.

TH135100

74 s

21. Select 1 (SAVE PARAMS)

22. Select ENTER to memorise the data in the controller.

23. At the end of the procedure, turn the key into position OFF.

603.67.010.02 - 01 - 2004

SECTION 35 -- HYDRAULIC SYSTEM

SPECIAL TOOLS NUMBER

SKETCH

DESCRIPTION

HOW TO USE/MODEL

380001586

Linkage for hoses inside the arm (32 mm)

ALL

380001587

Linkage for hoses inside the arm (36 mm)

ALL

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SECTION 55 – ELECTRICAL SYSTEM Chapter 1 – Electrical system general CONTENTS Section 55 000

Description

Page

Electrical equipment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Electrical system and fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Use of the tip--over prevention system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Bulb replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Protecting the electrical systems during charging or welding . . . . . . . . . . . . . . . . . . . . . . 26 Starting the machine using jump leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Temporary wiring repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical system--general fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Working platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

55 000 ELECTRICAL EQUIPMENT SPECIFICATIONS ELECTRICAL SYSTEM

88 kW

Alternator Battery type Standard 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

90 amp 12 volt negative earth 105 Ah (12v/505 A) 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

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

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 warning lamps are mounted in front of the operator, behind the steering wheel. The key start switch has three positions: I

OFF

Ignition (ON)

III

Engine start (cranking)

2 3

TH155116

1 The battery is located on the left--hand side of engine. The battery type is 12 volt, 105 Ah, standard or 150 Ah optional. There is an isolator switch (1) located on the negative cable to provide a battery disconnect facility.

TH155106

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

The alternator is 12 V, 90 A.

TH155003

3 The starter is a Bosch 3.5 kW unit.

TH155004

4 Fuses and relays The machine fuse and relay board is located in the rear compartment, behind the driver. The fuses are numbered and reference to Figure 5 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. TH155005

IMPORTANT: Do not replace a blown fuse with another of a different rating.

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Fuse board â&#x20AC;&#x201C; Fuses Fuse No. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 F31 F32 F33 F34 F35 F36 F37 F38 F39 F40 F41 F42

Rating 3A 7,5A 5A 15A 15A 10A 15A 15A 15A 15A 5A 10A 10A 10A 10A 10A 15A 5A 3A 15A 7,5A 5A 10A 10A 15A 7,5A 5A 5A 7,5A 15A 15A 3A 5A 10A 5A 5A 10A 10A 15A 10A 15A 20A

Colour Purple Brown Orange Blue Blue Red Blue Blue Blue Blue Orange Red Red Red Red Red Blue Orange Purple Red Brown Orange Blue Red Blue Brown Orange Orange Brown Blue Blue Purple Orange Red Orange Orange Red Red Blue Red Blue Yellow

Circuit Instrument + tilting prevention system Stabilisers Sensor power supply Front work headlights Horn Air conditioner recirculation motor Driving switch â&#x20AC;&#x201C; lights Seat Arm working headlights Rear window wiper At disposal Double optional Rexroth proportional power supply Optional manoeuvres Axle rocking lock Tension gauge power supply Rear working headlights Reversing buzzer, cabin buzzer Air conditioner control unit power supply Rotating beacon Axle sensor power supply + work selection control unit At disposal Cabin ventilation solenoid valve Switch lighting + instrument power supply Control car power supply At disposal + 30 roof lamp + sound system Micro--seat +30 CB Dipped beam headlights Upper window wiper + 15 sound system Stop lights Engine shut down RH side lights LH side lights + number plate lights Transfer system +30 warning Main beam headlights Air conditioner compressor Fridge socket Cigar lighter

Diagram 8 3 3 7 2 10 6 9 7 8 1 4 4 4 3 4 7 2 10 7 3 10 9 5 8 5 9 9 9 6 8 9 6 1 6 6 2 6 6 10 9 9

Relays K1 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23

Relays Double optional Optional (IN) Optional (OUT) Stabiliser power supply with low arm Low arm Transmission disconnect Dipped beam headlights Horn Main beam headlights At disposal Tension gauge Blinking Tilting--prevention Start--up consensus Out--low stabilisers Stabiliser power supply with arm in Aligned axle warning lamp Parking brake engaged 85% slow motion Reversing buzzer Air conditioner compressor Air conditioner on

603.67.010.02 - 01 - 2004

diagram 4 4 4 3 3 2 6 2 6 10 4 6 4 1 5 3 3 5 8 2 10 10

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

TH155006

TH155079

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

CONTROLS AND INSTRUMENTS CONTROL PANEL TABLE POS.

AIR FILTER WARNING LAMP

NEGATIVE

ENGINE OIL PRESSURE WARNING LAMP

NEGATIVE

GENERATOR WARNING LAMP

NEGATIVE

WATER TEMP. INSTRUMENT

ohm

FUEL LEVEL GAUGE

ohm

REV COUNTER INSTRUMENT

+ ILL

NIGHT LIGHTING (+)

GND

MASS (EARTH)

+ Ch

POSITIVE (+ Key)

L13

J10

FOUR WHEELS STEERING WARNING LAMP

POSITIVE

J11

MAIN BEAM LIGHT WARNING LAMP

POSITIVE

L10

J12

DIRECTION IND. WARNING LAMP

POSITIVE

J13

WARNING LAMP HANDBRAKE ON

NEGATIVE

L11

J14

TWO WHEEL STEERING WARNING LAMP

POSITIVE

J15

OUTER BUZZER OUTPUT (--)

J16

BRAKE OIL LEVEL WARNING LIGHT

NEGATIVE

L12

J17

CRAB STEERING WARNING LIGHT

POSITIVE

J18

TRANSMISSION OIL PRESS. WARNING LAMP

NEGATIVE

J19

TRANSMISSION OIL HIGH TEMP. WARNING LAMP

NEGATIVE

J20

GLOW PLUG PRE--HEAT. WARNING LAMP

NEGATIVE

603.67.010.02 - 01 - 2004

FUNCTION

SIGNAL

Hz + LIGHTS

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

PANEL

L10

L11

L12

L13

TH155080

PANEL INSIDE DIAGRAM

FUEL LEVEL

ENGINE RPM COUNTER

COOLANT TEMPERATURE GAUGE

TH155081

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 HAND AND FOOT OPERATING CONTROLS

Shown in Figure 10 is the cabin layout of a typical machine with a Powershift Transmission and Servo Controls for the Telescopic Arm. NOTE: The layout of controls in the diagram may vary between machines, depending upon options fitted to meet Legislation in different Countries.

1. Hydraulic control panel. 2. Instruments 3. Steering geometry selector Select all steering modes at least once a day to check correct operation. 4. Safety key for control mode selection -- jobsite -- road -- people--conveyance platform

IMPORTANT: When starting the engine, retract all arm segments until the relief valve is actuated and remains so for 10 seconds. This operation assures segment and arm pipe synchronisation. Failure to synchronise may damage the pipes.

11. Front multi--function loader lever -- telescopic arm extension/retraction -- arm lifting and lowering -- tool tilting and return -- transmission disconnect button -- horn button -- aux 1 function button -- aux 2 function button 12. Glove compartment compartment)

(upon

request,

radio

6. Engine starter key

13. Steering wheel IMPORTANT: Prior to driving the vehicle, always turn the steering wheel from side to side at engine start up, to circulate the hydraulic oil.

7. Switch panel for miscellaneous services

14. Accelerator foot pedal

8. Powershift selection lever, forward direction and horn

15. Brake pedal

5. Vehicle hazard light switches

9. Side light and direction indicator control lever 10. Vents

16. Tilting prevention lock force release button 17. Steering wheel height adjusting lever 18. Load handling monitor indicator 19. Climate system control panel 20. Rear straight wheels indicator light

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

20 3 5

8 10

16 14

15 6

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

ALIGNMENT OF THE WHEELS IMPORTANT: Prior to selecting one of the three possible steering modes, verify that the rear wheels alignment indicator light is activated and align the wheels perfectly. 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 (rear wheels aligned).

