Fiat Hitachi TELEHANDLERS T13 T14 T17 Service Manual – PDF DOWNLOAD

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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.

Model T13 T14 T17 Notstab. stab. Notstab. stab. Notstab. stab. Engine 88kW(120CV) TurboAftercooler 88kW(120CV) TurboAftercooler 88kW(120CV) TurboAftercooler Max.liftheight 12,30 12,45 13,30 13,45 16,24 16,60 Max.capacity (at500 mmfromforkledge) 4000 4000 4000 4000 4000 4000 Capacityatmaximum height 3000 4000 2500 3500 2000 3000 Extensionatmax. height 1,40 1,23 1,70 0,85 2,70 1,80 Max.longitudinal extension 8,65 9,33 12,54 Capacityatmax. extension 600 1500 450 1350 0 600 Weight (kg) 10700 11340 12090
Servicemanual
TELESCOPICHANDLERS 604.02.395.00 --12--2002 GENERALLISTOFCONTENTS SECTION00--GENERAL Description Page .............................................................................. Generalinstructions 1 ........................................................................... Safetyrules 3 Productidentification 6 Environmentalconsiderations 9 ................................................................... Maintenancetechniques 10 Specialtools 14 SECTION10--ENGINE Description Page Engineidentificationcode 2 Enginemaincharacteristics 3 Generalcharacteristicsofengines 4 ............................................................... General 6 Descriptionofthemainmechanicalcomponentsoftheengine12 Lubrication 23 .................................................................................. Cooling 28 Turbocharging 30 Mechanicalinjectionsupply system31 Injectionassembly 33 Timinggeardrive 43 Injectionpumpsetting 44 Electricalcomponents 45 ......................................................................... Troubleshooting 46 .............................................................................. Tools 50 Assemblyclearancedata 55
T13--T14--T17
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Description Page Gearboxassembly 5 ............................................................................ Idlergearcaseassembly 7 ...................................................................... Gearboxoperation 8 ............................................................................. TransmissionandHydraulicoilcircuitdiagrams15 ................................................... Modulationvalveoperation 31 Torqueconverterandheatexchangerhydraulicoilcircuit34 Troubleshootingprocedures 37 Pressuretestingclutchandhighpressurecircuit38 Pressuretestingtorqueconverterandcoolercircuit39 Checkpoints 40 Assemblyinstructions 42 Overhaul 45 SECTION25--FRONTAXLE Description Page Specifications 1 Description 2 Operation 3 Troubleshooting 4 Wheeltoe--incheck 5 Componentoverhaul 5 Frontaxleremoval 6 Frontaxleoverhaul 7 Axledrivepinionbearingadjustment51 Bevelgearpinioninstallationandadjustment53 Frontdriveshaft 57
GENERALLISTOFCONTENTS
SECTION21--POWERSHIFTGEARBOX
GENERALLISTOFCONTENTS 5 604.02.395.00 --12--2002 SECTION27--REARAXLE Description Page Specifications 1 Description 2 Operationdiagram 3 ............................................................................ Componentoverhaul 5 Rearaxleremovalprocedure 5 Overhaul 6 ..................................................................................... SECTION33--BRAKES Description Page Powerbrakes 2 Parkingbrake 3 ................................................................................ Brakerelease 6 ................................................................................. Brakediscadjustment 6 Troubleshooting 7 ............................................................................... Brakediscreplacement 8 ........................................................................ SECTION35--HYDRAULICSYSTEM Description Page Technicaldata 2 Descriptionandoperation 3 ...................................................................... Steeringsystemhydrauliccircuit 4 Steeringvalve 5 Telescopicboomhydrauliccircuit 7 ................................................................ Componentoperation 13 Frontloadercontrols 17 Powersteering(OSPQ) 21 Telescopicboomdistributor 23 .................................................................... Auxiliarycontrolsdistributor 26 .................................................................... Cylinders 27 Boomremoval 37
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Description Page Electricalequipmentspecifications 1 ............................................................... Electricalsystemandfuse 2 ...................................................................... Controlsandinstruments 6 ....................................................................... Bulbreplacement 20 ............................................................................. Systemprecautionsforbatterychargingandwelding23 Startingthemachineusingjumpleads24 Temporarywiringrepair 25 Electricalsyst emgeneralfaultfinding27 Listofconnectors 31 Listofcomponents 32 Cablekey 34 Howtousethecircuitdiagrams 36 Circuit1:Starting/Recharge/Warninglights/Indicatorlights38 Circuit2:Transmission 40 Circuit3:Wheelalignment/Hydraulicsolenoids/Brakesystem42 Circuit4:Armcontrol 44 Circuit5:Stabiliser 46 Circuit6:Lights/Windscreenwiper48 .............................................................. Circuit7:Worklamps/Roofbeacon50 Circuit8:Tiltingpreventionsystem/Roofwiper52 Circuit9:Sound system heating/Electricsocket/Rooflamp54 Circuit10:Airconditioner 56
GENERALLISTOFCONTENTS
SECTION55--ELECTRICALSYSTEM

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.

