WorkshopManual
PrintN.604.13.542.01(III--2006)
THISALERTSYMBOLSIGNALSIMPORTANTMESSAGESINVOLVINGYOURSAFETY.
Readandheedcarefullythesafetyinstructionslistedandfollowtheprecautionsrecommendedtoavoid potentialrisksandtosafeguardyourhealthandyoursafety.
YouwillfindthissymbolinthetextofthisManualreferredtothefollowingkeywords:
WARNING --Cautionsdirectedtoavoidimproperrepairinterventionsinvolvingpotentialconsequencesfor theoperator’ssafety.
DANGER --Thesewarningsqualifyspecificallypotentialdangersforthesafetyoftheoperatororother personsdirectlyorindirectlyinvolved.
IMPORTANTNOTICE
AllmaintenanceandrepairinterventionsexplainedinthisManual mustbeperformedexclusivelybytheService OrganizationoftheManufacturer,observingstrictlytheinstructionsexplainedusing,whenevernecessary,the recommendedspecifictools.
Whoeverperformstheoperationsreportedwithoutfollowingexactlytheprecautionsisresponsibleonhisown,for thedamagesthatmayresult.
NeithertheFactorynoranyOrganizationsinitsDistributionNetwork,includingbutnotlimitedtonational,regional orlocaldistributors,areresponsibleforanyliabilityarisingfromanydamageresultingfromdefectscausedbyparts and/orcomponentsnotapprovedbytheFactoryforuseinmaintainingand/orrepairingproductsmanufacturedor merchandizedbytheFactory.
Inanycase,nowarrantyofanykindismadeorshallbeimposedwithrespecttoproductsmanufacturedor merchandizedbytheFactory,whenfailuresarecausedbytheuseofpartsand/orcomponentsnotapprovedbythe Factory.
AVOIDACCIDENTS
Mostaccidentsandinjuriesoccurringinindustry,onthefarm,athomeorontheroad,arecausedbythefailureof someindividualtofollowsimpleandfundamentalsafetyrulesorprecautions.Forthisreason,MOST ACCIDENTSCANBEPREVENTEDbyrecognizingtherealcauseandtakingthenecessaryprecautions,before theaccidentoccurs.
Regardlessofthecareusedindesignandconstructionofanytypeofequipment,theremaybeconditionsthat cannotbecompletelysafeguardedagainstwithoutinterferingwithreasonableaccessibilityandefficient operation.
Acarefuloperatoristhebestinsuranceagainstaccidents.Thecompleteobservanceofonesimplerulewould preventmanythousandsseriousinjurieseachyear.
Thisruleis:Neverattempttoclean,lubricateoradjustamachinewhileitisinmotion.
WARNING
Onmachineshavinghydraulically,mechanicallyand/orcablecontrolledequipment(suchasshowels, loaders,dozers,scrapersetc.)becertaintheequipmentisloweredtothegroundbeforeservicing, adjustingand/orrepairing.
Ifitisnecessarytohavetheequipmentpartiallyorfullyraisedtogainaccesstocertainitems,besure theequipmentissuitablysupportedbymeansotherthanthehydraulicliftcylinders,cableand/or mechanicaldeviceusedforcontrollingtheequipment.
MODELCODES
Thecompleterangeoftelescopichandlers(Telehandler)describedinthismanualisidentifiedinthetextby referencetothemaximumextensionofthetelescopicarm.
Thevehicleslistedbelowmaynotbeavailableinallcountriesormarkets,thereforeforthelatestinformation consultyourauthoriseddealer.