A C

ATTENTION

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 wheels steering is by the front wheel only.

B – 2+2 WHEELS STEERING -- Shift the distributor control lever for steering selection to position ‘B’ for wheel pair steer. C – CROSS TRANSFER -- Shift the distributor control lever for steering selection to position C for crab steering. TH155011

11 s s s s s s s

A B C

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

INSTRUMENT CONSOLE IMPORTANT: Gauges and switches mounted in the Instrument panel may vary in position from that shown in this manual. This is dependant 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.

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13 1

Tachometer and hour meter The tachometer (1), graduated to 3000 rev/min, is driven from the alternator and reflects true engine speed. The hour meter (2), situated in the lower half of the tachometer, records hours of engine operation and is driven from the alternator when running. 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 â&#x20AC;&#x153;ONâ&#x20AC;? position.

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2 14

NOTE: When the key--start/stop switch is turned off the gauge needle assumes a random position.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

INDICATOR/WARNING LIGHTS – 1st Segment

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1 2

1. Main beam headlight warning lamp 2. Direction indicator warning light

INDICATOR/WARNING LIGHTS –

2nd

16 Segment

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The show the selected steering mode: 1. 2 wheel steering (front) 2. Cross transfer (crab diagram) 3. 4 wheel steering

INDICATOR/WARNING LIGHTS –

3rd

17 Segment

1. Alternator charge indicator 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 light will be extinguished. 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 (refer to Section 4). 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. It is extinguished once steering temperature is reached, whereupon the engine can then be started.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

INDICATOR/WARNING LIGHTS – 4th Segment 1. Transmission oil temperature warning light Should the transmission oil temperature exceed a predetermined level the warning light will illuminate.

ATTENTION

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

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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. Contact your Dealer to investigate the cause and consult the manual as for towing the machine as necessary. 3. Parking brake warning light The warning light is illuminated when the parking brake is applied and the ignition is switched ON.

ATTENTION

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.

4. Brake reservoir oil level low indicator lamp 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.

ATTENTION

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.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

LOAD STATUS INDICATOR PANEL The load status indicator warns the operator when the Telehander reaches the maximum authorised load condition.

ATTENTION

Any attempt to lift loads beyond this will result in an unsafe and unstable situation.

A – TWO GREEN SIGNAL LIGHT The two signal lights indicate decreasing stability situations, but regular. During normal operation, the light signal status is continuously updated and indicates the current situation.

s s s s s s s s s s s

B – TWO YELLOW SIGNAL LIGHT (VISUAL ALARM) The two signal lights indicate critical situations of instability. In these case the instability value is around 100% (tilting).

DANGER

It is required another operator to solve to the situation. Try to lower the vehicle centre of gravity as much as possible. Keep on lifting in the direction of the load closest to the vehicle centre of gravity, or retract the telescopic arm, if extended, to move the load as closest as possible to the vehicle centre of gravity.

C – RED SIGNAL LIGHT (VISUAL ALARM AND SOUND) This signal light illuminates, when the Telehandler reaches 100% of its maximum authorised load capacity. The sound alarm sounds simultaneously with the red signal light illuminated. When this alarm comes on, all load hydraulic handling operations, stabiliser lifting an axle tilting operations are locked. The only function allowed is the telescopic arm retraction, unless the function lock is forced by operating the relative button as described in the following pages.

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D 20

s s s s s s s s s s s s s s s s s s s s

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 D â&#x20AC;&#x201C; TEST SWITCH Operation of this switch 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.

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22 TILTING LOCK FORCING BUTTON

When the button is kept pressed, normal hydraulic control functions are restored during emergency situations. IMPORTANT: All functions must be performed while the button is pressed. Corrective actions include load weight approaching to the vehicle centre of gravity (load lifting or arm retraction), or operations to increase the vehicle stability such as, stabiliser lowering or axle inclination adjustment.

ATTENTION

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Operate this button only if it is possible to adjust the vehicle stability without retracting the telescopic arm. TILTING DANGER!!

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

USE OF THE TIP--OVER PREVENTION SYSTEM When the equipment is started, the tip--over prevention system is activated and performs automatically the test operation. The indication of the load conditions is activated with the state ON of the input “activation of SAR” (pin C of the 3--way connector). This input is associated with a switch, normally located on the control board of the equipment designated as “Working/Travel” that provides the operator, in case of substantial travelling of the equipment, the neutralisation of the SAR and switches to mode Travel (under this mode no movements of the arm are allowed). The longitudinal stability conditions of the equipment is indicated by the activation/cutting--off of the leds of the load curve. The approaching of the maximum load threshold is also indicated by a buzzer, coming ON at 90 % and by the activation of output “travel speed reduction” (pin 6 of the 8--way connector). When the equipment is in a pre--tipping condition, i.e. the maximum load threshold (100%) indicated by the coming ON of the last red led of the scale is exceeded, the buzzer sounds constantly and all the leds are flashing.

Calibration The calibration of the sensor is done by activating the auto learning function on the processing unit inserting the connection bridge between the two calibration inlets: pin A and pin B of the 3--way connector. The calibration procedure of the SAR is based upon the acquisition of the two points for the determination of the two work curves.

Preliminary conditions The device provides an unlimited number of calibrations. However, it is necessary that, prior to staring operating the equipment, the SAR is calibrated, complying with the following prescriptions: •

• •

all the calibration operations must be done under safe conditions with the equipment not braked, in an horizontal position on a firm surface (ex. A concrete platform), with straight steering and free from adverse ambient conditions (ex. Winds) and in an average time not exceeding 30 minutes. the load cell must be secured to the axle at least 12 hours prior to the calibration and subsequently tightened the equipment must stay activated with the cell connected for at least 15 minutes prior to the calibration.

Calibration procedure The calibration system requires: -- THE SETTING OF TWO SAFETY POINTS 0% (BOOM FULLY RETRACTED) 100% (BOOM FULLY EXTENDED) 1. PLACING THE MACHINE ON A FLAT SURFACE (check with a level gauge on the frame) -- brake disengaged -- straight steering -- engine running -- stabilisers lifted 2. PRESS THE TEST BUTTON AND KEEP IT PRESSED (instrument on right stud inside the cab) -- the red/yellow/green leds on the display flash and the buzzer sounds -- insert the magnetic key and move it until the leds stay permanently ON and the buzzer goes off -- keep the magnetic key in this position until the red led does not stay ON (this indicates that the system is in a calibration phase). 3. RELEASE THE TEST BUTTON, REMOVE THE MAGNETIC KEY WHILE THE BUZZER SOUNDS INTERMITTENTLY (system ready for the setting of point 0%)

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

4. SETTING OF POINT 0% (conditions): -- boom fully retracted -- forks lowered (just raised from the ground) -- no load applied -- press the test button once only; the buzzer gives a short sound signal indicating that the setting of point 0% has occurred -- the red and yellow leds on the display come ON the buzzer starts sounding again intermittently (the system is ready for the setting of point 100%) 5. SETTING OF POINT 100% (conditions): -- load a 2000 kg weight (with boom fully retracted) -- extract the boom in an horizontal position until the rear wheels start to raise (unstable equilibrium) -- retract the boom 600 mm (condition of 100% safety) -- press the test button once only, the buzzer gives a short sound signal indicating that the setting of point 100% has occurred PROCEDURE OF CALIBRATION ACCOMPLISHED NOTE: if the buzzer sounds in a prolonged manner, it indicates that an error occurred during the calibration procedure, thus the procedure must be repeated. The system provides 5 minutes to perform a complete calibration procedure. Should this time be exceeded, the system is zeroed and returns to the initial condition. The calibration must be performed without sharp movements and jumps on the rear axle.

