Manitou MXT 1740 ( With Perkins engine ) Lift Truck Repair Manual 53111319EN - PDF DOWNLOAD

53111319EN

MXT 1740 ( With Perkins engine )

REPAIR MANUAL

53111319EN

MXT 1740 ( With Perkins engine )

REPAIR MANUAL

2

EDITION DATE

OBSERVATION

2020\11

-1st Edition

Manitou Equipment India (P) LTD. Plot no. 22, Udyog Vihar, Greater Noida, P.O. Surjapur, Gautham Budha Nagar, U.P. 201306. INDIA www.manitou.com This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution or other, in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization that are found in this document, are the intellectual property of MANITOU. Any violation of the aforementioned may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU and may not be used without express and formal authorization.

All rights are reserved.

3

10

ENGINE

00

GENERAL CHARACTERISTICS

20

TRANSMISSION

30

AXLE

40

BRAKE

50

BOOM

70

HYDRAULICS

80

ELECTRICITY

85

DRIVER’S CAB

90

FRAME - BODY

110

OPTIONS - ATTACHMENTS

4

GENERAL CHARACTERISTICS

5

TABLE OF CONTENTS

1.1

1.2

1.3

GENERAL INSTRUCTIONS AND SAFETY NOTICE.......................................................................................... 7 1.1.1

FOREWORD................................................................................................................................................................................... 7

1.1.2

SERVICING POSITION.................................................................................................................................................... 7

1.1.3

EXPLANATION OF SYMBOLS................................................................................................................................ 8

1.1.4

SERVICING RULES.......................................................................................................................................................... 9

GENERAL CHARACTERISTICS AND SPECIFICATIONS...................................................................................12 1.2.1

GENERAL SPECIFICATIONS.............................................................................................................................................12

1.2.2

DIMENSIONS.................................................................................................................................................................15

1.2.3

LUBRICANTS AND FUEL.................................................................................................................................... 18

GENERAL LOCATION................................................................................................................................... 20 1.3.1

1.4

1.5

NAME AND IDENTIFICATION PLATE..................................................................................................................................20

MAINTENANCE......................................................................................................................................... 22 1.4.1

GENERAL LUBRICATION.........................................................................................................................................................22

1.4.2

PERIODIC MAINTENANCE SCHEDULE....................................................................................................................24

GENERAL CONTROL AND ADJUSTMENT.................................................................................................... 30 1.5.1

STANDARD TIGHTENING TORQUES............................................................................................................................30

1.5.2

METRIC - IMPERIAL UNIT CONVERSION...................................................................................................................31

6

1.1

GENERAL INSTRUCTIONS AND SAFETY NOTICE

1.1.1 FOREWORD This chapter deals with the general instructions and safety notice during inspection and maintenance work. Other instructions and warnings are indicated in each chapter concerned.

In order to reduce accident risks, make sure to: -

Read, understand, and follow all the instructions in the machine operation and maintenance manual.

Treat this manual as part of the machine and must be found in all the machines.

Follow all the safety instructions in this publication.

Do not start any job until that you are sure that you and those around you will be safe.

Use the appropriate tools to do any work.

Use the original Manitou spare parts.

Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily harm and even death.

An efficient, dependable and profitable combination will be formed if the operator follows the safety manual correctly and the machine is serviced properly.

1.1.2 SERVICING POSITION Before any intervention: 1.

2.

3.

4.

Park the machine on a flat surface and chock the wheels.

Turn off the engine and remove the ignition key.

Let the machine cool down.

Release all the pressure out of the circuits concerned.

7

1.1.3 EXPLANATION OF SYMBOLS The symbols shown below are used to warn of potential hazards as well as to provide useful information concerning a procedure.

DANGER

Indicates an imminent hazardous situation which, if not avoided will result in death or serious injury.

!

WARNING

Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury.

!

CAUTION

!

!

Indicates a potentially hazardous situation which, if not avoided, may result in minor injury or damage to property. It is also used to warn users of unsafe practices.

Indicates any additional instructions to follow while performing a procedure.

NOTE

Indicates a tip to facilitate the performance of a procedure.

TIP

Indicates a ,essage to draw attention to important information regarding environmental protection.

PROTECT THE ENVIRONMENT Indicates special tools for performing a task.

SPECIFIC TOOLING

“SEE”: Indicates a cross-reference to a manual.

“SEE”: Indicates a cross-reference to a page.

“SEE”: Indicates a cross-reference to a picture.

“WEIGHT”: Indicates the weight of an item.

(E.g.:It helps to anticipate an action linkes to a person’s health or the choice of lifting equipment).

“TIGHTENING TORQUE”: Indicates the value of tightening torque to be applied.

“OPTION”: Indicates the presence of an option.

The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions given in the manual are not exhaustive.

At any time, as an operator, you must consider, within reason, the possible risk to yourself, to others or to the machine itself when you repair, service or drive it.

Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other than those specified.

8

1.1.4 SERVICING RULES

Do not carry out any work on the machine unless you have followed a suitable training course and have the knowledge required for it.

Make sure you have taken into consideration all the indicator plates on the machine and in the instruction manual.

! CAUTION Be careful not to burn yourself when touching hot surfaces or fluids when operations have to be done before the machine has had time to cool down.

Wear suitable protective equipment.

! WARNING Before carrying out any operation on an electrically powered component, activate the battery cut-off.

! CAUTION Press the battery switch at least 30 seconds after disconnecting the electrical contact with the ignition key.

! WARNING Since the machine has ECUs and other electronics it is necessary to instruct the disconnection of negative cable first. ! CAUTION Before carrying out any welding operations, think of disconnecting computers. ! CAUTION A machine operating in a contaminated environment should be specifically equipped. Moreover, local safety notices deal with maintenance and repair work on such machines.

9

!

WARNING Do not step on any part of the machine that is not designed for it.

!

WARNING Never wear loose clothes, jewelry or objects that could get caught during work and cause accidents.

Always wear protection glasses, gloves, safety shoes as well as any other protection required for the work to be carried out.

!

DANGER

Before you do maintenance operations near a mobile object, make sure it is correctly secured.

PROTECT THE ENVIRONMENT When changing, or draining oils or fuel, or any other operation with liquids, solids, gases that are harmful to the environment, make sure the necessary precautions are taken to avoid contaminating the environment.

10

!

DANGER When lifting or shoring a component of the machine, make sure the equipment used is suitable for at least the loadfor which it is subjected by the component and that it meets the national standards for liftingdevices.

When using a jack, make sure it is used on a flat, uniform surface,issturdyenoughtosupporttheload,thatitslifting capacity is sufficient and that it is correctly placed and positioned under themachine.

!

CAUTION Make sure no object or tool which could cause an accident is left in the machine.

!

WARNING

Fine jets of fluid at high pressure can penetrate the skin.

Keep the face, hands, and other body parts away from the fluids under high pressure.

Wear the protective glasses and gloves.

!

CAUTION Never adjust a component to over the maximum capacity indicated by the manufacturer.

11

1.2. GENERAL INSTRUCTIONS AND SAFETY NOTICES 1.2.1 GENERAL SPECIFICATIONS Designation

Unit

Machine weight with standard attachment

Kg

11275

Overhaul length of fork carriage

M

6.2

Maximum lifting capacity

Kg

4000

Maximum lifting height

M

17.4

Designation

Type

Qty (Lts.)

Fuel tank

Gnr Hp (High-Performance Non-Road Diesel): En590 / Astm D975

78.5

Engine oil

Manitou Evology Oil 10W/40, API, CJ4

11.5

Radiator coolant

Cooling liquid (protection -35°C)

16

Gearbox

MANITOU Automatic transmission oil

15

Hydraulic tank

MANITOU ISO VG46 Hydraulic Oil

120

Brake system

MANITOU Mineral Brake Fluid

0.75

Air-conditioning System

R134a Gas

0.7

Axle differentialSpecial

MANITOU oil for immersed brake

8

Wheel reduction gear

MANITOU SAE 85W90 Mechanical Transmission oil

1.5

Lubrication of pins and pivots

MANITOU Blue multi-purpose grease

AR

Boom pad lubrication

MANITOU Blue multi-purpose grease

AR

LUBRICANTS AND FUEL

ENGINE Type

1104D-44T

Fuel

Diesel

Number of cylinders

4-in line

Suction

Turbocharged

Type Of Combustion

ChamberDirect

Ignition sequence

1342

Capacity ( CC)

4400

Bore and stroke (MM)

105 X127

Compression ratio

18.2:1

Min. rpm

800+/-50

Max. rpm

2200+/-50

Max. Net Power

70KW

Maximum torque

392 Nm @ 1400 RPM

Type of cooling

Liquid

Fan

Sucker, Plastic, 20”

Max. Fan Speed

2300 RPM

Lubrication System

Forced

12

BRAKING CIRCUIT Service brake

Hydraulic servo-brake, applied on the front and rear wheels

Type of brake

Multi-disc brake immersed in oil

Type of control

Foot controlled pedal

Parking brake

Mechanical hand lever applied on the front wheels

Type of brake

Multi-disc brake immersed in oil

Type of control

Hand controlled lever

ELECTRICAL CIRCUIT Battery

12V-130AH

Alternator

12V-75A

Starter

12V-3 KW

TRANSMISSION Type

TURNER POWERTRAIN SYSTEMS

Torque converter

SACHS

Gear box Number of forward speeds

4

Number of reverse speeds

4

Gear reverser

Electro-hydraulic

Front axle Type

DANA

Hub reducer

Epicyclic

Differential

Limited slip 45%

Rear axle Type

DANA

Hub reducer

Epicyclic

Differential

No Lock

Front tyres Size

400/70-20

Pressure

4.5 Bar

Rear tyres Size

400/70-20

Pressure

4.5 Bar

13

HYDRAULIC CIRCUIT Lifting, Tilting ,Telescoping & attachment circuit

250 Bar

Steering circuit

145 Bar

Braking Circuit

30-80 Bar

Type of pump

Gear

Flow rate at 2200 rpm

96.7

Braking Circuit Type of pump

Gear

Flow rate at 2200 rpm

11

Hydraulic Movements Maximum Speed of Travel Forward Unladen (km/h)

28

Rated Load (km/h)

9

Reverse Unladen (km/h)

28

Rated Load (km/h)

9

Standard Lift height (mm)

17400

Rated capacity with standard equipment (Kg)

4000

Load Center (mm)

500

Weight of forks (Each) (Kg)

114

Unladen time Lifting (sec)

13.6

Lowering (sec)

9.4

Extension (sec)

25

SPECIFICATIONS & WEIGHT Telescopic Motions (Lifting jib) Extending of telescope Unladen (sec)

25

Extending of telescope laden (sec)

-

Retracting of telescope Unladen (sec)

14.1

Retracting of telescope laden (sec)

-

Reverse tilt time unladen (sec)

4.1

Forward tilt time unladen (sec)

3.2

Truck weight with standard equipment Unladen (kg)

11275

Rated load (kg)

15275

Axle weight with standard equipment (Transport position) Front unladen (kg)

5560

Rated load (kg)

13760

Rear unladen (kg)

5715

Rated load (kg)

1515

FRONT AND REAR TYRES Dimensions

Pressure Transport

400/70-20 AT621 16PR TUBELESS BKT

4.0 BAR

Loading 5.0 BAR

14

Tyre Load Laden FRONT- 6700 KG REAR- 900KG

Unladen FRONT- 2650 KG REAR- 2950 KG

1.2.2 DIMENSION AND LOAD CHARTS

SIDE VIEW

REAR VIEW

FRONT VIEW

DIMENSIONS B1

2.38

B4

0.85

H17

2.59

L2

6.2

Y

2.9

M4

0.38

All dimensions are in meters.

