Fiat Hitachi TELEHANDLERS T13 T14 T17 Service Manual - PDF DOWNLOAD by www.heydownloads.com

T13 T14 T17 TELEHANDLERS ServiceManual

PrintN.604.02.395.00(XII--2002)

THISALERTSYMBOLSIGNALSIMPORTANTMESSAGESINVOLVINGYOURSAFETY.

Readandheedcarefullythesafetyinstructionslistedandfollowtheprecautionsrecommendedtoavoid potentialrisksandtosafeguardyourhealthandyoursafety.

YouwillfindthissymbolinthetextofthisManualreferredtothefollowingkeywords:

WARNING --Cautionsdirectedtoavoidimproperrepairinterventionsinvolvingpotentialconsequencesfor theoperator’ssafety.

DANGER --Thesewarningsqualifyspecificallypotentialdangersforthesafetyoftheoperatororother personsdirectlyorindirectlyinvolved.

IMPORTANTNOTICE

AllmaintenanceandrepairinterventionsexplainedinthisManual mustbeperformedexclusivelybytheService OrganizationoftheManufacturer,observingstrictlytheinstructions explainedusing,whenevernecessary,the recommendedspecifictools.

Whoeverperformstheoperationsreportedwithoutfollowingexactlytheprecautionsisresponsibleonhisown,for thedamagesthatmayresult.

NeithertheFactorynoranyOrganizationsinitsDistribut ionNetwork,includingbutnotlimitedtonational,regional orlocaldistributors,areresponsibleforanyliabilityarisingfromanydamageresultingfromdefectscausedbyparts and/orcomponentsnotapprovedbytheFactoryforuseinmaintainingand/orrepairingproductsmanufacturedor merchandizedbytheFactory.

Inanycase,nowarrantyofanykindismadeorshallbeimposedwithrespecttoproductsmanufacturedor merchandizedbytheFactory,whenfailuresarecaused bytheuseofpartsand/orcomponentsnotapprovedbythe Factory.

AVOIDACCIDENTS

Mostaccidentsandinjuriesoccurringinindustry,onthefarm,athomeorontheroad,arecausedbythefailureof someindividualtofollowsimpleandfundamentalsafetyrulesorprecautions.Forthisreason,MOST ACCIDENTSCANBEPREVENTEDbyrecognizingtherealcauseandtakingthenecessaryprecautions,before theaccidentoccurs.

Regardlessofthecareusedindesignandconstructionofanytypeofequipment,theremaybeconditionsthat cannotbecompletelysafeguardedagainstwithoutinterferingwithreasonableaccessibilityandefficient operation.

Acarefuloperatoristhebestinsuranceagainstaccidents. Thecompleteobservanceofonesimplerulewould preventmanythousandsseriousinjurieseachyear.

Thisruleis:Neverattempttoclean,lubricateoradjustamachinewhileitisinmotion.

WARNING

Onmachineshavinghydraulically,mechanicallyand/orcablecontrolledequipment(suchasshowels, loaders,dozers,scrapersetc.)becertaintheequipmentisloweredtothegroundbeforeservicing, adjustingand/orrepairing.

Ifitisnecessarytohavetheequipmentpartiallyorfullyraisedtogainaccesstocertainitems,besure theequipmentissuitablysupportedbymeansotherthanthehydraulicliftcylinders,cableand/or mechanicaldeviceusedforcontrollingtheequipment.

MODELCODES

Thecompleterangeoftelescopichandlers(Telehandler)describedinthismanualisidentifiedinthetextby referencetothemaximumextensionofthetelescopicarm.

Thevehicleslistedbelowmaynotbeavailableinallcountriesormarkets,thereforeforthelatestinformation consultyourauthoriseddealer.

Model T13 T14 T17 Notstab. stab. Notstab. stab. Notstab. stab. Engine 88kW(120CV) TurboAftercooler 88kW(120CV) TurboAftercooler 88kW(120CV) TurboAftercooler Max.liftheight 12,30 12,45 13,30 13,45 16,24 16,60 Max.capacity (at500 mmfromforkledge) 4000 4000 4000 4000 4000 4000 Capacityatmaximum height 3000 4000 2500 3500 2000 3000 Extensionatmax. height 1,40 1,23 1,70 0,85 2,70 1,80 Max.longitudinal extension 8,65 9,33 12,54 Capacityatmax. extension 600 1500 450 1350 0 600 Weight (kg) 10700 11340 12090

Servicemanual

TELESCOPICHANDLERS 604.02.395.00 --12--2002 GENERALLISTOFCONTENTS SECTION00--GENERAL Description Page .............................................................................. Generalinstructions 1 ........................................................................... Safetyrules 3 Productidentification 6 Environmentalconsiderations 9 ................................................................... Maintenancetechniques 10 Specialtools 14 SECTION10--ENGINE Description Page Engineidentificationcode 2 Enginemaincharacteristics 3 Generalcharacteristicsofengines 4 ............................................................... General 6 Descriptionofthemainmechanicalcomponentsoftheengine12 Lubrication 23 .................................................................................. Cooling 28 Turbocharging 30 Mechanicalinjectionsupply system31 Injectionassembly 33 Timinggeardrive 43 Injectionpumpsetting 44 Electricalcomponents 45 ......................................................................... Troubleshooting 46 .............................................................................. Tools 50 Assemblyclearancedata 55

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Description Page Gearboxassembly 5 ............................................................................ Idlergearcaseassembly 7 ...................................................................... Gearboxoperation 8 ............................................................................. TransmissionandHydraulicoilcircuitdiagrams15 ................................................... Modulationvalveoperation 31 Torqueconverterandheatexchangerhydraulicoilcircuit34 Troubleshootingprocedures 37 Pressuretestingclutchandhighpressurecircuit38 Pressuretestingtorqueconverterandcoolercircuit39 Checkpoints 40 Assemblyinstructions 42 Overhaul 45 SECTION25--FRONTAXLE Description Page Specifications 1 Description 2 Operation 3 Troubleshooting 4 Wheeltoe--incheck 5 Componentoverhaul 5 Frontaxleremoval 6 Frontaxleoverhaul 7 Axledrivepinionbearingadjustment51 Bevelgearpinioninstallationandadjustment53 Frontdriveshaft 57

GENERALLISTOFCONTENTS

SECTION21--POWERSHIFTGEARBOX

GENERALLISTOFCONTENTS 5 604.02.395.00 --12--2002 SECTION27--REARAXLE Description Page Specifications 1 Description 2 Operationdiagram 3 ............................................................................ Componentoverhaul 5 Rearaxleremovalprocedure 5 Overhaul 6 ..................................................................................... SECTION33--BRAKES Description Page Powerbrakes 2 Parkingbrake 3 ................................................................................ Brakerelease 6 ................................................................................. Brakediscadjustment 6 Troubleshooting 7 ............................................................................... Brakediscreplacement 8 ........................................................................ SECTION35--HYDRAULICSYSTEM Description Page Technicaldata 2 Descriptionandoperation 3 ...................................................................... Steeringsystemhydrauliccircuit 4 Steeringvalve 5 Telescopicboomhydrauliccircuit 7 ................................................................ Componentoperation 13 Frontloadercontrols 17 Powersteering(OSPQ) 21 Telescopicboomdistributor 23 .................................................................... Auxiliarycontrolsdistributor 26 .................................................................... Cylinders 27 Boomremoval 37

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Description Page Electricalequipmentspecifications 1 ............................................................... Electricalsystemandfuse 2 ...................................................................... Controlsandinstruments 6 ....................................................................... Bulbreplacement 20 ............................................................................. Systemprecautionsforbatterychargingandwelding23 Startingthemachineusingjumpleads24 Temporarywiringrepair 25 Electricalsyst emgeneralfaultfinding27 Listofconnectors 31 Listofcomponents 32 Cablekey 34 Howtousethecircuitdiagrams 36 Circuit1:Starting/Recharge/Warninglights/Indicatorlights38 Circuit2:Transmission 40 Circuit3:Wheelalignment/Hydraulicsolenoids/Brakesystem42 Circuit4:Armcontrol 44 Circuit5:Stabiliser 46 Circuit6:Lights/Windscreenwiper48 .............................................................. Circuit7:Worklamps/Roofbeacon50 Circuit8:Tiltingpreventionsystem/Roofwiper52 Circuit9:Sound system heating/Electricsocket/Rooflamp54 Circuit10:Airconditioner 56

GENERALLISTOFCONTENTS

SECTION55--ELECTRICALSYSTEM

GENERALINSTRUCTIONS IMPORTANTNOTICE

AllmaintenanceandrepairinterventionslistedinthisManualmustbeperformedexclusivelybytheService NetworkoftheManufacturer,complyingstrictlywiththeindicationshereinandusing,whenrequired,the prescribedspecialtools.

Whoeverperformsserviceoperationsdescribedhereinwithoutcomplyingstrictlywiththeinstructionsbecomes solelyresponsibleforanyconsequentialdamagethatcouldoccur.

ADJUSTINGSHIMS

Foreachadjustmentselecttheadjustingshims,measuringthemonebyonewithamicrometerandaddingto gethersubsequently,thevaluesmeasured.Donotrelyonthemeasurementoftheentirepack,thatcouldbe wrong,orthenominalvalueindicatedoneachring.

SEALSFORROTATINGSHAFTS

Forcorrectinstallationofthesealsforrotatingshafts,pleasecomplywiththefollowingprecautions:

--priortoinstallation,keepthesealssoakingforatleasthalfanhourinthesameoiltheyaregoingtoseal;

--cleanthoroughlytheshaftandmakesurethatitsworkingfaceisundamaged;

--directthesealingliptowardthefluid;intheeventthelipisofthehydrodynamictype,thegroovesmustbe directedsothat,inrelationtotherotatingdirectionoftheshaft,theytendtoreturnthefluidtowardtheinside ofthesealingdevice;

--smearthesealinglipwithafilmoflubricant(oiltobepreferredtogrease)andfillwithgreasethegapbetween sealinglipanddustlipintwinlipseals;

--insertthesealinitsseat,pressingitwithapunchwithaflatface;neverstrikeitwithahammerormallet;

--whenpressingintheseal,makesurethatitisinsertedperpendicularlyinrelationtotheseatand,oncein position,makesurethat,whenrequired,itcontactstheshoulder;

--topreventthesealinglipofthesealbeingdamagedbytheshaft,insertappropriateprotectionduringthe installationofthetwoparts.

“0--RING”TOROIDALSEALS

LubricateO--ringsbeforeinsertingthemintherelevantseatstopreventthembecomingtwistedandrolledduring installation,thusjeopardisingtheirsealingcapacity.

SELAINGCOMPOUNDS

MatingsurfacemarkedXmustbesmearedwithasealingcompoundrecommendedbytheManufactureroran adequateequivalent.

Priortoapplyingthecompound,preparethesurfacesinthefollowingmanner:

--removeallpossiblescalingwithametalbrush;

--degreasethesurfacesthoroughlyusingthedegreesingagentrecommendedbytheManufactureroran adequateequivalent.

BEARINGS

Wheninstallingbearings,itisrecommendedto:

--warmthemupto80–90 ° C(176–194 °F)beforeinstallingthemontherelevantshafts;

--coolthemdownbeforeinsertingthemintherelevantseatswithanouterfitting.

SPLITPINS

Wheninstallingsplitpins,makesurethatthecutispointinginthedirectionoftheloadonthepin.

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NOTESONSPAREPARTS

Usegenuine sparepartsguaranteedbytheManufacturer only. Genuinesparepartsaretheonlyonesensuringthesamequality,thesamelifeandthesamesafetyasthe originallymountedparts,sincetheyarethesameastheonesinstalledinproduction. Onlygenuinepartsfromthemanufacturerensurethisguarantee. Ordersforsparepartsmustincludethefollowingindications:

--modelofthevehicle(commercialdesignation)andserialnumber;

--typeandnumberoftheengine;

--partnumberfortheitemordered,asprovidedbythe“Microfiches”orthe“SparePartCatalogue”,onwhich theorderisbased.

NOTESONTOOLING

ThetoolingthattheManufacturerrecommendsandillustratesinthisManualis:

--studiedanddesignedspecificallyforservicingvehiclesofthisrange;

--requiredtoensureareliablerepair;

--accuratelydevelopedandinspectedtoprovideeffectiveandlonglastingworking. Youarealsoremindedthatcorrecttoolingallowsyouto:

--tooperateunderoptimisedtechnicalconditions;

--toachievethebestresults;

--tosavetimeandeffort;

--toworkinsaferconditions.

WARNING

Thewearlimitsprovidedforsomeitemsmustbeconsideredasrecommendedvalues,butnotabsolutelybinding. Theindications“front”,“rear,“right”,“left”refertodifferentpartsasseenseatingfromintheoperator’sseat orientedinthenormaltraveldirectionofthevehicle.

HOWTOMOVEAVEHICLEWITHOUTBATTERIES

Thecablesoftheexternalpowersupplymustbeconnectedexclusivelytotherespectiveterminalsofthepositive andnegativecablesofthevehicle,usingefficientclampsprovidingadequateandsafecontact.Intheeventit isnecessarytochecktheoperationoftheelectricalsystemofthevehicle,doitexclusivelywiththepowersupply connected.Attheendoftheinspection,disconnectallactuatorsanddeactivatethepowersupplybefore disconnectingthecables.

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SAFETYRULES

PAYATTENTIONTOTHISSYMBOL

Thisalertsymbolannouncesimportantmessagesinvolvingyoursafety. Readcarefullythesafetyinstructionslistedandfollowtheprecautionsrecommended toavoidpotentialrisksandtosafeguardyourhealthandyoursafety. YouwillfindthissymbolinthetextofthisManualwiththefollowingkeywords:

WARNING --Cautionsintendedtoavoidimproperrepairinterventionsinvolving potentialconsequencesforthesafetyofthepersonnelperformingtherepairs.

DANGER --Thesewarningsqualifyspecificallypotentialdangersforthesafetyofthe operatororotherpersonsdirectlyorindirectlyinvolved.

AVOIDACCIDENTS

Mostaccidents,whethertheyoccurinworkshop,on thefarm,athomeorontheroad,arecausedbythe failureofsomeindividualstofollowsimpleandfundamentalsafetyrulesandprecautions.ForthisreasonMOSTACCIDENTSCANBEPREVENTEDby recognisingtherealcauseanddoingsomething aboutitbeforetheaccidentoccurs.

Regardlessofthecareusedinthedesignandconstructionofanytypeofequipment,therearemany conditionsthatcannotbecompletelysafeguarded againstwithouthinderingreasonableaccessibility andefficientoperation.

Acarefuloperatoristhebestinsuranceagainstan accident.

Thecompleteobservanceofonesimplerulewould preventmanyseriousaccidents.

DANGER. Neverattempttoclean,lubricateormaintainamachinewhileitisinmotion.

SAFETYRULES SAFETYRULES

◊ Readandheedallsafetyrulesbeforeanyintervention.

◊ Donotwearrings,wristwatches,jewellery,and looseorhangingapparels,suchasties,torn clothing,scarves,unbuttonedorunzipped jacketsthatcancatchonmovingparts.Wear propersafetyequipmentasrecommendedfor thejob.Examples:hardhat,heavygloves,ear protection,safetyglassesorgoggles,reflector vests,respirator.Consultyouremployerforspecificsafetyequipmentrequirements.

◊ Donotperformanyserviceoperationonthe machinewithapersonseatedintheoperator’s compartment,unlessheisanauthorisedoperatorco--operatingintheoperationtobeperformed.

◊ Neverattempttooperatethemachineoritstools fromanypositionotherthanseatedintheoperator’sseat.

◊ Neverperformanyinterventiononthemachine withenginerunningunlessthisisprescribed.

◊ Cut--offtheengineandmakesurethatallpressuresinthehydraulicsystemsarereleased beforeremovingcaps,covers,valvesetc.

◊ Allserviceinterventionsmustbeperformedwith theutmostcareandattention.

◊ Shopand/orfieldserviceplatformsorladders mustbeconstructedandmaintainedinaccordancewithlocalandnationalregulations.

◊ Disconnectthebatteriesandtagallcontrolsto signalthataninterventionisinprogress.Block themachineandallequipmentthatmustbe lifted.

◊ Donotchecknorrefillfueltanks,aswellasbatteries,norusestartingfluidwhilesmokingor nearopenflamessincethesefluidsareflammable.

◊ Brakesareinactivewhenmanuallyreleasedfor serviceinterventions.Undersuchcircumstancesitisnecessarytomaintainthecontrolof themachineusingappropriateblocksorsimilar devices.

◊ Thefuel--fillingnozzlemustbekeptconstantly insidethefillingneck.Keepthiscontactfromthe beginningtotheendofthefuellingoperationto avoidthepossibilitythatsparksduetostatic electricityaregenerated.

◊ Useonlydesignatedtowingorattachingpoints. Usecareinmakingattachments.Makesurepins and/orlocksaresecurebeforepulling.Stayclear ofdrawbars,cablesorchainsunderload.

◊ Tomoveadisabledmachine,useatrailerora low--boy,ifavailable.

◊ Toload/unloadamachinefromtransporter, choosealevelsurfaceensuringfirmsupportto thewheelsoftruckortrailer.Anchorthemachine

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securelytothebedoftruckortrailerandblock wheelsortrackswithappropriatewedges.

◊ Useonlyapprovedgroundedauxiliarypower sourcesforheaters,chargers,pumpsandsimilarequipmenttoreducethehazardsofelectrical shocks.

◊ Liftandhandleheavypartswithaliftingdevice ofpropercapacity.

◊ Bewareofbystanders.

◊ Neverpourgasolineordieselfuelintoopen, wideandlowcontainers.

◊ Neverusegasoline,solventorotherflammable fluidtocleanparts.Useexclusivelyqualified, non--flammable,non--toxiccommercialsolvents.

◊ Whenusingcompressedairforcleaningparts, usesafetyglasseswithsideshieldsorgoggles.

◊ Limitpressureto2.1bar,inaccordancewith localandnationalregulations.

◊ Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaust fumes.

◊ Donotsmokeorpermitanyopenflamesorspark nearwhenre--fuellingorhandlingflammable materials.

◊ Donotuseanopenflameasalightsourceto lookforleaksorforinspectionanywhereonthe machine.

◊ Movewithextremecarewhenworkingunderthe machine,itsattachmentsandoronornear them.Alwayswearprotectivesafetyequipment asrequired,suchashardhat,goggles,safety shoes,earplugs.

◊ Whenperformingoperationsrequiringrunningof theengine,haveaqualifiedoperatorintheoperator’sseatatalltimeswiththemechanicon sight.Placethetransmissioninneutralandset thebrakesandsafetylock.

◊ Forfieldservice,movemachinetolevelground, ifpossible,andblockit.Ifworkonaninclineis absolutelynecessary,firstblockmachineandits attachmentssecurely,thanmoveittolevel

groundassoonaspossiblewithacertainmargin ofsafety.

◊ Donottrustwornand/orkinkedchainsand cables:donotusethemforliftingorpullingoperations.Tohandlethem,alwaysuseheavy gloves.

◊ Besurechainsandcablesareanchoredandthe anchorpointsarestrongenoughtohandlethe expectedload.Keepexposedpersonnelclearof anchorpointsandcablesorchains.No bystandersareallowednearthehookingpoints, chainsorcables.

◊ Keeptheareawheremaintenanceoperations areperformedCLEANandDRY.Eliminate immediatelyallwaterandoilspillages.

◊ Donotpileupoilyorgreasyrags;theyrepresent afirehazard.Storeinaclosedmetalcontainer. Beforestartingmachine,check,adjustandlock theoperator’sseatformaximumcomfortand controlofthemachine.Besureexposed personnelintheareaofoperationareclearofthe machinebeforemovingitoritsattachments. Soundthehorn.

◊ Donotcarrylooseobjectsinpocketsthatmight fallunnoticedintoopencompartments.

◊ Wearproperprotectiveequipmentsuchas safetygogglesorsafetyglasseswithside shields,hardhat,safetyshoes,heavygloves whenmetalorotherparticlesareapttoflyorfall.

◊ Wearweldersprotectiveequipmentsuchas darksafetyglasses,helmets,protectiveclothing,glovesandsafetyshoes,whenweldingor burning.Weardarksafetyglassesnearwelding zones.DONOTLOOKATARCWITHOUT PROPEREYEPROTECTION.

◊ Steelcablesarefrayedafterprolongeduse; alwayswearappropriateprotections(heavy gloves,gogglesetc.).

◊ Handleallpartscarefully.Keephandsand fingersawayfromstructures,gearsormoving parts.Useandwearalwaystheappropriate protections,suchassafetygoggles,glovesand safetyshoes.

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604.02.395.00 --12--2002

STARTING

◊ Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaust fumes.

◊ Donotplacehead,body,limbs,feet,handsor fingers,nearrotatingfansorbelts.Beespecially alertnearpusherfans.

ENGINE

◊ Loosentheradiatorcapveryslowly,torelease pressurefromthesystem,beforeremovingit.All coolantleveltop--upsmustbeperformedwith engineinoperativeoratlowidle,ifwarm

◊ Donotrunenginewhenrefuellingandusecare iftheengineishotduetotheincreasedpossibilityofafireiffuelisspilled.

◊ Neverattempttocheckoradjustfanbeltswhen engineisrunning.Donotadjustenginefuel pumpwhenmachineismoving.

◊ Neverlubricatethemachinewithenginerunning.

ELECTRICALSYSTEM

◊ Shouldboosterbatteriesbeused,rememberto connectbothendsoftheboostercablesinthe propermanner(+)with(+)and(--)with(--).Avoid short--circuitsoftheterminals.Followthoroughly theinstructionsofthisManual. Avoidshortcircuitingtheterminals.BATTERY GASISHIGHLYFLAMMABLE.Leavebattery boxopentoimproveventilationwhenrecharging batteries.Nevercheckchargebyplacingmetal objectsacrosstheposts.Keepsparksoropen flamesawayfrombatteries.Donotsmokenear batterytoguardagainstthepossibilityofcausing anexplosion.

◊ Beforeanyintervention,makesurethatthere arenofuelorelectrolyteleakages;eliminate thembeforeproceedingwithfurtherwork.

◊ Whenrechargingbatteriesinclosedambient, makesurethatthereisappropriateventilationto preventpossibleaccidentalexplosionsdueto theaccumulationofgasesgeneratedduringthe recharge.

◊ Beforeanyintervention,makesurethatthemain switchisOFF.

HYDRAULIC SYSTEM

◊ Fluidescapingunderpressurefromaverysmall holecanbealmostinvisibleandcanhavesufficientforcetopenetratetheskin.Useapieceof cardboardorwoodtosearchforsuspectedpressureleaks.donotusehands.Ifinjuredbyescapingfluid,seeadoctoratonce.Seriousinfection orreactioncandevelopifpropermedicaltreatmentisnotadministeredimmediately.

◊ Incasepressuresmustbemeasured,use instrumentsofadequatecapacity.Alwaysfollow therecommendedprocedures.

WHEELSANDTYRES

◊ Makesurethattheinflationpressureofthetyres isaccordingtothespecificationsissuedbythe Manufacturerandcheckitperiodically.

◊ Shouldthepressurebechanged,standonthe sideofthetyreatasafedistance.

◊ Pressurecheckoperationsmustbeperformed withunloadedmachineandcoldtyres.Never usereconditionedtyrerims,sinceeventual weldings,heat--treatmentsorrepairsnotperformedcorrectlycanweakenthewheel,thus causingsubsequentdamagesordangers.

◊ Donotperformtorchcuttingorweldingoperationsonrimswithinflatedtyresinstalled.

◊ Beforeoperatingontyres,blockallwheels,front andrear.Afterjackingthemachine,blockitwith standsaccordingtocurrentsafetyrulesand regulations.

◊ Beforeremovingobjectsfromthetyretread, deflateit.

◊ Neverinflatetyreswithflammablegas; explosionsandseriousbodilyinjuriesmay result.

REMOVALSANDINSTALLATIONS

◊ Liftandhandleallheavypartswithliftingdevices ofadequatecapacity.Makesuethattheparts areattachedtoliftingdevicesareproperly slinged.Usetheliftingeyesprovided.Bewareof personsinthevicinity.

◊ Handleallpartscarefully.Keephandsand fingersawayfromstructures,gearsormoving parts.Useandwearalwaystheappropriate protections,suchsgoggles,glovesandsafety shoes.

◊ Preventchainsandcablesfromkinking.To handlethem,alwaysuseheavygloves.

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PRODUCTIDENTIFICATION

TheTelehandleranditsmaincomponentsareidentifiedbyvariousnumbersandlettersprovidingits identificationbytheServicenetwork.Thefollowing informationgivesthelocationoftheidentification plates,ofthenumbersstampedonthemachineand variousexamplesofwhatcanbefoundonthe machine.

VEHICLESERIALNUMBER

Theserialnumberisstampedonthefrontpartofthe machine,ontheuppersideofthemainframe,right side. Example:*ZEFK1740A00000000*.

NOTE: Theserialnumberandtheidentification numberofthecomponentscanberequestedbythe DealerwhenSparePartsareorderedorinterventionsarerequired.Thesenumbersarealsorequired ashelpinidentifyingthemachineintheeventoftheft. Keeptheminasafeplace.

VEHICLEIDENTIFICATIONPLATES

Thevehicleidentificationplateislocatedontheleft sideoftheseatlocation.Recordherebelowthedata foryourmachine. TECHNICALTYPE/MODEL

IDENTIFICATIONOFENGINE

Theidentificationdataoftheengineareontheleft sideoftheenginecylinderblock.Pleaserecordhere belowthesedataforeasierconsultation,when required. MODELNO.

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TH001027 1

SERIALNO.OFVEHICLE YEAR TH001048 2

SERIALNO. DATECODE TH001029 3

IDENTIFICATIONOFFRONTAXLE

Theserialnumberandtheaxletypeareindicatedon plate(1)locatedonthefrontsideoftheaxlehousing. Pleaserecordherebelowthedataindicatedfor fasterconsultationwhenrequired.

AXLETYPE

SERIALNO.

DATECODE

IDENTIFICATIONOF4x3POWERSHIFT TRANSMISSION

Theserialnumberandthemodelareindicatedon plate(1)locatedonthelowersideofthetransmission.Pleaserecordherebelowthedataindicated forfasterconsultationwhenrequired. MODELNO.

IDENTIFICATIONOFREAR TRANSMSSION

Theserialnumberisindicatedonplate(1)locatedon thelowersideofthereartransmission.Please recordherebelowthedataindicatedforfasterconsultationwhenrequired.

AXLETYPE

SERIALNO.

DATECODE

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SERIALNO. DATECODE TH001030 1 4

IDENTIFICATIONPLATESINTHECAB

Thecabidentificationplatecontainsaseriesof furtherdetailsanditislocatedontheleftrearsideof theseat.Pleaserecordherebelowthedataindicated forfasterconsultationwhenrequired.

SERIALNO.

DATECODE

Thedatarelativetotheengineareindicatedonthe conformityplatesinstalledtogetherwiththeCab Plate.Pleaserecordherebelowtheserialnumber indicatedforfasterconsultationwhenrequired.

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DATECODE 5

SERIALNO.

ENVIRONMENTALCONSIDERATIONS

Thefollowingrecommendationscanbeuseful:

• Becomefamiliarandmakesureyouhavewell understoodtherelevantlegislationineffectin yourcountry.

• Intheeventnoregulationsexist,askforspecific informationwiththesuppliersoflubricants,antifreezeanddetergentsregardingtheireffectson humansandtheenvironmentandhowtostore, handleanddisposeofthesesubstancessafely.

4.Avoidspillagewhendrainingusedcoolantmixtures,engineoils,transmissionandhydraulic fluids,brakefluid.Afterdraining,donotmix brakefluidorfuelwithlubricants.Storethemina riskfreemanneruntilwhentheycanbedisposed ofinanadequateway,inaccordancewithlocal regulationsandtheresourcesavailable.

5.Moderncoolingmixtures,suchasantifreezeand otheradditives,mustbechangedeverytwo years.Maximumattentionmustbepaidtopreventthattheyspillovertheground.Theymustbe collectedanddisposedofsothatdonotcreate anydanger.

6.Donotunsealairconditioningsystembyyourselves,sincetheycancontaingasesthatmust notbereleasedintotheatmosphere.Thepersonnelspecialisedinairconditionersuses specialequipmenttochargeanddischargeair conditioningsystems.

Usefulindications

1.Donotfilltankswithinadequatecanistersordispensingpressurisedsystemsthatcouldcause considerablespillage.

2.Ingeneral,avoidthecontactoftheskinwithany fuel,oil,acid,solventetc.Themajorityofthem containsubstancedangerousforyourhealth.

3.Modernlubricantscontainadditives.Donotburn contaminatedfuelsand/orwedoilsinnormal heatingburners.

7.Repairatonceanyleakageordefectofthe enginecooling systemorhydraulicsystem.

8.Donotincreasethepressureofanypressurised system,sincethiscouldcauseseriousproblems tothecomponentsofthesystem.

9.Protecthoseswhenperforminganywelding, sinceasplashofweldingmaterialscouldpenetrateandburnthem,causingaholeorweakeningthewallwithsubsequentleakagesofoil, coolantetc.

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GENERALNOTICES

MAINTENANCETECHNIQUES

Cleantheoutsideofallthecomponentspriortoperforminganytypeofrepair.Dirtandabrasivedustcan reducetheefficientlifeexpectancyofacomponent andresultinexpensiverepairs.

Thetimespentinpreparingandcleaningworking surfacesisgivingresults,makingworkeasierand safer,andthecomponentsoverhauledwillbemore reliableandoperatebetter.

Usecleaningfluidsproventobesafe.Sometypesof fluidcancauseseriousproblemstoO--Ringsandirritatetheskin.Itisnecessarytocheckthatthesolventsaresuitabletocleanthecomponentsandthat oftheyarefreeofrisksforthehealthofworkers.

ReplaceO--Rings,sealingringsandsealseverytime theyaremoved.NeveruseoldO--Ringsorsealsand newonestogether,independentlyfromtheirconditions.AlwayslubricatenewO--Ringsandsealswith hydraulicoilbeforeinstallingthem.

Whenreplacingcomponents,alwaysusethetooling requiredbythistypeofwork.

HOSESANDSTEELPIPES

Alwaysreplacehosesandsteelpipeswhenthetaper endorconnectionsaredamaged.

Whenanewhoseisinstalled,connectitwithout tighteningtheendsandmakesurethatitisroutedin thecorrectmanner,beforetighteningtheends.Fixturesmustbetightenedjustenoughtoholdthehose withoutsqueezingit,avoidingrubbingaswell. Afterreplacingahoseofmovingcomponents,make surethatthehoseisnotdisturbedbythemovement ofthecomponentinanyposition.

Makesurethatallhosesinstalledarenotchokedor bent.

Ifhoseconnectionsaredamaged,dented,chokedor leaking,decreasetheflowofoilandtheproductivity oftherelevantactuators.Connectionsshowing signsofdisplacementfromtheiroriginalpre-pressedpositionmustbeconsideredasalready broken,sincetheyaregoingtofailorseparatesoon.

Ahosewitharaggedoutersleeveallowswaterto penetrate.Thus,hiddencorrosionofthereinforcing wirewilldevelopalongtheentirelengthofthehose, withthesubsequentfailureofthehoseitself.

Ifahoseswells,thisindicatesthatthereisaninternal leakageduetoastructuralfailure.Thiscondition deterioratesveryquicklyandcausesthefailureof thehose.

Clogged,squeezed,excessivelytensionedor deformedhosesaregenerallyeasilysubjecttoflow reduction,decrementoftheoperationalspeedofthe fluidandthefinalfailureofthehose.

Loosehosesmovefreelyandmustbeprevented fromtouchingeachotherandnearbysurfaces.This causesarubbingactionshorteningtheusefullifeof thehose.

CONNECTIONSWITHFRONTSEALING O--RINGS

Whenrepairingconnectionswithfrontsealing O--Rings,pleasecomplywiththefollowingprocedures.

WARNING:NEVERDISCONNECT,NOR TIGHTENAHOSEORASTEELPIPEUNDER PRESSURE.IFINDOUBT,MOVETHECONTROL LVERSSEVERALTIMESWITHTHEENGINE INOPERATIVEBEFOREDISCONNECTINGA HOSEORASTEELPIPE.

1.Loosentheconnectionsandseparatethehose orsteelpipe,thenremoveandeliminatethe O--Ringsfromtheconnection.

2.DipanewO--Ringinclean,hydraulicoilbefore installingit.InstallthenewO--Ringintheconnectionand,ifnecessary,holditinitsposition withvaseline.

3.Installanewhoseorsteelpipeandtightenmanuallytheconnectionholding,atthesametime, thepipestilltopreventitfromturning.

4.Usetwowrenchestotightentheconnectionto thetorqueprescribedforitssize.Pleasereferto thetabletofollowforthetighteningtorques.

NOTE:toensurethatajointdoesnotleak,itis importantthattheconnectionsareneither excessivelytightenednortoolittle.

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

SPECIFICSEALINGCOMPOUNDS

Thefollowingsealingcompoundsmustbeused,complyingwiththeindicationsprovidedbytheManual:

SEALANTSCOMMERCIALNAME

AnaerobicsealantLOCTITE518(liquidgasket)

RTVsiliconsealantLOCTITESUPERFLEX593,595or596 LOCTITEULTRABLUE587DOWCORNINGSILASTIC 732GENERALELECTRICRTV103or108

PipesealantPST592(pipesealantwithteflon)

Lockingcompoundfor threads LOCTITE271/RED(sealant/lockingforthreads)

TIGHTENINGVALUESFORFASTENERS

Checkperiodicallythatthefastenersareproperly tightened.

Baseduponthetablestofollow,determinethecorrecttighteningtorquewhenpartsofthefastening componentsarechecked,adjustedorreplaced.

IMPORTANT:DONOTusethevalueslistedinthe tableswhentheManualindicatesadifferenttorque

ortighteningprocedureforaspecificapplication.The torquevaluesareprovidedforgeneraluseonly. Makesurethatthethreadsofthefastenersareclean andundamaged.

NOTE: useatorquewrenchtotightenfastenerscorrectly.

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

MINIMUMTIGTENINGTORQUESFORFASTENERS

INNEWTON--METRES(Nm) FORNORMALINSTALLATIONAPPLICATIONS

METRICBOLTSANDLOCKNUTS

IDENTIFICATION

HEXSCREWS(WITHOUTNUT)ANDROUNDHEADBOLTS CLASS5.6ANDHIGHER

IDENTIFICATIONOFTHEMANUFACTURER

HEXNUTSANDTIGHTENINGNUTS CLASS05ANDHIGHER

IDENTIFICATIONOFTHEMANUFACTURER

12 SECTION00--GENERAL 604.02.395.00 --12--2002 M41.72.22.63.43.74.81.8 M65.87.68.91213176.3 M814182228314015 M1028364356617930 M124963759710713853 M16121158186240266344131 M20237307375485519671265 M244115316488398971160458

CLASS5.8 CLASS8.8CLASS10.9 NOMINAL DIMENSION NOT PLATED PLATED Zn/Cr NOT PLATED NOT PLATED PLATED Zn/Cr PLATED Zn/Cr LOCKNUT CL8 withBOLT CL8.8 COMMERCIALCLASS MARKING COMMERCIALCLASS

MINIMUMTIGTENINGTORQUESFORFASTENERS

GRADEIDENTIFICATION

GRADEA:NOCUTS

GRADEB:ONEPERIMETERCUT GRADEC:TWOPERIMETERCUTS

GRADEIDENTIFICATION

GRADEA:NEWMARK

GRADEB:THREEMARKS

GRADEC.SIXMARKS

THEMARKSARENOTCOMPULSORILY LOCATEDINTHECORNERS

GRADEA.NOMARKS

SECTION00--GENERAL 13 604.02.395.00 --12--2002 IDENTIFICATION SCREWS(WITHOUTNUT) ANDROUNDHEADEDSCREWS LOCKNUTS 1289373742960104813565237391 7/81932484956416989043504947/8 3/41982563063974325602173063/4 5/81121451742242443161221725/8 9/1681104125163176229881259/16 1/257738711312315961881/2 7/16374757738010441577/16 3/823303546506526353/8 5/1613172026283714205/16 1/46.28.19.71314186.99.81/4

INNEWTON--METRES(Nm) FORNORMALINSTALLATIONAPPLICATIONS INCHMEASUREMENTSCREWSANDLOCKNUTS GRADESAE2GRADESAE5GRADESAE8 LOCKNUTS NOMINAL DIMENSION NOMINAL DIMENSION NOT PLATED OR SILVER PLATED NOT PLATED OR SILVER PLATED NOT PLATED OR SILVER PLATED NOT PLATED OR SILVER PLATED PLATED Zn/Cr OR NOT PLATED PLATED Zn/Cr OR NOT PLATED PLATED Zn/Cr OR NOT PLATED PLATED Zn/Cr OR NOT PLATED

NORMALNUTS HEXNUTS GRADESAE5 HEXNUTS GRADESAE8

GRADESAE2 GRADESAE5 GRADESAE8

GRADEB:LETTERB

GRADEC:LETTERC

Sleevewrenchforpower-shiftoildeliverycontrolvalve

Hydraulicclutchspringscompressionadapter 1,2,3,4FWREV RECOMMENDED

Toolforinstallationofpower-shiftFWREVhydraulicclutch shaftneedlebearing COMPULSORY

Fortheinstallationofnew bearings(usewith 380000xxx)

Devicefortheinspectionof theaxlebrakeclutchdisc wear

Toolfortheinstallationofaxle housinguniversaljointseal Toinstallanewbushtobe usedwith(380000258)

Toinstallanewbushtobe usedwith(380000258)

14 SECTION00--GENERAL 604.02.395.00 --12--2002 SPECIALTOOLS POWERSHIFTTRANSMISSION Q.TY NUMBER SKETCH DESCRIPTION HOWTOUSE/MODEL

380000606

RECOMMENDED Foroildeliverycontrolvalve ALL

2 380000607

Topressthehydraulicclutch

ALL

springs

2 380000430

ALL FRONTANDREARAXLES Q.TY NUMBER SKETCH DESCRIPTION HOWTOUSE/MODEL

2 380000581

COMPULSORY Tocheckthewearofbrake

ALL

discs

2 380000582

2 380000583

Toolfortheinstallationofthe swingaxlehousinguniversal jointseal RECOMMENDED ALL

Setofpinsfordisassembly/ assemblyofaxledifferential planetarygearpins

2 380000591 (297410)

Wrenchforaxlebevelpinion ringnut

SECTION00--GENERAL 15 604.02.395.00

Q.TY NUMBER SKETCH DESCRIPTION HOWTOUSE/MODEL

Toolfortheinstallationofaxle

seal COMPULSORY Toinstallanewsealtobe usedw/(380000258) ALL

--12--2002

2 380000584

housingu--jointshaftspindle

2 380000585

COMPULSORY Toinstallanewsealtobe usedw/(380000258) ALL

COMPULSORY Toadjusttheplayofthe bevelgearset ALL

COMPULSORY Toholdtheplanetarygears forremovalofpins ALL

Toolforinstallationofaxle wheelhubseal

2 380000586 Wrenchforaxledifferential ringgear

2 380000587 Retainerforaxledifferential planetarygear

2 380000588

COMPULSORY Toguidethepins ALL

Guideforaxledifferential gearpin

2 380000589

COMPULSORY Toremove/installthepins. ALL

2 380000590

COMPULSORY Toholdthebevelpinion(to

ALL

Retainerforaxlebevelpinion slottedkey

beusedw/380000591

COMPULSORY Forbevelpinionringnut ALL

16 SECTION00--GENERAL 604.02.395.00 --12--2002 Q.TY NUMBER SKETCH DESCRIPTION HOWTOUSE/MODEL 2 380000592 Setofbracketsfordisassemblyofaxlebevelpinion RECOMMENDED Todisassemblethebevel pinionwithageneralpuller ALL 2 380000463 (293438) Adjusterforaxlebevelpinion bearings COMPULSORY Toadjustthebearings ALL 2 380000593 Spacer(tobeusedw/ 380000463) COMPULSORY ALL 2 380000594 Toolfortheinstallationofaxle bevelpinionseal COMPULSORY Toinstallanewseal ALL 2 380000595 Toolfortheinstallationof frontaxleparkingbrakeshaft supportseal COMPULSORY Toinstallanewseal ALL 2 380000609 Adapterforthearrangement ofaxlebevelpinion COMPULSORY Toadjustthepinion. ALL 2 380000281 (294056) Toolfortheinstallationof Roto--GlydDANFOSSseal COMPULSORY Toinstallanewseal ALL 2 380000306 (293389) Toolfortheinstallationof DANFOSSrotorsprings RECOMMENDED Toinstallthesprings ALL 2 380000210 Toolfortheinstallationof DANFOSSdustseal COMPULSORY Toinstallanewseal ALL

GENERAL

NOTE: “TheManufacturer”pursuesapolicyofconstantimprovements,thusreservestherighttomodifyatany momenttechnicalanddesigndata,withoutnotice,andwithoutanyobligationtomodifythemachinespreviously manufactured.

AllthedataprovidedinthisManualaresubjecttovariationsinproduction.Dimensionsandweightsare approximateandtheillustrationsdonotnecessarilyshowthemachinesinnormalconditions.Inordertohave specificinformationaboutadeterminedmachine,pleaseconsultanAuthorisedDealer.

SECTION00--GENERAL 17 604.02.395.00

--12--2002

Model T13 T14 T17 nonstab. stab. nonstab. stab. nonstab. stab. Engine 88kW(120CV) TurboAftercooler 88kW(120CV) TurboAftercooler 88kW(120CV) TurboAftercooler Max.liftheight 12.30 12.45 13.30 13.45 16.24 16.60 Max.capacity (at500 mmfromforkheel) 4000 4000 4000 4000 4000 4000 Capacityatmaximum height 3000 4000 2500 3500 2000 3000 Extensionatmax. height 1.40 1.23 1.70 0.85 2.70 1.80 Max.longitudinal extension 8.65 9.33 12.54 Capacityatmax. extension 600 1500 450 1350 0 600 Weight (kg) 10700 11340 12090

*Valuemeasuredwithtyres13.00--24

18 SECTION00--GENERAL 604.02.395.00 --12--2002 TH008001 6 T13 A1200mm B3120mm C1617mm D5850mm E7050mm F2080mm G452*mm I1100mm K1260mm T4396mm U2730mm V5204mm V1 980mm V2 3890mm W2445mm

SECTION00--GENERAL 19 604.02.395.00 --12--2002 TH001040 7

T13withoutstabilisersorstabilisersraised

20 SECTION00--GENERAL 604.02.395.00 --12--2002 TH001041 8

T13withlargestabiliserslowered

SECTION00--GENERAL 21 604.02.395.00 --12--2002 TH001042 9

T13withsmallstabiliserslowered

*Valuemeasuredwithtyres13.00--24

22 SECTION00--GENERAL 604.02.395.00 --12--2002 TH008001 10 T14 A1200mm B3120mm C18370mm D60700mm E7270mm F2080mm G452*mm I1100mm K1260mm T4552mm U2730mm V5390mm V1 980mm V2 3890mm W2445mm

SECTION00--GENERAL 23 604.02.395.00 --12--2002 TH001043 11

T14withstabilisersraised

24 SECTION00--GENERAL 604.02.395.00 --12--2002

TH001044

T14withlargestabiliserslowered

SECTION00--GENERAL 25 604.02.395.00 --12--2002

TH001045

T14withsmallstabiliserslowered

*Valuemeasuredwithtyres13.00--24

26 SECTION00--GENERAL 604.02.395.00 --12--2002 TH008002 14 T17 A1200mm B3120mm C1902mm D6135mm E7335mm F2080mm G452*mm I1100mm K1260mm T4598mm U12730mm V5445mm V1 980mm V2 3890mm W2445mm

SECTION00--GENERAL 27 604.02.395.00 --12--2002 TH001046 15 T17withstabilisersraised

28 SECTION00--GENERAL 604.02.395.00 --12--2002 TH001047 16 T17withstabiliserslowered

ENGINEDATA 88kW(120CV)

TurboAftercooler

ModelDiesel

Numberofcylinders4in--line

Boremm102

Strokemm120

Displacementcm3 3900

Totaldisplacement17:1

Firingorder1.3.4.2

Lowidlerpm825--875

Max.idlerpm2425--2475

Nominalspeedrpm2200

Maximumtorque450Nm

COOLINGSYSTEM

TypePressurised,full--flow, w/by--pass concameradiespansione

Fan7blades

Fanbeltdeflection10--16mm

Drivebeltdeflection

Airconditionercompressor16mm

Thermostat:

Startsopeningat81 °C

Radiatorcap1bar

INTAKESYSTEM

Injectionpump

TypeRotary

ColdstartdeviceThermostart

ExcessfueldeviceAutomaticgovernor

FuelshutoffSolenoid

LiftpumpMechanical

SECTION00--GENERAL 29 604.02.395.00

--12--2002

TRANSMISSION

POWERSHIFT–T120004x3=4speedsforwardand3reverse

ELECTRICALSYSTEM

Alternator65amp.