Error indications In the event the controller monitors a malfunction of the sensor, relative to installation problems, wiring or it is unable to provide guaranteed repeatability of the measurement, the buzzer sounds constantly and all the leds of the display flash. The typology of the malfunction monitored can be read by pressing the “Test” button providing a diagnosis of the system from the operator’s cab. Normal operational errors The leds are numbered from the bottom upward Ref.

Error code

101

Current out of scale

LED 1

LED 2

LED 3

LED 4

LED 5

LED 6

LED 7

Green

Yellow

Red

Errori di calibrazione The leds are numbered from the bottom upward Ref.

Error code

LED 1

LED 2

LED 3

LED 4

LED 5

LED 6

LED 7

102

Min >/= Max

103

Min + stab >/=

Green

Yellow

Red

Max The SAR signals error conditions of normal operations during the calibration procedure as well.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Hydraulics consent In the event the 100% load threshold is exceeded, the controller inhibits the “hydraulics consent” output, thus inhibiting the possibility of extracting the boom any further. At this point, the operator is only able to retract the boom to return within safe conditions.

“Man--basket” When a man--basket is installed, the controller receives a signal from the controller of the vehicle and lowers the tip--over threshold, considering a safety margin of 20% (real re--dimensioned tip--over threshold at 80%).

“Slow--motion”above the 90% threshold The “slow motion” function has the purpose of increasing the safety margins during the handling of loads in the “critical zone”. When the load exceeds 90% of the end of scale maximum threshold, the controller activates the “Slow motion” outlet slowing down the extraction and the lifting speed of the telescopic boom. When the man--basket is installed, the 1005 threshold acquired is re--dimensioned, thus under man--basket conditions, the “slow motion” is activated with a real load of 70%.

Intervention curves The three intervention curves memorised inside the controller can be modified via serial RS--232 (see connector mapping TABLE 1). The default intervention thresholds of the leds memorised are as follows: LED 1

LED 2

LED 3

LED 4

LED 5

LED 6

W/OUT STAB.

45%

60%

70%

80%

91%

100%

MAN--BASKET

45%

60%

70%

80%

90%

100%

MODALITY

In “MAN--BASKET” modality, a safety margin equivalent to 20% of end of scale is allocated during the calibration to the tip--over condition acquired (end of scale changes from 100% to 80%).

Safety notice for the use of the tip--over prevention system The SAR is already set during the first installation with standard stability curves, that, however, could not be suitable for the features of the vehicle on which it is installed. Therefore, the installation of the SAR always requires the performance of the calibration procedure. In case of structural changes on the machine, modifications of the distribution of weights or important mechanical interventions on rear axle the calibration procedure must always be repeated.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

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 INDICATOR 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.

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Main/dipped beam light selector When the dipped beam headlights are on, push the stalk (1) forward, compared to the central position, so the dipped beam headlights and the relative instrument panel warning lamp turn on. When the lever is pulled inwards, the dipped beam headlights start flashing.

Windscreen wiper

If you turn the lever, the windscreen wiper turns on (position 1); when you turn the lever in the opposite direction (position 0), the function is deactivated and the blade reaches the neutral position.

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26 Windscreen washer

If you press button (1) located on the multi--function lever external side, the windscreen washer is activated.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

POWERSHIFT 4 X 3 Gearshift The gearshift mounted on this vehicle is called Powershift. The Powershift lever is mounted to the left of the steering column and allows electronic selection of four forward gears and three reverse gears.

TH121230

28 HORN

The horn is actuated when the button on the gearshift lever tip is pressed.

DRIVING WITH THE POWERSHIFT

Neutral position The neutral position is selected by shifting the lever to the centre.

Forward gear selection

To select forward gear, pull the lever towards the steering wheel and push it upwards. Reverse gear selection To select reverse gear, pull the lever towards the steering wheel and push it downwards.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SWITCHES SWITCHES (right panel) 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, All switches are internally illuminated with ignition ‘On’ and will become brighter when each individual function is switch is selected.

1. Additional lights (optional) fitted on the telescopic arm. 2. Attachment electric control. 3. Optional rear wiper/washer. The function is activated by pressing the button. 4. Hydraulic function cut--off (optional) 5. Slow moving warning beacon – Depressing this switch operates the function of the roof beacon. 6. Road lights – three--position switch -- Off -- Sidelights -- Main/dipped beam headlights Main and dipped beam headlight selection is possible with the multifunction lever previously described. 7. Hazard flasher switch – Selected when required to warn of a hazard. 8. Front work light (2--way switch) – The front light comes ON when actuated 9. Rear work light (2--way switch) – The rear light comes ON when actuated

8 9

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SWITCHES (left panel) IMPORTANT: The rocker switch position may vary slightly or may not be all available from that shown. They are dependant upon the model and options fitted to your machines.

1. This switch provides two operational modes for the stabilisation system. a) Switch in neutral position. When the boom exceeds 30 degrees, the lifting of both stabilisers is inhibited. In this position, the operator must refer to the load capacity diagrams of section 00 “with stabilisers and axle lock”. b) Switch pressed. This provides the actuation of the stabilisers and the levelling of the frame with boom exceeding 30 degrees. In this position the operator must refer to the load capacity diagrams at section 00 “without stabilisers and without axle lock.

ATTENTION

With the arm lifted over 30° the lifting function of the right and left axle levelling stabilisers is inhibited. Under these conditions, it is impossible to lift one or both stabilisers or make a levelling of the frame. 2. Left stabiliser (3--position rocker switch). When the switch is in idle position (central) no function is activated. When the button upper side is pressed, the left stabiliser is lifted; when the button lower side is pressed, the stabiliser is lowered. 3. (3--position rocker switch). This switch controls the axle front levelling cylinder and makes it possible to change the vehicle tilting along the longitudinal axis. When the button upper side is pressed, the vehicle will tilt on the right--hand side; when the button lower side is pressed, the vehicle will tilt on the left--hand side. 4. Right stabiliser (3--position rocker switch). This switch works as switch (2), but controls the right stabiliser. When the button upper side is pressed, the right stabiliser is lifted; when the button lower side is pressed, the stabiliser is lowered.

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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 cap on the headlight rear side. 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. TH155032

32 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 follows the removal procedure in reverse. The headlight beam may be adjusted vertically and laterally by adjustment of the recessed slotted screws (3). The indicator bulb can be accessed by removal of the lens cover retaining screw (2).

1 2

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Loader mounted work lights To gain access to the bulb, extract the securing screws, gently remove the lens cover and remove the bulb. Replacement of the bulb follows the removal procedure in reverse.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Interior lamp bulb replacement The interior lamp bulb is accessible after removal of the moulded plastic cover lens cover. The bulb 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 follows the removal procedure in reverse.

TH155114

35 Rear work light To gain access to the bulb, extract the cap on the headlight rear side. 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. TH155076

36 Rear, stop and indicator All bulbs are accessible after the moulded plastic lens assembly screws 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 20Â° 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; they are of the twist bayonet type.

TH155115

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 1.2 W and is a push fit in the retainer. After changing the bulb, push the retainer into the back of the switch.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

PROTECTING THE ELECTRICAL SYSTEMS DURING CHARGING OR WELDING 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. 2. Never short any of the charging circuit components to earth (ground). 3. Do not use a slave battery of higher than 12 volt 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.

•

Never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress.

6. Always disconnect the negative cable from the batteries when charging the batteries in the machine with a battery charger.

ATTENTION

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 our 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.

603.67.010.02 - 01 - 2004

IMPORTANT: Failure to disconnect the two earth cable connection 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 STARTING THE MACHINE USING JUMP LEADS

•

Connect one end of the second jump leads to the auxiliary 12 volt battery negative (--) terminal and the other end to the machine cylinder block. Following this procedure will prevent sparks occurring near the batteries. Follow the starting procedure previously described.

ATTENTION

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.

NOTE: When using a slave battery to start the engine ensure that the polarity is correct, otherwise the alternator may be damaged.