SECTION55--ELECTRICALSYSTEM
Diagram1:Starter/Recharge/Warning/Indicatorslights53
Diagram3:Wheelalignment/Hydraulicsolenoids/Brakesystem57
Diagram5:Stabiliser
Diagram6:Lights/Windscreenwiper63
Diagram7:Worklamps/Roofbeaconlight65
Diagram8:Tiltingpreventionsystem/Roofwiper67
Diagram9:Heating/Soundsystem/Electricsocket/Interiorlamp69
GENERALINSTRUCTIONS
IMPORTANTNOTICE
AllmaintenanceandrepairinterventionslistedinthisManualmustbeperformedexclusivelybytheService NetworkoftheManufacturer,complyingstrictlywiththeindicationshereinandusing,whenrequired,the prescribedspecialtools. Whoeverperformsserviceoperationsdescribedhereinwithoutcomplyingstrictlywiththeinstructionsbecomes solelyresponsibleforanyconsequentialdamagethatcouldoccur.
ADJUSTINGSHIMS
Foreachadjustmentselecttheadjustingshims,measuringthemonebyonewithamicrometerandaddingto gethersubsequently,thevaluesmeasured.Donotrelyonthemeasurementoftheentirepack,thatcouldbe wrong,orthenominalvalueindicatedoneachring.
SEALSFORROTATINGSHAFTS
Forcorrectinstallationofthesealsforrotatingshafts,pleasecomplywiththefollowingprecautions: --priortoinstallation,keepthesealssoakingforatleasthalfanhourinthesameoiltheyaregoingtoseal; --cleanthoroughlytheshaftandmakesurethatitsworkingfaceisundamaged; --directthesealingliptowardthefluid;intheeventthelipisofthehydrodynamictype,thegroovesmustbe directedsothat,inrelationtotherotatingdirectionoftheshaft,theytendtoreturnthefluidtowardtheinside ofthesealingdevice;
--smearthesealinglipwithafilmoflubricant(oiltobepreferredtogrease)andfillwithgreasethegapbetween sealinglipanddustlipintwinlipseals;
--insertthesealinitsseat,pressingitwithapunchwithaflatface;neverstrikeitwithahammerormallet; --whenpressingintheseal,makesurethatitisinsertedperpendicularlyinrelationtotheseatand,oncein position,makesurethat,whenrequired,itcontactstheshoulder;
--topreventthesealinglipofthesealbeingdamagedbytheshaft,insertappropriateprotectionduringthe installationofthetwoparts.
“0--RING”TOROIDALSEALS
LubricateO--ringsbeforeinsertingthemintherelevantseatstopreventthembecomingtwistedandrolledduring installation,thusjeopardisingtheirsealingcapacity.
SELAINGCOMPOUNDS
MatingsurfacemarkedXmustbesmearedwithasealingcompoundrecommendedbytheManufactureroran adequateequivalent.
Priortoapplyingthecompound,preparethesurfacesinthefollowingmanner: --removeallpossiblescalingwithametalbrush; --degreasethesurfacesthoroughlyusingthedegreesingagentrecommendedbytheManufactureroran adequateequivalent.
BEARINGS
Wheninstallingbearings,itisrecommendedto: --warmthemupto80 –90 C(176–194 F)beforeinstallingthemontherelevantshafts; --coolthemdownbeforeinsertingthemintherelevantseatswithanouterfitting.
SPLITPINS
Wheninstallingsplitpins,makesurethatthecutispointinginthedirectionoftheloadonthepin. Ontheotherhand,spiralelasticpinsdonotrequireanyinstallationorientation.
NOTESONSPAREPARTS
Usegenuine sparepartsguaranteedbytheManufacturer only. Genuinesparepartsaretheonlyonesensuringthesamequality,thesamelifeandthesamesafetyasthe originallymountedparts,sincetheyarethesameastheonesinstalledinproduction. Onlygenuinepartsfromthemanufacturerensurethisguarantee. Ordersforsparepartsmustincludethefollowingindications: --modelofthevehicle(commercialdesignation)andserialnumber; --typeandnumberoftheengine; --partnumberfortheitemordered,asprovidedbythe“Microfiches”orthe“SparePartCatalogue”,onwhich theorderisbased.