15

LOAD CHARTS

16

LOAD CHARTS - ON STABILIZERS

17

1.2.3 LUBRICANTS AND FUEL

IMPORTANT USE THE RECOMMENDED LUBRICANTS AND FUEL: - For topping up, oils may not be miscible.

- For oil changes, MANITOU oils are perfectly appropriate.

DIAGNOSTIC ANALYSIS OF OILS If a service or maintenance contract has been set up with the dealer, a diagnostic analysis of engine, transmission and axle oils may be requested depending on the rate of use.

RECOMMENDATION ENGINE PART TO BE LUBRICATED

CAPACITY

GRADE

ENGINE

11.5 LTR

MANITOU EVOLOGY OIL 10W40 API CJ4

RADIATOR COOLANT

16 LTR

VALVOLINE COOLANT ALL WEATHER HD-RTU

FUEL TANK

78.5 LTR

• • • •

N590 -Auto/C0/C1/C2/C3/C4 BS2869 ClassA2 ASTM D975-91 Class 2-2DA, US DF1, US DF2, USDFA JIS K2204 (1992) Grades 1, 2, 3 and Special Grade3

TRANSMISSION PART TO BE LUBRICATED

CAPACITY

GRADE

GEAR BOX

15 LTR

VALVOLINE TRANSFLUID III

PART TO BE LUBRICATED

CAPACITY

GRADE

HYDRAULIC TANK

120 LTR

MANITOU ISO VG46 HYDRAULIC OIL

PART TO BE LUBRICATED

CAPACITY

GRADE

BRAKE CIRCUIT

0.75 LTR

MANITOU MINERAL BRAKE FLUID

PART TO BE LUBRICATED

CAPACITY

GRADE

DIFFERENTIAL

8 LTR

SAE 80W/90 (API GL4 OR GL5)

WHEEL REDUCER

2X0.8 LTR

SAE 80W/90 (API GL4 OR GL5)

HYDRAULICS

BRAKES

FRONT AXLE

FRONT WHEEL REDUCING GEAR PIVOTS

MANITOU BLUE MULTI-PURPOSE GREASE

FRONT AXLE OSCILLATION

MANITOU BLUE MULTI-PURPOSE GREASE

REAR AXLE PART TO BE LUBRICATED

CAPACITY

GRADE

DIFFERENTIAL

8 LTR

SAE 80W/90 (API GL4 OR GL5)

WHEEL REDUCER

2X0.8 LTR

SAE 80W/90 (API GL4 OR GL5)

FRONT WHEEL REDUCING GEAR PIVOTS

MANITOU BLUE MULTI-PURPOSE GREASE

FRONT AXLE OSCILLATION

MANITOU BLUE MULTI-PURPOSE GREASE 18

BOOM PART TO BE LUBRICATED

CAPACITY

GRADE

BOOM PAD SLIDE PATHWAYS

MANITOU BLUE MULTI-PURPOSE GREASE

GREASING OF THE BOOM

MANITOU BLUE MULTI-PURPOSE GREASE

BOOM CHAINS

MANITOU BLUE MULTI-PURPOSE GREASE

FRAME PART TO BE LUBRICATED

CAPACITY

STABILIZERS

GRADE MANITOU BLUE MUTLI-PURPOSE GREASE

ATTACHMENT PART TO BE LUBRICATED

CAPACITY

CARRIAGE

GRADE MANITOU BLUE MUTLI-PURPOSE GREASE

AIR CONDITIONING SYSTEM

PART TO BE LUBRICATED

CAPACITY

GRADE

AIR CONDITIONING SYSTEM

0.7 LTR

REFRIGERANT R134a

PART TO BE LUBRICATED

CAPACITY

GRADE

WINDSCREEN WASHER TANK

3 LTR

WINDSHIELD WASHER LIQUID

CABIN

19

1.3

GENERAL LOCATION

1.3.1 NAME AND IDENTIFICATION PLATE As our policy is to promote a constant improvements in our products, our range of telescopic lift trucks may undergo certain modifications, without our obligation to inform our customers.

When you order parts, or when you require any technical information, always specify: NOTE: For the owner’s convenience, it is recommended that a note of these numbers is made in the spaces provided against each component at the time of the delivery of the truck.

LIFT TRUCK MANUFACTURER’S PLATE (FIG.A) 1.

2.

3.

4.

5.

6.

A

Model Serial No. Year of manufacture Machine Mass Manufacturer Standard Reference

I.C. ENGINE (FIG.B1) 1.

B1

I.C. engine No.

GEAR BOX (FIG.C) 1.

2.

3.

C

Type MANITOU reference Serial No

FRONT AXLE (FIG.D) 1.

2.

3.

D

Type MANITOU reference Serial No

20

E

REAR AXLE (FIG.E) 1.

2.

3.

Type Serial No MANITOU reference

F

CAB (FIG. F) 1.

2.

Type Serial No

G

BOOM (FIG. G) 1.

2.

MANITOU reference Date of manufacture

H

FRAME (FIG. H) 1.

Serial No

I

ATTACHMENT MANUFACTURER’S PLATE (FIG. I) 1.

2.

3.

Model Serial No Year of manufacture

21

1.4

MAINTENANCE

1.4.1 GENERAL LUBRICATION To be carried out weekly, if the lift truck has been operated for less than 50 hours during the week.

IMPORTANT In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval to every 10 hours of service or everyday.

Clean, then lubricate the following points with grease (Refer: LUBRICANTS AND FUEL) and move the surplus.

BOOM 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Lubricators of the boom axle (2lubricators).

Lubricators of the carriage axle (2lubricators).

Lubricator of the tilt cylinder foot axle (1 lubricator).

Lubricator of the tilt cylinder head axle (1lubricator).

Lubricator of the lifting cylinder foot axle (1 lubricator).

Lubricator of the lifting cylinder head axle (1lubricator).

Lubricator of the compensation cylinder foot axle (1 lubricator).

Lubricator of the compensation cylinder head axle (1 lubricator).

Lubricator of the chain pulley axle of telescope 2 at the boom head (1 lubricator).

Lubricator of the chain pulley axle of telescope 1 at the boom head (1 lubricator).

Lubricator of the chain pulley axle of telescope 1 at the boom foot (1 lubricator).

Lubricator of the hose pulley axle at the boom foot (1 lubricator).

FRONT AND REAR WHEEL REDUCTION GEAR PIVOTS 13. Lubricators of the wheel reduction gear pivot pins (8lubricators).

STABILISERS 14. Lubricators of the stabilizer cylinders’ foot axle (2 lubricators).

15. Lubricators of the stabilizer cylinders’ head axle (2 lubricators).

16. Lubricators of the stabilizer axles (2 lubricators).

22

23

1.4.2 PERIODIC MAINTENANCE SCHEDULE DAILY AND WEEKLY MAINTENANCE

IMPORTANT

THE OPERATOR IS AUTHORISED TO CARRY OUT THIS MAINTENANCE. These maintenance operations enable the operator to maintain the lift truck in a clean and safe condition.

MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE

IMPORTANT

THIS SERVICE MUST BE CARRIED OUT AFTER THE FIRST 500 HOURS OF SERVICE OR WITHIN THE 6 MONTHS AFTER PUTTING THE MACHINE INTO SERVICE (WHICHEVER OCCURS FIRST).

PERIODIC MAINTENANCE

IMPORTANT

THE PERIODIC MAINTENANCE MUST BE CARRIED OUT BY A PROFESSIONAL APPROVED BY THE MANITOU NETWORK.

MAINTENANCE SCHEDULE

This schedule enables the operator to keep up with the periodic service of the lift truck by notifying the total number of hours of operation and the date of the service performed by the professional approved by the MANITOU network.

OCCASIONAL MAINTENANCE AND OPERATION

These maintenance tasks and operations are to be performed as required for the safety and upkeep of the lift truck.

DAILY AND WEEKLY MAINTENANCE

10 H - DAILY SERVICING OR EVERY 10 HOURS OF SERVICE - CHECK

Lift truck environment

- CHECK

Engine oil level

- CHECK

Radiator coolant level

- CHECK

Fuel pre-filter

- CHECK

Longitudinal stability limiter and warning device

- CHECK

Platform environment

- CLEAN

Pre-Cleaner

50 H - WEEKLY MAINTENANCE OR EVERY 50 HOURS OF SERVICE - CHECK

Gear box oil level

- CHECK

Tyre pressures

- CHECK

Wheel nut tightening

- CHECK

Front axle differential seal

- CHECK

Rear axle differential seal

- CHECK

Front wheel reducer seals

- CHECK

Rear wheel reducer seals

- CHECK

Brake fluid level

- CHECK

Boom pad slide pathways

- CHECK

Hydraulic oil level

- CHECK

Windscreen washer liquid level

- CLEAN

Radiator core

- CLEAN

Air filter primary

- CLEAN

Condenser harness (Air conditioning OPTION)

- LUBRICATE

General lubrication 24

MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE FIRST 500 HOURS BEFORE THE FIRST 6 MONTHS If the lift truck has reached the first 500 hours of service before the first 6 months have expired, perform both the mandatory service and routine 500 H service (Refer: 500 H - ROUTINE SERVICING - EVERY 500 HOURS OF SERVICE OR 1 YEAR).

FIRST 6 MONTHS BEFORE THE FIRST 500 HOURS If the lift truck has not completed 500 hours of service in the first 6 months, just carry out the mandatory service.

MANDATORY SERVICE - CHECK

Gear box oil level

- CHECK

Tyre pressures

- CHECK

Wheel nut tightening

- CHECK

Front axle differential seal

- CHECK

Rear axle differential seal

- CHECK

Front wheel reducer seals

- CHECK

Rear wheel reducer seals

- CHECK

Brake fluid level

- CHECK

Boom pad slide pathways

- CHECK

Hydraulic oil level

- CHECK

Windscreen washer liquid level

- CLEAN

Radiator core

- CLEAN

Air filter primary

- CLEAN

Condenser harness (Air conditioning OPTION)

- LUBRICATE

General lubrication

- CHECK

Alternator belt tension

- CHECK

Compressor belt tension (Air conditioning option)

- CHECK

Tension of boom outer chains

- CLEAN

Boom outer chains

- CHECK

Fork wear*

- CHECK

Safety belt

- CHECK

Engine mountings/Isolators*

- CHECK

Valve lash*

- CHECK

Gear box mountings/Isolators*

- CHECK

Gear box controls*

- CHECK

Brake system pressure*

- CHECK

Boom pad wear*

- CHECK

Condition of wiring harnesses and cables*

- CHECK

Lights and signals*

- CHECK

Warning indicators*

- CHECK

Condition of the rear view mirrors*

- CHECK

Cabin structure*

- CHECK

Frame structure*

- CHECK

Attachment carriage *

- CHECK

Condition of attachments* *Consult your dealer.

