Every 1000 hours

ENGINE:

17. FUEL FILTERS - Replace filters Open the left side panel of the engine compartment.

WARNING

Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, nonflammable, non-toxic commercial solvents. When using compressed air for cleaning parts, use safety glasses with side shields or goggles, so as to reduce the danger for personal injuries cause by flying particles. Limit pressure to 2 bar, in accordance with local and national regulations.

Clean the base of the support and the surrounding area. Loosen the filters indicated in the figure. Clean with a dry rag the support area contacting the filter gaskets.

Replace gaskets "1" fill the new filters with fresh fuel and smear a film of engine oil on the gasket, and tighten them against the support. Then, turn 1/2 turn further. 1

18-19. TORQUE CONVERTER/TRANSMISSION Changing the oil and cleaning the suction filters

D255-2M051 WARNING

AVOID POLLUTING THE ENVIRONMENT. Dispose of batteries, lubricating, cooling and hydraulic fluids, filter elements or cleaning rags impregnated with these fluids in accordance with national and local regulations, classifying these materials as polluting, hazardous or dangerous.

With the transmission oil hot, remove the cover as indicated and remove the plug underneath, draining the oil. To facilitate the draining, remove plug C.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

WARNING

Always wear safety glasses with side shields when using compressed air to clean parts, so as to minimize the danger of personal injuries caused by flying particles. Limit the pressure to 2 bar, in accordance with local or national regulations.

Never use gasoline, solvents or other inflammable fluids to clean parts. Use approved commercial solvents which are non-flammable and atoxic.

Clean accurately the area around the filters. With machine on flat ground, remove plug S and drain the oil. To facilitate the draining, remove the filler plug. Disconnect the oil suction piping from flanges M and N, loosen screws P and T and remove the flanges. Than, remove filters A and R, their gaskets and the O-ring on flange M. WARNING

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

After reinstalling the draining plug, refill the group through the filler shown up to the level marked on the dipstick incorporated with plug C. Start the engine, run it at idle for a few minutes; actuate a few times the gearshift lever. Stop the engine and, after a few minutes, top-up the oil level in the system, checking the dipstick on plug C.

P M A

C

D255-2M085

S

T R N

L. 559

Clean the filters, magnetic rod and covers with a brush and solvent and dry with compressed air, than reassemble all components and connect the pipings.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

ENGINE:

20. FUEL INJECTORS -

Calibrate setting of injectors

DANGER

Keep hands away from the tip of injectors, when checking efficiency. Fine sprayed fuel under pressure could penetrate the skin and cause blood poisoning. Also, when checking the efficiency of injectors, wear safety glasses with side shields.

Have the injectors checked by a Service specialised shop.

21. VALVE CLEARANCE -

Check valve clearance, with cold engine

Have the clearance between engine valves and rocker arms checked by specialised personnel. The adjustment of the valve clearance must be done with cold engine.

Valve clearance -Intake ....................................................0.30 mm -Exhaust .................................................0.60 mm 22. BEVEL GEAR - STEERING CLUTCHES/

BRAKES - Change oil

WARNING

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

WARNING

AVOID POLLUTING THE ENVIRONMENT. Dispose of batteries, lubricating, cooling and hydraulic fluids, filter elements or cleaning rags impregnated with these fluids in accordance with national and local regulations, classifying these materials as polluting, hazardous or dangerous.

Never use gasoline, solvents or other inflammable fluids to clean parts. Use approved commercial solvents which are non-flammable and atoxic.

With oil hot, remove the plug indicated and drain completely the oil. Reinstall the plug after cleaning it carefully.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

Fill with oil through the filler up to the prescribed level, indicated by a mark on the dipstick on the plug.

D255-2M080

Start the engine and let it run at about 1000 rpm. Actuate the steering clutch levers a few times. Stop the engine and after a few minutes check and if necessary add oil. 23. BEVEL GEAR AND STEERING CLUTCHES/

BRAKES - Change oil filter on suction line.

WARNING

Be careful when operating with the cowling open and hot engine to avoid eventual burns.