• 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 engine, proceed as follows: •

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.

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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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

TEMPORARY WIRING REPAIRS (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 machine 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. TH155040

40 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: 1. Locate damaged portion of cable then cut away outer protective cover on both sides of the damaged area, Figure 40. 2. Peel back the cable from both ends of the damaged 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. 3. Using a suitable solvent, clean about 2 inches (50 mm) from each cover end. Clean the grey cable cover and the individual leads.

TH155041

4. Twist two bare leads together for each damaged lead, being careful to match wire colours, then weld the leads using resin cored solder. Tape each repaired lead with vinyl insulation tape, Figure 41. 5. Wind a layer of vinyl insulation tape up to the grey cable cover at each end of the repaired section. Make a paper through, Figure 42, 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.

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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 43. 7. Check to ensure the repair is satisfactory and secure the repaired cable, so that repeated damage is avoided. NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent water or chemicals from entering.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 ELECTRICAL SYSTEM – GENERAL FAULT FINDING PROBLEM

Electrical system is inoperative

POSSIBLE CAUSE Loose or corroded battery connections

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

Establish reason for failure and replace fuse link

Starter speed low and engine Loose or corroded connection cranks slowly

Starter inoperative

Check battery open circuit voltage for 12.6 volts minimum. Check electrolyte level and specific gravity.

Incorrect viscosity engine oil

Use correct viscosity oil for temperature conditions

Transmission shift lever in gear

Place shift lever in neutral

Loose or corroded connections

Clean and tighten loose connections

Dead batteries

Charge or repair batteries Increase idle speed 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 corroded terminal connections

Clean and tighten loose 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.

Charge indicator flashing indicat- Malfunctioning alternator ing excessive charging voltage

603.67.010.02 - 01 - 2004

Clean and tighten loose connections

Low battery output

Charge indicator lamp stays on Low engine idle speed with engine running Loose belt

Batteries will not charge

REMEDY

Check alternator

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

WORKING PLATFORM The operation of the working platform utilizes the function of some components of the electric system:

TH135074

44 -- cable reel on the first telescopic section of the boom, for 4x1 cable;

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45 -- electronic controller for the control of PK valves and proportional solenoid valves for telescopic extension;

TH135075

46 -- central processing unit complete with platform system (inside cab);

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47 603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

-- wiring harness: 1. radio control 2. connections to proportional solenoid valves 3. connector to solenoid valves electronic controller 4. ground on machine frame 5. connection to cab wire 6. wires to be wound to cable reel.

5 TH155068

48 RADIO CONTROL (self--homologated for frequency and EMS) -- 12 V radio receiver on machine frame.

TH155069

49 -- radio transmitter on working platform

TH155070

50 Read the following paragraphs for main indications concerning the description, installation and operation of the radio control.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

RADIO CONTROL 1. Description of the radio control 2. Instructions for radio control installation 3. Transmitter unit and its operation 4. Receiver unit 5. Procedure for setting the proportional outputs 6. Radio frequency 7. Troubleshooting 8. Technical data 1. DESCRIPTION OF THE RADIO CONTROL A radio control is utilized to control machine operation from remote position. The radio control is composed of a portable transmitter unit which allows the operator to control the machine at some distance and a receiver unit installed on the machine itself. The transmitter unit sends a coded message, by radio--frequency transmission. This message contains a value denominated “address” that allows the receiver unit to decode exclusively the messages received from the proper transmitter unit (the one having the same address). This feature excludes interferences that might operate any control. In fact, if the radio--frequency transmission is disturbed, incorrect or interrupted, the receiver unit will autonomously stop the whole system. 2. INSTRUCTIONS FOR RADIO CONTROL INSTALLATION The installation must be exclusively carried out by qualified personnel, according to the regulations of the country where the radio control will be installed. Only correct installations can guarantee the required safety degree during the successive utilization of the radio control. Main indications Connect the Radio Control to the machine in accordance with the operational characteristics of the machine itself: the existing safety circuits of the radio control and/or the machine, cannot be excluded. The simple configuration adaptability of the harness of the receiver unit allows the installation of this device without need of interventions on the machine: do not modify the electric board of the machine without Manufacturer’s authorization. Exclude the power supply to the receiver unit by disconnecting all electric connectors when welding operations are carried out on the machine (welding damages electronic systems permanently).

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Installation The receiver unit must be installed in a favourable position for receiving the signals issued by the transmitter unit. Therefore, the receiver unit must be installed upright (antenna pointing up). The receiver unit must also have easy access, allowing safe conditions of operation. If the receiver unit is covered by metallic frames or installed inside metallic boxes, use the proper extension--kit for external antenna. The antenna must never be in contact with metal parts. It is forbidden to drill the receiver unit case. Drilling jeopardises weatherproof protection degree (IP65). Always install rubber cushions to reduce the effect of machine vibrations on the receiver unit. It is suitable positioning the receiver unit far from heat sources (exhaust pipes, alternators, etc.). Wiring The connection to the receiver unit, on most machines, is provided by a multiple plug which, in case of need, can be quickly disconnected when the radio control is to be replaced by a cable control. Even when the machine is not provided with this arrangement, it is always recommended to use this type of connection. The installation reliability depends on the wiring quality: therefore, it is recommended to prepare it according to the best principles utilizing multicore cable or single wires with a section adequate to the currents involved and with characteristics against flame propagation (refer to norm EN 60204--1 for more specific data). In case of external connections to the receiver unit, it is recommended to utilize oil--proof wires. The mains supply of the receiver unit must obligatorily have a switch to allow power supply shut off during operations of installation, wiring and/or maintenance. In order to get the best operation of the radio control, connect the receiver unit immediately downstream from the machine master switch. It is always opportune to check the power supply value also under maximum load so as to verify the maximum variations (the deviations allowed limit values can be found both in the Technical Data and in the technical card of the Radio Control). Voltage variations of power supply to the receiver unit beyond the limit values may jeopardise the normal operation of the radio control. The series C26--PRO radio controls are equipped with protection circuits against accidental movements of the actuators from their rest position (SAFETY function). This protection is effective if in the receiver unit the movement controls common supply is obtained from the series circuit of the STOP contact and the SAFETY contact (that is closed when a movement control is transmitted). Conversely, the selection controls common supply may not be in series with the SAFETY contact.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Setting of proportional outputs The Manufacturer supplies the radio control with setting values of proportional outputs already preset. During the installation, these values must be checked and possibly modified according to the operational necessities of the machine (refer to paragraph 5 “Procedure for setting the proportional outputs”). Checking and testing After completing installation and wiring, it is always necessary to: -- check that, operating the STOP push button of the radio control, the following functions take place: putting machine into safety condition (through direct operation of the general solenoid valve of the main circuit), possible engine stop and, if existing, opening of the main electromagnetic switch so as to cut voltage off; -- confirm the exact correspondence of the machine manoeuvres with the controls of the transmitter unit (this correspondence is indicated in the technical card); -- check the operation of the safety circuit (a simple method is to remove the fuse F3, located on the main board of the receiver unit, and to check that in these conditions no movement control can be effected; finally, reinstall the fuse F3 and check the correct operation). 3. TRANSMITTER UNIT AND ITS OPERATION Switch--on and start--up Make sure the key--switch is in position “O”, install the battery in its seat without forcing. Check that neither the stop push button nor the actuators are operated. Turn the key--switch to position “I” and operate the START push button until the green LED starts flashing.

⇒

The switch--on occurs only if the battery charge is sufficient and all actuators are cut out.

