T13 T14 T17 TELEHANDLERS ServiceManual
PrintN.604.02.395.00(XII--2002)
THISALERTSYMBOLSIGNALSIMPORTANTMESSAGESINVOLVINGYOURSAFETY.
Readandheedcarefullythesafetyinstructionslistedandfollowtheprecautionsrecommendedtoavoid potentialrisksandtosafeguardyourhealthandyoursafety.
YouwillfindthissymbolinthetextofthisManualreferredtothefollowingkeywords:
WARNING --Cautionsdirectedtoavoidimproperrepairinterventionsinvolvingpotentialconsequencesfor theoperator’ssafety.
DANGER --Thesewarningsqualifyspecificallypotentialdangersforthesafetyoftheoperatororother personsdirectlyorindirectlyinvolved.
IMPORTANTNOTICE
AllmaintenanceandrepairinterventionsexplainedinthisManual mustbeperformedexclusivelybytheService OrganizationoftheManufacturer,observingstrictlytheinstructions explainedusing,whenevernecessary,the recommendedspecifictools.
Whoeverperformstheoperationsreportedwithoutfollowingexactlytheprecautionsisresponsibleonhisown,for thedamagesthatmayresult.
NeithertheFactorynoranyOrganizationsinitsDistribut ionNetwork,includingbutnotlimitedtonational,regional orlocaldistributors,areresponsibleforanyliabilityarisingfromanydamageresultingfromdefectscausedbyparts and/orcomponentsnotapprovedbytheFactoryforuseinmaintainingand/orrepairingproductsmanufacturedor merchandizedbytheFactory.
Inanycase,nowarrantyofanykindismadeorshallbeimposedwithrespecttoproductsmanufacturedor merchandizedbytheFactory,whenfailuresarecaused bytheuseofpartsand/orcomponentsnotapprovedbythe Factory.
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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.
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.
NOTESONSPAREPARTS
Usegenuine sparepartsguaranteedbytheManufacturer only. Genuinesparepartsaretheonlyonesensuringthesamequality,thesamelifeandthesamesafetyasthe originallymountedparts,sincetheyarethesameastheonesinstalledinproduction. Onlygenuinepartsfromthemanufacturerensurethisguarantee. Ordersforsparepartsmustincludethefollowingindications:
--modelofthevehicle(commercialdesignation)andserialnumber;
--typeandnumberoftheengine;
--partnumberfortheitemordered,asprovidedbythe“Microfiches”orthe“SparePartCatalogue”,onwhich theorderisbased.
NOTESONTOOLING
ThetoolingthattheManufacturerrecommendsandillustratesinthisManualis:
--studiedanddesignedspecificallyforservicingvehiclesofthisrange;
--requiredtoensureareliablerepair;
--accuratelydevelopedandinspectedtoprovideeffectiveandlonglastingworking. Youarealsoremindedthatcorrecttoolingallowsyouto:
--tooperateunderoptimisedtechnicalconditions;
--toachievethebestresults;
--tosavetimeandeffort;
--toworkinsaferconditions.
WARNING
Thewearlimitsprovidedforsomeitemsmustbeconsideredasrecommendedvalues,butnotabsolutelybinding. Theindications“front”,“rear,“right”,“left”refertodifferentpartsasseenseatingfromintheoperator’sseat orientedinthenormaltraveldirectionofthevehicle.
HOWTOMOVEAVEHICLEWITHOUTBATTERIES
Thecablesoftheexternalpowersupplymustbeconnectedexclusivelytotherespectiveterminalsofthepositive andnegativecablesofthevehicle,usingefficientclampsprovidingadequateandsafecontact.Intheeventit isnecessarytochecktheoperationoftheelectricalsystemofthevehicle,doitexclusivelywiththepowersupply connected.Attheendoftheinspection,disconnectallactuatorsanddeactivatethepowersupplybefore disconnectingthecables.
SAFETYRULES
PAYATTENTIONTOTHISSYMBOL
Thisalertsymbolannouncesimportantmessagesinvolvingyoursafety. Readcarefullythesafetyinstructionslistedandfollowtheprecautionsrecommended toavoidpotentialrisksandtosafeguardyourhealthandyoursafety. YouwillfindthissymbolinthetextofthisManualwiththefollowingkeywords:
WARNING --Cautionsintendedtoavoidimproperrepairinterventionsinvolving potentialconsequencesforthesafetyofthepersonnelperformingtherepairs.
DANGER --Thesewarningsqualifyspecificallypotentialdangersforthesafetyofthe operatororotherpersonsdirectlyorindirectlyinvolved.