25

PERIODIC MAINTENANCE MAINTENANCE SCHEDULE

OR WHEN DUE PERIODIC MAINTENANCE

250 H

FIRST 6 MONTHS

FIRST 500 HOURS

500 H or 1 YEAR

750 H

1000 H or 2 YEARS

1

MANDATORY SERVICE

MANDATORY SERVICE + 2

1+2

1

1 +2 + 3

MACHINE COUNTER DATE OF SERVICING WHEN DUE PERIODIC MAINTENANCE

1250 H

1500 H or 3 YEARS

1750 H

2000 H or 4 YEARS

2250 H

2500 H or 5 YEARS

2750 H

1

1+2

1

1+2+3+4

1

1+2

1

MACHINE COUNTER DATE OF SERVICING WHEN DUE PERIODIC MAINTENANCE

3000 H or 6 YEARS

3250 H

3500 H or 7 YEARS

3750 H

4000 H or 8 YEARS

4250 H

4500 H or 9 YEARS

1+2+3+4

1

1+2

1

1+2+3+ 4+5

1

1+2

MACHINE COUNTER DATE OF SERVICING WHEN DUE PERIODIC MAINTENANCE

4750 H

5000 H or 10 YEARS

5250 H

5500 H or 11 YEARS

5750 H

6000 H or 12 YEARS

6250 H

1

1+2+3+4

1

1+2

1

1+2

1

MACHINE COUNTER DATE OF SERVICING

250 H - ROUTINE SERVICING - EVERY 250 HOURS OF SERVICE CHECK

Alternator belt tension

CHECK

Compressor belt tension (Air conditioning option)

CHECK

Tension of boom outer chains

CLEAN

Boom outer chains

26

500 H - ROUTINE SERVICING - EVERY 500 HOURS OF SERVICE OR 1 YEAR - CHECK

Hydraulic oil

- REPLACE

Hydraulic return oil filter

- REPLACE

Engine oil

- REPLACE

Engine oil filter

- REPLACE

Gear box oil filter

- REPLACE

Aircon filters

- CHECK

Fork wear*

- CHANGE

Front and Rear axle differential oil

- CHANGE

Front and Rear wheel reducer oil

*Consult your dealer.

1000 H - ROUTINE SERVICING - EVERY 1000 HOURS OF SERVICE OR 2 YEARS ALSO PERFORM THE 500 HOUR PERIODIC MAINTENANCE OPERATIONS. - CHECK

Boom outer chain wear

- CHECK

Safet ybelt

- REPLACE

Air filter primary**

- REPLACE

Fuel filter primary

- REPLACE

Fuel filter secondary

- REPLACE

Coolant

- REPLACE

Gear box oil

- REPLACE

Gear box oil filter

- CHECK

Engine mountings/Isolators*

- CHECK

Valve lash*

- CHECK

Gear box mountings/Isolators*

- CHECK

Gear box controls*

- CHECK

Brake system pressure*

- CHECK

Boom pad wear*

- CHECK

Condition of wiring harnesses and cables*

- CHECK

Lights and signals*

- CHECK

Warning indicators*

- CHECK

Condition of the rear view mirrors*

- CHECK

Cabin structure*

- CHECK

Frame structure*

- CHECK

Attachment carriage *

- CHECK

Condition of attachments*

- REPLACE

Brake fluid*

- BLEED

Brake circuit*

- ADJUST

Brake* * Consult your dealer. ** Can be replaced before the scheduled time depending upon the condition.

27

2000 H - ROUTINE SERVICING - EVERY 2000 HOURS OF SERVICE OR 4 YEARS ALSO PERFORM THE 500 HOUR AND 1000 HOUR PERIODIC SERVICE OPERATIONS. - CHECK

Wheel nut tightening torques

- CLEAN

Air conditioning (OPTION)*

- REPLACE

Air filter secondary element**

- REPLACE

Hydraulic oil

- REPLACE

Breather for the hydraulic oil tank

- CLEAN

Hydraulic oil tank suction strainer

- CLEAN

Fuel tank

- REPLACE

Fuel tank breather

- CHECK

Radiator*

- CHECK

Water pump and thermostat*

- CHECK

Alternator and starter*

- CHECK

Turbocharger*

- CHECK

Transmission pressures*

- CHECK

Steering*

- CHECK

Steering swivel joints*

- CHECK

Condition of boom assembly*

- CHECK

Bearings and bushings of the boom *

- CHECK

Condition of hoses and flexible pipes*

- CHECK

Condition of cylinders (leakage, rods) *

- CHECK

Hydraulic circuit pressures*

- CHECK

Bearings and bushings of the frame* * Consult your dealer. **Can be replaced before the scheduled time depending upon the condition.

4000H - ROUTINE SERVICING - EVERY 4000 HOURS OF SERVICE OR 8 YEARS OCCASIONAL MAINTENANCE AND OPERATION -CHECK

Boom innerchain wear

OCCASIONAL MAINTENANCE - REPLACE

Wheels

- REPLACE

Battery failure

- BLEED

Fuel supply system

- ADJUST

Front headlights

OCCASIONAL OPERATION -TRANSPORT

Lift truck

28

FILTER ELEMENTS AND BELTS 500 H - ROUTINE SERVICING - EVERY 500 HOURS OF SERVICE OR 1 YEAR ENGINE OIL FILTER Part number: 943343

HYDRAULIC RETURN OIL FILTER Part number:53109420

GEARBOX OIL FILTER Part number: 561749

AIRCON FILTER Part number: 53102113

1000 H -ROUTINE SERVICING - EVERY 1000 HOURS OF SERVICE OR 2 YEARS

ALSO ADD FILTER ELEMENTS FOR ROUTINE SERVICING AFTER 500 HOURS OF SERVICE. FUEL FILTER SECONDARY Part number: 962072

AIR FILTER PRIMARY Part number: 53107784

FUEL FILTER PRIMARY Part number: 960328

2000 H - ROUTINE SERVICING - EVERY 2000 HOURS OF SERVICE OR 4 YEARS

ALSO ADD FILTER ELEMENTS FOR ROUTINE SERVICING AT 500 HOURS AND 1000 HOURS OF SERVICE. BREATHER FOR THE HYDRAULIC OIL TANK Part number: 53108391

AIR FILTER SECONDARY Part number: 53108391

FUEL TANK BREATHER Part number: 53108789

OCCASIONAL MAINTENANCE PRE-CLEANER Part number: 10X1942

ALTERNATOR BELT Part number : 962060

SUCTION STRAINER FOR HYDRAULIC OIL TANK Part number: 3515254M1

COMPRESSOR BELT (AIR CONDITIONING OPTION) Part number: 53102411

GEAR BOX SUCTION STRAINER Part number : 943807

29

1.5

GENERAL CONTROL AND ADJUSTMENTS

1.5.1 STANDARD TIGHTENING TORQUES STANDARD TIGHTENING TORQUE TO USE WHEN IT IS NOT GIVEN IN THE DISMANTLING AND REMOUNTING INSTRUCTION

•

TIGHTENING TORQUE IN N.m (*) Thread Ø

Class 5.6

Class 5.8

Class 8.8

Class 10.9

Class 12.9

M3

0,54

0,76

1,16

1,7

2

M4

1,24

1,74

2,66

3,91

4,57

M5

2,47

3,46

5,2

7,7

9

M6

4,29

6

9,1

13,4

15,7

M8

10,4

14,6

22

32

38

M10

20

28

44

64

75

M12

35

49

76

111

130

M14

57

79

121

178

209

M16

88

124

189

278

325

M18

122

171

261

384

449

M20

173

243

370

544

637

M22

238

334

509

748

875

M24

298

418

637

936

1095

M27

442

619

944

1386

1622

M30

600

840

1280

1880

2200

30

•

•

Tightening torques are given for black or galvanized fittings with light lubrication.

Tightening torques are given for automatically triggered and reset torque wrenches and direct display torque wrenches.

For further information, see standard NFE25-030.

1.5.2 METRIC - IMPERIAL UNIT CONVERSION RULES The tolerance has the same unit as the value and is not a percentage : Example : 120 ± 12 Ω , not 120 ± 10 %.

The unit is separated from the value by a space and placed after the tolerance : Example : 120 Ω or 120 ± 12 Ω except for angle degrees : 40° or 40 ± 3°.

The conversion of some marks is not possible : Example : thread of a screw : M12x1.75.

Use decimals to convert precise values : Example : 190 mm = 7.48 In. Write lengths in feet-inches format : Example : 20 m = 65 ft 7.4 in or in a table 20 (m) = 65-7.4 (ft-in).

CONVERSION COEFFICIENTS Metric Unit (S.I.)

Coefficient

Imperial Unit US

°C (celsius degree) x 1.8 + 32 = °F (Fahrenheit degree) cm3 (centimeter cube) x 0.06102 = cu.in. (Cubic inches) cv (chevaux vapeur) x 0.9859 = hp (Horsepower) bar (bar) x 14.51 = psi (Pound-force/square inch) g (gram) x 0.0353 = oz (Ounces) kg (kilogram) x 2.2046 = Ib (Pound) km/h (kilometer per hour) x 0.6214 = mph (Miles per hour) kw (kilowatt) x 1.34048 = hp (Horsepower) l (litre) x 0.2642 = gal US (US gallon) l (litre) x 1.0567 = qt US (quart US gallon) m (meter) x 3.2808 = ft (Foot) m (meter) x 39.37 = in (Inch) ml (millilitre) x 0.0338 = fl oz (Fluid ounce) mm (millimeter) x 0.03937 = in (Inch) μm (micrometer) x 0.03937 = mil )Thousands of an inch) N (Newton) x 0.2248 = lbf (Pound-force) N-m (Newton meter) x 0.7376 = ft-lb (Pound-force-foot) rad/s (radian/second) x 9.5493 = rpm (Revolution per minute) t (metric ton) x 2204.62 = lb (Pound) tr/min (tour per minute) x 1 = rpm (Revolution per min)

Other unit conversions

Coefficient

Imperial Unit US

ft (foot) x 12 = in (Inch) lb (pound) x 16 = oz (Ounces) m (meter) x 1000 = mm (Millimeter) μm (micrometer) x .001 = mm (Millimeter) t (metric ton) x 1000 = kg (kilogram) ° (angle degree) X 0.01745 = rad (Radian)

31

Intentionally Left Blank 32

ENGINE

1

Intentionally Left Blank 2

TABLE OF CONTENTS 10.1

ENGINE COMPONENTS LOCATION................................................................................................................ 4 10.1.1

10.2

10.3

TIGHTENING TORQUES................................................................................................................................. 5 10.2.1

SILENT BLOCK TIGHTENING TORQUES ............................................................................................................................... 5

10.2.2

DIESEL CIRCUIT TIGHTENING TORQUES.............................................................................................................................. 5

10.2.3

COOLING CIRCUIT TIGHTENING TORQUES........................................................................................................................ 6

10.2.4

EXHAUST CIRCUIT TIGHTENING TORQUES........................................................................................................................ 6

AIR INTAKE SYSTEM - REMOVAL AND INSTALLATION................................................................................. 7 10.3.1

10.4

10.7

10.6.1

COMPONENT LOCATION.......................................................................................................................................................... 9

10.6.2

PREPARATION AND SAFETY INSTRUCTIONS...................................................................................................................10

FUEL CIRCUIT - REMOVAL AND INSTALLATION.......................................................................................... 11

PREPARATION AND SAFETY INSTRUCTIONS...................................................................................................................15

ENGINE - REMOVAL..................................................................................................................................... 17 10.9.1

10.10

PREPARATION AND SAFETY INSTRUCTIONS...................................................................................................................11

COOLING SYSTEM - REMOVAL AND INSTALLATION.................................................................................. 15 10.8.1

10.9

PREPARATION AND SAFETY INSTRUCTIONS..................................................................................................................... 9

EXHAUST SYSTEM - REMOVAL AND INSTALLATION.................................................................................... 9

10.7.1 10.8

PREPARATION AND SAFETY INSTRUCTIONS..................................................................................................................... 8

ATTACHMENT BELT - REMOVAL AND INSTALLATION................................................................................... 9 10.5.1