AVOID POLLUTING THE ENVIRONMENT. Dispose of batteries, lubricating, cooling and hydraulic fluids, filter elements or cleaning rags impregnated with these fluids in accordance with national and local regulations, classifying these materials as polluting, hazardous or dangerous.

Clean accurately the area around the filter. Remove the filter cartridge indicated from its support using the chain wrench provided. Prior to the installation of the new filter, oil the gasket. After the gasket contacts the support, tighten further 3/4 turn.

D255-2M052

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

24. SIDE FINAL DRIVES - Change oil

WARNING

AVOID POLLUTING THE ENVIRONMENT. Dispose of batteries, lubricating, cooling and hydraulic fluids, filter elements or cleaning rags impregnated with these fluids in accordance with national and local regulations, classifying these materials as polluting, hazardous or dangerous.

Unscrew lower plug B (one to each case) and allow oil to drain out completely. Re-fit drain plug, pour in new oil through filler A. Repeat the operation on the other one. 25. DRIVE SHAFT - Lubricate To perform this operation, it is preferable to lift the cab to facilitate the access to the drive shaft located between torque converter and transmission. Inject grease (3 or 4 shots) in each fitting on universal joint spiders.

Note – Perform this operation more frequently if machine is used under extreme dust conditions.

1

3 1

4

2 3 4

L. 563

1. Grease fittings - 2. Drive shaft - 3. Spiders 4. Screws

A

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

26. BATTERIES - Check electrolyte level

WARNING

Batteries contain "Sulfuric Acid". Shield your eyes when working near the battery to protect against possible spilling of the acid solution. In case of acid contact with skin, eyes or clothing, "FLUSH IMMEDIATELY WITH WATER FOR A MINIMUM OF 15 MINUTES". Get medical attention immediately. Be sure to connect booster cables for the proper terminal, (+ with +) and (- with -) at both ends. Avoid shorting cable clamps. FLAMMABLES VAPORS. Extinguish all smoking materials or open flames before checking and filling batteries due to the presence of flammable gases. Do not check battery by sparking.

Check electrolyte level: it must reach reference mark on battery side panel. To make up level add distilled water. Caution To maintain batteries in efficient condition follow instructions: - Do not leave lights on for extended periods when engine is off or idling. - To prevent running down the batteries, idle the engine rather than shutting it off if the machine is to be stopped for a short period. - Make sure that cable terminals are properly secured to battery posts and are covered with a thin layer of petroleum jelly. - Keep batteries clean, especially on top. - Disconnect ground cable before touching terminals.

To avoid possible damages to the electrical system: - do not mismatch the terminal connection on batteries; - do not let the engine run when batteries are disconnected; - if batteries are partially discharged and auxiliary batteries are used to start engine, or in the event of battery charging through external sources, connect terminals of the same sign (+ to + and - to -).

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel

27. FAN-ALTERNATOR BELT - Check condition and sagging of belt, replace

WARNING

Do not inspect the tension or adjust belts with the engine running. Be particularly aware of fans. Do not place the head, body, limbs, feet or hands near belts or moving fans. Be particularly aware of blowing fans.

Open the right and left engine panels and inspect visually. Eventual crosswise cracks on the belt are acceptable. Crosswise cracks combind with longitudinal cracks, fraying, breakage points on the belt are not acceptable. In such a case, replace it.

Acceptable condition

Belt to be replaced

Measure the belt sag on the long span of the belt that under a pressure of a finger deflects a minimum of 9.5 mm and a maximum of 12.7 mm. A more accurate inspection can be done using a belt dynamometer located in the middle of the longest span of the belt. Under these circumstances, the tension limits must be included between a minimum of 36 daNm and a maximum of 49 daNm.

Inspection of belt tension

D255-2M048

Replacing a belt

Actuate the tensioner with a leverage and remove the belt. To install a new belt, place it on the fan and crankshaft pulleys, raise the tensioner and complete the turning of the belt, as illustrated. Also, check that the tensioner securing nut is tightened to a torque of 4.3 daNm.

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel