Fiat Hitachi Dump Truck ADT25 Workshop Manual – PDF DOWNLOAD

WORKSHOP MANUAL

ADT 25

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ADT 25

INTRODUCTION

WORKSHOP MANUAL

ADT 25

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

I

IIą

INTRODUCTION

ASTRA VEICOLI INDUSTRIALI Product Service Via Caorsana, 79 - 29100 PIACENZA (Italy) Tel. 0523/5431 - Fax 0523/597068 - Telex 530148 ASTRA I Publication no. A3000021 First edition APRIL 2001 Second edition MARCH 2002 Prepared by SIPAL S.p.A. - TORINO (Italy) Complete or partial copying of the text and illustrations herein is prohibited.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

ADT 25

ADT 25

INTRODUCTION

III

Figure 1

174CU01

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

IVą

INTRODUCTION

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

ADT 25

ADT 25

INTRODUCTION

V

SECTIONS

TITLE

SECTION

INTRODUCTION

PAGES from I to VIII

CONDITIONS OF USE

1.1

from 1 to 16

SAFETY INSTRUCTIONS

1.2

from 1 to 18

GENERAL SPECIFICATIONS

2

from 1 to 28

ENGINE

3

from 1 to 52

AUTOMATIC TRANSMISSION

7

from 1 to 82

PROPELLER SHAFT

10

from 1 to 10

FRONT AXLE

12.1

from 1 to 50

INTERMEDIATE AXLE

12.2

from 1 to 58

REAR AXLE

12.3

from 1 to 48

BRAKES

13.1

from 1 to 20

WHEELS AND TYRES

13.2

from 1 to 8

SUSPENSION

14

from 1 to 10

STEERING SYSTEM

15

from 1 to 6

HYDRAULIC SYSTEM

16

from 1 to 44

ELECTRICAL SYSTEM

17

from 1 to 30

CAB AND CHASSIS

18

from 1 to 24

BODY

20

from 1 to 4

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VIą

INTRODUCTION

ADT 25

PARTS Figure 2

1

4

6

9

3

2

5

7

10

8 174CU02

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Cab Body Central joint Engine Transmission Front axle Intermediate axle Rear axle Suspension cylinder Tipper cylinder

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ADT 25

INTRODUCTION

VII

Main vehicle assemblies production numbers You are advised to make a note of the model and serial number (PN) and/or production code (PIN) of the main vehicle assemblies written on the respective plates applied to the assembly.

The plate location is shown in Section 2-GENERAL SPECIFICATIONS. This will ensure faster identification of the parts required for partial or total replacement.

engine

automatic transmission

front axle

intermediate axle

rear axle

suspension cylinder

tipper cylinder

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

VIIIą

INTRODUCTION

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ADT 25

SECTION 1.1 CONDITIONS OF USE

ADT 25

SECTION 1.1

CONDITIONS OF USEą1

CONTENTS

Page

Page

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

WARRANTY AND LIABILITY OF THE MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CONFORMITY MARKING . . . . . . . . . . . . . . . . . . . . . 4 INFORMATION ON THIS HANDBOOK . . . . . . . . . 5 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Purpose of this handbook . . . . . . . . . . . . . . . . . . . . . . 6 To whom this handbook is addressed . . . . . . . . . . . 6 Safekeeping of this handbook . . . . . . . . . . . . . . . . . . 6 Updates to this handbook . . . . . . . . . . . . . . . . . . . . . . 6 Units of measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SCHEDULED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 VEHICLE REPAIR SERVICEMEN . . . . . . . . . . . . . . . 7

Warranty conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Warranty coupons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GENERAL OPERATION RULES . . . . . . . . . . . . . . . 10 Pre-disassembly preparation . . . . . . . . . . . . . . . . . 10 During disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10 After disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 During assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Interchangeable parts . . . . . . . . . . . . . . . . . . . . . . . . 13 Welding on the chassis . . . . . . . . . . . . . . . . . . . . . . . 15

WASTE DISPOSAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SCRAPPING THE VEHICLE . . . . . . . . . . . . . . . . . . . 8

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

2ąCONDITIONS OF USE

SECTION 1.1

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For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

ADT 25

ADT 25

SECTION 1.1

CONDITIONS OF USEą3

INTRODUCTION This technical handbook contains a series of repair procedures relating to the articulated dump trucks.