TH155071

51 Controls The machine can perform the radio--controlled manoeuvres only after having completed the radio--electric link between transmitter and receiver units (signalled by the pilot light ENABLE existing in the receiver unit (refer to paragraph 4 “Receiver unit”)). Operate the actuators corresponding to the manoeuvres the operator intends to control (all movement controls comply with the requirements of category 3 according to the norm EN 954--1). Some of the available controls on the transmitter unit are the following:

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Change of frequency In case of interferences or conflict with other radio systems, it is possible to change the radio frequency in operation. With transmitter unit switched on and started up, it is necessary to keep START push button actuated for 5--6 seconds: a long beep joined by the lighting up of both signalling LEDs will indicate that the change of frequency has occurred. During this operation the receiver unit will switch off: the operation can be resumed pressing the START push button again as the usual start--up operation. LED signalling Some operating conditions of the transmitter unit are pointed out by two signalling LEDs (one green and one red). Led

Signalling pattern

green

red

Slow flashing

Normal operation

Quick flashing

Warning: battery almost exhausted

Warning: battery exhausted Control connected during start--up

Light on at start--up*

Change of frequency accomplished

Light of both LEDs is on at the same time* * joined by a sound signal

When the battery has delivered approximately 90% of its charge, the green LED increases the flashing speed giving a pre--alarm that battery needs charging. If the operator continues to use the radio control, approximately 3 minutes before the battery will be fully exhausted, the red LED starts flashing and at the same time a sound alarm is activated. When this situation occurs, the machine must be put immediately in safety condition, the transmitter unit must be switched off and the battery must be charged (or replaced with other full--charged battery). Automatic switch--off The switch--off of the transmitter unit can occur automatically when: -- the battery is not sufficiently charged and/or; -- the radio control has not been operated during approximately 3.5 minutes (the automatic switch--off can be disabled). For all instructions, warnings and technical data regarding the batteries and battery--chargers, refer to the supplied booklet.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

4. RECEIVER UNIT

A N G

B C C E

H I L

G D

TH155072

52 A

antenna

POWER signal light

ENABLE signal light

RI97--08 module (refer to chapter 9)

connecting plug

F1 fuse

identification plate

F2 fuse

technical data plate

F3 fuse

cover screws

inner LEDs

External signalling The POWER signal light indicates the presence (if on) or absence (if off) of power supply into the receiver unit. The ENABLE signal light indicates the radio--link has occurred (if on) or is missing (if off) between transmitter and receiver units. Therefore, with receiver unit getting power supply, the correct operation is signalled by: -- POWER and ENABLE constantly on, with transmitter unit started up; -- POWER constantly on and ENABLE off, with transmitter unit not started up.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Internal signalling The existing LEDs indicate that a relay activation has occurred: when a LED is on it indicates that the relevant relay is activated for the control that is illustrated by the following chart (available also on the inner part of the receiver unit cover):

53 Functions SAFETY

In order to protect the system from accidental movements due to possible failures of the radio control, the C26 PRO series is equipped with a safety function denominated SAFETY. This function constantly monitors the rest position (neutral) of the movement actuators in the transmitter unit and is available as output on the SAFETY relay of the receiver unit.

FLOW

Operating a movement control, the FLOW function will also be activated: this function controls the solenoid valve that puts the oil under pressure in the primary hydraulic circuit of the control valve.

T.S.

The T.S. (TIME STOP) is the control that stops the diesel engine of the machine: it remains activated for 10 seconds after activation of STOP push button.

Fuses The three fuses installed inside the receiver unit have the following characteristics: Function

Fuse

Technical features

POWER SUPPLY protection

4A (32Vdc, autofuse)

STOP circuit protection

10A (32Vdc, autofuse)

SAFETY circuit protection

10A (32Vdc, autofuse)

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

5. PROCEDURE FOR SETTING THE PROPORTIONAL OUTPUTS (REMOTE SET UP) The procedure for setting the proportional outputs must be performed only by qualified and trained personnel. Information on module RI97--08 The proportional outputs of module RI97--08 are set to the values indicated in the technical card. The number of the technical card relating to the radio control can be found on the sticker of data memory (K2). C1

connector for proportional outputs

connector for auxiliary proportional outputs

connector for power supply

connector for setting key

connector for connection to the board

green LED

setting key

data memory

reset push button

rotary dial

K2 C5

TH155073

54 Never leave the setting key K1 inserted during the operation of the radio control: it is required only during the setting stage and, when it is inserted, it gives consent to just one proportional control at a time. To restore the initial proportional outputs values (i.e. the values indicated in the technical card), insert the setting key and press the restore push button P until the green LED stops flashing and remains continuously on. In case of module replacement, the same proportional outputs values can be kept shifting the K2 data memory from the old module to the new module. Preparation for setting 1. Make sure the transmitter unit is switched off. 2. Disconnect power supply from the receiver unit. 3. Open the receiver unit and insert the setting key K1 into the connector C4. 4. Connect power supply to the receiver unit. WARNING: From this moment, until the setting is completed, do not touch the receiver unit (there is a risk of losing the entered settings). 5. Turn the key--switch of the transmitter unit to position “I” and press the START push button. 6. Turn the key--switch to position “

” (REMOTE SET UP).

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Setting 7. Select the parameters to be set by means of the selector knob S installed on module RI97--08: determine the setting by operating the selector RPM+/− installed on the transmitter unit (where sign + is for increasing the value to be set and the sign − is for decreasing this value).

⇒ ⇒ ⇒

The modules with voltage outputs can be set in positions 1, 2, 3, 4 and 5. The modules with current outputs (PWM) can be set in positions 0, 1, 3 and 4. During the setting, when the joystick is moved out of rest position, a blow of 0.5 seconds of horn/ alarm indicates that we are in the area of setting the minimum. The settings must be carried out for every single position of the speed selector installed on the transmitter unit.

Settings of modules with voltage outputs Position 1

Turn selector knob S to position 1 to adjust the maximum and minimum voltage (or current) values of the two semiaxis of each joystick. Proceed as follows: 1. To set the maximum value, move the joystick to maximum stroke on the semiaxis to be set. Holding the joystick in this position, operate the selector RPM+/− installed on the transmitter unit and set the desired value. 2. To set the minimum value, move the joystick immediately out of rest position on the semiaxis to be set. Holding the joystick in this position, operate the selector RPM+/− installed on the transmitter unit and set the desired value.

Position 2

Turn selector knob S to position 2 to adjust the voltage value corresponding to the rest position of the joystick. Normally, this value should not be modified. If necessary, proceed as follows: -- move any joystick immediately out of rest position; -- holding the joystick in this position, operate the selector RPM+/− installed on the transmitter unit and set the desired value.

Position 3 & 4

Turn selector knob S to positions 3 and 4 to adjust the minimum and maximum voltage of the auxiliary outputs Z8 and Z9, respectively. Proceed as follows: 1. To set the maximum value, turn the knob (installed on the transmitter unit) relevant to control Z8 (or Z9) completely clockwise. Holding the knob in this position, operate the selector RPM+/− installed on the transmitter unit and set the desired value. 2. To set the minimum value, turn the knob (installed on the transmitter unit) relevant to control Z8 (or Z9) completely anticlockwise. Holding the knob in this position, operate the selector RPM+/− installed on the transmitter unit and set the desired value.

Position 5

Turn selector knob S to position 5 to reverse the direction of the semiaxis. Proceed as follows: -- move the joystick relative to the axis to be reversed immediately out of rest position; -- holding the joystick in this position, operate the selector RPM+/− installed on the transmitter unit putting it in position + to reverse the direction of the semiaxis or in position − to restore the direction of the semiaxis.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Settings of modules with voltage outputs Position 0

Turn selector knob S to position 0 to adjust the frequency of the PWM signal (current). Normally, this value should not be modified. If necessary, proceed as follows: -- move any joystick immediately out of rest position; -- holding the joystick in this position, operate the selector RPM+/− installed on the transmitter unit and set the desired value.

