DOWNLOAD PDF Fiatallis FD40 Crawler Tractor Service Manual FN 73149519

...

,.,."

~~

IIIF. . . .

-IATALLIS® FD40 Crawler Tractor

SERVICE MANUAL CAB

~---

FORM 73149519

9/85

AVOID ACCIDENTS Most aCCidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the faIlure of some indMdual to follow simple and fundamental safety rules or precautrons. For thIs reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the real cause and doing something about it before the accident occurs.

Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and effrcient operation.

A careful operator is the best insurance against an accident The complete observance of one simple rule would prevent many thousand serious injuries each year.

That rule is:

Never attempt to clean, oil or adjust a machine whffe it is in motion.

WARNING On machines having hydraulically, mechanically, and/or cable controlled equipment (such as shovels, loaders, dozers, scrapers, etc.) be cartain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have tha hydrauUcaUy, mechanically, and/or cable controlled equipment partially or fully raised to gain access to certain items, be sure the equipment Is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical devices used for controlling the equipment.

CALIFORNIA

Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

COPYRIGHT BYFIATALLIS

• All rights reserved. Reproductron o.f text and tnustratJons in whole or in part, is strictly prohibited.

FD40 Crawler Tractor SERVICE MANUAL CAB

SIN

89A03001-UP

Form 73149519

English

A WARNING

STUDY THE OPERATION AND MAINTENANCE INSTRUCTION MANUAL THROUGH BEFORE STARTING. OPERATING, MAINTAINING, FUELING OR SERVICING THIS MACHINE.

A A A

The Operation and Maintenance Instruction Manual provides the instructions and procedures for starting, operating. maintaining, fueling, shutdown and servicing that are necessary for properly conducting the procedures for overhaul of the related components outlined in this Service Manual.

This symbol is your safety alert sign. It MEANS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. Read and heed all safety instructions carrying the signal words WARNING and DANGER. Machine mounted safety signs have been color coded yellow with black borders and lettering for warning and red with white borders and lettering for danger points.

TABLE OF CONTENTS

TOPIC

TiTlE

PAGE

SAFETY RULES FOREWORD ~-----------------------------

VI

1

GENERAL DESCRIPTION ------------~---------­

1

2

TILTING CAB ---------------------- - - - - - - - - - -

3

3

CAB ACCESSORIES - - - - - - - - - - - - - - - - - - - - - - - - - - -

12

4

SERVICES,SPECIFICATIONS AND CAPACITIES -------------------

14

5

ELECTRICAL SYSTEM ------------------------------

19

6

GLASS ------------------------------..._-------------------

21

7

INSULATION -------------------------------------------

22

8

AIR CONDITIONER ------------------------------------------

23

9

TILT CYLINDER ----------------------------------------

40

10

CAB ASSEMBLY REFERENCE ILLUSTRATIONS ------------------------

43

11

TORQUES AND ADJUSTMENTS ---------------------------

51

12

SERVICE TOOLS --------------------,.---------

53

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

73149519

GENERAL

SAFETY RULES

Study the Operation and Maintenance Instruction Manual before starting, operating, maintaining, fueling. or servicing machine.

Do not use machine to carry loose objects by means other than attachments for carrying such objects.

Read and heed all machine-mounted safety signs before slarting, operating . maintaining. fueling or servicing machine.

DO NOT CARRY RIDERS unless the machine is equipped for carrying people to reduce personal exposure to being thrown off.

Machine-mounted safety signs have been color coded yellow with black border and lettering for WARN ING and red with white border and lettering for DANGER points.

Do not operate machinery in a conditio(l of extreme fat ig ue or illness. Be especially careful towards the end of the shift.

Rol! Over Protective Structures are required on wheel loaders, dozer tractors, track type loaders, graders and scrapers by local or national requ ire ments . DO NOT operate this machine without a Roll over Protective Structure.

Never attempt to operate the machine or its tools from any position other than seated in the operator's seal. Keep head, body, limbs, hands and feet inside operator's compartment at all times to reduce exposure to hazards outside the operator's compartment.

Do not operate a machine withOut a fal li ng object protective structure (FOPS).

Do not allow unauthorized personnel to operate, service or maintain th is machine.

Do not operate this machine without a rear canopy screen when machine is equipped with rear mounted tow ing winch.

Always check work area for dangerous features. The following are examples of dangerous work areas: slopes. overhangs, timber, demolitions, fire , high wa lls. dropoff , backfills. rough terrain. ditches, ridges, excavations, heavy traffic, crowded parking, crowded maintenance and closed areas. Use extreme care when in areas such as these.

Seat belts are required to be provided with roll over protective structures or ro ll protection cabs by local or national regulations. Keep the safety belt fastened around you during operation.

Where noise exposure exceeds 90 dBA for 8 hours, wear authorized ear protective equipment per local or national requ irements that apply.

An operator must know the machine's capabilities. When working on slopes or near dropoffs be aJert to avoid loose or soft conditions that cou ld cause sudden tipping or loss of control.

Keep clutches and brakes on machine and attachments such as power control units, winches and master clutches adjusted according to Operation and Maintenance Instruction Manuals of the manufacturers at all times. DO NOT adjust machine with eng ine running except as specified.

Do not jump on or off machine. Keep two hands and one foot , or two feet and one hand , in contact with steps, grab ra ils and handles at all times.

Do not use controls or hoses as handholds when climbing on or off mach ine. Hoses and controls are movable and do not provide a solid support . Controls also may be inadvertently moved causing accidental machine or equipment movement.

Do not operate a machine with brakes out of adjustment. See the Operation and Maintenance Instruction Manual.

Move carefully when under, in or near machine or implements.

Wear req uired protective equipment, such as hard hat , safety glasses , safety shoes, ear protectors.

Keep operator's compartment, stepping pOints, grab-rails and handles clear of foreign objects, oi!, grease, mud or snow accumulation to min imize the danger of slipping or stumbling.

Clean mud or grease from shoes before attempting to mount or operate the mach ine.

TO move a disab led machine, use a trailer or low boy truck If available. If towing is necessary, provide warning signals as required by local rules and regulations and follow Operation and Maintenance Instruction Manual recommendations. Load and unload on a level area that gives full support to the trailer wheels. Use (amps of adequate strength, low angle and proper height. Keep trailer bed clean of clay, oil and all materials that become slippery. Tie machine down Securely to truck or trailer bed and block tracks (or wheels) as required by the carrier.

Be careful of slippery conditions on stepping points, hand rails, and on the ground. Wear safety boot s or shoes that have a high sli p resistant sole material.

For your personal protection, do not attempt to climb on or off machine while machine is in motion.

Never leave the machine unattended with the engine running.

To prevent entrapment in cabs or mounted enclosures, observe and know the mechanics of alternate exit routes.

Always lock up machine when leaving it unattended. Return keys to authorized security. Heed aU shutdown procedures of the Operation and Maintenance Instruction Manua l. Always set the parking brake when leaving the machine for any reason.

On mach ines equipped with suction radiator fans, be sure to periodically check all engine exhaust parts for leaks as exhaust gases are dangerous to the operator. Keep a vent open to outside air at at! times when operating within a closed cab.

Do not wear rings, wrist watches, jewelry, loose or hanging apparel. such as ties, torn clothing, scarves, unbuttoned, or unzipped jackets that can catch on moving parts. Wear proper safety equipment as authorized for the job. Examples: hard hats, safety shoes, heavy gloves, ear protectors. safety glasses or goggles, reflector vests, or respirators. Consult your employer for specif ic safety equipment requirements.

STARTING FLUID IS FLAMMABLE. Follow the recommendations as outlined in the Operation and Maintenance Instruction Manual and as marked on the containers. Store containers in COOl. well-ventilated place secure from unauthorized personnel. DO NOT PUNCTURE OR BURN CONTAINERS. Follow the recommendations of the manufacturer for storage and disposal.

Do not carry loose objects in pockets that might fall unnoticed into open compartments.

Wire rope develops steel slivers. Use authorized protective equipment such as heavy gloves, safety glasses when hand· fing.

I

SAFETY RULES OPERATION

When counterweights have been provided , do not work machine it they have been removed un less their equiva lent weight has been replaced. See the Operation and Maintenance Instruction Manual.

Before starting machine, check, adjust and lock the operator's seat for maximum comfort and control of the machine.

When operating a machine know what clearances will be encountered, overhead doors, wires, pipes, aisles, roadways; also the weight limitations of ground, floor, and ramps.

00 NOT STAAT OR OPERATE AN UNSAFE MACHINE Before working the machine, be sure that any unsafe condition has been satisfactorily remedied. Check brakes, steering and attachment controls before moving. Advise the proper maintenance authority of any malfunctioning part or system.

Be sure all protect ive guards or panels are in place, and aH safety devices provided are in place and in good operating condition.

Know bridge and culvert load nmits and do not exceed them.

Know machine's height, width, and weight. Use a signal person when Clearance is close. lines, util ity lines, Be sure that the exact location of sewers, overhead and buried power and other obstruc· tions or hazards are known. Such locations should be precise..

Iy marked by lhe proper authorities to reduce the riSk of accidents. Obtain shut·down or relocation o! any such facilities before starting work, if necessary.

Check instruments at start-up and frequently during operation.

Do not run the engine 01 this mach ine in closed areas without proper ventilation to remove deadly exhaust gases.

Be sure exposed personnel in the area of operation are clear of the machine before moving the machine or its attachments.

WALK COMPLETELY AROUND machine before mounting.

Sound hom. Obey flagman. safety signals and signs.

Be certain to comply with ali local, state, and federa l regula· tions regarding working in the vicinity of power lines.

When reading find out what condittons are likely to be me! . clearances, congestion, t ype of surface, etc. Be aware of fog, smoke or dust elements that obscure visibility.

Know the prinCiples of cross steering of crawler tractors. Read section in Operation and Maintenance Instruction Manual on cross steerrng.

When backing, always look to where the machine is to be moved. Be alert to the position of exposed personnel. 00 NOT OPERATE if exposed personnel enter the immediate work area.

Keep engine exhaust system and exhaust manifolds clear of combustible material. Equip machine with screens and guards when working under conditions of flying combustible materiaL

Never travel a machine on a iob site, in a congested area, or around people without a signal person to guide the operator.

If engine has a tendency to stall for any reason under road or idle, report this for adjustment to a proper maintenance authority immediately. Do not continue to operate machine un· til condit ion has been corrected.

In darkness, check area of operation carefully before moving in with machine. Use aU lights provided. Do not move into area of restricted visibility.

Never use bucket as a man· lit!.

Maintain clear vision of all areas of travel or work. Keep cab windows clean and repaired. Carry blade low for maximum visibility while traveting. Obta in and use fan blast deflectors where tractors are used as pusher tractors in tandem.

Use recommended bucket for machine and material loadabili· ty and heaping characteristics of material, terrain, and other pertinent job conditions.

Avoid abrupt starts and stops when transporting a loaded bucket.

Transport a loaded bucket with the bucket as far tipped back and in as Iowa position as possible fOf maximum visibility, stabimy, and safest transport of the machine. Carry it at a proper speed tor the load and ground conditions.

Inspect your seat belt webbing and hardware at least twice a year for signs of fraying, wear or other weakness that could lead to tailure.

Carry the bucket low when traveling with a load.

Use only des ignated towing or puWng attachment pOints. Use care in making attachment Se sure pins and locks as provided are secure before pulling. Stay clear of drawbars, cables or chains under load.

Maintain a safe distance from other machines. Previde sufficient clearance for ground and visibility conditions. Yield right· of·way to loaded machines.

AVOid going over obstacles such as rough terrain, rocks, logs, curbs, ditches, ridges, and raHroad tracks whenever possible.

When obstructions must be crossed, do so with extreme care at an angie if possible. Reduce speed· down-shift. Ease up to the breakover point· pass. Ihe balance pOint slowly on the obstruction and ease down on the other side.

When putting or lowing through a cable or chain, do flOt start suddenly at full throttle. Take up slack carefully. Guard against kinking chains or cables. Inspect carefully for flaws before USing. Do not purl through a kinked chain or cable due to the high stresses and possibility of failure of the kinked area. Aways wear heavy gloves when handHng chain or cable.

Cross gullies or ditches at an angle with reduced speed after insuring ground conditions wiH permit a safe traverse.

Be sure cables are anchored and the anchor pOint is strong enough to handle the expected load. Keep exposed personnel clear of anchor point and cable or chain. 00 NOT PULL OR TOW UNLESS OPERA TORS COMPARTMENTS OF MACHINES INVOLVED ARE PROPERLY GUARDED AGAINST POTENTIAL CABLE OR CHAIN BACKLASH.

Be alert to soft ground conditions close to newly constructed walls. The fill material and weight of machine may cause the wall to con apse under the machine.

Operale at speeds slow enough to insure complete control at at! times. Travel slowly over rough ground, on slopeS or near dropoffs, in congested areas or on ice or slippery surfaces.

During operat ion always carry fipper in full raised position when not in use and lower to ground when parked.

n

SAFETY RULES Be alert to avoid changes in traction conditions that could cause loss of control. DO NOT drive on ice or frozen ground conditions when working the machine on steep slopes or near dropoffs.

When stopping operation of the machl<:e for any reason, always return the transmission or hydrostatic ddve control to neutral and engage the control lock to secure the machine for a sale start up. Set parking brake, if so equipped.

Keep the machine wei! back from the edge of an excavation.

Never lower attachments or tools from any position other than seated in operator's seat Sound the horn. Make sure the area near the attachment is clear. Lower the attachment slowly. DO NOT USE float pOsition to lower hydraulic equipment

Be especial!y careful when traveling up or down slopes. Posi· tion the bucket in such a way as to provide a possible anchorage on the ground in case of a slide.

Always before leaving the operator's seat and after making certain all people are clear of the machine, slowly lower the attachments or tools flat to the ground in a positive ground support position. Move any multipurpose tool to positive closed position. Return the controls to hold. Place transmission control in neutral and move engine controls to off posi· tion. Engage all control locks, set parking brake, and open and lock the master (key, if so equipped) switch. Consult Operation and Maintenance Instruction Manual.