Read this handbook carefully before carrying out any repairs on the vehicle.

Scrupulous observance of the rules and instructions herein will ensure that repairs are carried out safely and efficiently.

Copyright The copyrights of this handbook belong to the vehicle manufacturer.

The text, drawings and illustrations contained in this handbook cannot be circulated or given to third parties, totally or partially, without the written consent of the vehicle manufacturer.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

4ąCONDITIONS OF USE

SECTION 1.1

CONFORMITY MARKING This vehicle was made in compliance with Community Directive 98/37/EEC and amendments (Machinery Directive).

All parts of the vehicle comply with the aforesaid directive, as shown by the CE marking.

The plate is located in the position shown in the figure and must be legible at all times.

ADT 25

Figure 1

LEVEL OF NOISE Noise outside the vehicle: Lwa = 108 dB (A) Noise at driver's seat: Lpa = 76 dB (A) measured on identical vehicle, in accordance with Directive 86/662/EEC.

174CU01A

Figure 2

VIBRATIONS TRANSMITTED TO OPERATOR Acceleration transmitted to the operator's arms: weighed average quadratic level < 2.5 m/s2 (8.2 ft/s2) Acceleration transmitted to the operator's body: weighed average quadratic level < 0.5 m/s2 (1.6 ft/s2) Measured by means of accelerometer on identical vehicle running on medium unsurfaced terrain.

Figure 3 174CU02

174CU03 For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

ADT 25

SECTION 1.1

CONDITIONS OF USEą5

INFORMATION ON THIS HANDBOOK Definitions Handbook is this WORKSHOP MANUAL. Vehicle is the machinery described in this manual.

Manufacturer is the company manufacturing the vehicle.

Dealership is the company or organisation officially representing the Manufacturer.

Supplier is any company supplying components and/or consumable material used by the vehicle.

User is the person directly or indirectly involved in repairing the vehicle.

Symbols You will find the following symbols highlighting parts of the handbook. Their meaning is: procedures, technical information and precautions which, if not respected and/or incorrectly carried out, could cause injury to users (safety symbol, also see SECTION 1.2-SAFETY INSTRUCTIONS). procedures, technical information and precautions which, if not respected and/or incorrectly carried out, could damage the vehicle.

Contents This manual contains the repair instructions for all the vehicle parts.

Some devices described in this handbook may not be fitted in your vehicle, according to the outfit and the market for which the vehicle was made.

This handbook is organised in several sections, which are organised in chapters and, where required, paragraphs to ensure rapid and easy retrieval of information.

Refer to the general list of contents at the beginning of this Handbook for further information on how the various topics are set out.

procedures, technical information and precautions which, if not respected and/or incorrectly carried out, could pollute the environment.

.

very important procedures, information and precautions.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

technical

6ąCONDITIONS OF USE

SECTION 1.1

Purpose of this handbook Purpose of this handbook is to allow users to get to know the vehicle and repair it as specified, in a safe and long-lasting fashion, taking the required actions and arranging human and material resources as needed.

To whom this manual is addressed This manual is addressed to those persons who need to and/or have been delegated to carry out repairs on the vehicle and/or whose job it is to give instructions on how to carry out such repairs.

These persons are: D operative units/site/department managers; D users directly concerned in vehicle maintenance.

Safekeeping of this handbook This handbook must be kept inside the vehicle, in a dry place, and must be readily available for consultation.

You are advised to file a copy.

Keep the handbook for the entire life of the vehicle, until it is scrapped. Users are required to purchase a new copy if the handbook is either lost or damaged. Copies must be exclusively ordered from the manufacturer.

Updates to this handbook The information, descriptions and illustrations in this handbook reflect the state of the art at the time of marketing of the vehicle.

The manufacturer reserves the right to implement changes to vehicles, for technical or marketing reasons, at any time. The manufacturer will not be obliged either to implement such changes in the vehicles marketed before or to consider this handbook obsolete.