Position 1

Position 3 & 4

Setting storage 8. Switch the transmitter unit off to store the settings. 9. Cut out the power supply to the receiver unit. 10. Pull out the setting key K1. 11. Close the receiver unit cover and turn power supply on.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

6. RADIO FREQUENCIES The radio frequencies programmed for the radio control pertain to the system of frequencies admitted by the European regulations in force at the moment of the market launch. Check if there are possible restrictions in the country where the radio control will be operated. A radio control can be programmed in AUTOMATIC SCANNING or MANUAL SELECTION mode. Automatic scanning Usually, a radio control is programmed by the Manufacturer in Automatic Scanning mode: consequently, it can be operated in any available frequency. In case of interference or conflict with other systems, this mode allows shifting the operating frequency (refer to â&#x20AC;&#x153;Change of operating frequencyâ&#x20AC;?) without need of internal adjustments neither for the transmitter unit nor for the receiver unit. Manual selection To set this operational mode for operating radio frequency, call the assistance of authorized personnel only. A radio control operating in Manual Selection mode allows to operate at a specific frequency. To set this frequency, it is necessary to set the dip switches installed in the transmitter and receiver modules.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

7. TROUBLESHOOTING In case the â&#x20AC;&#x153;radio control + machineâ&#x20AC;? system does not start up, it is suitable to check if it is a radio control problem or a machine problem. Therefore, before starting any check, connect the cable control: if the machine does not start up, it is a machine problem. If, on the contrary, the machine starts up normally when operated by cable control only, the problem is in the radio control. In this case, carry out the following checks.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

8. TECHNICAL DATA General Operating frequency Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433,050 ÷ 434,790 MHz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 869,7 ÷ 870 MHz United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458,500 ÷ 458,800 MHz Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472,0125 ÷ 472,1125 MHz USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 ÷ 470 MHz Operative radio channels (step 25 kHz) Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 (at 433 MHz); 12 (at 870 MHz) United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 groups of 128 Channalizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 kHz (optional 12.5 kHz) Hamming distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≥ 8 Probability of missing error detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 10-- 11 Typical operating range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 m Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . --20º C ÷ + 70º C Passive emergency time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5/1,5 sec Response time of controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 ÷ 120 ms Response time of STOP function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 ÷ 120 ms Transmitter unit Number of available controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 + 2 analogic + 12 on/off + start + stop Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . internal Modulation type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GFSK Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 10 mW (at 433 MHz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 5 mW (at 870 MHz) Power supply: battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NiMH 7,2V -- 1,3 Ah Shut--off voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,0 V Autonomy with charged battery (at 20°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ÷ 10 ms Pre--alarm time battery almost exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 15 min. Pre--alarm time battery exhausted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approximately 3 min. Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PA6 fg 20% Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP65 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (173 x 160 x 236) mm Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ≤ 2 kg

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Receiver unit Power supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 รท 30 Vdc (< 40W) Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . external, whip type Current carrying capacity of STOP and SAFETY relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (30 Vdc) Current carrying capacity of the relays for movement controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 A (30 Vdc) Current carrying capacity of the relays for selection controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 A (30 Vdc) Receiver sensibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 ฮผV for 20 dB SINAD Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PA6 fg 20% Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP65 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (180 x 230 x 95) mm Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,8 kg Drilling template . . . . . . . . . . . . . . . . . . . A = 148 mm B = 116 mm C = 253 mm D = 253 mm

TH155074

55 Battery charger and Batteries Technical data available in specific booklet.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SPECIAL TOOLS NUMBER

SKETCH

DESCRIPTION

HOW TO USE/MODEL

380001303

BB3 Diagnostic instrument

ALL

380001471

Cable with adapter for BB3

ALL

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

SECTION 55 -- ELECTRICAL CIRCUITS Chapter 2 â&#x20AC;&#x201C; Circuit diagrams CONTENTS Section

Description

Page

List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 How to use the circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Diagram 1: Starter/Recharge/Warning/Indicators lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Diagram 2: Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Diagram 3: Wheel alignment/Hydraulic solenoids/Brake system . . . . . . . . . . . . . . . . . . . 58 Diagram 4: Arm control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Diagram 5: Stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Diagram 6: Lights/Windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Diagram 7: Work lamps/Roof beacon light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Diagram 8: Tilting prevention system/Roof wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Diagram 9: Heating/Sound system/Electric socket/Interior lamp . . . . . . . . . . . . . . . . . . . 70 Diagram 10: Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

LIST OF CONNECTORS CON.

DESCRIPTION

CON.

DESCRIPTION

3--way connector for RH stabiliser sensor

X33

1 way connector left front work light

X10

2--way connector for reversing buzzer

X68

1--way connector for rear RH work lamp

X100

4--way connector for inside air sensor

X37

8--way connector for tilting prevention instrument

X102

2--way connector for recycle motor

X39

4--way connector for rear wiper

X106

4--way connector for solenoid valve

X40

3--way connector for roof lamp

X11

4--way connector for arm work lamp

X42

4--way connector for parking brake switch

X12

3--way connector for low arm sensor

X43

9--way connector rear line--dashboard

X129

8--way connector for instrument panel--air conditioner line

X44

2--way connector for seat

X132

4--connector for heater

X48

12--way connector for Telehandler

X137

17--way connector for work selection control unit

2--way connector for fuel level

X138

2--way connector for filter thermistor

X52

2--way connector for CB

X139

2--way connector for filter pre--heating

X53

2--way connector for cigar lighter

X14

3--way connector for retracted arm sensor

X55

8--way brown connector for sound system

X16

Engine--dashboard 6--way connector

X56

8--way black connector for sound system

X17

6--way connector for front LH headlight

15--way connector for instrument panel--rear line

X18

6--way connector for front RH headlight

X60

20--way connector for instrument

X19

3--way connector for number plate lights

X62

12--way connector for gear switch

X1A2

2--way connector for A2 steering solenoid valve

X63

12--way connector for light switch

X1B2

2--way connector for B2 steering solenoid valve

X65

4--way connector for micro--stop

3--way connector for LH stabiliser sensor

X67

4--way connector for front wiper

X301

2--way connector for LH stabiliser lowering

X69

3--way connector tip--over prevention

X302

2--way connector for LH stabiliser raising

18--way connector for instrument panel--front line

X303

2--way connector for RH stabiliser lowering

X70

10--wa connector for thermo--starting control unit

X304

2--way connector for RH stabiliser raising

3--way connector for rear axle sensor

X305

2--way connector for LH levelling solenoid valve

2--way connector for loading cell

X306

2--way connector for RH levelling solenoid valve

X91

2--way connector for air conditioner pressure gauge

X308

4--way connector for proportional solenoid valve

X92a

2--way connector for electric fan

X309

2--way connector for optional solenoid valve rentrĂŠe

X92b

2--way connector for electric fan

X21

12--way connector rear line--dashboard

X94

8--way connector for air conditioner control unit

X310

2--way connector for optional solenoid valve sortie

X95

9--way connector for air conditioner control unit

X311

2--way connector for servo--control solenoid valve

X96

2--way connector for outside temperature sensor

X312

2--way connector for tilting prevention solenoid valve

X97

2--way connector for mixed air sensor

X213

2--way connector for reversing solenoid valve

X98

2--way connector for tap

X214

2--way connector for forward gear solenoid valve

X99

2--way connector for defrosting sensor

X215

2--way connector for gearshift solenoid valve

XA1

2--way connector for alternator

X216

2--way connector for 1st gear solenoid valve

XA1a

1--way connector for alternator

X217

2--way connector for 2nd gear solenoid valve

XC1

9--way connector for bridges

X218

2--way connector attachment solenoid valve

XC2

21--way connectors for bridges

X23

2--way connector for double optional solenoid valve

XC3

21--way connector for control unit

X24

28--way connector APC50 controller

XC4

18--way connector for control unit

X25

21--way connector for instrument panel--engine line

XC5

12--way connector for control unit

X26

2--way connector speed sensor

XC6

6--way connector for control unit

X27

9--way connector for dashboard--cabin line

XC7

15--way connector for control unit

X28a

2--way connector for axle lock solenoid valves

XC8

21--way connector for control unit

X28b

2--way connector for axle lock solenoid valves

XC9

18--way connector for control unit

X29

2--way connector for thermo--starting relay

X13

3--way German connector

3--way connector for front axle sensor

X15

2--way connector air cleaner pressure switch

X31

17--way connector for instrument panel--cabin line

X32

1--way connector for front RH work lamp

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

LIST OF COMPONENTS COMP. B BS1 BS2 C D D EVA EVA2 EVB EVB2 FG1 FG2 FG3 FG4 FV1 G G1 G2 H H1 H11 H12 H13 H14 H2 H3 H4 H5 H6 H7 H8 H9 HA1 HA2 HX I1 I10 I11 I12 I13 I14 I2 I3a I3b I4 I5 K2 I7 I8 K103 K105 K107 KA KB