WhE'n proceeding across a hillside proceed slowly. Never turn sharply uphill or downhill, Avoid sldeh,1l travel whenever possible. Drive up and down the slope. Should the machine start slipping sideways on a grade, turn it immediately downhill.

In steep downhHI operation, do not aHow engine to overspeed.

Select proper gear before starting downgrade.

Always follow the shut·down instructions as outlined in the Operation and Maintenance Instruction Manual.

There is no substitute for good judgement when working on slopes.

MAINTENANCE

The grade of slope you should attempt will be limited by such factors as condition of the ground, load being handled, the type of machine, speed of mach ine and visibility.

Do no! perform any work on equipment that is no! authorized.

Follow the Maintenance or Service Manual Procedures.

NEVER COAST the machine down grades and slopes with the transmission in neutral on power shift maChines, or clutch ' disengaged on manuaHy shifted machines.

Machine should not be serviced with anyone in the operator's seat unless they are qualified to operate the machine and are assisting in the servicing.

To reduce the danger of an uncontrolled machine, choose a gear speed before proceeding down grade that will hold machine 10 proper speeds for conditions.

Shut off engine and disengage the Power Take·Off lever if so equipped before attempting adjustments or service.

Always tum the master switch (key switch if so equipped) to the off position before cleaning, repairing, or servicing and when parking machine to forestall unintended or unauthorized starting.

Operating in virgin rough terrain that includes previously mentioned hazards is called pioneering. Be sure you know how this is done. Danger from falling branches and upturning roots is acute in these areas.

Disconnect batteries and TAG all controls according to local or national requirements to warn that work is in progress. Block the machine and all attachments that must be raised per local or national requ irements.

When pushing over trees, the machine must be equipped with proper overhead guarding. Never anow a machine to climb up on the roo! structure particularly while the Iree is being fetled.

Use extreme care when pushing over any tree with dead branches.

Never lubricate, service or adjust a machine with the engine running, except as caUed for in the Operation and Maintenance Instruction Manuals. Do no! wear loose clothing or jewelry near moving parts.

AVOid brushpHes, togs or rocks. DO NOT DRIVE THE MACHINE ONTO BRUSHPILES, LOGS, LARGE ROCKS or other surface irregularities that break traction with the ground especially when on slopes or near dropoffs.

Do not run engine when refueling and use care if engine is hot due to the increased possibility of a fire if fuel is spilled.

Avoid operating equipment too close to an overhang or highwall either above or below the machine. Be on the lookout for caving edges. falling objects and slides. Beware of concealment by brush and undergrowth of these dangers.

Do not smoke or permit any open f lame or spark near when refueling, or handling highly flammable materials.

Always place the fuel nozzle against the side of the filler open· ing before starting and during fuel How. To reduce the chance of a static electricity spark, keep contact unW after fuel flow is shut ofL

Park in a non-operating and non·traffic area or as instructed.

Park on firm level ground if possible. Where not possible, posi· tion machine at a right angle to the slope, making sure there is no danger of uncontroHed sliding movement. Set the parking brake.

Do not adjust engine fuel pump when the machine is in motion.

Never park on an incline without carefully blocking the machine to prevent movement.

Never attempt to check or adjust fan belts when engine is running.

If parking in traffic lanes cannot be avoided, provide appropriate flags, barriers, flares and warn ing signals as required. Also provide advance warning Signals in the traffic lane for approaching traffic.

When making equipment checks that require running 01 the engine, have an operator in the operator's seat at all limes with the mechanic in sight Place the transmission in neutral and set the brakes and lock. KEEP HANDS AND CLOTHING AWAY FROM MOVING PARTS.

Move the machine away from pits, trenches, overhangs and overhead power lines before shutting down for the day.

III

SAFETY RULES Avoid running engine with open unprotected air inlets. If such running is unavoidable for service reasons, place protective screens over all inlet openings before servicing engine.

Do not remove hoses or check valves in the hydrauliC system without first removing load and relieving pressure on the support ing cylinders.

Do not place head, body, limbs, feet, fingers , or hands near rotating jan or belts. Be especially alert around a pusher fan.

Turn radiator cap slowly to relielle pressure betore removin g.

Add coolant only with engine stopped or idling jf hot. See Operation and Maintenance Instruction Manual.

Keep head, body, limbs, feet, hands, and fingers away from bucket, blade or ripper when in raised position.

Fluid escaping under pressure from a very small hole can almost be invisible and can have sufficient force to penetrate the skin. Use a piece of cardboard or wood to search for suspected pressure leaks. DO NOT USE'HANDS, If injured by escaping fluid, see a doctor at once. Serious infection or reac· lion can develop if proper med ical treatment is not administered immed iately.

If movement of an attachment by means of machine's hydraulic system or winches is required for service or maintenance, do not raise or lower attachments from any posi· tion other than when seated in the operator's seal. Before starting machine or moving attachments or tools, set brakes, sound horn and call for an all clear. Raise attachments slowly.

Never use any gas other than dry nit rogen to charge accumulators. See Operation and Maintenance In struct ion Manual.

Never place head, body, li mbs, fingers, feet or hands into an exposed portion between uncontrolled or unguarded scissor pOints of mach ine without first providing secure blocking.

When making pressure checks use the correct gauge for expected pressure. See the Operation and Maintenance Instruction Manual or Service Manuals for guidance.

Never align holes with fingers or hands - Use the proper aligning tool.

For fie ld service, move machine to level ground if possible and block machine. If work is absolutely necessary on an inc li ne, block machine and its attachments securely. Move the machine to level ground as soon as possible.

Disconnect batteries before work ing on electrical system or repair work of any kind .

Check for fuel or battery electrolyte leaks before starting service or maintenance work. Eliminate leaks before proceeding.

Brakes are inoperative when manually released for servicing.

Provision must be made to maintain control of the machine by blocking or other means.

BAITERY GAS lS HIGHLY FLAMMABLE. Leave battery box open to improve ventilation when charging batteries. Never check charge by placing metal objects across the posts. Keep sparks or open flame away from batteries. Do not smoke near battery to guard against the possibility of an accidental exploSion.

Block all wheels before bleeding or disconnecting any brake system lines and cylinders.

Never use makeshift jacks when adjusting track tenSion.

Follow the Undercarriage Service Manual.

Do not charge batteries in a closed area. Provide proper ventilation to guard aga inst an accidental explosion from an ac· cumu lation of exp losive gases given off in the charging pro· cess.

Know your jacking equipment and its capac ity. Be sure the jacking point used on the machine is appropriate for the load to be applied. Be sure the support of the jack at the machine and under the jack is appropriate and stable. Any equipment up on a jack is dangerous. Transfer load to appropriate blocking as a safety measure before proceeding with service or maintenance work according to local or national requirements.

Be sure to connect the booster cables to the proper terminals { + to + } and (- to - ) at both ends. AVOid shorting clamps.

Follow the Operation and Maintenance Instruction Manual procedure.

Due to the presence of f lammable fluid, never check or fill fuel tanks, storage batteries, or use starter fluid near lighted smok· ing materials or open f lame or sparks.

Always block with external support any linkage or part on machine that requires work under the raised linkage, parts, or machine per local or national requirements. Never allow anyone to walk under or be near unblocked raised equipment.

Avoid working or wafking under raised blocked equipment unless you are assured of your safety.

Rust inhi bitors are volatile and flammable. Prepare parts in well ventilated place. Keep open flame away . DO NOT SMOKE. Store containers in a cool well-ventilated place secured against unauthorized personnel.

DO NOT pile oily or greasy rags - they are a fire hazard. Store in a closed metal conta iner.

When servicing or maintenance requi res access to areas that cannot be reached from the ground, use a ladder or step plat· form that meels local or national requirements to reach the service point . If such ladders Of platforms are not availabfe, use the mach ine handholds and steps as provided. Perform all service or maintenance carefully.

Never use gaSOline or solvent or other Hammable fluid to clean parts. Use authorized commercial, non-flammable, non-toxic solvents.

ShOp or field service platforms and ladders used to maintain or service machinery should be constructed and maintained according to local or national requ irements.

Never place gaSO li ne or diesel fuel in an open pan.

Lift and handle all heavy parts with a lifting device of proper capacity. Be sure parts are supported by proper slings and hooks. Use lifting eyes if provided. Watch out for people in the vicinity.

Do not use an open flame as a light source to look for leaks or for inspection anywhere on the machine.

Shut off engine and be sure all pressure in system has been relieved before remov ing panels, housings, covers, and caps.

See Operat ion and Maintenance Instruction Manual.

IV

SAFETY RULES In liHi ng and handling heavy parts, slings must be of adequate strength for Ihe purpose intended and must be in good condl, tion.

WeaJ proper protective equipment such as safety goggles Of safety glasses with side shields. hard hat, safety shOes, heavy gloves when metal or other particles are apt to l1y or fal"

Handle all parts with extreme care. Keep hands and fingers from between parts. Wear authorized protective equipment such as safety glasses, heavy gloves, safety shoes.

Use only grounded auxiliary power source for heaters, chargers. pumps and simHar equipment to reduce the hazardS of electrical shock.

When using compressed air for cleaning parts use safely glasses with side shields Of goggles. Limit the pressure to 207 kPa (30psi) according to local or national requirements .

Keep maintenance area CLEAN and DRY. Remove waler or oil slicks immediately.

Remove sharp edges and burrs from reworked parts.

Wear welders protective equipment such as dark safety glasses, helmets, protective clothing. gloves and safety shOes when welding or burning, Wear dark safety glasses near welding. DO NOT LOOK AT ARC WITHOUT PROPER EYE PRO, TECTION .

8e sure al! mechanics tools are in good condition. DO NOT use tools with mushroomed heads Always wear safety grasses with side shields.

Do not strike hardened steel parts with anything other than a soft iron or non,ferrous hammer.

v

FOREWORD

Always furnish serial number jf making an inquiry to dealer or factory about this machine.

Many equipment owners employ the Dealer's Service Department for all work other than routine lubrication and minor service. This practice is encouraged, as our Dealers are well informed and equipped to render efficient service by factory trained mechanics.

This manual may not be reprinted or reproduced, either in whole or in part, without written permission of Fiatallis.

Illustrations show standard and optional items.

IMPORTANT

The information In this manual was current at the time of publication. It Is our policy to constantly improve our product and to make available additional optional items.

These changes may affect procedures outlined in this manual. If variances are observed, verify the information through your Dealer,

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

VI

TOPIC 1 GENERAL DESCRIPTION

FIG. 1 CAB MOUNTED ON TRACTOR T-85139

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

1

73149519

TOPIC 1 GENERAL DESCRIPTION

1.1 GENERAL INFORMATION The cab consists of ROPS (roll-over protective structure) designed into the cab, cab heater,wind~ shield defroster, windshield wiper, windshield washer , air filter, cab pressurizer and recirculation system, electrical circuit breakers, dome light, tinted, laminated safety glass and insulation. Early units have hinged and adjustable side windows. late units have sliding rear window. The cab is equipped with door locks. The cab may be equipped with an air conditioner as optionat equipment The pressurizer and recirculation system conSists of serviceable filter element, pressure blower and three speed control switch. An air recirculator is buitt into this system.

1.2

FIG.2 SERIAL NUMBER LOCATION T-35140

When major repairs to transmission, torque converter, steering clutches, bevel gear and brakes or removal of fuel tank is necessary. the cab must be tilted or removed. The only recommended method of tilting the; cab is by means of a speCial cab tilt cylinder, consisting ' of a cylinder and holding valve,obtainable from your FiataUis dealer. If the cab is to be removed. a hoist with .

2275 kg (5000 Ibs) capacity will be required.

Study SAFETY RULES in the front of this manual thorough ly for the protection of machine and safety of personnel.

2 73149519

TOPIC 2 TilTING CAB

A WARNING

If engine is to be started indoors, proper ventilation to remove deadly gases.

insure

A WARNING Warn all people working around engine.

who may be servicing or machine before starting

A WARNING Sound horn before starting.

A WARNING

Never leave machine unattended with engine running.

it. WARNING Always turn the master switch to the position before cleaning, repairing servicing the unit to prevent injury.

off or FIG.4 ENGINE COMPARTMENT RIGHT SIDE PLATES

2.1 GENERAL

T-85141

1.Valve compartment cover 2.Engine compartment upper plate (special equipment) 3.Englne compartment lower plate(specia! equipment) Lower dozer and ripper to surface. Ripper teeth should · be in lowest pin hole to provide safe clearance when cab is tilted on rest It is not necessary to discharge the air conditioner system.

2.2 PREPARATION

2.2.1 Open the filter compartment access cover, Fig.3and: turn electrical master switch to the ~OFP position.

Leave cover open.

FIG.3 MASTER SWITCH LOCATION T-83112

A WARNING THE MACHINE MUST BE LOCATED ON ,A LEVEL AREA AND WITH SUFFICIENT HEIGHT TO PERMIT TILTING OF CAB WITHOUT ANY INTERFERENCE. DO NOT MOVE MACHINE · WITH CAB IN TILTED POSITION.

Park tractor on a level area. Tractor requires a height clearance of 5.5 m (18') (plus requirement for hoist and safety chain) to permit tilting of cab without any interference.

2.2.2 Unlatch and open left side plates, Fig.S, of engine . compartment (If so equipped).

2.2.3 Unlatch and open right side plates, FigA, of engine compartment (if so equipped).

2.2.4 Refer to Fig.S and remove the right and left !owerfiller plates (5) from support.

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

3

73149519

TOPIC 2 TILTING CAB

FIG.5 ENGINE COMPARTMENT LEFT SIDE PLATES AND CAB MOUNTING BRACKET T-S5142

FiG.S HOOD SUPPORT AND FILLER STRIp ·

1. Engine compartment lower plate (special equipment 2.Cab mounting bracket . 3.Engine compartment upper plate (special equipment) 4. Filter compartment cover

T-85143

2.2.5 Refer to Fig.6 and remove the support to cab fHler strip (1) and the rubber seal (2). · 2.2.6 Refer to Fig.7, and close heater hose valves below the · water pump inlet elbow and at the engine water manifold (top right front) .