Any additional information which the manufacturer may deem suitable to provide at a later time will be kept with the handbook as an integral part of the publication.

Units of measure International System (SI) units of measure as used in this handbook.

Imperial System values are expressed in brackets.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

ADT 25

ADT 25

SECTION 1.1

SCHEDULED USE

The vehicle described in this handbook was designed and made for the following use: D to haul excavation material in general; D to haul material resulting from interventions on industrial or civilian artefacts in general; D to haul material required to make infrastructures and/or industrial or civilian artefacts in general.

The vehicle must be used for such purposes.

The vehicle must be in proven and checked conditions of efficiency for said use, fully respecting the envisaged criteria and restrictions of use.

Specific care must be paid to the following aspects: D do not exceed the payloads specified by the manufacturer; D do not exceed the gradients specified by the manufacturer; D do not drive the vehicle on loose terrain which can compromise stability; D do not use the vehicle to remove objects or products; D use the vehicle paying special care to the safety instructions and specifications; D carry out the ordinary maintenance interventions specified by the manufacturer; D carry out the extraordinary maintenance interventions which are required, specifically those related to safety of use.

.

CONDITIONS OF USEą7

VEHICLE REPAIR SERVICEMEN Any repairs to the vehicle must be carried out exclusively by qualified repair servicemen with the necessary ability and technical knowledge.

Vehicle servicemen must: D have the operative skills required for construction site vehicle maintenance; D be sensitised to respect and adopt safety instructions and precautions.

The servicemen must be put in the condition to be able to work in total safety by means of suitable training periods or courses, so that they are fully aware of the rules of professional demeanor that must be followed during repairs to the vehicle.

The direct reporting manager must ensure respect of general safety instructions, specifically those contained in this handbook.

The manager will also ascertain suitability of operating personnel, in terms of technical skills and psychological-physical conditions.

The manufacturer declines liability for injury to persons and for damage to the vehicle and/or to the transported goods in the event of other use or use in other conditions than those specified.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

8ąCONDITIONS OF USE

WASTE DISPOSAL

SECTION 1.1

Collect and properly dispose of replaced material (brake pads, filters, etc.) and waste material, resulting from maintenance operations and repairs (material soaked in fuel, oil, powder, etc.) according to the laws in force, separately from normal waste.

Collect and dispose of used lubricants and fluids, according to the laws in force.

Collect and dispose of used batteries according to the laws in force.

Drain and recharge the air conditioning system using the specific devices, according to the laws in force.

Furthermore, you are advised to separate ferrous materials, light alloys and waste plastic materials for separate recycling.

ADT 25

SCRAPPING THE VEHICLE The vehicle must be scrapped according to the laws in force, at the end of the vehicle's working life.

Recycle and demolish the vehicle according to the laws in force.

The vehicle must be demolished by expert personnel using suitable working tools to ensure the required safety conditions.

Demolish the vehicle by separating and collecting the various materials by type to allow recycling and disposal.

Please note that it is forbidden to abandon an obsolete vehicle at a quarry, building site, dump or in the environment.

Specific attention must be devoted to certain components and substances which can pollute the environment and/or cause injuries, i.e.: D presence of fuels, coolant fluids, hydraulic oil and lubricating oils on board; D presence of batteries and respective electrolyte; D presence of pressurised gas (tyres, suspension components, air conditioner); D presence of solid polluting materials (tyres, brake pads, plastic parts, filters) or hazardous materials (glass, windows).

Dispose of these materials according to the laws in force.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

ADT 25

SECTION 1.1

CONDITIONS OF USEą9

WARRANTY AND LIABILITY OF THE MANUFACTURER

SERVICE

Warranty conditions

The manufacturer provides a warranty card to the user with each vehicle.

You are advised to use the coupon during the first hours of operation of the vehicle.

The user must scrupulously observe the precautions illustrated in this handbook to ensure validity of the contractual warranty. Specifically, the user will: D respect restrictions of use specified by the manufacturer; D not implement changes or variants to the vehicle without the manufacturer's written approval; D always carry out the maintenance interventions; D always use genuine spare parts; D ascertain that the personnel called to use the vehicle have the necessary requirements in terms of skills and training.