DESCRIPTION Rexroth handler button RH loudspeaker LH loudspeaker Reset button Rexroth handler button Reset button Axle lock solenoid valve A2 steering solenoid valve Axle lock solenoid valve B2 steering solenoid valve Main fuse 80A Air conditioner fuse 30A Filter pre--heating fuse 20A Spare fuse Converter fuse 30A Rexroth handler button Battery Alternator Rexroth handler button Front LH headlight Rear RH work lamp Beacon light Cigar lighter lamp Roof lamp Front RH headlight LH taillight RH taillight Number plate light Arm work lamp Arm work lamp Front RH work lamp Front LH work lamp Reversing buzzer Buzzer Climate lighting Transmission oil pressure gauge Air conditioner pressure gauge Mixed air sensor Outside temperature sensor Defrosting sensor Inside air sensor Transmission oil high temperature sensor Spark plug thermistor Engine water temperature transducer Pressure gauge for engine oil low pressure Clogged air filter pressure gauge Transmission controller Filter thermistor Parking brake pressure gauge Electric fan 1st speed relay Electric fan 2nd speed relay Electric fan 3rd speed relay Starting relay Air conditioner relay

DIAG. 4 9 9 8 4 8 3 3 3 3 1 1 1 1 10 4 1 1 4 6 7 7 9 9 6 6 6 6 7 7 7 7 2 8 10 1 10 10 10 10 10 1

COMP. KC KD KT M1 M11 M12 M13 M14 M2 M4 M5 M7 M8 M9 S15 S131 P R1 R2 R3 RL1 RL2 RL3 RL4 S1 S11 S12 S13 S14 S15a S2 S3 S30 S31 S32 S33 S34 S35 S36 S38 S39 S4 S40 S5 S50 S51 S52

1 2 1 5 10 10 10 1 10

S6 S7 S8 S9 SCX XA4 X53 X54 S65

1 1

DESCRIPTION Filter pre--heating relay Unswitched circuit relay Thermo--starting relay Starter Recycling Tap Cooling fan Electric fan Front wiper motor Windscreen washer pump Rear washer motor Fan Air Conditioning fan Compressor Rear axle unlocking switch. Heating switch Potentiometer Available resistance â&#x20AC;&#x201C; 1K0hm 1W Thermo--starting Filter pre--heating Work selection control unit relay Work selection control unit relay Work selection control unit relay Work selection control unit relay Parking brake micro LH stabiliser switch Levelling switch RH stabiliser switch Attachment switch Starting panel Beacon light switch Warning switch Battery disconnection with key Fuel level Steering selection switch Rear axle sensor Front axle sensor LH stabiliser sensor RH stabiliser sensor Low arm sensor Retracted arm sensor Light switch Brake oil level Front work lamp switch Climate switch 4 gear switch + hobbs horn Light--direction indicator--wiper switch Rear work lamp switch Arm work lamp switch Upper/front wiper switch Rear wiper switch Climate switch Horn Cigar lighter Fridge socket Stop light micro

DIAG. 1 1 1 1 10 10 10 10 6 8 8 9 10 10 4 9 4 3 1 1 3 3 3 3 5 5 5 5 7 1 7 6 1 1 3 3 3 5 5 3 3 6 6 7 10 2 6 7 7 8 8 10 2 9 9 6

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

COMP. Y1 Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17 Y18 Y19 Y2 Y3 Y4 Y5 Y6 Y9

DESCRIPTION LH stabiliser lowering solenoid valve Optional solenoid valve (out) Servo--control solenoid valve Tilting prevention solenoid valve Reverse solenoid valve Forward gear solenoid valve Gearshift solenoid valve 1st gear solenoid valve 2nd gear solenoid valve Engine stop solenoid valve Attachment solenoid valve LH stabiliser lifting solenoid valve RH stabiliser lowering solenoid valve RH stabiliser lifting solenoid valve LH levelling solenoid valve RH levelling solenoid valve Optional solenoid valve (in)

DIAG. 5 4 4 4 2 2 2 2 2 1 7 5 5 5 5 5 4

WIRE COLOUR KEYS A B C G H L M N R S V Z

Azure White Orange Yellow Grey Blue Brown Black Red Pink Green Purple

NOTE: wires with two colours have compound acronyms, e.g.: G/V -- Yellow/green (cross colouring) G--V -- Yellow--Green (longitudinal colouring)

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

HOW TO USE THE CIRCUIT DIAGRAMS The circuit 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: 1. All diagrams are located on the right hand pages. Within the diagram there are a number of references. Diagram number and electric function Line reference Component identification reference Connector x70, connector code, 3, references (pin) Wire colour code Fuse code. G1, fuse number, 10A, capacity Line continues on another diagram. In this instance: diagram 3 at line reference 1. 8. Alphabetical wire colour key 9. Diode 10. Component pin code 1. 2. 3. 4. 5. 6. 7.

2. Each component and connector appears only once in a set of circuit diagrams. 3. The circuit diagrams are broken up into sections. However, where 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.

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 1 â&#x20AC;&#x201C; STARTING/RECHARGE/WARNING LAMPS/INDICATORS 1

5 8 9

TH155084

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 1 â&#x20AC;&#x201C; STARTING/RECHARGE/WARNING /INDICATORS LIGHTS COMPONENTS AND FUSES G2 I1 I2 I3a I3b I4 I5 I7 K15 KA KC KD KT M1 R2 R3 S15a S31 Y18 F11 F34 FG1 FG2 FG3 FG4 G1 S30

DESCRIPTION Alternator Transmission oil pressure gauge Transmission oil high temp. pressure gauge Spark plug thermistor Engine water temperature transducer Pressure gauge for engine oil low pressure Clogged air filter pressure gauge Filter thermistor Relay Starting relay Filter pre--heating relay Under key relay Thermo--starter relay Starter Thermo--starting Filter pre--heating Starting panel Fuel level Engine stop solenoid valve Spare fuse 5A Engine stop fuse 10A Main fuse 80A Air conditioner fuse 30A Filter pre--heating fuse 20A Fuse available Battery Keyed battery cut--off

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 1 â&#x20AC;&#x201C; STARTER / RECHARGE / WARNING / INDICATORS LIGHTS

TH155085

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 2 â&#x20AC;&#x201C; TRANSMISSION COMPONENTS AND FUSES F5 HA1 K7 K9 K21 K2 XA4 Y13 S51 Y14 Y15 Y16 Y17 F18 F37

DESCRIPTION Horn fuse 15A Reverse buzzer Transmission cut--off relay Horn relay Back--up alarm relay Transmission controller bio Horn Reverse solenoid valve 4 gear switch + Hobbs horn Forward gear solenoid valve Gearshift solenoid valve 1st gear solenoid valve 2nd gear solenoid valve Reverse buzzer, cabin buzzer fuse 5A Transfer system fuse 10A

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 2 -- TRANSMISSION

TH155086

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 3 – WHEEL ALIGNMENT/HYDRAULIC SOLENOIDS/BRAKE SYSTEM COMPONENTS AND FUSES EVA EVA2 EVB EVB2 K5 K6 K17 K18 R1 RL1 RL2 RL3 RL4 S32 S33 S34 S38 S39 F2 F3 F15 F21