Typeofbattery12Voltgroundednegative

Optional160Amph

Batterycut--offbyswitchonnegative/framecable

RegulatorTransistor

GroundNegative

StartermotorPositiveengagement,electricallycontrolled(3.1kW)

Lightbulb40/45W

Stoplight/taillight5/21Wwithbayonetsocket

Outerlightbulb5W(string)10Wbayonetsocket

Flashinglightbulb21Wwithbayonetsocket

Worklightbulb55WH3halogen

Instrument/indicatorlightsbulb1.2Ww/outsocket

Switchlightbulb1.2Ww/outsocket

BRAKES

TypeOil--bath,multipledisc.8peraxle Discdiameter203.2mm

TypeofparkingbrakeNegativeonfrontaxle

STEERING

SteeringtypeOrbitrol

PumptypeGear

Systempressure175bar

Wheeltoe--in0--2mm

FRONTTRANSMISSION

MountedonfrontframeSwingingwithlevellingcylinder DifferentiallockNo

REARTRANSMISSION

MountedonframeFloatingwithswingandautomaticlockingwhenboom angleexceeds10°

604.02.395.00 --12--2002

30 SECTION00--GENERAL

Speed Ratio Stallspeed(RPM) I 4.025 2349 II 2.048 2309 III 1.000 2248 IV 0.662 2170

HYDRAULICSYSTEM

GearpumpHydraulicandsteeringsystem Hydraulicsystempressure: Mainsystempressure245bar Steeringsystempressure175bar

TORQUES Nm

Wheelnuts540 Cabsecuringscrews380

RADIATORCOOLANT

Theantifreezemustbechangedevery1000hoursorevery24months

NOTE: Toreducedeposits andlimitcorrosion,thewaterusedinthecoolingsystemmustnotexceedthefollowinglimits:

TotalhardnessChlorideSulphates 300ppm100ppm100ppm

TYRECOMBINATIONFOR4--WHEELDRIVEVEHICLES

Thetyresmountedon4--wheeldrivemachinesareselectedsothattheyarecompatiblewiththetransmission andaxlegears.Whendamagedorworntyresarereplaced,alwaysmounttyresofbrand,modelanddimension equaltothepreviousones.Theinstallationofcombinedtyrescanresultinanexcessivewear,lossofavailable powerorseriousdamagetothetransmissioncomponents.Ifindoubt,consultyourDealer.

IMPORTANT: Thedatalistedhereaboveandbelow aregeneraldataprovidedasaguidetoevaluatethe weightofthemachineanddonotnecessarilyconsiderthetyresinstalled,theleveloffluidsorthepres-

enceofadditionalequipment.Toestablishprecisely theweightofyourmachine,itisnecessarytoplace itonanofficialweightbridge.

SECTION00--GENERAL 31 604.02.395.00 --12--2002

MACHINEWEIGHT Weight 12metre=8.950kg 14metre=11.050kg 16metre=11.700kg

TH001001

TYREPRESSURES

Thetablesareprovidedforreferenceonly.Forspecificinformationrelativetoinflationpressuresandtheload ofthetyresused,pleaseconsultyourDealer.

*Thepressureslistedrefertoinflationforsiteuse.

Thedatalistedhereabovecorrespondtothe“approximateweight”ofastandardmachine,withoutequipment.

604.02.395.00 --12--2002

32 SECTION00--GENERAL

Model TYRE DIMENSION FRONT REAR PRESSURE [bar]* AXLEWEIGHT (static,empty) [kg] AXLEWEIGHT (Dynamic,nominal) [kg] 1 4 0 0 2 4 1 2 p ly front 4.5 4650 6390 14.00--2412ply rear 4.5 6060 5321 1 3 0 0 2 4 1 4 p ly front 4.5 4650 6390 13.00--2414ply rear 4.5 6060 5321 4 0 5 /7 0 2 4 1 4 p ly front 4 4650 6390 T1 3 405/70--2414ply rear 4 6060 5321 T13 1 5 5 R2 5 front 4.5 4650 6390 15.5R25 rear 4.5 6060 5321 1 5 R2 2 5 front 4.5 4650 6390 15R22.5 rear 4.5 6060 5321 4 0 0 /8 0 2 4 1 4 p ly front 4.25 4650 6390 400/80--2414ply rear 4.25 6060 5321 1 4 0 0 2 4 1 2 p ly front 4.5 5380 7300 14.00--2412ply rear 4.5 6000 5200 1 3 0 0 2 4 1 4 p ly front 4.5 5380 7300 13.00--2414ply rear 4.5 6000 5200 4 0 5 /7 0 2 4 1 4 p ly front 4 5380 7300 T1 4 405/70--2414ply rear 4 6000 5200 T14 1 5 5 R2 5 front 4.5 5380 7300 15.5R25 rear 4.5 6000 5200 1 5 R2 2 5 front 4.5 5380 7300 15R22.5 rear 4.5 6000 5200 4 0 0 /8 0 2 4 1 4 p ly front 4.25 5380 7300 400/80--2414ply rear 4.25 6000 5200 1 4 0 0 2 4 1 2 p ly front 4.5 5730 7470 14.00--2412ply rear 4.5 6360 5620 1 3 0 0 2 4 1 4 p ly front 4.5 5730 7470 13.00--2414ply rear 4.5 6360 5620 4 0 5 /7 0 2 4 1 4 p ly front 4 5730 7470 T1 7 405/70--2414ply rear 4 6360 5620 T17 1 5 5 R2 5 front 4.5 5730 7470 15.5R25 rear 4.5 6360 5620 1 5 R2 2 5 front 4.5 5730 7470 15R22.5 rear 4.5 6360 5620 4 0 0 /8 0 2 4 1 4 p ly front 4.25 5730 7470 400/80--2414ply rear 4.25 6360 5620

TELEHANDLERTELESCOPICLIFTER

LUBRICANTSANDCOOLANTS

Engineoilcorrectviscositygradedependsonambient temperature.Refertothetableontherightforselecting engineoilforyourmachine.

NOTE: Inareaswithlongperiodsofextremetemperature, locallubricationproceduresareadmissible,suchasusing SAE5W30wherethereareextremelylowtemperaturesor SAE50wherethereareextremelyhightemperatures.

EngineoilreplacementintervalisshowninSection3.Local fuelcanhoweverhaveahighsulphurcontent:inthiscase engineoilreplacementintervalmustbechangedasfollows:

NOTE: Fluidandlubricantquantitiesarecomprehensive.Drainedquantitiesmaybeless,duetocertainamonnts offluidorlubricantremainingtrappedinsidethemachine.

SECTION00--GENERAL 33 604.02.395.00 --12--2002

Sulphurcontentsinfuel.

Sulphurcontentsin%Oilreplacementinterval Below0.5Normal 05.5to1.0Halfthenormal Over1.0Onefourththenormal --30 °C +20 °C --25 °C +40 °C --22 ° F --13 °F +5 °F +68 °F +104 °F SAE15W--40 SAE10W--30 SAE5W--30 --15 °C

Itisadvisedtousefuelwithasulphurcontent below1.3% SUGGESTEDFLUIDSANDTHEIR APPLICATION InternationalSpecification Quantity Ambient Temperature(°C) Oil–ENGINE APICF--4/SG AmbraSuperGold15W40ACEAE2 7,6litres From–10to+50 AmbraSuperGold10W30MIL--L--2104E (includingengineoilfilter) Oil–POWERSHIFT TRANSMISSION ATFTypeASuffixA 12,9+4litres (linesandradiator) AmbraHydropowerALLISONC4 Oil–FRONTANDREARAXLE APIGL5eAPIGL5LS GO90LS FUCHSTitanGearLS85W90ZFTE--ML05 7litres From--20to+50 Oil–DROPBOX AmbraHypoideLS9080W90APIGL5 0,75litres OIL–FRONT/REARAXLEHUB AmbraHypoideLS9080W90APIGL5 0,65litres OIL–FRONTLOADER HYDRAULICSYSTEM ISOVG46 AmbraHydrosystem46HVDIN51524 185litres ENGINERADIATOR Water AmbraAgriflu H2O 12litres 12litres BRAKECONTROLCIRCUIT–OIL AmbraBrakeLHMM6C59--A 1litre CRANEARMSHOES–GREASE AmbraTutelaMRM2NLGI2 Asrequired GENERAL–GREASE AmbraGR9NLGI2 Asrequired From--40to+50 CONDITIONERCOMPRESSOR FreonR134a FUEL DieselFuel 135litres

NOTE:

SECTION10--ENGINE 1 604.02.395.00 --12--2002 SECTION10--ENGINE CONTENTS SectionDescriptionPage 10000Engineidentificationcode2 Enginemaincharacteristics3 Generalcharacteristicsofengines4 General 6 Descriptionofthemainmechanicalcomponentsoftheengine12 Lubrication 23 Cooling 28 ..................................................................... Turbocharging 30 ............................................................... Mechanicalinjectionsupply system31 Injectionassembly33 Timinggeardrive43 Injectionpumpsetting44 Electricalcomponents45 Troubleshooting46 Tools 50 Assemblyclearancedata55 ......................................................

ENGINEIDENTIFICATIONCODE

F4BE0484F*D+

Emissionslevel

Approvedpower

Application

Fuel/injection

NºCylinders

Cylinderposition: 0=4verticalstrokes

Engine Enginecrankcasetype: B =Non--structuralcrankcase

4 =4cylinders

D =TIER2

Engine family

8 =turbochargeddiesel IDwithIntercooler

4 =Groundmachines

X=6Two--valverotativeinjectionpump Y=Engineversions

Sequentialproductionnumber

604.02.395.00 --12--2002

2 SECTION10--ENGINE

XYYYYYYYY

SECTION10--ENGINE 3 604.02.395.00 --12--2002 ENGINEMAINCHARACTERISTICS F4BE0484 A G*D600 F*D601 B C 3900cm3 D 74kW 2200rpm. 88kW 2200rpm. E Directinjection F Rotativeinjectionpump G T.C.A. (Turbochargedwithaftercooler) A Enginetype En ine t B Numberof cylinders Number o linders C Totaldisplacement p D Maximumpowercurrentlyavailable p y E Injectiontype F Injectionsystem G Ai d li Airdeliverysystem

GENERALCHARACTERISTICS OFENGINES

604.02.395.00 --12--2002

TURBOCHARGING

Withaftercooler HOLSETHX25W

LUBRICATION

Forcedbymeansofgearpump, pressurereliefvalve, oilfilter

4 SECTION10--ENGINE

Type F4BE0484 ype G*D600 F*D601 Cycle Diesel4stroke Supply Turbochargedwithaftercooler Injection Direct Numberofcylinders 4inline Boremm 102 Strokemm 120 Totaldisplacementcm3 3900 Compressionratio 17:1 MaximumpowerkW (HP) rpm 74 100 2200 88 120 2200 MaximumtorqueNm(kgm) rpm Lowidlespeedrpm 850 850 Highidlespeedrpm 2450 2450

Turbochargertype:

Oilpressurewithenginewarm: atidlespeedbar atmaximumspeedbar 1.2 3.8

SECTION10--ENGINE 5 604.02.395.00 --12--2002 Type F4BE0484 ype G*D600 F*D601 COOLING Liquid Waterpumpdrive:Belt Thermostat: startstoopenat: °C81÷ 2 Uraniac UraniaTurbo U i T b LD REPLENISHINGFLUIDS Totalcapacity1stfillinglitres kg UraniaTurbo --enginesumplitres kg Uraniac UraniaTurbo UraniaTurboLD --enginesump+filterlitres kg SUPPLY Boschtypeinjection VE4/12F1100L Pumptiming 0°÷ 0°,5 Beginingofdeliverymm 1 Injectors DSLA145P603 Firingorder 1--3--4--2 Injectionpressure 245bar

6 SECTION10--ENGINE 604.02.395.00 --12--2002 GENERAL TH110001 D C B A G F E 1

A. Drivebeltfor:waterpump–alternator–fan

B. Alternator C. Waterpump

D. Oilpump

Beltrightener

F. Rotaryinjectionpump

G. Airheaterforcoldstart

SECTION10--ENGINE 7 604.02.395.00 --12--2002 Topview

DEFG B A C 2

TH110002 A. Alternator B. Injector C. Turbocompressor D. Blow--by E. Injectionpump F. Inletmanifold G. Fuelfilter

8 SECTION10--ENGINE 604.02.395.00 --12--2002 Frontview TH110003 A B C D E I H G F 3

A. Blow--by B. Fuelfilter C. Primingpump D. Fixedbelttensioner E. Oilfilter F. Poly–Vbelt G. Waterpump H. Alternator I. Thermostat

SECTION10--ENGINE 9 604.02.395.00 --12--2002 Rightsideview TH110004 L I H A B C D E F G 4

A. Blow--by B. Turbocompressor C. Thermostat D. Alternator E. Waterpump F. Poly--Vbelt G. Unionforoilfilter H. Startermotor I. Oilexhaustpipefromturbocompressor L. Exhaustmanifold

10 SECTION10--ENGINE 604.02.395.00 --12--2002 Leftsideview TH110005 L I H G F E D C B A 5

A. Blow--by B. Fuelpipesforinjectors C. Injectionpump D. Oilfilter E. Primingpump F. Fuelfilter G. Fuelheater H. Poly–Vbelt I. Airheater L. Intakemanifold

C. WASTEGATEValve

D. Turbocompressor

E. Oilexhaustpipefromturbocompressor

F. Alternator

G. Exhaustmanifold

H. Startermotor

I. Engineflywheel

L. Oilfilter

M. Injectionpump

N. Airheater

O. Intakemanifold

SECTION10--ENGINE 11 604.02.395.00 --12--2002 Rearview TH110006 OABCD E F G H I L M N 6

A. Blow--by B. Fuelpipesforinjectors

DESCRIPTIONOFTHEMAINMECHANICAL COMPONENTSOFTHEENGINE

Cylinderblock

Thecyliderblockisacastironstructurecontaining thecylinderliners(1),themainbearinghousings(5) andthefollowinghousings:forthecamshaft bushings(3)andthetappets,forthewater/oilheat exchanger(7),forthewaterpump 2 andfortheoil pump(4).

Thecylinderblockalsocontainsthechambersfor circulationofcoolantandoilpassagesforthe lubricationcircuitfeedingthevariousmovingparts. Soleplate(6)isappliedtotheundersideofthe cylinderblocktoincreaseresistancetomechanical stress. TH110008

604.02.395.00 --12--2002

12 SECTION10--ENGINE

1 2 3 4 5 6 7 7

Thecrankshaftismadeofsteel. Thecrankshaftisheldinfivebearingsforthefour cylinderversionofengineF4andinsevenbearings forthesixcylinderversion.Thebearingsare inductionhardened.

Thecrankshaftfeaturesaseriesofinternaloil passagesforlubricationpurposes.

Therearspigotofthecrankshaftisfittedwiththe timinggearandtheengineflywheelattachmenthub. Themainbearingshellsaremadeofsteelwithan antifrictionalloyplating.

Thepenultimatemainbearingshellsareequipped withshoulderstolimitcrankshaftendfloat.

Parts(1,2)aremountedonthecrankshaftrear spigotwithaninterferencefitandcannotbe replaced. TH110009

Thecrankshaftfrontspigotisfittedwiththeoilpump drivegear,thespeedsensorphonicwheel,the damperflywheel,andtheauxiliaryequipmentdriving pulley.

Frontandrearsealringsareofdrawertype,with radialtightness.Theymustbeextractedwithtools 380000663and380000665,andmountedwithtools 380000664and380000666.

SECTION10--ENGINE 13 604.02.395.00 --12--2002

Crankshaft

1 2 3 8

1. Timinggear 2. Flywheelhub 3. Oilpumpdrivegear Crankshaftoilseals

Connectingrods

Forgedinsteel,theconnectingrodbigendsare madewithanobliquesplittingplaneangle,withseparationofrodandcapachievedbymeansofthe innovativefracturesplittingsystemrat herthanthe conventionalmachiningprocedure.

Eachconnectingrodismarked:

• Onthebodyandonthecapbyanumberindicatingthematchandthecylinderinwhichtheyare assembled.

• Therodshankismarkedwithaletterindicating theweightclassoftheconnectingrodinstalled inproduction.

604.02.395.00 --12--2002

14 SECTION10--ENGINE

Theconnectingrodbigendbearingshellsaremade ofsteelplatedwithanantifrictionalloy.

TH110010

TH110011

Thepistoncrownfeaturesahighturbulencecombustionchamber.Thepistoncrowniscooledby engineoildeliveredbyaspraynozzleinstalledinthe crankcase,throughtheannularchamberinsidethe piston.

Therearethreepistonringgrooves;thefirstiscomposedofatrapezoidalsectioncastironinsert. Thepistonringshavedifferentfunctionsanddifferentgeometry.

1st pistonringwithtrapezoidalsectionandceramic chromeplating.

2nd pistonringwithtorsionalconicalrectangularsection.

3rd pistonringwithdoubleoilwiperwithinternal spring.

Theidentificationnumberandmanufacturingdata areprintedinthepistoncrownarea(1). TH110012

SECTION10--ENGINE 15 604.02.395.00 --12--2002 Pistons

1 11

Camshaft

Thecamshaftismountedinthecylinderblockon5 bearings.

Thefrontandrearbearingsareequippedwithsteel bushingsplatedwithantifrictionmaterialassembled bymeansofaninterferencefit.Thecamshafthas twocamlobesforeachcylinder.

A. Intakevalvescontrol

B. Exhaustvalvescontrol

Thecamshaftisdrivendirectlybythecrankshaftby meansofspurtoothgears.

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16 SECTION10--ENGINE

A B 12

TH110013 TH110014

SECTION10--ENGINE 17 604.02.395.00 --12--2002 Valveoperation TH110015 3 4 5 6 9 8 7 1 2 13

1. Rockerarm 2. Rockersupport 3. Adjustingscrew 4. Rod 5. Half--cones 6. Springcup 7. Spring 8. Tappet 9. Camshaft

Thecastironcylinderheadismachinedtoaccommodatethefollowingparts:

• valveseatinserts(4);

• injector(6);

• thermostat(5);

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Thecylinderheadisalsoequippedwith:

• exhaustmanifold(1)inoneblock;

• intakemanifold(2)withseatforcoldstartair heater(3)(ifpresentintheapplication).

18 SECTION10--ENGINE

Cylinderhead

2 3 4 5 6 1 14

TH110016 Cylinderheadwithinsertedvalveseats

Thevalveseatsmachinedinthecylinderheadhave thefollowingangles:

• 45° fortheexhaustvalves

• 60° fortheintakevalves

Theexhaustvalves(2)haveanidentificationrecess atthecentreofthepoppet. TH110018

SECTION10--ENGINE 19 604.02.395.00 --12--2002 Valvesandvalveseats TH110017 2 A S 1 15

1. Intakevalve 2. Exhaustvalve A. Intakeside S. Exhaustside.

Figure16showstheoilsealsmountedonthevalve stems.

Valveguides

Thevalveguidesarenotinserted.

TH110019

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20 SECTION10--ENGINE

Engineflywheel

Theflywheel(1)needsnotbefittedinaspecificpositiononthecrankshaft,asitisnotequippedwith punchmarkings,notches,orreferenceholesforsen-

sorsorfortimingpurposes.Thefixingholes(2)are equallyspacedsothattheflywheelcaneffectivelybe installedinvariousdifferentpositions.

SECTION10--ENGINE 21 604.02.395.00 --12--2002

TH110020 1 2 18

AccessoryComponentDrive

APoly--V(1)belttransmitsdrivefromthecrankshaft (4)tothewaterpump(3)andthealternator(2).

Thebeltistensionedthroughtheslotonthealternatorbracket.

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22 SECTION10--ENGINE

1 2 3 4 5 19

TH110021 1. Poly--Vbelt 2. Alternator 3. Waterpump 4. Pulleycamshaft 5. Fixedpulley

LUBRICATION

Theforcedcirculationlubricationsystemismadeup ofthefollowingcomponents:

• rotoroilpump,housedinthefrontofthecrankcaseanddrivenbyaspurtoothgearfittedonthe crankshaftspigot;

• water/oilheatexchanger,housedinthecrankcase,withoilfiltersupport;

• oilpressurecontrolvalveincorporatedinthefilter support;

• by–passvalvetoexcludeacloggedoilfilter, incorporatedinthefiltersupport;

• cartridgetypeoilfilter.

TH110022

Gravityoilreturncircuit

Pressurizedoilcircuit

Oilfilling

SECTION10--ENGINE 23

--12--2002

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24 SECTION10--ENGINE 604.02.395.00 --12--2002 Heatexchanger TH110023 2 3 4 5 6 1 21

1. Heatexchangerbody 2. Internalgasket 3. Water--oilheatexchanger 4. Gasketbetweenheatexchangerandcylinderblock 5. Oilreturntofilter 6. Oilinletfromfilter

SECTION10--ENGINE 25 604.02.395.00 --12--2002 Oilpump TH110024 22 TH110025 1 23

1. Crankshaftwithoilpumpdrivegear

Sump

Thesump(1)isflexiblyfixedtothecylinderblockby meansofanaluminiumplate(3),Figure25.

The“C”sectionrubbergasket(2),fittedonthesump attachmentprofile,servestoenhanceoiltightness whilealsoreducingthenoiselevel.

Thistypeofgasketshouldberenewedexclusivelyin theeventofdeteriorationorbreakage.

Itneednotberenewedateachdisassembly--reassembly.

26 SECTION10--ENGINE

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TH110026 24 TH110027 2 1 3 25

Recirculationofoilvapour

Theoilvapourrecirculationisensuredbyvalve(1) installedonthetappetcover(2).

Duetogravity,thecondensedvapoursfalldown underthetappetcover(2)whiletheremaining vapoursarecollectedbythebreather(3)anddispersed(i.e.,intake).

SECTION10--ENGINE 27 604.02.395.00 --12--2002

TH110028 2 3 1 26

COOLING

Theenginecoolingsystemisaclosedcircuitforced circulationtypecomposedofthefollowingcomponents:

• heatexchangertocoollubricatingengineoil;

• centrifugalwaterpumphousedatthefrontofthe crankcase;

• thermostatcontrollingcoolantcirculation.

TH110029

Waterfromthethermostat

Watercirculatingintheengine

Watertothepump

28 SECTION10--ENGINE

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Waterpump

Thewaterpump,whichisaccommodatedinahousinginthecrankcase,isdrivenbyaPoly–Vbelt.

Thealmosttotalabsenceofexternalpipes,hoses andhoseclampseliminatesthenumberofconnectionsandreducespossiblesourcesofleaks.

Theenginetemperatureiscontrolledbyathermostat.

Thecoolantcirculatesalsointheoilheatexchanger.

SECTION10--ENGINE 29 604.02.395.00 --12--2002

TH110030 28 TH110031 29

TURBOCHARGING

TurbochargingsystemwithHOLSETHX25Wturbochargerandaftercooler.

30 SECTION10--ENGINE

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Operatingdiagramforturbocharger TH110032 30 Exhaust Hotintakeair

MECHANICALINJECTIONSUPPLY SYSTEM

Fuelfilter

Thefuelfilter(4)typeisofthehighwaterseparation type;thewaterdrainscrew(3)isinstalledatthebase ofthecartridge.Theheater(2)andthetemperature sensor 5 forfiltersonF4BE0484F*D601–G*D600 enginesareinstalledonthesupport(1).

SECTION10--ENGINE 31 604.02.395.00 --12--2002

Engine

TH110034 2 3 4 5 1 31

F4BE0484G*D600 F48E0484F*D601

Primingpump

Theprimingpump(1)isinstalledonthecylinder blockanditisdrivenbythecamshaft(2).Itsfunction

isprimingthefuelinthetankandsendingittothe injectionpump.

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32 SECTION10--ENGINE

2 1 32

TH110036

SECTION10--ENGINE 33 604.02.395.00 --12--2002 INJECTIONASSEMBLY TH110037 2 3 4 5 6 9 10 8 7 1 33

1. Injector1fuelpipe 2. Injector2fuelpipe 3. Injector3fuelpipe 4. Injector4fuelpipe 5. Fuelexhaustpipefrominjectors 6. ConnectionwhiththeintakemanifoldforLDA 7. ThermalbulbforKKSB 8. Injectionpump 9. Solenoidvalve 10. Injector

34 SECTION10--ENGINE

Injectionpump

Marking V=rotarydistributorpiston;

L=anticlockwiserotationdirection TH110038 1 2 3 4 5 6 8 7 9 13 12 11 10 14 15 34

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Thepumpisoftherotarytypeanditisdrivenbya

gearengagingwiththecamshaftgear.

E=sizeofpump; 4=for4--cylinderengines; 12=diameterdistributorpistoninmm; 1100=pumprpm;

Longitudinalsectionofinjectionpump 1. Membrane 2. Adjustinghubnut 3. Feeler 4. Controllever 5. Speedcontroller 6. Boosterpump 7. Driveshaft 8. Camdisk 9. Timingadjuster 10. Distributorpiston 11. Feedconnectionpiece 12. Hydraulichead 13. Controlplate 14. Controlrod 15. Counterspring

Thedistributorpiston(6)isplacedatB.D.Candslide valve(8)shutstheboreforthefuelcut--off(7).The

fuelisfedintothecompressionchamberviafeed pipe(1)thatiskeptopenbythesolenoidvalve(2).

SECTION10--ENGINE 35 604.02.395.00 --12--2002 Modeofoperationofinjectionpump Supplystep TH110039 1 2 4 9 5 8 7 6 3 35

1. Fuelintakepipe 2. Solenoidvalve 3. Axialspline 4. Compressionchamber 5. Fuelpipebetweenpumpelementandinjectors 6. Distributorpiston 7. Boreforfuelcut--off 8. Slidevalve 9. Injector

Thedistributorpiston(5)isliftedunderinfluenceof thecamdisktoT.D.C.androtatesatthesametime arounditsownaxis.Bymeansofthesetwomovementsthefuelintakepipe(1)isclosedandthefuel

inthecompressionchamber(2)issimultaneously compressed.Theinnerpipe(3)ofthedistributorpistonisconnectedtopipe(4)andmakesthefuelfeed totheinjectors(6)possible.

36 SECTION10--ENGINE 604.02.395.00 --12--2002 Feedstep TH110040 534 1 2 6 36

1. Fuelintakepipe 2. Compressionchamber 3. Innerpipeofdistributorpiston 4. Fuelpipebetweenpumpelementandinjectors 5. Distributorpiston 6. Injectors

Thedistributorpiston(6)opensthehigh--pressure chamberbymeansofpipe(4)duringitslifttoT.D.C., ensuringpressurecompensationbetweentheinner chamberofthedistributorpiston,feedpipetothe

injectionvalvesandinnerchamberofthepump housing.

Asthepressuresubsequentlyistoolowtooperate theinjectionvalve,thefueliscut--off.

SECTION10--ENGINE 37 604.02.395.00 --12--2002 Feedend TH110041 1 2 3 4 5 6 37

1. Fuelintakepipe 2. Compressionchamber 3. Feedpipe 4. Pipeforfuelcut--off 5. Slidevalve 6. Distributorpiston

L.D.A.Modeofoperation

TheLDAdeviceadjuststhefuelflowindependently oftheairpressureinthesuctionmanifold.Thisair pressureactsuponthemembrane(1)whichisrigidly connectedtothecontrollerpin(4).Thelowerpartof thecontrollerpin(4)isprovidedwithaconicalmounting(5)withafeelerpin(6).Bymeansofthe

axialdisplacementofthecontrollerpin(4)thefeeler pin(6)isalsodisplacedandactsuponthestoplever (7).Thestopleverrotatesonitsownaxis(8)andacts uponthecontrollerdiskinsuchawaythatthefuel flowisadjustedtomatchtheairquantityfedintothe cylinders.

38 SECTION10--ENGINE

Stoppingtheengine TH110042 4 3 2 1 5 38

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1. Fuelintakepipe 2. Moveablevalvepin 3. Spring 4. Solenoidvalve 5. Compressionchamber Theengineisstoppedbymeansofdisconnectingthe startercontact. Thesolenoidvalvecurrentsupply(4)isinterrupted.

LDAdevice(load--dependentfeedadjustment) TH110043 1 2 3 4 5 6 7 8 39

Bymeansofthespring(3)thesolenoidvalvepressesthemoveablevalvepin(2)tothestop,andthus thefuelintakepipe(1)isclosed.

Ifthesolenoidvalve(6)issuppliedwithcurrent,fuel isfedintothecompressionchamber(7);inthiscase thegovernorweightsofthegovernorcollar(5)are closed,andtheleafspring(2)pressesthelifter(1) andtheslider(4)intotheadditionalfeedposition.

Thusthewholeliftofthepumpelementisusedfor thefeedtotheinjectionvalve.

Afterstartingoftheenginethegovernorcollar(5) movesaxiallyasaresultofthecentrifugalforce causedbytheexpansionofthegovernorweights(7), andcausesthestarterlifter(1)tocontactthetension lever(3)andcompresstheleafspring(2).

Undertheseconditionstheslider(4)ismovedto idlingposition.

SECTION10--ENGINE 39 604.02.395.00 --12--2002 Starting TH110044 6 7 5 24 1 40

1. Starterlifter 2. Leafspring 4. Slider 5. Governorcollar 6. Solenoidvalve 7. Compressionchamber

Startingdevicedisconnected TH110045 7 2 4 6 5 1 3 41

1. Starterlever 2. Leafspring 3. Tensionlever 4. Slider 5. Governorcollar 6. Solenoidvalve 7. Weight

Designofthecontrollerwithfeed--dependentadjustment ofthestartofdelivery

Description

Theload--dependentadjustmentofthestartofdelivery(LFB)enablesa”smoother”engineoperation (reducednoise).

TheLFBeffectisobtainedbymeansofthefollowing changes:

• Governorcollarwithanadditionalboretothe antipumpbore.

• Controllershaftwithanoblongholeandtwo crossholes

• Pumphousingwithaholethatisclosedfromoutsidebymeansofaballandthatisconnectedto thefeedchamber.

40 SECTION10--ENGINE 604.02.395.00 --12--2002 Load--dependentstartofdelivery(L.F.B.)

12 3 4 5 6 8 7 42

TH110046

1. Controlspring 2. Governorcollar 3. Tensionlever 4. Starterlever 5. Slider 6. Distributorpiston 7. Controlshaft 8. Governorweights

Modeofoperation

Independentlyofthepositionoftheouteraccelerator pedalthefuelfeedisreduced,ifthegovernorcollar (4)isdisplacedbythegovernorweightsofthecontrollerbymeansofthecentrifugalforceincaseofan increaseofthespeed.

Forsmootherengineoperationandreducedfuel feedthestartofdeliverymustbereduced.Asthe injectionadjustmentdeviceintherotarypistonpump isahydraulicdevice,thepressureincreasemustbe

reducedinordertoobtainadecreasingstartofdelivery:thisisobtainedbymeansoftheLFBdevice. Ifthegovernorcollar(4)thatrunsonthecontroller shaft(2)connectsthebore(3)tothehub(6)andthe bore(7),apartofthedieselfuelunderpressureisfed viathepipe(1and5)intothefeedchamber.Thisfuel causesareducedpressureincreaseinthepumpand areducedstartofdelivery.

SECTION10--ENGINE 41 604.02.395.00 --12--2002 Positionofthegovernorcollar intheLFBdevice TH110047 1234 7 6 5 43

a. Collarinidlingposition b. Collarinmovement c. Collarinadjustmentcondition,innerpressureloss 1. Longitudinalorificeincontrollershaft 2. Controllershaft 3. Crossingorifice,governorcollar 4. Governorcollar 5. Crossingorifice,controllershaft 6. Edgefromcontrollercenter 7. Crossingorifice,controllershaft

42 SECTION10--ENGINE 604.02.395.00 --12--2002 Coldstartautomaticinjectionadvancesystem (KKSB) TH110048 1 44

requiredcoldstartinjectionadvance. 45

1. KKSBBulb TheKKSBdevicemakesitpossibletodeterminethe

TIMINGGEARDRIVE

Thetiminggeardriveisobtainedbymeansofaspur toothgearfittedontherearspigotofthecrankshaft, whichmesheswithacorrespondingspurtoothgear onthecamshaft.

Correcttimingisachievedbyaligningthe(⇐)marks punchedonthetwogears.

SECTION10--ENGINE 43 604.02.395.00 --12--2002

TH110049 46

INJECTIONPUMPSETTING

Aftersettingthedriveshaftandcamshafttiming, takethefirstcylindertothetopdeadcentre.Thiscan beachievedbyturningthedriveshaftuntilthegearcasepinnexttothepumpfitsintothehousingonthe timinggear.

Whentheinjectionpumpisremovedandhasalready beenpreset,itisenoughtokeyitonthetiminggear, fastenittothegearcaseandremovethesealwhich guaranteesthepumppresettingandthenfasten shaft.

Tocheckcorrectsetting,installdialgauge 380000228(2)andadapter380000229(1)onthe pump,asillustratedinFigure47.

Turnthedriveshaftforthegearclearancesandput backtheenginefirstcylinderintopdeadcentreposition.

Thedialgaugeshoulddisplay1mm,corresponding tothepumpdistributorpistonstrokecomparedtothe bottomdeadcentre.Iftheprescribedvalueisnot detected,slackenthescrewsfasteningthepumpto thegearcaseandturnthepumpbodythroughthe slots,untilthecorrectpresetvalueisreached.

Iftheinjectionpumphasbeenoverhauled,whenitis keyedontheengine,itshouldbepresetat1mm comparedtothedistributorpistonbottomdead centre.

Installdialgauge380000228anditssupport 380000229asillustratedinFigure47,thenturnthe bodypumpthroughtheslots,untilthedialgaugedisplays1mm.Fastenthepumptothegearcaseand checkasdescribedabove.

44 SECTION10--ENGINE 604.02.395.00 --12--2002

TH110050 1 2 47

ELECTRICALCOMPONENTS

• Pre--postheatingkit(forF4BE0484G*D600–F4BE0484F*D601engines)(*).

• KKSBwatertemperaturesensoroninjection pump.

• Oilpressuresensorsfortheoilpressurewarning lampontheinstrumentpanel.

• ThermalbulbforKKSBoninjectionpump.

Pre--postheatingcontrolunit Controlunit(1)setstheheater(pre--postheating) operatingtimeaccordingtothesignalreceivedby theenginewatertemperaturesensor(2).

SECTION10--ENGINE 45

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(*)Controlunit,enginewatertemperaturesensor, heater

Operationdiagram

1 5 2 4 3 48

TH110051 1. Pre--postheatingcontrolunit 2. Watertemperaturesensor 3. Heaterelectromagneticswitch 4. Heater 5. Warninglamponpre--heatingwarningpanel

TROUBLESHOOTING

Enginedoesnotstart

Possiblecauses

1.Batterypartiallydischarged.

2.Batteryterminalconnectionscorrodedorloose.

3.Injectionpumptimingincorrect.

Remedies

1.Checkandrechargebattery. Replaceifnecessary.

2.Clean,inspectandtightenterminalnuts. Replaceterminalsandnutsifexcessivelycorroded.

3.Adjustinjectionpumptiming.

4.Disconnectfuellinesfrominjectionpumpand cleanthoroughly. Ifnecessarycleananddrythefueltank.

5.Filltank.

6.Checkandreplacepumpifnecessary.

7.Checkfuellines,unions,supplypump,filtersand injectionpumpforair,thenbleedsystem.

8.Repairorreplacestartermotor.

9.Checkandreplacethermostarterifnecessary.

Enginestalls

Possiblecauses 1.Idlespeedtoolow. 2.Irregulardeliveryfrominjectionpump.

Remedies

1.Adjustidlespeed.

2.Checkinjectionpumpdeliveryontestbench.

3.Disconnectfuellinesfrominjectionpumpand cleanthoroughly.Ifnecessarycleananddrythe fueltank.

4.Renewfiltercartridges.

5.Adjustvalveclearances.

6.Replacevalves.

7.Checkfuellines,unionssupplypump,filtersand injectionpumpforair,thenbleedsystem.

8.Injectionpumpdrivemechanismdamaged.

Coolantpumpmalfunction

Possiblecauses

4.Depositsincylinderheadandcylinderblock coolantpassages.

8.Replacedamagedparts.

Remedies

1.Overhaulpumporreplace.

2.Replacethermostat.

3.Removeinternaldepositsbyflushing.Checkfor leaksandrepair.

4.Flushoutcoolantsystem.

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46 SECTION10--ENGINE

4.Impuritiesorwaterinfuellines.

6.Fuelsupplypumpmalfunction. 7.Airinfuelsystem.

9.Faultycoldstartdevice.

5.Nofuelintank.

8.Startermotorfaulty.

3.Impuritiesorwaterinfuellines.

5.Incorrectvalveclearances. 6.Burntorcrackedvalves. 7.Airinfuelsystem.

4.Fuelfiltersclogged.

3.Radiatorinefficient.

1.Coolantpumpmalfunction. 2.Thermostatfaulty.

Coolantpumpmalfunction(tofollow)

Possiblecauses

5.Coolantpumpandfandrivebeltslack.

6.Coolantlevellow.

7.Incorrecttimingmotorphasing.

8.Injectionpumpcalibrationincorrect–delivering toomuchortoolittlefuel.

9.Airfilterclogged.

Enginelackspowerandrunsunevenly

Possiblecauses

1.Injectionpumptimingincorrect.

2.Autoadvanceininjectionpumpdamaged.

3.Distributorjournalworn.

4.Injectionpumpdeliveryirregular.

5.All--speedgovernordamaged.

6.Injectorspartiallyobstructedordamaged.

7.Impuritiesorwaterinfuellines.

8.Fuelsupplypumpdamaged.

9.Incorrectvalveclearances. 10.Cylindercompressionlow.

11.Airfilterclogged.

12.Tie--rodinlinkagebetweenacceleratorandinjectionpumpincorrectlyadjusted.

13.Maximumspeedscrewoninjectionpumpincorrectlyadjusted.

Remedies

5.Checkandadjustbelttension.

6.Topupexpansiontankwithspecifiedcoolant mixture.

7.Checkandadjust.

8.Calibratepumpontestbenchtovaluesspecified incalibrationtables.

9.Cleanfilterunitandreplacefilterelementif necessary.

Remedies

1.Carryoutthecorrectinjectionpumpphasingon theengine.

2.Overhaulinjectionpumpandadjustontest benchtovaluesspecifiedincalibrationtable.

3.Overhaulinjectionpumpandadjustontest benchtovaluesspecifiedincalibrationtable.

4.Overhaulinjectionpumpandadjustontest benchtovaluesspecifiedincalibrationtable.

5.Overhaulinjectionpumpandadjustontest benchtovaluesspecifiedincalibrationtable.

6.Clean,overhaulandcalibrateinjectors.

7.Disconnectfuellinesfrominjectionpumpand cleanthoroughly. Ifnecessarycleananddrythefueltank.

8.Replacefuelsupplypump.

9.Adjustvalveclearances.

10.Testcompressionandoverhaulengineifnecessary.

11.Cleanairfilterunitandreplaceelementifnecessary.

12.Adjusttocorrectlength.

13.Adjustmax.speedscrew.

SECTION10--ENGINE 47

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Engineproducesabnormalknockingnoises

Possiblecauses

1.Injectorspartiallyobstructedordamaged.

2.Impuritiesaccumulatinginfuellines.

3.Incorrectinjectionpumptiming.

4.Crankshaftknockingduetotoexcessiveplayin oneormoremainorbig--endbearingsorexcessiveendfloat.

5.Crankshaftunbalanced.

6.Flywheelboltsloose.

7.Connectingrodaxesnotparallel.

8.Pistonknockduetoexcessivewear.

9.Noisecausedbyexcessiveplayofgudgeonpins insmall--endandpistonbushings,orloosefitof small--endbushing.

10.Excessivetappet/valvenoise.

Remedies

1.Clean,overhaulandcalibrateinjectors.

2.Cleanfuellinesandreplaceseverelydented pipes.Cleaninjectionpumpifnecessary.

3.Adjustinjectionpumptiming.

4.Re--grindcrankshaftjournalsandcrankpins.Fit oversizeshellbearingsandthrustwashers.

5.Checkcrankshaftalignmentandbalance; replaceifnecessary.

6.Replaceanyboltsthathaveworkedlooseand tightenallboltstothespecifiedpreliminaryand angulartorquevalues.

7.Straightenconnectingrods,checkaxesparallelism;replaceconrodsifnecessary.

8.Reborecylinderlinersandfitoversizepistons.

9.Fitoversizegudgeonpin,reborepistonseats andsmall--endbushings.Replacebushings.

10.Checkforbrokenspringsorexcessiveplay betweenvalvestemsandguides,camfollowers andbores.Adjustvalveclearances.

Engineproducesexcessiveblackordarkgreysmoke Possiblecauses

1.Maximumdeliveryofinjectionpumptoohigh.

2.Injectionpumpdeliveryexcessivelyretardedor automaticadvanceregulatordamaged.

3.Injectionpumpdeliveryexcessivelyadvanced.

4.Injectorspartiallyortotallyobstructedorincorrectlyadjusted.

5.Airfilterclogged.

6.Lossofenginecompressiondueto:

--pistonringssticking;

--cylinderlinerwear;

--wornorincorrectlyadjustedvalves.

7.Damagedhigh--pressurefuellines.

Remedies

1.Adjustinjectiopumpontestbenchtothevalues specifiedincalibrationtable.

2.Adjustinjectinpump/enginetimingorcheck automaticadvanceregulator.

3.Adjustinjectionpump--enginetiming.

4.Cleanandoverhaulinjectorsandadjustpressure setting;replaceifnecessary.

5.Cleanairfilterunitandreplaceelementifnecessary.

6.Replacedamagedpartsor,ifnecessary, reconditionengine.

7.Inspectandreplaceifnecessary.

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48 SECTION10--ENGINE

Blue,grey--blueorgrey--whitesmoke

Possiblecauses

1.Injectionpumpdeliveryexcessivelyretardedor automaticadvanceregulatordamaged

2.njectorsobstructedordamaged

3.Oillealingpastpistonringsduetostickingrings orcylinderlineswear

4.Oilleeakingthroughtheinletvalveguidesdueto guideorvalvestemwear

5.Enginedoesnotreachcorrectoperatingtemperature(thermostatfaulty)

Enginerunsonafterswitchingoff

Possiblecauses

1.Enginestopsolenoiddamaged

2.All--speedgovernordamaged

Remedies

1.Adjustinjectionpump/enginetimingorcheck automaticadvanceregulator

2.Cleanandoverhaulinjectorsandadjustpressure setting;replaceifnecessary.

3.Replacedamagedpartsor,ifnecessary, reconditionengine.

4.Reconditioncylinderhead

5.Replacethermostat.