2.2.7 Refer to Fig.S (4) and disconnect the main electrical cable (orange), air conditioner magnetic clutch cable (light blue) and rear flood light cable (dark blue) at lower left front side of cab. ~ )

2.2.8

v

Disconnect windshield washer hose from front of cab, Fig.S (3). · 2.2.9 Refer to Fig.S and disconnect the two air conditioner to compressor hoses (5) making certain hose connectors are covered and protected against dirt or damage.

1. Filler strip 2.Rubber seal 3.Windshield washer reservoir access plate.

4.Hood support 5.Finer plates 2.2.10 Refer to Fig.S and remove the heater hose clamps and heater hoses from connections (1 and 2).

2 .2.11 Refer to Fig.4; open access cover (1).

2.2.12 loosen jam nut under decelerator pedal, Fig.S (2), .and remove decelerator pedal. Remove brake pedal foot pads (3).

2.2.13 Remove foot rest and plate, Fig.11 (5), brake pedal plate (2) and decelerator pedal plate (4).

2.2.14 Remove small vertical floor mat retaining plate below dozer control console. Fig.1 O. 2.2.15 Remove the floor mat, Fig.11 (7). Remove the centrand left floor plates (3,1).

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

4

73149519

TOPIC 2 TilTING CAB

FIG. 9 FOOT CONTROLS T-79254

1. Foot rest bracket

FIG.7 HEATER SHUT OFF VALVES SIDE T-80246

*

2.Decelerator pedal 3. Brake foot pad

RIGHT

2.2.17 Remove knob,Fig. 13 (1) from dozer control rod (6).

Remove capscrews (4) and remove boot from console.

1.Heater outlet valve 2.Heater inlet valve

2.2.18 loosen jam nut (5) at bottom of dozer control rod(S) and ~ remove control rod from lever (7).

2.2.19 If tractor is equipped with ripper, refer to Flg.14 and remove yoke pin (4) by reaching through the dozer rod opening. Disconnect ripper pitch control rod (if so equipped) 2.2.20 Remove the vertical trim strip located to left of seat and against the control tower, Fig.15

5

' - - - - FIG.S DISCONNECT POlNTS _ _- - J T-79621 i .Return hose (to water pump) 2.lnlet hose (to water manifold) 3.Windshield washer hose 4.Electrical cable connections 5.Compressor refrigerant hoses 2.2.16 Refer to fig.12 and remove the instrument panel attaching capscrews (3). Push panel assembly forward ' as far as possible and secure with tiewire.

NOTE: Since electrical master switch is in "OFF" position no concern for shorts is necessary; however, 00 NOT damage instrument lugs or tubing on rear side of panel.

FIG.10 FLOOR MAT RETAINING PLATE

in the front of this manual thoroughly for the protection of machine and safety of personnel.

5

73149519

TOPIC 2 TILTING CAB

FIG.12 INSTRUMENT PANEL

T-82445 i .Dash light 3.Capscrew 2Jnstrument panel 2.2.21 'Refer to Fig.16 and remove the cab front right and left mounting bracket to tractor attaching capscrews.

'Each bracket has four 1" capscrews: the right front 'bracket has one additional. 75" capscrew. ~--- FIG.'!''!' FLOOR MATS - - - --,

'NOTE: Do not remove cab-to-mounUng-bracket- capscrew that goes through rubber bushing because it is difficult to reassemble without damage to rubber bushing.

T-796i5

I.Left floor plate 2.Brake pedal plate 3.Center floor plate 4. Decelerator pedal plate 5.Foot rest plate 6. Right floor plate 7. Floor mat

2.2.22 ·Refer to Fig.16; loosen the four tilt cylinder bracket capscrews so that bracket (4) can be aligned when installing tilt cylinder. Remove safety lock from rest bracket (right rear). ,2.2.23 Position tilt cylinder in lower tilt cylinder bracket with valve outward, Fig. 18; install pin (4) and secure with Clip. Position cylinder rod in upper cab bracket and secure with pin and clip. Tighten the four lower tilt bracket capscrews to 575Nm (425 Ibs. ft).

NOTE: It maybe necessary to use the hydraulic. pump assembly to extend the tilt cylinder rod to align to the cab upper bracket.

IMPORTANT: Before using the pump assembly check the fluid level in the pump reservoir; add oil if necessary. Make certain the tilt cylinder valves are known to be properly adjusted (see Topic 9), before attempting to raise the cab.

Study SAFETY RULES in the front of this manual thorough~y for the protection of machine and safety of personnel.

6

73149519

TOPIC 2 TILTING CAB 2.2.24 Hest the hydraulic pump on left rear of the track assembly . Refer 10 Fig.18 and attach upper pump hose to upper cylinder valve coupling. Connect the lower pump hose to lower valve coupling.Make certain couplings are secure

4

2.3 TilTING CAB BACK ON REST BRACKET

5

2.3.1.

Its is advisable to review 2.2 to make certain that cab isproper!y prepared for tilting, to prevent damage or interference. Remove all loose objects from cab.

Remove safety lock from rest bracket,Fig.21 (2) .

7

2.3.2 Make certain cab doors are closed and latched and battery and valve compartment access doors (left and right) are open.

' - - --

FIG. 13 DOZER CONTROLS - - - - - '

2.3.3 For maximum protection it is recommended that a 2275 Kg (5000 lb.) capacity hOist and safety chain be used along with tilt cylinder. Install safety chain on cab front bracket,Fig.16 {1} and while raising the cab with tilt clinder ,keep slack from safety chain . When cab tilts over -center allow slack in safety chain to prevent over-loading of tilt cylinder.

T-79569 5. Jam nut 6. Dozer control rod 7. lever

1.Knob 2.Clamp 3.8oot 4.Capscrew

A WARNING

Lift and handle all heavy parts with a lifting device of proper capacity. Be sure parts are supported by proper slings and hooks.

Use lifting eyes if provided. Watch out for people in the vincinity .

.4

3

" ' - - - - FIG.14 RIPPER CONTROtS 1.Valve assembly 2 Pitch lever 3. lift lever 4. Pin w I cotter pin

---...I

T-79871 5.lift control lever 6. Pitch control lever 7.Seat support

in the front of this manual thorougft)v for the protection of machine and safety of personneL

7

73149519

TOPIC 2 TilTING CAB

FIG.16 CAB BRACKETS T-85146

FIG.15 CONTROL TOWER TRIM STRIP T-85145

i.Safety chain bracket (use when tilting cab).

2.Ufting bracket (use when removing cab) .

3. Uppertitt cylinder bracket .

4 . Lower tift cylinder bracket 5.Rear mounting brackets.

6. Front mounting brackets.

IMPORTANT: Before tilting the cab, check to make certain there are no interferences, leaks in hydraulic pump hoses or tilt cylinder,and that pump hose are properly connected, Fig.iS.

A WARNING

Use only grounded auxiliary power source for heater, chargers, pumps and similar equipment to reduce the hazard of electrical shock.

2.3.4 Attach electric power supply cable to hydraulic pump making certain pump operating voltage is the same as the power supply voltage. Observe for any irregularities while tilting the cab.

FIG.17 CAB TILT CYLINDER T-79624

2.3.5 Tilt the cab with titt dinder carefully and continuously (observing safety chain slack) until cab just contacts block on right rear mounting bracket Fig.21 (1) then release pump control switch. Use care to prevent excess load on tilt c!inder and bracket.

2.3.6 With the cab resting on block welded to right rear mounting bracket , secure cab with safety lock and capscrew and nut , Fig. 21 (2).

.. 1.Tilt cylinder .. 2.Pins w! clip ., 3.Tube

* 4.valve assembly

• See Service Too!s

2.3.7 in order to clear the track assembly and to prevent possible damage to the hose assembly during work • remove the pump and hoses from the tilt cylinder as follows:

A WARNING

2.3.7.1 Disconnect the electric power supply cable from the pump.

When cab is tilted do not remove tilt cylinder.Use safety lock as provided to .' secure cab in the tilted position. Do not substitute other devices.Secure safety lock to the machine immediately after use to prevent loss.

2.3.7.2 Remove the pump hoses from the tilt cylinder valve.

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

8

73149519

TOPIC 2 TILTING CAB

2.3.7.3 Remove pump and hose assembly from tractor.

A

WARNING

Use only grounded auxiliary power source for heaters, chargers, pumps,and similar eqUipment to reduce the hazard of electrical shock.

NOTE: If it becomes necessary to start the engine for service with cab tilted, do not turn the electrical master switch to the ON position without first protecting the instrument panel against possible electric shorting. Do not move machine with cab in ti ~ position.

2.4.3 Connect the electrical power supply cable to the hydraulic pump making certain pump operating voltage is the same as the power supply voltage.

2.4 TILTING CAB DOWN IN POSITION

2.4.1 Refer to Fig. 18 .Connect upper pump hose to upper cylinder valve coupling. Connect lower pump hose to lower valve coupling.

2.4.2 Take up all slack in safety chain-When cab tilts overcenter, allow slack in safety chain to prevent overloading of tilt cylinder (refer to 2.3.3 and Fig. 1 {5). Remove the safety lock. Fig.21 (2).

a

FIG. 19 CAB BEING TILTED (21*C shown FD 40 similar) T-79626

2.4.4 Make certain master switch is in "OFF" position and the instrument panel pushed forward and secured with t ie-wire. Remove tools and loose objects from tractor.Clean the cab bracket and pad mounting surfaces. When operating hydraulic pump, observe for any irregularities while tilting the cab.

2.4.5

FIG.18 CAB TILT CYUNDER AND INSTALLED (21-C shown;FD 40 Similar) T-79625 *1. Hydraulic pump 2.Tilt cylinder bracket '"3Tilt cylinder and valve *4.Pinsw/clip .. 5.Safety chain 6. Bracket "See Service Tools

.Raise the cab smoothly and continuously taking up 'the slack on safety chain, Fig. 18 (5) as the cab raises.

When cab is over -center keep slack in safety chain until cab is resting lightly on mounting bracket pads.

Allow the tilt cylinder to bear the weight of the cab until mounting bracket capscrew holes are aligned on pad holes, then rest cab on mounting brackets.

Start capscrews in mounting brackets.

PUMP

2.4.6 Remove safety chain from top of cab; remove the tilt cylinder upper clip and pin. Retract the piston rod in tilt cylinder and disconnect the pump hoses from tilt cylinder valve,Fig 18 (3) . Remove tilt cylinder lower pin and clip and remove cylinder assembly from bracket

in the f ront of this manual thoroughly for the protection of m achine and safety of personnel.

9

73149519

TOPIC 2 TilTING CAB 2.4.7 Remove electrical power supply cable from pump and set pump aside .Secure cab safety lock on right rear post of cab,Fig. 21 (5).

2.5.6 Position the instrument panel in cowl of cab and secure with capscrews. Fig.12 (3).

FIG. 20 CAB TILTED BACK ON REST BRACKET (21·C shown;F040 similar).

T·79627 2.5 PREPARING CAB FOR SERVICE

2.5.1 Tighten the cab front mounting bracket capscrews.

Torque the eight 1"(25.4mm) capscrews to 12201490 Nm(900-1100 Ibs.ft.}. Torque the .75"(19.05 mm} capscrewto 515-645Nm(380-475Ibs.ft.}

FIG.21 CAB POSlTION

2.5.2 :-'. Refer to Fig~ 8. Connect the air conditioner hoses (5), (if so equipped) making certain the couplings are clean and properly secured. "

TILT SAFETY T-79970

LOCK

IN

1.Right rear mounting bracket 2.Safety lock (cab in tilt position) 3.Cab (in tilt position) 4.Cab (in down position) 5.Satety lock (cab in down position)

2.5.3 Refer to Fig. 8, and connect the cab he,ater bose(1.2 ) making certain they are installed to Inlet and outlet correctly. Secure with hose clamps.

2.5.7 Install the vertical trim strip Fig. 15,on right side of 'control tower ; secure the trim strip with attaching capscrews and tighten securely.

2.5.4 Refer to Fig.8 (4) and connect the main electrical cable (orange),air conditioner magnetic clutch cable (lJght blue) and rear flood light cable (dark blue) located at lowerleft front of cab.

2.5.8 ,Refer to Fig. 14; position the ripper and pitch control rod yoke to lever and secure with pin (4) and cotter pin(if 50 equipped).

2.5.5 Connect windshield washer hose Fig. 8 (3) to Connector at front of cab.

2.5.9 Install and secure the dozer control rod Fig.13(6}.

Install the control rod boot and secure with capscrew5 (4)and clamp (2). Install knob (1 ).

Study SAFETY RULES in the front of this manual thorough ly for the protection of machine and safety of personnel.

10

73149519

TOPIC 2 TILTING CAB

A WARNING

2.5.10 Refer 10 Fig. 11; instal! and secure the center floor plate(3) and left floor plate (1). Install floor mat (7).

Install decelerator pedal plate(4) foot rest plate(5),foot rest ,brake pedal plate (2) and secure with capscrews. Position and secure brake boots on pedals and secure with clamps.

Never leave machine engine running.

unattended

with

2.S.19 Checi< the coolant level in engine radiator.After the engine has been started and brought to operating 1emperature and coolant Circulating through heater, the coolant level should again be checked and brought to proper level.

2.5.11 Install the floor mat retaining vertical plate.Fig 10,(located below the dozer control rod console), and secure with capscrews.

A DANGER Fluid under pressure; turn radiator cap

2.5.1 2

slowly to relieve pressure before removing,

.lnstall decelerator pedal,Fig. 9(2),on decelerator rod; secure with jam nut.

2.5.13 Refer to Fig. 9 and install the two brake foot pads (3)on pedal ;secure with capscrews.

2.5.14 Refer to Fig. 7 ;open the cab heater inlet and outlet shut off cocks on engine.

2.5.15 Install the support-fa-cab filler strip, Fig. 6(1) with rubber seal. Install support filler plates(S).

2.S.16 Close right hood side plates Fig.4,and latch. Close left hood plates,Fig.S, and latch.

2.5.17 Refer to Fig. 4. Close valve compartment cover and latch.

2.5.18 Refer to Fig.S and turn the master switch to "ON" position. Close access cover and secure.

A WARNING

J"his machine and its attachments are to be operated only by a qualified operator seated in the operator's seat.