AVOIDACCIDENTS
Mostaccidents,whethertheyoccurinworkshop,on thefarm,athomeorontheroad,arecausedbythe failureofsomeindividualstofollowsimpleandfundamentalsafetyrulesandprecautions.ForthisreasonMOSTACCIDENTSCANBEPREVENTEDby recognisingtherealcauseanddoingsomething aboutitbeforetheaccidentoccurs.
Regardlessofthecareusedinthedesignandconstructionofanytypeofequipment,therearemany conditionsthatcannotbecompletelysafeguarded againstwithouthinderingreasonableaccessibility andefficientoperation.
Acarefuloperatoristhebestinsuranceagainstan accident.
Thecompleteobservanceofonesimplerulewould preventmanyseriousaccidents.
DANGER. Neverattempttoclean,lubricateormaintainamachinewhileitisinmotion.
SAFETYRULES SAFETYRULES
◊ Readandheedallsafetyrulesbeforeanyintervention.
◊ Donotwearrings,wristwatches,jewellery,and looseorhangingapparels,suchasties,torn clothing,scarves,unbuttonedorunzipped jacketsthatcancatchonmovingparts.Wear propersafetyequipmentasrecommendedfor thejob.Examples:hardhat,heavygloves,ear protection,safetyglassesorgoggles,reflector vests,respirator.Consultyouremployerforspecificsafetyequipmentrequirements.
◊ Donotperformanyserviceoperationonthe machinewithapersonseatedintheoperator’s compartment,unlessheisanauthorisedoperatorco--operatingintheoperationtobeperformed.
◊ Neverattempttooperatethemachineoritstools fromanypositionotherthanseatedintheoperator’sseat.
◊ Neverperformanyinterventiononthemachine withenginerunningunlessthisisprescribed.
◊ Cut--offtheengineandmakesurethatallpressuresinthehydraulicsystemsarereleased beforeremovingcaps,covers,valvesetc.
◊ Allserviceinterventionsmustbeperformedwith theutmostcareandattention.
◊ Shopand/orfieldserviceplatformsorladders mustbeconstructedandmaintainedinaccordancewithlocalandnationalregulations.
◊ Disconnectthebatteriesandtagallcontrolsto signalthataninterventionisinprogress.Block themachineandallequipmentthatmustbe lifted.
◊ Donotchecknorrefillfueltanks,aswellasbatteries,norusestartingfluidwhilesmokingor nearopenflamessincethesefluidsareflammable.
◊ Brakesareinactivewhenmanuallyreleasedfor serviceinterventions.Undersuchcircumstancesitisnecessarytomaintainthecontrolof themachineusingappropriateblocksorsimilar devices.
◊ Thefuel--fillingnozzlemustbekeptconstantly insidethefillingneck.Keepthiscontactfromthe beginningtotheendofthefuellingoperationto avoidthepossibilitythatsparksduetostatic electricityaregenerated.
◊ Useonlydesignatedtowingorattachingpoints. Usecareinmakingattachments.Makesurepins and/orlocksaresecurebeforepulling.Stayclear ofdrawbars,cablesorchainsunderload.
◊ Tomoveadisabledmachine,useatrailerora low--boy,ifavailable.
◊ Toload/unloadamachinefromtransporter, choosealevelsurfaceensuringfirmsupportto thewheelsoftruckortrailer.Anchorthemachine
securelytothebedoftruckortrailerandblock wheelsortrackswithappropriatewedges.
◊ Useonlyapprovedgroundedauxiliarypower sourcesforheaters,chargers,pumpsandsimilarequipmenttoreducethehazardsofelectrical shocks.
◊ Liftandhandleheavypartswithaliftingdevice ofpropercapacity.
◊ Bewareofbystanders.
◊ Neverpourgasolineordieselfuelintoopen, wideandlowcontainers.
◊ Neverusegasoline,solventorotherflammable fluidtocleanparts.Useexclusivelyqualified, non--flammable,non--toxiccommercialsolvents.
◊ Whenusingcompressedairforcleaningparts, usesafetyglasseswithsideshieldsorgoggles.
◊ Limitpressureto2.1bar,inaccordancewith localandnationalregulations.
◊ Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaust fumes.
◊ Donotsmokeorpermitanyopenflamesorspark nearwhenre--fuellingorhandlingflammable materials.
◊ Donotuseanopenflameasalightsourceto lookforleaksorforinspectionanywhereonthe machine.
◊ Movewithextremecarewhenworkingunderthe machine,itsattachmentsandoronornear them.Alwayswearprotectivesafetyequipment asrequired,suchashardhat,goggles,safety shoes,earplugs.