10.6

PREPARATION AND SAFETY INSTRUCTIONS..................................................................................................................... 7

STARTER MOTOR - REMOVAL AND INSTALLATION...................................................................................... 8 10.4.1

10.5

ENGINE COMPONENTS............................................................................................................................................................. 4

PREPARATION AND SAFETY INSTRUCTIONS...................................................................................................................17

ENGINE - INSTALLATION............................................................................................................................. 19

3

10.1 ENGINE COMPONENTS LOCATION 10.1.1 ENGINE COMPONENTS 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Accelerator Connector Flywheel Housing Engine Lifting Hook Turbocharger outlet Turbocharger inlet Starter Belt Crank Pulley Oil Filler Dipstick

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Alternator Pressure Switch FAN Adaptor Oil Filter Breather Pipe Oil Sump Water Temperature Switch Fuel Injection Pump Engine Outlet (RadiatorHose) Engine Inlet (Radiator Hose)

4

13 7

8 2

3 19 5 1 17 9

15 11

18 10

20 12

6 14

16

4

10.2 TIGHTENING TORQUES 10.2.1 SILENT BLOCK TIGHTENING TORQUES

USE LOCTITE 262 TORQUE TO 50 NM SUPPLIED WITH ENGINE TORQUE TO 87 NM

USE LOCTITE 262 TORQUE TO 102 TORQUE TO 102 NM

10.2.2 DIESEL CIRCUIT TIGHTENING TORQUES

TORQUE TO 5 NM

TORQUE TO 40 NM TORQUE TO 2.5-3.5 NM

TORQUE TO 10 NM

TORQUE TO 20 NM

TORQUE TO 20 NM

TORQUE TO 40 NM

TORQUE TO 20 NM

TORQUE TO 85 NM

5

10.2.3 COOLING CIRCUIT TIGHTENING TORQUES TORQUE TO 20 NM TORQUE TO 95 NM TORQUE TO 5 NM

TORQUE TO 20 NM

TORQUE TO 20 NM TORQUE TO 69 NM

TORQUE TO 90 NM

TORQUE TO 130 NM TORQUE TO 20 NM

TORQUE TO 69 NM

TORQUE TO 120 NM TORQUE TO 95 NM TORQUE TO 5 NM TORQUE TO 95 NM TORQUE TO 102 NM

TORQUE TO 20 NM CONNECTION A

CONNECTION B

TORQUE TO 20 NM

10.2.4 EXHAUST CIRCUIT TIGHTENING TORQUES

TORQUE TO 20 NM

TORQUE TO 20 NM TORQUE TO 20 NM

6

10.3 AIR INTAKE SYSTEM-REMOVAL AND INSTALLATION 10.3.1 PREPARATION AND SAFETY INSTRUCTIONS • • • •

Stabilize the machine on level ground, fully retract the boom, place transmission control lever in neutral position.

Ensure the engine is Shut OFF. Disconnect the battery.

Unlock the Latch (1) and Open the Hood (2) .

1

2

•

Remove the Side Cover (3).

3

•

Remove the Worm Drive Clip Composite (5) and uninstall the Hose-Air Intake (6).

5 6

•

Unscrew the Mudguard Screws (7) and loosen or remove the Mudguard (8).

8

7 7

7

7

7

•

Uninstall the Hex Bolts (9) from the Air Intake Bracket (10).

9

10

9

9

• •

Disconnect all electrical connections.

Remove the Air Intake System (11) using proper lifting aid.

11

•

Installation is the reverse of removal procedure.

10.4 STARTER MOTOR - REMOVAL AND INSTALLATION 10.4.1 PREPARATION AND SAFETY INSTRUCTIONS • • • •

Stabilise the machine on level ground, fully retract the boom, place transmission control lever in neutral position.

Ensure the engine is ShutOFF. Disconnect thebattery.

Open engine cover. Allow system fluids to cool.

1 2

• • • •

Remove all electrical connections from theStarter (2).

Uninstall the Hex Bolts(1) on the engine.

Remove theStarter (2).

Installation is the reverse of removal procedure.

8

10.5 ACCESSORY BELT - REMOVAL AND INSTALLATION 10.5.1 PREPARATION AND SAFETY INSTRUCTIONS • • • • •

Stabilise the machine on level ground, fully retract the boom, place transmission control lever in neutral position.

Ensure the engine is Shut OFF. Disconnect the battery.

Open engine cover. Allow system fluids to cool.

Pull the belt by hand to release it, continue turning and remove the Belt (1).

1

•

Installation is the reverse of removal procedure.

10.6 EXHAUST SYSTEM - REMOVAL AND INSTALLATION 10.6.1 COMPONENT LOCATION

9

10.6.2 PREPARATION AND SAFETY INSTRUCTIONS • • • • •

Stabilise the machine on level ground.

Retract the Boom fully and lower it.

Engage Parking Brake.

Ensure the engine is Shut OFF. Disconnect the battery.

!

NOTE Open engine cover, allow hot oils and fluids to cool down to room temperature.

•

Unscrew the Hex Nut (1) and the Hex Bolt (2) and uninstall the U Clamp (3) from the Exhaust Silencer (4).

4 3 1

• • • • • • • • • • • • • • •

2

Uninstall the 4 Hex Head Bolts (5), the 4 Washers (6) and the 4 Hex Nuts (7) from the Supporting Bracket (8).

6

7

9

5 8

Slide up the Exhaust Silencer(4) from the Exhuast Tube Flexible(9,F10-11) using proper lifting aid.

4

10

• •

Uninstall the 2 Hex Bolts(10), the 4 Washers(11) and the 2 HexNuts(12).

Remove the Exhuast Tube Flexible(9) from theEnigne(13).

13

12 11

10

11

9

• •

Uninstall the Hex Bolts (14), the Washers (15) and the Hex Nuts (16) on the LH Rear Fender side.

Remove the Exhuast Tube Flexible (9).

9

15

14 16

•

Installation is the reverse of removalprocedure.

10.7 FUEL CIRCUIT - REMOVAL AND INSTALLATION 10.7.1 PREPARATION AND SAFETY INSTRUCTIONS • • •

Stabilise the machine on level ground, fully retract the boom, place transmission control lever in neutral position.

Ensure the engine is Shut OFF. Disconnect the battery.

! CAUTION Hot oils and fluids must be left to cool down before performing any disassembly procedure. !

NOTE The fuel must be drained before tank removal. Always dispose of fuel properly.

•

Remove the Hood (1).

1

11

• • • •

Remove the Weldment Side Cover (2).

Uninstall the Hex Bolts (3) and Washers (4).

Remove the Fuel Filler Cap (5).

Uninstall the Weldment-Fuel (6).

2

5

6 3 4

•

Uninstall the Worm Drive Clip Composite (7) and uninstall the Fuel Hose (8).

7

7

8

• • • • •

Uninstall the Air Intake Sytem. Refer Air Intake Sytem removal for procedure.

Uninstall the Assembly HOC. Refer Assembly HOC removal for Procedure.

Unscrew the Bolt (9) and the P - Clamp (10).

Uninstall the Bolt (11) and the Twin Clamp (12).

Uninstall the Worm Drive Clip Composite (13) and remove the Hose Return (14).

9 10

11

14

12 13

• • •

Uninstall the Hose- Fuel Tank (15) from the Mud Separator (16).

Uninstall the Worm Drive Clip Composite (17).

Remove the Hose Fuel Tank (15).

15

16

17

12

•

Uninstall the Hose - Mud Separator (18) at the feed pump side and at the Mud Separator side.

18

• •

Uninstall the 4 Hex Head Bolts (19) and 4 Washers (20) from the MTG. Bracket - Water Separator (21).

Remove the Mud Separator (16).

21

19 20

16

•

Uninstall the Hose Filter to FIP (22) and Hose Feed Pump to Filter(23) from the Fuel Filter (24).

23

22

•

24

Uninstall the Bolts, Washers and Nuts (25) from the Plate Fuel Filter Mount (26) and remove the Fuel Filter (24).

26

25

24

13

• •

Uninstall the Hex Bolts (27) and the Washers (28).

Remove the Fuel Sensor (29) from the Fuel Tank (30).

29 27 28

30

•

Uninstall the Hex Bolts (31) and the Washers (32) from the Fuel Tank (30)

31 30

• • •

32

Uninstall the Hex Bolts, the Washers and the Nuts (33) from the Chassis.

Uninstall the Hex Bolts, the Washers and the Nuts (34) from the Chassis.

Remove the Fuel Tank Using a proper lifting aid.

34

33

!

NOTE If a leak is suspected in the fuel tank, contact MANITOU Service Department. !

NOTE The fuel tank is a one-piece unit and cannot be disassembled.

Installation of the Fuel Circuit is the reverse of the removal procedure.

14

10.8 COOLING SYSTEM - REMOVAL AND INSTALLATION 10.8.1 PREPARATION AND SAFETY INSTRUCTIONS • • •

Stabilise the machine on level ground, fully retract the boom, place transmission control lever in neutral position.

Ensure the engine is Shut OFF. Disconnect the battery.

!

NOTE Hot oils and fluids must be left to cool down before carrying out the uninstallation procedure. ! CAUTION Before considering radiator or oil cooler replacement for other than obvious damage, conduct a cooling system pressure test check the coolant specific gravity, coolant level, fan belt tension and dash panel temperature indicator.

• •

Unscrew the Bolts - Washers (1) and remove the license plate (2).

Unscrew the Bolts - Washers (3) and uninstall the Grill (4).

4

3 2

1

•

Uninstall the Hex Socket Head Screw - Washers (5) and remove the Towing Hook (6).

5 7

•

6

Uninstall the Counterweight (7).

7

15

•

Uninstall the following hoses on the radiator:

!

NOTE Unintall the respective clamps prior to removal of the following hoses from the Radiator.

Cut the Cabie Ties. Use new Cable Ties while installation.

1.

2.

3.

4.

5.

6.

Hose - Gear Box To Radiator IN (8) Hose - Gear Box To Radiator Out (9) Hose - Lower Rad (10) Hose - Hvac Upper Rad (11) Weldment - Cac Upper(12) Pipe Cac IN (13)

11

12

8

10 9

\ • • • •

13

Disconnect the Rad Hose to expansion tank (14).

Uninstall the Over flow hose (15).

Uninstall the Clamp (16).

Remove the Expansion Tank (17) from the chassis.

!

NOTE Disconnect all electrical connections.

15

16

17

14

• •

Uninstall the Hex Bolts (18) from the Radiator Mounts (19).

Uninstall the Hex Bolts (20) from the base of the radiator.

! CAUTION Take help of an assistant for removal of Radiator from chassis.

18 19

20

18 19

20

16

•

Loosen the Gear Pump Assembly (21) and release it down to allow Radiator assembly to pass through the cut out provided on the chassis.

! CAUTION Provide support at the bottom of Gear Pump assembly on the chassis to avoid falling down.

21

• •

Manoeuvre the radiator assembly out of the chassis through the cut out.

Installation is the reverse of removal procedure.

10.9 ENGINE - REMOVAL 10.9.1 PREPARATION AND SAFETY INSTRUCTIONS • • • • • • • •

Stabilise the machine on level ground, fully retract the boom, place transmission control lever in neutral position.

Ensure the engine is Shut OFF. Disconnect the battery.

Open engine cover. Allow system fluids to cool.

Uninstall and remove the Air Intake System. Refer Air Intake System removal for procedure.

Uninstall and remove the Exhaust System. Refer Exhaust System removal for procedure.

Disconnect Fuel lines from the Engine.

Disconnect all electrical connections from the Engine.