A WARNING

If the engine is to be started Indoors, insure proper ventilation to remove deadly exhaust gases.

A WARNING

Warn all people who may be servicing or working around machine before starting engine.

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

11

73149519

TOPIC 3 CAB ACCESSORIES

FIG. 22 AIR CONDITONER,CAB HEATER CONTROLS AND lOUVERS. T-83151

FIG.23 SERiAL NUMBER, DEFROSTER AND DOME LIGHT lOCATION

·1.Louvers 2.Heater control knob 3.Pressurizer control switch ·4.Air conditioner cold control switch

T-85140 1.Serial number plate 2. Defroster louvers 3. Defroster control switch 4.Oome Ught switch 5.1n!et

Accessories covered in this topic include those· required for a cab equipped with air conditioner. If ·cab is not equipped with air conditioner, omit information that is pertinent to conditioner. For the comfort and safety of operator and equipment, it is 1mperative that aU accessories are kept in good condition and function properly at all times.

3.1.2 WINDOWS AND DOORS The only windows that open are these: - side windows on early units.

- rear window on late units.

3.1 PRESSURE VENTilATION SYSTEM

The pressure ventilation system consists .pressurizer blower and control and louvers.

Either door can be used to go into or out of the cab.

Doors can be latched in the open position.

of

3.1 .3 LOUVERS The louvers, Fig.22 (1) located on top and front of . the console are adjustable to direct the air for the operators comfort.

3.1 .1 PRESSURIZER CONTROL The pressurizer (blower) is controlled by a three speed switch, Fig.22 (3) and protected by a circuit breaker in electrical system. The switch is located on the console to the right of the operator. The blower is used for pressurizing the cab, air conditioning, and cab heater. The volume 01 air discharged from blower is affected by the condition of air filter.

. 3.2 AIR CONDITIONER The air conditioner cold control, Fig.22 (4) engages and disengages compressor magnetic clutch. When turned clockwise it lowers the cab temperature.

When using the air conditioner, the pressurizer control (3) should be run at desirable speed. !f the temperature becomes too low,use cab heater (2) to temper the air as desired.The air conditioner efficiency is dependant on cleanliness of air filter, condenser and evaporator. Operate air conditioner at least 10 minutes each month to protect

in the front of this manual thoroughly for the protection of machine and safety of personnel.

12

73149519

TOPIC 3 CAB ACCESSORIES 3.3 CAB HEATER

wipers are controlled by single speed switches.

-Before operating the wipers (front upper and lower },use window washers to minimize scratching of windows. DO NOT turn wipers on if blades are frozen to windows or the windows are dry or caked. .Keep blades in good condition.

The cab heater control Fig.22 (2) is located on top of console to right of operator. Pull the heater control knob (2) up to increase the temperature by allowing more hot water (from engine) to circulate In heater coils. Pushing the control knob down,shuts off water flow to heater. When heater is used, pressurizer blower speed can be controlled as desired.

.3.6 WINDSHIELD WASHER The washer controls, Fig. 24 (2,4) located to the right of instrument panel operate the washer pumps. A reservoir for washer fluid is located in front of cab on . the left side,in the area between cab and hood. s upport,Fig. 27. Always use washer fluid that is (a) suitable for prevailing temperature to prevent freezing and (b) has proper cleaning qualities. Use washers frequently to prevent a build-up on windows and to minimize scratching of windows.

3.7 CAB DOME LIGHT The dome light switch Fig.23 (4) is located on right side of dome light This light will provide adequate lighting in cab for locating accessory controls and switches and for the convenience of operator. It is -not recommended to use dome light whire operating ·the tractor. Use dome light only when necessary.

FIG. 24 WINDSHIELD WIPERS AND WASHER CONTROLS T-82445

1. Instrument panel 2. Front washer switch 3. Fuses 4. Side windshield washer switch 5. Side wiper knob 6. Rear wiper knob 7. Front windshield wiper knob

3.4 WINDSHIELD DEFROSTER The windshield defroster control, Fig,23 (3) located above the front windshield on the defroster panel,regulates the fan speed. The fan forces air through adjustable louvers (2) to the windshield to prevent frost and moisture from collecting on windshield. The defroster fan control provides two fan speeds. Adjust the louvers to direct the air as necessary.

3.5 WINDSHIELD WIPERS The windshield wiper controls, Fig. 24 (5,6,7) located to the right of instrument panel.operate the wipers. The wipers are located on front windshield, the two lower front windows and rear window. All this manual thoroughly for the protection of machine and safety of personnel.

13

73149519

TOPIC 4 SERVICE, SPECIFICATION AND CAPACITIES 4.2.1 .2 To clean element with compressed air, direct dry, clean air up and down the pleats from reverse side (opposite at screen) of element until all dust is removed.

FIG. 25 FILTER COMPARTMENT T·85147 1. Access door 3. Filter element 2. Screen

WAS.HNG

4.1 GENERAL The specification and capacities will be included in the service steps as they are performed.

4.2 DAILY SERVICES 4.2.1 PRESSUR IZER AI R FILTER

A WARNING

00

not use gasoline, solvent, flammable fluids to clean element.

or

other

4.2.1.1 Refer to Fig. 25 and open access door. Remove · screen (2). Using the tab on filter, remove filter from compartment Filter may be temporarily cleaned (mid- . shift) by tapping filter on flat surface (dirty side down); however, for daily service clean filter with . compressed air (step 4.2.1.2) or by washing (step 4.2.1.3 thru 4.2.1.7 ). If contaminant on element is . mostly dry dust, either method is satiafactory; if element is caked, washing method is recommended.

FIG.26 WASHING AND INSPECTING FILTER ELEMENT T·79632 4.2.1.3 Wash element in a solution of 57grams (2 ounces) low detergent soap or filter cleaner in 4 liters (1 . gaL)of water. For best mixing results, dissolve detergent or cleanser in a small amount of cool water, then add warm water [approximately 370 C (1 000 F) ] to obtain proper proportion.

NOTE: Keep clean spare elements on hand to reduce downtime.

4.2.1.4 Soak element in the solution fo r at least fifteen minutes; then agitate element ior abou1 two minutes to loosen dirt.Rinse element with water from hose or faucet until clean; water pressure must not exceed 2.8 bar (40 psi).

A WARNING

Wear safety glasses with side shields or goggles when using compressed air for cleaning to reduce the danger of personal injury from flying particles.

Umit the pressure to :2 bar (30 psi) according to local or national requirements.

4.2.1.5 Air dry element for 24 hours before using.

MeChanized drying methods may be used but heated air [82DC (1800 F) maximum ] must be circulated. Do not use light bulbs to dry element.

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

14

73149519

TOPIC 4 SERVICE, SPECIFICATION AND CAPACITIES 4.2.1.6 After element has been cleaned and dried, it must be inspected (Fig.26), for rupture or holes. Place bright light on backside (opposite arrows) of element and inspect element; light will shine through any holes or tears making them visible. If any holes are evident, new element must be installed.

IMPORTANT: Use washer fluid with good detergent quality and protection for prevailing ambient temperature.

4.2.3.2 Check the wiper blades and linkage. The edges of blades should not be nicked or split. Replace the blades when worn. Make certain washer nozzles are open.

4.2.1.7 Clean the inside of filter compartment. Replace seals if necessary.

4.2.4 CAB INTERIOR Clean the cab interior, removing all loose objects in the cab. A clean cab wi!! prolong recirculating filter cleaning period.

4.2.1 .8 Install tHter element in filter compartment making certain arrows on filters are directed inward; install screen . Close access door and secure with thumb screw.

FIG. 28 ,PLATE

FIG.27 WINDSHIELD WASHER RESERVOIR

RECIRCULATING

FILTER

ACCESS ·

T-79633

T-85143

1. Access plate 2. Plate screws

4.2.2 GLASS Clean all windows by washing with clean water and mild detergent. Flush with clean water. Dry windows with squeegee or clean cloth (preferably a . squeegee).

3. Filter 4.3 PERIODIC SERVICES 4.3.1 RECIRCULATING FILTER

4.2.3 WINDSHIELD WASHER RESERVOIR AND WIPERS

4.3.1.1 Remove plate screws, Fig.28 (2), then remove plate (1) and filter (3) . Wash filter in low detergent and water solution, similar to that used in 4.2.1 .3 and squeeze solution from filter. Dry the filter thoroughly.

4.2.3.1 Fill reservoir with washer fluid. Reservoir is located in front of windshield on left side. Fig.27.

St udy SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel.

i5

73149519

TOPIC 4 SERVICE,SPECIFICATION AND CAPACITIES 4.3.2.4 Evaporator condensation drain, Fig.30, is located in valve compartment at front end of evaporator.

Periodically check drain to make sure it is open.

FIG.29 AIR CONDITIONER EVAPORATORTOP COVER REMOVED T-79634

1.Filter access door 2. Air conditioner evaporator 4.3.1.2 Posnion the filter in console; position the plate (1) over the filter and secure plate with screws.

FIG.30 EVAPORATOR COt,mENSATtON DRAIN T-8514B

4.3.2 AIR CONDITIONER EVAPORATOR

4.3.2.1 When the air conditioner efficiency has dropped because the evaporator is dirty. it should be cleaned as outlined in following steps.

4.3.2.2 ,

Refer to Fig.25; loosen thumb screw and open access door. Remove sceen. Remove the filter element from compartment. Remove cover above fitter compartment. Fig.29.

A WARNING Wear safety glasses with side shields or goggles when using compressed air for cleaning to reduce the danger of personal injury from flying particles. Limit the pressure to 2 bar (30 psi) according to local or national requirements.

FIG.31 AIR CONDITIONER CONDENSER

4.3.2.3 ..

..

AND FANS T-85149

Using an air hose and nozzle (approximately 2 bar - 30 psi air pressure) direct the air through the coils trom inner side, until the coils are clean. If the coils have a coating of dirt that air cannot remove, it will be necessary to soak the coils with a water and detergent solution. Flush with clean water making certain the water is directed through the coils from inner side preventing water from accumulating in blower compartment. Normally any accumulation of condensate from coil will be removed through drain.

1.Condenser housing plate 2.Condenser fan 4.3.2.5 Check the seal gaskets on lower side of compartment cover to see that they are in good condition. Replace seals if necessary. Position the cover on the filter compartment and secure with capscrews.

of this manuat thoroughly for the protection of m achine and safety of personnel.

16

73149519

TOPIC 4 SERVICE, SPECIFICATION AND CAPACITIES

4.3.2.6 Make certain the filter compartment is clean and dry.

Install a clean filter element in compartment with arrows on top side of filter directed inward. Install screen. Close access door and secure with thumb screw.

4.3.3 AIR CONDITIONER CONDENSER 4.3.3.1 When the air conditioner efficiency has dropped because the condenser coils are dirty or plugged, it should be cleaned as outlined in following steps.

A WARNING

FJG.32 COMPRESSOR BELT

Always turn the master switch to the off position before cleaning, repairing or servicing the unit to prevent injury.

ADJUSTMENT

T·S5t50

1.Clamping capscrew 2.Mounting bracket 3.Compressor 4.Drive belt 5.Adjusting screw

4.3.3.2 Open !eft battery compartment cover and turn electrical master switch to "OFF" position.

4.3.3.3 Remove coondenser housing plate, Fig. 31 (1).

4.3.3.6 Install condenser housing plate. Fig.31 (1) and secure with attaching capscrews. Torque 1!4~ capscrews to 11Nm (iDa Ibs.in). Torque 5/16" capscrews to 27 Nm (20 Ibs. ft).

4.3.3.4 Use care to prevent damage to fan blades. motors and wiring while cleaning.

A WARNING

4.3~3.7

,N~

Crean the cab rear window. Turn electrical master switch to the "ON" position.

Wear safety glasses with side shields or goggles when using compressed air for cleaning to reduce the danger of personal injury from flying particles.

Limit the . pressure to 2 bar (30 psi) according to local or national requirements.

4.3.4 COMPRESSOR BELT ADJUSTMENT

-A WARNING

00 not check or adjust belts when engine is running.

4.3.3.5 Using an air hose and nozzle (maximum of 2 bar -- 30 psi air pressure). blow the dirt from the coils, directing the air through coil from motor side toward cab. If air pressure does not remove caked residue then use a solution of water and low detergent to remove the residue. (Protect motors with plastic cover). Flush with clean water and dry with compressed air.

4.3.4.1 Compressor is located in engine compartment on left side. Belt is correctly adjusted if there is 12.7 mm (0.5") deflection when pressed by hand at a point midway between compressor pulley and drive pulley wtth a force of 11 kg (25Ibs) .

If checking with a belt tension gauge (#75300811) oorrect adjustment is 135 !be tension for new beIt, 85 - 951bs for used belt (cold).

in the front of this manual thoroughly for the protection of machine and safety of personnel.

17

73149519

TOPIC 4 SERVICE, SPECIFICATION AND CAPACITIES 4.3.4.2 To adjust belt, loosen four clamping capscrews.

Fig.32 (1). Loosen jam nut on adjusting screw (5).

Turn adjusting screw (5) clockwise to tighten belt, counterclockwise to loosen belt.

When correct adjustment is obtained tighten jam nut on adjusting screw (5) and the four clamping capscrews (1).

NOTE: Compressor has a small steel plate belted 10 the bottom of it to absorb the thrust of the adjusting screw. If the compressor is changed, install this plate on the replacement compressor.

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

18

73149519

TOPIC 5 ELECTRICAL SYSTEM pressurizer motor circuits. The air conditioner condenser motors are 24 V. Rear flood lights are 'controlled by a switch on the instrument panel.

5.2 REPAIRS TO ELECTRICAL ACCESSORIES

A WARNING

Always turn the master switch to the off pOSition before cleaning, repairing or servicing the unit to prevent injury.

If failures occur in the electrical accessories such as 'wiper motors, washer pumps, switches, fan motors, blowers, controls, and compressor magnetic clutch, they should be replaced with new parts, after it has been determined the cause is normal wear or usage. If an abnormal condition exists causing the failure, make necessary correction before installing new part. Frayed or damaged wires should be replaced.