NOTESONTOOLING
ThetoolingthattheManufacturerrecommendsandillustratesinthisManualis: --studiedanddesignedspecificallyforservicingvehiclesofthisrange; --requiredtoensureareliablerepair; --accuratelydevelopedandinspectedtoprovideeffectiveandlonglastingworking. Youarealsoremindedthatcorrecttoolingallowsyouto: --tooperateunderoptimisedtechnicalconditions; --toachievethebestresults; --tosavetimeandeffort; --toworkinsaferconditions.
WARNING
Thewearlimitsprovidedforsomeitemsmustbeconsideredasrecommendedvalues,butnotabsolutelybinding. Theindications“front”,“rear,“right”,“left”refertodifferentpartsasseenseatingfromintheoperator’sseat orientedinthenormaltraveldirectionofthevehicle.
HOWTOMOVEAVEHICLEWITHOUTBATTERIES
Thecablesoftheexternalpowersupplymustbeconnectedexclusivelytotherespectiveterminalsofthepositive andnegativecablesofthevehicle,usingefficientclampsprovidingadequateandsafecontact.Intheeventit isnecessarytochecktheoperationoftheelectricalsystemofthevehicle,doitexclusivelywiththepowersupply connected.Attheendoftheinspection,disconnectallactuatorsanddeactivatethepowersupplybefore disconnectingthecables.
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SAFETYRULES
PAYATTENTIONTOTHISSYMBOL
Thisalertsymbolannouncesimportantmessagesinvolvingyoursafety.
Readcarefullythesafetyinstructionslistedandfollowtheprecautionsrecommended toavoidpotentialrisksandtosafeguardyourhealthandyoursafety. YouwillfindthissymbolinthetextofthisManualwiththefollowingkeywords:
WARNING --Cautionsintendedtoavoidimproperrepairinterventionsinvolving potentialconsequencesforthesafetyofthepersonnelperformingtherepairs.
DANGER --Thesewarningsqualifyspecificallypotentialdangersforthesafetyofthe operatororotherpersonsdirectlyorindirectlyinvolved.
AVOIDACCIDENTS
Mostaccidents,whethertheyoccurinworkshop,on thefarm,athomeorontheroad,arecausedbythe failureofsomeindividualstofollowsimpleandfundamentalsafetyrulesandprecautions.ForthisreasonMOSTACCIDENTSCANBEPREVENTEDby recognisingtherealcauseanddoingsomething aboutitbeforetheaccidentoccurs.
Regardlessofthecareusedinthedesignandconstructionofanytypeofequipment,therearemany conditionsthatcannotbecompletelysafeguarded againstwithouthinderingreasonableaccessibility andefficientoperation.
Acarefuloperatoristhebestinsuranceagainstan accident.
Thecompleteobservanceofonesimplerulewould preventmanyseriousaccidents.
DANGER. Neverattempttoclean,lubricateormaintainamachinewhileitisinmotion.
SAFETYRULES
SAFETYRULES
Readandheedallsafetyrulesbeforeanyintervention.
Donotwearrings,wristwatches,jewellery,and looseorhangingapparels,suchasties,torn clothing,scarves,unbuttonedorunzipped jacketsthatcancatchonmovingparts.Wear propersafetyequipmentasrecommendedfor thejob.Examples:hardhat,heavygloves,ear protection,safetyglassesorgoggles,reflector vests,respirator.Consultyouremployerforspecificsafetyequipmentrequirements.
Donotperformanyserviceoperationonthe machinewithapersonseatedintheoperator’s compartment,unlessheisanauthorisedoper-
atorco--operatingintheoperationtobeperformed.
Neverattempttooperatethemachineoritstools fromanypositionotherthanseatedintheoperator’sseat.
Neverperformanyinterventiononthemachine withenginerunningunlessthisisprescribed.
Cut--offtheengineandmakesurethatallpressuresinthehydraulicsystemsarereleased beforeremovingcaps,covers,valvesetc.