!

NOTE Fuel pipes and Electrical cables must be disconnected, capped (If the end is open) and labelled.

!

NOTE Remove the Heater Hoses attached to the engine (if equipped.

• •

Drain and remove the radiator assembly. Refer Cooling System removal for procedure.

Label and disconnect all electrical wire connections on the engine.

! CAUTION Engine harness is routed and attached to engine using hold-down clamps and plastic wire ties at various places on engine. Before removing engine, ensure that harness has been completely separated (disconnected) from engine. Move harness clear of engine, and with help of an observer, ensure that engine clears harness during removal.

17

• •

Secure the engine with a lifting strap or chain from the appropriate lifting points. Use a suitable hoist or overhead crane.

Unscrew the Bolts-Washers (1) from the Engine mounts(3) on both LH and RH side.

1

3

• •

Engine lifting point 4 & 5.

Engine weigh tis approximately 400 kg.

4

5

•

Remove Hex Head Bolts - Washers (2) securing engine mounts (3).

! WARNING Place a support or jack under transmission to hold transmission in place while engine is being removed.

2

3

2 3

•

Removethe12 Hex Bolts (4) holding the Gear Box Assembly to the Engine.

4

18

• •

Slightly lift and pull engine out of machine, ensure that engine clears all frame components during removal.

Place engine on a flat, level surface.

10.10 • •

ENGINE -INSTALLATION

Secure the engine with a lifting strap or chain from the appropriate lifting points. Use a suitable hoist or overhead crane.

Install the Engine Mounts on both RH and LH side on to the Engine with Bolts and washers.

!

NOTE Apply Loctite 242 to mount bracket bolt threads before installation.

• • • •

Lift engine and slowly push and lower into engine bay, ensure that engine clears frame, hose and harness components during engine installation.

Position the Engine Mounts (3) on both LH and RH sides over the Transmission Isolator (5).

Install the Hex Head Bolts- Washers (2) on to the Engine Mounts (3).

Push engine towards the Gear Box Assembly aligning with the corresponding holes and install the 12 Hex Bolts (4) and washers.

!

NOTE Guide Studs can be used to align the holes of Engine and Gear Box Assembly.

2

3

• • • • • • • •

5

Install the Exhaust System.

Install the Air Intake System.

Connect the Fuel lines to the Engine.

Install Cooling System.

Reconnect the Battery.

Install the engine cover and adjust.

Check that all hydraulic system, electrical system, cooling system, fuel system and exhaust system connections are correct and connected appropriately.

Start the engine and run to normal operating temperature then shut off engine. While engine is cooling, check for leaks.

! CAUTION Keep a Class B fire extinguisher handy.

• • • • • •

Allow engine to cool. Check radiator coolant level and add coolant if required. Replace pressure cap.

Check for leaks from engine, main hydraulic pump and lines, gear box assembly, hydraulic reservoir and fuel tank. Check the levels of all fluids and lubricants. Fill as required.

Obtain and connect an appropriate engine analyzer or tachometer. Check engine rpm at full throttle.

Purge hydraulic system of air by operating all boom functions through their entire range of motion several times. Check hydraulic oil level.

Check for proper operation of all components.

Turn OFF the Engine.

19

Intentionally Left Blank 20

TRANSMISSION

Intentionally Left Blank 1

TABLE OF CONTENTS 20.1

20.2

TRANSMISSION ASSEMBLY................................................................................................................................ 3 20.1.1

COMPONENTS......................................................................................................................................................................3

20.1.2

TRANSMISSION SERIAL NUMBER PLATE............................................................................................................................4

TRANSMISSION REMOVAL AND INSTALLATION............................................................................................... 5 20.2.1

COMPONENT LOCATION.........................................................................................................................................................5

20.2.2

PREPARATION AND SAFETY INSTRUCTIONS....................................................................................................................5

20.3

TRANSMISSION TIGHTENING TORQUES............................................................................................................ 6

20.4

GEAR BOX AND CONVERTER............................................................................................................................ 10

20.5

GEAR BOX (DETAILS)......................................................................................................................................... 11

20.6

GEAR BOX (DETAILS)......................................................................................................................................... 12

20.7

GEAR BOX (MECHANISM DETAILS - GEARS).................................................................................................... 13

20.8

GEAR BOX (MECHANISM DETAILS - GEARS).................................................................................................... 14

20.9

GEAR BOX (ELECTRICAL CONTROL VALVE DETAILS)...................................................................................... 15

20.10

TRANSMISSION HYDRAULIC CIRCUIT............................................................................................................. 16

20.11

DESCRIPTION OF THE TRANSMISSION SHAFT HYDRAULIC CIRCUIT............................................................ 17 20.11.1

CLUTCH CIRCUIT..................................................................................................................................................................... 17

20.11.2

CONVERTER CIRCUIT............................................................................................................................................................. 17

20.11.3

COOLING AND LUBRICATION CIRCUIT............................................................................................................................ 17

20.12

TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT........................................................................................... 18

20.13

TRANSMISSION MAINTENANCE...................................................................................................................... 19 20.13.1

RECOMMANDED LUBRICANTS : GRADE , SPECIFICATION, CLASSIFICATION..................................................... 19

20.13.2

OPERATING TEMPERATURE................................................................................................................................................. 19

20.13.3

OIL AND FILTER CHANGING................................................................................................................................................ 19

20.1.4

CAPACITY (GEAR BOX ONLY).............................................................................................................................................. 19

20.1.5

OIL LEVEL................................................................................................................................................................................... 19

20.14

PRESSURE CHECKING....................................................................................................................................... 20

20.15

PRESSURE READING ON GEARBOX.................................................................................................................. 22

20.16

SPECIAL TOOLS................................................................................................................................................. 23

20.17

SHAFT AND GEAR END FLOAT TOLERANCES.................................................................................................. 24 20.17.1

SHAFT END FLOATS................................................................................................................................................................ 24

20.17.2

GEAR END FLOATS.................................................................................................................................................................. 24

DISASSEMBLY & RE - ASSEMBLY.................................................................................................................................... 25 20.18

GENERAL INFORMATION.................................................................................................................................. 26 20.18.1

TOOLS......................................................................................................................................................................................... 26

20.18.2

CLEANLINESS........................................................................................................................................................................... 26

20.18.3

BEARINGS.................................................................................................................................................................................. 26

20.18.4

REPLACEMENT PARTS........................................................................................................................................................... 26

20.18.5

SEALS.......................................................................................................................................................................................... 26

20.19

TRANSMISSION DIS-ASSEMBLY....................................................................................................................... 27

20.20

INPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY......................................................................................... 32

20.21

20.20.1

DIS-ASSEMBLY......................................................................................................................................................................... 32

20.20.2

RE-ASSEMBLY........................................................................................................................................................................... 32

DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COUNTER SHAFT...................................................................... 36 20.21.1

DIS-ASSEMBLY......................................................................................................................................................................... 36 2

20.21.2 20.22

20.23

20.24

RE-ASSEMBLY........................................................................................................................................................................... 36

DIS-ASSEMBLY AND RE-ASSEMBLY OF THE REVERSE IDLER SHAFT............................................................. 37 20.22.1

DIS-ASSEMBLY......................................................................................................................................................................... 37

20.22.2

RE-ASSEMBL...........................................................................................................................................................................Y37

OUTPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY...................................................................................... 38 20.23.1

DIS-ASSEMBLY......................................................................................................................................................................... 38

20.23.2

RE-ASSEMBLY........................................................................................................................................................................... 40

PERMANENT 4 WHEEL SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY............................................................... 42 20.24.1

DIS-ASSEMBLY......................................................................................................................................................................... 42

20.24.2

RE-ASSEMBLY........................................................................................................................................................................... 42

20.25

DIS-ASSEMBLY AND RE-ASSEMBLY OF THE OIL PUMP.................................................................................. 43

20.26

DIS-ASSEMBLY AND RE-ASSEMBLY OF THE VALVE........................................................................................ 44

20.27

GEAR LEVER HOUSING DIS-ASSEMBLY AND RE-ASSEMBLY.......................................................................... 45

20.28

TRANSMISSION RE-ASSEMBLY........................................................................................................................ 46

TEST PROCEDURE........................................................................................................................................................... 53 20.29

COMPACT PLUS TEST PROCEDURE.................................................................................................................. 54 20.29.1

TROUBLE SHOOTING............................................................................................................................................................. 54

20.29.2

FAULT DIAGNOSIS HYDRAULIC SYSTEM......................................................................................................................... 54

20.29.3

FAULT DIAGNOSIS MECHANICAL SYSTEM..................................................................................................................... 55

3

20.1 TRANSMISSION ASSEMBLY To understand the repair information presented in this section, it is necessary that the operator/mechanic be familiar with the names and locations of the major assemblies of the transmission. The following illustration identifies the components that are referred to throughout this section.

20.1.1 COMPONENTS Key: 30. Yoke 31. TransmissionPump 32. Controlvalve 33. Inputshaft 34. Countershaft 35. Idlershaft 36. Front outputshaft 37. Rear outputshaft 38. Transmission rearcase 39. Transmission frontcase

20.1.2 TRANSMISSION SERIAL NUMBER PLATE Transmission serial number plate is located on side of the transmission case below the lever gear shift . Serial number plateprovidesinformationofTransmissionmanufacturer, Type of transmission, Part number and serial number of the Transmission fitted on themachine.

!

WARNING

DO NOT service the machine without following all safety precautions as outlined in “Safety Practices,” section of this manual.

!

CAUTION Before attempting to remove transmission, thoroughly clean exterior of transmission to help prevent dirt from entering during replacement process. Do not spray water or cleaning solution onto or near transmission solenoid and other electrical components.

4

20.2 TRANSMISSION REMOVAL AND INSTALLATION 20.2.1 COMPONENT LOCATION

20.2.2 PREPARATION AND SAFETY INSTRUCTIONS – – – – –

Chock the Rear Axle to prevent tilting using Lifting Support(5) as shown.

Stabilize the machine on level ground.

Manoeuvre the machine a number of times in forward and reverse (wheels straight) in order to release any stresses acting on the steering and tyres.

Ensure the engine is Shut OFF. Disconnect the battery.

Raise the boom to mid - height and install the safety strut 1.

5 1

– – –

5

Uninstall the Gear Lever Knob(1).

Uninstall the 8 Fir Tree Button(2).

Remove the Retainer-Gear Lever Bellow(4) and the Gear Lever Bellow(3).

1

3

2 4 5

20.3 TRANSMISSION TIGHTENING TORQUES

PRELIMINARY TORQUE TO 33 NM FINAL TORQUE TO 67 NM USE ACRO BOND PU 284/30

TORQUE TO 450 NM

TORQUE TO 501 NM

TORQUE TO 501 NM

TORQUE TO 450 NM

FIG (A)

TORQUE TO 30 NM USE LOCTITE 243 TORQUE TO 55 NM USE LOCTITE 243

TORQUE TO 30 NM

FIG (B)

6

TORQUE TO 59 NM USE LOCTITE 243

TORQUE TO 80 NM USE LOCTITE 243

TORQUE TO 30 NM USE LOCTITE 243

FIG (C)

7

8

Lift the Front Axle to have a minimum height of 70 cm.

Remove the rear drive shaft (8)from gear box side.

6

9

Remove the Engine Cover (6).

Remove the front drive shaft(9) from the gear box side.

!

NOTE Allow the system fluids to cool to room temperature.

!

NOTE Worn or damaged drive shafts ,UJ cross and bearing assemblies may cause an excessive amount of vibration or noise.