FIG.33 ELECTRICAL CIRCUIT BREAKER LOCATION T-82398 1.Access plate 2Jnstrument panel 3.Fuses (4 amp) 4.Circuit breaker (20 amp) 5.Circuit breaker (15 amp) 6.Terminalblock "

IMPORTANT; Never paint the compressor magnetic .clutch; this can cause premature failure of clutch assembly.

5.1 GENERAL INFORMATION The cab electrical syslem consists of one 15 amp and one 20 amp circuit breakers (automatic reset), three 4 amp fuses, four windshield wipers, two windshield washer electric pumps, dome light, cab pressurizer blower, defrost fan, air conditioner magnetic clutch, and condenser fans, including the controls for items mentioned. The current (24 V dc) is supplied to cab by a single cable and is grounded through a strap at the rear left cab post The fuses . protect the wiper circuits. The 15 amp breaker protects the washer and defroster fan circuits. The 20 amp breaker protects the air conditioner and

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

19

73149519

TOPIC 5 ELECTRICAL SYSTEM 16

16

18

y

I..BL~ .LBLU

"" ( R

23

24 8

'"

26

- - - - - - - - - - - FIG. 34 CAB ELECTRICAL SCHEMATIC _ __ _ _ _ _ _ _..J T-79638

1.To air conditioner compressor clutch 2.To tractor instrument panel(switch) 3.From tractor electrical supply (24V) 4.Upper front windshield washer pump 5.Lower bottom window washer pump 6.Upper front windshield washer switch 7.lower bottom window washer switch 8.Wiper fuse{4 amp) 9.Air conditioner and pressurizer circuit breaker(20 amp) 10.Washer and defroster circuit breaker{1 5 amp) 11 .Upper front windshield wiper switch 12.Rear wiper switch 13.lower front wiper switch 14.lowerwiper motor 1S.Upper front wiper motor is.Rear flood lights 17.Ail' conditioner condenser fan motor 18.Rear window wiper motor 19.Air conditioner control switch 20.Pressurizer control switch

21 .Pressurizer motor (blower) 22.Compressor clutch cutout control (low pressure) 23.Compressor clutch cutout control(high pressure) 24.0efroster motor 25. Defroster control switch 26.Dome light and switch 27.Cab ground strap(located at left rear of cab) 28.Terminal block 29.Resistor B - Black BR - Brown BL - Dark blue lBl- light blue G - Green o - Orange R - Red W -White Y -Yellow

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

20

73149519

TOPIC . 6 GLASS 6.1 GENERAL INFORMATION

The glass used throughout the cab is tinted and laminated safety type. When glass must be replaced, it can be obtained locally; however, it should meet standards in 6.2. The glass should be kept clean at all times for good visibility.When cleaning the glass, presoaking with a detergent and water solution or a commercial cleaner along with the use of a squeegee, will reduce abrasion and will make it easier to clean.

IMPORTANT: Never use hot water solution on cold glass or cold water solution on hot glass. Solution . should be near glass temperature to prevent fracturing the glass. Wet both sides simultaneously.

6.2 GLASS REPLACEMENTS

A WARNING

Always wear safety glasses with side shields when removing, replacing or handling glass panels.

EARLY UNITS ONLY

A WARNING

For replacement use only safety glass as specified.

FIG.3S GLASS SETTING SEALS _ _ T·79639

A WARNING Do not strike glass to remove it from cab parts. Glass personal injury.

,

may

shatter

and

_

....J

6.2.4 The glass can be set in the seals without the aid of a special tool, however, the use of a tool is recommended. Always cut seal2S mm (1«) longer to provide a tight fit inframe.

cause

6.2.1 All glass, with the exception of the front, requires .

S.Smm (0.22") thick,laminated and 70% single tint glass, with 0.38mm (O.01S")plastic sheet. The edges must be SAE Type 3 finish.

6.2.5 Glass dimensions can be obtained from Tractor Parts ,.

Catalog. It should be cut and finished by a glass speCialist.

6.2.2 The front glass requires 6.3 mm (0.25") thick, laminated and 70% slngle tint glass, with 0.76 mm (0.03") plastic sheet. The edges must be SAE Type .

3 finish.

6.2.3 The glass is held in place by rubber seals, Fig.35.

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

21

73149519

.

TOPIC 7 INSULATION 1,1 GENERAL INFORMATION The cab uses two types of insulation. The cab interior uses a perforated vinyl covered insulation; the cab underside uses a special insulation sheet lead laminated between insulation pUes to produce a sound and vibration barrier. It is important that both types of insulation be kept in good condition to provide good insulation. Repair underside insula- . tioo when cab is tiUed back.

1.2 REPAIRING INSULATION 1.2.1 If the insulation (under side or interior) becomes loose from the cab, it should be partially removed or peeled back and the cab surface cleaned. Apply a coating of suitable adhesive and place insulation back in position.

NOTE: MIRACLE Construction Adhesive #296 is a suitable adhesive.

A DANGER

Adhesives are extremely Following the manufacturer's when applying.

flammable. instructions

7.2.2 If a hole has been poked or tom in the insulation cut a new piece of material large enough to cover the damaged area. Place it over the area (area to be replaced) and mark around the edges. Cut the old insulation on the mark and remove damaged area.

Clean the cab surface and apply a coat of suitable adhesive on cab surface, including the edges of the old insulation. Position the new piece in place making certain it makes good contact with surface of cab, A good fit is important.

' - - - - FIG.35A CAB INSULATION - - - ' T-82406

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

22

73149519

TOPIC 8 AIR CONDITIONER

A WARNING If engine is to be proper gases.

A WARNING started indoors, insure to remove deadly

ventilation

Do not use hands to search for pressure leaks.

A

A WARNING

WARNING

Warn all people who may be servlcmg or working around machine before starting engine.

Refrigerant is extremely cold and will freeze flesh on contact. Use care to prevent contact with skin, eyes or other parts of the body to avoid personal injury.

A

WARNING

A WARNING

A

WARNING

Sound horn before starting.

Never leave machine engine running.

3--"'"

unattended

Wear goggles to protect your eyes when handling refrigerant or when checking refrigerant lines for leaks. Liquid refrigerant in the eyes can cause injury.

with

5

00

6

16

2

10 4

7

15

14 13

1....-_ __ _ __ _ __

8

12

FlG.36 REFRIGERATION SYSTEM SCHEMATIC

T-80257 1.Suction hose (low pressure) 2.Refrigerant compressor 3. Discharge hose(high pressure} 4.Clutch cutout control (high pressure, 23.4 - 24.8 bar (340 - 360 psi) 5.Condenser 6.High pressure (liquid) 7.Sight g!ass(refrigerant) 8.Clutch cutout control (low pressure, 0.8 -1.2 bar (12 -18 psi)

9.Thermostatic expansion valve 10.Temperature control switch 11.Temperature sensing tube 12.Evaporator 13.Refrigerant line 14.Equalizing line 15.Sensingtube 16. Receiver/dryer

in the front of this manual thorough!y for the protection of machine and safety of personnel.

23

73149519

TOPIC 8 AIR CONDITIONER 8.1 GENERAL INFORMATION

8.1.5 The system does not have to be d ischarged to perform the fonowing: Tiltlngcab Removing compressor clutch cutout control (high pressure) Removing compressor clutch cutout control (!ow pressure) Removing compressor clutch pulley Removing compressor clutch coil

8.1.1 An air conditioner test kit is available to aid in servicing the system. See TOPIC 12 SERVICE TOOLS for part number and components of kit

8.1 .2 During the off-season when air conditioner is not in use operate compressor at least 10 minutes each month for lubrication and to help keep seal in good condition.

8.2 COMPRESSOR OIL LEVEL CHECK

8.1.3 The refrigerant in this system is R-12. Although R-12 is nonflammable, noncorrosive , non explosive and nontoxic, some precautions must be taken when handling it.

8.2.1 Compressor oil level can only be checked with . engine stopped and air conditioning system d ischarged. The compressor crankcase is under suction side pressure w hen the system is charged.

8.1 .3.1

. If air conditioning system is operating properly there

Never smoke around or expose a flame to any part of the air conditioning system. R-12 in contact with an open flame forms a gas that is harmful.

is no need to check oil level. But make an oil level check if there has been a loss of refrigerant or if the system has been discharged.

8.1.3.2

8 .2.3 Check oil level through plug hole, Fig.37 (2) in side of compressor (1). Use 75300458 dipstick (3). Leve! should be 28.5 mm (1.12") on dipstick.

8.2.2

Always wear goggles. R- i 2 will freeze flesh on contact so use care to prevent injury. Be especially careful to protect the eyes.

8.1.3.3 R-12 comes in pressurized containers. Protect the container from excessive heat and physical damage.

Keep the container out of direct sunlight. Do not transport the container in the cab of the truck or loose in the truck bed. Secure container in an upright position, in a place where it will not be bumped or crushed.

8 .2.4 Refrigeration oil has the characteristic of absorbing water. Therefore special care must be exercised when handling the oil. Always keep oil in small quantities and in sealed containers to prevent 011 from being contaminated.

8.2.5 Compressor requires 296 ml (10 oz) of oll for a complete fill. Use Texaco Capella "E" grade· 500 viSCOSity or equivalent.

8.1.4 The system must be discharged before performing any of the following: Removing or disconnecting hoses Removing compressor Removing condenser Removing receiver/dryer Removing evaporator Removing thermostatic expansion valve Checking compressor oil level

Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of person nel.

24

73149519

TOPIC 8 AIR CONDITIONER

6

7

FIG.37 COMPRESSOR OIL LEVEL PLUG T-S51SO

1. Compressor 2. Plug *3. Oil level dipstick

FIG.39 TEST MANIFOLD AND GAUGES T-79641

1. High pressure hose connection 2. Charging,discharging and evacuating connection 3. Low pressure hose connection 4.Low pressure/vacuum valve SLow pressure/vacuum gauge (compound) 6.High pressure gauge 7.High pressure valve

·See Service Tools

FIG.38 RECEIVER/DRYER

(located in right rear outside of cab)

FIG. 40 COMPRESSOR SERViCE VALVES T-851 SO

T-7964Q

·1. Receiver/dryer 2. Sight gauge 3. Clutch cutout control (high pressure)

i.Cap 2. Suction service valve (low pressure) 3. Discharge service valve (high pressure)

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

25

73149519

TOPIC 8 AIR CONDITIONER 8.3 TEST MANIFOLD AND GAUGES(Flg.39) 8.3.1 The manifold and gauge set is a mUlti-purpose tool and must be used in the servicing and testing of the air conditioner system. The low pressure gauge (5} has two scales: 0 to i 20 psi and 0" to 30" Hg VACUUM. This gauge is normally located on left side of manifold. This gauge is used to read pressures on the low side (suction side) of the system, and to read in the vacuum range when used for evacuation. The compound pressure gauge should never be connected to the high pressure side (discharge) service valve.

8.3.2 The high pressure gauge is usually on the right side of the manifold. It is graduated from 0 to 500 psi and is used to check pressure on the high pressure side (discharge) oUhe systemon!y.

8.3.3 The test manifold has three connections. The one directly below the compound gauge is connected to compressor suction service valve. The one directly below the high pressure gauge is connected to the compressor discharge service valve. The center connection is for the purpose of attaching a line for evacuating, adding and discharging refrigerant. This center connection is common to the other two connections and hand valves on either side of manifold control flow from the center connection to either or both the suction and discharge valves.

These hand valves do not close off pressure or vacuum to the gauges -- they only control the ppenings to the center connection.

9

FIG.41 TEST MANIFOLD AND GAUGES REFRIGERANT CONNECTED TO AND SERVICE VALVES T-79641

1. R-12 refrigerant 2.Low pressurelvacuum valve 3.Low pressure/vacuum gauge (compound) 4.High pressure gauge 5.High pressure valve 6.Discharge service valve 7.Suction service valve S.Compressor 9.Drive end {for clutch)

8.3.4 When storing manifold, cap connections to keep out dirt. If stored with hoses attached, loosen hoses so no pressure is trapped in manifold.

'8.4 INSTALLING AND MANIFOLD GAUGE SET (Fig.41)

IMPORTANT: Use care to avoid the entrance of air or moisture in system at all times to prevent high head pressure and improper operation.

REMOVING

A WARNING

8.4.1 Manifold gauges must be instaHed when checking system pressures, partial charging, evacuating the system, full charging, and removing excess refrigerant

Refrigerant is extremely cold and win freeze flesh on contact. Use care to prevent contact with skin, eyes or other parts of the body to avoid personal injury.

A WARNrNG Wear goggles to protect your eyes when handling refrigerant or when checking refrigerant lines for leaks. Liquid refrigerant in the eyes can cause injury.

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

26

73149519

TOPIC 8 AIR 'CONDITIONER 8.4.2 INSTALLATION

8.4.3.4 Remove hose from discharge service valve (6). Install dust cap on service valve. Plug the free end of hose.

Loosen end of hose connected to manifold so ' pressure can escape.

8.4.2.1 Close both hand valves, Fig,41 (2 and 5) on gauge . manifold. Attach center hose 10 R-12 container.

Open valve on top of R-12 container.

8.4.3.5 Make sure valve on top of R-1 2 container is closed.

Slowly remove center hose from container, allowing pressure to escape. Plug hose.

8.4.2.2 Attach and tighten suction hose to manifold connection. Remove cap from suction service valve (7).

8.4.2.3 While holding the suction hose end away from all . personnel, open hand valve (2) under low pressure gauge (3). Leave valve open one to two seconds to purge the hose of air and moisture. Shut valve (2) . and immediately attach hose to suction service valve (7).

8.4.2.4 Attach and tighten discharge hose to manifold connection. Remove cap from discharge service valve (6).

8.4.2.5 While holding the discharge hose end away from aU personnel, open hand valve (5} under high pressure gauge (4). Leave valve open one to two seconds to purge the hose of air and moisture. Shut valve (5) and immediately attach hose to discharge service valve (6).

8.4.2.6 Do not open hand valves at this time. Any pressures in the air conditioner system will show on the gauges even though the hand valves are closed.

9

" ' - - - - - FIG.42 CHARGING SYSTEM - _- o f

8.4.3 REMOVAL

T-79641

8 .4.3.1 Close both hand valves, Fig. 41 (2 and 5) on gauge manifold. Close valve on top of R-12 container. 00 not remove center hose from R-12 container at this time.