Remedies

1.Replacesolenoid

2.Reconditioninjectionpumpandadjustontest benchtovaluesspecifiedincalibrationdata chart.

SECTION10--ENGINE 49 604.02.395.00 --12--2002

TOOLS

TOOLNo.

DESCRIPTION

Toolkitforvalveseatregrinding

Springloadcheckingtool

380000301

Rotarystandforengineoverhaul (1000Nlifting,120N/mtorque)

380000322

Pullerforinjectionpumptoenginemountinggear

380000665

Crankshaftfrontsealpuller

380000663

Crankshaftrearsealpuller

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50 SECTION10--ENGINE

SECTION10--ENGINE 51 604.02.395.00 --12--2002 TOOLNo. DESCRIPTION 380000671 Injectorremovaltool Doubleactingbridge Bracketspair Pipe--clampfixture 380000666 Driverforcrankshaftfrontoilseal 380000664 Driverforcrankshaftrearoilseal

Toolfordisassembling/reassemblingenginevalves 380000667

Driftforremovingandfittingcamshaftbushings (usewith380000668) 380000262

Liftingtoolforcrankshaft 380000216

Equalizerforremovingandfittingengine

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52 SECTION10--ENGINE

TOOLNo. DESCRIPTION 380000670

Engineoilfilterwrench 380000221

Pliersfordisassembling/reassemblingpistonrings(65--110mm) 380000302

Gaugesupporttoolforrotarypumptiming (usewith380000228)

SECTION10--ENGINE 53 604.02.395.00 --12--2002 TOOLNo. DESCRIPTION 380000220 Insertionbandforpistonintocylinderliner(60--125mm) 380000661 Bracketsforsecuringenginetorotarystand380000301 380000669 Oilsealpullertool 380000668 Handleforinterchangeabledrivers 380000364

380000229

Gaugesupportfordifferentmeasurements (usewith380000228)

TOOLNo.

380000304

DESCRIPTION

Pairofgaugesforangletighteningwith1/2“ and3/4“squareconnector

380000228

Completesquareforconnectingrodquadraturecheck

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54 SECTION10--ENGINE

Gauge(0--5mm)

ASSEMBLYCLEARANCEDATA

SECTION10--ENGINE 55 604.02.395.00 --12--2002

Type F4BE0484 ype G*D600 F*D601 CYLINDERBLOCKANDCRANKMEMBERS mm Cylinder ∅ 1 102.01 ÷ 102.03 Pistons:suppliedasspares type DistanceX Outsidediameter ∅ 1 Seatforpin ∅ 2 61 101.777 ÷ 101.795 40.006 ÷ 40.012 Piston–cylinderliners 0.215 ÷ 0.253 Pistondiameter ∅ 1 0.5 Protrusionofpistons fromcylinderblockX 0.28 ÷ 0.52 Gudgeonpin ∅ 3 39.9968 ÷ 40.0032 Gudgeonpin–pinseat 0.0028 ÷ 0.0152 PistontypeX1* PistonringgroovesX2 X3 *measuredover ∅ 99mm 2.69 2.425 ÷ 2.445 4.04 ÷ 4.06 S1* PistonringsS2 S3 *measuredover ∅ 99mm 2.560 ÷ 2.605 2.310 ÷ 2.340 3.075 ÷ 4.000 1 Pistonrings–grooves2 3 0.245 ÷ 0.265 0.085 ÷ 0.135 0.040 ÷ 0.985 Pistonrings 0.5

56 SECTION10--ENGINE 604.02.395.00 --12--2002 Type F4BE0484 ype G*D600 F*D601 CYLINDERBLOCKANDCRANKMEMBERS mm Pistonringgapsincylinderliner: X1 X2 X3 0.40 ÷ 0.70 0.25 ÷ 0.55 0.25 ÷ 0.55 Smallendbushingseat ∅ 1 Connectingrodbearingseat ∅ 2 42.987 ÷ 43.013 77.075 ÷ 78.25 Smallendbushingdiameter Outside ∅ 4 Inside ∅ 3 43.279 ÷ 43.553 40.019 ÷ 40.033 Smallendbushing–seat 0.266 ÷ 0.566 Gudgeonpin–bushing 0.0158 ÷ 0.0362 MeasurementdistanceX Maximumerroronparallelismof connectingrodaxes= Mainjournals ∅ 1 Crankpins ∅ 2 MainbearingshellsS1* BigendbearingshellsS2* *suppliedasspareparts 82.99 ÷ 83.01 68.987 ÷ 69.013 2.456 ÷ 2.464 1.955 ÷ 1.968 Mainbearinghousingsno: no.1--5 ∅ 3 no.2--3--4 87.982 ÷ 88.008 87.977 ÷ 88.013

SECTION10--ENGINE 57 604.02.395.00 --12--2002 Type F4BE0484 ype G*D600 F*D601 CYLINDERBLOCKANDCRANKMEMBERS mm Bearingshells–mainjournals: no.1--5 no.2--3--4 0.041 ÷ 0.119 0.041 ÷ 0.103 Bearingshells–crankpins 0.033 ÷ 0.041 Mainbearingshells Bigendbearingshells +0.250;+0.500 Mainjournalof thrustbearingX1 37.475 ÷ 37.545 Mainbearinghousingof thrustbearingX2 25.98 ÷ 26.48 ShoulderhalfringsX3 37.28 ÷ 37.38 Crankshaftshoulder 0.068 ÷ 0.41

58 SECTION10--ENGINE 604.02.395.00 --12--2002 Type F4BE0484 ype G*D600 F*D601 CYLINDERHEAD–TIMINGSYSTEM mm Valveguideseats oncylinderhead ∅ 1 8.019 ÷ 8.039 Valves: ∅ 4 α ∅ 4 α 7.96 ÷ 7.98 60° 7.96 ÷ 7.98 45° Valvestemandvalveguide 0.052 ÷ 0.092 Seatonheadforvalveseat: ∅ 1 ∅ 1 46.987 ÷ 47.013 43.637 ÷ 43.663 Valveseatoutsidediameter;angle ofvalveseatsoncylinderhead: ∅ 2 α ∅ 2 α 47.063 ÷ 47.089 60° 43.713 ÷ 43.739 45° RecessingX X 0.356 ÷ 1.102 0.104 ÷ 0.840 Betweenvalveseat andhead 0.050 ÷ 0.102 0.050 ÷ 0.102 Valveseats

SECTION10--ENGINE 59 604.02.395.00 --12--2002 Type F4BE0484 ype G*D600 F*D601 CYLINDERHEAD–TIMINGSYSTEM mm Valvespringheight: freespringH underloadof: 329NH1 641NH2 63.5 49.02 38.2 InjectorprotrusionX notadjustable Seatsforcamshaftbushingsn° 1–5 Seatsforcamshaftpinsn° 2–3–4 Camshaftmainjournals: 1 ⇒ 5 ∅ 53.995 ÷ 54.045 Camshaftbushings outsidediameter: ∅ Bushinginsidediameter ∅ 54.083 ÷ 54.147 Bushingsandseatsincrankcase Bushingsandmainjournals 0.038 ÷ 0.162 Usefulcamlift: 6.045 7.239

60 SECTION10--ENGINE 604.02.395.00

Type F4BE0484 ype G*D600 F*D601 CYLINDERHEAD–TIMINGSYSTEM mm ∅1 Tappetplate seat incylinderblock ∅ 1 16.000 ÷ 16.030 ∅2 ∅3 ∅2 Tappetplateoutside diameter: ∅ 2 ∅ 3 15.929 ÷ 15.959 15.965 ÷ 15.980 Betweentappetsandseats 0.020 ÷ 0.065 Tappets ∅1 Rockercarriershaft ∅ 1 18.963 ÷ 18.975 ∅2 Rockers ∅ 2 19.000 ÷ 19.026 Betweenrockersandshaft 0.025 ÷ 0.063

--12--2002

SECTION21--POWERSHIFTGEARBOX

SECTION21--POWERSHIFT 1 604.02.395.00 --12--2002

CONTENT SectionDescriptionPage 21000 Gearboxassembly5 Idlergearcaseassembly7 Gearboxoperation8 TransmissionandHydraulicoilcircuitdiagrams15 Modulationvalveoperation31 Torqueconverterandheatexchangerhydraulicoilcircuit34 Troubleshootingguide35 ........................................................ Troubleshootingprocedures35 ................................................... Troubleshooting37 Pressuretestingclutchandhighpressurecircuit38 Pressuretestingtorqueconverterandcoolercircuit39 Checkpoints 40 Assemblyinstructions42 Overhaul 45

POWERSHIFTGEARBOX4X3

Gearboxcontrol

Themicroprocessor--controlledgearboxassembled onthismachineiscalledPowershift. ThePowershiftgearboxleverisassembledonthe leftsideofthesteeringcolumnanditenablesthe electronicselectionoffourforwardgearsandthree reversegears.

DRIVINGWITHTHEPOWERSHIFT GEARBOX

Neutralposition

Selecttheneutralpositionbyshiftingthegearbox leveltothecentre.

Selectingtheforwardgear

Toselecttheforwardgear,pullthelevertowardsthe steeringwheelandpushitupwards.

NOTE: Actualforwardgearselectionatthistime dependsuponvehicleconditions;ifitismoving,the microprocessorwilltakeintoconsiderationspeedon roadandrunningdirectionbeforeanygearshiftcan takeplace.

Selectingthereversegear

Toselectthereversegearpullthelevertowardsthe steeringwheelandpushitdownwards.

NOTE: Actualreversegearselectionatthistime dependsuponvehicleconditions;ifitismoving,the microprocessorwilltakeintoconsiderationspeedon roadandrunningdirectionbeforeanygearshiftcan takeplace.

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2 SECTION21--POWERSHIFT

A R N 2

Automaticgearincrease

Automaticincreasefromthe1st gearpositiontothe requiredgearisachievedbyturningthehandgrip anticlockwisebysinglemovements.Iftheleveris keptonthisposition,theprocessorwillmakethe gearselectionadvancefromthe2nd geartothe4th gearbyintervalsof1.8seconds.

NOTES: Therequestforautomaticincrease,aftera decrease,isdelayedby2seconds.Inthecaseofa speedsensorerror,themicroprocessorwillnotauthorizeincreasesoverthe2nd gear.

NOTES: Shouldasteepslopebedrivenup,select the2nd gearspeedandproceed,ifenabledbyspeed andpower,tothe3rd and4th gearspeed.

Automaticgeardecrease

ATTENTION

Todrivedownasteepslope,selectthe2ndspeed gearandproceedbyincreasingitonlywhenthisis possibleinfullsafety.AsamatteroffactITISNOT POSSIBLETOSHIFTDOWNAGEARTO REDUCEVEHICLESPEEDIFTHISISOVER15 Km/h.

Automaticgeardecreasedowntotherequiredspeed gearisobtainedbyturningthehandgripclockwiseby singlemovements.

Changingdirection

Runningdirectionissimplyinvertedbymovingthe Powershiftlevertothereversegearandtheother wayround,andthisoperationisallowedatanytime.

Systemresponseinanycasedependsuponvehicle speedanduponthespeedgearusedatthemoment. Whendrivingin1stor2ndspeedgear,changesin directionhavenolimitsandtheyareperformed immediately.

SECTION21--POWERSHIFT 3

604.02.395.00 --12--2002

Whendrivingin3rdor4thforwardspeedgear,two responsesarepossible,dependingonvehicle speed.

RESPONSE1:Ifvehicleforwardspeedisover15 km/handareversegearisselected,automaticdown shiftisactivated,butinertiahoweverremainsuntil speedisreducedsufficientlytoenableperforming inversionin2ndspeedgear.

RESPONSE2:Ifvehicleforwardspeedisbelow15 km/h,thereversegearisimmediatelyobteinedin 2ndspeedgear.

ShownspeedrangesrefertoaPowershiftgearboxwith13.00–2hwheelscorrespondingtoa wheeldiameterof1200mm.

DISCONNECTINGTHEGEARBOX

Gearboxdisconnectioncanbeperformedinfourdifferentways:

Gearboxdisconnectionisaconsequenceofapplying theparkingbrake.Normalgearboxoperationis restoredassoonasthebrakeisreleased.

604.02.395.00 --12--2002

SECTION21--POWERSHIFT

1.Powershiftspeedgearlever 2.Parkingbrakepushbutton 3.Pushbuttononmanipulator

2 3 2 3 1 5

SECTION21--POWERSHIFT 5 604.02.395.00 --12--2002

GEARBOXASSEMBLY Thegearboxcomprisesfivemainassemblies

2 3 4 5 1 6

TH121001 1. Theconverter 2. Theinputshaftanddirectionalclutches: A–Reverse B–Forward 3. TheoutputshaftwithC(4 th speed)andD (3 rd speed)clutchassemblies 4. ThelowershaftwithE(1 st speed)andF(2 nd speed) clutchassemblies 5. Theoutputshafttotheidlergearcase

TH121002

Reverse(A)/Forward(B)

1st speed(E)/2nd speed(F)

Idlergear

4th speed(C)/3rd speed(D)

Outputshaftwithgear

6 SECTION21--POWERSHIFT

--12--2002 GEARANDCLUTCHPOSITION

604.02.395.00

F E 7

IDLERGEARCASEASSEMBLY

Theidlergearcaseismounteddirectlyonthetransmission.Thesleeve(3)connectsthetransmission outputshaftdirectlytotheidlergearcaseinputshaft (1).Thefrontandrearaxlesaresetinmotionbythe outputshaft(2)viathedriveshafts. TH121003

SECTION21--POWERSHIFT 7 604.02.395.00 --12--2002

3 1 2 8

1. Theinputshaft 2. Theoutputshaft 3. Theconnectingsleeve

GEARBOXOPERATION

Throughtheconverter,thethermalenginetransmits motiontothegearboxinputshaft,onwhichthe advance/reversemotionclutchesareassembled. Dependingonthegearboxcontrolleverselection,solenoidvalvesareenergised/de--energisedtoenableoil

underpressuretoengagetheclutchpackagescorrespondingtotheselecteddirectionandspeed.

NOTE: Fordetails,seethefollowingpages.

604.02.395.00 --12--2002

8 SECTION21--POWERSHIFT

TH121004 1.Controlpumpconverterandpressure adjustingvalve 2. Inputshaftanddirectionclutches (forward/reverse) 3. Speedgears 4. Outputshaft 5. Speedclutches

Converter,pumpcontrolsection andpressureadjustmentvalve

Enginepoweristransmittedfromtheengineflywheel totheimpellerthroughtheimpellercover.

Thiselementisthepumpportionofthehydraulic torqueconverterandistheprimarycomponentwhich startstheoilflowingtotheothercomponentswhich resultsintorquemultiplication.Thiselementcanbe comparedtoacentrifugalpump,thatpicksupfluidat itscentreanddischargesitattheouterdiameter.

Thetorqueconverterturbineismountedopposite theimpellerandisconnectedtotheturbineshaftof thetorqueconverter.Thiselementreceivesfluidat itsouterdiameteranddischargesitatitscentre.

Thereactionmemberofthetorqueconverteris locatedbetweenandatthecentreoftheinnerdiametersoftheimpellerandturbineelements.Itsfunctionistotakethefluidwhichisexhaustingfromthe innerportionoftheturbineandchangeitsdirection toallowcorrectentryforrecirculationintothe impellerelement.Thisrecirculationwillmakethe convertermultiplytorque.

Thetorquemultiplicationisfunctionoftheblading (impeller,turbineandreactionmember)andtheconverteroutputspeed(turbinespeed).Theconverter willmultiplyenginetorquetoitsdesignedmaximum multiplicationratiowhentheturbineshaftisatzero RPM(stall).

Thereforewecansaythatastheturbineshaftis decreasinginspeed,thetorquemultiplicationis increasing.

Thehydraulicpumpisconnectedtothepumpmechanism.Thecompressorhubgeardrivesthismechanism.Sincethecompressorhubgearisconnected tothecompressorcover,pumpspeedisdirectly relatedtoenginespeed.

NOTE: Thepressureregulatorvalveismounted behindthefilter,inthefilteradapterhousing.

SECTION21--POWERSHIFT 9 604.02.395.00 --12--2002

TH121005 A B C D E F 10

Converter,pumpcontrolsectionandpressureadjustmentvalve.

Inputshaftanddirectionalclutches

Theturbineshaft,drivenbytheturbine,transmits powertoforwardgear,at4th speedoratreverse speed.

Theseclutchesconsistofadrumwithinternal splinesandaboretoreceiveahydraulicallyactuated piston.Thepistoniskeptoiltightbytheuseofsealing rings.Thesteeldiscswithexternalsplines,andfrictiondiscswithinternalsplines,arealternateduntil therequiredtotalisachieved.

Aback--upplateistheninsertedandsecuredwitha retainerring.Ahubwithouterdiametersplinesis insertedintothesplinesofdiscswithteethonthe innerdiameter.Thediscsandhubarefreeto increaseinspeedorrotateintheoppositedirection aslongasnopressureispresentinthatspecific clutch.

Toengagetheclutch,thesolenoidwilldirectoilunder pressurethroughtubesandpassagestothe selectedclutchshafts.

Oilsealingringsarelocatedontheclutchshafts. Theseringsdirecttheoilthroughadrilledpassage intheshafttothedesiredclutch.

Pressureoftheoilforcesthepistonanddiscsagainst theback--upplate.Thediscswithsplinesonthe outerdiameterclampingagainstdiscswithteethon theinnerdiameterenablesthedrumandhubtobe lockedtogetherandallowsthemtodriveasoneunit. Whentheclutchisreleased,areturnspringwillpush thepistonbackandoilwilldrainbackviathesolenoid,thebleedvalveorholesintheclutchpistoninto thetransmissionsump.

Thesebleedvalveswillonlyallowquickescapeofoil whenthepressuretothepistonisreleased.

Thetransmissionisequippedwithareversegear andtwoforwardgears(forwardand4th gear):These speedscombinedwitha3--speedclutch,produces atypeoftransmissionwith4--forwardgearsand 3--reversegearsatdifferentspeeds.

Theengagementofthedirectionalclutches(forward andreverse)aremodulated.Thismeansthatclutch pressureisbuiltupgradually.Thiswillenabletheunit tomakeforward,reverseshiftswhilethevehicleis stillmovingandwillallowsmoothengagementof drive.Themodulationisdonehydraulically.

604.02.395.00 --12--2002

10 SECTION21--POWERSHIFT

B C D F A E 11

TH121006

Theinputshaftanddirectionalclutches

Therangeclutches

Onceadirectionalclutchisengagedpoweristransmittedtotherangeclutches(1st,2nd or3rd).

Operationandactuationoftherangeclutchesis similartothedirectionalclutches.

Theengagementoftherangeclutchesisnotmodulated.

Theoutputsection

Witharangeclutchengaged,powerisfinallytransmittedtotheoutputshaft.

Outputrotationissameastheenginerotationwhen theforwardclutchisengaged.

Afrontaxledisconnectisoptionalandislocatedon theoutputshaft.Thedrivetothefrontaxlecanbe disconnectedorconnectedbymanualshifting.

SECTION21--POWERSHIFT 11 604.02.395.00 --12--2002

TH121007 A B C D E F 12 TH121008 A B C D E F 13 Therangeclutches Theoutputsection

Thetransmissioncontrols (refertohydraulicdiagram)

Thetransmissioniscontrolledbythedirectionand rangesolenoids.Thesolenoidsaremountedonthe leftsideofthetransmissioncase.Whentheselected directionandrangesolenoidsareenergised,oil underpressurewillflowthroughtubesandpassages

totheselectedclutchshafts.Oilsealingringsare locatedontheclutchshafts.Theseringsdirectoil underpressurethroughadrilledpassageintheshaft tothedesiredclutch.

TH121009

Thetransmissioncontrols

R.Reversegearsolenoidvalve

T.Forwardgearsolenoidvalve

S.Splittersolenoidvalve

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12 SECTION21--POWERSHIFT

1. Solenoidvalve(1) 2. Solenoidvalve(2)

SOLENOID/CLUTCHCOMBINATION

The6transmissionclutchpacksarecontrolledby5 solenoids,thereforecombinationsofbetween1and 3activatedsolenoidsarerequiredforclutch engagement.Thesecombinationsareshowninthe tablebelow.

Theclutchesareengagedbyhydraulicpressureand disengagedbyspring.

Theforwardandreverseclutchpacksare hydraulicallymodulatedusingamechanicalvalve.

Theotherfourspeedclutchesarenotmodulated duringengagement.

Outputisintheopositedirectiontoenginerotation.

SECTION21--POWERSHIFT 13 604.02.395.00 --12--2002

F E D C B A 2 1 S T R GEAR A4 A3 A2 A1 N R1 R2 R3 SOLENOIDSCLUTCHPACKS 15

14 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 TH121010 1 2 8 3 4 5 6 7 16

OperatingValvesandSolenoids 1. ForwardFeatheringValve 2. ReverseFeatheringValve 3. Solenoid(R) 4. Solenoid(T) 5. Solenoid(S) 6. Solenoid(1) 7. Solenoid(2) 8. Housing

TRANSMISSIONANDHYDRAULICOILCIRCUITDIAGRAMS

NEUTRALGEARENGAGED

A–Reverseclutch

B–Forwardclutch

C–4th speedclutch

D–3th speedclutch

E–1st speedclutch

F–2nd speedclutch

Operatingsolenoids:none

TH121011

SECTION21--POWERSHIFT 15 604.02.395.00 --12--2002

Pressureoilfromthesystem regulatingvalveflows tothe1st solenoidandforwardsolenoidT. Noneofthesolenoidsareengaged,allowingtheoil toflowthroughtotheclutchDonly.

16 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 TH121012 1 2 A B C D E T S R F VR VT 18 Aspiratedoil Highpressureoil(16.5--19.5bar) Torqueconverterandlubricationoil

Returntoreservoir VT Forwardmodulationvalve VR Reversemodulationvalve

(2--7bar)

ClutchesB,C,DandFareopentoreservoir.

A–Reverseclutch

B–Forwardclutch

C–4th speedclutch

D–3th speedclutch

E–1st speedclutch

F–2nd speedclutch

SECTION21--POWERSHIFT 17 604.02.395.00 --12--2002 TRANSMISSIONOPERATIONFIRSTGEARENGAGED

Operatingsolenoids:T,1and2 TH121013

Pressurisedoil comingfromthe systemregulation valvearrivesatsolenoidvalve1andattheforward gearsolenoidvalve.

Solenoidvalve1isenergisedandit enables system pressuretoengageclutchE.

Atthispointsolenoidvalve2isenergisedenabling pressurisedoilpossiblypresentinclutchesDorFto bedischargedintothesump.

Theforwardsolenoidis energisedallowingsystem pressuretoflowthroughthesplittersolenoid,tothe forwardBclutch.Modulationiscontrolledbythe modulationvalveinthecircuit.

Aspressureincreasesintheforwardclutchlinedrive increaseswithsmoothmodulation.

ClutchesA,C,DandFareopentothereservoir.

18 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 TH121014 1 2 A B C D E T S R F VR VT 20 Aspiratedoil Highpressureoil(16.5--19.3bar) Torqueconverterandlubricationoil (2--7bar) Returntoreservoir VT Forwardmodulationvalve VR Reversemodulationvalve

A–Reverseclutch

B–Forwardclutch

C–4th speedclutch

D–3th speedclutch

E–1st speedclutch

F–2nd speedclutch

Operatingsolenoids:Tand2

TH121015

SECTION21--POWERSHIFT 19 604.02.395.00 --12--2002

TRANSMISSIONOPERATIONSECONDGEARENGAGED

Pressurisedoil comingfromthe systemregulation valvearrivesatsolenoidvalve1andattheforward gearsolenoidvalve.

Solenoidvalve2isenergisedenabling systempressuretoengageclutchF.

Theforwardsolenoidis energisedallowingsystem pressuretoflowthroughthesplittersolenoid,tothe

forwardBclutch.Modulationiscontrolledbythe modulationvalveinthecircuit.

Aspressureincreasesintheforwardclutchline, driveincreaseswithsmoothmodulation.

ClutchesA,C,DandEareopentothereservoir.

20 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 TH121016 1 2 A B C D E T S R F VR VT 22 Aspiratedoil Highpressureoil(16.5--19.3bar) Torqueconverterandlubricationoil

Returntoreservoir VT Forwardmodulationvalve VR Reversemodulationvalve

(2--7bar)

TRANSMISSIONOPERATIONTHIRDGEARENGAGED

A–Reverseclutch

B–Forwardclutch

C–4th speedclutch

D–3th speedclutch

E–1st speedclutch

F–2nd speedclutch

Operatingsolenoids:T

TH121017

SECTION21--POWERSHIFT 21

--12--2002

604.02.395.00

Pressurisedoil comingfromthe systemregulation valvearrivesatsolenoidvalve1andattheforward gearsolenoidvalve.

Sinceneithersolenoidvalve1,norsolenoidvalve2 areenergised,pressurisedoilcanengageclutchD.

ForwardgearTsolenoidvalveisenergisedandit enablesoiltoflowthroughtheseparationsolenoid valveS.whichisnotenergised,andfromthereto clutchB.

ClutchesA,C,EandFareopentothereservoir.

22 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 TH121018 1 2 A B C D E T S R F VR VT 24 Aspiratedoil Highpressureoil(16.5--19.3bar) Torqueconverterandlubricationoil

Returntoreservoir VT Forwardmodulationvalve VR Reversemodulationvalve

(2--7bar)

A–Reverseclutch

B–Forwardclutch

C–4th speedclutch

D–3th speedclutch

E–1st speedclutch

F–2nd speedclutch

Operatingsolenoids:TandS

TH121019

SECTION21--POWERSHIFT 23 604.02.395.00 --12--2002

TRANSMISSIONOPERATIONFOURTHGEARENGAGED

Pressurisedoil comingfromthe systemregulation valvearrivesatsolenoidvalve1andattheforward gearsolenoidvalve.

Oilflowsthroughsolenoidvalve2andengagesthe multi--diskclutchD.

(2--7bar)

OilflowsthroughforwardgearTsolenoidvalve whichisenergised,thenthroughseparationsolenoid valveSwhichisalsoenergised,andwhichengages multi--diskCclutch.

ClutchesA,B,EandFareopentothereservoir.

24 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 TH121020 1 2 A B C D E T S R F VR VT 26

Returntoreservoir VT Forwardmodulationvalve VR Reversemodulationvalve

Aspiratedoil Highpressureoil(16.5--19.3bar) Torqueconverterandlubricationoil

A–Reverseclutch

B–Forwardclutch

C–4th speedclutch

D–3th speedclutch

E–1st speedclutch

F–2nd speedclutch

SECTION21--POWERSHIFT 25 604.02.395.00 --12--2002

TRANSMISSIONOPERATIONREVERSEFIRSTGEARENGAGED

Operatingsolenoids:R,1and2 TH121021

Pressurisedoil comingfromthe systemregulation valvearrivesatsolenoidvalve1andattheforward gearsolenoidvalve.

Solenoidvalve1isenergisedand enables system pressuretoengageclutchE.

Atthispointsolenoidvalve2isenergisedenabling pressurisedoilpossiblyexistinginclutchesFandD tobedischargedintothesump.

Theforwardsolenoidisnotenergisedallowingoilto flowthroughthereversesolenoidwhichisthen energised.Oilflowstothereverseclutch.Modulation iscontrolledbythemodulationvalveinthecircuit. ClutchesB,C,DandFareopentothereservoir.

26 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 TH121022 1 2 A B C D E T S R F VR VT 28 Aspiratedoil Highpressureoil(16.5--19.3bar) Torqueconverterandlubricationoil (2--7bar) Returntoreservoir VT Forwardmodulationvalve VR Reversemodulationvalve

A–Reverseclutch

B–Forwardclutch

C–4th speedclutch

D–3th speedclutch

E–1st speedclutch

F–2nd speedclutch

SECTION21--POWERSHIFT 27 604.02.395.00 --12--2002

TRANSMISSIONOPERATIONREVERSESECONDGEARENGAGED

Operatingsolenoids:Rand2 TH121023

Pressurisedoil comingfromthe systemregulation valvearrivesatsolenoidvalve1andattheforward gearsolenoidvalve.

Solenoidvalve1isnotenergisedanditenablesoil atsystempressuretocont inuetowardssolenoid valve2.

Atthispointsolenoidvalve2isenergisedenabling oiltoflowtowardsclutchFandopeningclutchDat thesametimetowardsthetank.

28 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 TH121024 1 2 A B C D E T S R F VR VT 30 Aspiratedoil Highpressureoil(16.5--19.3bar) Torqueconverterandlubricationoil (2--7bar) Returntoreservoir VT Forwardmodulationvalve VR Reversemodulationvalve

TRANSMISSIONOPERATIONREVERSETHIRDGEARENGAGED

A–Reverseclutch

B–Forwardclutch

C–4th speedclutch

D–3th speedclutch

E–1st speedclutch

F–2nd speedclutch

Operatingsolenoids:R

TH121025

SECTION21--POWERSHIFT 29 604.02.395.00 --12--2002

Pressurisedoil comingfromthe systemregulation valvearrivesatsolenoidvalve1andattheforward gearsolenoidvalve.

Solenoidvalve1isnotenergisedanditenablesoil atsystempressuretoflow towardssolenoidvalve2. Solenoidvalve2isnotenergisedandhenceoilflows towardsclutchD.

30 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 TH121026 1 2 A B C D E T S R F VR VT 32 Aspiratedoil Highpressureoil(16.5--19.3bar) Torqueconverterandlubricationoil (2--7bar) Returntoreservoir VT Forwardmodulationvalve VR Revesemodulationvalve

MODULATIONVALVEOPERATION

Themodulationvalveshownonthepagesopposite consistsofthefollowingcomponents:

1.ModulationValveHousing

2.ModulationSleeve

3.AccumulatorValve

4.RegulatorValve

5.StopPin

Thegraphshowshowthepressureincreasesinthe clutchpackfromthemomentofsolenoidactivation (A)untilmaximumclutchpressureisachieved(F).

DiagramA

Oilisjustabouttoenterthemodulationvalvesand boththeaccumulatorandregulatorvalvesare seatedonthestoppins.

DiagramB

Oilinitiallyflowsintothebottomoftheregulatorvalve andunseatstheregulatorvalve.Thismomentarily sendsahighpressurepulsetotheclutchpackwhich takesupthefreeplaybetweentheclutchpackplates.

DiagramC

Oilstartstoflowthroughthesmallorificeinthe regulatorvalveandequalisesthepressureoneither side.

DiagramD

Whenthetopsideoftheregulatorvalveisfullofpressurizedoilthespringpressurepushestheregulator valvebacktoitsseat.Pressurethenbeginstoacton thebottomoftheaccumulatorvalve.

DiagramE

Theaccumulatorvalvestartstomoveupthesleeve andasitdoestheoilpressurerequiredtopushitup becomesgreaterandgreaterastheopposingspring pressureincreases.Thisgradualincreasein pressurefeatherstheclutchplatesintoengagment. Thepressureincreasestopswhentheaccumulator hitsthelimitrodatthetop.

DiagramF

Astheoilsupplycontinuestotheclutchpackexcess flowisbledoffviatheregulatorvalve.

DiagramG

Whenthesupplyofoiltotheclutchpackiscutoffthe regulatorvalveseatsonthebottompinallowingoil toflowoutthetopoftheregulatorvalveallowingthe modulationvalvetobecomeseated.

SECTION21--POWERSHIFT 31 604.02.395.00 --12--2002

32 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Modulatedpressure Clutchpressure ZeroPressure(Reservoir) TH121229 TH121230 TH121231 TH121232 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 Pressure Time Modulated pressure Clutchpressure A B C D E F A B C

SECTION21--POWERSHIFT 33 604.02.395.00 --12--2002 TH121233TH121234 TH121235 TH121236 1 2 3 4 5 1 2 4 5 3 1 2 4 5 3 1 2 4 5 3 D E F G

34 SECTION21--POWERSHIFT

TORQUECONVERTERANDHEATEXCHANGERHYDRAULICOILCIRCUIT TH121027 1 8 10 2 3 4 5 6 7 9 11 12 13 14 15 16 33 Aspiratedoil

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Highpressureoil(16.5--19.3bar)

Torqueconverterandlubricationoil (2--7bar) Returntoreservoir 1. Transmissionsump 2. Transmissionbreather 3. Suctionfilter 4. Oilpump 5. Pressurefilter 6. Filterbypassvalve 7. Toclutchpacksolenoids 8. Clutchpressure(240--280psi)(16.5--19.5bar) 9. Systempressureregulatingvalve 10. Safetyvalve(10bar) 11. Oilcoolertestport 12. Torqueconverterpressure 13. Torqueconverter 14. Torqueconvertertemperature 15. Lubricationgalleries 16. Forwardandreverseclutchlubrication

TROUBLESHOOTINGGUIDE

Thefollowinginformationispresentedasanaidto isolatinganddeterminingthespecificproblemarea inatransmissionthatisnotfunctioningcorrectly.

Whentroubleshootinga“transmission”problem,it shouldbekeptinmindthatthetransmissionisonly thecentralunitofagroupofrelatedpowertraincomponents.Properoperationofthetransmission dependsontheconditionandcorrectfunctioningof theothercomponentsofthegroup.Therefore,to properlydiagnoseasuspectedprobleminthetransmission,itisnecessarytoconsiderthetransmissionfluid,chargingpump,torqueconverter,transmissionassembly,oilcooler,filter,connectinglines, andcontrols,includingtheengine,asacomplete system.

Byanalysingtheprinciplesofoperationtogetherwith theinformationinthissection,itshouldbepossible toidentifyandcorrectanymalfunctionwhichmay occurinthesystem.

Thetransmission(powershiftwithtorqueconverter transmission)troublesfallintothreegeneralcategories:

1.Mechanicalproblems.

2.Hydraulicproblems.

3.Electricalproblems.

Inadditiontothemechanicalandelectricalcomponents,allofwhichmustbeinthepropercondition andfunctioningcorrectly,thecorrectfunctioningof thehydrauliccircuitismostimportant.Transmission fluidisthe“lifeblood”ofthetransmission.Itmusbe suppliedinanadequatequantityanddeliveredtothe systematthecorrectpressurestoensureconverter operation,toengageandholdtheclutchesfromslipping,andtocoolandlubricatetheworkingcomponents.

TROUBLESHOOTINGPROCEDURES Stalltest

Astalltesttoidentifiestransmission,converter,or engineproblems.

Usefollowingprocedure:

1.Putthevehicleagainstasolidbarrier,suchasa wall,and/orapplytheparkingbrakeandblockthe wheels.

2.PutthedirectionalcontrolleverinFORWARD(or REVERSE,asapplicable).

3.Selectthehighestspeed.

Withtheenginerunning,slowlyincreaseengine speedtoapproximatelyone--halfthrottleandhold untiltransmission(converteroutlet)oiltemperature reachestheoperatingrange.

ATTENTION

Donotoperatetheconverteratstallconditionlonger than30secondsatonetime,shifttoneutralfor15 secondsandrepeattheprocedureuntildesiredtemperatureisreached.

Excesssivetemperature120 °C(250F)maximum willcausedamagetotransmissionclutches,fluid, converter,andseals.

SECTION21--POWERSHIFT 35 604.02.395.00 --12--2002

Transmissionpressurechecks

Transmissionproblemscanbeisolatedbytheuseof pressuretests.Whenthestalltestindicatesslipping clutches,thenmeasureclutchpackpressureto determineiftheslippageisduetolowpressureor clutchplatefrictionmaterialfailure.

Inaddition,converterchargingpressureandtransmissionlubricationpressurecanalsobemeasured.

Mechanicalandelectricalchecks

Priortocheckinganypartofthesystemforhydraulic function(pressuretesting),thefollowingmechanical andelectricalchecksshouldbemade:

• Checktheparkingbrakeandinchingpedalfor correctadjustment.

• Besureallleverlinkageisproperlyconnected andadjustedineachsegmentandatallconnectingpoints.

• Thecontrolsareactuatedelectrically.Checkthe wiringandelectricalcomponents.

• Besurethatallcomponentsofthecoolingsystemareingoodconditionandoperatingcorrectly.Theradiatormustbecleantomaintainthe propercoolingandoperatingtemperaturesfor theengineandtransmission.Aircleantheradiator,ifnecessary.

• Theenginemustbeoperatingcorrectly.Besure thatitiscorrectlytunedandadjustedtothecorrectidleandmaximumno--loadgovernedspeed specifications..

Hydraulicchecks

Also,beforecheckingthetransmissionclutches, torqueconverter,chargingpump,andhydrauliccircuitforpressureandrateofoilflow,itisimportantto makethefollowingtransmissionfluidcheck.

Checkoillevelinthetransmission.Thetransmission fluidmustbeatthecorrect(fulllevel).Allclutches andtheconverteranditsfluidcircuitlinesmustbe fullycharged(filled)atalltimes..

NOTE: Thetransmissionfluidmustbeatoperating temperatureof82--93 C(180--200F)toobtaincorrectfluidlevelandpressurereadings.

Donotattempttomakethesecheckswithcoldoil. Toraisetheoiltemperaturetothisspecificationitis necessarytoeitheroperate(work)thevehicleorrun theenginewithconverterat“stall”(Referto“Stall test”).

ATTENTION

Becarefulthatthevehicledoesnotmoveunexpectedlywhenoperatingtheengineandconverteratstall rpm.

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36 SECTION21--POWERSHIFT

TROUBLESHOOTING

Refertothefollowingtroubleshootingguideforthe diagnosisoftypicaltransmissiontroubles.

Lowclutchpressure

Cause

1.Lowoillevel.

2.Clutchpressureregulatingvalvestuckopen.

3.Faultychargingpump.

4.Brokenorwornclutchshaftorpistonsealingrings.

5.Valvoladispurgopistonedellafrizioneaperta.

Lowchargingpumpoutput

Cause

1.Lowoillevel.

2.Suctionscreenplugged.

3.Defectivechargingpump.

Overheating Cause

1.Wornoilsealingrings.

2.Wornchargingpump.

3.Lowoillevel.

4.Dirtyoilcooler.

5.Restrictionincoolerlines.

Noisyconverter Cause

1.Wornchargingpump.

2.Wornofdamagedbearings.

Lackofpower Cause

1.LowengineRPMatconverterstall.

2.See“Overheating”andmakesamechecks.

Remedy

1.Filltoproperlevel.

2.Cleanvalvespoolandhousing.

3.Replacepump.

4.Replacesealingrings.

5.Cleanbleedvalvesthoroughly.

Remedy

1.Filltoproperlevel.

2.Cleansuctionpump.

3.Replacepump.

Remedy

1.Remove,disassemble,andrebuildconverter assembly.

2.Replacechargingpump.

3.Filltoproperlevel.

4.Cleancooler.

5.Changecoolerlines.

Remedy

1.Replacechargingpump.

2.Acompletedisassemblywillbenecessaryto determinewhichbearingisfaulty.

Remedy

1.Tuneenginecheckgovernor.

2.Makecorrectionsasexplainedin“Overheating”.

SECTION21--POWERSHIFT 37

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TH121028

Port1Systempressure Enginesettoidle. Minimumpressure13bar. Desiredoilpressure16--19bar.

Port2EClutch Enginesettoidle.

Pressurerangeclutchactivated16--19bar. Clutchreleased0--0.2bar(0--3lb/in2).

Port3FClutch Enginesettoidle.

Pressurerangeclutchactivated16--19bar. Clutchreleased0--0.2bar(0--3lb/in2).

Port4DClutch

Enginesettoidle.

Pressurerangeclutchactivated16--19bar. Clutchreleased0--0.2bar(0--3lb/in2).

Port5CClutch

Enginesettoidle

Pressurerangeclutchactivated16--19bar. Clutchreleased0--0.2bar(0--3lb/in2).

Port6BClutch

Enginesettoidle.

Pressurerangeclutchactivated16--19bar. Clutchreleased0--0.2bar(0--3lb/in2).

Port7AClutch

Enginesettoidle.

Pressurerangeclutchactivated16--19bar. Clutchreleased0--0.2bar(0--3lb/in2).

38 SECTION21--POWERSHIFT

--12--2002 PRESSURETESTINGCLUTCHANDHIGHPRESSURECIRCUIT

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1 2 3 4 5 6 7 A B C D E F 34

Allpressureandflowtestingshouldbemeasured withanoiltemperatureof82--93degreesCelsius (180--200F).Foroperatingspeedrefertoeachtest.

Port1Systempressure Enginesetto2000revs/min. Minimumpressure13bar(lb/in2). Desiredpressure16.5--19.5bar(--lb/in2).

Port8Oilcoolerin Enginesetto2000revs/min. Pressurerange2--7bar(--lb/in2).

Port9Heatexchanger(output)

Port10Converteroutputtemperature

SECTION21--POWERSHIFT 39 604.02.395.00 --12--2002 PRESSURETESTINGTORQUECONVERTERANDCOOLERCIRCUIT TH121029 8 1 9 10 35

40 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 CHECKPOINTS TH121030 1 2 3 4 36

Lefthandsideview

1. Forwardclutchpressureoil(Bclutch) 2. Reverseclutchpressureoil(Aclutch) 3. Clutchcircuitpressurisedoil

1 2 3 37

4. Heatexchangerpressureoil TH121031 Topview 1. Regulatedclutchpressure 2. Oiltemperaturetocooler 3. Pressurefromcooler

SECTION21--POWERSHIFT 41 604.02.395.00 --12--2002 TH121032 1 2 3 4 5 38 Righthandsideview

1. Emulti--discclutchpressureoil 2. Fmulti--discclutchpressureoil 3. Converteroutputtemperature 4. Dmulti--discclutchpressureoil

TH121033 1 2 3 4 5 39

5. Cmulti--discclutchpressureoil

Rearview

1. Visualoilindicatoronidlergearcase 2. Magneticplugforoildrainingfromidlegearcase 3. Transmissionoildrainingmagneticplug 4. Transmissionoillevelcheckbar 5. Transmissionoilbreather

42 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 ASSEMBLYINSTRUCTIONS TH121034 2 5 7 1 2 4 5 7 11 10 8 2 3 4 6 7 10 13 R 4 6 7 H K T 40

SECTION21--POWERSHIFT 43 604.02.395.00 --12--2002 TH121036 TH121035 20 20 20 19 20 20 16 22 21 21 23 18 17 41

UsePermatexandLoctiteonlywherespecified. Allleadinchamfersforoilseals,pistonrings,and “O”--ringsmustbesmoothandfreefromburrs. Inspectbeforeassembly. Lubricateallpistonringgroovesand“O”--ringswith oilbeforeassembly.

Applyathincoatofgreasebetweenseallipsonlip typesealspriortoassembly.

ApplyathincoatofPermatexNo.2orLoctiteNo.641 toO.D.ofalloilsealsbeforeassembly.

ApplyathincoatofLoctiteNo.592or506Drysealto allpipeplugs.

AfterassemblyofpartsusingLoctiteorPermatex, theremustnotbeanyfreeorexcessmaterialwhich mightentertheoilcircuit.

1. Assembleoilfilterandtightento27--34Nm.

2. Teflonsealsmustbesizedpriortoassembly.

3. 10outersteelplates,10innerplates,alternately assemble,startingwithoutersteelplate.

4. 6outersteelplates,6innerplates,alternately assemble,startingwithoutersteelplate.

5. 5outersteelplates,5innerplates,alternately assemble,startingwithoutersteelplate.

6. Shieldbearing,assemblywithshieldasshown AddacoatingofLoctite641toouterdiameterof bearings.

7. Fwd.,Rev.,2nd and3rd clutchreturndiscsprings. Concavesideoffirstdiscspringtobeplaced againstclutchpistonwearsleeve. Remainingfourspringstobestackedalternately asshown.

8. Lowerclutchdiscreturnspringconcavesideis tobeplacedagainstclutchpistonwearsleeve. Remainingsixspringstobestackedalternately asshown.