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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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--12--2002
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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,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

SECTION00--GENERAL 3 604.02.395.00 --12--2002

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.

4 SECTION00--GENERAL
604.02.395.00 --12--2002

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.

SECTION00--GENERAL 5 604.02.395.00 --12--2002

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.

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TH001027 1
SERIALNO.OFVEHICLE YEAR TH001048 2
SERIALNO. DATECODE TH001029 3

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

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SERIALNO. DATECODE TH001030 1 4

IDENTIFICATIONPLATESINTHECAB

Thecabidentificationplatecontainsaseriesof furtherdetailsanditislocatedontheleftrearsideof theseat.Pleaserecordherebelowthedataindicated forfasterconsultationwhenrequired.

SERIALNO.

DATECODE

Thedatarelativetotheengineareindicatedonthe conformityplatesinstalledtogetherwiththeCab Plate.Pleaserecordherebelowtheserialnumber indicatedforfasterconsultationwhenrequired.

8 SECTION00--GENERAL 604.02.395.00 --12--2002
DATECODE 5
SERIALNO.

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 enginecooling systemorhydraulicsystem.

8.Donotincreasethepressureofanypressurised system,sincethiscouldcauseseriousproblems tothecomponentsofthesystem.

9.Protecthoseswhenperforminganywelding, sinceasplashofweldingmaterialscouldpenetrateandburnthem,causingaholeorweakeningthewallwithsubsequentleakagesofoil, coolantetc.

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GENERALNOTICES

MAINTENANCETECHNIQUES

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.

10 SECTION00--GENERAL 604.02.395.00 --12--2002

SPECIFICSEALINGCOMPOUNDS

Thefollowingsealingcompoundsmustbeused,complyingwiththeindicationsprovidedbytheManual:

SEALANTSCOMMERCIALNAME

AnaerobicsealantLOCTITE518(liquidgasket)

RTVsiliconsealantLOCTITESUPERFLEX593,595or596 LOCTITEULTRABLUE587DOWCORNINGSILASTIC 732GENERALELECTRICRTV103or108

PipesealantPST592(pipesealantwithteflon)

Lockingcompoundfor threads LOCTITE271/RED(sealant/lockingforthreads)

TIGHTENINGVALUESFORFASTENERS

Checkperiodicallythatthefastenersareproperly tightened.

Baseduponthetablestofollow,determinethecorrecttighteningtorquewhenpartsofthefastening componentsarechecked,adjustedorreplaced.

IMPORTANT:DONOTusethevalueslistedinthe tableswhentheManualindicatesadifferenttorque

ortighteningprocedureforaspecificapplication.The torquevaluesareprovidedforgeneraluseonly. Makesurethatthethreadsofthefastenersareclean andundamaged.

NOTE: useatorquewrenchtotightenfastenerscorrectly.

SECTION00--GENERAL 11 604.02.395.00 --12--2002

MINIMUMTIGTENINGTORQUESFORFASTENERS

INNEWTON--METRES(Nm) FORNORMALINSTALLATIONAPPLICATIONS

METRICBOLTSANDLOCKNUTS

IDENTIFICATION

HEXSCREWS(WITHOUTNUT)ANDROUNDHEADBOLTS CLASS5.6ANDHIGHER

IDENTIFICATIONOFTHEMANUFACTURER

HEXNUTSANDTIGHTENINGNUTS CLASS05ANDHIGHER

IDENTIFICATIONOFTHEMANUFACTURER

12 SECTION00--GENERAL 604.02.395.00 --12--2002 M41.72.22.63.43.74.81.8 M65.87.68.91213176.3 M814182228314015 M1028364356617930 M124963759710713853 M16121158186240266344131 M20237307375485519671265 M244115316488398971160458
CLASS5.8 CLASS8.8CLASS10.9 NOMINAL DIMENSION NOT PLATED PLATED Zn/Cr NOT PLATED NOT PLATED PLATED Zn/Cr PLATED Zn/Cr LOCKNUT CL8 withBOLT CL8.8 COMMERCIALCLASS MARKING COMMERCIALCLASS

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