1. R-12 refrigerant 2.Low pressure/vacuum valve 3.Low pressurelvacuum gauge(compoul1d) 4.High pressure gauge 5.High pressure valve 6.0ischarge service valve 7.Suction service valve 8.Compressor 9.0rive end (fer clutch)

8 .4.3.2 Slowly open both hand valves (2 and 5) on gauge manifold. When pressures equalize, close both hand valves.

8.4.3.3 Remove hose from suction service valve (7). install dust cap on service valve. Plug the free end of hose .

Loosen end of hose connected to manifold so pressure can escape.

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

27

73149519

TOPIC 8 AIR CONDITIONER 8.5 PARTIAL CHARGE

A WARNING

When it has been determined that air conditioner system is low on refrigerant, a partial charge is required.

00 not run engine of this machine closed areas without proper ventilation remove deadly exhaust gases.

A WARNING

A WARNING

Refrigerant is extremely cold and will freeze flesh on contact. Use care to prevent contact with skin, eyes or other parts of the body to avoid personal injury.

Warn aU people who may be servicing or working around machine before starting engine.

A WARNING

8.5.3 Start engine and run at low idle. Turn air conditioner on cold and pressurizer blower on high speed.

Wear goggles to protect your eyes when or when checking handling refrigerant refrigerant lines for leaks. Liquid refrigerant in the eyes can cause injury.

8.5.4 Open refrigerant supply valve, Fig.42 (1) slightly and allow refrigerant vapor into system through manifold hand valve (2) on the suction side.

IMPORTANT: Keep refrigerant supply container in upright position to insure that only non-liquid refrigerant is introduced into the system.

90· 60'

The flow of refrigerant can be increased by placing refrigerant container in a pan of hot water. Do not use water above 500 e (12SoF) to heat container. Do no! apply direct heat to container. Direct heat or water hotter than sooe (12S0 F) will cause excessive pressure in container and possible container explosion.

f\\ \Y 2940 ps.

;~

in to

F!G.43 TURE

2850 psi

8.5.S Observe sight glass while adding refrigerant. When sight glass • Fig. 38, is clear and free of bubbles, close refrigerant supply valve.

RELATIONSHIP OF TEMPERAAND MOISTURE VAPORIZATION T-79644

8.5.S Run engine at 1500 RPM for 5 to 10 minutes.

Observe gauges, Fig.42. Gauge (3) should read 20 40 psi; gauge (4) should read 125 - 225 psi. If pressures remain constant, system is normal. If pressures gradually drop, then the system should be checked for leaks. Refer to 8. S.

8.5.1 Refer to 8.4.2 and install the manifold and gauge set on compressor service valves.

8.5.2 Connect the manifold center hose to refrigerant (R12), making certain hose is purged with refrigerant at manifold connector before tightening.

A WARNING

Observe all start procedures and the Operation and Manual.

8.5.7 Refer to 8.4.3 and remove the manifold and gauge

set up

and shut down WARNINGS listed in Maintenance Instruction

A

Study SAFETY RULES in the front of th is manual thorough Iy for the protection of machine and safety of personnel.

28

73149519

TOPIC 8 AIR CONDITIONER 8.6.2 .Protect the area from wind or excess ventilation, 'when checking lor leaks.

8.6.3 Use electronic leak detector, manufacturer's instructions.

2

following

the

·8.6.4 When a leak has been detected. it should be corrected and tested. Make certain the entire system is thoroughly checked. If the leak was minor not requiring replacement of any components, then it should require only a partial charge.

8.7 EVACUATING SYSTEM

8.7.1 GENERAL INFORMATION The system must be evacuated when components have been replaced or system has been opened to atmosphere. If the system has lost its charge due to a leak, the leak must be repaired and the system evacuated and charged. Refer to Fig. 44 for evacuating.

Evacuation should only be done using an approved vacuum pump. Ambient temperature will determine the length of time it requires for evacuating the system. The higher the ambient temperature the shorter the time required to evacuate the system.

Moisture and air are removed from the system by reducing the internal pressure to a point where the moisture vaporizes and then expelled to atmosphere by the vacuum pump.

10 "----FIG. 44 EVACUATING SYSTEM - - - T-79641

1 Vacuum pump valve 2.Low pressurelvacuum valve S.Low pressurelvacuum gauge 4.High pressure gauge S.High pressure valve 6. Discharge service valve 7.Suction service valve a.Compressor 9.Drive end 1O.Electrical supply cord

EXAMPLE: Moisture in an air conditioning system at an ambient temperature of 150 C (600 F) requires a, vacuum of 29.40" of mercury to vaporize the moisture. If the temperature is 320 C (900F), It wi!! .only require the vacuum pump to pull down to .

28.50" of mercury for moisture to vaporize. To evacuate the system a pumping period of 30 minutes (divided into two fifteen minute periods) is satisfactory for temperatures above 320 C (900 F).

One hour is the minimum pumping time when temperatures fall below 320 C (900 F) especially when the humidity is high.

6.6 LEAK DETECTION

8.6.1 Before testing for leaks, make certain the system has a minimum charge of 50 psi. See Topic 12 fortest kit.

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

29

73149519

TOPIC 8 AIR CONDITIONER

2

FIG.46 COLO CONTROL TUBE fNSERTED T~79673 IN EVAPORATOR

1. Evaporator coil 2. Filter access door 3. Outer coil 4. Cold controltube

(5"",,121mm)

8.1.2.4 . Operate the vacuum pump for approximately 30 minutes. The low pressure gauge (3) should indicate between 27" ~ 29" of mercury, and will go no lower.

Close the manifold valve (2) . Shut off vacuum pump and close valve (1). If the gauge rise is very slight in a i5 minute period, this may be due to release of trapped refrigerant in compressor oiL It may be necessary to repeat the above steps.

"'""--- FIG. 45 DISCHARGING SYSTEM _ - . 1 T·79641

1. Cloth/shop towel 2. Low pressure/vacuum valve 3. Low pressurelvacuum gauge (compound) 4. High pressure gauge 5. High pressure valve 6. Discharge service valve 7. Suction service va1ve 8. Compressor 9. Drive end (for clutch)

NOTE: If vacuum pump will not pump down to proper vacuum or a excessive rise in vacuum gauge is noted, then a leak is evident in the system and must be corrected, repeating the above procedure.

8.7.2 EVACUATING PROCEOURES(Fig.44}

IMPORTANT: 00 not remove or open manifold valves or lines until charging procedure is in progress (8.8), to reduce possibility of system contamination.

8.7.2.1

Close manifold hand valves (2 and 5) and attach the vacuum hose to the center connector of manifold and pump valves. Close valve (1) on vacuum pump.

8.7.2.5

Remove hose from vacuum pump valve (1), and connect it to R·12 container.

8.7.2.2 Connect the respective hoses to compressor service valves (6 and 7) and tighten connectors.

Open valve (2).

8.1.2.3 Start the vacuum pump and SLOWLY open pump valve (1) to prevent pulling oil from compressor crankcase.

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

30

73149519

TOPIC a AIR "CONDITIONER 8.8 COMPLETE CHARGE (Fig.42).

8 ..8.1 Connect charging hose to refrigerant container.

Loosen the charging hose (center connector on manifold) slightly to permit a leak and slowly open valve on refrigerant supply and allow hose to purge · at the manifold connection. Tighten connector at manifold.

A WARNING

Refrigerant is extremely cold and will freeze flesh on contact. Use care to prevent contact with skin, eyes or other parts of the body to avoid personal injury.

8.8.2

A WARNING

With the refrigerant container in upright position, . open the manifold valve, Fig.42 (2) and allow approximately 0.5 kg (1 !b) of refrigerant into the syslem; then close valve (2).

Wear goggles to protect your eyes when handling refrigerant or when checking refrigerant lines for leaks. Liquid refrigerant in the eyes can cause injury.

A WARNING Observe aU start

After replacing components or opening the system to atmosphere. it is necessary to first evacuate the system, then make a complete charge. Approximately 1 A kg (3 Ibs) of R-12 refrigerant is required to charge the system after evacuating. After evacuating the system. the manifold and gauge set will already be installed on compressor. Charge the system as follows :

procedures and the Operation and ··Manual.

up

and

shut

down

A WARNINGS listed in Maintenance

Instruction

A WARNING

Do not run engine of this machine closed areas without proper ventilation remove deadly exhaust gases.

in to

A WARNING

Warn all people who may be servlcmg or ' working around machine before starting engine.

4

8.8.3 Start engine and run at 1500 rpm, IMPORTANT: Keep refrigerant supply container in an upright position to insure that only non-liquid refrigerant is introduced into the system.

3 - -....

The flow of refrigerant can be increased by placing refrigerant container in a pan of hot water. Do not use water above 500 C (1250 F) to heat container. Do not apply direct heat to container. Direct heat or water hotter than 500 C (1250 F) will cause excessive pressure in container and possible container explosion.

\

8.8.4

2

Open manifold valve (2) slightly allowing refrigerant into the system slowly; observe sight glass. When sight glass becomes clear and free of bubbles or foam, close the refrigerant container valve. The system should require approximately 1.4 kg (3 Ibs) of R-12 refrigerant .

' - ' - - FIG.47 CONDENSER FAN BLADE _ _. J LOCATION T-79674

1. Condenser coil 2.Housing cover 3 .Fanblade 4 .Condenser housing

in the front of this manual thoroughly fo r the protection of machine and safety of personneL

31

73149519

TOPIC 8 AIR. CONDITIONER 8.8.5 With engine running at 1500 rpm, temperature control set in coldest position, and blower at high speed, the gauges should read 20 - 40 psi on the · low side (gauge 3) and 125 - 225 psi on the high side (gauge 4) after several minutes of operation. When ambient temperature is high, the pressures will read toward the high end. If the pressures are excessive, this is an indication of over-charge (see 8.9 to remove excess refrigerant).

A WARNING Observe all start procedures and the Operation and . Manual.

up

and shut down WARNINGS listed in Maintenance Instruction

A

A WARNING

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

8.8.6 Refer to 8.4.3 and remove the manifold and gauge

A WARNING

set

Warn all people who may be servJcmg or working around machine before starting engine.

8.9 REMOVING EXCESS REFRIGERANT

8.9.2.3 Start engine and run at 1500 rpm. Check the pressures in system (see 8.8.5).

8.9.1 GENERAL INFORMATION Excess refrigerant in system will cause high operating pressures and the compressor belt to slip.

However, cooling will be adequate.

8.9.2.4 Refer to 8.4.3 and remove manifold and gauge set.

A WARNING

8.10 DISCHARGING THE SYSTEM

'R efrigerant is extremely cold and will freeze flesh on contact. Use care to prevent contact with skin, eyes or other parts of the body to avoid personal injury.

When the compressor oil must be checked andlor added to, or repairs and components replaced, the system must be discharged.

A WARNING

A WARNING

Wear goggles to protect your eyes when 'handling refrigerant or when checking refrigerant lines for leaks. Liquid refrigerant in the eyes can cause injury.

Refrigerant is extremely cold and will freeze flesh on contact. Use care to prevent contact with skin, eyes or other parts of the body to avoid personal injury.

.

8.9.2 PROCEDURE

A WARNING

8.9.2.1 Refer to 8.4.2 and connect a manifold and gauge set to compressor service valves making certain that manifold valves are closed first. Close valve on R-12 container and disconnect center hose from container.

Wear goggles to protect your eyes when handling refrigerant or when checking refrigerant lines for leaks. Liquid refrigerant in the eyes can cause injury.

8.10.1 Refer to 8.4.2 and install manifold and gauge set on compressor service valves making certain manifold hand valves are closed.

8.9.22 S lowly open manifold low pressure valve, Fig.45 (2) to allow refrigerant to escape through charging line (center). Hold a cloth over the end of hose and allow only a small amount of refrigerant out to prevent iosing compressor oil or letting out too much refrigerant. Close the manifold low pressure valve.

8.10.2 Close valve on R-12 container and disconnect center hose from container.

Study SAFETY RULES in the front of th is manual thoroughly for the protection of machine and safety of personnel.

32

73149519

TOPIC 8 AIR CONDITIONER 8.10.3 Open the low pressure manifold valve, FigA5 (2) allowing gas to slowly escape through charging hose. Allowing gas to escape slowly prevents pulling oil from compressor. Place a cloth over end of charging hose to prevent refrigerant from contacting personnel. When all pressure has been released, open the hand valve(5) on the high pressure side of compressor to relieve any pressure. Close manifold hand valves.

8.11.5 COMPRESSOR CLUTCH REMOVAL AND INSTALLATION

8.11.5.1 Remove clutch retaining capscrew and washer.

Remove drive belt.

8.11.5.2 Fabricate a spannertool to hold clutch, Fig. 47A (1).

Install a 5/8" NC capscrew (2) into hub of clutch pulley to force clutch from shaft.

8.10.4 leave manifold and gauge setinstailed to evacuate and recharge system.

8.11 MISCELLANEOUS INFORMATION

8.11.5.3 Install compressor clutch on shaft . Install clutch retaining capscrew and washer. Torque capscrew to 27·33 Nm (20· 25Ibs.ft}.

8.11.1 COLD CONTROL

8.11.5.4 Install and adjust drive belt (4.3.4).

If the cold control requires replacement or for some reason the sensing tube was mislocated in the evaporator coils, causing improper operation, relocate tube to dimension as shown in Fig.4S. 8.11.2 CONDENSER FANS

2

If fan motor requires replacement, the fan blades should be located in condenser housing opening as shown in FigA7 when insta!ied. The brushes are the only parts of the motor that are serviced.

8.11.3 HOSE CLAMPS Make certain the hose clamps are properly located (with integral gauge) on hose before tightening the clamp. Torque the clctmps to 3.4 Nm (30 lbs in).

8.11.4 RECEIVER/DRYER The receiver/dryer contains a screen, desiccant, filter, fusible plug, high pressure switch and a sight glass. If system has a major failure or system has been open allowing the desiccant to become saturated with moisture, replace the receiver/dryer. A fuse plug located adjacent to the sight glass. protects the system from heat and excessive high pressure. If fuse is damaged the receiver/dryer must be replaced. To replace this unit the system must be discharged, evacuated and charged.