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10. Clearancebetweenclutchpistonandsteelseparatorplatetobe1.22--2.74mm.Ifover2.74mm clearance,addonesteelouterdiscunderend plate.

11. Clearancebetweenclutchpistonandsteelseparatorplatetobe2.03--3.43mm.Ifover3.43mm clearance,addonesteelouterdiscunderend plate.

13. Tightenregulatorsleeveto61--68Nm.

14. Usesolenoidborepluginmiddlepositionfor 3--speedversiononly.

15. Solenoidcartridgetobeassembledandtightenedto22--27Nm.

16. Tightennutto339--407Nm.

17. Tightenallcartridgenutsto5--7Nm.

18. Tightenmodulationvalveandinchingvalveto 81--88Nm.

19. M10x30.

20. M10x60.

21. Use5/16–18screw.

22. Use5/16–18screw.

23. Use3/8–16screw.

44 SECTION21--POWERSHIFT

SECTION21--POWERSHIFT 45 604.02.395.00 --12--2002 OVERHAUL Removethecapscrewsandwashersconnectingthe driveplatetothetorqueconverterandremovethe driveplatesandbackingring. TH121037 42 Supporttheidlergearcaseappropriatelyand removethelockscrewsandtheirwashers. TH121038 43 Usealevertoremovetheidlergearcase. TH121039 44 Removethetorqueconverterplugsnapringand thenleverouttheplug. TH121040 45

46 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Removethetorqueconvertertoturbineshaftsnap

TH121041 46 Removethetorqueconvertertoshaftlocatingring. TH121042 47 Removethefilterassembly. TH121043 48 Removethepumpmountingboltsandwashersand

TH121044 49

ring.Thenpulloffthetorqueconverter.

detachthemfromthepumpbodywiththerelative gasket.

Removethepressureadjusteranditshousingwhere thefilterisscrewedinwiththetoolshowninthefollowingfigure.

NOTE: Thereisahexheadscrewattachingthe converterhousingtothemiddlemanifoldplate,this islocatedatthetopofthetransmissionontheother sideandmustalsoberemoved.

SECTION21--POWERSHIFT 47 604.02.395.00 --12--2002

TH121045 50 Tooldiagramtoremovethepressureadjusterandits housing. TH121046 51

Removetheconverterhousingtotransmissioncase boltsandwashers.

TH121047 52 Removetheconverterhousingandgasket. TH121048 53

NOTE: Insomecasesthepumpdriveshaftcanbe removedwiththeconvertercaseplate,butwhen subsequentlyreassemblingit,thecountershaftand thegearmustbemountedonthemanifoldplate.

48 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Removeimpellerhubgear. TH121049 54 Removepumpdrivegearwasher. TH121050 55 Removepumpdrivegearandbearing. TH121051 56 Removepumpdriveshaftandwasher.

TH121052 57

Removethesolenoidcoverretainingnutsandthe cover(1).Thenremovethefivesolenoidvalves(2) byfirstlyremovingtheretainingnuts,thenthe solenoidcoilsandfinallyunscrewthevalveand remove.

Removethemanifoldplateretainingboltsand washers.Positionthetransmissionsothemanifold plateishorizontalandliftthemanifoldplateupwards andawayfromtheshaftsandmaintransmission housing.Theendofthegearshaftsmayneedtobe

Removethegearclustersintheordershowninthe drawing.

(1)E/Fclutchandshaft

(2)InputshaftandA/Bclutches,andfinally

(3)C/Dclutchesandoutputshaft. RemovetherollerbearinglocatedbehindtheF clutch.

Removetheoilsupplytube’O’ringandremovethe supplytubeandscreenassembly.

SECTION21--POWERSHIFT 49 604.02.395.00 --12--2002

TH121053 1 2 58

TH121054 59

tappedwitharubbermallettokeeptheminthe transmission.

TheDclutchgearmustremaininthe transmission. TH121055 1 2 3 60

NOTE:

TH121056 1 2 61

FrominsidethetransmissionremovetheDclutch gearandtherollerbearinginwhichitwaslocated, alsoremovethebearinglocatingring.

Thenusingasuitablebrassdriftandhammertapout thedriveshaft,seal,ballbearingandsnapring,and removetheremainingretainingringfromthecasing.

Removetheinnercasesetscrewplug.Removethe clutchshaftdistributorsleevesetscrew.

Usingasuitablepuller,removethedistributorsleeve andshaftpilotbearing.

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50 SECTION21--POWERSHIFT

TH121057

TH121058

TH121059

TH121060

SECTION21--POWERSHIFT 51 604.02.395.00 --12--2002 Removethecouplingsleeve. TH121061 66 Removetheoutputshaftfrontbearingsnapring. TH121062 67 Removetheoutputgearsnapring TH121063 68 Fromtherear,removetheoutputshaftboreplug. TH121064 69

52 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Fromthefronttaptheoutputshaftandrearbearing fromthehousing. TH121065 70 Outputshaftandrearbearingremoved. TH121066 71 Removetheoutputshaftgearandsnapring. TH121067 72 Removetheoutputshaftfrontbearing. TH121068 73

SECTION21--POWERSHIFT 53 604.02.395.00 --12--2002 Removetheoutputshaftfrontbearingsnapring. TH121069 74 Removetheclutchshaftrearbearingouterraces. TH121070 75 Fromtherear,removetherearbearingsnapring. TH121071 76

54 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 ModulationValveRemoval Removethemodulationvalvehousingand’O’ring. TH121072 77 Removetheinner,middleandoutervalvesprings,

TH121073 78 Removethemodulationhousingsleeveand’O’ring. TH121074 79

thevalvestoppinandtheaccumulatorspool.

TH121075 80

Toassistinremovingthediverter,usea5/16--24 threadedrod.

SECTION21--POWERSHIFT 55 604.02.395.00 --12--2002 DisassemblyoftheAandBclutches Aclutchdisassembly(Reverse) Removetheouterthrustwasher,thrustbearingand innerthrustwasher. A TH121076 81 Removetheclutchhubandgearassemblyandpress outthe2bearingsandspacer. A TH121077 82 Removetheouterthrustwasher,thrustbearingand innerthrustwasher. A TH121078 83 Removetheendplateretainingring. A TH121079 84

56 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Removetheendplateandalsothe6frictiondiscs and6separatorplates. A TH121080 85 Compressthebellevillewashersandremovethe snapring,alsoremovethesnapringretainer, bellevillewashersandtheclutchpistonwearplate. A TH121081 86 Toremovethepistonturntheclutchpackupside downandtaptheshaftonablockofwood. A TH121082 87 DisassemblyofBclutch(Forward) Removethe3oilsliprings. B TH121083 88

SECTION21--POWERSHIFT 57 604.02.395.00 --12--2002 Removetheexternalthrustwasher,thethrustbearingandtheinternalthrustwasher. B TH121084 89 Slideofftheclutchhubandgearassemblyandpress outthe2bearingsandspacer. B TH121085 90 Removetheouterthrustwasher,thrustbearingand innerthrustwasher. B TH121086 91 Leverouttheendplateretainingring. B TH121087 92

58 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Removetheendplateandthe6frictiondiscsand6 steelsparatorplates. B TH121088 93 Compressthebellevillewashersandremovethe snapring,thenproceedtoremovethesnapring retainer,bellevillewashersandtheclutchpiston wearplate. B TH121089 94 Turntheclutchpackupsidedownandtaptheshaft onablockofwood,thiswilldislodgethepistonfor removal. B TH121090 95 Aclutchreassembly(Reverse) Installtheclutchpistonintheclutchhousing. A TH121082 96

Installtheclutchpistonwearplate,followedbythe fivebellevillewashersstartingwiththefirstwasher withthelargerdiametertowardsthewearplate,then alternatetheremainingfour.Positionthesnapring retainerontothebellevillewashersandthenfitthe snapring.

TochecktheAclutchpackdiscclearanceposition theclutchpackupsidedown.Measurethedistance betweentheclutchpistonandthefirststeelsparator discbyinsertingafeelergauge(1).

Therequiredclearanceis1.22--2.74mm(0.48-0.108inches).Iftheclearanceisgreaterthan 2.74mm(0.108inches)addonesteeldiscunderthe endplate.

SECTION21--POWERSHIFT 59 604.02.395.00 --12--2002

A TH121081 97 Fitthe6steelseparatorplatesandthe6frictiondiscs andthetheendpate. A TH121080 98 Thenfittheendplateretainingring. A TH121091 99

A TH121092 A B 1 100

60 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Positiontheinnerthrustwasher,thrustbearingand outerthrustwasher. A TH121078 101 Pressonebearingintotheclutchhubandgear assemblythenplacethespacerandsecondbearing ontopandpressthesecondbearingflushtothetop ofthegear.Theninstallthehubassemblyintothe clutchpack. A TH121077 102 Thenplacetheinnerthrustwasher,thrustbearing andouterthrustwasherovertheshaft. A TH121076 103 ReassemblyoftheBclutch(Forward) Installthepistonintotheclutchpack. B TH121090 104

Placethepistonwearplateovertheshaftandthen placethefirstbellevillewasherwiththelarger diametertowardsthepistonwearplate,then alternatetheremaining4washers.

Tochecktheclutchdiscclearanceplacetheclutch packupsidedownandplaceafeelergauge(1) betweentheclutchpistonandthesteelseparator plate.

Therequiredclearanceshouldbe1.22--2.74mm (0.048--0.108inches).Iftheclearanceisgreater than2.74mm(0.108inches)addonesteeldisc undertheendplate.

SECTION21--POWERSHIFT 61 604.02.395.00 --12--2002

Positionthesnapringretainer,compressthe bellevillewashersandfitthesnapring. B TH121089 105 Installthe6steelseparatorplatesand6friction discs,startingwithasteelseparatorplatefirst,then fittheendplate. B TH121088 106 Installtheendplateretainingring. B TH121093 107

B TH121094 B 1 108

62 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Thenpositiontheinnerthrustwasher,thrustbearing andouterthrustwasherovertheshaft. B TH121086 109 PressonebearingflushtothetopoftheBclutchhub gearthenplacethespacerandbearingontopofthe pressedbearingandpressthesecondbearingflush tothegearface. B TH121085 110 Installtheinnerthrustwasher,thrustbearingand outerthrustwasher. B TH121084 111 Fitthe3oilsliprings. B TH121083 112

SECTION21--POWERSHIFT 63 604.02.395.00 --12--2002 DisassemblyofCandDclutchesandshaft Cclutchdisassembly(4th speed) Removeclutchshaftoilsliprings. C TH121095 113 Usingasuitablepuller,removetheclutchgearand frontbearing. C TH121096 114 Removetheclutchgearlocatingsnapring,thrust washerretainingringandthentheouterthrust washer,thrustbearingandinnerthrustwasher. C TH121097 115 Removetheclutchgearandhubassemblyandpress the2bearingsandspacerfromthegear. C TH121098 116

64 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Removetheendplateretainingring. C TH121099 117 Removetheendplateandsixfrictiondiscsandsix separatorplates. C TH121100 118 Compressthebellevillewashersandremovethe snapring,thenproceedtoremovethesnapring retainer,bellevillewashersandclutchpistonwear plate. C TH121101 119 Removetheclutchpistonbyturningtheclutchpack upsidedownandtappingtheshaftonablockof wood. C TH121102 120

SECTION21--POWERSHIFT 65 604.02.395.00 --12--2002 DisassemblyofDclutch(3rd speed) Useanextractortoremovetheclutchpackgear. D TH121107 121 Removealsotheshaftbearinginnerrace,thethrust bearingwithitsinnerandouterwashersandthetwo gearbearings. D TH121108 122 Removethethrustwasherretainingring,then removetheouterthrustwasher,thrustbearingand innerthrustwasher. D TH121103 123 Removetheendplateretainingring. D TH121104 124

66 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Removetheendplateandthefivefrictiondiscsand fivesteelseparatorplates. D TH121105 125 Compressthebellevillewashersandremovethe snapring,snapringretainer,bellevillewashersand theclutchpistonwearplate. D TH121106 126 Removetheclutchpistonbyturningtheclutchpack upsidedownandtappingtheshaftonablockof wood. D TH121109 127 ReassemblyofCclutch(4th speed) Installtheclutchpistonintothehousing. C TH121102 128

Assembletheclutchpistonwearplate. FirstentertheBellevillewasherbysettingitwiththe largerdiameterturnedtowardsthewearplate,and thenadd,byalternatingthemtheotherfoursprings. Positiontheelasticringcheckdeviceovertheshaft, compresstheBellevillewashers,thenassemblethe elasticring.

Checkthattheelasticringiscorrectlyfittedinitsown channel.

Installthe6separatordiscs andfrictiondiscs.Install asteelseparatorfirstandthenalternatethe remainingdiscsandfinishwiththeendplate.

Tocheckclearance,positionthediskpackage upsidedownanduseathicknessgauge(1)to measurethedistancebetweenclutchpistonandthe steelseparationdisk.

Thedesiredclearanceshouldbe1.22--2.74mm (0.048--0.108inches)iftheclearanceisgreaterthan 2.74mm(0.108inches)thenfitanothersteeldisc undertheendplate.

SECTION21--POWERSHIFT 67 604.02.395.00 --12--2002

C TH121101 129

C TH121100 130 Fittheendplateretainingring. C TH121099 131

C TH121110 C 1 132

68 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Positionthethrustbearinginnerwasher,thrust bearingandthrustbearingouterwasheroverthe shaft. C TH121111 133 Pressonebearingintothehubthenplacethespacer ontopandpressthenextbearingflushtothefaceof thegear.Installintotheclutchassembly. C TH121098 134 Positiontheinnerthrustwasher,thrustbearingand outerthrustwasherovertheshaft.Thenfitthesnap ringontopandendgearlocatingsnapring. C TH121112 135 Installtheendgearandthenpressonthebearing withthebearingshieldupwards. C TH121113 136

Installtheclutchpistonwearplateandthenthe bellevillewashers,placethefirstbellevillewasher withthelargerdiametertowardsthewearplate, alternatetheremainingfour.Thenpositionthesnap ringretainer,compressthebellevillewashersandfit thesnapring.

Fitthe5steelseparatorplatesand5frictiondiscs, startwithasteelseparatorplateonthepistonand thenalternatebetweenfrictiondiscandsteel separatorplates.Finallyinstalltheplatewiththe thickessection.

SECTION21--POWERSHIFT 69 604.02.395.00 --12--2002

C TH121095 137 DisassemblyofDclutch(3rd speed) Refittheclutchpiston. D TH121109 138

D TH121106 139

Refitthetwooilslipringsandlubricate.

D TH121105 140

70 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Fittheendplateretainingring. D TH121104 141 Installthethrustbearingwasher,thrustbearingand theouterthrustwasher. D TH121103 142 Installthefirstthegearwithitstwobearings,the innerwasher,thethrustbearing,theouterwasher andtheshaftbearinginnerrace. D TH121108 143

SECTION21--POWERSHIFT 71 604.02.395.00 --12--2002 DisassemblyandreassemblyoftheE/Fclutch packs DisassemblyofEClutch(1st speed) Removetheclutchshaftoilsliprings. E TH121114 144 Removethefrontbearingusingasuitablepuller. E TH121115 145 Removetheouterthrustwasher,bearingandinner thrustwasher. E TH121116 146 Removetheclutchgearandhubassemblyandpress outthetwopilotbearings. E TH121117 147

72 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Removetheouterthrustwasher,thrustbearingand innerthrustwasher. E TH121118 148 Removetheclutchdiscendplateretainingring. E TH121119 149 Removetheclutchdiscendplate,thenremovethe 10frictionand10st eelseparat ordiscs. E TH121120 150

E TH121121 151

Compressthebellevillewashersandremovethe snapring,thebellevillewashersandtheclutchpiston wearplate.

SECTION21--POWERSHIFT 73 604.02.395.00 --12--2002 Toremovetheclutchpistonturntheclutchoverand taptheshaftonablockofwood. E TH121122 152 DisassemblyofFClutch(2nd speed) Usingasuitablepuller,removethegearandrear bearinginnerrace. F TH121123 153 Removethegearlocatingringfromtheshaft. F TH121124 154 Removethethrustbearingandclutchgearsnapring,

gearandhubwiththepilotbearings. F TH121125 155

followedbytheouterthrustwasher,thrustbearing andinnerthrustwasher.Thenremovetheclutch

74 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Removetheouterthrustwasher,thrustbearingand innerthrustwasher. F TH121126 156 Removetheclutchdiscendplateretainingring. F TH121127 157 Removetheendplateand5frictionand5steel separatordiscs. F TH121128 158

F TH121129 159

Compressthebellevillewashersandremovethe snapring,followedbythesnapringretainer, bellevillewashersandtheclutchpistonwearplate.

Removetheclutchpistonbyturningtheclutchpack overandtappingtheshaftonablockofwood.

Cleanandinspectallpartsfordamage.Where damageisevidentreplacepartsandalsoallgaskets.

NOTE: Itismoreeconomicaltoreplacepartswhen theunitisdisassembledthantocarryoutoverhaul duetoprematurefaliure.

ReassemblyoftheEClutch(1st speed)

Ifnewsealringshavebeenfittedtothepistonmake suretheyhavebeensized.Aftersizingwipethe surfaceswithalittletransmissionoil,thefittothe clutchhousing.

Placetheclutchpistonwearplateontothepiston, thenplacethefirstbellevillewasherontopofthe wearplatewiththelargediameterdownwards,then alternatetheremaining6washersfollowedbythe snapringretainer.Compressthewashersandfitthe snapring.

SECTION21--POWERSHIFT 75 604.02.395.00 --12--2002

160

TH121130

161

TH121131

162

TH121132

Thenfitthe10steelseparatordiscsand10friction discs.

Fitasteelseparatorplatefirstandthenalternatethe frictionandseparatordiscs.Finish withtheclutch discendpate.

Tochecktheclutchdiscclearance,placetheclutch plateonendasshownsothattheclutchdiscsare restingonthepiston.Measurethedistancebetween theendplateandtheretainerringusingasetof feelergauges.Themeasurementshouldbewithin thelimitsof2.03--3.43mm(0.08--0.135inches).

Iftheclearanceisgreaterthan3.43mm(0.135 inches)addonesteelsepatarordiscundertheend plate.

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76 SECTION21--POWERSHIFT

E TH121133 163

E TH121134 164

Thenfittheendplateretainingring.

E TH121135 E F 1 165

E TH121136 166

Positiontheinnerthrustwasher,thrustbearingand outerthrustwasherovertheshaft.

SECTION21--POWERSHIFT 77 604.02.395.00 --12--2002 Pressthe2pilotbearingsintotheclutchgearand hub.Pressthebearingsflushwiththefaceofthe gear.Placetheclutchgearandhubontheshaft. E TH121137 167 Positiontheinnerthrustwasher,thrustbearingand outerthrustwasherovertheshaftontothetopofthe gear. Offerthesideofthebearinguptotheshaftontopof thethrustwasherandvisuallycheckthesnapring willfit.Ifitdoesnot,ensurethegearandhub assemblyisfullyseatedonthediscs. E TH121138 168 Withthebearingshieldupwardspressontheshaft bearing. E TH121139 169 Fittheoilsliprings.Usesomevaselinetofacilitate reassemblyintothehousing. E TH121140 170

ReassemblyoftheFClutch(2nd speed)

Ifnewsealringshavebeenfittedtothepistonmake suretheyhavebeensized.Aftersizingwipethe surfaceswithalittletransmissionoil,thenfittothe clutchhousing.

thenplacethefirstbellevillewasherontopofthe wearplatewiththelargediameterdownwards.Then alternatetheremaining4washersfollowedbythe

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78 SECTION21--POWERSHIFT

F TH121141 171

snapringretainer. F TH121142 172 Fitthe5steeland5frictiondiscs.

withtheclutch discendplate. F TH121143 173 Installtheendplateretainingring. F TH121144 174

Installtheclutchpistonwearplateontothepiston,

Fitasteelseparatordiscfirstandthenalternatethe frictionandseparatordiscs.Finish

SECTION21--POWERSHIFT 79 604.02.395.00 --12--2002 Installtheinnerthrustwasher,thrustbearingand outerthrustwasherovertheshaft. F TH121145 175 Pressthepilotbearingsontotheclutchgearandhub, ensuringthebearingsarepressedflushwiththegear face.Placetheclutchgearandhubontotheshaft. F TH121146 176 Placetheinnerthrustwasher,thrustbearingand outerthrustwasherovertheshaft. F TH121147 177

F TH121148 178

Usingsnapringpliers,positionthethrustwasher retainingsnapringandclutchshaftlocatingsnap ring.Theninstallthegearwiththeconicalsection downwardsontothesnapring.

Presstherollerbearinginnerraceontotheclutch shaftwiththebearingraceshoulderdown.

Usingasuitablepunchtapthevalveretainingpin fromtheregulatorvalvesleeve.

Reassembly

Regulatorvalvereassemblyisinreverseorderofdisassembly.Cleanandinspectallparts.

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80 SECTION21--POWERSHIFT

F TH121149 179

Regulatorvalvedisassembly

NOTE:

TH121150 180 Removetheregulatorvalvepistonandspring. TH121151 181

Thevalveisunderspringpressure.

SECTION21--POWERSHIFT 81 604.02.395.00 --12--2002 Disassemblyofthemodulatorvalve Removetheinner,middleandouterspringsandstop pinfromthehousingsleeve. TH121237 182 Removetheaccumulatorspool. TH121152 183 Removethecrosspinwhichisapproximately1/3the wayupthehousingsleeve,itshouldalsobethe shorterofthetwopinsinthesleeve. TH121153 184 Removetheregulatorspool,springretainer,spring andspacerfromthesleevehousing. TH121154 185

Removethecrosspinintheendofthesleeve,this willbethelongestofthetwopins.

IMPORTANT: Makesuretheneckontheregulator spoolisnotclogged. Refittheshortestpin1/3thewayupthesleeveand fitthespringretainer,spacer,springandregulator spool.Compresstheregulatorspoolbyhandand pushintheend(larger)pin.

NOTE: Theregulatorspoolcanbottomoutonthe springretainer.Careshouldbetakentoensurethe springretainerslidesinsidethespool.

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82 SECTION21--POWERSHIFT

TH121155 186 Reassembly

TH121156 187 Intheotherendofthesleeve,placetheaccumulator

TH121157 188

TH121158 189

spoolasshown.

Thenfittheouter,middleandinnerspringsandthen installthestoppins.

SECTION21--POWERSHIFT 83 604.02.395.00 --12--2002 Disassemblyofthemanifoldplate Removethereverseidlergearretainingnutand washer. TH121159 190 Thenremovetheendplatewithdowelpin,reverse idlergear,bearingandthrustwasher. TH121160 191 Ifthereverseidlershaftistobereplaced,supportthe manifoldplatearoundtheidlershaftandpressthe idlershaftfromtheplate. TH121162 192

bullrings,removethebullringonthestatorconverter side. TH121163 193

Thestatorsupportiskeptinpositionbymeansoftwo

84 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Pushdownthesupportintothetransmissionto exposetheretainingringandmakeitpossibleto removeit. TH121164 194 Removethestatorsupportandthrustwasher. TH121165 195 Removethestatorsupportoilsealingringand expanderring. TH121166 196

TH121167 197

Ifthebushingand/orbearingneedtoberemoved, thebushingmustberemovedfromthesameendas theneedlebearing.

Compressthesafetyvalveusingasuitablehandtool andremovetheretainingwasher.Removethe spring,andfromtheothersideofthemanifoldplate, removethepoppetvalve.

SECTION21--POWERSHIFT 85 604.02.395.00 --12--2002

TH121168 198 Reassemblyofthemanifoldplate Reassembleinthereverseorderofdisassembly.

Disassemblyoftheconverter housing

86 SECTION21--POWERSHIFT 604.02.395.00 --12--2002

Fromthetopofthehousingremovethehexagonal headplug.Thenusingasmallscrewdriver,leverout thecheckvalveballassemblyandremoveitfromthe topofthehousing. TH121169 199 Removethetorqueconverterbearing. TH121170 200 Removetheoildistributor. TH121171 201 Removetheconverteroilseal. TH121172 202

RemovethepressuretestplugfortheCclutchand thenusingasuitablehexagonalwrenchremovethe distributorlockscrew.

UsingasuitablepullerremovetheC&Doildistributor sleeve.

RemovetheFclutchpressuretestpointplugandusing ahexagonalwrenchremovethedistributorlocking screw.ThenusingapullerremovetheE&Fdistributor sleeve.

Reassembly

Reassemblyoftheconverterhousingiscarriedout inthereverseorderofdisassembly. Ensurethechamferedendofthedistributorsare upwards.

SECTION21--POWERSHIFT 87 604.02.395.00 --12--2002

TH121173 203

TH121174 204

TH121175 205

88 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Disassemblingthetransmissionidlergearcase Useapercussionwrenchtoremovetheretainernut, washer,O--ringandthefrontoutputflange. TH121176 206 Removesleeveouter“O”ring. TH121177 207 Useanextractortoremovetheoutersleeveand innerO--ring. TH121178 208 Removethecouplingsleevesnapring. TH121179 209

SECTION21--POWERSHIFT 89 604.02.395.00 --12--2002 Useapercussionwrenchtoremovetheretainernut, washer,O--ringandthefrontoutputflange. TH121180 210 Removetheidlergearcasecoverscrewsand washers. TH121181 211 Hookthe(front)coverandfastenittoahoist. Usealevertoseparatethetwocoversandthen removethefrontone. TH121182 212 Removetheidlergearsandtheshafts. TH121183 213

90 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Prytheinputasssemblyfromcover. TH121184 214 Removetheoutputshaftassembly. TH121185 215 Ifthebearingouterraceshavetobereplaced, removetheouterraces. TH121186 216 Removethesealsleevesnapring. TH121187 217

SECTION21--POWERSHIFT 91 604.02.395.00 --12--2002

TH121188 218 Transfercaseassembly Reversethedisassemblyproceduretocarryoutthe assembly. Attheendofassembly,locktheoutputflangesand tightenthenutsat339–407Nm. TH121189 219

Useanappropriatedrivertoremovethesleevegasket.

92 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Transmissionassembly Fromtherear,installtherearbearingsnapring. TH121071 220 Installtheclutchshaftrearbearingouterraces. TH121070 221 Installtheoutputshaftfrontbearingsnapring. TH121069 222 Fromthefrontoftransmissioncase,positiontheoutputgearwiththelonghubofthegeartowardsthe front. TH121190 223

SECTION21--POWERSHIFT 93 604.02.395.00 --12--2002 Installtheoutputshaftrearbearingincaseagainst thelocatingring. TH121191 224 Puttheoutputshaftinposition.Alignthesplineson theshaftwiththesplinesintheoutputgear.Tapthe shaftintoposition. TH121192 225 Installanewboreplug. TH121193 226 Installtheoutputshaftgearsnapring. TH121194 227

94 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Installtheoutputshaftfrontbearinginthecase againstthelocatingring. TH121195 228 Installthefrontbearingsnapring. TH121196 229 Installthecouplingsleeve. TH121061 230

Installtheforward/reverse(A/B)distributorsleeve withtheinsidediameterchamferout,andthenotch inthedistributoralignedupwardswiththeretaining screwholeinthehousing.

SECTION21--POWERSHIFT 95 604.02.395.00 --12--2002

TH121197 231 Applysomethreadlocktothelockscrewandinstall itinthehousing.Theninstalltheplug. TH121198 232 Installthemodulationdiverterinthehousing. TH121075 233 InstallanewO--ringonthetransmissionvalvebody

thetransmissioncase. TH121074 234

bottomandtheninstallthevalvesandthespringin

InstallthemodulationvalvecasewiththenewO--ring inthetransmissioncaseandtightentothecorrect

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96 SECTION21--POWERSHIFT

TH121072 235 Installtheforward/reverseshaftrearbearing. TH121199 236 InstalltheC/Dshaftrearbearing. TH121200 237

TH121201 238

torque.

PositiontheDclutchgearandshaftthroughthebearingandontotheoutputflange.

ReplacetheO--ringgasket(2)oftheoildeliverytube (1)andinstallthedeliverytubetogetherwiththenet filter.

FirstlypositiontheC/Dclutchpack.Alignthesplines oftheDgear&hubalreadyfittedwithinternalteeth ofthefrictiondisc.

Positionthereverse/forward(A/B)clutchpacksand shaft.Usecautionsoasnottodamagetheshaftoil sliprings. TH121203

InstalltheE/Fclutchpackandshaftrearrollerbearing intothecasingandthenfittheshaftandclutches.

SECTION21--POWERSHIFT 97 604.02.395.00 --12--2002

1 2 239

TH121056

240

TH121202

241

242

TH121204

Fitanewgaskettothetransmissioncaseusinga lightcoatofgreasetoholditinposition. TH121205

Installthethrustwasherandthepumpcontrolshaft onthemanifoldplate.

Installthemanifoldplateontothemaintransmission housing.Usethedowelpinstolocatethemanifold platecorrectly.Ensurethemanifoldplateistight againstthetransmissioncasebeforeinstallingthe bolts.Donotusetheboltstopulltheplatetothe housing. NOTE: Becarefulnottodamagetheoilseals. TH121206

Installthemanifoldplatetotransmissionhousingbolts andtightentothecorrecttorque.

Rememberthehexheadboltontheothersideofthe manifoldplate. TH121207

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98 SECTION21--POWERSHIFT

243

244

245

246

Positiontheswivelhubgearonthestatorsupport. TH121208

SECTION21--POWERSHIFT 99 604.02.395.00 --12--2002 Installthepumpidlergearbearingonidlershaft. TH121210 247 Installthepumpidlergearonbearing. TH121211 248 Installtheidlergearthrustwasher,aligningthehole withtherollpin. TH121212 249 Withthe“O”--ringsinposition,installthesolenoid cartridges. TH121213 250

100 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Tightenthecartridgestothespecifiedtorque. TH121214 251 Withcartridgetocoil“O”--ringsinplace,positionthe solenoidcoilsonthecartridges. TH121215 252 WIthnew“O”--ringsinposition,installthecoilto cartridgenuts. Tightenthecartridgenutstospecifiedtorque. TH121216 253 Installsolenoidprotectioncoverandmounting screws. Tightenthescrewstothespecifiedtorque. TH121217 254

Positionthemanifoldplatetoconverterhousing gasketusingalightcoatofgreasetoholdthegasket inplace.

Positiontheconverterhousingontothemanifold plate.Toassistwiththisthetransmissioncanbelaid onitsbacksothemanifoldplateishorizontal.The converterhousingtomanifoldplateboltsmustnotbe fitteduntilthetwofacesaretightagainsteachother.

Installtheconverterlocatingsnapringontheturbine shaft.

SECTION21--POWERSHIFT 101 604.02.395.00 --12--2002

TH121209 255

TH121218 256

TH121219 257

TH121220 258

Fitthehousingboltsandtightentotherecommended torque.

102 SECTION21--POWERSHIFT 604.02.395.00 --12--2002 Slideonthetorqueconverterandfitthetorque convertersnapring. TH121221 259 Withanew’O’ringfitted,installtheboreplugintothe converterassemblyandfittheplugsnapring. TH121222 260 Installtheregulatorvalveusingthefabricatedtool andtightentothecorrecttorque. TH121223 261 Refitthefilterontotheregulatorvalve. TH121224 262

SECTION21--POWERSHIFT 103 604.02.395.00 --12--2002 Withanewgasketinplace,installthetransmission pumpandtightentothecorrecttorque. TH121225 263 Installthetransfercaseassembly. TH121227 264 Installthetransfercasewashersandlockscrews. Tightenthescrewstothecorrecttorque. TH121228 265 Installthedriveplateontothetorqueconverterand tightentheboltstothespecifiedtorques. TH121226 266

Type

SECTION25--FRONTAXLE

SPECIFICATIONS

Finalreductionratio1:6(4satellites)

Steering 40degrees

Differential Withoutlock

BrakeWetdiscwith8discs+parkingbrake withinnernegativecontrol

SteeringcylinderWithpositionsensor

NOTE: Astoreplacementintervals,oilandlubricantquantityandtypeforthefrontaxle,refertotheOPERATOR’SMANUAL.

SECTION25--FRONTAXLE 1 604.02.395.00 --12--2002

CONTENT SectionDescriptionPage 25100 Specifications 1 ................................................................ Description 2 Operation 3 .................................................................... Troubleshooting 4 Wheeltoe--incheck5 Componentoverhaul5 Frontaxleremoval6 Frontaxleoverhaul7 Axledrivepinionbearingadjustment51 ............................................ Bevelgearpinioninstallationandadjustment53 .................................... Frontdriveshaft57 .............................................................

Overallwidth2050mm(flange--to--flange) .......................................................... Crownwheelandpinionratio 9:34

Steeringdifferentialwithfinal epicycloidsreductions

TH125160

Theaxlefittedtothisunitincorporates:

• Integralsteeringcylinder

• Steeringsensor

• Centraldrive

• Doublereduction(crownwheelandpinionplus planetaryhubs)

• Servicebrakesandparkbrakewithinnernegativecontrol

2 SECTION25--FRONTAXLE

DESCRIPTION

604.02.395.00 --12--2002

Frontview Topview

OPERATION

Enginepower(1)istransmittedfromtheengine throughthepowershifttransmission(2)andthedrop box(3)tothefrontaxle(4)viathedriveshaft(5).

SECTION25--FRONTAXLE 3 604.02.395.00 --12--2002

TH125161 1 2 3 5 4 2

4 SECTION25--FRONTAXLE 604.02.395.00 --12--2002

PROBLEM CAUSE REMEDY Samenoiseforengagementand release 1.Hubbearingsdamaged Replacedamagedelements Highernoiseduringengagement ratherthanrelease 2.Lowoillevel Topupoil 3.Crownwheelandpinionworn Checkthroughtheuppercover. Replaceworncrownwheelandpinion 4.Crownwheelandpinionbearingsworn Replacedamagedelements 5.Epicycloidsplanetaryhubor bearingworn Replacedamagedelements 6.Pinionringnutloose Checkthecrownwheelandpinion andrespectivebearings.Iftheyare notdamaged,tightentheringnut 7.Onlyonepinionbearingworn SeeremedyNo.4 Noiseundersteering 8.Differentialsatellitesand/orplanetaryhubsdamaged Replacedamagedelements “Stickslip”noisewhenchanging directionoftravel. 9.Universaljointdamaged Checkandreplacethejointas showninthevehiclehandbook 10.Wheelloose Checkpossiblewheelhubdiscand studboltdamages.Ifneeded,repla-cedamagedelementsandtighten thenutstoprescribedtorque 11.Steeringpinseals,axleshafts orsteeringpivotsdamaged Checkandreplacedamaged elements 12.Differentialcasesatellitesfree Checkthroughtheuppercover. Replacedamagedelements 13.Differentialadjustingbushes worn SeeremedyNo.8

TROUBLESHOOTING

WHEELTOE--INCHECK

Whencheckingthetoe--in,ensurethefrontwheels arepointingstraightaheadusingthesteering positionindicatorlampinthecabin.

Measurethedistancebetweenthetwofrontwheels atthefrontoftherim(A).Thenmeasurethedistance betweenthefrontwheelsattherearoftherim(B).

ThevariancebetweenAandBshouldbe0–2mm (0–0.078in)=toe--in. i.e.:B--A=0--2mm

Toadjustfrontwheeltoe--in,slackenbothlocknuts (2)andturnrimsequally(1)inthesameway. Re--tightenbothlocknuts(2).

Thesteeringstops(1)areincorporatedinthehubs ateachendoftheaxle.Thestopsareadjustableto preventthetyrescontactinganypartoftheframeor cabwhenonfulllockandheldbythelocknut.

COMPONENTOVERHAUL

Axleinsitu

Thefollowingcomponentscanbeoverhauledwiththe axlemountedontheunit.

• Planetaryreductionhubassembly

• Steeringknuckle

• Tierodpins

• Axledriveshafts,sealsandbushes

Axleremoved

Thefollowingcomponentscanbeoverhauledwiththe axleremoved.

• Brakeassemblies

• Differentialassembly

• Pinionassembly

SECTION25--FRONTAXLE 5 604.02.395.00 --12--2002

TH125162 1 2 3

TH125163 1 4

FRONTAXLEREMOVALPROCEDURE

• Extendtheboomandlowertotheground.

• Chocktherearwheels.

• Placewoodenwedgesbetweentheaxlesand theframetopreventtheTelescopicHandlerfrom swinging.

• Jack--upthemachineupperpartandsecureiton suitablestands.

• Removethefrontdriveshaft.

• Removethewheels.

• Disconnectthesteeringhoses(1).

NOTE: Ensurebothpipesarepluggedtopreventconstantoilleaking.

• Disconnectthesteeringanglesensor(2).

• Removethepower(3)andpark(4)brakepipes.

• Removethefouraxlelevellingcylinderfixing screws(5).

• Supporttheaxleandremovethefourfixing screws(6).

• Lowerandremovetheaxlefromthevehiclebottomwithawheeledjack.

NOTE: Someitemswhichrequireservicingafteraxle removalmaybemoreeasilyloosenedwhiletheaxle isin--situ,i.e.steeringtierodends.

6 SECTION25--FRONTAXLE

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TH125164 5

TH125165 1 2 6

TH125166 3 4 7

TH125167 5 6 8

Supporttheaxle(1)orleaveitmountedandremove thesteeringtierodpins(2).

Slingthewholeassembly(7)andhookittothehoist, slightlypullingthetierod.

Unlooseandremovethefittingscrews(3)fromthe bottompivotpin(4).

NOTE: Screwscannotbere--used.

Removethebottompivotpin(4)completewiththe frontsealingring(5).

Removethefrontsealingrings(5).

NOTE: Notedownthesideforassembly. Iftheballcoverneedsreplacing,removeitfromthe bottompivotpin.

Unlooseandremovethefittingscrews(3)fromthe toppivotpin(6).

SECTION25--FRONTAXLE 7 604.02.395.00 --12--2002

FRONTAXLEOVERHAUL STEERINGCASEREMOVAL

TH125001 1 2 7 9

TH125002 3 4 10

TH125003 4 5 11

TH125004 3 6 12

Usingtwolevers,removethetoppivotpin(6)completewithfrontseal(5).Payattentionnottodamage thesurfaces. Removethefrontsealingrings(5).

8 SECTION25--FRONTAXLE

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TH125005 5 6 13

NOTE: Notedownthesideforassembly. Iftheballcoverneedsreplacing,removeitfromthe bottompivotpin.

TH125006 7 14

Removethecompletesteeringknuckle(7).

TH125007 8 9 15

Usingapullerforinnerparts,removethetopbush(8) andthebottomball--bush(9).

HOWTOASSEMBLETHECOMPLETE STEERINGKNUCKLE

Fitanewseal(5)ontothetoppivotpin(6).Lubricate andinstalltheunitinthesteeringcase.Positionthe screws(3)andlightlytighten.

Fitanewseal(5)ontothebottompivotpin(4).Lubricateandfittheunitinthesteeringcase.Positionthe screws(3)andlightlytighten.

Checkforthecorrectassemblysideoftheseal(5).

SECTION25--FRONTAXLE 9 604.02.395.00 --12--2002

UsetoolsT3andT4. TH125009 8 9 T3 T4 16

Paydueattentionnottodamagethedustcoverrings andthesealingrings. TH125006 7 10 17

Lubricatethetopbush(8)andthebottomballbush (9)andfitthemintothefulcrumholesofthearm.

Lubricatetheterminaloftheu--joint(10)andinstall thesteeringcase(7).

Checkthecorrectassemblysideoftheseal(5). TH125005 5 6 18

TH125003 4 5 19

Tightenthenewfittinigscrews(3)oftopandbottom pivotpinsinsequenceusingthecrosstightening method.

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10 SECTION25--FRONTAXLE

Torquewrenchsetting:128÷142Nm.

3 3 20

TH125010 Connectthesteeringtierod(2)(See“STEERING CYLINDERINSTALLATION”). NOTE: LubricatejointswithMolikote.

2 21

TH125001

SECTION25--FRONTAXLE 11 604.02.395.00 --12--2002

Loosenandremoveupperandlowerdowel(3)lock nuts(2). Removeupperandlowerbushretainingdowels(3). TH125012 2 3 22 Removetheentireu--joint(4). NOTE: Toremovetheu--jointuse,ifnecessary,a plastichammeroralever. TH125013 4 23 Removethesnapring(5)fromthebushingunit(9). TH125014 5 9 24 Positiontheentireu--joint(4)underapressand removethecompletebush(9). TH125015 4 9 25

DOUBLEUNIVERSALJOINTREMOVAL

Removethesnapring(6)fromthebearing(7).

Useapullertoremovethebearing(7)thesealingring (8)andtheO--ring.

NOTE: Notedowntheassemblysideofthering(8).

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12 SECTION25--FRONTAXLE

TH125016 8 6 7 7 26 TH125017 1 2 3 2 3 5 6 8 7 9 10 4 27

INSTALLATIONOFU--JOINT

UsingtoolsT5andT6,insertthesealingring(9)and thebearing(8)inthebush(7).

NOTE: Carefullychecktheassemblysideoftheseal (8).

Fitthesnapring(5)onthebushingunit(9);also installtheO--ring(10).

SECTION25--FRONTAXLE 13 604.02.395.00 --12--2002

TH125018 8 7 9 9 T6 T5 28

TH125019 7 6 29

TH125020 4 9 30

Fitthesnapring(6)onthebearing(7).

Heatthebearinginoilatanapprox.temperatureof 100 °Candfittheentirebush(9)ontheu--joint(4).

TH125014 5 9 10 31

14 SECTION25--FRONTAXLE 604.02.395.00 --12--2002

Torquewrenchsetting:Max.15Nm.

Inserttheu--jointandtightenthetopandbottom dowels(2).

TH125022 2 32

NOTE: Foru--jointcomingwithabush,centrethe pointofthecheckdowelsintheslot..

Torquewrenchsetting:122Nm. TH125023 2 3 33

ApplyLoctite242tothejuttingpartsofthedowels (2).

Screwthechecknuts(3)ofthedowels(2)andlock themusingatorquewrench.

HOWTODISASSEMBLETHEPLANETARY REDUCTIONGEAR Disconnectthetierodfromthesteeringknuckle. Fordetails,see“HOWTOREMOVETHECOMPLETESTEERINGKNUCKLE”.

SECTION25--FRONTAXLE 15 604.02.395.00 --12--2002

TH125024 1 2 1 34

TH125025 2 3 35 Removethecompleteplanetarycarriercover(2). TH125026 2 36

Removethesecuringscrews(1)fromtheplanetary carriercover(2).

Loosentheplanetarycarriercover(2)fromthesteeringknuckle(3)byalternativelyforcingascrewdriver intotheappropriateslots.

TH125027 4 5 37

Unlooseandremovethetighteningnuts(4)fromthe crownflange(5).

16 SECTION25--FRONTAXLE 604.02.395.00 --12--2002 Removethesafetyflange(6). TH125028 6 38 Usingapuller,removethecompletecrownflange(5) byactingonthestudbolts. TH125029 5 39 Partiallyextractthehubusingaplastichammer. NOTE: Alternatelyhammeronseveralequidistant points. Removetheexternalbearing(8). TH125030 8 40 Removethecompletehub(7)byhand. TH125031 7 41

SECTION25--FRONTAXLE 17 604.02.395.00 --12--2002 Removethepivotpinsandremovethesteering knuckle(3). Fordetails,see“HOWTOREMOVETHECOMPLETESTEERINGCASE”. TH125032 3 42 Removethesnaprings(9). TH125033 9 43 Withthehelpofapuller,removetheplanetarygears (10). NOTE: Notedownthecorrectassemblypositionof theplanetarygears. TH125034 10 44 Removethesnapring(12)fromthecrown(13). TH125035 12 13 45

(8)and(15)forcingapin--driverintotheappropriate slotsonthehub(7).

NOTE: Hammerinanalternatewaysoastoavoid seizureordeformationofthethrustblocks.