The contractual warranty will not be applicable if the aforesaid conditions are not respected, even in part.

Liability The manufacturer declines all direct or indirect liabilities deriving from: D disrespect of the instructions contained in this handbook; D use of the vehicle by untrained or unauthorised personnel; D use non complying with the regulations in force in the country where the vehicle was marketed; D unauthorised changes and/or repairs; D use of other than genuine spare parts.

Warranty coupons

Warranty coupon: after 250 hours of work.

.

Different warranty conditions are valid only if stated on the vehicle purchasing contract.

Service Dealerships are available for all types of interventions.

Equipment and expert personnel are available for overhauling and repairing operations.

Dealerships can provide information and advice to ensure the best use of the vehicle.

Spare parts Use genuine spare parts for replacements which can be ordered from dealers and authorised workshops.

Please remember that the following information will be required to order spare parts: D vehicle type; D chassis number; D reference and catalogue numbers shown in the Spare Parts Catalogue.

If the part belongs to a main assembly (engine, transmission, axles, motors, etc.), you will also need to specify the assembly model and serial number.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

10ąCONDITIONS OF USE

SECTION 1.1

ADT 25

GENERAL OPERATION RULES Pre-disassembly preparation Cleaning before bringing the vehicle into service shop Remove mud and dirt completely before bringing the vehicle into the service shop. Carrying mud and dirt into the service shop impedes cleaning operations when disassembling and increases the possibility of contamination of parts during reassembly.

Preliminary survey before disassembly Before disassembly, make an accurate preliminary survey and make a note of the results. This will save unnecessary labour and component costs and will be useful to give advice to the user to prevent problems in the future.

In particularly: D Check the type and number of the machine and service meter reading.

D Check the reason for disassembly.

D Check the symptom, location and cause of the problem and make another visual check if necessary.

D Check the contamination of the air cleaner and air leakage.

D Check the characteristics of the fuel being used, contamination of the fuel filter and for any water in the fuel, loss of fuel, deformed pipes.

D Check the oil level, oil contamination (viscosity, colour and impurity) presence of water in the oil, oil leakage and clogged oil filter.

D Check the tension of the V belts; D Check for any faulty components or loosened connections.

Disassembly preparation To save unnecessary labour, make sure that the equipment, area and space on the shelves is available, according to the specific type of disassembly to be carried out, and clean the area beforehand.

D All units, especially those which look alike, should be placed in order and tagged or marked when necessary.

D Standard parts such as nuts and bolts are to be kept, noting the assembly position and the quantity.

D Shims and washers used to adjust clearances are to be kept so they can be re-assembled in the same conditions.

D During disassembly, carefully inspect for any seizure, interference or contact with moving parts to find the cause of the problem.

D When measuring, record all the values, such as end clearances, backlash or projection which only have significance if measured during disassembly.

D Keep the same adjustment values of the rods as far as possible. If it is necessary to disassemble adjustment devices, measure the length before disassembly and make a note of the value so as to be able to reassemble in the identical condition.

D If tapered or fitted parts that should fit tightly come off easily, inspect the parts involved to find the cause so that the same problem does not occur again when reassembling.

Figure 4

1730101

D Use an appropriate jig and do not try to force them.

During disassembly Removal of parts D Before removing parts, check the assembly conditions and front/rear, left/right and up/down relations and the removal procedures D Make sure there are the relevant mating marks indicating the mounting positions and if necessary mark clearly to avoid errors during reassembly.

D Use the special disassembly tools where specified.

D If it is difficult to remove a part even after the mounting screws have been removed, do not force it, but check the part to find where the problem lies.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

ADT 25

SECTION 1.1

CONDITIONS OF USEą11

After disassembly

Disconnecting hydraulic lines Operate each control lever several times to relieve any pressure in the lines to be removed.

Open the air bleeder cap of the hydraulic tank.

Figure 5

1730102

D To disconnect a rigid tube from another one, or a rigid tube from a hose, grasp the male end with a wrench and loosen the female nut side.