Disassemble and clean all parts using an approved cleaning fluid. Allow to dry.

12 11

7

10

Drain the gear box oil through drain plug (7) into a receptacle.

Uninstall the Hex Bolt(10)and the Spring(11).

Remove the gear shift lever (12).

!

CAUTION Spilled oil must be cleaned immediately. Always keep the work area clear of any spills to avoid any injuries.

Dispose used oil in accordance with local environmental regulations.

8

13 14

Disconnect the Hose - Gearbox to Radiator IN(13) and disconnect the Hose - Gearbox To Radiator OUT(14)

Attach the Sling assembly(18).

15 15

20 19

15

Uninstall the 2 Hex Bolts(19), 2 Washers(20) on both LH & RH sides of the gear box.

Disconnect all connectors (15) from coil and sender of the gear box assembly.

17 16

Uninstall the 12 Hex Bolts(16 and the 12 Washers(17).

Lower the gear box assembly.

!

! CAUTION Use suitable lifting chain which can support the gear box properly . Care should be taken to avoid rubbing of lifting chain with solenoid coil while the gear box is lifted from the lift truck .

NOTE Secure the Hex Bolts and Washers in a container.

9

20.4 GEAR BOX AND CONVERTER

1.

2.

3.

4.

5.

6.

7.

8.

9.

Complete gear box Converter Intermediate piece Screw Washer Converter reinforcement plate Screw Screw Washer

10

20.5 GEAR BOX (DETAILS)

11

20.6 GEAR BOX (DETAILS) 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

70.

71.

72.

73.

74.

75.

76.

77.

78.

79.

Transmission housing Transmission rear case Plug “O” ring Screw Stud-bolt Screw “O”ring Plug Seal Brake assy Plug “O” ring Drain plug “O” ring Air breather Transmission oil pressure switch Complete electrical control valve Screw Plug Filtrer housing Gasket Connection Oil filter Screw Ball Spring ”O”ring Plug Plug Plug Complete pump Seal “O” ring Screw Washer

12

Oil temperature sensor O”ring Suction trainer Washer “O” ring Cover Screw Valve (Pressure regulation) Sealkit Over pressure valve Seal kit Upper seat Gear lever foot Pin Clamp Dust cover Clamp Screw Washer “O” ring Plate Screw Oil leve “O”ring Connection “O”ring Pumpekit Small parts kit Seal kit Seal kit Repair kit Kit (Brake lining +Spring) Kit (Screw +Nut) Kit brake lining Gasket “O” ring

20.7 GEAR BOX (MECHANISM DETAILS -GEARS)

13

20.8 GEAR BOX (MECANISM -DETAILS - GEARS)

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

67.

68.

Reverse idler gear Bearing Shim Spacer Input shaft Seal Seal (inner) “O”ring Seal (outer) “O” ring Piston Clutch disc Friction disc Piece Circlips Spring Bushing Circlips Thrust washer Forward primary gear Roller bearing Spacer Bearing Stop washer Backward primary gear Countershaft Bearing Bearing Shim Spacer Output shaft 3rd gear 2nd gear Coupling sleeve Synchro assyW Circlips 4th gear Washer Bearing Plug WVAVW

14

Synchro assy Output shaft 1st gear Bearing Spacer Coupling Out put shaft drive gear Seal Coupling flange “O” ring Washer Screw Out put shaft Gear (37teeth) Bearing Shim Spacer Spacer End yoke 1st and 2nd shift rod 3th and 4th shift rod Ball Spring Plug “O”ring 1st and 2nd shift fork 3th and 4th shift fork Screw

20.9 GEAR BOX( ELECTRICAL CONTROL VALVE DETAILS)

1.

2.

3.

4.

Complete electrical control valve Solenoid coil Seal kit Plug

15

20.10

TRANSMISSION HYDRAULIC CIRCUIT

20

16

20.11

DESCRIPTION OF THE TRANSMISSION SHAFT HYDRAULIC CIRCUIT

20.11.1 CLUTCH CIRCUIT The oil is sucked into the casing via the suction strainer.

The oil leaving the pump passes into the filter and is directed towards the clutch circuit.

The filter is protected by a cold start valve calibrated to 26 bars.

On the filter outlet, the pressure regulator mark A maintains a pressure of 14 +/- 1 bar in the clutch circuit.

The same regulator supplies the converter circuit.

The electrovalves mark B enable the pressure to be directed towards the front and reverse gear clutches, and in neutral gear they enable the clutches to be decompressed towards the casing.

On the 4WD “sprung on” version, the clutch is engaged by a spring. When the 4WD electrovalve mark C is fed,the pressure is applied on the piston which pushes the spring back and frees the 4WD clutch V. 20.11.2 CONVERTER CIRCUIT The oil passes into the converter circuit through the pressure regulator mark A. The pressure limiter mark D maintains a pressure of 6.5 +/- 1.5 bar in the circuit.

20.11.3 COOLING AND LUBRICATION CIRCUIT The oil returning from the converter passes via the inside of the pump’s hollow shaft, heads towards the oil cooler and then returns into the transmission shaft to lubricate the gears and the bearings on the inlet shaft A.

17

20.12

P1 P2 P3 P4 P5 P6 T1

TRANSMISSION HYDRAULIC PRINCIPLE CIRCUIT

= = = = = = =

Oil pump pressure test point (14,5 ± 1 bar).

Forward clutch pressure test point (14,5±1,5bar).

Reverse clutch pressure test point (14,5 ± 1,5 bar).

Converter relief pressure test point (6,5 ± 1,5 bar).

Four wheel drive pressure test point (14,5±1,5bar).

Lubrication pressure test point (1,5±1bar).

Temperature test W.

18

20.13

TRANSMISSION MAINTENANCE

20.13.1 RECOMMANDED LUBRICANTS: 10W or 10W 30 Grade mineral oils or automatic transmission fluids which meet at least one of the following specifications are allowable for use in ambient temperatures of between -20 and40 Deg. C :DEXRON III The following lubricants meet these requirements :Transfluid III (Valvoline ) 20.13.2 OPERATING TEMPERATURE : 85° - 90°C In order to ensure a good lubrication and a good operating temperature, it is important to use the specified oil and to maintain the correct level.

! CAUTION To prevent a lack of lubrication in the transmission when towing the machine on long distances, it is recommended to uncouple the gear box out put shaft.

20.13.3 OIL AND FILTER CHANGING It is recommended to change the oil at the following intervals: – – –

Replace oil at every 1000 hour or 2 years ,whichever is earlier.

Replace the filter at every 500 hours or 1 year , whichever is earlier.

Always clean the strainer when changing the oil.

20.13.4 CAPACITY (GEAR BOX ONLY) : 15, 5 L

11

20.13.5 OIL LEVEL The oil level must be checked with the engine idling and with the transmission oil cold. In this condition the oil level should fall between the Max and Min marks on the dipstick 1. At normal operating temperature, ( 80 Deg.C.) the oil level will rise to 20 - 30 mm above the Max. mark on the dipstick.

Do not overfill the transmission as this may result in oil breakdown due to excessive heat and aeration from the churning action of the gears. Early breakdown of the oil will result in heavy sludge deposits that block oil ports and build up on splines and bearings. Overfilling may also cause oil leaks.

19

11

20.14 – – – – –

PRESSURE CHECKING

The transmission oil, should be at an approximate temperature of 80°C during pressure tests.

The handbrake must be applied.

All test ports have a 9 / 16” UNF thread.

A pressure gauge of 0-20 bar minimum is necessary.

Forward, reverse and 4WD clutch pack pressures should not be more than 1 barl ower than the oil pump pressure.

CONVERTER RELIEF PRESSURE TEST POINT.

OIL PUMP PRESSURE TEST PORT.

!

!

NOTE Pressure should be 14,5 ± 1 bar at maximum engine speed (approx. 2200 RPM).

NOTE Pressure should be 6,5 ± 1,5 bar at maximum engine speed (approx. 2200 RPM).

FORWARD CLUTCH PRESSURE TEST POINT.

REVERSE CLUTCH PRESSURE TEST POINT.

!

NOTE Pressure should be 14,5 ± 1,5 bar at maximum engine speed (approx. 2200 RPM).

!

NOTE Pressure should be 14,5 ± 1,5 bar at maximum engine speed (approx. 2200 RPM).

20

LUBRICATION PRESSURE TEST POINT.

FOUR WHEEL DRIVE LUBRICATION PRESSURE TEST POINT.

!

NOTE Pressure should be 14 ± 1,5 bar at maximum engine speed (approx. 2200 RPM).

!

NOTE Pressure should be 1,5 ± 1 bar at maximum engine speed (approx. 2200 RPM).

STALLING SPEED OF TORQUE CONVERTER : 1600 ± 50 tr/mn

21

20.15

PRESSURE READING ON GEAR BOX

MACHINE TYPE and N° : ................................................... N° of HOURS : ..........................................

GEAR BOX TYPE and N° : ................................................

(To be carried out with gear box oil at 80° mini).

NEUTRAL

PUMP

FOWARD GEAR

REVERSE GEAR

Mini r.p.m........................

Maxi r.p.m........................

CONVERTER

Mini r.p.m........................

Maxi r.p.m........................

DRAINAGE

Mini r.p.m........................

Maxi r.p.m........................

REVERSE GEAR

Mini r.p.m........................

Maxi r.p.m........................

Mini r.p.m........................

4 WD

Maxir.p.m........................

COMMENTS: ............................................................................................................................................................................................................................ ....................................................................................................................................................................................................................................................... * BREAKDOWN AT THE ORIGIN: ........................................................................................................................................................................................ ...................................................................................................................................................................................................................................................... * DETERMINED CAUSE OFTHE BREAKDOWN: ........................................................................................................................................................... ..................................................................................................................................................................................................................................................

22

20.16

SPECIAL TOOLS

NUMBER

DESIGNATION

–

479307

Hand press.

–

479309

Input & Rev. Idler shaft brg. removal collet.

–

563390

4WD brg removal collet.

–

563391

Out put shaft front brg. removal collet.

–

563392

C / shaft and output shaft rear brg. removal collet.

–

563394

C / shaft front bearing remova lcollet.

–

563393

Input shaft spring compressor.

–

563395

Shimming Adapter

RECOMMENDED TUBE SIZES FOR REPLACING BEARINGS.

Ø INTERIOR

Ø EXTERIOR

C / shaft, Output shaft rear & 4WD brg.

41mm

47 mm

Reverse idler, output shaft front & input shaft brgs.

36 mm

41 mm

Output shaft 1st gear brg. sleeve

50,5 mm

55 mm

The dummy plug for re-fitting inner detent spring & ball can be made using a piece of bar 18mm dia. x 25 mm long.

23

20.17

SHAFT AND GEAR END FLOAT TOLERANCES

20.17.1 SHAFT END FLOATS All shaft end floats should be 0.025 to 0.075 mm ( 0.001 to 0.003 ins. ) 20.17.2 GEAR END FLOATS Input shaft forward and reverse primary gears : 0.061 to 0.41 mm ( 0.0024 to 0.016 ins.).

Output shaft gears : – – – –

4th Gear : 0.20 to 0.56 mm. ( 0.008 to 0.022ins.)

3rd Gear : 0.38 to 0.84 mm. ( 0.015 to 0.033ins.)

2nd Gear: 0.36 to 0.56 mm. ( 0.014 to 0.022ins.)

1st Gear : 0.33 to 0.51 mm. ( 0.013 to 0.020ins.)

4 wheel drive : 0.051 mm. to 0.28 mm. ( 0.002 to 0.011 ins.).