DESCRIPTION Axle lock solenoid valve A2 steering solenoid valve Axel lock solenoid valve B2 steering solenoid valve Relay for stabiliser conditioned powering with low boom Low boom relay Relay for stabiliser conditioned powering with boom retracted Aligned axles indicator light Spare resistor – 1 kOhm 1W Work selection control unit relay Work selection control unit relay Work selection control unit relay Work selection control unit relay Steering selector switch Rear axle sensor Front axle sensor Low arm sensor Retracted arm sensor Stabiliser fuse 7.5A Sensor power supply fuse 5A Axle swinging stop fuse 10A Axle sensor power supply fuse + work selection control unit 7.5A

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 3 â&#x20AC;&#x201C; WHEEL ALIGNMENT/HYDRAULIC SOLENOIDS/BRAKE SYSTEM

TH155087

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 4 â&#x20AC;&#x201C; ARM CONTROL COMPONENTS AND FUSES B D G H K1 K3 K4 K12 K14 P Y9 Y10 Y11 Y12 S15 F12 F13 F14 F16

DESCRIPTION Rexroth handler button Rexroth handler button Rexroth handler button Rexroth handler button Optional dual relay Optional relay (IN) Optional relay (OUT) Voltage comparator Tip--over prevention relay Potentiometer Optional solenoid valve (in) Optional solenoid valve (out) Servo--control solenoid valve Tilting prevention solenoid valve Rear axle unlocking switch Double optional fuse 10A Rexroth proportional power supply fuse 10A Optional handling fuse 10A Voltage indicator power supply fuse 10A

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 4 â&#x20AC;&#x201C; ARM CONTROL

TH155088

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 5 -- STABILISER COMPONENTS AND FUSES I8 K16 K19 S1 S11 S12 S13 S35 S36 Y1 Y2 Y3 Y4 Y5 Y6 Y9 F24 F26

DESCRIPTION Parking brake pressure gauge Extended--lowered stabilisers relay Parking brake engaged relay Parking brake micro LH stabiliser switch Levelling switch RH stabiliser switch LH stabiliser sensor RH stabiliser sensor LH stabiliser lowering solenoid valve LH stabiliser lifting solenoid valve RH stabiliser lowering solenoid valve RH stabiliser lifting solenoid valve LH levelling solenoid valve RH levelling solenoid valve Optional solenoid valve (IN) Switch lighting fuse + instrument power supply 10A Spare fuse 7.5A

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 5 -- STABILISER

TH155089

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 6 – LIGHTS/WINDSCREEN WIPER COMPONENTS AND FUSES H1 H2 H3 H4 H5 K8 K10 K13 M2 S3 S4 S40 S52 F7 F30 F33 F35 F36 F38 F39 X65

DESCRIPTION Front LH headlight Front RH headlight Rear LH headlight Rear RH headlight Number plate light High beam relay Low beam relay Flasher Front wiper motor Warning switch Light switch Brake oil level Light – direction indicator -- wiper switch Driving--light switch fuse 15A Dipped beam headlight fuse 15A Brake light fuse 5A RH sidelight fuse 5A LH sidelight + number plate light fuse 5A Fuse + 30 warning 10A Main beam headlight fuse 15A Stop lights micro

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 6 -- LIGHTS/WINDSCREEN WIPER

TH155090

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 7 â&#x20AC;&#x201C; WORK LAMPS/ROOF BEACON LIGHT COMPONENTS AND FUSES H6 H7 H8 H9 H11 H12 S14 S2 S5 S6 S7 F4 F9 F17 F20 Y19

DESCRIPTION Arm work lamp Arm work lamp Front RH work lamp Front LH work lamp Rear RH work lamp Beacon light Attachment switch Beacon light switch Front work lamp switch Rear work lamp switch Arm work lamp switch Front work lamp fuse 15A Arm work lamp fuse 15A Rear work lamp fuse 15A Beacon light fuse 10A Attachment solenoid valve

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 7 â&#x20AC;&#x201C; WORK LAMPS/ROOF BEACON LIGHT

TH155091

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 8 â&#x20AC;&#x201C; TILTING PREVENTION SYSTEM/ROOF WIPER COMPONENTS AND FUSES C D. HA2 S8 S9 K20 M4 M5 F1 F10 F25 F31

DESCRIPTION Reset button Reset button Buzzer Roof/front wiper switch Rear wiper switch 85% slow motion relay Windscreen washer pump Rear wiper motor Instrument fuse + tilting prevention system 3A Rear wiper fuse 15A Control car power supply fuse 15A Roof wiper fuse 15A

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 8 â&#x20AC;&#x201C; TILTING PREVENTION SYSTEM/ROOF WIPER

TH155092

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 9 â&#x20AC;&#x201C; HEATING/SOUND SYSTEM/ELECTRIC SOCKET/ROOF LAMP COMPONENTS AND FUSES BS1 BS2 H13 H14 M7 S131 F8 F23 F27 F28 F29 F32 F41 F42 X53 X54

DESCRIPTION RH loudspeaker LH loudspeaker Cigar lighter illumination Roof lamp Fan Heating switch Seat fuse 15A Cabin ventilation solenoid valve fuse 10A Fuse + 30 roof lamp + sound system 5A Micro seat fuse 5A Fuse + 30 CB 7.5A Fuse + 15 sound system 3A Fridge socket fuse 15A Cigar lighter fuse 20A Cigarette lighter Fridge socket

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 9 â&#x20AC;&#x201C; HEATING/SOUND SYSTEM/ELECTRIC SOCKET/INTERIOR LAMP

TH155093

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 10 â&#x20AC;&#x201C; AIR CONDITIONER COMPONENTS AND FUSES FV1 HX I10 I11 I12 I13 I14 KB K103 K105 K107 K11 K22 K23 M8 M9 M11 M12 M13 M14 F6 F19 F22 F40 S50 SCX

DESCRIPTION Converter fuse 30A Climate lighting Air conditioner pressure gauge Mixed air sensor Outside temperature sensor Defrosting sensor Inside air temperature Conditioner relay Electric fan 1st speed relay Electric fan 2nd speed relay Electric fan 3rd speed relay Relay available Conditioner compressor relay Activated conditioner relay Solenoid valve Climate switch Recirculation Cock Cooling fan Solenoid valve Air conditioner recirculation motor fuse 10A Air conditioner control unit power supply fuse 3A Spare fuse 5A Air conditioner compressor fuse 10A Climate switch Compressor

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 2

DIAGRAM 10 â&#x20AC;&#x201C; AIR CONDITIONER

TH155094

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

SECTION 55 -- ELECTRIC CIRCUITS Chapter 3 -- Wiring list CONTENTS

Section

Description

Page

Instrument panel wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Cab wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Front wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Rear wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

603.67.010.02 - 01 - 2004

SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

INSTRUMENT PANEL WIRING (1)

TH155095

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

INSTRUMENT PANEL WIRING (2)

TH155096

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

INSTRUMENT PANEL WIRING (3)

TH155097

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

INSTRUMENT PANEL WIRING (4)

TH155098

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

INSTRUMENT PANEL WIRING (5)

TH155099

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

INSTRUMENT PANEL WIRING (6)

TH155100

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

CAB WIRING

TH155101

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

FRONT WIRING

TH155102

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

REAR WIRING (1)

TH155103

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

REAR WIRING (2)

TH155104

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SECTION 55 -- ELECTRICAL CIRCUITS -- CHAPTER 3

ENGINE WIRING

TH155105

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NEW HOLLAND -- CNH MOVIMENTO TERRA S.p.A. LECCE (ITALY)

â&#x20AC;¢ Reproduction of text or illustration, in whole or in part, is strictly prohibited.

Print No. 603.67.010.02 -- English -- I -- 2004 Printed by Satiz -- Turin (Italy) Coordinamento Editoriale Satiz -- Torino