"""'--- FIG.47A REMOVING COMPRESSOR CLUTCH T-8S'l89

1 . Spanner tool 2. Forcing capscrew

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

33

73149519

I rouOIesnoollng

~.14!

8.12.1

VERIFY THE COM?lAlIiT

CHECK FOR RESTRICTED AIR FILTER <:LEMENT OR RESTRICTED EVAPORAiCR AIR PASSAGES OK

CHECK fOR RESTRICTED AIR PASSAGES IN CONDEliSER

OPEAA1t PRESSURIZER CONTROL slino, THROUGH ALL

SPrED RANGES. CHECK fOR PROGRESSIVELY lNCREASEO SOUND AUO AIR ¥OlUUf AT TH£ REGISTERS

OK

lIiTH THE ENGINE STOPPED AND THE AAST£ THE '011" POSlTION, PLACE THE PRESSURIZER SWiTCH IN THE "LOW" POSITION, THEN Ol'fAATt THt COLD CONTROl SWITCH TO THE wv: I MUM CCOl! IIG POS IT ION. USTEN fOR A CUCKHiG SOUN!) THAT INlllCATES . THE AAGNETIC CLUTCH 1S OPfAATING PROPER!. Y.

RtPAIR OBSTRllCTlONS OR RtSTRIcnONS AS REQUIRED IF PRESSURIlER OOtS NOT OPERATE SATlS'ACTORlL ¥, REFER TO 'PRESSURIZER MOTOR OOES NOT OPERATE PROPERLY"

OK

NOT OK

i 1500 RPM, SET THE ON MAXIMUM COOLING, SLOWER ON KWlI $ THE CLUTCH ANO DRIVE BELT fOR PROPER OPERATION

REfER TO lNOPfAATl'lf MGNHIC CLUTCll OR ERRATl CLUTCH OPERATJON

OK

REPLACE ~'ORN OR OAAAG(O OR!VE aElT, AOJU$T ORIVE SELT If SLlPPAGE IS IN!llCAT£D,

CHECK THE H£Il.TU: CONTROL VALVE FOR P~OPER

()l'fAATlON,

PERFOru4 $ [GIlT GLASS CHECK (SEE NOTE 11

OK

'lIT!! REflHGERA1'iT, NOTE L

SIGHT GLASS CHECL REMOVE THE RllaS£R nUG IN fRONT OF SIGH! GLASS (ON TOP Of RECEIVER-DRYER) CLEAN THE SIGHT GLASS. aSSERVE 'THE SIGHt GLASS FOR sueSlES 1I1TH THE ENGl~£ OPERATlNG AT 1500 RPM ANa THE Ale CDNTROlS SET AT ~AX1Mll~ COOLING, BUBBLES IN THE SIGHT GLASS llDICATE •• UIDERCHARSE '

or REfRIGERANT,

LOSS OF REFRIGERANT , WHilE OBSERVING THE SIGHT GLASS, CYCLE THE MAGNETIC CLUTCH Off ANO ON, WITH THt ENGINE RUNNING AT 1$00 RPM, OURING TUE TIME THt CLUTCH IS O,F, SUBSlES WlLL APPEAR If REfRIGERANT IS IN THE SYSTEM ANn D!SAPPEAR WHEN THE CLUTCH lS ON, IF NO SUSSlES APP(A~ CURING THE ON ANO OFF CYCLE O. THE CLUTCH, TKfRE IS NO REfR!GERANT IN THE SYSTEM,

ASSENCE OF euaSL£S INOICATE

tiTHER A FULL CHARGE OF REfRIGERANT DR A COMPLETE

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

34

73149519

TOPIC 8 AIR CONDITIONER

1

CONT1NUW fllOl PRfV1C!fS PACr

OPEAATE THE AIR CONOlnONER ON MAXlMUM COOL, W!TH THE PRESSURIZER OIi H1Gi< SPEED .

CLOSE TllE COlRS ANO 1I!NO(¥.\. OPEq:.

ATE TH< t~(i!NE AT 1500 RPI!. THE TEMPEAATURE !NStO<: THE CAS SMOULD BE AT LEAST lS"-200f BELOW THE (JUTSlOE Al R T£MPE~ft fUR!'. AS REl ATlVE HUMIDITY ! NCREASE.$ THE TEMPEAATURE OlFFERENCE &rr.'H~ THE INSIDE AND ODTStDE THE CAS WI LL DECREASe

nOTE 2. IF TH£ sun JON PR£SSUR!' roES NOT STABl U zt AND YAPIES MORE THAll 10 ROUSDS PER SWAPE I~CH ON THI, liAUCE, STOP TH E!;GIN£. REMOn THE EXPANSlON VALH In·

SULATlON . REMQVE THE THERMAL auLS Alill eLA"l? fR(»l THE SUCTIOO miL CLEAN THE SUlS, ctJ:iP ANO SUCTIOO LINt CONTACT ?OlNrs. INSTALL THE SOlB ANO ClAM!' IT St(U,tu TO THE 'SuCTION UN£. INSTAll THE IWSULATlON CAREFULLY START iKE ENGINE AriD CHHK SYSTEM PRESSURES AGAllL

'f.i6ffT""" ATlACl! TM, MANIFOLD GAUCl: sn AS 01 REctEe IN TEXT. SET BOTH MANIFOLD liAUCE VALVES TO THE CLOSED POS 01 SCOIINECT THE LOll PRESSURE QUICK OISCONNECT (LARGE HOst) . ()PEAATE THE

moo.

.EHeINE AT lSCC R?M. SET THE CONTROLS TO O?!'AATE TlfE COMI'R!'SSOR (LVTtH . THE SueT! 011 GAUCl: SHOOLO READ 20 INCHES OF VACUUM WITllIN ONE !!INurE. orSENWE THE CLUTCH TO STOP THE COMPRESSOR. iKE sucnON GAUCE SHOUl!) R!'MAIN BELOW ZERO FOR AT l EAST ONE I<IJ)tUTE. I F THE COMPRESSOR rors NOT SAil sn THESE 7.,0 CCrtOlT! OtiS AFTER AT lEAS i THR!'E CYCLES OF CLUTCH ttiGAGtMfNT. R£?AIR OR R!'PtACE THE COMPRESSOR.

NOT OK AOJUST COLO CONTROL

PROVE OR ~£PtACE SWITCH AS NECESSARY

CHECK 1r PRESSUR£> OK SOMETIMES. THfN svalO!!

LOW AND COMl'RrSSOR oom.

THEN AFTER SEVEAAL H!NUTES

OK AGAIN (MOlSTURE IN S ~ $TEH)

NOT OK O! SCWlRGE. REPLACE RE C£!VER..oRYEII:. EVACUATr AMI RtCWlR!it WITH CORRECT

AIIOtJIIr Of ~ -It

RULES in the front of this manual thoro ughly for the protection of machine and safety of personneL

35

73149519

TOPIC a AIR CONDITIONER 8.12.2

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

36

73149519

TOPIC 8 AIR CONDITIONER 13.12.3

RfPA!R ~lRr ,~ PRe· SU!l!Z!R COOROl $IHCH TO 0)1.0 C(lNTRCl $IlTCH CA R£HAC£ COtC C(ATROl swnCH AS H£CI:5SARr

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

37

73149519

I

'EliF! THE COM'LA I.T . CHECK THt COMPRE SSOR HOUNTING TO HAKE CERTAIN MO VNTI~G SOLTS ARE

Nc r MI SSI NC OR tAMAG EC.

CHE CK FOR BROK EN OR

CRACK ED SRAC KEn OR SRActS. C" EeX MOUnT! SG SOL T$ TO MAKE SURf THEY ARt TORQutD TO SPECl Fl CA rlON

I

r

I

NO I OK

OK

REPA IR OR RE PLACE BRACKE TS OR 6~AC£ S if REQUIR E RtPl At. MIStiNG OR DAMAGEO MO UNT! NG SOLiS.

CHE CK ALL OP1V[ SELTS fOR ADJ US TM EN T, HI ,ALIGNMENT . CHE CK ALL HiLER, AND?

!CRQU£ THE MOUN T)NG SOL TS TO $P£one.nOM

REPAIR OR REPlACE DAMAGED IDLERS 0 REQUIRED . REPLAC E WORN DR DANAIED CORRECT CAUS ! OF e,L T MISAL IGN MENT

VISUALLY CHECK SuRF ACES OF CO~DfN,fR FO. ACCUMULAT i ON or LEAV ES . Mun OR OTHER FOREIGN ~ATERIAl WHI CH CAN CAUS E HI GH SYST EM PRESS URE S. CHECK OP ERATION OF CONOENS ~R FAN MOTO,S

NOT OK

OK

REMOH LOOSE

III TH THE ENG WE RVNNIM; AT IOCE sr:,). U $ TE~ fOR Ruea IN. ~O!$E I<MEN CLureK 1S ON OR OFf. IF THERE IS RUSSING, ru:mVE CLUTCH_ I NSPECT fUR: CLUTCH ROTOR USING ClUTCH flELO. IMPROPER

FLUSH SURFACES n Oli!

CONDENSE, FA~S.

BRUSH CONTACT OR IMWSH CUP SOT REMOVED, A1I1l

ClUTCH fIELD (II' SO EWIPPtD) NO! INSTAU.En p~Qr'RU ON COMPRESSOR,

or

NOT OK RE lA tE WORN OR CA MAGE

CHECK CLUTCH fOk LOOSENESS OR PL AY ON COMPRESSOR SHArT . RE MOVE CLUTCH AND INSPECT TA?£R ANO ~E rW AY IF LOOSENES S I S SUSPECTED

MAKE SU RE CLUTCH Fl EL D INSTALLE D WITH PROP ER

~()t

OK

REPLA CE KEY IF ~()RN.

OPERATE ENGINE AT IDLE SPEES WITH Al e CLUTCH

fECTIONS fROM TAPER

SO! 5( WIL L STOP WH eN !HE CLUTCK 1S E~GAHD

OlSENGAGED.

n N[ !lONIkG nOu E

H

Cl llTC ~

SEARING IS DP<!oIMED . THE

K

I W!I " ENGINE OPERITING AT lOLl S'EED. CHECI Ale CLUiCH FO R SC RAP I Nil· ~o 1$ E IIHEN CLUTCH IS DISEnGAGED. ENCASE CLUiCK TO SH I f NQISE

DISAPPEARS

I

r

SOi OK eLE CLUTCH A FEW TiMES TO SU RS!SH AN O SEAT

E CLUTCH FICE WHE~ ACTIVATED, urCH. IF REQUIIED

RE'LAC E

PE RFORM SI STE M PRESSU~E CHECK.

?ORTION Of R- lZ .

DISCHARIE

IK

RUN TnE ENGINE AT 1500 RPM. Ale ON MAXIMUM

COOLING Aun HIGH SLOWER.

ll STf ij

AT THE COM-

PRESSOR fOR AN EI C£SS I •• RUMe lt OR rNOC( TH AT OISAPPfARS WH EN CLUTCH IS OEACTIVATE D

I

I

NOT OK REPA IR OR REPLACE COMP lfSSOR IF

KNOCK

~ UM a lE

OR

DiSAPPEARS WH EN CLVTCH IS OEACTIVATE C

731495t9

MEMO

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

39

73149519

TOPIC 9 TILT CYLINDER

15

17

16

18

19

13 12

" ' - - - - - - - - - - - FIG. 48 TILT CYLINDER ·SECTIONAL VIEW -------~ T-79647

1. Cylinder

2. Back-up washer 3. O-ring 4. Back-up ring 5. "T"seal 6. Piston 7. Washer 8. Screw 9. Cylinder end cap 10. End block

11 . Capscrew 12. O-ring 13. Back-upwasher 14. Bushing i5. Screw 16. Valve assembly 17. Tube 18. Back-up washer 19. O-ring 20. Fitting

21. C-ring 22. Packing Cup 23. Rod 24. Rod nut 25 . Cylinder end cap(Rod end) 26. Back-up washer 27. C-ring 28. Packing cup 29. Piston rod

9.1 GENERAL INFORMATION

A WARNING Never use gasoline, solvent or other

9.1.1 Service parts Service Tools.

flammable fluids to clean parts.

A WARNING

cylinder

are

listed

in

9.1 .2 The valve assembly Fig. 48 (16).atlached to the tilt cylinder should be checked periodically for proper relief pressures; however repairs other than adjustment should not be attempted.

Make certain tilt cylinder is in good condition before checking and adjusting valve (9.3) .

Wear safety glasses with side shields or goggles when using compressed air for cleaning to reduce the danger of persona! injury from flying particles. limit the pressure to 2 bar according to local or requirements.

for tilt

(30 psi), national

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

40

73149519

TOPIC 9 TILT CYLINDER 9.2 CYLINDER REPAIR (Fig. 48)

9.2.10 Install piston rod(29)in end cap (25). Install back-up washer (2) and O-ring (3) in groove of piston rod. Position piston (6) on piston rod and secure it with washer (7) screw (8).

Torque screw (8) 10 545 - 575 Nm (400 425 Ibs.ft).

9.2.1 Remove the four rods nuts (24)from rod end of cylinder and remove the end cap and piston rod assembly from cylinder.

9.2.2 Remove oil tube (17); then remove the valve assembly (16) from cylinder.

Wrap the cylinder in a clean cloth or paper to prevent contaminants from entering valve ports. If bushing (14) remained in valve, remove it Discard items 18 and 19 from each end of tube (17).

9.2.11 Install back-up washer (26) and a-ring (27) in groove of end cap (9). Install end cap on cylinder (1).

9.2.12 Instal! O-ring (12) and back-up washer (13) in each end of bushing (14); then insert bushing in end cap (9).

9.2.3 Remove end cap (9) from cylinder.

9.2.13 Position valve assembly (16) onto bushing (14).

Secure valve assembly to end cap with screw (15); torque screw to 5.7 -6.7 Nm (50 - 60 Ibs. in).

9.2.4 Place the piston rod clevis in a vise and remove screw (8) from end of piston; then remove piston (6) from piston rod (29).