Allserviceinterventionsmustbeperformedwith theutmostcareandattention.
Shopand/orfieldserviceplatformsorladders mustbeconstructedandmaintainedinaccordancewithlocalandnationalregulations.
Disconnectthebatteriesandtagallcontrolsto signalthataninterventionisinprogress.Block themachineandallequipmentthatmustbe lifted.
Donotchecknorrefillfueltanks,aswellasbatteries,norusestartingfluidwhilesmokingor nearopenflamessincethesefluidsareflammable.
Brakesareinactivewhenmanuallyreleasedfor serviceinterventions.Undersuchcircumstancesitisnecessarytomaintainthecontrolof themachineusingappropriateblocksorsimilar devices.
Thefuel--fillingnozzlemustbekeptconstantly insidethefillingneck.Keepthiscontactfromthe beginningtotheendofthefuellingoperationto avoidthepossibilitythatsparksduetostatic electricityaregenerated.
Useonlydesignatedtowingorattachingpoints. Usecareinmakingattachments.Makesurepins and/orlocksaresecurebeforepulling.Stayclear ofdrawbars,cablesorchainsunderload.
Tomoveadisabledmachine,useatrailerora low--boy,ifavailable.
Toload/unloadamachinefromtransporter, choosealevelsurfaceensuringfirmsupportto thewheelsoftruckortrailer.Anchorthemachine securelytothebedoftruckortrailerandblock wheelsortrackswithappropriatewedges.
Useonlyapprovedgroundedauxiliarypower sourcesforheaters,chargers,pumpsandsimilarequipmenttoreducethehazardsofelectrical shocks.
Liftandhandleheavypartswithaliftingdevice ofpropercapacity.
Bewareofbystanders.
Neverpourgasolineordieselfuelintoopen, wideandlowcontainers.
Neverusegasoline,solventorotherflammable fluidtocleanparts.Useexclusivelyqualified, non--flammable,non--toxiccommercialsolvents.
Whenusingcompressedairforcleaningparts, usesafetyglasseswithsideshieldsorgoggles.
Limitpressureto2.1bar,inaccordancewith localandnationalregulations.
Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaust fumes.
Donotsmokeorpermitanyopenflamesorspark nearwhenre--fuellingorhandlingflammable materials.
Donotuseanopenflameasalightsourceto lookforleaksorforinspectionanywhereonthe machine.
Movewithextremecarewhenworkingunderthe machine,itsattachmentsandoronornear them.Alwayswearprotectivesafetyequipment asrequired,suchashardhat,goggles,safety shoes,earplugs.
Whenperformingoperationsrequiringrunningof theengine,haveaqualifiedoperatorintheoperator’sseatatalltimeswiththemechanicon sight.Placethetransmissioninneutralandset thebrakesandsafetylock.
Forfieldservice,movemachinetolevelground, ifpossible,andblockit.Ifworkonaninclineis absolutelynecessary,firstblockmachineandits attachmentssecurely,thanmoveittolevel groundassoonaspossiblewithacertainmargin ofsafety.
604.13.542.01 --03--2006
Donottrustwornand/orkinkedchainsand cables:donotusethemforliftingorpullingoperations.Tohandlethem,alwaysuseheavy gloves.
Besurechainsandcablesareanchoredandthe anchorpointsarestrongenoughtohandlethe expectedload.Keepexposedpersonnelclearof anchorpointsandcablesorchains.No bystandersareallowednearthehookingpoints, chainsorcables.
Keeptheareawheremaintenanceoperations areperformedCLEANandDRY.Eliminate immediatelyallwaterandoilspillages.
Donotpileupoilyorgreasyrags;theyrepresent afirehazard.Storeinaclosedmetalcontainer.
Beforestartingmachine,check,adjustandlock theoperator’sseatformaximumcomfortand controlofthemachine.Besureexposed personnelintheareaofoperationareclearofthe machinebeforemovingitoritsattachments. Soundthehorn.