18 SECTION25--FRONTAXLE 604.02.395.00 --12--2002 Removethecrownflange(5). TH125036 5 46 Removethesealingringfromthehub(14). TH125037 14 47 Removetheinternalbearing(15). TH125038 15 48

Removetheexternalthrustblocksfromthebearings

TH125039 7 49

Useapullertoremovethecentringring(16),the sealingring(17)andthebearing(18)fromthesteeringknuckle(3).

NOTE: Notedowntheorientationofbothcentring ring(16)andsealingring(17).

SECTION25--FRONTAXLE 19 604.02.395.00 --12--2002

TH125040 3 16 17 18 18 17 16 50

ASSEMBLINGTHEPLANETARYREDUCTION GEAR

Lubricatethebushing(18)andtheseatofthesteeringknuckle(3).

Installthebushing(18),usingtoolT7.

Lubricatetheoutersurfaceofthesealingring(17) andcentringring(16);fitthemintotheirseatusing toolT8.

PositionthelowerpartoftoolT9Aandthethrust blockoftheexternalbearing(8)underthepress.

Lubricatetheseatsofthebearingsandpositionthe hub(7);ontoolT9A;positionthethrustblockofthe internalbearing(15).

NOTE: Checkthatthethrustblockiscorrectly oriented.

20 SECTION25--FRONTAXLE 604.02.395.00 --12--2002

TH125041 3 18 T7 51

TH125042 16 17 T8 52

TH125043 8 T9A 53

TH125044 15 T9A 7 54

SECTION25--FRONTAXLE 21 604.02.395.00 --12--2002 PositiontheupperpartoftoolT9Bandpressthe thrustblocksintothehub(7)allthewaydown. TH125045 T9B 7 55 Fitthebearing(15)intotheinternalthrustblock. TH125046 15 56 Applyajointingcompoundforrepositionablefixtures totheoutersurfaceofthesealingring(14). Positionthesealingring(14)inthehub(7). NOTE: Checkthatthering(14)iscorrectlyoriented. TH125047 7 14 57 PositiontoolT10andpressthesealingring(14)into itsseat. TH125048 T10 14 58

22 SECTION25--FRONTAXLE 604.02.395.00 --12--2002 Inserttheflange(5)inthecrown(13). TH125036 13 5 59

NOTE: Carefullycheckthatring(12)isproperly

TH125156 5 12 13 60

Insertthesnapring(12)inordertofixtheflange(5) inthecrown(13).

insertedintheslotofthecrown(13).

Accuratelychecktheorientation. TH125050 2 10 T11 61

WiththehelpoftoolT11,inserttheplanetwheel gears(10)intothecover(2).

TH125033 9 10 62

Lockthegears(10)intopositionbyfittingthesnap rings(9).

Fitthesteeringknuckle(3)ontotheU--joint(19)and installthearticulationpins.Forpinassemblydetails, see“HOWTOASSEMBLETHECOMPLETE STEERINGCASE”.

NOTE: Usingaplastichammer,drivethebearingto thelimitstopbylightlyhammeringaroundtheedge.

NOTE: Inordertofastentheflange(5),useaplastic hammerandalternatelyhammeronseveralequidistantpoints.

ApplyTecnolubeSeal101greasetothesurfaceof thesafetyflange(6)whichtouchesthecrownflange (5).

SECTION25--FRONTAXLE 23 604.02.395.00 --12--2002

TH125032 3 19 63 Installthehub(7). TH125031 7 64 Installtheexternalbearing(8).

TH125030 8 65 Fitthecompletecrownflange(5).

Fitthesafetyflange(6). TH125028 5 6 66

24 SECTION25--FRONTAXLE 604.02.395.00 --12--2002 ApplyLoctite242tothestudsandfitinthenuts(4). Crosstightenthenuts(4)intwostages. Initialtorquewrenchsetting:120Nm Finaltorquewrenchsetting:255÷285Nm TH125053 4 67 Fittheplanetarycarriercover(2)ontothehub(3). ATTENTION CheckthattheO--ring(20)isingoodconditionand inposition. TH125026 20 2 3 68 Locktheplanetarycarriercover(2)bytighteningthe screws(1). Torquewrenchsettingforscrews:40÷50Nm TH125055 1 2 1 69

HOWTOREMOVETHESTEERINGCYLINDER

Iftheconnectionofthesteeringbarsincludesa safetycollar(13),raisetheborder.

SECTION25--FRONTAXLE 25 604.02.395.00 --12--2002

Removethecentringsensor(1)ofthesteeringpis-

TH125056 1 70 Removethesafetycotterpins(3)fromthearticula-

ATTENTION Disposeofusedcotterpins. Removethecastellatednuts(6)thatlockthearticulationpins(4). TH125057 5 6 3 4 71 Disconnectthetaperedpinsofthearticulation(4) fromthesteeringknuckle(7)bymeansofapuller. TH125058 4 7 72

ton,ifsupplied.

tionpins(4)ofthetierodbars(5).

TH125059 13 73

Removethesecuringscrews(8)fromthesteering cylinder(9).

Extractthecylinder(9)usingaplastichammer. NOTE: Forcylinderdisassembly,referto“HOWTO DISASSEMBLETHESTEERINGCYLINDER”.

26 SECTION25--FRONTAXLE 604.02.395.00 --12--2002

TH125060 2 74

Disconnectleftandrighttierodsfromthepiston(2).

TH125061 9 8 75

HOWTOINSTALLTHESTEERINGCYLINDER

CheckthattheO--ringsoftheaxleunitareingood condition;lubricatetheseatsofthesealsandfitthe steeringcylinder(9)intoitsseat.

Lockthecylinderbycross--tighteningthescrews(8). Torquewrenchsetting:116÷128Nm

ApplyLoctite242tothethreadandconnectthetie rodsbyscrewingtheterminalsontothepistonstem.

Torquewrenchsetting:240÷270Nm

NOTE: Versionswithcouplingrequirethantherimof thearticulation(13)isrivetedontothesurfaceofthe pistonstem.

Insertthepins(4)inthesteeringknuckle(7)andlock theminthatpositionbytighteningthenutsto 260÷290Nm.

Findthenotchpositiononthebasisofthesplitpin holeandtightenthenutsfurther.

ATTENTION

Checkrubberguardintegrity(A).

Iffitted,inserttheproximitysensor(1)tocheckthe pistonlocationandtightenthescrews(10).

Tighteningtorque:5÷6Nm.

SECTION25--FRONTAXLE 27 604.02.395.00 --12--2002

TH125063 8 9 76

TH125064 13 77

Usenewsplitpins. TH125065 7 A 78

Insertsplitpinsandbendsafetystems. ATTENTION

TH125056 10 79

ATTENTION

Eliminatetheactionofthenegativebrakeniffitted. ApplytoolsT12tothehubsandlockthem. Usingalevel“B”,checkthattoolsareperfectlyflat andparalleltoeachother.

28 SECTION25--FRONTAXLE 604.02.395.00 --12--2002

TH125067 B T12 T12 80 Connectthesensor(1)totheinspectiondevice accordingtoeitherdiagram. TH125068 1 81 Sensorconnectioncard,STANDARDversion. TH125069 82 Sensorconnectioncard,OPTIONALversion. TH125070 83

Centrethepistonbyslowlymovingitfirstinone directionthenintheotherandpositionithalfwayon thestroke,whichisdeterminedbytheswitchingon andoffofthesignallampoftheinspectiondevicein thereversalstage.

Inspectjut“C”ononesideofthepistonandnote downthesizeforcheckinglateradjustments.

NOTE: Ifcylinderscomewithoutasensormthecentringofthepistonmustbecarriedoutonthebasisof themaximumstroke.

Withoutmovingthepiston,checkfrontandrearsize attheedgeoftoolsT12.

Max.difference:0.6÷0.7mm

NOTE: Inordertochecktherearsize,rotatethe bevelgearpinionandcheckthattoolsT12areflat.

Ifnecessary,adjustconvergencywithoutmovingthe centringofthepistonandadjustthelengthofthetie rods(5).

NOTE: Withahalfturnofscrew,thefrontsizeis reducedbyabout3mm,whereastherearoneis increasedbyabout3mm.

SECTION25--FRONTAXLE 29 604.02.395.00 --12--2002

TH125071 = = 84

TH125072 C 85

TH125073 T12 T12 86

TH125074 5 87

Loosenthenuts(11)andscrewthemontotheball-and--socketjoints. Holdthesteeringknucklesstillandrotatetheball-and--socketjoints.Oncetheconvergencyhasbeen adjusted,lockthenuts(11).

Torquewrenchsettingfornuts:298÷328Nm

604.02.395.00 --12--2002

30 SECTION25--FRONTAXLE

11 88

TH125075

Withthehelpofadrift,applypressuretothestopring (4)thatisplacedinsidethecylinder(3)andextract theringusingascrewdriver.

Hammerthepiston(5)uptotherearofthehead(2) usingaplastichammer. Continuehammeringuntilthehead(2)isejected fromthecylinder(3).

SECTION25--FRONTAXLE 31 604.02.395.00 --12--2002

TH125077 1 2 89

HOWTODISASSEMBLETHESTEERING CYLINDER Removethesnapring(1)fromthecylinderhead(2). Withthehelpofaplastichammer,pushthehead(2) insidethecylinder(3).

TH125078 2 3 90

NOTE: Theheadshouldlineupwiththeedgeofthe cylinder.

TH125079 3 4 91

TH125080 2 3 5 92

Disassemblethecylinderunit(3)byextractingfirst thehead(2),thenthepiston(5).

ATTENTION

Notedowntheassemblysideofthepiston.The bevelledpart“A”ofthepistonisorientedtowardsthe head(2).

Removeallseals,anti--extrusionringsandscraper ringsfromhead(2),cylinder(3)andpiston(5).

NOTE: 1--Allsealsmustbereplacedeverytimethe unitisdisassembled.2--Particularattentionmustbe paidnottodamagetheseatsofbothsealsandpiston slide.

604.02.395.00 --12--2002

32 SECTION25--FRONTAXLE

TH125081 2 3 5 A 93 TH125082 8 1 2 3 4 5 6 7 9 11 10 12 13 6 8 7 94

HOWTOASSEMBLETHESTEERINGCYLINDER

Afterapplyinggrease,installthesealingring(6)of theshaft,theanti--extrusionring(7)andthescraper ring(8)insidethecylinder(3).

ATTENTION

Thoroughlycheckthetpositioningoftheanti--extrusion(7).

Afterapplyinggrease,installthesealingring(6)of theshaft,theanti--extrusionring(7)andthescraper ring(8)inthehead(2).

ATTENTION

Thoroughlycheckthatpositioningoftheanti--extrusion(7)ringiscorrect.

Fittheseal(9)ontotheoutsideofthehead(2).

ATTENTION

1--Inordertofacilitateassembly,applygreasetothe outersurfaceofthepiston.

2--Donotrolltheseal(9)up.

Preparethepiston(5)byfittingitwiththeguidering (10),themagneticring(11),theO--ring(12)andthe seal(13).

ATTENTION

1--Inordertofacilitateassembly,applygrease.

2--Ifacentringsensorisnotfitted,thenthemagnetic ring(11)shouldbereplacedbyguidering(10).

SECTION25--FRONTAXLE 33 604.02.395.00 --12--2002

TH125083 8 6 7 95

TH125084 8 6 7 96

TH125085 9 97

TH125086 5 11 10 12 13 98

ApplytoolT18totheshaftontheoppositesideofthe headandcentreitonthecylinder(3)sothatitfitsinto thepiston(5).

NOTE: Applyalittlegreasetosealsandcylinder.

RemovetoolT18andapplyittotheoppositesideof thepiston(5).

Applygreasetohead(2)seals,fittheheadontothe pistonandpushitintothecylinder(3)usingaplastic hammer.

NOTE: Inserttheheadastolineitupwiththeedge ofthecylinder.

604.02.395.00 --12--2002

34 SECTION25--FRONTAXLE

TH125087 T18 3 5 99

TH125088 3 5 100

Pushthepiston(5)intothecylinderfor100mmusing aplastichammer.

TH125089 2 5 T18 101

TH125090 3 4 102

Insertthestopring(4)ensuringthatitfitsintotheseat ofthecylinder(3).

SECTION25--FRONTAXLE 35 604.02.395.00 --12--2002 Applypressuretotheheadusingtwoscrewdrivers

TH125091 2 103 Fitthesnapring(1)onthehead(2). ATTENTION Makesurethatthesnapring(1)issecurelyfastened initsseat. Ifnecessary,forceitintoitsseatusingadriftanda hammer. TH125077 1 2 104

orleversuntiltheheadisfastenedontothestopring (4).

HOWTOREMOVEANDDISASSAMBLE

Uniformlyheattheringnuts(1)uptoatemperature

36 SECTION25--FRONTAXLE 604.02.395.00 --12--2002

Removethecompletearms. Fordetails,see“CHECKINGWEARANDREPLACINGTHEBRAKINGDISKS”. TH125092 105 Markthepositionoftheringnuts(1). Removethefittingscrews(3)fromtheringnuts(1). TH125093 3 1 106

THEDIFFERENTIALUNIT

of80°C.

Accuratelycleanthethreadedportionsof ringnuts,bodyandcover. TH125094 T13 107 Removethefittingscrews(4)fromthemiddlecover (5). TH125095 4 5 4 108

ApplytoolT13andremovetheringnuts. NOTE:

Insertascrew--driverintheopposingslotsthenforce andremovethemiddlecover(5)andthecomplete differentialunit(6).

Ifthebearingsneedreplacing,extracttheexternal thrustblocksofthebearings(7)and(8)frommiddle cover(5)andcentralbody(2).

NOTE: AccuratelychecktheO--ring(9).

Ifthebearingneedreplacing,extractthebearing(7) andremovethecrown(12).

SECTION25--FRONTAXLE 37 604.02.395.00 --12--2002

NOTE: Supportthepiecesusingarod. TH125096 5 6 109

TH125097 5 9 7 2 8 110 Removethefittingscrews(11)fromthecrown(12). TH125099 11 12 111

TH125100 7 12 112

38 SECTION25--FRONTAXLE 604.02.395.00 --12--2002 Removetheshimwasher(13)andtheplanetarygear (14). TH125101 13 14 113 Ifthebearingneedreplacing,extractthebearing(8) fromthedifferentialcarrier(15). TH125102 8 15 114 Removethesnaprings(16)fromthetwopins(17)of theplanetwheelgears(18). TH125103 16 17 115 InserttoolT14betweentheplanetwheelgears(18). TH125104 18 18 T14 116

ForcetoolT14in--betweentheplanetwheelgears (18)usingtwopin--drivers.

ATTENTION

MakesurethattoolT14isperfectlylinedupwiththe pins(17)whenlocked.

Placethedifferentialcarrier(15)underapress,positionbushT15andinsertgudgeonT16A.PressT16A pintolimitposition.

RemovegudgeonT16AandbushT15.

NOTE: InthisconditionthetoolT14containspin (17).

RemovetoolT14togetherwiththepin(17)ofthe planetwheel.

SECTION25--FRONTAXLE 39 604.02.395.00 --12--2002

TH125105 17 117

TH125106 15 17 T15 T16B T16B 118

TH125107 T16A T15 119

TH125105 17 120

40 SECTION25--FRONTAXLE 604.02.395.00 --12--2002 Leavethereleasedplanetarygearinpositionand againlocktoolT14. Repeattheoperationsfortheextractionofthepinof the2nd planetwheel. Repeattheoperationsforallotherpins. TH125104 18 18 T14 121 RemovetoolT14andremovethelasttwoplanet wheelgears(18),the2nd differentialunitgear(14) andtherelativeshimwasher(13)fromthedifferential carrier. TH125108 13 14 15 122 TH125109 1 3 4 5 6 9 11 10 12 13 14 15 16 17 18 19 20 8 7 13 16 20 17 19 18 19 17 20 16 19 17 20 16 2 123

SECTION25--FRONTAXLE 41 604.02.395.00 --12--2002 ASSEMBLING Inserttheshimwasher(13),andtheplanetarygear (14)inthedifferentialcarrier(15). TH125108 13 14 15 124 Positiontheshimwasher(19)andthefirstplanet wheelgear(18). HoldtheminpositionusingbarT16C. TH125110 18 19 T16C T16A 125 WiththehelpofgudgeonT16A,positionthesecond planetwheelgear(18)andtherelativeshimwasher (19). TH125111 18 19 T16C 126 InserttoolT14betweenthetwoplanetarygears(18). LineuptheentireunitbypushingbarT16Callthe waydownuntilgudgeonT16Aisejected. TH125112 T14 T16C 127

42 SECTION25--FRONTAXLE 604.02.395.00 --12--2002 LocktoolT14behindtheplanetwheelgears(18). Afterlocking,removebarT16C. TH125104 18 T14 18 128 Fitthesnaprings(20)ontothepins(17). TH125113 17 20 129 Placethedifferentialcarrier(15)underthepress, positionbushT15andinserttheplanetwheelpin (17). PutgudgeonT16Bontopoftheplanetwheelpin (17). TH125114 17 17 T15 T16B T16B 130 PressT16Bpinallthewaydown. TH125106 T16B T16B T15 17 15 131

RemovegudgeonT16B,bushT15andfitthesnap ring(16)onthepin(17).

ATTENTION

Positionthesecondplanetarygear(14)inthedifferentialcarrier(15).

Positionthecrown(12)onthedifferentialcarrier(15) andlockitwithscrews(11)appliedwithLoctite242. Torquewrenchsettingforscrews:128÷142Nm.

NOTE: Securethescrewsusingthecross--tighteningmethod.

SECTION25--FRONTAXLE 43 604.02.395.00 --12--2002

Makesurethatthesnapringcentrestheseatand thatitrestsonthesurfaceonthedifferentialcarrier. Repeattheoperationsontheotherplanetwheelpin orplanetwheelaxle. TH125115 16 17 132

TH125116 14 15 133 Positiontheshimwasher(13)onthecrown(12). NOTE: Inordertoholdtheshimwasher(13)inposition,applygreasetoit. TH125117 12 13 134

TH125118 11 12 15 135

Installthebearings(7)and(8)usingtoolT17.

Ifthebearingsarereplaced,inserttheexternalthrust blocksinthemiddlecover(5)andinthecentralbody (2).

Positionthedifferentialunit(6)inthecentralbody(2) withthehelpofabarandfitthemiddlecover(5).

NOTE: ThoroughlycheckthestateoftheO--ring(9) andmakesurethatthecoverisfittedwiththeoildischargeinthelowerposition.

Lockthemiddlecover(5)withscrews(4).

Torquewrenchsettingforscrew:23.8÷26.2Nm.

44 SECTION25--FRONTAXLE

604.02.395.00 --12--2002

TH125119 7 T17 T17 8 136

TH125120 2 5 137

TH125121 1 2 5 9 138

TH125122 4 5 4 4 139

NOTE: Iftheringnuts(1)areremoved,spreadthem withLoctite242.

Tightenringnutsonthecrownsideuntilclearance betweenpinionarecrowniszero,thenlockthe crown;goback1/4÷1/2turn.

Pre--setthebearingsbymeansoftheringnutsituatedontheoppositesideofthecrown,soasto increasepiniontorqueupto140÷210Ncm.

ATTENTION

Ifbearingsarenotnew,checkthestatictorque;if bearingsarenew,checkthecontinuoustorque.

Introduceadialgaugewithadjustablepointer“A” throughthetopplughole.

Positionthedidsensewithadjustablepointeronthe centreofoneoftheteethofthecrown(12),pre--load to1mmandthenresetittozero.

Manuallymovethecrown(12)inbothdirectionsin ordertochecktheexistingbacklashbetweenthepinionandthecrown.

SECTION25--FRONTAXLE 45 604.02.395.00 --12--2002

TH125123 T13 140

TH125124 T19 141

TH125125 A 12 142

TH125126 12 143

crownbylooseningoneoftheringnuts(1)and tighteningtheoppositetocompensate.

46 SECTION25--FRONTAXLE

Normalbacklash:0.18--0.23. DifferencebetweenMINandMAXclearancefor wholecircumferenceshouldnotexceed0.09mm. TH125123 T13 144

ofthetwoholesandtighten. Torquewrenchsetting:23.8÷26.2Nm. Fitthetopplugafterapplyingrepositionablejointing compoundforsealstotherims. TH125127 3 145 Re--installthecompletearms. Fordetails,see“CHECKINGWEARANDREPLACINGTHEBRAKINGDISKS”. TH125092 146

604.02.395.00 --12--2002 Adjustthebacklashbetweenthepinionandthe

ApplyLoctite242tothescrews(3),fitthemintoone

SECTION25--FRONTAXLE 47 604.02.395.00 --12--2002

Removethecompletearmsandthedifferentialunit. Fordetails,see“CHECKINGWEARANDREPLACINGTHEBRAKINGDISKS”and“REMOVINGTHE DIFFERENTIALUNIT”. TH125092 147

HOWTOREMOVETHEAXLEDRIVEPINION

°C. NOTE: HeatingismeanttoloosenthesettingofLoctiteonthenut(1). TH125128 1 2 148 PositiontoolT20A(orT20B),soastoavoidpinion rotation. Unlooseandremovethenut(1);alsoremovethe O--ring(3). TH125129 3 T20A (T20B) 149

TH125130 2 4 150

Ifdisassemblyisawkward,heatthechecknut(1)of theflange(2)at80

Removetheflange(2)completewithguard(4)by meansofapuller.

ApplyblocksT23and,withthehelpofapuller, extractthepinion(8)completewiththeinternalbearing,thedistancepieceandshims.

48 SECTION25--FRONTAXLE 604.02.395.00 --12--2002 Removetheswingingsupport(5). TH125131 5 151 Removethesealingring(6). TH125132 6 152 PositionwrenchT22ontotheringnut(7)andapply barholdT21tothepinion. StopwrenchT22androtatethepinionsoasto releaseandremovetheringnut(7). NOTE: Ifdisassemblyprovesawkward,heatthering nuttoapprox.80 ° C. TH125133 7 T21 T22 153

TH125134 8 T23 154

NOTE: Thethrustblocksofthebearingsremainin thecentralbody(12).

SECTION25--FRONTAXLE 49 604.02.395.00 --12--2002 Removethepinion(8),shims(11)andspacer(10). TH125135 11 10 8 155 Usingapullerandapress,removetheinnerbearing (9)fromthepinion(8). TH125136 9 8 156 Removetheexternalbearing(13)thrustblock. TH125137 13 157 Insertadriftintheappropriateholesandremovethe internalbearing(9)thrustblockaswellastheshim washers(14). TH125138 9 14 158

50 SECTION25--FRONTAXLE 604.02.395.00 --12--2002 TH125139 1 2 3 4 5 6 9 11 10 13 8 7 14 159

AXLEDRIVEPINIONBEARING ADJUSTMENT

Useadepthgauge(range0--15mm)tomeasurethe Qvaluebetweenthetooluppersurfaceandthepush rod.

Mountthebearingouterhousingonthedifferential case.

Installthebearingsandthespacerinthedifferential casewiththetool.

Tightenthenuttoolsothatthebearing/spacerunit ispacked.

SECTION25--FRONTAXLE 51 604.02.395.00 --12--2002

Usethespecifictool. Tightenthetoolinaviceandinsertthebearing(1)

TH125140 1 2 3 160

TH125141 4 161

fromabove,thespacer(2)andtheotherbearing(3).

Inserttheothertoolelementsandtightenthenut(4) untilthebearing/spacerunitispacked.

TH125142 Q 162

TH125143 163

Useadepthgauge(range0--15mm)tomeasurethe Q1valuebetweenthetooluppersurfaceandthe pushrod(asitwasdoneinthevice).

S1=Q1--Qcorrespondstotheshimtobeinserted betweenthespacerandthebearinginnerrace. TH125144

Checkthenominalvalue(X)indicatedonthepinion (5)andaddtoitorsubtractfromittheYvariationindicatedonthepinionheadinordertoobtainmeasurementZ.

E.g.X=118mmY=0.1mmZ=118--0.1=117.9mm

InstalltoolXXXXXonthedifferentialcaseand measuretheQ2valuebetweentheflangeandthe bearinginnerhousing.IfQ2isaddedtothefixed valueQ3=50mm(valuefromthetheoreticalstarting pointofthepinionprimitivegeneratinglinetothesurfacemeasuredbythetool)theWvalueisobtained.

E.g.:Q2=68.7mmW=68.7+50=118.7mm

TheS2valueisobtainedalsofromW--Zcorrespondingtotheshimtobeinsertedbetweenthebearing andthepinionhead.

E.g.:S2=118.7--117.9=0.8mm

604.02.395.00 --12--2002

52 SECTION25--FRONTAXLE

164

TH125146 (+0.1) 118 5 X Y 165 TH125145 166

SECTION25--FRONTAXLE 53 604.02.395.00 --12--2002 HOWTOINSTALLANDADJUSTTHEAXLE DRIVEPINION Placetheinnerbearing(9),theshim“S2”previously defined(ifneeded),andthepinion(8)underapress. Forcethebearingagainstthepinion. TH125147 9 8 167

themainbody. NOTE: Thefinershimsmustbeplacedbetweenthe thickerones. TH125135 11 10 8 168 Inserttheexternalbearing(13)inthecentralbodyin ordertocompletethepackarrangedasinthefigure. TH125148 9 11 10 13 169

Fitthepinion(8),shim“S1”(11)andspacer(10)in

TH125149 8 170

Connectthepinion(8)tothetierodT28AandT28B; connectthetierodT28C(seespecialtools)tothe pressandblock.

ApplyLoctite242tothethreadoftheringnut(7)and screwthenutontothepinion(8).

ApplyspecialwrenchT22totheringnut(7)andbar-holdT21tothepinion(8).

LockthewrenchT22androtatethepinionusinga torquewrench,uptoaminimumrequiredtorquesettingof500Nm.

Installthebar--holdT19ontothepinion(8)andwith thehelpofatorquemetre,checktherotationtorque ofthepinion(8).

Torque:120--170Ncm.

ATTENTION

Iftorqueexceedsthemaximumvalue,thenthesize ofshim“S1”(11)betweenthebearing(13)andthe spacer(10)needstobeincreased.

Iftorquedoesnotreachthesetvalue,increasethe torquesettingoftheringnut(7)indifferentstagesto obtainamaximumvalueof570Nm.

ATTENTION

Iftorquedoesnotreachtheminimumvalue,thenthe sizeofshim“S1”(11)needstobereduced.

ATTENTION

Whencalculatingtheincreaseordecreaseinsizeof shim“S1”,bearinmindthatavariationofshim(11) of0.01mm,correspondstoavariationof60Ncmin therotationtorqueofthepinion(8).

604.02.395.00 --12--2002

54 SECTION25--FRONTAXLE

TH125150 8 7 171

TH125151 T21 T22 172

TH125124 T19 173

Lubricatetheoutersurfaceofthenewsealingring(6) andfititontothecentralbody(12)usingtoolT27.

Fittheflange(2)completewiththeguard(4)and fastenit.

Forseatingtheflange(2),useaplastichammerif necessary.

NOTE: Makesurethattheguard(4)issecurelyfastenedontotheflangeandthatitisnotdeformed.

ApplyLoctite242tothethreadedpartofthepinion.

PositiontoolT20A(orT20B)andfastenitinorderto avoidrotation.InsertO--ring(3),thenut(1)andtighten itusingatorquewrench.

Torquewrenchsetting:280÷310Nm.

SECTION25--FRONTAXLE 55 604.02.395.00 --12--2002

TH125152 6 12 T27 174 Installtheswingingsupport(5). NOTE:

TH125131 5 175

Checkthatitisproperlyoriented.

TH125153 2 4 176

TH125154

177

T20A (T20B)

RemoveblocksT23(usedforextractingthepinion) andre--installthedifferentialunitandthearms. Fordetails,see“HOWTOASSEMBLEANDINSTALL THEDIFFERENTIALUNIT”and“CHECKINGWEAR ANDREPLACINGTHEBRAKINGDISKS”.

604.02.395.00 --12--2002

56 SECTION25--FRONTAXLE

T23 178

TH125155

Slackenthelockingstudbolt(2)screws(1)todisconnectthedriveshaft(3)frontpart.Carryoutthesame operationforthedropboxsideandremovethedrive shaft(3).

SECTION25--FRONTAXLE 57 604.02.395.00 --12--2002 FRONTDRIVESHAFT Specifications Length(A)closed:662mm Extension(B):72mm ........................ TH125168 179 FRONTDRIVESHAFTREMOVAL ATTENTION Supportthedriveshaftwithsuitableinstrumentsduringremoval.

TH125169 1 2 3 1 180

Spiderremoval

1.Cleantheassemblycomponentsthoroughlyafter removingthedriveshaft.

NOTE: Sincethedriveshaftisaslidingassembly,it isrecommendedtomarktheforkandtheshaftboth sideswithapieceotchalk. TH125170

2.Removethelubricatorfromthespiderandinstall aflangedfork(1)ontheviceshoestomakeit possibletoextractthedriveshaftspider(5).

sidewithahammer. Removethebearings(3)andtheshaft.

theflangedforktoremovethebearings.

(onlyforfrontshaft). TH125172

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58 SECTION25--FRONTAXLE

181

1 2 3 3 182

3.Removesafetysnapringsandhittheshaftupper

TH125171

4.Placethespiderpinsontheviceshoesandbeat

183

5.Repeatthesameoperationsontheoppositeside

Spiderinstallation

1.Locktheflangedfork.Insertthespiderinthe flangedforkfollowingthelubricatorholedirection.

2.Itisrecommendedtousealocatingpunchto positionthebearingcorrectly.Inthiswaythe bearingcanbeinsertedoverthespiderpininthe rightway.

3.Removethelocatingpunchandinsertthesecondbearingontheoppositeside.Theninsert snaprings.

4.Repeatoperations2and3tomatchthespider andtheshaft.

5.Fitagainthelubricator.

6.Repeattheabovementionedoperationsonthe universaljointoppositeside(onlyforfrontshaft).

7.Applygreasewiththelubricatorsuntilitisvisible nexttoeachbearinggasket.

SECTION25--FRONTAXLE 59 604.02.395.00 --12--2002

TH125173 Lubricatorhole 184

TH125174 Punch Bearing Locatingpin 185

NOTE: Forreplacementintervals,oilandlubricantquantityandtypefortherearaxle,refertotheOPERATOR’S MANUAL.

SECTION27--REARAXLE 1 604.02.395.00 --12--2002 SECTION27--REARAXLE CONTENT SectionDescriptionPage 27100 Specifications 1 ................................................................ Description 2 Operationdiagram3 ............................................................ Componentoverhaul5 Rearaxleremovalprocedure5 Overhaul 6 SPECIFICATIONS Type Steeringdifferential ......................................................................... withfinal epicycloidsreductions Overallwidth2050mm(flange--to--flange) .......................................................... Crownwheelandpinionratio 9:34 Finalreductionratio1:6(4satellites) Steering 40degrees Differential Withoutlock Brake Wetdiscwith8discs SteeringcylinderWithpositionsensor

Theaxlefittedtothisunitincorporates:

• Integralsteeringcylinder

• Steeringsensor

• Centraldrive

• Doublereduction(crownwheelandpinionplus planetaryhubs)

• Powerbrakes

2 SECTION27--REARAXLE 604.02.395.00 --12--2002 DESCRIPTION TH127001 TH127002

Frontview Topview

OPERATIONDIAGRAM

Enginepower(1)istransmittedfromtheengine throughthetransmission(2)andthedropbox(3)to therearaxle(4)viathedriveshaft(5).

SECTION27--REARAXLE 3 604.02.395.00 --12--2002

TH127003 4 5 3 1 2 2

REARDRIVESHAFT

Specifications

Length(A)closed:1347mm Extension(B):72mm

TH127005

ATTENTION

Supportthedriveshaftwithsuitableinstrumentsduringremoval.

Slackenthelockingstudbolt(2)screws(1)todisconnectthedriveshaft(3)frontpart.Makethesame operationontherearsideandremovethedriveshaft (3).

NOTE: RefertoSection25“FRONTAXLE”fordrive shaftspiderremoval. TH127004

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4 SECTION27--REARAXLE

1 2 3 4

COMPONENTOVERHAUL

Axleinsitu

Thefollowingcomponentscanbeoverhauledwith theaxlemountedontheunit.

• Planetaryreductionhubassembly

• Steeringknuckle

• Tierodpins

• Axledriveshafts,sealsandbushes

Axleremoved

Thefollowingcomponentscanbeoverhauledwith theaxleremoved.

• Brakeassemblies

• Differentialassembly

• Pinionassembly

REARAXLEREMOVALPROCEDURE

• Chockthefrontwheels.

• Placewoodenwedgesbetweentheaxlesand theframetopreventtheTelescopicHandlerfrom swinging.

• Jack--upthemachineupperpartandsecureiton suitablestands.

• Removethereardriveshaft.

• Removethewheels.

• Disconnectthesteeringhoses(1).

NOTE: Ensurebothpipesarepluggedtoprevent constantoilleaking.

• Disconnectthesteeringanglesensor(2).

• Removethepowerandparkbrakepipes.

• Removethefouraxlelevellingcylinderfixing screws.

• Supporttheaxleandremovethefourfixing screws.

• Lowerandremovetheaxlefromthevehiclebottomwithawheeledjack.

NOTE: Someitemswhichrequireservicingafter axleremovalmaybemoreeasilyloosenedwhilethe axleisin--situ,i.e.steeringtierodends.

SECTION27--REARAXLE 5 604.02.395.00 --12--2002

TH127006 5 TH127007 1 2 6

OVERHAUL

Pivotbushes

Removethefrontandrearpivotcasingfromtheaxle andleverthebushingfromthecasing.Inspectthe bushandpivotforwear.

TheaxlefittedtotherearoftheTelescopicHandler isalmostidenticaltothatfittedtothefront.Therefore whenoverhaulingthefollowingcomponentsreferto Section25.

• Axlehubs

• Steeringknuckle

• Tierodpins

• Axleshafts

• Axletrumpethousing

• Brakehousing

• Differentialcrownwheelandpinion

• Steeringcylinder

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6 SECTION27--REARAXLE

TH127008

SPECIFICATIONS

Brakediscs(frontaxle,perside)4 (rearaxle,perside)4

NOTE: Forreplacementintervals,oiland lubricantquantityandtypeforthe brakesystem,refertotheOPERATOR’SMANUAL.

SECTION33--BRAKES 1 604.02.395.00 --12--2002

CONTENT SectionDescriptionPage 33000 Powerbrakes 2 ................................................................. Parkingbrake 3 Brakerelease 6 ................................................................ Brakediscadjustment6 Troubleshooting 7 Brakediscreplacement8

SECTION33--BRAKES

...............................................................

BrakeoperationPoweredhydraulic Brakes Wetdiscs,pistonoperated

Descriptionandoperation

2 SECTION33--BRAKES

POWERBRAKES

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TH133043 1.Brakepedal 2.Brakepump 3.Oilsump 4.Frontaxle

1 2 3 4 5 1

5.Rearaxle Thevehiclebrakesonthefrontandrearaxles.All frontandrearaxlesareequippedwith4+4discs(4 foreachside). Thefootbrakeoperatesthepumpwhichactuatesthe frontandrearassemblieshydraulically.

Descriptionandoperation

Whentheparkingbrakeswitchisoperated(1),the oilflowstothedrainreservoirandnegativebrakeis actuated.

Whenthebrakeswitchisreleased,thevalvemakes theoilflowagaininthe systemanddisengagesbrake discs.

SECTION33--BRAKES 3 604.02.395.00 --12--2002 PARKINGBRAKE

PRESSURESUPPLY MAX35BAR 2

TH133044 BRAKERELEASEVALVE FORPASSIVEPARKING

TH133045 1

BRAKEBLEEDINGPROCEDURE

NECESSARYCONDITIONS

• Engineoff.

• Twooperatorsrequired.

--1inthecabintopressthebrakepedalandtop upthereservoir

--1outside,ontheaxle,toopenandclosebleed screws

EQUIPMENT

• Transparentflexhose(L=500mm ∅ i=5mm)

• Oilrecoverycontainer.

BLEEDINGSTEPS

• Removetheuppercabinstrumentpanel(1)(to accessthepumpreservoir)

• Removethechassisguard(uppersideabove frontaxle) TH133052

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4 SECTION33--BRAKES

1 4

• Loosenthefrontandrearaxle(3)bleedscrew (2).Usuallystartwithrearaxleandthenproceed asfollows:

• Removethebrakepumpreservoircap(4)andfill thereservoirwithoil.

• Pushthepedalrepeatedly,downandup,sooil circulatesthroughthesystemandtheairout.

• Asthereservoirleveldrops,topup.

• Whentheoilstartstoflowdownthetransparent hose,tightenthebleedscrewwiththepedalstill pusheddown.

• Repeatstepsforeachofthebleedscrewsinthe abovementionedorder.

• Testthebrakeswiththeengineoffandthepedal shouldbecomehardbeforereachinghalfits downwardstroke.Ifthepedalcanbepressed furtherortothefloor,repeatthebleedingprocedure.

• Re--installfrontaxlecoverandinstrumentpanel insidethecabin.

SECTION33--BRAKES 5 604.02.395.00 --12--2002

--rearright--handsideaxle --rearleft--handsideaxle --frontright--handsideaxle --frontleft--handsideaxle

Attachtherubberhosetotheendofthebleed

collectioncontainer. TH133047 2 5 TH133048 3 3 6

•

screw.Placetheotherendofthehoseinthe

TH133049 4 7

BRAKERELEASE

Intheeventthebrakesremainlockedanditisnot possibletore--starttheengine,butyouwishtomove thevehicle,itisnecessarytotightenthefrontaxle screws(1)(twoforeachside)afterslackeningthe locknut(2).Whenthevehicleisoperativeagain, slackenthescrewsandfastenthemwiththelocknut.

BRAKEDISCADJUSTMENT

Performoperationsonbothaxlearms.Removethe oillevelcap(1).

Operatethebrakesandkeepthempressedtocheck thickness“S”betweenthediscswithathickness gauge(minimumvalueof“S”=4.5mm)

ATTENTION

Replacebrakediscsandintermediatediscsonboth sides,ifneeded.

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6 SECTION33--BRAKES

TH133050 2 1 8

TH133051 1 S 9

TROUBLESHOOTING

Remedy

Checkthebrakediscthickness.Ifthebrakediscs canbere--used,adjustthemasdescribedinthe vehiclemanual.

Checkthebrakediscthicknessandreplacethem,if needed.

Replaceallaxleandmaincylindersealringswhich cameintocontactwiththewrongfluid.Replacealso thehoses.

Checkandrepairalloutsideandmaincircuitleakages.

Ifthecauseisthewrongfluid,seeremedyno.3. Iftheleakagegoesoutwards,replaceO--rings betweenthecentralcaseandtheintermediatecover. Iftheleakagegoesinwards,replacetheabovementionedO--ringsandthoseofthebrakepiston. Seeproblem:overheating. Brakepedaldoesnotreact

Remedy

Bleedthebrakingcircuitasdescribedforthevehicle manualbleeding.

Remedy Seeremedyno.1.

Remedy Discharge,washandfilluntillevelisreached. Adjustthebrakeasdescribedforthevehiclemanual. Releasethebrakebycorrectingclearance. Seeremedyno.3.

Checkandrepairdamagedpipes. Replacethebrakesystemandpumpsealrings.

Remedy Seeremedyno.2andno.3. Seeremedyno.3.

SECTION33--BRAKES 7 604.02.395.00 --12--2002

Insufficientbraking Cause 1.Wrongadjustment

3.Wrongfluidinthecircuit

2.Brakediscsworn

4.Fluidleakfrombrakecircuit 5.Axleoverheatingwithfluidevaporation(brakes returnwhenaxlecoolsdown)

Cause

6.Airinbrakingcircuit

Insufficientnegativebrake Cause 7.Wrongadjustment 8.Brakediscsworn

Seeremedyno.2. Overheating Cause 9.Wrongoillevel 10.Littleclearancebetweenbrakediscs 11.Parkbrakeonduringtraction 12.Wrongfluidinthecircuit 13.Brakecircuitchoked 14.Wronglubricant

Oilcomingout Cause 15.Hydraulicfluidleakagefrombrakingsystem 16.Hydraulicfluidleakagefromdifferentialcircuit

BRAKEDISCREPLACEMENT

Brakeandparkingbrakefrontdiscremoval Connectanexternalpumptothenegativebrakepipe union“P”andselectapressureof15–30bartoeliminatetheBellevillewasherload.

Removethesteeringtierodpinsfromthesteering knuckle(see“STEERINGCYLINDERREMOVAL”).

Slingtheaxleshafttoberemoved(1)withahoist. Removescrewsandnuts.

Removetheaxleshaft(1)withthebrakesandthe halfshaft.Placetheaxleshaftinverticalposition. Extractpressure.

Removethepistonreturnsprings(2).

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8 SECTION33--BRAKES

TH133001

TH133002 1 11

TH133003 1 12

TH133004 2 13

ATTENTION

SECTION33--BRAKES 9 604.02.395.00 --12--2002 Removethepistondrivescrews(3).

Ifthescrewsneedtobereplaced,takenoteofdiffer-

TH133005 3 14 Writedowntheirassemblysequenceandremove theintermediatedisc(4). TH133006 4 15 Slackenandremovestudbolts. TH133007 16 Extractthecylinder(5). TH133008 5 17

entcoloursforbrakeclearances.

RemoveBellevillewashers(6)andtakenoteoftheir assemblyposition.

Removethepiston(7)byblowingcompressedair graduallythroughthenegativebrakepipeunion.

ATTENTION

Holdthepiston(7)becauseitmightbeejected suddenlyandgetdamaged.

RemovetheO--ringsfromthepiston(7).

NOTE: O--ringsmustbereplacedwheneverthe assemblyisdisassembled.

Beforeremovingthenegativepiston,markitsposition. TH133011

Removethepiston(8)byblowingcompressedair graduallythroughthenegativebrakepipeunion.

ATTENTION

Holdthepiston(8)becauseitmightbeejected suddenlyandgetdamaged.

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10 SECTION33--BRAKES

6 18

TH133009

TH133010 7 19

8 21

TH133012

SECTION33--BRAKES 11 604.02.395.00 --12--2002 Removethebrakediscs(9)fromtheaxleshaftand takenoteoftheirassemblyposition. NOTE: Ifthediscsneedtobereplaced,makesure theiroriginalpositionisrespected. TH133013 9 22 Removethespacer(10)andtheshims(11). TH133014 10 11 23 TH133043 1 2 3 4 5 6 7 9 11 10 13 8 9 24

12 SECTION33--BRAKES 604.02.395.00

Assembly InstalltheO--ringsonthepiston(8). LubricatethepistonandtheO--rings,theninsertthe pistoninthecylinder(5). NOTE: Piston“C”bleedingvalveshouldfacedownwards. TH133015 5 8 8 25 Hitthepiston(8)withaplastichammertoinsertitin thecylinder(5). NOTE: Slightlybeatincrosswise,alternatefashion aroundtheedge. TH133016 5 8 26 InstalltheO--ringonthepiston(7). LubricatethepistonandtheO--rings,theninsertthe pistoninthecylinder(5). TH133017 5 7 27 Hitthepiston(7)withaplastichammertoinsertitin thecylinder(5). NOTE: Slightlybeatincrosswise,alternatefashion aroundtheedge. TH133018 5 7 28

--12--2002

SECTION33--BRAKES 13 604.02.395.00 --12--2002

TH133019 12 29

CheckthecylinderO--ring(12)conditionsandposition. InserttheBellevillewasher(6)andreattachthecylinder(5).

TH133020 5 6 30

NOTE: ChecktheBellevillewasher(6)assembly directionandtheirlocation.

Fastenthecylinder(5)bytighteningthescrewswith atorquewrenchtoatorqueof86 ÷ 89Nm.

TH133021 5

Fillthepistonchamberswiththeappropriateoil.