9.2.14 Position back-up washer (18) and a-ring (1 9) on each end of tube (17). Install tube in bore of valve (16).

9.2.5 Remove the piston rod (29) from end cap (25).

9.2.15 Carefully instatl end cap (25), piston and rod assembly on cylinder making certain that piston rigns are not damaged and that end caps are aligned for rod holes and tube (17).

9.2.6 If bushing (14) remained in end cap (9),remove the bushing and discard back-up washer and O-ring. Remove items 26 and 27 from both end caps (9 and 25).

9.2.16 Install the four rod nuts (24) and torque to 170 - 200 Nm (125 - 150 Ibs.ft).

9.2.7 Remove seals,back-up rings,and a-ring from piston (6),piston rod (29)and end cap (25).

Remove packing cups (22 and 28).

A WARNING

Never use gaSOline, solvent flammable fluids to clean parts.

or

9.2.17 Check block attaching capscrews (1 i). They should have a torque of 95 - 108 Nm (70 - 80 IOO.ft).

other

9.2.8 Clean all components thoroughly with commercial non-flammable, non-toxic solvent and before assembling,lubricate all parts with clean oiL 9.2.9 Install new packing cups (22 and 28) in their respective bores in end cap (25).

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

41

73149519

TOPIC 9 TILT CYLINDER 9.3.2 Activate pump to position tilt cylinder piston rod in full retract position (piston rod in). When piston rod bottoms, read pressure gauge. Correct pressure is 345·372 bar (5000 - 5400 psi).

4

9.3.2.1 If pressure is incorrect, remove plug (2). Adjust pressure by turning valve (3) in to increase pressure or out to decrease pressure. Install p!ug (2).

9.3.3 Activate pump to position piston rod in full extend position (piston rod out). When piston rod bottoms, read pressure gauge. Correct pressure is 138·165 bar (2000 ·2400 psi).

9.3.3.1 If pressure is incorrect, remove plug (5) . Adjust pressure by turning valve (6) in to increase pressure or out to decrease pressure. Install plug (5).

7

9.3,4 Operate the tilt cylinder to the full extend and retract limits several times to recheck pressure settings. If pressure readings are inconsistent, do not attempt to tilt cab until malfunction is corrected. Remove hydraulic pump.

' - - - - FIG.49 TILT CYUNDERVALVE - - - ' T-80261

1.Retract port 2.Retract relief port plug 3.Retract relief valve 4.Extend port 5.Extend relief port plug 6.Extend relief valve 7.Cylinder 8.Holding valve (do not tamper with this valve setting)

9.3

VALVE

TESTING AND (Fig.49)

ADJUSTMENT

9.3.1 Attach hydraulic pump (75300611 or 75300612) with 700 bar (10,000 psi) capacity gauge to valve ports (1 and 4).

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

42

73149519

TOPIC 10 CAB ASSEMBLY REFERENCE ILLUSTRATIONS 21

5 '"

22

23

6

25

' - - - - - - - - - - - - - - - FIG. 50 CAB ASSEMBLY

1. Cab 2.Bushing 3.Glass 4.Glass 5.Seal S.Seal 7. Decal S.Plate 9Jnsulation

1O.Leveling device 11 .Plate i2.Latch 13.Latch 14.Glass 15.Seal is.Ground cable i7Jnsu!ation is.Plate

T-82396

------------1 19.Cover 20.Wlper 21.Wlper 22.Door 23.Wlndow 24. Pressurizer 25.Shie!d 26Jnsulation 27.Plate

this manual thoroughly for t he protection of machine and safety of personnel.

43

73149519

TOPIC 10 CAB ASSEMBLY R.EFERENCE ILLUSTRATIONS

1.Front bracket 2. Rear bracket 3. Guard 4. Guard 5. Lowertilt cylinder bracket 6. Safety lock 1-79877

'------FIG.51 CAB MOUNTING BRACKETS _ _ _ _ _ _ _----1

12

1.Door

2. lock 3.Shim 4 Handle 5.Handle 6.Latch 7.Shim 8.Seal 9.Pad 10.Seal 11.Seal 12.Glass 13.Gla55

1-79614

' - - - - - - - - - - FIG.52 DOOR _ _ _ _ _ _ _ _ _ _----J

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

44

73149519

TOPIC 10 CAB ASSEMBLY REFERENCE ILLUSTRATIONS

3

1.Window 2.Plate 3.Glass 4.Seaf 5.Sear

4

Usage: Cabs prior to SIN 32157, excluding 31929

6.Ar'li't

T-79608 FIG.53 SIDE WINDOW - - - - - - - - - - - - - '

2

--(

3

1.Window 2. Upper frame 3. Lower frame 4.Bar 5.Channel 6.Latch 7.Stop a.Glass 9.Channel 10.Strip 11 .Frame 12.Lock 13.Glass 14.5ea! i5.Strip

USAG€: CABS SIN >2 157 AND tJ> t~LUDING SIN 31929 ,

T-81289 '--_ _ _ _ _ _ _ FIG.54 REAR WINDOW _ _ _ _ _ _ _ _ _ _ _-1 Study SAFETY RULES in the front of this manual thorough ly for the protection of machine and safety of personnel.

45

73149519

TOPIC 10 CAB ASSEMBLY REFERENCE ILLUSTRATIONS

T·83066

FIG. 55 LOWER FRONT WrPERS AND WASHERS - - - - - - ' 1.Wiper blade 2.Arm 3.Motor 4.Wire 5.Grommet 6.Termina! block 7. Switch 8.Fuse holder

9.Fuse 10.Wire 11.Wire 12,Wire 13,Switch 14,Wire 1S.Wire 16.Wire

17.Wire 18.Washerpump 19.Nozz!e 20.Hose 2LHose 22.Hose 23.Connection 24.Hose

2S.Hose 26.Hose 27.Hose 28.Hose 29.Connection 30.Reservoir 31.Bracket

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

46

73149519

TOPIC 10 CAB ASSEMBLY REFERENCE ILLUSTRATIONS

2

1.Front wiper blade 2.Arm 3. Front motor 4.Wlre 5.Switch 6.Wire 7.Fuse holder a.Fuse 9.Wire 10.Block ii.Cable harness i2.Rear motor 13.Rear wiper blade

T-83065

' - - - - - - FIG.56 FRONT AND REAR WINDSHIELD WIPERS _ _ _ _- - J

\0

i .Panel 2.Bracket 3.Motor 4. Spacer 5.Fan 6.Grille (early units) 7.Light assembly 8.louver 9.Plate 10Jnsutation 11.Switch 12.Decal 13.Knob 14.Connector 15.Washer

16.Cable 17.CHp 1a.Clip T-83179 ' - - - - - - FIG.57 DEFROSTER FAN _ _ _ _ _ _ _ _ _ _ _ _--J Study SAFETY RULES in the front of this manual thorough ly for the protection of machine and safety of personneL

47

73~49519

TOPIC 1 0 CAB ASSEMBLY REFERENCE ILLUSTRATIONS

6-11-15

12-16

T-79616

FIG. 58 PRESSURIZER _ _ _ _ _ _ _ _ _---J

1.Door 2.Screw 3.Filter 4.Cover 5.!nsulation 6.Seal 7.Seal a.Pressurizer 9.Blower 10.Grommet 11.8eal 12,Seal

i3.Cover 14.Grommet 15.Seal 16.Seal 17.Panel 18.Louver 19.Panel 20.Decal 21.Knob 22.Switch 23. Deflector 24.Plate

25.Filter 26.Plate 27.Resistor 28.8ase 29. Switch 30.Knob 31.Screen 32.Cable harness 33.Wheel 34. Motor 35.Pad 36.Clip

Study SAFETY RULES in the front of this manual thorough ly for the protection of machine and safety of personneL 73149519

TOPIC 10 CAB ASSEMBLY REFERENCE ILLUSTRAnONS

1.Coil 2.Plate 3.Hose 4,Grommet S.Valve S.Cable 7.0ecaJ a.Hose 9.shut-off cock 10.Hose 11.C!amp 12.Hose 13.Ang\e 14.Clamp 1S.Strap is.Clamp 17.Nipp!e T-79669

1....-_ _ _ _ _

FIG. 59 HEATER

- - ---....::------------1

i .Clutch 2. Pulley 3.Coi! 4.Be/t S.Wire 6.Compressor 7.Adjusting screw a.Fitting 9.Fitting 10.Gasket 11 .Hose 12.Hose i3.Bracket i4.Plate lS.Wire lS.Angle 17.Clamp la.Strap i9.Coupling 20.Coupling T-79965

' - - - - - - - - FIG.SO COMPRESSOR AND MOUNTING

- - - - - - -- . . . 1

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

49

73149519

TOPIC 10 CAB ASSEMBLY REFERENCE ILLUSTRATIONS

1.Plate 2.Spacer 3.Deca!

4.Hose 5.Hose 6.Grommet 7. Bracket 8.Seal 9.Clutch cutout control (low pressure) 10.Thermostatic expansion valve 11.Evaporator coil 12.Clamp 13.Clamp 14.Condenser 15.Todryel' 16.Hose 17.Clamp

3

T·79966 FIG.51 EVAPORATOR AND LINES - - - - - - - - - - '

9

20 T·79967

1.Bracket 2.Dryer 3.C!utch cutout contrC)·f (high pressure) 4.Hose 5.Cover 6.Bracket 7. Grommet B.Condenser 9.Pad 10.Motor 11.Blade 12.Guard 13.Housing 14.Seal 15.Sea! 16.Grommet 17.Trimming 18.Hose 19.Clamp 20.To thermostatic expansion valve 21. Wire

16 FIG.52 DRYER AND CONDENSER Study SAFETY RULES in the front of this manual thoroughly for the protection of machine and safety of personnel,

50

73149519

TOPIC 11 TORQUES AND ADJUSTMENTS 11.1 TORQUES 11.1.1 Cab mounting bracket capscrews 19.05 mm {.750")-------------------------------------25.4mm(1

515 - 645 Nm (380-475 Ibs.ft) 1220-1490 Nm (900 -1100 Ibs.ft)

11.1,2 Condenser housing plate capscrews 6.35 mm (.25")--------------------------------7.92 m.m (.312") -----------------------------------------------------

11 Nm (100100. in) 27 Nm (20 Ibs.ft)

11.1.3 Floor plate capscrews ----------------------------._-----------------.--

61 Nm (45Ibs.ft)

11.1 .'4 Hose clamps ----------------------------------------------

3.4 Nm (30 lbs.in)

11.1.5 Tilt cylinder bracket mounting capscrews ----------------

575 Nm (425IOO.ft)

11 .1.6 Tilt cylinder Piston to rod retaining screw -------------------------------,;..-----Valva attaching screws -----------------------------End cap pin block screws ----------------------. ---Cylinder rod bolt nuts ----------------------------------------,-------

545-575 Nm (400-425Ibs.ft) 5.7-6.7 Nm{50-60 lbs -in) 95-108 Nm(70-BO Ibs.ft} 170-200 Nm{i 25-150 !bs.ft)

11.1.7 Compressor clutch retaining capscrew ------._-------------

27-33 Nm(20-2Slbs.ft)

11.2 ADJUSTMENTS 11.2.1 Compressor drive belt manual------------------------------------

beh tension gauge - used belt ----------------------------.---- new belt--------------------- , 11 .2.2 Condenserfan blade (from face of housing) ----------------

12.7 mm(O.5") deflection with a force of 11 kg (25Ibs) 85-95lbs 135100 15.5 mm (0.61")

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

51

73149519

TOPIC 11 TORQUES AND ADJUSTMENTS 11.3 TtLT CYLtNOERVALVE 11 .3.1 Relief pressure w/extended piston rod ---------------Relief pressure w/retracted piston rod ----------------------

138-165 bar (2000-2400 psi) 345-372 bar (500Q..5400 psi)

11.4 COMPRESSOR 11.4.1 Compressor discharge pressure (at rated charge) --------~-------------------------Oil type (refrigerant oil) .-----------------------------------Oil level (in compressor) ------------------------------------._-------Oil capacity -------------------------------------------Current to engage clutch ----------------------------

10.3-15.5 bar (150-225 psi) Texaco Capella "Eu , 500 viscosity 28.5 mm (1.12") 296 m! (10 oz) 2 amp

11.5 COMPRESSOR CLUTCH CUTOUT CONTROL 11.5.1 Low pressure (open) --------------------------------------._-------------- 0.8 - 1.2 bar (12 - i 8 psi) (close) -----_.----------------------------------- 2.4 - 3.1 bar (35 - 45 psi)

11.5.2 High pressure (open) ------------------------------------_..------- 23.4 - 24.8 bar (340-360 psi) (close) --------------------------------------- 11 .4 - 12.8 bar( 165-185 psi) 11.6 AIR CONDITIONER SYSTEM OPERATING PRESSURE

Suction side -------------------------------------~----- 1.4 - 2.8 bar (20-40 ps~ Discharge side ------------------------------------------- 8.6 - 1S.5 bar (125-225 psi)

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

52

73149519

TOPIC 12 SERVICE TOOLS Service tools required to perform the various repairs explained in this manual are listed below.

Order service tools from your Fiatallis dealer.

IMPORTANT: Refer to Fiatallis Tool Catalog No. 73128466 for complete illustrations, descriptions and usage.

All other tools required are considered 10 be standard service tools; these tools can be ordered from local tool suppliers. .

FIGURE NO.

FtATALLIS PART NO.

DESCRIPTION

15,16

75294525

Cab Tm Cylinder Includes: 75300741 Bushing (Fig.48, item 14) 75300743 Valve Assembly 75300740 Tube 75300734 Pin Assembly 75300742 Seal Kit

16

75300611 (110V 60 Hz) 75300612 (220V50 Hz)

Hydraulic Pump

37

75300458

Compressor Oil DipsticK

39,41,42,44,45

75300835

Air Conditioner Test Kit Includes: 75300392 Thermometer 75300393 Electronic Leak Detector 75300394 Electronic Leak Detector Tip Replacement Kit ----_.-. Gauge and Manifold Set ---Goggles --.----- Vacuum Pump

75300811

Belt Tension Gauge

Hydraulic Pump

Study SAFETY RULES in the front of this manual thorough ly for the protection of machine and safety of personnel.

53

73149519