Donotcarrylooseobjectsinpocketsthatmight fallunnoticedintoopencompartments.
Wearproperprotectiveequipmentsuchas safetygogglesorsafetyglasseswithside shields,hardhat,safetyshoes,heavygloves whenmetalorotherparticlesareapttoflyorfall.
Wearweldersprotectiveequipmentsuchas darksafetyglasses,helmets,protectiveclothing,glovesandsafetyshoes,whenweldingor burning.Weardarksafetyglassesnearwelding zones.DONOTLOOKATARCWITHOUT PROPEREYEPROTECTION.
Steelcablesarefrayedafterprolongeduse; alwayswearappropriateprotections(heavy gloves,gogglesetc.).
Handleallpartscarefully.Keephandsand fingersawayfromstructures,gearsormoving parts.Useandwearalwaystheappropriate protections,suchassafetygoggles,glovesand safetyshoes.
STARTING
Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaust fumes.
Donotplacehead,body,limbs,feet,handsor fingers,nearrotatingfansorbelts.Beespecially alertnearpusherfans.
ENGINE
Loosentheradiatorcapveryslowly,torelease pressurefromthesystem,beforeremovingit.All coolantleveltop--upsmustbeperformedwith engineinoperativeoratlowidle,ifwarm Donotrunenginewhenrefuellingandusecare iftheengineishotduetotheincreasedpossibilityofafireiffuelisspilled.
Neverattempttocheckoradjustfanbeltswhen engineisrunning.Donotadjustenginefuel pumpwhenmachineismoving.
Neverlubricatethemachinewithenginerunning.
ELECTRICALSYSTEM
Shouldboosterbatteriesbeused,rememberto connectbothendsoftheboostercablesinthe propermanner(+)with(+)and(--)with(--).Avoid short--circuitsoftheterminals.Followthoroughly theinstructionsofthisManual. Avoidshortcircuitingtheterminals.BATTERY GASISHIGHLYFLAMMABLE.Leavebattery boxopentoimproveventilationwhenrecharging batteries.Nevercheckchargebyplacingmetal objectsacrosstheposts.Keepsparksoropen flamesawayfrombatteries.Donotsmokenear batterytoguardagainstthepossibilityofcausing anexplosion.
Beforeanyintervention,makesurethatthere arenofuelorelectrolyteleakages;eliminate thembeforeproceedingwithfurtherwork. Whenrechargingbatteriesinclosedambient, makesurethatthereisappropriateventilationto preventpossibleaccidentalexplosionsdueto theaccumulationofgasesgeneratedduringthe recharge.
Beforeanyintervention,makesurethatthemain switchisOFF.
HYDRAULIC SYSTEM
Fluidescapingunderpressurefromaverysmall holecanbealmostinvisibleandcanhavesufficientforcetopenetratetheskin.Useapieceof cardboardorwoodtosearchforsuspectedpressureleaks.DONOTUSEHANDS.Ifinjuredby escapingfluid,seeadoctoratonce.Serious infectionorreactioncandevelopifpropermedicaltreatmentisnotadministeredimmediately. Incasepressuresmustbemeasured,use instrumentsofadequatecapacity.Alwaysfollow therecommendedprocedures.
WHEELSANDTYRES
Makesurethattheinflationpressureofthetyres isaccordingtothespecificationsissuedbythe Manufacturerandcheckitperiodically.
Shouldthepressurebechanged,standonthe sideofthetyreatasafedistance.
Pressurecheckoperationsmustbeperformed withunloadedmachineandcoldtyres.Never usereconditionedtyrerims,sinceeventual weldings,heat--treatmentsorrepairsnotperformedcorrectlycanweakenthewheel,thus causingsubsequentdamagesordangers.
Donotperformtorchcuttingorweldingoperationsonrimswithinflatedtyresinstalled.