BOLT TORQUES Strainer bolts

18 to 31Nm.

13 to 23 lbft.

Pump retaining bolts

18 to 31Nm.

13 to 23 lbft.

Output Yoke bolts

68 to 88Nm.

50 to 65 lbft.

Pressure test plugs

41 to 54Nm.

30 to 40 lbft.

Main transmission case bolts

45 to 64Nm.

33 to 47 lbft.

Shift detent plug

41 to 54Nm.

30 to 40 lbft.

Shift fork screws

18 to 25 Nm.

13 to 18 lb ft.

Shift lever assembly screws

16 to 24 Nm.

12 to 18 lb ft.

Drain plugs

34 to 54 Nm.

25 to 40 lb ft.

Converter relief valve

23 to 30 Nm.

17 to 22 lb ft.

Pressure regulator valve

46 to 60 Nm.

34 to 44 lb ft.

Cold start valve

46 to 60 Nm.

34 to 44 lb ft.

4WD solenoid valve spool

20 to 27 Nm.

15 to 22 lb ft.

4WD solenoid coil retaining nut

5.4 Nm. Max.

4 lb ft. Max.

Directional control valve ret. screws

6.8 to 8.5 Nm.

5 to 6.3 lb ft.

4WD hydraulic pipe connections

6.8 to 10.2 Nm.

5 to 7.5 lb ft.

Filter housing bolts

45 to 64 Nm.

33 to 47 lb ft.

Oil filter

7 to 10 Nm.

5 to 7.5 lb ft.

Temperature sender

20 to 27 Nm.

15 to 20 lb ft.

24

DISASSEMBLY & RE-ASSEMBLY

25

20.18

GENERAL INFORMATION

We recommend that the procedures as outlined in this manual be followed when performing maintenance work on this transmission.

20.18.1 TOOLS This transmission can be repaired with ordinary mechanics hand tools however this procedure is not only slow but may damage otherwise serviceable parts. To reduce maintenance costs and vehicle downtime, we recommend that the special tools listed in this manual be procured from a tool manufacturer, as stated.

20.18.2 CLEANLINESS Transmission should be steam cleaned externally prior to disassembly. Seal all opening before cleaning to prevent entry of dirt and water which can damage serviceable parts. Dirt is abravise and will cause premature wear and failure of clutch plates, hydraulic valves and bearings. *Due to the nature of operation of the hydraulic system cleanliness is of prime importance and the following guidelines should be observed: – – –

Not lint or cotton rags should be used in order to prevent any possible clogging.

When fitting new clutch plates they should be soaked in clean new oil as recommended for 3hours.

All parts should be thoroughly cleaned and lubricated with new oil prior to reassembly.

20.18.3 BEARINGS When a transmission is removed at relativity low mileage, bearings should be removed with pullers designed for the purpose.

Wrap the bearings to keep outdirt.

Clean, inspect and lubricate all bearings just prior to reassembly. If accumulated mileage is over 1500 hours we suggest that all bearings be replaced.

Always use adapted tools to avoid damaging the new bearing assembly. Prefer the hot mounting of bearings, if possible. Use tools with plastic or brass tips.

20.18.4 REPLACEMENT PARTS The exploded views of sub-assemblies which are incorporated in this manual are for the mechanic’s convenience and show the latest material. The parts are arranged in their correct order and may also be used as a reference for assembly or disassembly of this unit.

! CAUTION When inserting shim packs, it is essential that the thinnest shims are placed between the thicker shims to prevent any possible damage to the shims.

20.18.5 SEALS The seals which have been removed on the disassembly shall be replaced by new on reassembly.

26

20.19

TRANSMISSION DIS-ASSEMBLY

Invert the transmission on a suitable bench. For convenience the bench top should have a hole in it to accommodate the input shaft and pump. Remove 3 screws and withdraw the gear shift lever assembly.

Remove the Pressure Regulator Valve

Remove the cold start housing, spring and ball.

Remove 4 capscrews and withdraw the direction control valve.

Remove the temperature sender.

Remove the Converter Relief Valve.

27

Remove the bolt, washer and “ O”ring and withdraw the output yoke.

4WD VERSION : Remove the 4 wheel drive shaft assembly.

(Not fitted on 2 wheel drive model).

4WD VERSION : Remove the bolt, washer and “O”ring and withdraw the 4 wheel drive yoke and spacer. (Not fitted on 2 wheel drive model).

Tilt the countershaft and withdraw the input shaft assembly.

Remove the reverse idler shaft assembly.

Remove 17 screws and using a suitable hoist take off the rear.

! CAUTION The bearing cones and shims may fall from the rear case during removal.

28

Remove the 3rd / 4th shift fork screw.

Remove the outer detent plug, spring and ball.

! CAUTION The bearing cones and shims may fall from the rear case during removal.

Ensure both synchronisers are in the neutral position then remove the 1st / 2nd shift fork screw.

Turn the 3rd / 4th shift rod through 90 degrees and withdraw from the housing.

Withdraw the 1st / 2nd shift rod from the housing Then using a magnetic probe remove the interlock ball from the detent bore v.

Remove the detent plug, inner detent ball and spring.

29

Remove the counter shaft assembly.

Remove the 4th gear lock out screw. (If fitted).

Remove the 1st / 2nd and 3rd / 4th shift forks.

Remove 2 screws and withdraw the strainer cover, “O”rings, spacer and strainer.

Remove the output shaft assembly.

Using a strap wrench remove and discard the oil filter.

30

Remove 2 bolts and withdraw oil filter housing and gasket.

Remove and discard the expansion plug from the shimming access hole.

4WD VERSION : Remove the 4 wheel drive solenoid coil and retaining nut.

Invert the case. Remove 4 screws and coppe washers then withdraw the pump assembly and sealing ring.

4WD VERSION : Remove the 4 wheel drive solenoid spool.

31

20.20

INPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY

20.20.1 DIS-ASSEMBLY

Position the shaft in a soft jawed vice as shown.

Remove the thrust washer and needle bearing.

Remove and discard the 3 sealing rings.

Remove the reverse primary gear.

Using the appropiate bearing puller remove the rear bearing.

Remove the bearing, spacer, bearing and thrust washer.

32

Remove the clutch pack retaining ring.

Remove the circlip, retainer and spring.

Remove the clutch pack retaining plate.

Using pliers, as shown, pull the piston out of the drum.

Remove the clutch pack.

Invert the shaft and remove the sealing ring. Repeat steps 2,3 to 2,12 to dismantle the forward clutch pack.

Using the appropriate tool compress the piston spring and release the circlip.

Remove and discard the piston sealing rings and “O”rings.

33

20.20.2 RE-ASSEMBLY

Replace an externally splined (plain) disc and then an internally splined (friction) disc alternately until six of each have been replaced.

Re-new the piston sealing rings and “O”rings. To assist assembly bend the inner sealing ring into a heart shape as shown.

! CAUTION New friction discs should be soaked in transmission fluid for a minimum of 3 hours prior to assembly.

Using transmission fluid to lubricate the seals push the piston into the drum.

Replace the clutch pack retaining plate and refit the retaining clip.

Replace the spring, retainer and circlip as shown.

Replace the thrust washer, bearing, spacer and bearing.

Using the appropriate tool compress the spring and locate the circlip ingo its groove.

34

Line up the clutch plate splines and replace the primary gear. Then replace the needle bearing anhd thrust washer as shown.

Finally fit 3 new sealing rings to the rear of the shaft as shown.

Using an appropriately sized tube replace the bearing as shown.

Invert the shaft and repeat steps 2:15 to 2:23. Then fit a new sealing ring as shown.

35

20.21

DIS-ASSEMBLY AND RE- ASSEMBLY OF THE COUNTERSHAFT

The countershaft assembly.

20.21.1 DIS-ASSEMBLY

Using the appropriate bearing puller remove the countershaft front and rear bearings.

20.21.2 RE-ASSEMBLY

Using an appropriately sized tube replace the countershaft front and rear bearings.

36

20.22

DIS-ASSEMBLY AND RE- ASSEMBLY OFT HE REVERSE IDLER SHAFT

The reverse idler assembly.

20.22.1 DIS-ASSEMBLY

Using the appropriate bearing puller remove the countershaft front and rear bearings.

20.22.2 RE-ASSEMBLY

Using an appropriately sized tube replace the front and rear bearings.

37

20.23

OUTPUT SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY

20.23.1 DIS-ASSEMBLY

Position the shaft assembly in a soft-jawed vice as shown.

Remove the 3rd / 4th synchro assembly.

Using the appropriate bearing puller remove the front bearing.

Remove the circlip and synchro hub.

Remove the thrust washer and 4th gear.

Remove the 3rd gear.

38

Invert the shaft and using the appropriate bearing puller remove the rear bearing.

Remove the 1st / 2nd synchroniser assembly.

4WD VERSION : Remove the 4 wheel drive gear.

2WD VERSION : On 2 wheel drive models a spacer is fitted in place of a gear.v

Using a suitable bearing puller or press. Remove the bearing sleeve , synchro hub and 2nd gear.

Remove the 1st gear.

Removal of the bearing sleeve, synchro hub and 2nd gear.

Remove the needle bearings and spacer.

39

2.23.2 RE - ASSEMBLY

Replace the 2nd gear and synchro hub.

Replace the 1st gear

Using an appropriately sized tube refit the 1st gear bearing sleeve.

Replace the 4 wheel drive gear using stop threaded product (P / N° 548110).

! CAUTION The gear should be fitted with the fluted boss against the 1st gear. (On 2 wheel driv models a spacer is fitted in place of the gear).

Replace the 1st / 2nd synchroniser assembly

Using an appropriately sized tube refit the rear bearing.

Replace the 1st gear needle bearings and spacer as shown.

40

Invert the shaft and refit the 3rd gear, synchro hub and circlip.

Re-fit the 3rd / 4th synchroniser assembly.

Refit the 4th gear and thrust washer as shown.

Using an appropriately sized tube replace the front bearing.

41

20.24

PERMANENT 4 WHEEL SHAFT DIS-ASSEMBLY AND RE-ASSEMBLY 20.24.2 RE-ASSEMBLY

The permanent 4 wheel drive shaft.

Replace the 4 wheel drive gear using stop threaded product (P/ N°548110), on the shaft splines. Then using a suitably sized tube re-fit the front and rear bearings.

20.24.1 DIS-ASSEMBLY

Using the appropriate bearing puller remove the front and rear bearings.

Remove the 4 wheel drive gear.

42

20.25

DIS-ASSEMBLY AND RE-ASSEMBLY OF THE OIL PUMP

! CAUTION Individual components of the oil pump are non serviceable. The pump may, however, be stripped for cleaning and examination purposes.

The pump oil seal may be replaced using an approprietely sized tube.

View showing a dismantled pump assembly.

43

20.26

DIS-ASSEMBLY AND RE-ASSEMBLY OF THE VALVE

! CAUTION Individual components of the oil pump are non serviceable. The pump may, however, be stripped for cleaning and examination purposes.

The retaining nut, coil and washers removed.

The modulation components removed.

There are 4 “O”rings fitted to the underside of the valve which may be renewed if necessary.

44

20.27

GEAR LEVER HOUSING DIS-ASSEMBLY AND RE-ASSEMBLY

Remove the plastic ties from the rubber gaiter and pull the assembly apart as shown.

Apply a airtightness product (P / N° 562228) to the sealing face as shown.

! CAUTION Before re-assembly remove all traces of old sealant from the joint faces.

Lubricate the ball seating with a light grease and push the two halves of the assembly together. Secure the rubber gaiter with two new plastic ties.