TH133022

Reinstallthereturnsprings(2)backonthepiston. ApplyLOCTITE270onthepistonadjustingnut threading. Tightenwithatorquewrenchtoatorqueof10–15 Nm.

14 SECTION33--BRAKES 604.02.395.00 --12--2002 Connectanexternalpumptothenegativebrakepipe

TH133001 33 Insertthetravelautomaticadjustingsprings(13)and alignthemwiththepiston. TH133023 13 34 Inserttheintermediatedisc(4). TH133006 4 35

TH133004 2 36

union“A”andselectapressureof15–30bar.

IMPORTANT: Screw(3)setfor1mmclearance(y). Tightenthedrivescrews(3)andmakesuretheyall havethesamecolour.

Establishtheshimstobeinsertedunderthespacer. Withasetpressureof30bar,measurethedistance betweentheintermediatediscandthecylinder.

Placethebrakeassemblyfittedwiththespacer underthepress,loaditto1000Kgandmeasure value“V”.

Armfixedvalue68mm. Shimstobeappliedunderthespacer. S=68mm–(x+y+v)=Shimstobeapplied

SECTION33--BRAKES 15 604.02.395.00 --12--2002

ApplyLOCTITE270onthethreading. Tighteningtorque:5 ÷ 7Nm. TH133005 3 37

EXAMPLE:x=25.4mm TH133024 38

EXAMPLE:V=40mm TH133025 39

TH133026 40

Slightlylubricatethebrakediscs(9)andinstallthem ontheaxleshaftinthecorrectorder.Theyshouldbe positionedsothattheoilcirculationholesmatchwith marks“B”.

NOTE: Whensteeldiscsarefitted,ensuretheslot nexttotheoilplugisfree.

Checkthatthesealringhousingontheaxleshaftis intact.Fastenitwithtwooppositescrewsandrespectivewashers.

Checktheaxleshaftflangesmatchwitheachotherand tightentherespectivefasteningscrewsandwashersin crosswised,alternatetighteningfashion.

16 SECTION33--BRAKES 604.02.395.00 --12--2002 Insertthepreviouslyestablisheddimensionshims andthespacer. TH133014 11 10 41

Tighteningtorque:298Nm. TH133027 1 9 B 42

Removetheswivelsupport(2).

NOTE: Ifthebush(1)iswornandneedstobe replaced,takenoteofthefitting“A”notchassembly side.

Removethesteeringtierodpinsfromthesteering knuckle(see“STEERINGCYLINDERREMOVAL”).

tensionthehoistalittle.

Removethebrakediscs(7)andwritedownthe assemblyorder.

NOTE: 1–Ifthediscsdonothavebereplaced, ensuretheiroriginalpositionismaintained. 2–Removethedoubleuniversaljoint(18).

SECTION33--BRAKES 17 604.02.395.00 --12--2002

Rearbrakeremoval

TH133028 1 2 A 43

Slingtheaxleshafttoberemoved(3)withahoistand

Slackenandremovethescrews(4)andthewashers (5)fasteningtheaxleshaft(3)tothecentralunit(6). TH133029 3 4 5 6 44 Removetheaxleshaft(3)andthebrakediscunit(7). Settheaxleshaftonabench. TH133030 3 7 45

TH133031 18 7 46

ATTENTION

Slowlyblowcompressedairthroughthebrakingcircuitattachmentinordertoremovethewholepiston (9).

ATTENTION

Holdthepistonbecauseitmightbeejectedsuddenly andgetdamaged.

18 SECTION33--BRAKES 604.02.395.00 --12--2002 Removethepiston(9)returnsprings(8). NOTE: Ifthesprings(8)aredistorted,replacethem. TH133032 9 8 8 47 Removethepistondrivepinscrews(10).

TH133033 10 48

Ifthescrewsneedtobereplaced,writedowncolours forbrakeclearances(See“BRAKINGUNITASSEMBLY”).

TH133034 9 49

SECTION33--BRAKES 19 604.02.395.00 --12--2002 TH133035 1 2 3 6 9 11 10 12 13 14 15 16 18 8 7 50

20 SECTION33--BRAKES 604.02.395.00 --12--2002 Rearbrakeassembly Cleanthepiston(9)andthesliding/sealhousings thoroughly. ReplacetheO--rings(11)and(12)andtheanti--extrusionrings(13)and(14).Respectassemblydirection. ATTENTION Makesureanti--extrusionrings(13)and(14)are positionedcorrectly. TH133036 3 9 11 12 13 14 51 Insertthesprings(15)onthepiston(9)circumferencefortravelcompensation. TH133037 9 15 15 52 Lubricatethesealsandinstallthepiston(9)inthe arm(3). ATTENTION Makesurethepistonhousingmatcheswiththestop (A)insidethearm. TH133038 9 A 53 Insertthepiston(9)bylightlybeatingthecircumferencewithaplastichammer. TH133039 9 54

Insertthepinscrews(10)andensuretheyallhave thesamecolour.

Slightlylubricatethebrakediscs(7)andinstallthem onthearminthecorrectorder.Theyshouldbepositionedsothattheoilcirculationholesalignwith marks“B”.

Checkthearmsealring(16)integrityandlocation. Installthewholearm.

Fastenitwithtwooppositescrews.

SECTION33--BRAKES 21 604.02.395.00 --12--2002

Yellow:clearance0.75mm Blue:clearance0.5mm ApplyLoctite270onthethreading Tighteningtorque:5 ÷ 7Nm TH133033 10 55

Becarefulnottodamagespringattachments. TH133032 9 8 8 56

White:clearance1mm

Insertthepiston(9)returnsprings(8). ATTENTION

NOTE: Whensteeldiscsarefitted,ensuretheslot nexttotheoilplugisfree. TH133040 B 7 57

TH133041 16 58

Checkthearmflatnessandfastenthemwiththe screws(4)andthewashers(5)inacrosswise,alternatetighteningfashion.

Tighteningtorque:298Nm.

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22 SECTION33--BRAKES

4 5 59

TH133042

SECTION35--HYDRAULICSYSTEM 1 604.02.395.00 --12--2002 SECTION35--HYDRAULICSYSTEM LISTOFCONTENTS SectionDescription Page 35000Technicaldata 2 Descriptionandoperation3 Introduction 3 Parkingbrakecircuit3 ....................................................... Steeringsystemhydrauliccircuit4 Steeringvalve 5 Telescopicboomhydrauliccircuit7 Componentoperation13 Hydraulicpump13 Deliverysidedividervalve13 Pressurereducingvalve15 ................................................... Frontloadercontrols17 Powersteering(OSPQ)21 Telescopicboomdistributor23 Auxiliarycontrolsdistributor26 ................................................... Cylinders 27 Boomremoval 37

TECHNICALDATA

Hydraulicoil SpecificationAmbra Hydrosystem 46HVNH646H

InternationalspecificationISOVG46,DIN51524

Totalsystemcapacity185litres

Hydraulicoilfilterchangeinterval250hours

Hydraulicoilchangeinterval500hours

Checkinginterval10hours

Hydraulicpump

Gearpumpwithbuilt--inflowdividervalvesensitivetotheloadanddeliveringpriorityflowtothesteering circuit.

DeliveryNewpump130lt./min@ 2500rpm@230bar

Wornpump110lt./min@ 2500rpm@230bar

Pressurereducingvalve

Controlpressure35bar

Reliefvalvepressure45bar

Balancingandloadcheckingvalves

Location

Liftingcylinder,pistonside

Tiltingcylinder,pistonside

Telescopiccylinder(s),pistonside

Safetyvalveagainstloadpeaks350bar

Hydraulicdistributor

Multi--elementdistributorwithopencentreandindividualcircuitreliefvalves.

Powersteering

Mainreliefvalve175bar

Secondaryreliefvalves240bar

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2 SECTION35--HYDRAULICSYSTEM

DESCRIPTIONANDOPERATION

INTRODUCTION

Thehydrauliccircuitincludes:

• parkingbrakecircuit

• (primary)steeringcircuit

• (secondary)telescopicboomcircuit

Thelatteralsoincludesthe systemcomponents responsiblefortheselectionofthestabilisers,frame levellingandrearaxlelock--up.

Theoperatingdiagramsoftheabove--mentionedcircuitsandtherelativedescriptionsaregivenbelow;the diagramsgiveanoverallviewofthehydraulicsand includesomeindicationsontheelectrics,asneededto provideanunderstandingof thesystem’soperating logic.

PARKINGBRAKECIRCUIT

Themachineisfittedwithaparkingbrakemounted onthefrontaxle.

Theparkingbrakeworksontheoil--bathmultipledisk servicebrakesequippingthefrontaxle(3).

Asarule,thebrakesareappliedwiththeengineoff. Iftheparkingbrakeisusedwiththeenginerunning, themachinecanbeblockedbypressingonswitch (2)aftercuttingoutthesafetydevice.Thisactivates thetransmissionblock(neutral)and,byenergising thesolenoidvalve(1),pressurisestheoil(det.4)in thebrakingassembliesequippingthefrontaxle(3). Tocutoutthebrake,firstpressontheswitch(2)after cuttingoutthesafetydevice.

SECTION35--HYDRAULICSYSTEM 3 604.02.395.00 --12--2002

3 1 5 2 4 6 TH135001 2 1

1. Solenoidvalve 2. Controlswitch 3. Frontaxle 4. Representationofvalvewithbrakeapplied 5. Pressurecontroltappingfitting 6. Supplyblock N.B.: Forcomponentlocation,seefigureonpage9.

STEERINGSYSTEMHYDRAULICCIRCUIT

Basiccircuitoperation

Pump(3)takesintheoilthrougha100micronfilter locatedinthehydraulicreservoiranddeliversit throughtheloadsensingdividervalve(2)attheback ofthepump.Inthismanner,theoilreachesfirstthe steeringsystemcircuit(primarycircuit)andtherest oftheoilistransferredtothetelescopicboomandthe auxiliaryhydrauliccircuits(secondarycircuits)(Ref. A).

Theflowofoilgoesthroughthepriorityholeofthe dividervalveandreachesthesteeringsystemmotor (1)andthentheselectionvalve(7)forthreesteering modes:

—Twosteeringwheels

—Fourconcentricordiscordantwheels —Fourconcordantorunilateralcrabwheels. (seefig.TH135003,page5)

Withthesteeringwheelstationary,thepowersteeringdistributorisinneutralandtheoilcanflowtothe returnpath(frominletPtooutletT).Intheseconditions,intheeventofcollisionsagainstthewheels, thelatteraredampenedbytheshock--proofing valvesandarenottransmittedtothesteeringwheel. Moreover,twoanticavitationvalvespreventcavitationphenomenafromoccurringinthesteeringcylinderschambers.

Whenthesteeringwheelisturned,themovementis transferredtothedistributorwhichgraduallyopens theconduitstothecylinderways,whileneutralcontactsclose.

Followingwheelrotation(andtheensuingdistributor rotation)thevolumeofoilthatgoesthroughisdirectly proportionaltotheangularmovementofthesteering wheelandproducestheangularmovementofthe drivewheels.

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4 SECTION35--HYDRAULICSYSTEM

TH135002 2 3 4 5 6 8 7 1 2

Steeringsystemhydrauliccircuitdiagram

1. Powersteering 2. Priorityflowdividervalv 3. Hydraulicpump 4. Tankwithintakefilter 5. Plugwithinletandoutletsideoverpressurevalve 6. Rearaxlecontrolcylinder 7. Steeringmodeselectionvalve 8. Frontaxlecontrolcylinder A. Deliverylinetotelescopicboomcircuit B. Heatexchangerdischargeline C. Dischargelinefromtelescopicboomdistributor

STEERINGVALVE

Themachineisequippedwithtwosteeringaxlesand therelatedsteeringcylinderswhichprovideforthree differentsteeringmodesasafunctionofsolenoid valveposition.

Ifthesolenoidvalve(5)isnotactivated,steeringis achievedbymeansofthefrontaxle(7)andtheoil containedinthesteeringcylinderchamber,whichis notpressurised,iscontrolledbythesamedistributor thatconveystheoiltothedischargeline(T)and hencetothereservoirsimultaneouslywiththeoil pressurisationcommand.

Ifthesolenoidvalve(5)isactivatedineitherdirection thetwosteeringcylindersareconnectedinseries andthedeliveryoilentersthechamberofarearaxle cylinder(6)toreturntothechamberoftheothercylinder.

SECTION35--HYDRAULICSYSTEM 5 604.02.395.00 --12--2002

1. twosteeringwheels 2. fourconcentric(ordiscordant)steeringwheels 3. fourunilateral(orconcordant)steeringwheels(crab) 4. Frontaxlesolenoidvalve 5. Rearaxlesolenoidvalve 6. Rearaxlecylinder 7. Frontaxlecylinder A.Connectiontocylinder(6) T. Connectiontocylinder(7)

TH135004 P T A B 3 TH135003 1 2 3 4 TH135006 4 5 6 7 5

B.Connectiontocylinder(6) P.Steeringsystemdeliveryline R. Steeringsystemdeliveryline

6 SECTION35--HYDRAULICSYSTEM

--12--2002 STEERINGSYSTEMHYDRAULICCIRCUIT

1 2 3 4 5 6 6

604.02.395.00

TH135007

1. Hydraulicpump 2. Steeringcylinderonfrontaxle 3. Reservoir 4. Powersteering 5. Steeringmodeselectionvalve 6. Steeringcylinderonrearaxle

TELESCOPICBOOMHYDRAULICCIRCUIT Basiccircuitoperation

Thepump(1)takesintheoilthrougha100micron filtersituatedinthehydraulictankandsendsitonto thesteeringcircuitthroughline(a)inprioritymode, andhencetothedistributors(11)and(22)supply lines(secondarycircuit).

Takenasawhole,thecircuitismainlycontrolledby theoperationofthecontrolunit(14)andthepush buttons(13)situatedonthepaneltotheleftofthe driver.

Thepumpdeliveryhydraulicoilflowstothedistributorsthatcontrolthevarioushydraulicfunctionsby managingtheflow--ratetothevariousactuators:the hydraulicoilcomingbackfromtheactuatorsthrough thedistributorsistransmittedtotheoilcooler,where itiscooledandhencereturnstothehydraulicreservoirviathetotalcapacityfilter,whichholdsbackany impuritiesasmaybecontainedintheoilreturning fromtheactuators.

Whentheoiltemperatureislow,oilviscosity increasesandsodoestheresistancetothepassage oftheoilthroughthecooler.Iftheoilpressure exceeds5bar,whetherbecauseofthehighviscosity oftheoil(thermostaticvalvefunction)orduetoradiatorclogging,theoilreturnsdirectlytothetank,by-passingtheradiator.

Tooldistributor

Stemliftingisachievedbyworkingonthehandlever (14),whichdistributesthepressureloadtothetwo centralhydraulic(slide)valvesofthedistributor(22), whichsupplyboththeliftingcylinder(30)andthe compensationcylinder(17).Thecircuitofthelatter

isconnectedtotheliftingcylinder(30)andmakesits possibletokeepthetool(fork,bucket,etc.)inhorizontalpositionduringcylinder(30)lifting.

Thetelescopicboomisextractedbymeansofan unstablecursortypeswitchlocatedonthefrontofthe unit’scontrollevethandle(14).Theoperationiselectricallycontrolledbymeansofatrimmer(35),which activateselectricallytheproportionalsolenoidvalve ofthedistributor(22).Thelatterdistributestheload totheliftingcylinders(27)and(28)(iffixed).

Thefrontpartofthehandlehousestwoswitches(34) fortheoperationofthesolenoidvalveequippingthe distributor(28)thatsuppliesthecylinder(6)(OPT.). Thedistributor(22)alsocontains,foreachslide valve,loadsensingvalves,connectedtotheload sensinglineG.

Rearaxlelock

Therearaxlelockingcylinderusesthesystem’sdischargelinewhichhasapressureof3--4bar.Its activationtakesplaceautomaticallyduringtheboom liftingstage:atca15°,thesensorfittedtotheboom itselfsendsasignaltothecontrolunitwhichactivates thevalve(20).

Auxiliarycontroldistributor

Thepump(1)supplies,inparallelwiththedistributor (22),thestabiliserandlevellingcontrolassembly (11).

Thesecontrolsareoperatedbymeansofpushbuttons(13)whichactivatethedistributor’ssolenoid valvesandhencecontroltheoutputpressuresinthe circuititself,balancedbytheloadsensingline(G).

SECTION35--HYDRAULICSYSTEM 7 604.02.395.00 --12--2002

Telescopicboomcircuitcomponents 1.

26. Cylinderlockingvalve(16mversion)

27. Telescopiccylinders

28. Telescopiccylinder(16mversion)

29. Liftingcylinderblockingvalve

30. Liftingcylinder

31. Heatexchanger

32. Tiltcylinderlockingvalve

33. Tiltcylinder

34. Pushbuttonsforauxiliarycylindercontrol(OPT)

35. Trimmerforcontrolunit(handlever)

36. Hornswitch

37. ITransmissiondisengagement(neutral)switch

A. Steeringcircuitdeliveryline

B. Steeringpriorityflowpilotline

C. Horn

D. Outputsignalfortransmissionlocking(neutral)

E. Dischargelinefromtransmissionlocking(neutral)

F. Parkingbrakecircuitline

G. Stabilisercircuitline

H. Powersteeringdischarge

16. Steeringselectionsolenoidvalve

18. Rearaxlesteeringcontrolcylinder

24. Parkingbrakesolenoidvalve

604.02.395.00 --12--2002

SECTION35--HYDRAULICSYSTEM

Hydraulicpumpwithdividervalve

Levellingcylinderlockingvalve 3. Levellingcylinder 4. Rightstabilisercylinderlockingvalve 5. Rightstabilisercylinder

Connectiontoaux iliarycircuit(OPT) 8. Leftstabilisercylinder 9. Leftstabilisercylinderlockingvalve 11. Auxiliarycontrolsdistributor 13. Unstablerockerforauxiliarycontrols 14. Controlunit(handlever) 15. Reservoir 17. Compensationcylinder(pump) 19. Rearaxlelockingcylinder 20. Rearcylinderlockingcontrolvalve 21. Oilfilter 22. Telescopicboomdistributor 23. Supplylockingvalveforcontrolunitandparking brake 25. Telescopiccylinderlockingvalve

Frontaxlesteeringcontrolcylinder 10. Parkingbrakeassembly 12. Powersteering

Componentsofsteeringsystemandparkingbrakecircuits 7.

SECTION35--HYDRAULICSYSTEM 9 604.02.395.00 --12--2002 TH135008 1 19 5 4 8 9 3 2 27 11 13 34 35 36 37 14 23 26 28 31 21 29 33 17 20 32 22 6 30 15 25 7 Telescopicboomcircuit

SECTION35--HYDRAULICSYSTEM

Arrangementofhydraulicsystemcomponents,complete with:

604.02.395.00 --12--2002

--telescopicboom TH135009 1 23 19 5 4 8 3 13 6 28 27 30 2 9 15 16 31 12 10 11 7 20 20 20 24 22 21 18 37 35 14 36 34 26 25 17 14 C 29 8

--steering --parkingbrake

SECTION35--HYDRAULICSYSTEM 11 604.02.395.00 --12--2002 TH135010 32 33 28 27 30 29 17 31 18 11 7 10 9 8 6 4 5 2 3 1 13 12 15 16 19 20 22 21 24 37 14 35 36 34 26 25 23 14 9 Completetopographicdiagramofhydrauliccircuit

604.02.395.00 --12--2002

SECTION35--HYDRAULICSYSTEM

COMPONENTOPERATION

Hydraulicpump

Thehydraulicpump(1)isaconstantflowgearpump withabuilt--individervalve(2)thatdividestheload sensinglinedeliveryflow.

Thepumpmovesatthespeedoftheengineandhas arateddeliveryflowof130lt./minatan enginespeed of2500rpm,at230bar.

Itcanworkattemperaturesrangingfrom--25°Cto +80°C.

Thehydraulicconnectionstothepumpandflow dividervalveare:

Deliverysidedividervalve

Theflowdividervalve(2)mountedatthebackofthe hydraulicpump(1)ensuresthatapriorityflowcorrespondingtothedemandisalwaysdeliveredtothe steeringcircuit(prioritycircuit),whiletheremaining flowistransmittedtothetelescopicboomactivated bythedistributorandtotheauxiliarycircuits(secondarycircuit).

SECTION35--HYDRAULICSYSTEM 13 604.02.395.00 --12--2002

gears. TH135011 3 2 1 10 Hydraulicscheme TH135012 1 2 3 4 11

Thepumpinputcontrol(3)isdirecttype,withoutidle

1. tothehydraulicdistributor 2. pumpintakeline 3. loadsensingline

TH135013 1 3 4 12

4. topowerassistedcircuitofsteeringsystemwith reducingvalve 1. Housing 2. Loadsensinglineconnector 3. Shim 4. Spring

TH135014 1 2 3 4 5 6 13

5. Pin 6. Plug

Theloadsensingdividervalveensuresthatapriority flowcorrespondingtothedemandisalwaysdeliveredtothesteeringcircuit(prioritycircuit),whilethe remainingflowistransmittedtothetoolcircuit(secondarycircuit).

Atkey--on,thepinintheloadsensingvalveispushed totheleftbyaspring(8)enablingthepumpflowto enterthevalvethroughahole(3)whichensuresthe deliveryofthepriorityflowtothesteeringandbraking systemcircuits.Thepressureofthepumpisalso appliedtothecentreofthepinandtransmittedtothe lefthandsideofthepinthroughhole(10).Thebalancinghole(9)sensesthepressurebutworksasa dampertopreventthepinfrommovinginanirregular manner.

Assumingthatduringenginestartingthebrakingand steeringcircuitsarenotused,theloadsensingline openstowardsthereservoirandthepumppressure

appliedtothelefthandsideofthepinmovesthepin totheright,therebyconveyingthedeliveryflowtothe loaderarmcircuit.

Assoonasthesteeringwheelisrotated,thepressuregeneratedinthesecircuitsissensedintheload sensinglineandappliedtotherighthandsideofthe pin.Whenthecombinedeffectsoftheloadsensed andtheforceofthespringagainsttherighthandside ofthepinexceedsthepressureappliedtotheleft handsideofthepin,thepinmovestotheleft,thereby increasingtheflowdeliveredtothesteeringcircuit. Sincetheoilintheloadsensinglineflowsthroughthe steeringmotoradjustmentholesbeforereachingthe dividervalve,theloadsensingpressureisalways proportionaltothedemand.Thisensuresthatthe valvetransmitsonlythequantityofoilnecessaryto thesteeringcircuit,whiletherestofthepump’soutputflowisroutedtotheloaderarmcircuit.

14 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002 TH135015 2 3 4 5 1 6 7 8 9 10 11 14 Operationofthedeliverysideflowdividervalve Tosteeringcircuit Totoolcircuit Steeringcircuitloadsensingsignal

1. Pin 2. Toloaderarmcircuit 3. Hydraulicpumpintakehole 4. Steering/brakingcircuit 5. Hole 6. Loadsensingconnector 7. Shim(iffitted) 8. Spring 9. Balancinghole 10. Hole 11. Plug

Pressurereductionvalve

Pressurereductionvalve(1)regulatesthepressure at35barintheportionofthecircuitprovidingoilto thehydraulicpowerassistedcontrols,thejoystick andtheparkingbrake.

SECTION35--HYDRAULICSYSTEM 15 604.02.395.00 --12--2002

TH135016 15 Hydraulicdiagram

1. Deliveryline 2. Dischargefornegativebrakesolenoidvalve 3. ConnectiontoPSTofmaincontrolvalve 4. Poweringforjoystick

TH135017 4 1 2 3 5 16

5. Dischargetoreservoir

16 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002 TH135018 17 Pressurereductionvalve

FRONTLOADERCONTROLS

Tolift,lower,retractandtilttheparts,movethelever (1)asfollows:

Uppercontrolplate

Thisconsistsofanunstablecursortypethree--positionswitch(2)andtwobuttons(3)and(4). Thecursor(2)makesitpossibletopulloutthetelescopicboom(whenpushedforward)orretractits (whenpulledback).

Thetwobuttons,buttons(3)and(4),areavailablefor auxiliaryfunctions.

Undertheloadhandlinglevertherearetwounstable buttonsthathavebeenassignedthefollowingfunctions:

5.Optionalfunction

6.Transmissiondisengagement(neutral)

Beingunstable,button(6)keepsthetransmission disengageduntilitisreleased.

Thebottompartofthepowerassistedcontrolunit includessixhydraulicconnectionsthatgotothejoystickasfollows:

• Returntoreservoirorifice(T)

• Fouroutletholes(1--2--3and4)forproportional pressure,eachofwhichisconnectedtoeach endoftheslidevalvesoftheliftingandtilting controldistributor.

• Aninletorificefortheoilsupplyatapressureof 35bar(P).

Eachofthefouroutletholesisequippedwithsmall pistonswithplungersthatmakeitpossibletoapply apilotpressureproportionaltothemovementofthe joystickattheendofapinandhencetomoveitby theextentnecessarytoactivateit.

Thejoystickisconnectedtoatiltingplate;boththe joystickandtheplatearemovableabovethecontrol unitbody.

Whenthejoystickisused,thetiltingplatemoves overoneofthepistonandplungerassembliesto transfertheoiltothehydraulicdistributorspools.

SECTION35--HYDRAULICSYSTEM 17 604.02.395.00 --12--2002

TH135020 1 2 3 4 6 5 18

--forward,tolowerthearm --back,toliftthearm --totheleft,toretractthefrontloader/tool --totheright,totipthefrontloader/tool.

TH135021 1 2 3 4 19 Hydraulicscheme 1--2Cylinderliftinglines 3--4Frontloadertraininglines P--Supplyline T--Dischargeline

1 2 3 4 P T 20

TH135022

Thehydrauliccylindersemployedtooperatethetelescopicboomareshowninthefigure.

Thetelescopiccylinder(2)ishousedintheboom structure;however,whenthetelescopicboomis fittedwiththethreesectionsoption,anadditionalcylinder(1)ismounteddirectlyontheboom.

Thecompensationcylinder(8)isconnected hydraulicallytothetiltcylinder(9)andensuresthe

self--levellingoftheloadforksduringtheboomlifting cycle.

Asafetyfeaturecharacterisingtheboomcylindersis thepresenceofbalancingvalvesthatensurethatthe cylinderstayslockedinitspositionevenintheevent ofhydraulicpipefailure.Thecylindersfittedwith thesevalvescannotberetractediftheengineisnot running.

18 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002 TH135024 1 2 3 4 5 6 9 8 7 21

Hydrauliccylinders 1. Telescopiccylinderwithdoublebalancingvalve (onlyfortelescopicboomintwosections) 2. Telescopiccylinder 3. Rearaxleblockingcylinder 4. Leftstabilisercylinder 5. Rightstabilisercylinder 6. Framelevellingcylinder(frontaxle) 7. Liftingcylinderwithbalancingvalve 8. Compensationcylinder 9. Tiltcylinderwithbalancingvalve.

Thebalancingandloadholdingvalvesaremounted onthepistonsideofthelifting,tiltingandtelescopic extensioncylinders.

Operationofbalancing(loadholding)valves-Seenextpage

Thebalancing(loadholding)valvesaremountedon thelifting,tiltingandtelescopiccylinderstoensure thatthecylinderstemstayslockedinitsposition evenintheeventofhydraulicpipefailure.Withthis typeofloadholdingvalvesthecylinderscannotbe retractediftheengineisnotrunningandwithout operatingthecontrolvalvespools.

Whenthetwo--sectiontelescopicboomisused,a centraliseddouble--actingbalancingvalveisalso providedtopreventtheactivationofthetelescopic cylinder,onboththepistonandthestemsides,ifthe engineisoff.

A.Extendingthecylinder

Whenacylinderwithabalancingvalveisextended, theoilflowsfromthecontrolvalvespooltoorificeV2 andthroughthecheckvalveuptoorificeC2.Theoil fromthecylinderreturnsfreelyfromorificeC1toorificeV1andthentothereseervoirthroughthecontrol valvespool.

B.Loadholding(inneutral)

Whenthecontrolpinisinneutral,thebackpressure generatedinthecircuitbytheweightofthetelescopicboomandtheloadkeepsthelockholding valveinitsseatandpreventscylinderretraction.

C.Cylinderretraction

Whenacylinderhastoberetracted,theoilflows fromorificeV1toorificeC1,butthepressureofthe oildischargedfromthecylinderintoorificeC2isnot sufficientbyitselftomovethedoublepilotspool againsttheforceofthesafetyvalvespringandbring aboutcylinderretraction.Thepressureappliedtothe cylinderthroughorificesV1/C1isthereforeapplied aspilotpressurealsototheendsurfaceofthepin throughthethreadingofthepilotscrew.Thispressure,togetherwiththebackpressureappliedtothe spoolviaorificeC2,movesthespoolagainstthe actionofthesafetyvalvespringenablingtheoildischargedfromthecylindertoflowbackintothereservoir.

Sinceittakesboththeloadsensingpressureapplied totheendofthedoublepilotspoolandthecylinder dischargepressurethroughorificeC2tomovethe orificeandenabletheoildischargedfromthecylindertoflowbackintothereservoir,intheeventofcylinderhosefailure,thebalancingvalvewouldclose duetotheactionofthespring,therebypreventing cylinderretraction.Similarly,iftheengineisnotrunning,butthein--cabcontrolsaremoved,therewillbe nopressureatorificeV1/C1tosupplementtheback pressureappliedtoorificeC2,movethepinandlet theoilflowbackintothereservoir.

D.Operationofcircuitrelief(shock)valve Ifacylinderissubjectedtoasuddenloadvariation, asmaybecaused,forinstance,byacollisionagainst awallwhiledrivingwiththetelescopicboom extended,thesuddenloadvariationappliedtothe cylinderistoohigh.Insuchcircumstances,thepressuregeneratedatdischargeorificeC2issufficientto movethespoolagainsttheforceofthesafetyvalve springanddischargetheexcesspressureintothe reservoirviathecircuitreliefvalveinthehydraulic distributorelement.Assoonasthepressurehas beenrelieved,thecircuitreliefvalveclosesagain andholdsthecylinderinitsposition.

SECTION35--HYDRAULICSYSTEM 19 604.02.395.00 --12--2002

TH1350070

20 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002 V2 V1 kg TH135028 C1C2 V2 V1 A 1 2 3 4 B V1V2 C1C2 D C1C2 V1V2 C1C2 C 23 Operationofbalancingvalve

Staticoil Returntoreservoir

Oilatpumppressure Counter--pressureoil

A. Extension B. Loadholding C. Retracting D. Circuitrelieffunction 1. Pilotscrew 2. Doublepilotspool 3. Checkvalve 4. Circuitreliefvalve

POWERSTEERING(OSPQ)

ThemaincomponentsoftheOSPQarethecontrol valveandtherotorassembly.Thecontrolvalveisa revolvingvalvethatmodifiesthealignmentoftheoil passagesasitrevolves,therebyactivatingthesteeringcylinders.Therotorassemblyisunderthecontrol valve.

Itsnormalfunctionistoworkasahydraulicmotorto performmeteringoperations.Inanemergency,withoutfluidpower,itisonlypossibletoperformshort steeringmanoeuvreswhilethevehiclecontinues movingoverashortdistance.

TheactiongeneratedbythesteeringwheeltransmitspressurethroughtheLSlinetothedividervalve onthepump,which,initsturn,givesprioritytothe powersteeringPline.

Thedeliveryflowtothemotorassemblyiscontrolled byvalve(B).

Steeringlockiscontrolledbyananti--collisionvalve (A)whichredirectstheoilflowtothedischargeline

SECTION35--HYDRAULICSYSTEM 21 604.02.395.00 --12--2002

1. Pipefittingflange 2. Flangetofastenthepowersteering

L Cylindersupplyline,forrearaxle R Cylindersupplyline,forfrontaxle P Frompump T Dischargelinetoreservoir LS Loadsensingline TH135025 1 2 3 L P T R LS 24

3. Housingforsteeringcolumn

TH135026 25

T. 1. Pilotandflowamplificationvalve 2. Flowamplificationcircuit

TH135027 1 2 3 26

3. Flowpilotcircuit

22 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002 TH135029 25 20 20 1 6 10 11 8 3 4 9 23 22 21 19 18 15 17 16 13 26 12 2 14 24 5 7 27 Powersteeringcomponents

1. Dustguard 2. Powersteeringbody 3. Checkballvalve 4. Threadedbushing 5. Seals 6. Steeringlockparts 7. Rings 8. Rotaryvalve 9. Sleevereturnsprings(11) 10. Sleeve(11)drivingpinandshaft(12) 11. Valveseatsleeve(8) 12. Rotor(17)driveshaft 13. O--ring 14. Overpressurevalve 15. O--ring 16. Distributionplate 17. Rotor 18. O--ring 19. Fixedringforrotor(17) 20. Anti--collisionvalve 21. Cover 22. Washers 23. Screwwithpin 24. Cover(21)fasteningscrews 25. Pilotvalve 26. Spacer

TELESCOPICBOOMDISTRIBUTOR

Themaindistributorisa”compensatedloadsensing” typedistributorthatcontrolstheliftingoftheboom andthetravelandcompensationeffectsfortool training.

Itsmaincomponentsinclude:

• aninputplate(1)

• foursections(slidevalves)(2)todistributethe flow

• aclosingplate(3).

Thetaskofeachdistributorsectionistotransferthe hydraulicoilflowtothevarioususerdevicesasa functionofthedemandcommunicatedbytheoperatorusingthehandlever.

Whenthehandleverissetonneutral,thehydraulic oilfromthepumpreachesthedistributorandiscut-offbythepositionofthefourslidevalves,aftergoing throughthecircuitofthetooltobemoved.

Workinginconjunctionwiththepumpandtheauxiliarycontroldistributor,thedistributorensuresthatthe hydraulicsupplyisdistributedindependentlyofthe loadapplied.This system--called”LoadSensing”-workstoensurethatthepumpdeliversonlytheoutputdemanded.

Aslongasthehandleverisnotactivatedandthe userdevicesrequirenoflow,theLoadSensingline, andhencethe”LS”inletofthedistributor,isnotpressurised.Intheseconditions,thepumpflowisrouted tothedischargeline(T)byvalve(9)(quickdischarge valve).

Intheseconditions,themainpumpdeliversexactly theamountofoilneededtocompensatelossesfrom thesystem;thepressureinthepumpdeliveryline, called”stand--bypressure”,isca25bar.

Whenadistributorslidevalveisopenedbytheaction ofthehandlever,thepathofthehydraulicoilfromthe pumptotheuserdeviceisopenedup.Inactualpractice,thecross--sectionalareaoftheopening,which isproducedbythemovementofthedistributorslide valve,behaveslikeacalibratedrestriction.

Anyvariationinoilflow(userdevicemovement speed)requiredbytheoperatorisreflectedinpump outputthroughtheLoadSensingsignal.

Whenasingledistributorslidevalveisactivated, pumppressureissuppliedtotheuserdeviceand, throughtheLoadSensingline,isappliedtothe springsideoftheLoadSensingvalve(3)slidevalve. Thepositionofthepumpplatewillvarysoasto increaseflow--rateasafunctionofdemand.When thepump’sdeliverypressureexceedstheloadpressure,theuserdevicebeginstomoveandtheflowof oildeliveredbythepumpcausesapressuredrop throughtheslidevalverestriction.WhenthispressuredropcorrespondstotheloadoftheLoadSensingvalvecalibrationspring,abalanceisestablished.

SECTION35--HYDRAULICSYSTEM 23 604.02.395.00 --12--2002

TH1350071 2 1 3 28

TH135030

Distributorhydrauliccircuitscheme

24 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002

1 2 3 8 7 9 8 4 3 5 3 6 9 30

1. Inputsidevalve-- 2. AuxiliarycylindercontrolOn--Offsolenoidvalve(OPT)-- 3. Compensationvalves(loadsensing)-- 4. Hydraulic(slide)valvefortool(forks)tiltcylindercontrol-- 5. Hydraulic(slide)valveforboomliftingcylindercontrol-- 6. Telescopicboom(12or16m)extensionproportionalsolenoidvalve-- 7. Distributorclosingslidevalve-- 8. Max.pressure controlvalves-- 9. Quickdischargeforflowdischargewithalluserdevicesinneutral(stand--by)-- 10. Flowregulator-- P. Pump deliveryline-- LS. Loadsensingline-- T. Dischargeline-- A1--B1. Tocompensationandtiltcylinders-- A2--B2. Totelescopic boomliftingcylinders-- A3--B3. Toauxiliarycylinder-- A4--B4. Totelescopicboomextractioncylinders.

TH135031

SECTION35--HYDRAULICSYSTEM 25 604.02.395.00 --12--2002 MAINCOMPONENTSOFTELESCOPIC BOOMDISTRIBUTOR

1 10 8 2 9 4 5 6 7 3 3 3 3 31

TH135032 N.B.:Forthedefinitionofthecomponentsshowninthisdiagram,seelegendtoFigure30.

AUXILIARYCONTROLDISTRIBUTOR

Thisisacompensatedtypedistributor,likethemain distributorofthetelescopicboom.Itcontrolstheright andleftfrontstabilisersandframelevellingbymeans ofthecylinderfittedtothefrontaxle.

Itislocatedinthefrontpartoftheframe,nearthe frontaxleitself,andisconnectedtothemaindistributoroftheloadsensinglineandtheflowdischargeline (T).

Itreceivestheflowdirectlyfromthepumpandhence fromtheflowdividervalve.Itismanagedbytheoperatorbymeansofunstableswitches(1)locatedonthe controlpanelinfrontofthedriver’scompartment.

A1--B1. Connectiontotherightstabilisercylinder

A2--B2. Connectiontotheleftstab ilisercylinder

A3--B3. Connectiontoframeleve llingcylinderonfront axle

P. Pumpoutputflow

604.02.395.00 --12--2002

26 SECTION35--HYDRAULICSYSTEM

1. Controlswitches T. Dischargelinetoreservoir LS. Loadsensingline

TH135072

1 33

TH135034

SECTION35--HYDRAULICSYSTEM 27 604.02.395.00 --12--2002 CYLINDERS TH135024 1 2 3 4 5 6 9 8 7 34

1. Outertelescopiccylinder(16mmodelonly) 2. Innertelescopiccylinder 3. Rearaxlelock--upcylinder 4. Leftstabilisercylinder 5. Rightstabilisercylinder 6. Framelevellingcylinder 7. Compensationcylinder(matedtoliftingcylinder) 8. Liftingcylinder(matedtocompensationcylinder) 9. Tiltcylinder

Calibrationofcircuitreliefvalveonstemside(V1)=260bar

Calibrationofcircuitreliefvalveonplungerside(V2)=160 bar

Tighteningtorque

1 480--530Nm

2 1070--1120Nm

3 20--25Nm

4 380--430Nm

5 1070--1120Nm

6 120--125Nm

28 SECTION35--HYDRAULICSYSTEM

--12--2002 INNERTELESCOPICCYLINDER TH135051 27 10 11 9 2217 5 14 13 1 4 25 21 19 7 12 14 29 11 10 9 16 15 6 3 2 25 18 20 12 8 26 23 30 6 5 3 4 3 3 2 1 5 24 31 28 35

604.02.395.00

Model Stroke(C) Stroke(D) T13 3400mm 3350mm T14 3800mm 3750mm T17 3650mm 3600mm

SECTION35--HYDRAULICSYSTEM 29 604.02.395.00 --12--2002 1. Completecylinderliner 2. Completecylinderliner 3. Completerod 4. Completerod 5. Frontbottom 6. Frontbottom 7. Plunger 8. Plunger 9. Guidering 10. Wiperring 11. Gasket 12. Dowel 13. O--ring 14. Anti--extrusionring 15. O--ring 16. Anti--extrusionring 17. O--ring 18. Plungerring 19. Plungerring 20. Plungerguidering 21. Plungerguidering 22. O--ring 23. Plug 24. O--ring 25. Anti--extrusionring 26. O--ring 27. Rodeye 28. Valve 29. Screw 30. Valve 31. Pistonring

Calibrationofcircuitreliefvalveonrodside(V1)=260bar Calibrationofcircuitreliefvalveonplungerside(V2)=160 bar

30 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002 OUTERTELESCOPICCYLINDER (only16mmodel) TH135050 67103 1 9 85 12 15111341213 1416 17 2 3 3 36 Stroke(B):3450mm Operatingpressure:260bar 7 Tighteningtorque:550--600Nm 8 Tighteningtorque:1300--1350Nm 9 Tighteningtorque:20--25Nm

1. Completecylinderliner 2. Completerod 3. Frontbottom 4. Plunger 5. Guidebush 6. Wiperring 7. Gasket 8. O--ring

9. Anti--extrusionring 10. O--ring 11. O--ring 12. Plungerring 13. Plungerguidering 14. Dowel 15. Spacer 16. Valve 17. Screw

1 500--600Nm

2 2100--2150Nm

3 20--25Nm

SECTION35--HYDRAULICSYSTEM 31 604.02.395.00 --12--2002 FRAMELEVELLINGANDREARAXLE LOCKINGCYLINDER TH135052 61073985 1 23 1211 13 412 14 37 Stroke(A):195mm Max.retractionpressure:180bar Max.operatingpressure:260bar

Tighteningtorque

1. Completecylinderliner 2. Completerod 3. Frontbottom 4. Plunger 5. Guidebush 6. Wiperring

O--ring

7. Rodring 8.

9. Anti--extrusionring 10.

11.

12. Plungerring 13. Plungerguidering 14. Dowel

32 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002 SMALLSTABILISERCYLINDER (12mand14mmodelsonly) TH135053 11 4 1 9 2 12 3 11 8 2 1 5 7 10 6 3 38 Stroke(A):200mm Max.operatingpressure:310bar Circuitreliefvalvemax.pressure:330bar (*)payattentiontodirectionofassembly Tighteningtorque

31.5Nm

1 530Nm 2 1538.6Nm 3

1. Completerod 2. Completecylinderliner 3. Rodgasket 4. Frontbottom 5. O--ring 6. O--ring 7. Anti--extrusionring 8. Plungerring 9. Plunger 10. Guidering 11. Greasenipple 12. Dowel

1 775--835Nm

2 2400--2500Nm

3 20--25Nm

SECTION35--HYDRAULICSYSTEM 33 604.02.395.00 --12--2002 LARGESTABILISERCYLINDER (standardon16mmodel,availableon12mand14mmodels) TH135054 6 7 103598 1 1211134 2 121314 3 39 Stroke(A):475mm Max.operatingpressure:260bar Tighteningtorque

1. Completecylinderliner 2. Completerod 3. Frontbottom 4. Plunger 5. Guidering 6. Wiperring

O--ring

7. Rodring

9. Anti--extrusionring 10.

11. O--ring 12. Plungerring 13. Plungerguidering 14. Dowel

3 20--25Nm

34 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002 COMPENSATIONCYLINDER TH135055 6710 52 983 1 11 13 41214 1 2 3 40 Stroke(A):1224mm Max.Operatingpressure:260bar

Tighteningtorque

300--350Nm

700--750Nm

1. Completecylinderliner 2. Completerod 3. Frontbottom 4. Plunger 5. Guidering 6. Wiperring 7. Rodring

O--ring

Anti--extrusionring

O--ring

10.

11.

12. Plungerring

13. Plungerguidering

14. Dowel

SECTION35--HYDRAULICSYSTEM 35 604.02.395.00 --12--2002

TH135056 6 7310 59812 11 4 131214 3 2 1 41 Stroke(A):1220mm Max.operatingpressure:260bar

1500--1500Nm

LIFTINGCYLINDER

Tighteningtorque 1

5500--6000Nm

20--25Nm

1. Completecylinderliner 2. Completerod 3. Frontbottom 4. Plunger 5. Guidering 6. Wiperring

O--ring

7. Rodring O--ring

8. 9. Anti--extrusionring 10. O--ring 11.