Beforeoperatingontyres,blockallwheels,front andrear.Afterjackingthemachine,blockitwith standsaccordingtocurrentsafetyrulesand regulations.
Beforeremovingobjectsfromthetyretread, deflateit.
Neverinflatetyreswithflammablegas; explosionsandseriousbodilyinjuriesmay result.
REMOVALSANDINSTALLATIONS
Liftandhandleallheavypartswithliftingdevices ofadequatecapacity.Makesuethattheparts areattachedtoliftingdevicesareproperly slinged.Usetheliftingeyesprovided.Bewareof personsinthevicinity.
Handleallpartscarefully.Keephandsand fingersawayfromstructures,gearsormoving parts.Useandwearalwaystheappropriate protections,suchsgoggles,glovesandsafety shoes.
Preventchainsandcablesfromkinking.To handlethem,alwaysuseheavygloves.
PRODUCTIDENTIFICATION
TheTelehandleranditsmaincomponentsareidentifiedbyvariousnumbersandlettersprovidingits identificationbytheServicenetwork.Thefollowing informationgivesthelocationoftheidentification plates,ofthenumbersstampedonthemachineand variousexamplesofwhatcanbefoundonthe machine.
VEHICLESERIALNUMBER
Theserialnumberisstampedonthefrontpartofthe machine,ontheuppersideofthemainframe,right side.
NOTE: Theserialnumberandtheidentification numberofthecomponentscanberequestedbythe DealerwhenSparePartsareorderedorinterventionsarerequired.Thesenumbersarealsorequired ashelpinidentifyingthemachineintheeventoftheft. Keeptheminasafeplace.
VEHICLEIDENTIFICATIONPLATE
Themachineidentificationplateislocatedontheleft handoftheseatpod.Recordthedataofyour machinebelow.
TECHNICALTYPE/MODEL
ENGINEIDENTIFICATION
Theengineidentificationinformationislocatedon theleft--handsideoftheengineblock.Recordthe informationbelowforquickreferenceincaseof necessity.
MODELNO.
SERIALNO.
DATECODE
FRONTAXLEIDENTIFICATION
Theserialnumberandaxletypeisprintedonthe plate(1)locatedonthefrontoftheaxlehousing. Recordtheinformationbelowforquickreferencein thecaseofnecessity.
AXLETYPE
SERIALNO.
DATECODE
4x3POWERSHIFTTRANSMISSION IDENTIFICATION
Theserialnumberandtypeisprintedontheplate(1), onthelowersideofthetransmission.Recordthe informationbelowforquickreferenceinthecaseof necessity.
MODELNo.
SERIALNo.
DATECODE
IDENTIFICATIONOFREAR TRANSMISSION
Theserialnumberisindicatedonplate(1)secured onthereartransmissionhousing.Copyherethe serialnumber,forapromptconsultationincaseof necessity.
AXLETYPE
SERIALNo.
DATECODE
IDENTIFICATIONOFCAB
Thecabidentificationplateincludestheserial numberandadditionaldataandislocatedonthe frontsideoftheseat.Pleasecopyherebelowthe serialnumberforapromptconsultationincaseofnecessity.
SERIALNo.
DATECODE
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ENVIRONMENTALCONSIDERATIONS
Thefollowingrecommendationscanbeuseful:
Becomefamiliarandmakesureyouhavewell understoodtherelevantlegislationineffectin yourcountry.
Intheeventnoregulationsexist,askforspecific informationwiththesuppliersoflubricants,antifreezeanddetergentsregardingtheireffectson humansandtheenvironmentandhowtostore, handleanddisposeofthesesubstancessafely.
4.Avoidspillagewhendrainingusedcoolantmixtures,engineoils,transmissionandhydraulic fluids,brakefluid.Afterdraining,donotmix brakefluidorfuelwithlubricants.Storethemina riskfreemanneruntilwhentheycanbedisposed ofinanadequateway,inaccordancewithlocal regulationsandtheresourcesavailable.