D Plug the end of the removed tube or hose and the oil port on the part, to prevent foreign matter from entering.

D Since the tube or hose to be removed contains oil, pour this off into a suitable container.

D Clean up any oil spills in the working area.

D Attach a tag with an appropriate marking to each tube, hose and hydraulic component line connection for easier reassembly.

When using detergents, make sure you fully understand the use instructions and take care not to bring them into contact with the eyes or skin. Dispose of used detergents correctly.

Cleaning D Clean the disassembled parts and arrange them in order. Completely remove sludge and dust from the oil ports of each part.

D To clean more efficiently, divide the detergent into two containers; one to remove the dirt and one for finishing. When cleaning more important parts, divide the containers further to avoid using dirty detergent.

D When cleaning large castings, such as the cylinder head or block, , immerse them in a container for 5 to 10 minutes with a pH 10-12 detergent, at a temperature of 50 °C and 70 °C (122Ą÷Ą158 °F), then rinse thoroughly.

Rust and dust prevention D Cover clean parts to avoid rusting.

D Place caps on the ends of tubes and hoses.

D If it will be some time before assembly, use rust inhibitor.

During assembly Installing the parts D Before starting to assemble, clean all the components and repair any damage. Dirt and dust have adverse effects on moving parts and can shorten the machine life, so take all precautions to limit their penetration.

D Before assembly, remove the layer of rust inhibitor if present on new parts.

D Parts with mating marks are to be mounted so that the marks are correctly aligned.

D Use a press and appropriate tools when installing bearings, bushings, oil gaskets etc. When mounting special parts, use the specific special tools.

D Coat the surface of press-fit parts with molybdenum disulphate grease or other specific lubricant, where prescribed.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

12ąCONDITIONS OF USE

SECTION 1.1

ADT 25

Connecting hydraulic lines D Clean all rigid tubes with a suitable detergent and blow dry with compressed air.

D Do not use coupling liquids (three components).

D When installing high pressure hoses, do not allow any torsion. Avoid that other parts interfere with the hoses if they have no protective spring.

D Install correctly, checking the tags on each rigid tube or hose and on hydraulic component connections.

Screw and nut tightening Figure 6

Figure 8

1730103

D Tighten nuts and bolts alternately so that average torque can be applied evenly. The numbers on the figure indicate the order of tightening.

D Unless indicated otherwise, apply lubricant to the threaded part of the bolts, so as to obtain even tightening.

Figure 7

1730105

1730104

a: b:

correct assembly incorrect assembly

D The nuts and bolts that cannot be inspected externally, or those for more important parts are to be installed and locked with an appropriate device to prevent loosening (lock wire, split pin, bent washer).

D Bolts on which a thread stop has been applied (residue can be seen when removed) are to be cleaned with light oil and dried before tightening.

Apply 2 or 3 drops of thread stop to the threaded part of the bolts, then tighten.

D When connecting the lines, slightly tighten the nuts at both ends, then tighten alternately.

D After completing the line connections, run the engine at low speed and from the operator's seat move each hydraulic component through the control levers. Make a further inspection then top up the oil in the hydraulic tank D Points such as end clearances, end plates, projections, steps and backlash that cannot be checked except during the assembly process, are to be checked and measured before passing on to the next step.

D Shims and washers used to adjust clearances are to be refitted in the same condition as they were before disassembly, unless worn or damaged.

D After reassembly, check the adjustment values.

D Assemble the linkage with the rod adjustment value identical to that before disassembly.

D If parts fitted by pressure are easily inserted, check the insertion dimensions again and correct any flaws before assembling.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

ADT 25

SECTION 1.1

Interchangeable parts

CONDITIONS OF USEą13

Figure 10

Gaskets D As a rule, replace all gaskets with new ones.

D Apply sealing liquid to the sealing gaskets of certain parts.

D Remove all flaws, dust, paint, oil or previously used seal liquids.

D Apply an even coating of the specified sealing liquid and allow to dry for a few minutes.

D When the liquid is dry to the touch, mate the gaskets.

O-rings D If the O-rings have become hardened after long storage, discard them even if they have never been used.