◊ Whenperformingoperationsrequiringrunningof theengine,haveaqualifiedoperatorintheoperator’sseatatalltimeswiththemechanicon sight.Placethetransmissioninneutralandset thebrakesandsafetylock.
◊ Forfieldservice,movemachinetolevelground, ifpossible,andblockit.Ifworkonaninclineis absolutelynecessary,firstblockmachineandits attachmentssecurely,thanmoveittolevel
groundassoonaspossiblewithacertainmargin ofsafety.
◊ Donottrustwornand/orkinkedchainsand cables:donotusethemforliftingorpullingoperations.Tohandlethem,alwaysuseheavy gloves.
◊ Besurechainsandcablesareanchoredandthe anchorpointsarestrongenoughtohandlethe expectedload.Keepexposedpersonnelclearof anchorpointsandcablesorchains.No bystandersareallowednearthehookingpoints, chainsorcables.
◊ Keeptheareawheremaintenanceoperations areperformedCLEANandDRY.Eliminate immediatelyallwaterandoilspillages.
◊ Donotpileupoilyorgreasyrags;theyrepresent afirehazard.Storeinaclosedmetalcontainer. Beforestartingmachine,check,adjustandlock theoperator’sseatformaximumcomfortand controlofthemachine.Besureexposed personnelintheareaofoperationareclearofthe machinebeforemovingitoritsattachments. Soundthehorn.
◊ Donotcarrylooseobjectsinpocketsthatmight fallunnoticedintoopencompartments.
◊ Wearproperprotectiveequipmentsuchas safetygogglesorsafetyglasseswithside shields,hardhat,safetyshoes,heavygloves whenmetalorotherparticlesareapttoflyorfall.
◊ Wearweldersprotectiveequipmentsuchas darksafetyglasses,helmets,protectiveclothing,glovesandsafetyshoes,whenweldingor burning.Weardarksafetyglassesnearwelding zones.DONOTLOOKATARCWITHOUT PROPEREYEPROTECTION.
◊ Steelcablesarefrayedafterprolongeduse; alwayswearappropriateprotections(heavy gloves,gogglesetc.).
◊ Handleallpartscarefully.Keephandsand fingersawayfromstructures,gearsormoving parts.Useandwearalwaystheappropriate protections,suchassafetygoggles,glovesand safetyshoes.
STARTING
◊ Donotruntheengineinclosedareaswithout 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.Ifinjuredbyescapingfluid,seeadoctoratonce.Seriousinfection orreactioncandevelopifpropermedicaltreatmentisnotadministeredimmediately.
◊ 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. Example:*ZEFK1740A00000000*.
NOTE: Theserialnumberandtheidentification numberofthecomponentscanberequestedbythe DealerwhenSparePartsareorderedorinterventionsarerequired.Thesenumbersarealsorequired ashelpinidentifyingthemachineintheeventoftheft. Keeptheminasafeplace.
VEHICLEIDENTIFICATIONPLATES
Thevehicleidentificationplateislocatedontheleft sideoftheseatlocation.Recordherebelowthedata foryourmachine. TECHNICALTYPE/MODEL
IDENTIFICATIONOFENGINE
Theidentificationdataoftheengineareontheleft sideoftheenginecylinderblock.Pleaserecordhere belowthesedataforeasierconsultation,when required. MODELNO.
IDENTIFICATIONOFFRONTAXLE
Theserialnumberandtheaxletypeareindicatedon plate(1)locatedonthefrontsideoftheaxlehousing. Pleaserecordherebelowthedataindicatedfor fasterconsultationwhenrequired.
AXLETYPE
SERIALNO.
DATECODE
IDENTIFICATIONOF4x3POWERSHIFT TRANSMISSION
Theserialnumberandthemodelareindicatedon plate(1)locatedonthelowersideofthetransmission.Pleaserecordherebelowthedataindicated forfasterconsultationwhenrequired. MODELNO.
IDENTIFICATIONOFREAR TRANSMSSION
Theserialnumberisindicatedonplate(1)locatedon thelowersideofthereartransmission.Please recordherebelowthedataindicatedforfasterconsultationwhenrequired.
AXLETYPE
SERIALNO.
DATECODE
IDENTIFICATIONPLATESINTHECAB
Thecabidentificationplatecontainsaseriesof furtherdetailsanditislocatedontheleftrearsideof theseat.Pleaserecordherebelowthedataindicated forfasterconsultationwhenrequired.
SERIALNO.
DATECODE
Thedatarelativetotheengineareindicatedonthe conformityplatesinstalledtogetherwiththeCab Plate.Pleaserecordherebelowtheserialnumber indicatedforfasterconsultationwhenrequired.