5.Moderncoolingmixtures,suchasantifreezeand otheradditives,mustbechangedeverytwo years.Maximumattentionmustbepaidtopreventthattheyspillovertheground.Theymustbe collectedanddisposedofsothatdonotcreate anydanger.
6.Donotunsealairconditioningsystembyyourselves,sincetheycancontaingasesthatmust notbereleasedintotheatmosphere.Thepersonnelspecialisedinairconditionersuses specialequipmenttochargeanddischargeair conditioningsystems.
Usefulindications
1.Donotfilltankswithinadequatecanistersordispensingpressurisedsystemsthatcouldcause considerablespillage.
2.Ingeneral,avoidthecontactoftheskinwithany fuel,oil,acid,solventetc.Themajorityofthem containsubstancedangerousforyourhealth.
3.Modernlubricantscontainadditives.Donotburn contaminatedfuelsand/orwedoilsinnormal heatingburners.
7.Repairatonceanyleakageordefectofthe enginecoolingsystemorhydraulicsystem.
8.Donotincreasethepressureofanypressurised system,sincethiscouldcauseseriousproblems tothecomponentsofthesystem.
9.Protecthoseswhenperforminganywelding, sinceasplashofweldingmaterialscouldpenetrateandburnthem,causingaholeorweakeningthewallwithsubsequentleakagesofoil, coolantetc.
MAINTENANCETECHNIQUES
GENERALNOTICES
Cleantheoutsideofallthecomponentspriortoperforminganytypeofrepair.Dirtandabrasivedustcan reducetheefficientlifeexpectancyofacomponent andresultinexpensiverepairs.
Thetimespentinpreparingandcleaningworking surfacesisgivingresults,makingworkeasierand safer,andthecomponentsoverhauledwillbemore reliableandoperatebetter.
Usecleaningfluidsproventobesafe.Sometypesof fluidcancauseseriousproblemstoO--Ringsandirritatetheskin.Itisnecessarytocheckthatthesolventsaresuitabletocleanthecomponentsandthat oftheyarefreeofrisksforthehealthofworkers.
ReplaceO--Rings,sealingringsandsealseverytime theyaremoved.NeveruseoldO--Ringsorsealsand newonestogether,independentlyfromtheirconditions.AlwayslubricatenewO--Ringsandsealswith hydraulicoilbeforeinstallingthem.
Whenreplacingcomponents,alwaysusethetooling requiredbythistypeofwork.
HOSESANDSTEELPIPES
Alwaysreplacehosesandsteelpipeswhenthetaper endorconnectionsaredamaged.
Whenanewhoseisinstalled,connectitwithout tighteningtheendsandmakesurethatitisroutedin thecorrectmanner,beforetighteningtheends.Fixturesmustbetightenedjustenoughtoholdthehose withoutsqueezingit,avoidingrubbingaswell. Afterreplacingahoseofmovingcomponents,make surethatthehoseisnotdisturbedbythemovement ofthecomponentinanyposition.
Makesurethatallhosesinstalledarenotchokedor bent.
Ifhoseconnectionsaredamaged,dented,chokedor leaking,decreasetheflowofoilandtheproductivity oftherelevantactuators.Connectionsshowing signsofdisplacementfromtheiroriginalpre-pressedpositionmustbeconsideredasalready broken,sincetheyaregoingtofailorseparatesoon. Ahosewitharaggedoutersleeveallowswaterto penetrate.Thus,hiddencorrosionofthereinforcing wirewilldevelopalongtheentirelengthofthehose, withthesubsequentfailureofthehoseitself.
Ifahoseswells,thisindicatesthatthereisaninternal leakageduetoastructuralfailure.Thiscondition deterioratesveryquicklyandcausesthefailureof thehose.
Clogged,squeezed,excessivelytensionedor deformedhosesaregenerallyeasilysubjecttoflow reduction,decrementoftheoperationalspeedofthe fluidandthefinalfailureofthehose.