D Use only the O-rings indicated in the spare parts lists. For the engine, in particular, O-rings of special material, like silicone rubber are used for their resistance to heat and deterioration. Do not use substitutes.

D Before installation, apply a coating of oil to the O-ring to prevent cracking. Silicone rubber tears easily and must therefore be handled with care.

Oil seal gaskets (oil seal rings) Figure 9

1730107

D When assembling oil seal gaskets, apply some grease to prevent initial dry friction. a.

b.

Single lip type oil seal gasket Apply the grease evenly over the entire external border of the side opposite to the sealing part of the lip (arrow), taking care that there is no build up.

Double lip type oil seal gasket Apply grease to 40-60% of the external border of the section between the lips (arrow).

D Make sure that the contact surface (shaft area) of the oil seal gasket is free of dust, cracks or rust and apply lubricant to facilitate the installation.

Figure 11

1730106

A: B: a: b.

inner side (possible pressure) outer side main lip (seal) dust protection lip

D Pay attention to the direction of the oil seal gasket lips.

D Take care that no dust settles on the oil seal gasket, and ascertain that there is no rust or cracking (especially on the lip surfaces).

1730108

D To install, use a guide and an assembly jig to avoid damaging the oil seal gasket lip.

D After inserting the oil seal gasket and pushing it into its seat, the gasket should have no inclination.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

14ąCONDITIONS OF USE

SECTION 1.1

D When an adhesive product is applied to the external part of the gasket, take care that none drops onto the lip surfaces. Since the adhesive remaining on the assembly tools could easily pass onto the lips, use clean guides and assembly jigs.

ADT 25

D Bearings to be mated with large interference values are to be inserted by shrink fitting. To avoid damaging the heat treatment hardening, keep the temperature below 120 °C (248 °F).

Figure 13

Bearings D Since dust adversely affects bearing wear, when disassembling and reassembling, care must be taken to protect them from dust.

D Handle the bearings with care when cleaning and do not allow them to spin in compressed air.

D When installing, do not knock on the bearing inner or outer ring, as this could cause indentations on the rolling surfaces.

Figure 12 1730110

D Non-separating bearings that require interference on both inner and outer rings are to be inserted using an appropriate assembly jig.

Snap rings (seeger rings) D To insert and remove snap rings, use snap ring pliers taking care not to widen excessively.

D After installation, make sure the snap rings are completely fitted into their groove.

1730109

D If interference is required on the inner ring, push it in using an appropriate assembly jig.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

ADT 25

SECTION 1.1

Welding on the chassis Before starting these operations, disconnect the negative terminal of the battery and connect the welder earth directly onto the piece to be welded.

Work on plastic tubes is only to be carried out by skilled experts, using the appropriate equipment and performed with perfect workmanship.

CONDITIONS OF USEą15

D turn over and weld as specified in the previous step; allow the side members to cool slowly and evenly; do not use jets of air or other methods, immediately remove excess material by grinding; Figure 15

Figure 14

1730112

1730111

Remove the paint and any oxidation from the parts to be welded. On the yield point, on the internal part of the side member and along the entire length of the part involved, make a 60° chamfer.

Cuts on the side member are not allowed that correspond to the stress variation zones, furthermore the line of separation is not to involve the existing holes on the side member.

The operating instructions for correct welding follow below: D heat all around the zone to be welded; make the arc welding passing several times using carefully dried basic tips , or MIG-MAG procedures with a suitable filling material; avoid current overloads; the welding is to be free of border incisions and spatter;

A = 0.3 H B = H .175 mm (7 in) S = (0.8 ć 1) S1 D apply internal corner reinforcements in steel having the same characteristics as the chassis (minimum indicative dimensions are shown on the figure); D they should be fixed only to the vertical rib of the side member and welding beads can be used. The section and length of the weld bead is to be adequate to transmit the section bending and cutting moments.

D After welding the part involved is to be efficiently protected with a rust inhibitor.

For the personnel and vehicle safety, read carefully the SAFETY INSTRUCTIONS contained in this handbook

16ąCONDITIONS OF USE

SECTION 1.1

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ADT 25

SECTION 1.2 SAFETY INSTRUCTIONS

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