12. Plungerring

13. Plungerguidering 14. Dowel

Tighteningtorque

1 775--825Nm

2 2500--2600Nm

3 20--25Nm

36 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002

TH135057 6710 3 5 9 81 2 11 4 1213 14 3 2 1 42 Stroke(A):442mm Max.operatingpressure:260bar

TILTCYLINDER

1. Completecylinderliner 2. Completerod 3. Frontbottom 4. Plunger 5. Guidering 6. Wiperring 7. Rodring 8. O--ring 9. Anti--extrusionring 10. O--ring 11. O--ring 12. Plungerring 13. Plungerguidering 14. Dowel

BOOMREMOVAL

Descriptionofsteps

• Lifttheboomtomaketherod(1)oftheliftingand compensationcylindersaccessibleandremovable(topofenginebonnet)

• Turnofftheengine

• Harnesstheboom(topreventitfromslippingout orfallingoff)withchainsor”bands”(usethetwo connectingplatesequippingtheboom). TH135058

• Placeasupportunderthelifting+compensation cylinderssoastopreventthemfromfallingand keepthemintherequiredpositionfor re--assembly. TH135059

SECTION35--HYDRAULICSYSTEM 37 604.02.395.00 --12--2002

1 43

• Toremovethepin(1)fromthelifting+ compensationcylinders,removethestaticring (2)fromthecabsideandpulloutthepinfromthe oppositesidewiththeaidofanextrector.

• Toremovetheboomrearfasteningpin(1), unscrewscrew(2)anddriveoutthepinwiththe aidofarubbermallet.

• Disconnectthehydraulicsystempipes: --outertelescopiccylinderpipes(16mversion) --pipesontheboom(cabside)

• Removetheboom.

38 SECTION35--HYDRAULICSYSTEM 604.02.395.00 --12--2002

TH135060 1 2 45

TH135061 1 2 46

BOOMINSTALLATION

Descriptionofsteps

• Harnesstheboom,thenliftitandplaceitonthe machineinthecorrectposition

• Fittheboomfasteningpin(torearpartofthe machine)

• Fitthelifting+compensationcylinderspinand removethesupport

• Connectthehydraulicsystempipes: --outertelescopiccylinderconnectionpipes (16mversion)

--pipesonboom

• Removechechains/bands

SECTION35--HYDRAULICSYSTEM 39 604.02.395.00 --12--2002

BOOMDISASSEMBLY

Generalconditions

A. Ifyouhavetoworkonthemachine,insteadofthe innerpartoftheboom,orhavetoworkonthe innerpartbutitisnotpossibletouseanon--board pumptoactivatethecylinders,proceedasfollows:

Takedowntheboomassembly(seeBoom RemovalandInstallationprocedure)

B. Ifyouhavetoworkontheinnerpartoftheboom andtheengineisON,proceedasfollows:

Werecommendthatyouremovetheboomsectionsfromthemachineoneatatime.

C. Ifyouhavetoworkontheinnerpartoftheboom andtheengineisOFF,oritthereisnoon--board pump,proceedasfollows:

Takedownalltheboomsectionssimultaneously withtheaidofacraneorahoistanddonotforget todeactivatethelockingvalvebeforeremoving theindividualboomsections(byfasteningthe1st onthepinsideandpullingouttheboomsections fromtheoppositesidewiththeaidofanoverheadcraneoralifttruck).

604.02.395.00 --12--2002

40 SECTION35--HYDRAULICSYSTEM

SECTION35--HYDRAULICSYSTEM 41 604.02.395.00 --12--2002

TH135073 1 2 4 5 6 3 47

Descriptionof boomdisassemblyprocedure (12m+14m)

1. Firstboom 2. Secondboom 3. Thirdboom 4. Lifting+comp.cylinder 5. Outertelescopiccylinder 6. Tiltcylinder

1 48

• Pulloutthethirdboombyca500mmtomakeit possibletoremovepin(1)(takedownthesplit ringandpulloutthepin).

TH135062

TH135063 49

• Unscrewandremoveallthemountinghardware thatfastentheshoessoastoreleasethem(you canunscrewtheseonallthesections).

• Disconnectthehydraulicpipesofthe”tilt” cylinderandthehydraulicpipesoftheauxiliary toolsystem.

• Pulloutthethirdboomsection;togetherwiththis, pullouttherelativeshoes.

• Unscrewthemountinghardware(1)forthe supports(2)oftheinnertelescopiccylinderpin artherearandpulloutthepin.

• Takedowntheinnerhydraulicpipes(ifthe hydraulicsystemisnotactive,thesepipescan beremovedatthebeginningoftheprocedure)

• Pullouttheinnertelescopiccylinderfromthe backofthefirstboom.

• Remove(pullitoutfromthefront)thesecond boomsection(andtogetherwiththis,removethe accompanyingshoes,themountinghardwareof whichhasbeenremovedpreviously).

604.02.395.00 --12--2002

42 SECTION35--HYDRAULICSYSTEM

1 2 50

TH135064

SECTION35--HYDRAULICSYSTEM 43 604.02.395.00 --12--2002

Descriptionof boomdisassemblyprocedure(16m)

1 2 3 4 8 5 6 7 51

TH135073 1. Firstsection 2. Secondsection 3. Thirdsection 4. Fourthsection 5. Outertelescopiccylinder 6. Lifting+compensationcylinder 7. Innertelescopiccylinder 8. Tiltcylinder

1 52

• Pulloutthefourthsectionbyca500mmtomake itpossibletotakeoutthepin(removethesplit ringandpulloutthepin). TH135062

• Unscrewandremoveallthemountinghadware fasteningtheshoessoastoreleasethem(you canunscrewthisonallthesections).

• Disconnectthehydraulicpipesofthe”tilt” cylinderandthehydraulicpipesoftheauxiliary systemtool.

• Pulloutthefourthsection;togetherwiththisthe accompanyingshoesarealsoremoved.

• Totakeoutthepin(1)oftheoutertelescopic cylinder,removethecentralscrew(2)andthen pulloutthepin(1).

• Disconnecttheinnertelescopiccylinderpipes.

• Removethethirdandsecondsections(still connectedtogether)andpulloutsimultaneously theshoesofthesecondsection.

• Removethescrews(1)ofthesupports(2)ofthe innertelescopiccylinderpinonthebackofthe secondsectionandpulloutthepin.

• Pullouttheinnertelescopiccylinderfromthe backofthesecondsection.

• Removethethirdsection(bypullingitoutfrom thefrontend)fromthesecondsection(andthe accompanyingshoes).

BOOMASSEMBLYPROCEDURE

Fitbacktheboomsectionsbyrepeatingthesame stepsinreverseorder.

604.02.395.00 --12--2002

44 SECTION35--HYDRAULICSYSTEM

TH135063

TH135065 1 2 54

TH135064 1 2 55

SECTION55–ELECTRICALSYSTEM

Chapter1–Electricalsystemgeneral

55000ELECTRICALEQUIPMENTSPECIFICATIONS

ELECTRICALSYSTEM88kW

Alternator90amp

Batterytype12voltnegativeearth Standard105Ah(12v/505A)

BatterydisconnectviatheisolatorswitchOnnegative/chassiscable

RegulatorTransistorised

Ground(Earth)Negative StartingmotorPositiveengagement,solenoidoperated(3,5kw)

Headlightbulb40/45WH4Halogen

Stop/Taillightbulb5/21WBayonetcap

Interiorlightbulb5WFestoonand10Wbayonetcap

Flasherlightbulb21WBayonetcap

Worklightbulbs55WH3Halogen

Instrument/Warninglightbulbs1,2WCapless

Rockerswitchbulbs1,2WCapless

SECTION55--ELECTRICALSYSTEM--CHAPTER1 1 604.02.395.00 --12--2002

Electricalequipmentspecifications1 Electricalsystemandfuse2 ..................................................... Controlsandinstruments6

......................................... Temporarywiringrepair25 Electricalsyst emgeneralfaultfinding27

CONTENTS SectionDescriptionPage 55000

Bulbreplacement20 ........................................................... Systemprecautionsforbatterychargingandwelding23 Startingthemachineusingjumpleads24

ELECTRICALSYSTEMANDFUSES

Theelectricalsystemofallmodelsconsistsofvariouswiringharnesses,instrumentclusters,and switches.Amicro--processorisalsousedtocontrol thepowershifttransmission.

Theinstrumentconsoleandwarninglampsare mountedinfrontoftheoperator,behindthesteering wheel.

Thekeystartswitchhasthreepositions:

IIIgnition‘ON’

Thebatteryislocatedontheleft--handsideof engine.

Thebatterytypeis12volt,105Ah,standardor150 Ahoptional.Thereisanisolatorswitch(1)locatedon thenegativecabletoprovideabatterydisconnect facility.

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2 SECTION55--ELECTRICALSYSTEM--CHAPTER1

IOFF

IIIEnginestart(cranking) TH155001 1 2 3 1

TH155002 1 2

Themachinefuseandrelayboardislocatedinthe rearcompartment,behindthedriver. ThefusesarenumberedandreferencetoFigure5 willpermitrapididentificationofthecircuitstheyprotect.

NOTE: Certainoptionalitemsofequipmentmaynot beinstalledonyourmachine.However,thefusesare stillinstalledandmaybeusedasspares.

IMPORTANT: Donotreplaceablownfusewith anotherofadifferentrating. TH155005

SECTION55--ELECTRICALSYSTEM--CHAPTER1 3 604.02.395.00 --12--2002

Thealternatoris12V,90A.

TH155003 ThestarterisaBosch3.5kWunit.

TH155004 Fusesandrelays

4 SECTION55--ELECTRICALSYSTEM--CHAPTER1 604.02.395.00 --12--2002 Fuseboard–Fuses FuseNo. Rating Colour Circuit Schema F1 3A Purple Instrument+tiltingpreventionsystem 8 F2 7,5A Brown Stabilisers 3 F3 5A Orange Sensorpowersupply 3 F4 15A Blue Frontworkheadlights 7 F5 15A Blue Horn 2 F6 10A Red Airconditionerrecirculationmotor 10 F7 15A Blue Drivingswitch–lights 6 F8 15A Blue Seat 9 F9 15A Blue Armworkingheadlights 7 F10 15A Blue Rearwindowwiper 8 F11 5A Orange Atdisposal 1 F12 10A Red Doubleoptional 4 F13 10A Red Rexrothproportionalpowersupply 4 F14 10A Red Optionalmanoeuvres 4 F15 10A Red Axlerockinglock 3 F16 10A Red Tensiongaugepowersupply 4 F17 15A Blue Rearworkingheadlights 7 F18 5A Orange Reversingbuzzer,cabinbuzzer 2 F19 3A Purple Airconditionercontrolunitpowersupply 10 F20 10A Red Rotatingbeacon 7 F21 7,5A Brown Axlesensorpowersupply+workselectioncontrolunit 3 F22 5A Orange Atdisposal 10 F23 15A Blue Cabinventilationsolenoidvalve 9 F24 10A Red Switchlighting+instrumentpowersupply 5 F25 15A Blue Controlcarpowersupply 8 F26 7,5A Brown Atdisposal 5 F27 5A Orange +30rooflamp+soundsystem 9 F28 5A Orange Micro--seat 9 F29 7,5A Brown +30CB 9 F30 15A Blue Dippedbeamheadlights 6 F31 15A Blue Upperwindowwiper 8 F32 3A Purple +15soundsystem 9 F33 5A Orange Stoplights 6 F34 10A Red Engineshutdown 1 F35 5A Orange RHsidelights 6 F36 5A Orange LHsidelights+numberplatelights 6 F37 10A Red Transfersystem 2 F38 10A Red +30warning 6 F39 15A Blue Mainbeamheadlights 6 F40 10A Red Airconditionercompressor 10 F41 15A Blue Fridgesocket 9 F42 20A Yellow Cigarlighter 9 Relays Relays diagram K1 Doubleoptional 4 K3 Optional(INI) 4 K4 Optional(OUT) 4 K5 Stabiliserpowersupplywithlowarm 3 K6 Lowarm 3 K7 Transmissiondisconnect 2 K8 Dippedbeamheadlights 6 K9 Horn 2 K10 Mainbeamheadlights 6 K11 Atdisposal 10 K12 Tensiongauge 4 K13 Blinking 6 K14 Tilting--prevention 4 K15 Start--upconsensus 1 K16 Out--lowstabilisers 5 K17 Stabiliserpowersupplywitharmin 3 K18 Alignedaxlewarninglamp 3 K19 Parkingbrakeengaged 5 K20 85%slowmotion 8 K21 Reversingbuzzer 2 K22 Airconditionercompressor 10 K23 Airconditioneron 10

SECTION55--ELECTRICALSYSTEM--CHAPTER1 5 604.02.395.00 --12--2002 TH155006 6 TH155007 7

6 SECTION55--ELECTRICALSYSTEM--CHAPTER1

--12--2002 CONTROLSANDINSTRUMENTS CONTROLPANELTABLE POS. PIN FUNCTION SIGNAL L3 J1 AIRFILTERWARNINGLAMP NEGATIVE L2 J2 ENGINEOILPRESSUREWARNINGLAMP NEGATIVE L1 J3 GENERATORWARNINGLAMP NEGATIVE S4 J4 WATERTEMP.INSTRUMENT ohm S1 J5 FUELLEVELGAUGE ohm S2 J6 REVCOUNTERINSTRUMENT Hz +ILL J7 NIGHTLIGHTING(+) +LIGHTS GND J8 MASS(EARTH) +Ch J9 POSITIVE(+Key) L13 J10 FOURWHEELSSTEERINGWARNINGLAMP POSITIVE L9 J11 MAINBEAMLIGHTWARNINGLAMP POSITIVE L10 J12 DIRECTIONIND.WARNINGLAMP POSITIVE L7 J13 WARNINGLAMPHANDBRAKEON NEGATIVE L11 J14 TWOWHEELSTEERINGWARNINGLAMP POSITIVE B J15 OUTERBUZZEROUTPUT(--) L8 J16 BRAKEOILLEVELWARNINGLIGHT NEGATIVE L12 J17 CRABSTEERINGWARNINGLIGHT POSITIVE L6 J18 TRANSMISSIONOILPRESS.WARNINGLAMP NEGATIVE L5 J19 TRANSMISSIONOILHIGHTEMP.WARNINGLAMP NEGATIVE L4 J20 GLOWPLUGPRE--HEAT.WARNINGLAMP NEGATIVE

604.02.395.00

SECTION55--ELECTRICALSYSTEM--CHAPTER1 7 604.02.395.00 --12--2002 PANEL TH155008 L1L10S2L11L12L13 S4 L8 L7 L6 L5 S3 L4 L3 L2 L1 S1 8 PANELINSIDEDIAGRAM TH155009 9

HANDANDFOOTOPERATINGCONTROLS

ShowninFigure10isthecabinlayoutofatypical machinewithaPowershiftTransmissionandServo ControlsfortheTelescopicArm.

NOTE: Thelayoutofcontrolsinthediagrammay varybetweenmachines,dependinguponoptions fittedtomeetLegislationindifferentCountries.

1.Hydrauliccontrolpanelandparkingbrake.

2.Instruments

3.Steeringgeometryselector

Selectallsteeringmodesatleastonceadayto checkcorrectoperation.

4.Safetykeyforcontrolmodeselection

--jobsite

--road

--people--conveyanceplatform

5.Vehiclehazardlightswitches

6.Enginestarterkey

7.Switchpanelformiscellaneousservices

8.Powershiftselectionlever,forwarddirectionand horn

9.Sidelightanddirectionindicatorcontrollever

10.Vents

604.02.395.00 --12--2002

IMPORTANT: Whenstartingtheengine,retractall armsegmentsuntilthereliefvalveisactuatedand remainssofor10seconds.

Thisoperationassuressegmentandarmpipesynchronisation.Failuretosynchronisemaydamage thepipes.

11.Frontmulti--functionloaderlever

--telescopicarmextension/retraction

--armliftingandlowering

--tooltiltingandreturn

--transmissiondisconnectbutton

--hornbutton

--aux1functionbutton

--aux2functionbutton

12.Glovecompartment(uponrequest,radio compartment)

13.Steeringwheel

IMPORTANT: Priortodrivingthevehicle,always turnthesteeringwheelfromsidetosideat enginestartup,tocirculatethehydraulicoil.

14.Acceleratorfootpedal

15.Brakepedal

16.Tiltingpreventionlockforcereleasebutton

17.Steeringwheelheightadjustinglever

18.Loadhandlingmonitorindicator

19.Climate systemcont rolpanel

8 SECTION55--ELECTRICALSYSTEM--CHAPTER1

SECTION55--ELECTRICALSYSTEM--CHAPTER1 9 604.02.395.00 --12--2002 TH155010 8 1 3 4 5 6 7 9 11 10 12 13 14 15 16 17 18 19 10 5 7 6 2 10

ALIGNMENTOFTHEWHEELS

IMPORTANT: Beforeselectingoneofthethree possiblesteeringpositions,bringthefourwheelsinto alignment,thatisinthestraightaheadposition.

A--TWOWHEELSTEERING--Shiftthedistributor controlleverforsteeringselectiontoposition‘A’for HighwayUse(twowheelsteer),turnthesteering wheeltoensureengagementandmonitortheilluminationoflamps(rearwheelsaligned).

ATTENTION

Beforedrivingonthehighway,itisessentialtocheck thealignmentofthewheelsandtodrivewithonlytwo wheelssteering.

Unlessotherwisestated,twowheelssteeringisby thefrontwheelonly.

B–2+2WHEELSSTEERING--Shiftthedistributor controlleverforsteeringselectiontoposition‘B’for wheelpairsteer.

C–CROSSTRANSFER--Shiftthedistributorcontrolleverforsteeringselectiontoposition‘C’forcrab steering.

Checktheselectedsteeringwarninglamponthe instrumentpanelcomesandstayson.

Ifthewarninglampstartsflashing,makesurethe wheelalignmentreachesrequiredalignment.Slowly turnthesteeringwheelfromsidetosidetoletthe controlsystemreachtheselectedsetting.

Ifthewarninglampskeepsonflashing,havethe vehiclecheckedbyyourdealership.

604.02.395.00 --12--2002

10 SECTION55--ELECTRICALSYSTEM--CHAPTER1

TH155011 C B A CB A 11

C B A 12

TH155012

INSTRUMENTCONSOLE

IMPORTANT: Gaugesandswitchesmountedinthe Instrumentpanelmayvaryinpositionfromthat showninthismanual.Thisisdependantuponmodel andoptionsfitted.Ensureyouarefamiliarwithallthe functionsbeforeoperation.

Enginecoolanttemperaturewarninggaugewith warningbuzzer

Theenginecoolanttemperatureindicatorresponds toasensorfittedintheengine.Duringnormaloperationstheindicatorwilltendtorisefromthelowpoint ofthegreensegmenttothecentreofthegauge. Whenoperatingunderheavyloadconditions,the indicatormaycontinuetorisetojustbelowthered segmentandreturntoalowerpositionwhennormal machineoperationisresumed.

Shouldtheindicatorriseintotheredsegmentawarningbuzzerwillsound.Stoptheengineimmediately andinvestigatethecause.Normaloperationscanbe resumedoncetheenginehascooledsufficientlyor thecausecorrected.

NOTE: Whenthekey--start/stopswitchisturnedoff thegaugeneedleassumesarandomposition.

Tachometerandhourmeter

Thetachometer(1),graduatedto3000rev/min,is drivenfromthealternatorandreflectstrueengine speed.

Thehourmeter(2),situatedinthelowerhalfofthe tachometer,recordshoursofengineoperationand isdrivenfromthealternatorwhenrunning.

Fuellevelgauge

Thisgaugeindicatestheleveloffuelinthetankon acontinuousbasisbutisonlyoperativewiththekey-start/stopswitchinthe‘ON’position.

NOTE: Whenthekey--start/stopswitchisturnedoff thegaugeneedleassumesarandomposition.

SECTION55--ELECTRICALSYSTEM--CHAPTER1 11 604.02.395.00 --12--2002

TH155013 1 13 TH155014 1 2 14 TH155015 1 15

INDICATOR/WARNINGLIGHTS–3rd Segment

1.Alternatorchargeindicatorlight.Thealternator chargewarninglightilluminateswhenthekey startisturnedonandwillremainonuntilthe engineisstarted.Oncestartedthebatteryis beingchargedbythealternatorandthelightwill beextinguished.

2.Engineoilpressurewarninglightwithwarning buzzer:Indicateslowoilpressureandshould extinguishimmediatelyaftertheenginestarts. Shouldtheoilpressuredropbelowthe predeterminedlevel,thewarninglightwill illuminateandanaudiblealarmwillsound.

3.Airfilterrestrictionlight.Whenilluminatedthe enginemustbestoppedassoonaspossibleand thefilterserviced(refertoSection4).

IMPORTANT: Ifthemachineislefttorunwiththe warninglight‘on’,engineperformanceandfuelconsumptionwillsuffer.

4.Thermostartheaterlight.Withthekeystart‘ON’ thislightisilluminatedduringthewarmupperiod ofthethermostartheaterelement.Itis extinguishedoncesteeringtemperatureis reached,whereupontheenginecanthenbe started.

12 SECTION55--ELECTRICALSYSTEM--CHAPTER1 604.02.395.00 --12--2002 INDICATOR/WARNINGLIGHTS–1st Segment 1.Mainbeamheadlightwarninglamp 2.Directionindicatorwarninglight TH155016 1 2 16 INDICATOR/WARNINGLIGHTS–2nd Segment Theshowtheselectedsteeringmode: 1.2wheelsteering(front) 2.Crosstransfer(crabdiagram) 3.4wheelsteering TH155017 1 2 3 17

TH155018 1 2 3 4 18

INDICATOR/WARNINGLIGHTS–4th Segment

1.Transmissionoiltemperaturewarninglight

Shouldthetransmissionoiltemperatureexceeda predeterminedlevelthewarninglightwillilluminate.

ATTENTION

Ifthelightstays‘on’,stoptheengineassoonas possibleandinvestigatethecause.Donotcontinue todrivethemachineasfailureofthetransmission couldoccurandresultinseriousinjurytoyouor bystanders.

2.Transmissionoilpressurewarninglightwith buzzer

Shouldthetransmissionoilpressuredroptoapredeterminedlevelthewarninglightwillilluminateandthe buzzerwillsound.

Ifthewarninglightilluminates,placethetransmissioninneutralandstoptheengineimmediately. Checkthattheoilleveliscorrectandadjustas required.Ifthetransmissionoilislostorextremely lowDONOTATTEMPTTODRIVETHEMACHINE. ContactyourDealertoinvestigatethecauseand consultthemanualasfortowingthemachineas necessary.

3.Parkingbrakewarninglight

Thewarninglightisilluminatedwhentheparking brakeisappliedandtheignitionisswitchedON.

ATTENTION

Donotattempttodisconnectthewarningapparatus inanyway.Donotattempttodrivethemachinewith theparkingbrakeapplied,asseriousdamagetothe machinebrakeswithpossiblefailurewilloccur.This couldresultinseriousinjurytoyouandotherpeople.

4.Brakereservoiroillevellowindicatorlamp

Thiswarninglampilluminateswhentheoillevelinthe reservoirisataLOWLEVEL.Ifthelampilluminates atanytimestopthemachineimmediatelyand investigatethecause,correctandortopupwithnew oiltothelevelspecified.Totestthewarninglightrefer tothemaintenancesectionofthemanual.

ATTENTION

Correctiveactionmustbetakenimmediatelywhen thislampilluminates.Ifnot,failureofthebrakesystemcouldoccur,resultinginseriousinjurytoyourself andothers.

SECTION55--ELECTRICALSYSTEM--CHAPTER1 13 604.02.395.00 --12--2002

TH155019 1 2 3 4 19

LOADSTATUSINDICATORPANEL

Theloadstatusindicatorwarnstheoperatorwhen theTelehanderreachesthemaximumauthorised loadcondition.

ATTENTION

Anyattempttoliftloadsbeyondthiswillresultinan unsafeandunstablesituation.

A–TWOGREENSIGNALLIGHT

Thetwosignallightsindicatedecreasingstability situations,butregular.Duringnormaloperation,the lightsignalstatusiscontinuouslyupdatedandindicatesthecurrentsituation.

B–TWOYELLOWSIGNALLIGHT (VISUALALARM)

Thetwosignallightsindicatecriticalsituationsof instability.Inthesecasetheinstabilityvalueis around100%(tilting).

DANGER

Itisrequiredanotheroperatortosolvetothesituation.Trytolowerthevehiclecentreofgravityas muchaspossible.

Keeponliftinginthedirectionoftheloadclosestto thevehiclecentreofgravity,orretractthetelescopic arm,ifextended,tomovetheloadasclosestas possibletothevehiclecentreofgravity.

C–REDSIGNALLIGHT (VISUALALARMANDSOUND)

Thissignallightilluminates,whentheTelehandler reaches100%ofitsmaximumauthorisedload capacity.Thesoundalarmsoundssimultaneously withtheredsignallightilluminated. Whenthisalarmcomeson,allloadhydraulichandlingoperations,stabiliserliftinganaxletiltingoperationsarelocked.

Theonlyfunctionallowedisthetelescopicarm retraction,unlessthefunctionlockisforcedbyoperatingtherelativebuttonasdescribedinthefollowing pages.

TH155021

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14 SECTION55--ELECTRICALSYSTEM--CHAPTER1

TH155020 C B A D 20

D–TESTSWITCH

Operationofthisswitchteststhealarmandilluminatesthewarninglamptoensureallisworkingcorrectly.Checkeachdaybeforecommencingworkand ifeitherarenotfunctioningcorrectly,intheinterests ofyoursandbystandersafety,donotattempttouse themachineasaloaderuntilarepairhasbeenperformed.

TILTINGLOCKFORCINGBUTTON

Whenthebuttoniskeptpressed,normalhydraulic controlfunctionsarerestoredduringemergency situations.

IMPORTANT: Allfunctionsmustbeperformedwhile thebuttonispressed.

Correctiveactionsincludeloadweightapproaching tothevehiclecentreofgravity(loadliftingorarm retraction),oroperationstoincreasethevehiclestabilitysuchas,stabiliserloweringoraxleinclination adjustment.

ATTENTION

Operatethisbuttononlyifitispossibletoadjustthe vehiclestabilitywithoutretractingthetelescopicarm.

SECTION55--ELECTRICALSYSTEM--CHAPTER1 15 604.02.395.00 --12--2002

1 22

TH155022

TILTINGDANGER!!

TH155023

TH155024

MULTI--FUNCTIONLEVER

Directionindicatorstalk

Thedirection(turn)indicatorsareoperated(withthe keystarton)bythestalkswitch(1)mountedtothe rightofthesteeringwheel.

--WhenpushedFORWARD:theLEFTHANDINDICATORFLASH

--WhenpulledREARWARD:fromtheneutralposition,theRIGHTHANDINDICATORSWILLFLASH. Thewarninglampwillflashwhenthedirectionindicatorsareflashing.

Main/dippedbeamlightselector

Whenthedippedbeamheadlightsareon,pushthe stalk(1)forward,comparedtothecentralposition,so thedippedbeamheadlightsandtherelativeinstrumentpanelwarninglampturnon. Whentheleverispulledinwards,thedippedbeam headlightsstartflashing.

Windscreenwiper

Ifyouturnthelever,thewindscreenwiperturnson (position1);whenyouturntheleverintheopposite direction(position0),thefunctionisdeactivatedand thebladereachestheneutralposition.

Ifyoupressbutton(1)locatedonthemulti--function leverexternalside,thewindscreenwasherisactivated.

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16 SECTION55--ELECTRICALSYSTEM--CHAPTER1

TH155025 1 25

TH155026 1 26

Windscreenwasher

TH155027 1 27

POWERSHIFT4X3

Gearshift

ThegearshiftmountedonthisvehicleiscalledPowershift.

ThePowershiftleverismountedtotheleftofthe steeringcolumnandallowselectronicselectionof fourforwardgearsandthreereversegears.

HORN

Thehornisactuatedwhenthebuttononthegearshift levertipispressed.

DRIVINGWITHTHEPOWERSHIFT

Neutralposition

Theneutralpositionisselectedbyshiftingthelever tothecentre.

Forwardgearselection

Toselectforwardgear,pullthelevertowardsthe steeringwheelandpushitupwards.

Reversegearselection

Toselectreversegear,pullthelevertowardsthe steeringwheelandpushitdownwards.

SECTION55--ELECTRICALSYSTEM--CHAPTER1 17 604.02.395.00 --12--2002

TH155028 28

TH155029 A R N 29

SWITCHES

SWITCHES(rightpanel)

IMPORTANT: Therockerswitchpositionsmayvary slightlyormaynotbeallavailablefromthatshown. Theyaredependantuponthemodelandoptions fittedtoyourmachine,

Allswitchesareinternallyilluminatedwithignition ‘On’andwillbecomebrighterwheneachindividual functionisswitchisselected.

1.Slowmovingwarningbeacon–Depressingthis switchoperatesthefunctionoftheroofbeacon.

2.Roadlights–three--positionswitch

--Off

--Sidelights

--Main/dippedbeamheadlights

Mainanddippedbeamheadlightselectionis possiblewiththemultifunctionleverpreviously described.

3.Hazardflasherswitch–Selectedwhenrequired towarnofahazard.

4.Additionallights(optional)fittedonthetelescopic arm.

5.Frontworklamps(2--positionswitch)–When operatedthefrontlightsareilluminated.

6.Rearworklamps(2--positionswitch)–When operatedtherearlightsareilluminated.

7.Rearwindowwashandwipe.Depressingthis switchoperatestherelativefunction.Depressing itagain(temporaryposition)operatestherear windowwasher.

8.Roofwindowwashandwipe.Depressingthis switchoperatestheroofwiperblade.The washingfunctionisoperateddepressingthe switchagain.

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18 SECTION55--ELECTRICALSYSTEM--CHAPTER1

TH155030 8 1 2 3 4 5 6 7

SWITCHES(leftpanel)

IMPORTANT: Therockerswitchpositionsmayvary slightlyormaynotbeallavailablefromthatshown. Theyaredependantuponthemodelandoptions fittedtoyourmachine.

Allswitchesareinternallyilluminatedwithignition ‘On’andwillbecomebrighterwheneachindividual functionisswitchisselected.

1.Parkingbrake(temporary2--positionswitchwith safetycatch).

Depressingtheswitchoperatestherelative function.Tounlockthevehicle,movethelever locatedontheswitchdownwards,sothatthe switchcanreturntoitsoriginalposition.The parkingbrakewillnonbeengagedifthevehicle ismovingat5Km/h.Whentheparkingbrakeis operated,transmissionisdisconnectedandwill berestoredonlyreleasingthebrake.

2.Leftstabiliser(temporary3--positionswitch). Whentheswitchisincentralposition(neutral), nofunctionisoperated.Depressingtheswitch upperpart,theleftstabiliserislifted;depressing theswitchlowerpart,thestabiliserislowered.

3.Axlelevelling(temporary3--positionswitch). Depressingthisswitch,theaxlefrontlevelling cylinderisoperatedtochangethevehicletilting alongthelongitudinalaxis.Presstheswitch upperpartfortiltingontheright.Presstheswitch lowerpartfortiltingontheleft.

4.Rightstabiliser(temporary3--positionswitch). Thisswitchworksasswitch(2),butoperatesthe rightstabiliser.Depressingtheswitchupperpart, therightstabiliserislifted;depressingtheswitch lowerpart,thestabiliserislowered.

ATTENTION

Whenthearmisliftedorremoved,therightandleft stabiliserliftingfunctionisinhibited.Insuchconditionsitisnotpossibletoliftoneorbothstabilisers.

SECTION55--ELECTRICALSYSTEM--CHAPTER1 19 604.02.395.00 --12--2002

TH155031 1 2 3 4 30

BULBREPLACEMENT

Worklampbulbreplacement,front Togainaccesstothebulb,extractthecaponthe headlightrearside.Replacementofthebulbfollows theremovalprocedureinreverse.

NOTE: Modernheadlightsandworklampstendto havehalogenbulbsfitted.Nevertouchahalogen bulbwiththefingers.Naturalmoistureintheskinwill causethebulbtoburnoutwhenthelampisswitched on.Alwaysuseacleanclothortissuewhenhandling halogenbulbs.

Headlightandindicatorbulbreplacement

Togainaccesstotheheadlightbulbs,extractthefour securingscrews(1),gentlyremovethelenscover andremovetheplugfromtherearofthebulb, releasetheretainingspringandextractthebulb.The sidelightbulbisremovedbypullingthebulbcarrier outofthereflectorassembly.Replacementofthe bulbsfollowstheremovalprocedureinreverse.

Theheadlightbeammaybeadjustedverticallyand laterallybyadjustmentoftherecessedslotted screws(3).

Theindicatorbulbcanbeaccessedbyremovalofthe lenscoverretainingscrew(2).

Loadermountedworklights

Togainaccesstothebulb,extractthesecuring screws(1),gentlyremovethelenscoverandremove thebulb.Replacementofthebulbfollowsthe removalprocedureinreverse.

20 SECTION55--ELECTRICALSYSTEM--CHAPTER1

604.02.395.00 --12--2002

TH155032

1 2 3 32

TH155033

1 33

TH155034

Interiorlampbulbreplacement

Theinteriorlampbulbisaccessibleafterremovalof themouldedplasticcoverlenscover.Thebulbmay beremovedbyexertingoutwardpressureononeof theretainingtangsandslidingtheoppositeendofthe bulbfromitsretainingtang.Installationofthebulb andlenscoverfollowstheremovalprocedurein reverse.

Rearworklamps

Togainaccesstothebulb,extractthecaponthe headlightrearside.Replacementofthebulbfollows theremovalprocedureinreverse.

Rear,stopandindicator

Allbulbsareaccessibleafterthemouldedplastic lensassemblyscrewshavebeenremoved. Thebulbshaveabayonetcapfittingwithoffsetpins forthebrakelightbulbandparallelpinsfortheflasher bulb.Bothbulbsmayberemovedbydepressing slightlyandrotatingapproximately20° anti--clockwise.

Replacementofthebulbsfollowstheremovalprocedureinreverse,howeverensurethebrakelight offsetpinsalignwiththesocketcorrectly.Thelens canbereplacedaftertheelectricshavebeentested.

SECTION55--ELECTRICALSYSTEM--CHAPTER1 21 604.02.395.00 --12--2002

TH155035

TH155036

TH155037

Reversinglamps

Wherefittedthelampscanberemovedafterremoval ofthelenscover;theyareofthetwistbayonettype. TH155038

Rockerswitchbulbreplacement

Therockerswitchesareinternallyilluminatedbya bulbwhichcanberemovedfromtherearofthe switchassembly(1).

Togainaccesstotheswitchremovetheconsole attachingscrewsandrotatetheconsole.

Thebulbisofthecaplesstype,ratedat1.2Wand isapushfitintheretainer.Afterchangingthebulb, pushtheretainerintothebackoftheswitch.

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22 SECTION55--ELECTRICALSYSTEM--CHAPTER1

1 38

TH155039

PROTECTINGTHEELECTRICALSYSTEMS DURINGCHARGINGORWELDING

Toavoiddamagetotheelectronic/electricalsystems,alwaysobservethefollowing:

1.Nevermakeorbreakanyofthechargingcircuit connections,includingthebatteryconnections, whentheengineisrunning.

2.Nevershortanyofthechargingcircuitcomponentstoearth(ground).

3.Donotuseaslavebatteryofhigherthan12volt nominalvoltage.

4.Alwaysobservecorrectpolaritywheninstalling thebatteriesorusingaslavebatterytojumpstart theengine.Followtheinstructionsintheoperator’smanualwhenjumpstartingthemachine. Connectpositivetopositiveandnegativeto negative.

5.Alwaysdisconnectthenegativecablefromthe batteriesbeforecarryingourarcweldingonthe machineoronanyimplementattachedtothe machine.

• Positiontheweldergroundcableclampasclose totheweldingareaaspossible.

• Ifweldingistobecarriedoutincloseproximity toacomputermodule,thenthemoduleshould beremovedfromthemachine.Itisrecommendedthatthisprocedurebecarriedoutbyan authoriseddealer.

• Neverallowweldingcablestolayon,nearor acrossanyelectricalwiringorelectroniccomponentwhileweldingisinprogress.

6.Alwaysdisconnectthenegativecablefromthe batterieswhenchargingthebatteriesinthe machinewithabatterycharger.

ATTENTION

Batteriescontainsulphuricacid.Incaseofcontact withskin,flushtheaffectedareawithwaterforfive minutes.Seekmedicalattentionimmediately.Avoid contactwiththeskin,eyesorclothing.Weareye protectionwhenworkingnearbatteries.

IMPORTANT: Failuretodisconnectthetwoearth cableconnectionatthebatterypriortochargingthe batteriesorweldingonthemachineorattached implementwillresultindamagetotheelectronicand electricalsystems.

SECTION55--ELECTRICALSYSTEM--CHAPTER1 23 604.02.395.00 --12--2002

STARTINGTHEMACHINEUSINGJUMPLEADS

• Connectoneendofthesecondjumpleadstothe auxiliary12voltbatterynegative(--)terminaland theotherendtothemachinecylinderblock.Followingthisprocedurewillpreventsparksoccurringnearthebatteries.Followthestartingprocedurepreviouslydescribed.

ATTENTION

Operatethestartingmotoronlyfromtheoperator’s seat.Iftheneutralstartswitchisby--passedthe enginemaybestartedinadvertentlywiththetransmissioningear.

NOTE: Whenusingaslavebatterytostartthe engineensurethatthepolarityiscorrect,otherwise thealternatormaybedamaged.

Weareyeprotectionwhenchargingthebatteryor startingthemachineenginewithaslavebattery.

Ifitisnecessarytousejumpleadsfromanexternal batterytostarttheengine,proceedasfollows:

• Connectoneendofthejumpleadtothemachine 12voltbatterypositive(+)terminalandtheother totheauxiliary12voltbatterypositive(+)terminal.

• Whentheenginestarts,allowittorunatidle speed,turnonallelectricalequipment(lights, etc.)thendisconnectthejumpleadsinreverse ordertotheconnectingprocedure.Thiswillhelp protectthealternatorfromdamagedueto extremeloadchanges.

NOTE: Yourmachinehasanelectro--magneticfuel shut--off,itisthereforenotpossibletooperatethe machinewithoutabatteryinstalled.Themachinewill shutdownwhenthepowersupplytothefuelshut--off solenoidisdisconnected(batteryremoved).

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24 SECTION55--ELECTRICALSYSTEM--CHAPTER1

Temporarywiringrepairs (OpNo.55100)

Thefollowingmethodtorepairwiringisatemporary expedientonly.Wiringshouldbereplacedassoonas possible.Replacementoftemporaryrepairedcables withnewisparticularlyimportantifthemachineisto beusedforsprayingaschemicalscanenterthe repairedarea,travelupthecableanddamageelectricalcomponents.Donotattempttorepairthewire onanysystemsensorsasthesearesealedand shouldonlybereplacedwithanewcomponent.

NOTE: WhenconductingacablerepairitisimportantthatonlyRESINCOREDSOLDERisused.Use ofothertypesofsoldermayresultinfurthercable damage.

Tocarryoutatemporaryrepair,proceedasfollows:

1.Locatedamagedportionofcablethencutaway outerprotectivecoveronbothsidesofthedamagedarea,Figure39.

2.Peelbackthecablefrombothendsofthedamagedareaandcarefullycutawaytheinnercable coveratthedamagedareaandstripabout13 mm(1/2inch)ofinsulationfromthewires.Donot cutawayanywirestrands.

3.Usingasuitablesolvent,cleanabout2inches (50mm)fromeachcoverend.Cleanthegrey cablecoverandtheindividualleads.

4.Twisttwobareleadstogetherforeachdamaged lead,beingcarefultomatchwirecolours,then weldtheleadsusingresincoredsolder.Tape eachrepairedleadwithvinylinsulationtape,Figure40.

5.Windalayerofvinylinsulationtapeuptothegrey cablecoverateachendoftherepairedsection. Makeapaperthrough,Figure41,thenapplysiliconrubbercompound(nonhardeningsealant) overtherepairedsectionuptothecoverends. Sufficientsealantmustbeusedtofilltheendsof thecutawayarea.

SECTION55--ELECTRICALSYSTEM--CHAPTER1 25 604.02.395.00 --12--2002

TH155040 39

TH155041 40 TH155042 41

6.Allowthecompoundtocurethencoverthearea withinsulatingtapetakingthetapewellover eachendoftherepair.Anoverlapofatleast2 inches(50mm)oftapeateachendisnecessary, Figure42.

7.Checktoensuretherepairissatisfactoryand securetherepairedcable,sothatrepeateddamageisavoided.

NOTE: Thisisatemporaryrepaironly.Ensurethe damagedcableisreplacedassoonaspossibleto preventwaterorchemicalsfromentering.

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26 SECTION55--ELECTRICALSYSTEM--CHAPTER1

TH155043 42

ELECTRICALSYSTEM–GENERALFAULTFINDING

PROBLEMPOSSIBLECAUSE REMEDY

Electricalsystem isinoperative Looseorcorrodedbattery connections

Sulphatedbatteries

Cleanandtightenconnections

Checkbatteryopencircuitvoltage for12.6voltsminimum.Check electrolytelevelandspecificgravity

Batteryisolatorswitchturned‘off’ Re--instateisolatorswitch Mainmachinefuselinkblown Establishreasonforfailureand replacefuselink

Starterspeedlowandengine cranksslowly

Looseorcorrodedconnection

Lowbatteryoutput

Cleanandtightenloose connections

Checkbatteryopencircuitvoltage for12.6voltsminimum.

Checkelectrolytelevelandspecific gravity.

Starterinoperative

Incorrectviscosityengineoil

Transmissionshiftleveringear

Looseorcorrodedconnections

Deadbatteries

Usecorrectviscosityoilfor temperatureconditions

Placeshiftleverinneutral

Cleanandtightenloose connections

Chargeorrepairbatteries

Chargeindicatorlampstayson with engine running

Increaseidlespeed eng nerunn ng

Batterieswillnotcharge

Lowengineidlespeed

Loosebelt

Malfunctioningbattery

Checkbelttension

Checkbatteryopencircuitvoltage for12.6voltsminimum.

Checkelectrolytelevelandspecific gravity.

Chargeindicatorflashingindicatingexcessivechargingvoltage

Malfunctioningalternator

Looseorcorrodedterminal connections

Sulphatedbatteries

Checkalternator

Cleanandtightenloose connections

Checkbatteryopencircuitvoltage for12.6voltsminimum.

Checkelectrolytelevelandspecific gravity.

Looseorwornbelt

Malfunctioningalternator

Checkautomaticbelttensioner. Replacebeltifrequired.

Checkalternator

SECTION55--ELECTRICALSYSTEM--CHAPTER1 27

--12--2002

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28 SECTION55--ELECTRICALSYSTEM--CHAPTER1 604.02.395.00 --12--2002

SECTION55--ELECTRICALCIRCUITS

Chapter2–Circuitdiagrams

SectionDescriptionPage

Listofconnectors31

Listofcomponents32 ..........................................................

Cablekey 34

Howtousethecircuitdiagrams36 ...............................................

Circuit1:Starting/Recharge/Warninglights/Indicatorlights38

Circuit2:Transmission40 .......................................................

Circuit3:Wheelalignment/Hydraulicsolenoids/Brakesystem42

Circuit4:Armcontrol44

Circuit5:Stabiliser46

Circuit6:Lights/Windscreenwiper48

Circuit7:Worklamps/Roofbeacon50 ............................................

Circuit8:Tiltingpreventionsystem/Roofwiper52

Circuit9:Soundsystem, heating/Electricsocket/Interiorlamp54 .....................