Loosehosesmovefreelyandmustbeprevented fromtouchingeachotherandnearbysurfaces.This causesarubbingactionshorteningtheusefullifeof thehose.
CONNECTIONSWITHFRONTSEALING O--RINGS
Whenrepairingconnectionswithfrontsealing O--Rings,pleasecomplywiththefollowingprocedures.
WARNING:NEVERDISCONNECT,NOR TIGHTENAHOSEORASTEELPIPEUNDER PRESSURE.IFINDOUBT,MOVETHECONTROL LVERSSEVERALTIMESWITHTHEENGINE INOPERATIVEBEFOREDISCONNECTINGA HOSEORASTEELPIPE.
1.Loosentheconnectionsandseparatethehose orsteelpipe,thenremoveandeliminatethe O--Ringsfromtheconnection.
2.DipanewO--Ringinclean,hydraulicoilbefore installingit.InstallthenewO--Ringintheconnectionand,ifnecessary,holditinitsposition withvaseline.
3.Installanewhoseorsteelpipeandtightenmanuallytheconnectionholding,atthesametime, thepipestilltopreventitfromturning.
4.Usetwowrenchestotightentheconnectionto thetorqueprescribedforitssize.Pleasereferto thetabletofollowforthetighteningtorques.
NOTE:toensurethatajointdoesnotleak,itis importantthattheconnectionsareneither excessivelytightenednortoolittle.
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SPECIFICSEALINGCOMPOUNDS
Thefollowingsealingcompoundsmustbeused,complyingwiththeindicationsprovidedbytheManual:
SEALANTSCOMMERCIALNAME
AnaerobicsealantLOCTITE518(liquidgasket)
RTVsiliconsealantLOCTITESUPERFLEX593,595or596 LOCTITEULTRABLUE587DOWCORNINGSILASTIC 732GENERALELECTRICRTV103or108
PipesealantPST592(pipesealantwithteflon)
Lockingcompoundfor threads LOCTITE243/RED(sealant/lockingforthreads)
TIGHTENINGVALUESFORFASTENERS
Checkperiodicallythatthefastenersareproperly tightened.
Baseduponthetablestofollow,determinethecorrecttighteningtorquewhenpartsofthefastening componentsarechecked,adjustedorreplaced.
IMPORTANT:DONOTusethevalueslistedinthe tableswhentheManualindicatesadifferenttorque
ortighteningprocedureforaspecificapplication.The torquevaluesareprovidedforgeneraluseonly. Makesurethatthethreadsofthefastenersareclean andundamaged.
NOTE: useatorquewrenchtotightenfastenerscorrectly.
METRICBOLTSANDLOCKNUTS
IDENTIFICATION
HEXSCREWS(WITHOUTNUT)ANDROUNDHEADBOLTS
CLASS5.6ANDHIGHER
IDENTIFICATIONOFTHEMANUFACTURER
HEXNUTSANDTIGHTENINGNUTS CLASS05ANDHIGHER
IDENTIFICATIONOFTHEMANUFACTURER
DIMENSION
INCHMEASUREMENTSCREWSANDLOCKNUTS GRADESAE2GRADESAE5GRADESAE8
GRADESAE2 GRADESAE5 GRADESAE8
GRADEIDENTIFICATION
GRADEA:NOCUTS
GRADEB:ONEPERIMETERCUT
GRADEC:TWOPERIMETERCUTS
NORMALNUTS HEXNUTS GRADESAE5 HEXNUTS GRADESAE8
GRADEIDENTIFICATION
GRADEA:NEWMARK
GRADEB:THREEMARKS
GRADEC.SIXMARKS
THEMARKSARENOTCOMPULSORILY LOCATEDINTHECORNERS
GRADEA.NOMARKS
GRADEB:LETTERB GRADEC:LETTERC
GRADEIDENTIFICATION
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