Circuit10:Airconditioner56

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 29

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30 SECTION55--ELECTRICALCIRCUITS--CHAPTER2 604.02.395.00 --12--2002

LISTOFCONNECTORS

CON. DESCRIPTION

X1 3--wayconnectorforRHstabilisersensor

X10 2--wayconnectorforreversingbuzzer

X100 4--wayconnectorforinsideairsensor

X102 2--wayconnectorforrecyclemotor

X106 4--wayconnectorforsolenoidvalve

X11 4--wayconnectorforarmworklamp

X12 3--wayconnectorforlowarmsensor

X129 8--wayconnectorforinstrumentpanel--airconditioner line

X132 4--connectorforheater

X133 4--wayconnectorforparkingbrakeshunt

X134 17--wayconnectorforgearshiftcontrolunit

X137 17--wayconnectorforworkselectioncontrolunit

X138 2--wayconnectorforfilterthermistor X139 2--wayconnectorforfilterpre--heating X14 3--wayconnectorforretractedarmsensor X16 3--wayconnectorforpre--fitting

X17 6--wayconnectorforfrontLHheadlight

X18 6--wayconnectorforfrontRHheadlight X19 3--wayconnectorfornumberplatelights

X1A2 2--wayconnectorforA2steeringsolenoidvalve

X1B2 2--wayconnectorforB2steeringsolenoidvalve

X2 3--wayconnectorforLHstabilisersensor X201 2--wayconnectorforLHstabiliserlowering X202 2--wayconnectorforLHstabiliserraising X203 2--wayconnectorforRHstabiliserlowering

2--wayconnectorforRHstabiliserraising X205 2--wayconnectorforLHlevellingsolenoidvalve X206 2--wayconnectorforRHlevellingsolenoidvalve X207 2--wayconnectorforhandbrakesolenoidvalve X208 4--wayconnectorforproportionalsolenoidvalve X209 2--wayconnectorforoptionalsolenoidvalverentrée

2--wayconnectorforhammersolenoidvalve

2--wayconnectorforoptionalsolenoidvalvesortie

2--wayconnectorforservo--controlsolenoidvalve

2--wayconnectorfortiltingpreventionsolenoidvalve

2--wayconnectorforreversingsolenoidvalve

2--wayconnectorforforwardgearsolenoidvalve

2--wayconnectorforgearshiftsolenoidvalve X216 2--wayconnectorfor1st gearsolenoidvalve

X217 2--wayconnectorfor2nd gearsolenoidvalve

X23 2--wayconnectorfordoubleoptionalsolenoidvalve

X25 18--wayconnectorforinstrumentpanel--engineline

X27 9--wayconnectorfordashboard--cabinline

X28a 2--wayconnectorforaxlelocksolenoidvalves

X28b 2--wayconnectorforaxlelocksolenoidvalves

X29 2--wayconnectorforthermo--startingrelay

X3 3--wayconnectorforfrontaxlesensor

X30 12way--connectorforinstrumentpanel--engineline

X31 17--wayconnectorforinstrumentpanel--cabinline

X32 2--wayconnectorforfrontRHworklamp

CON. DESCRIPTION

X33 2--wayconnectorforfrontLHworklamp

X34 2--wayconnectorforrearRHworklamp

X36 4--wayconnectorforupperwiper

X37 8--wayconnectorfortiltingpreventioninstrument

X39 4--wayconnectorforrearwiper

X40 3--wayconnectorforrooflamp

X42 4--wayconnectorforparkingbrakeswitch

X43 2--wayconnectorforinterconnection

X44 2--wayconnectorforseat

X47 4--wayconnectorforwindscreenwasher

X48 12--wayconnectorforTelehandler

X5 2--wayconnectorforfuellevel

X52 2--wayconnectorforCB

X53 2--wayconnectorforcigarlighter

X55 8--waybrownconnectorforsound system

X56 8--wayblackconnectorforsound system

X6 40--wayconnectorforinstrumentpanel--rearline

X60 20--wayconnectorforinstrument

X62 12--wayconnectorforgearswitch

X63 12--wayconnectorforlightswitch

X65 4--wayconnectorformicro--stop

X67 4--wayconnectorforfrontwiper X68 2--wayconnectorforrearLHworklamp

24--wayconnectorforinstrumentpanel--frontline

10--waconnectorforthermo--startingcontrolunit

3--wayconnectorforrearaxlesensor

2--wayconnectorforloadingcell

X92a 2--wayconnectorforelectricfan

X92b 2--wayconnectorforelectricfan

X94 8--wayconnectorforairconditionercontrolunit

X95 9--wayconnectorforairconditionercontrolunit

X96 2--wayconnectorforoutsidetemperaturesensor X97 2--wayconnectorformixedairsensor

X98 2--wayconnectorfortap

X99 2--wayconnectorfordefrostingsensor

XA1 2--wayconnectorforalternator

XA1a 1--wayconnectorforalternator

X01 9--wayconnectorforbridges

X02 21--wayconnectorsforbridges

X03 21--wayconnectorforcontrolunit

X04 18--wayconnectorforcontrolunit

X05 12--wayconnectorforcontrolunit

X06 6--wayconnectorforcontrolunit

X07 15--wayconnectorforcontrolunit

X08 21--wayconnectorforcontrolunit

X09 18--wayconnectorforcontrolunit

X13 3--waydeutschconnector

X15 2--wayconnectorforcloggedairfilterpressuregauge

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 31 604.02.395.00 --12--2002

X21

X210

X211

X212

X213

X214

X204

X215

X70

X91

2--wayconnectorforairconditionerpressuregauge

LISTOFCOMPONENTS

COMP.DESCRIPTIONDIAG.

BRexrothhandlerbutton4

BS1RHloudspeaker9

BS2LHloudspeaker9

CResetbutton8

DRexrothhandlerbutton4

DResetbutton8

EVAAxlelocksolenoidvalve3

EVA2A2steeringsolenoidvalve3

EVBAxlelocksolenoidvalve3

EVB2B2steeringsolenoidvalve3

FG1Mainfuse80A1

FG2Airconditionerfuse30A1

FG3Filterpre--heatingfuse20A1

FG4Sparefuse1

FV1Converterfuse30A10

GRexrothhandlerbutton4

G1Battery1

G2Alternator1

HRexrothhandlerbutton4

H1FrontLHheadlight6

H10RearLHworklamp7

H11RearRHworklamp7

H12Beaconlight7

H13Cigarlighterlamp9

H14Rooflamp9

H2FrontRHheadlight6

H3LHtaillight6

H4RHtaillight6

H5Numberplatelight6

H6Armworklamp7

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32 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

HA1Reversingbuzzer2 HA2Buzzer8 I1Transmissionoilpressuregauge1 I10Airconditionerpressuregauge10 I11Mixedairsensor10 I12Outsidetemperaturesensor10 I13Defrostingsensor10 I14Insideairsensor10 I2Transmissionoil hightemperaturesensor 1 I3aSparkplugthermistor1 I3bEnginewatertemperature transducer 1 I4Pressuregaugeforengineoil lowpressure 1 I5Cloggedairfilterpressuregauge1 I6Doormicro9 I7Filterthermistor1 I8Parkingbrakepressuregauge5 K103Electricfan1 st speedrelay10 K105Electricfan2 nd speedrelay10 K107Electricfan3 rd speedrelay10 KAStartingrelay1 KBAirconditionerrelay10 COMP.DESCRIPTIONDIAG. KCFilterpre--heatingrelay1 KDUnswitchedcircuitrelay1 KTThermo--startingrelay1 M1Starter1 M11Recycling10 M12Tap10 M13Coolingfan10 M14Electricfan10 M2Frontwipermotor6 M3Upperwipermotor8 M4Windscreenwasherpump8 M5Rearwashermotor8 M6Rearwindowwasherpump8 M7Fan9 M8AirConditioningfan10 M9Compressor10 PPotentiometer4 R1Availableresistance–1K0hm1W3 R2Thermo--starting1 R3Filterpre--heating1 RL1Workselectioncontrolunitrelay3 RL2Workselectioncontrolunitrelay3 RL3Workselectioncontrolunitrelay3 RL4Workselectioncontrolunitrelay3 S11LHstabiliserswitch5 S12Levellingswitch5 S13RHstabiliserswitch5 S15Startingpanel1 S1Parkingbrake5 S2Beaconlightswitch7 S3Warningswitch6 S30Batterydisconnectionwithkey1 S31Fuellevel1 S32Steeringselectionswitch3 S33Rearaxlesensor3 S34Frontaxlesensor3 S35LHstabilisersensor5 S36RHstabilisersensor5 S38Lowarmsensor3 S39Retractedarmsensor3 S4Lightswitch6 S40Brakeoillevel6 S5Frontworklampswitch7 S50Heatingswitch9 S514gearswitch+hobbshorn2 S52Light--directionindicator--wiper switch 6 S6Rearworklampswitch7 S7Armworklampswitch7 S8Upper/frontwiperswitch8 S9Rearwiperswitch8 X4Horn2 X53Cigarlighter9 X54Fridgesocket9 X65Stoplightmicro6 Y1LHstabiliserloweringsolenoidvalve5

H7Armworklamp7 H8FrontRHworklamp7 H9FrontLHworklamp7

COMP.DESCRIPTIONDIAG.

Y10Optionalsolenoidvalve(out)4

Y11Servo--controlsolenoidvalve4

Y12Tiltingpreventionsolenoidvalve4

Y13Reversesolenoidvalve3

Y14Forwardgearsolenoidvalve2

Y15Gearshiftsolenoidvalve2

Y161 st gearsolenoidvalve2

Y172 nd gearsolenoidvalve2

Y18Enginestopsolenoidvalve1

Y2LHstabiliserliftingsolenoidvalve5

Y20Hammersolenoidvalve4

Y3RHstabiliserloweringsolenoid valve 5

Y4RHstabiliserliftingsolenoidvalve5

Y5LHlevellingsolenoidvalve5

Y6RHlevellingsolenoidvalve5

Y7Parkingbrakesolenoidvalve5

Y9Optionalsolenoidvalve(in)4

WIRECOLOURKEYS

AAzure

ZPurple

NOTE: wireswithtwocolourshavecompoundacronyms,e.g.:

G/V--Yellow/green(crosscolouring)

G--V--Yellow--Green(longitudinalcolouring)

WIREKEY KEYUSE

0XXXMassreturn(earth)

1XXXVisualandsoundsignals

2XXXWorkarea(outside)lighting

3XXXSideandposition(outside)lighting

4XXXInsidelighting

5XXXControlsignalsensorsandtransmitters

6XXXWarningsignalsensorsandtransmitters

7XXX Mainpowersupplyandnon--keyswitched services

8XXX Mainpowersupplyandkeyswitchedservices

9XXX Electricallyservo--assistedmechanical components

NAMEX

NAMEXX NAMEXXX Controlunits

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 33 604.02.395.00 --12--2002

BWhite COrange GYellow HGrey LBlue MBrown NBlack RRed SPink VGreen

CABLEKEY

KEYSPECIFICFUNCTION

0001Rightloudspeakernegative

0002Leftloudspeakernegative

0051Solenoidvalvemass(airconditioner)

00523rd speedmass(airconditioner)

1002Flickeringpowersupplyfromhazardswitch

1003Rightdirectionindicator(lightswitch)

1005Steeringcontrolunitbuzzernegative

1006Leftdirectionindicator (fromhazardtolightswitch)

1007Rightdirectionindicator (fromhazardtolightswitch)

1009Leftdirectionindicator(lightswitch)

1010Beaconlightswitchpowersupply

1011Sidelightpowersupply (fromfusetohazardswitch)

1012+15Flashing

1015Directionindicatorwarninglamp

1017Stoplightpressuregaugepowersupply (fromfusetopressuregauge)

1018Lightswitchpowersupply

1020Rearleftdirectionindicator

1021Beaconlight

1023Frontrightdirectionindicator

1025Rearrightdirectionindicator

1029Frontleftdirectionindicator

1030Hazardlightdirectpowersupply (fromfusetohazardswitch)

1031Buzzerpowersupply

1041Thermo--startervisualindicator

1049Lightmainswitchpowersupply

1050Flickeringcharge

1053+30Lightmainswitch(redcolour)

1063Reversebuzzer

1064Startingrelaycoil

1066Sidelightsfrommainswitch

1067Frontworklampswitches

1068Rearworklampswitches

1072Rearrightbrakelight

1077Rearleftbrakelight

1086Rightloudspeakerpositive

1087Leftloudspeakerpositive

1088Roundsteeringwarninglamp

1089Fridgesocket

1090LHdirectionindicator (fromhazardtoindicatorswitch)

11002wheelssteeringwarninglamp

1101Warninglampmainbeamheadlightson

1890Crabsteeringwarninglamp

2000Mainbeamheadlightcontrol (fromlightswitchtofuseorrelay)

2001Dippedbeamheadlightcontrol (fromlightswitchtofuseorrelay)

2003Flashingpowersupply (fromfusetosteeringcolumnstalk)

2006Main/dippedbeamheadlightswitchpowersupply

2007Sidelightswitchdirectpowersupply

2019Leftmainbeamheadlight

2021Rightmainbeamheadlight

2023Rightdippedbeamheadlight

2025RearRHworklamp

2026RearLHworklamp

2029FrontRHworklamp

2030Cabinfrontleftheadlightpowersupply

2031Leftdippedbeamheadlight

2032Armworklamp

2033Armlightswitchpowersupply

2037Main/dippedbeamheadlightpowersupply (fromswitchtolightswitch)

2085Mainbeamheadlightvisualindicator

3030Frontrightsidelight

3031Rearrightsidelight

3032Rearleftsidelight

3035Sidelightpowersupply(fromswitchtofuses)

3037Numberplatelight

KEYSPECIFICFUNCTION

3039Frontleftsidelight

4040Rooflampswitchondoor

4041Rooflamppowersupply(redcolour)

4042Multi--functioninstrumentlighting

4043Cigarlighterillumination

4050Multi--functioninstrumentlighting

4058Soundsystemlighting

4059Airconditionercontrollighting

4060Switchlighting

5003Engineoillowpressurevisualindicator

5022“W”revcountersignal

5029Enginewatertemperaturesignalfor thermo--startercontrolunit

5036Speedsensor

5037Speedsensor

5043Gearshiftsolenoidvalve

5044Gearshiftpowersupply

5046Agearsolenoidvalvepowersupply(1st speed)

5047Bgearsolenoidvalvepowersupply(2nd gear)

5048Solenoidvalvereversing

5049Solenoidvalveforwardgear

5052Enginewatertemperatureproportionalinstrument signal

5059Transmissionoiltemperaturesensor

5068Batterychargewarninglampfromcontrolunit instrumentA(relaycard)

5081Transmissionoillowpressuresensor

5088Flickeringchargefromdirectionindicatorswitch tohazardswitch

5090RHdirectionindicator (fromhazardtodirectionindicatorswitch)

5093Mainbeamheadlightsignal (fromlightswitchtorelay)

5094Dippedbeamheadlightsignal (fromlightswitchtorelay)

5095Hornswitchfromgearshift

5096Retractedarmsensorpowersupply

5097Lowarmsensorsignal

5098Lowarmsensorpowersupply

5099Frontaxlesensorsignal

5100Frontaxlesensorpositive

5101RHoutstabilisersensorsignalfromLHstab.sign.

5102RHstabilisersensorpositive

5103Sensorpowersupply(prearrangement)

5104LHstabilisersensorpositive

5105Sensorsignal(prearrangement)

5106Sparkplugthermistor

5107100%cutenginesignalfromtiltingprevention controlunittorelaycard

510885%cutenginesignalfromtiltingprevention instrumenttorelaycard

5109Framesignalfromtiltingpreventioninstrumentto relaycontrolunit

5110Lowstabilisersignalfromrelaycontrolunitto tiltingpreventioninstrument

5111Limit5Km/h

5112Outroundsignal

5113Outgrabsignal

5114Estab.Lowering(workselector)

5115Yardselection(workselector)

5116Signal+steeringswitch(steeringselector)

5117Thermo--startingkit

5118In,optionalsignal

5119Out,optionalsignal

5120Telehandler

5120Doubleoptionalsignal

5121Transmissiondisconnectionsignal

5122Prop.Handlersignal

5123+5Vhandler

5930Rearaxlesensorsignal

5940+Rearaxlesensor

5950Retractedarmsensorsignal

6037Batterychargewarninglampfrom“D+”alternator

6061Brakeoilminimumlevelsensor

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34 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

KEYSPECIFICFUNCTION

6062Visualindicatorparkingbrakeengaged

6063Cloggedairfilter

6094+loadingcell

6095--loadingcell

7000100Asafetyremotecontrolswitchforstarter

7006Heating1st speed

7008+30warning(redcolour)

7009Heating2nd speed

7011Heatingpowersupply

7021Cigarlighterpowersupply(redcolour)

7045Heating3rd speed

7072Positiveafterfuselink

7077Nonprotectedpositivefrombattery(redcolour)

7084Powersupply+30(airconditionercontrolunit)

7095Fuelfilterheatingpowersupplyafterremote controlswitch

7097Fuelfilterheatingpowersupplybeforeremote controlswitch

7099Sound systempowers upply+30(redcolour)

7100C.B.powersupplyprearrangement(redcolour)

8001+15afterservicerelay

8004Servicerelaypowersupply

8009Climatecontrol systempowers upply

8013Rearwipermotor1st speedpowersupply

8019Fromairconditionerthermostattoairconditioner relay

8022Frontwiperreset

8023“53a”rearwipermotor

8058Instrumentpowersupply

8073Frontwiperreturn

8077Rearwipermotorreset

8079+15Hazardswitch

8080Frontwiperswitchpowersupply

8082Frontwiper1st speed

8085Frontwashermotor(pump)

8086Rearwashermotor(pump)

8088Starterelectricmagnetpowersupply

8089Rearwindowwiperswitchpowersupply

8090Airconditionercompressor

8094Fuelfilterpre--heatingthermistor

8097Fuelfilterpre--heatingremotecontrolswitch powersupply

8099Sound systempowers upply+15

8100Airconditionercontrolunitpowersupply+15

8101Fromconverterrelaytomaxifuse (airconditioning)

8102Converterpowersupplyfrommaxifuse (airconditioning)

8103Norecyclemotor(airc onditioner)

8104Norecyclemotor(airc onditioner)

8105Upperwipermotor“53a”

8106Upperwipermotor1st speedpowersupply

8107Upperwipermotorreset

8108Tiltingpreventioninstrumentpowersupply

8109RHstabiliserswitchpowersupply (fromworkselector)

8110Stabiliserpowersupply (workselectorcontrolunit)

8111LevelGpowersupply(workselectorcontrolunit)

8112LHstabiliserswitchpowersupply (fromworkselector)

8113Steeringcontrolunitpowersupply

8114Ashared(workselector)

8115Aservicerelaypowersupply(workselector)

8116Bkeyselectorpowersupply(workselector)

8117Upperwiperswitchpowersupply

8118Thermo--startercontrolunitpowersupply

8119Handlerbuttonpowersupply

8120Seatneutrallockinter.micropowersupply

8121LevelGpowersupply

KEYSPECIFICFUNCTION

brakeengaged 9044Parkingbrakeswitchpowersupply 9045Parkingbrakesolenoidvalve 9049Q.A.gear

(telescopicarm)

9107Solenoidvalve.doubleoptional 9108SteeringA2solenoidvalve

9109SteeringA3solenoidvalve

9110SteeringB2solenoidvalve

9111SteeringB3solenoidvalve

9114LHstabiliserloweringsolenoidvalve 9115LHstabiliserliftingsolenoidvalve

9116RHstabiliserloweringsolenoidvalve

9117RHstabiliserliftingsolenoidvalve

9118LHlevellingsolenoidvalve

9119RHlevellingsolenoidvalve

9120Doublespeedsolenoidvalve

APC1+gearshift(APC50controlunit)

APC2Directmassfrombattery

APC10+gearshift(APC50controlunit)

APC11Directmassfrombattery

APC12Forwardgearsignal(APC50controlunit)

APC141st gearsignal(APC50controlunit)

APC152nd gearsignal(APC50controlunit)

APC174th gearsignal(APC50controlunit)

APC19Reversesignal(APC50controlunit)

APC26Neutrallock(APC50controlunit)

APC3Start(APC50controlunit)

CLIMA01Cockmotor(airconditionercontrolunit)

CLIMA02Electricfan3rd speedcontrol (airconditionercontrolunit)

CLIMA03Electricfan2nd speedcontrol (airconditionercontrolunit)

CLIMA04Electricfan1st speedcontrol (airconditionercontrolunit)

CLIMA05Electricfan4th speedcontrol (airconditionercontrolunit)

CLIMA06Mixedairsensor(airconditionercontrolunit)

CLIMA07Insideairsensor(airconditionercontrolunit)

CLIMA08Outsidetemperaturesensor (airconditionercontrolunit)

CLIMA11Airconditionerconsensus (airconditionercontrolunit)

CLIMA12Sharedsensors(airconditionercontrolunit)

CLIMA14Recyclemotor(airc onditionercontrolunit)

CLIMA16Recyclemotor(airc onditionercontrolunit)

CLIMA17Vanemotor(airconditionercontrolunit)

CLIMA7006Electricfan1st speed

CLIMA7009Electricfan2nd speed

CLIMA7045Electricfan3rd speed

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 35 604.02.395.00 --12--2002

9084Thermo--starterrelay 9089Thermo--starterfromrelay 9100Servo--controlsolenoidvalvepowersupply 9101Tiltingpreventionsolenoidvalvepowersupply 9102Proportionalsolenoidvalvepowersupply

9103Solenoidvalveproportionalsignal

9104+5Vproportionalsolenoidvalve(telescopicarm) 9105Optionalsolenoidvalveoutpowersupply 9106Optionalsolenoidvalveinpowersupply

8122CentralHstabiliserpowersupply,workselection 9003Enginestopsolenoidvalve 9007StartQ.A. 9021Switchwarninglampspowersupply 9025Hornbuttonpowersupply 9032Seatcompressor 9033Transmissiondisconnectionsignalwithparking

9112Hammersolenoidvalvepowersupply 9113Axlelocksolenoidvalve

HOWTOUSETHECIRCUITDIAGRAMS

Thecircuitdiagramshavebeendrawninalinear format,meaningt hatthecompletevehiclesystemis drawnoveranumberofpages,withreferencesto linkthepages,whereapplicable.Theflowofpower isgenerallyspeaking,fromtop,positive,tobottom, negative.

Hereareanumberofexplanationstothelayoutand referencescontainedwithinthediagrams:

1.Alldiagramsarelocatedontherighthandpages. Withinthediagramthereareanumberof references.

1. Diagramnumberandelectricfunction

2. Linereference

3. Componentidentificationreference

4. Connectorx70,connectorcode,3,references(pin)

5. Numericalwirecolourkey

6. Fusecode.G1,fusenumber,10A,capacity

7. Linecontinuesonanotherdiagram.Inthisinstance: diagram3atlinereference1.

8. Alphabeticalwirecolourkey

9. Diode

10. Componentpincode

2.Eachcomponentandconnectorappearsonly onceinasetofcircuitdiagrams.

3.Thecircuitdiagramsarebrokenupintosections. However,wheresinglecomponentisusedina numberofcircuits,suchasaprocessorormulti-functionswitch,itisdrawneitheronitsownorin thecircuitwhichitinfluencesthemost.

604.02.395.00 --12--2002

36 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 37 604.02.395.00 --12--2002 DIAGRAM1–STARTING/RECHARGE/WARNINGLAMPS/INDICATORS TH155044 2 3 4 5 9 10 8 7 6 1 1

DIAGRAM1–STARTING/RECHARGE/WARNING/INDICATORSLIGHTS

38 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

604.02.395.00 --12--2002

DESCRIPTION D10 Diode G2 Alternator I1 Transmissionoilpressuregauge I2 Transmissionoilhightemp.pressuregauge I3a Sparkplugthermistor I3b Enginewatertemperaturetransducer I4 Pressuregaugeforengineoillowpressure I5 Cloggedairfilterpressuregauge I7 Filterthermistor K15 Relay KA Startingrelay KC Filterpre--heatingrelay KD Underkeyrelay KT Thermo--starterrelay M1 Starter R2 Thermo--starting R3 Filterpre--heating S15 Startingpanel S31 Fuellevel Y18 Enginestopsolenoidvalve F11 Sparefuse5A F34 Enginestopfuse10A FG1 Mainfuse80A FG2 Airconditionerfuse30A FG3 Filterpre--heatingfuse20A CONNECTORS DESCRIPTION X5 2--wayconnectorforfuellevel X6 40--wayconnectorforinstrumentpanel--rearline X13 DEUTSCH3--wayconnector X15 2--wayconnectorforcloggedairfilterpressuregauge X25 18--wayconnectorforinstrumentpanel--engineline X30 12--wayconnectorforinstrumentpanel--engineline X60 20--wayconnectorforinstrument X70 10--wayconnectorforthermo--startercontrolunit X138 2--wayconnectorforfilterthermistor X139 2--wayconnectorforfilterpre--heating XA1 2--wayconnectorforalternator XA1a 1--wayconnectorforalternator XC1 9--wayconnectorforbridges XC2 21--wayconnectorforbridges XC3 21--wayconnectorforcontrolunit XC4 18--wayconnectorforcontrolunit XC5 12--wayconnectorforcontrolunit XC6 6--wayconnectorforcontrolunit

COMPONENTS ANDFUSES

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 39 604.02.395.00 --12--2002 DIAGRAM1–STARTER/RECHARGE/WARNING/INDICATORSLIGHTS TH155045 2

40 SECTION55--ELECTRICALCIRCUITS--CHAPTER2 604.02.395.00

COMPONENTS ANDFUSES DESCRIPTION D02 Diode D03 Diode D06 Diode D07 Diode D11 Diode D12 Diode DL1 Diode DL2 Diode DL3 Diode DL4 Diode DL5 Diode F5 Hornfuse15A HA1 Reversebuzzer K07 Relay K09 Relay K21 Relay RL1 Workselectioncontrolunitrelay RL2 Workselectioncontrolunitrelay RL3 Workselectioncontrolunitrelay RL4 Workselectioncontrolunitrelay S51 4gearswitch+Hobbshorn Y14 Forwardgearsolenoidvalve Y15 Gearshiftsolenoidvalve Y16 1st gearsolenoidvalve Y17 2nd gearsolenoidvalve F18 Reversebuzzer,cabinbuzzerfuse5A F37 Transfersystemfuse10A CONNECTORS DESCRIPTION X4 Horn X6 40--wayconnectorforinstrumentpanel--rearline X7 24--wayconnectorforinstrumentpanel--frontline X10 2--wayconnectorforreversebuzzer X23 2--wayconnectorfordoubleoptionalsolenoidvalve X25 18--wayconnectorfordashboard--engineline X43 2--wayconnectorforinterconnection X62 12--wayconnectorforgearswitch X134 17--wayconnectorforgearshiftcontrolunit X214 2--wayconnectorforforwardgearsolenoidvalve X215 2--wayconnectorforgearshiftsolenoidvalve X216 2--wayconnectorfor1st gearsolenoidvalve X217 2--wayconnectorfor2nd gearsolenoidvalve XC2 21--wayconnectorforbridges XC4 18--wayconnectorforcontrolunit XC5 12--wayconnectorforcontrolunit XC7 15--wayconnectorforcontrolunit XC8 21--wayconnectorforcontrolunit

--12--2002 DIAGRAM2–TRANSMISSION

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 41 604.02.395.00 --12--2002 DIAGRAM--2TRANSMISSION TH155046 3

DIAGRAM3–WHEELALIGNMENT/HYDRAULICSOLENOIDS/BRAKESYSTEM

COMPONENTS ANDFUSES

604.02.395.00 --12--2002

42 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

DESCRIPTION DL1 Diode DL2 Diode DL3 Diode DL4 Diode DL5 Diode EVA Axlelocksolenoidvalve EVA2 A2steeringsolenoidvalve EVB Axellocksolenoidvalve EVB2 B2steeringsolenoidvalve K5 Relay K6 Relay K17 Relay R1 Spareresistor–1K0hm1W RL1 Workselectioncontrolunitrelay RL2 Workselectioncontrolunitrelay RL3 Workselectioncontrolunitrelay RL4 Workselectioncontrolunitrelay S32 Steeringselectorswitch S33 Rearaxlesensor S34 Frontaxlesensor S38 Lowarmsensor S39 Retractedarmsensor Y13 Reversesolenoidvalve F2 Stabiliserfuse7.5A F3 Sensorpowersupplyfuse5A F15 Axleswingingstopfuse10A F21 Axlesensorpowersupplyfuse+workselectioncontrolunit7.5A CONNECTORS DESCRIPTION X1A2 2--wayconnectorforsteeringsolenoidvalveA2 X1B2 2--wayconnectorforsteeringsolenoidvalveB2 X3 3--wayconnectorforfrontaxlesensor X6 40--wayconnectorforinstrumentpanel--rearline X7 24--wayconnectorforinstrumentpanel--frontline X8 3--wayconnectorforrearaxlesensor X12 3--wayconnectorforlowarmsensor X14 3--wayconnectorforliftedarmsensor X25 18--wayconnectorforinstrumentpanel--engineline X28a 2--wayconnectorforaxlelocksolenoidvalves X28b 2--wayconnectorforaxlelocksolenoidvalves X137 17--wayconnectorforworkselection X213 2--wayconnectorforreversesolenoidvalve XC2 21--wayconnectorforbridges XC3 21--wayconnectorforcontrolunit XC5 12--wayconnectorforcontrolunit XC6 6--wayconnectorforcontrolunit XC7 15--wayconnectorforcontrolunit XC9 18--wayconnectorforcontrolunit

DIAGRAM3–WHEELALIGNMENT/HYDRAULICSOLENOIDS/BRAKE SYSTEM

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 43 604.02.395.00 --12--2002

TH155047 4

44 SECTION55--ELECTRICALCIRCUITS--CHAPTER2 604.02.395.00

COMPONENTS ANDFUSES DESCRIPTION B Rexrothhandlerbutton D Rexrothhandlerbutton D4 Diode D5 Diode D8 Diode D9 Diode D13 Diode G Rexrothhandlerbutton H Rexrothhandlerbutton K1 Relay K3 Relay K4 Relay K12 Relay K14 Relay K18 Relay P Potentiometer Y8 Solenoidvalve Y9 Optionalsolenoidvalve(in) Y10 Optionalsolenoidvalve(out) Y11 Servo--controlsolenoidvalve Y12 Tiltingpreventionsolenoidvalve Y20 Hammersolenoidvalve F12 Doubleoptionalfuse10A F13 Rexrothproportionalpowersupplyfuse10A F14 Optionalhandlingfuse10A F16 Voltageindicatorpowersupplyfuse10A CONNECTORS DESCRIPTION X6 40--wayconnectorforinstrumentpanel--rearline X7 24--wayconnectorforinstrumentpanel--frontline X21 2--wayconnectorforhammersolenoidvalve X48 12--wayconnectorforhandler X208 4--wayconnectorforproportionalsolenoidvalve X209 2--wayconnectorforoptionalsolenoidvalvein X210 2--wayconnectorforoptionalsolenoidvalveout X211 2--wayconnectorforservo--controlsolenoidvalve X212 2--wayconnectorfortiltingpreventionsolenoidvalve XC2 21--wayconnectorforbridges XC3 21--wayconnectorforcontrolunit XC4 18--wayconnectorforcontrolunit XC5 12--wayconnectorforcontrolunit XC6 6--wayconnectorforcontrolunit XC7 15--wayconnectorforcontrolunit XC8 21--wayconnectorforcontrolunit

--12--2002 DIAGRAM4–ARMCONTROL

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 45 604.02.395.00 --12--2002 DIAGRAM4–ARMCONTROL TH155048 5

46 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

604.02.395.00 --12--2002

ANDFUSES DESCRIPTION I8 Parkingbrakepressuregauge K16 Relay K19 Relay S1 Parkingbrake S11 LHstabiliserswitch S12 Levellingswitch S13 RHstabiliserswitch S35 LHstabilisersensor S36 RHstabilisersensor Y1 LHstabiliserloweringsolenoidvalve Y2 LHstabiliserliftingsolenoidvalve Y3 RHstabiliserloweringsolenoidvalve Y4 RHstabiliserliftingsolenoidvalve Y5 LHlevellingsolenoidvalve Y6 RHlevellingsolenoidvalve Y7 Parkingbrakesolenoidvalve F24 Switchlightingfuse+instrumentpowersupply10A F26 Sparefuse7.5A CONNECTORS DESCRIPTION X1 3--wayconnectorforRHstabilisersensor X2 3--wayconnectorforLHstabilisersensor X6 40--wayconnectorforinstrumentpanel--rearline X7 24--wayconnectorforinstrumentpanel--front X16 3--wayconnectorforpre--fittinginstallation X42 4--wayconnectorforparkingbrakeswitch X133 4--wayconnectorforparkingbrakeshunt X201 2--wayconnectorforLHstabiliserloweringsolenoidvalve X202 2--wayconnectorforLHstabiliserliftingsolenoidvalve X203 2--wayconnectorforRHstabiliserloweringsolenoidvalve X204 2--wayconnectorforRHstabiliserliftingsolenoidvalve X205 2--wayconnectorforLHlevellingsolenoidvalve X206 2--wayconnectorforRHlevellingsolenoidvalve X207 2--wayconnectorforparkingbrakesolenoidvalve XC2 21--wayconnectorforbridges XC3 21--wayconnectorforcontrolunit XC4 18--wayconnectorforcontrolunit XC6 6--wayconnectorforcontrolunit XC7 15--wayconnectorforcontrolunit XC8 21--wayconnectorforcontrolunit

DIAGRAM5--STABILISER COMPONENTS

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 47 604.02.395.00 --12--2002 DIAGRAM5--STABILISER TH155049 6

DIAGRAM6–LIGHTS/WINDSCREENWIPER COMPONENTS

604.02.395.00 --12--2002

48 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

ANDFUSES DESCRIPTION H1 FrontLHheadlight H2 FrontRHheadlight H3 RearLHheadlight H4 RearRHheadlight H5 Numberplatelight K8 Relay K10 Relay K13 Relay M2 Frontwipermotor S3 Warningswitch S4 Lightswitch S40 Brakeoillevel S52 Light–directionindicator--wiperswitch F7 Driving--lightswitchfuse15A F30 Dippedbeamheadlightfuse15A F33 Brakelightfuse5A F35 RHsidelightfuse5A F36 LHsidelight+numberplatelightfuse5A F38 Fuse+30warning10A F39 Mainbeamheadlightfuse15A CONNECTORS DESCRIPTION X6 40--wayconnectorforinstrumentpanel--rearline X7 24--wayconnectorforinstrumentpanel--frontline X17 6--wayconnectorforfrontLHheadlight X18 6--wayconnectorforfrontRHheadlight X19 3--wayconnectorfornumberplatelight X63 12--wayconnectorforlightswitch X65 4--wayconnectorformicrostop X67 4--wayconnectorforfrontwiper XC3 21--wayconnectorforcontrolunit XC4 18--wayconnectorforcontrolunit XC5 12--wayconnectorforcontrolunit XC8 21--wayconnectorforcontrolunit XC9 18--wayconnectorforcontrolunit

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 49 604.02.395.00 --12--2002 DIAGRAM6--LIGHTS/WINDSCREENWIPER TH155050 7

DIAGRAM7–WORKLAMPS/ROOFBEACONLIGHT

604.02.395.00 --12--2002

50 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

ANDFUSES DESCRIPTION H6 Armworklamp H7 Armworklamp H8 FrontRHworklamp H9 FrontLHworklamp H10 RearLHworklamp H11 RearRHworklamp H12 Beaconlight S2 Beaconlightswitch S5 Frontworklampswitch S6 Rearworklampswitch S7 Armworklampswitch F4 Frontworklampfuse15A F9 Armworklampfuse15A F17 Rearworklampfuse15A F20 Beaconlightfuse10A CONNECTORS DESCRIPTION X6 40--wayconnectorforinstrumentpanel--rearline X11 4--wayconnectorforarmworklamp X27 9--wayconnectorforinstrumentpanel--cabinline X31 17--wayconnectorforinstrumentpanel--cabinline X32 2--wayconnectorforfrontRHworklamp X33 2--wayconnectorforfrontLHworklamp X34 2--wayconnectorforrearRHworklamp X68 2--wayconnectorforrearLHworklamp XC7 15--wayconnectorforcontrolunit XC8 21--wayconnectorforcontrolunit XC9 18--wayconnectorforcontrolunit

COMPONENTS

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 51 604.02.395.00 --12--2002 DIAGRAM7–WORKLAMPS/ROOFBEACONLIGHT TH155051 8

DIAGRAM8–TILTINGPREVENTIONSYSTEM/ROOFWIPER

COMPONENTS ANDFUSES

604.02.395.00 --12--2002

52 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

DESCRIPTION C Resetbutton D. Resetbutton HA2 Buzzer S8 Roof/frontwiperswitch S9 Rearwiperswitch K20 Relay M3 Roofwipermotor M4 Windscreenwasherpump M5 Rearwipermotor M6 Rearwindowwashingpump F1 Instrumentfuse+tiltingpreventionsystem3A F10 Rearwiperfuse15A F25 Controlcarpowersupplyfuse15A F31 Roofwiperfuse15A

DESCRIPTION X6 40--wayconnectorforinstrumentpanel--rearline X9 2--wayconnectorforloadingcell X27 9--wayconnectorforinstrumentpanel--cabinline X31 17--wayconnectorforinstrumentpanel--cabinline X37 8--wayconnectorfortiltingpreventioninstrument X39 4--wayconnectorforrearwiper X47 4--wayconnectorforwindowwasher XC2 21--wayconnectorforbridges XC3 21--wayconnectorforcontrolunit XC4 18--wayconnectorforcontrolunit XC8 21--wayconnectorforcontrolunit

CONNECTORS

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 53 604.02.395.00 --12--2002 DIAGRAM8–TILTINGPREVENTIONSYSTEM/ROOFWIPER TH155052 9

DIAGRAM9–HEATING/SOUNDSYSTEM/ELECTRICSOCKET/ROOFLAMP

COMPONENTS

604.02.395.00 --12--2002

54 SECTION55--ELECTRICALCIRCUITS--CHAPTER2

ANDFUSES DESCRIPTION BS1 RHloudspeaker BS2 LHloudspeaker H13 Cigarlighterillumination H14 Rooflamp I6 Microdoor M7 Fan S50 Heatingswitch F8 Seatfuse15A F23 Cabinventilationsolenoidvalvefuse15A F27 Fuse+30rooflamp+soundsystem5A F28 Microseatfuse5A F29 Fuse+30CB7.5A F32 Fuse+15soundsystem3A F41 Fridgesocketfuse15A F42 Cigarlighterfuse20A

DESCRIPTION X27 9--wayconnectorforinstrumentpanel--cabinline X31 17--wayconnectorforinstrumentpanel--cabinline X40 3--wayconnectorforrooflamp X44 2--wayconnectorforseat X52 2--wayconnectorforCB X53 2--wayconnectorforcigarlighter X54 Fridgesocket X55 8--waybrownconnectorforsoundsystem X56 8--wayblackconnectorforsoundsystem XC3 21--wayconnectorforcontrolunit XC7 15--wayconnectorforcontrolunit XC8 21--wayconnectorforcontrolunit XC9 18--wayconnectorforcontrolunit

CONNECTORS

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 55 604.02.395.00 --12--2002

TH155053 10

DIAGRAM9–HEATING/SOUNDSYSTEM/ELECTRICSOCKET/INTERIORLAMP

DIAGRAM10–AIRCONDITIONER

56 SECTION55--ELECTRICALCIRCUITS--CHAPTER2 604.02.395.00 --12--2002

COMPONENTS ANDFUSES DESCRIPTION FV1 Converterfuse30A I10 Airconditionerpressuregauge I11 Mixedairsensor I12 Outsidetemperaturesensor I13 Defrostingsensor I14 Insideairtemperature K8 Relay K9 Relay K103 Electricfan1st speedrelay K105 Electricfan2nd speedrelay K107 Electricfan3rd speedrelay K11 Relay K22 Relay K23 Relay M8 Solenoidvalve M11 Recirculation M12 Cock M13 Coolingfan M14 Solenoidvalve F6 Airconditionerrecirculationmotorfuse10A F19 Airconditionercontrolunitpowersupplyfuse3A F22 Sparefuse5A F40 Airconditionercompressorfuse10A CONNECTORS DESCRIPTION X6 40--wayconnectorforinstrumentpanel--rearline X25 18--wayconnectorforinstrumentpanel--engineline X30 12--wayconnectorforinstrumentpanel--engineline X43 2--wayconnectorforinterconnection X91 2--wayconnectorforairconditionerpressuregauge X94 8--wayconnectorforairconditionercontrolunit X95 9--wayconnectorforairconditionercontrolunit X96 2--wayconnectorforoutsidetemperaturesensor X97 2--wayconnectorformixedairsensor X98 2--wayconnectorforcock X99 2--wayconnectorfordefrostingsensor X100 4--wayconnectorforinsideairsensor X102 2--wayconnectorf orrecyclemotor X129 8--wayconnectorforinstrumentpanel--airconditionerline X92a 2--wayconnectorforsolenoidvalve X92b 2--wayconnectorforsolenoidvalve XC1 9--wayconnectorforbridges XC4 18--wayconnectorforcontrolunit XC5 12--wayconnectorforcontrolunit XC8 21--wayconnectorforcontrolunit XC9 18--wayconnectorforcontrolunit

SECTION55--ELECTRICALCIRCUITS--CHAPTER2 57 604.02.395.00 --12--2002 DIAGRAM10–AIRCONDITIONER TH155054 11

58 SECTION55--ELECTRICALCIRCUITS--CHAPTER2 604.02.395.00 --12--2002

SECTION55--ELECTRICCIRCUITS

SECTION55--ELECTRICALCIRCUITS--CHAPTER3 59 604.02.395.00 --12--2002

Chapter3--Wiringlist CONTENTS SectionDescriptionPage Instrumentpanelwiring61 Cabwiring 66 ................................................................. Frontwiring 67 Rearwiring 68 Enginewiring 70

60 SECTION55--ELECTRICALCIRCUITS--CHAPTER3 604.02.395.00 --12--2002

SECTION55--ELECTRICALCIRCUITS--CHAPTER3 61 604.02.395.00 --12--2002 INSTRUMENTPANELWIRING(1) TH155055 1

TH155056

604.02.395.00 --12--2002

62 SECTION55--ELECTRICALCIRCUITS--CHAPTER3

INSTRUMENTPANELWIRING(2)

SECTION55--ELECTRICALCIRCUITS--CHAPTER3 63 604.02.395.00 --12--2002 INSTRUMENTPANELWIRING(3) TH155057 3

TH155058

604.02.395.00 --12--2002

64 SECTION55--ELECTRICALCIRCUITS--CHAPTER3

INSTRUMENTPANELWIRING(4)

SECTION55--ELECTRICALCIRCUITS--CHAPTER3 65 604.02.395.00 --12--2002 INSTRUMENTPANELWIRING(5) TH155059 5

66 SECTION55--ELECTRICALCIRCUITS--CHAPTER3 604.02.395.00 --12--2002 CABWIRING TH155060 6

SECTION55--ELECTRICALCIRCUITS--CHAPTER3 67 604.02.395.00 --12--2002 FRONTWIRING TH155061 7

68 SECTION55--ELECTRICALCIRCUITS--CHAPTER3 604.02.395.00 --12--2002 REARWIRING(1) TH155062 8

SECTION55--ELECTRICALCIRCUITS--CHAPTER3 69 604.02.395.00 --12--2002 REARWIRING(2) TH155063 9

70 SECTION55--ELECTRICALCIRCUITS--CHAPTER3 604.02.395.00 --12--2002 ENGINEWIRING TH155064 10

PrintNo.604.02.395.00--English--XII--2002 PrintedbySatiz--Turin(Italy) CoordinamentoEditorialeSatiz--Torino

COPYRIGHTBYFIATKOBELCOCONSTRUCTIONMACHINERYS.p.A. • Reproductionoftextorillustration, inwholeorinpart,isstrictlyprohibited.

Pr int No. 604.02.395.00 English - Pr inted in Italy