45

20.28

TRANSMISSION RE-ASSEMBLY

! CAUTION All shafts and bearing should be lubricate with transmission fluid prior to assembly.

To prevent possible contamination of hydraulic parts lint or cotton rags should not be used.

Invert the case and then re-fit the bearing cups if previously removed..

4WD VERSION : Position the front case as shown and using a suitably sized tube fit a new 4 wheel drive output shaft oil seal to a depth of 6mm below the housing face. Fill the seal lip with light grease.

Using a suitable tool push the inner detent spring and ball into the case and secure in place with a dummy plug as shown. (ø 18 mm, lg. 25 mm).

Re-fit the oil pump assembly and sealing ring. Tighten 4 bolts to a torque of 13-23 Ib / ft. New copper washers must be fitted under the bolt heads.

Dummy plug in place

If previously removed, replace the two plug and “O”ring assemblies and tighten to a torque of 30 to 4 Ibs /ft.

46

Replace the countershaft and reverse idler shaft assemblies.

Re-fit the 1st / 2nd shift rail and tighten the shift fork screw to a torque of 13 to 18 Ibs / ft. Check that the interlock ball is correctly positioned in between the two rails.

Slide the 1st / 2nd fork onto the 3rd / 4th rail then refit the 3rd / 4th shift fork and tighten the screw to a torque of 13 to 18 Ibs / ft. Hold the forks and rail in place on the output shaft then re-fit the complete assembly into the case. The shift rail should displace the dummy plug as it enters the bore.

Replace the outer detent ball and spring. Tighten the plug to a torque of 30 to 40 Ibs /ft.

! CAUTION Check that the inner detent spring and ball have not become displaced and remove the loose dummy plug from the case sump.

4WD VERSION : Replace the 4 wheel drive shaft assembly.

Lubricate the rear seal with a light grease.

Push the interlock ball into the detent bore.

47

Lubricate the input shaft front and rear seals a light grease and re-fit the shaft assembly into the case.

Re-fit the rear case, (without sealant at this stage), and secure with at least 6 equally spaced bolts. When fitting the rear case be careful to avoid damaging the input shaft sealing rings.

Rear case with all shaft assemblies fitted.

Position a D.T.I. on the end of the input shaft as shown, and using a suitable pry bar through the side access hole, measure and note the shaft end float.

Position the rear case as shown and using a suitably sized tube fit a new output shaft oil seal to a depth of 6mm below the housing face. Fill the seal lip with a light grease.

Attach a suitable shimming tool, (with a 12mm thread), to the end of the reverse idler shaft. Position a D.T.I. as shown, and using a pry bar lift the shaft, then measure and note the end float.

Invert the case and replace the shim packs and bearing cups. The 2mm thick spacer shim should be fitted into the case first, then fit the remaining shims followed by the bearing cup. A light grease may be used to help hold the cups in the case.

48

Attach a suitable shimming tool, (with a 12mm thread), to the end of the countershaft. Position a D.T.I. as shown, and using a pry bar lift the shaft, then measure and note the end float .

Replace the 4 «O»rings in the front case. (There are only 3 fitted on the 2 wheel drive model).

Re-fit the rear case using an approved liquid gasket taking care not to damage the input shaft sealing rings. Tighten the 17 bolts to a torque of 33 to 47 Ibs / ft.

Attach a suitable shimming tool, (with a 12 mm thread), to the end of the output shaft. Position a D.T.I. as shown, and using a pry bar lift the shaft, then measure and note the end float..

Replace the shaft end plug and «O»ring assemblies. Note the special breather plug es fitted in vthe reverse idler position. Tighten to a torque of 30 to 40 Ibs / ft.

4WD VERSION : Attach a suitable shimming tool, (with a 12mm thread), to the end of the 4 wheel drive shaft. Position a D.T.I. as shown, and using a pry bar lift the shaft, then measure and note the end float.

Remove the rear case and add or remove shims as necessary to give .001” to .003” end float on all shafts. Repeat steps 11.17 to 11.22 until all shaft end floats are correct.

49

Fit a new expansion plug to the shimming access hole using an approved sealant. Stop threaded product (P / N° 562227).

Lubricate the seals with transmission fluid then re-fit the pressure regulator valve and tighten to a torque of 34 to 44 Ibs / ft.

Replace the output yoke, «O»ring, washer and bolt. Then tighten to a torque of 50 to 65 Ibs / ft.

Lubricate the seals with transmission fluid then re-fit the converter regulator valve and tighten to a torque of 17 to 22 Ibs / ft.

4WD VERSION : Replace the spacer, 4WD yoke, «O»ring, washer and bolt. Then tighten to a torque of 50 to 65 Ibs / ft.

Re-fit the temperature sender and tighten to a torque of 15 to 20 Ibs / ft.

Re-fit the cold start ball, spring and housing. Then tighten to a torque of 34 to 44 Ibs / ft.

50

applications an additionnal sealing plug may be fitted.

Ensure the 4 «O»ring are in place then re-fit the control valve assembly and tighten the 4 caps crews to a torque of 5.0 to 6.3 Ibs / ft. The valve can only be fitted one way round as it is located by a small dowel pin.

Apply a bead of RTV joint compound (P / N° 562228) to the gear case as shown.

Re-fit the strainer, spacer, «O»ring and cover plate. Then tighten the two screws to a torque of 13 to 23 Ibs / ft.

Re-fit the gear lever assembly and tighten the three bolts to a torque of 12 to 18 Ibs / ft.

Re-fit the drain plug and “O”ring assembly. Tighten to a torque of 25 to 40 Ibs / ft.

Re-fit the filter housing and gasket. Tighten the two bolts to a torque of 33 to 47 Ibs / ft.

Re-fit the 4th gear lock out screw, (when this feature is not required a shorter blanking screw is fitted). On some

Lubricate the seals with a light grease and screw on a new oil filter.

51

4WD VERSION : Lubricate the seals with a light grease and re-fit the 4 wheel drive solenoid spool. Tighten to a torque of 15 to 20 Ibs / ft.

4WD VERSION : Re-fit the 4 wheel drive solenoid coil and nut. Tighten to a torque of 4 Ibs / ft maximum.

4WD VERSION : If previously removed re-fit the 4 wheel drive clutch supply pipe, apply air tightness product (P/N° 62175) to threads and thighten nuts to a torque of 5 to 7.5 Ibs / ft.

52

TEST PROCEDURE

53

20.29

COMPACT PLUS TEST PROCEDURE

20.29.1 TROUBLE SHOOTING Whenever the transmission shaft is observed to malfunction, prior to dismantling anything or operating on the transmission shaft, you should first carry out a thorough inspection so as to determine the cause of the failure. The table below has been drawn up to make this task easier for you.

When checking pressures, please consult the section “CHECKING PRESSURES”.

20.29.2 FAULT DIAGNOSIS - HYDRAULIC SYSTEM

FAULT

POSSIBLE CAUSES

Transmission fails to drive in either direction.

Low or no pump pressure.

Low or no oil in transmission.

Mechanical failure in transmission.

Worn or broken input shaft sealing rings.

Pressure regulator valve faulty.

Direction control valve not operating.

Blockage in oil ports restricting flow.

Transmission drives in one direction only.

Low oil pressure to clutch pack.

Clutch pack excessively worn.

Direction valve or coil faulty.

Mechanical failure in transmission.

Blockage in oil ports restricting flow.

Worn or damaged input shaft sealingring.

Delay in taking up drive.

Low converter pressure.

Low oil level.

Low clutch pressure.

Faulty modulation in direction control valve.

Blockage in direction valve.

Blockage in oil ports restricting flow.

No drive from 4WD

4WD solenoid valve or coil not operating.

Mechanical failure in transmission .

Low pressure 4WD clutch pack pressure.

4WD clutch pack worn.

Transmission overheating.

Oil level too high or low.

Restriction in cooler flow.

Low oil pressure.

Clutch packs slipping due to low pressure or wear.

Mechanical failure in transmission.

Excessive stall operation.

Difficult gear selection.

Fwd or Rev. clutch pack pressurised when not selected.

Direction valve faulty.

Input shaft sealing rings leaking.

Mechanical failure in transmission.

Fwd or Rev. clutch pack not releasing due to mechanical failure.

Vehicle moves with direction valve in neutral position.

See” Difficult gear selection”.

High stall speed.

Low oil level.

Air in oil.

Clutch plates slipping due to low pressure or wear.

Torque converter faulty.

Converter relief valve faulty.

Low stall speed.

Poor engine performance. Torque converter defective.

Low pump pressure.

Worn or broken pump.

Leaking pump sealing ring or oil seal.

Blocked oil strainer or filter.

Blockage in oil ports between transmission sump and oil pump.

Pressure regulator valve stuckopen.

Cold start valve stuck open.

54

FAULT

POSSIBLE CAUSES

High pump pressure.

Pressure regulator valve faulty.

Has normal operating oil temperature been reached ?

Low forward or reverse clutch pack pressure.

Faulty direction control valve or coil.

Piston seal or «O»ring leaking.

Input shaft sealing ring leaking.

High forward / reverse clutch pack pressure.

Pressure regulator valve faulty.

Converter pressure low.

Converter relief valve faulty.

Leak in converter, oil cooler or connecting hoses.

Pump oil seal leaking.

Converter pressure high.

Converter relief valve faulty.

Blockage or restriction in oil cooler

Low 4WD clutch pack pressure.

4WD piston seals leaking.

4WD shaft sealing ring leaking.

Leak from 4WD clutch supply pipe.

Faulty 4WD Solenoid Blockage or restriction in 4WD clutch supply pipe.

High 4WD clutch pack pressure.

Pressure regulator valve faulty.

Low lubrication pressure.

Blockage or restriction in oil cooler.

Input shaft front sealing ring leaking.

20.29.3 FAULT DIAGNOSIS - MECHANICAL SYSTEM

FAULT

POSSIBLE CAUSES

Noise

Vehicle Driveline Problem : Axles, Propshafts, Engine, Engine mounts.

Mis-alignment of transmission / engine.

Bearings worn or damaged.

Gear teeth damaged or brocken.

Excessive end float of shafts orgears.

Clutch plate failure forward, reverse or 4WD. Incorrect grade of oil intransmission.

Low oil level.

Gear or thrust washer beginning to seize.

Difficult gear selection.

Shift rods worn or bent.

Synchroniser assemblies worn or damaged.

Clutch pack not releasing due to mechanical fault.

Clutch pack not releasing due to hydraulic fault.

Gear shift stub lever worn ordamaged.

Incorrect grade of oil in transmission.

Low oil level.

Jumping out of Gear.

Detent springs worn or broken.

Synchroniser or gear dog teeth worn or damaged.

Synchroniser assemblies worn or damaged.

Shift forks worn, loose or twisted.

Restriction or wear in gear linkage or stub lever assy. not allowing gears to be fully selected.

Excess end float on output shaft assembly or gears.

55

Intentionally Left Blank 56

AXLE

56

Intentionally Left Blank

TABLE OF CONTENTS

30.1.

SPECIFICATIONS.................................................................................................................................................. 5 30.1.1

DEFINITION OF VIEWPOINTS.................................................................................................................................................5

30.1.2

DATA PLATE..................................................................................................................................................................................5

30.1.3

CONVERSION TABLES...............................................................................................................................................................5

30.1.4

TORQUES PECIFICATIONS.......................................................................................................................................................6 COARSE PITCH............................................................................................................................................................................6 FINE PITCH....................................................................................................................................................................................6 WHEEL NUT TIGHTENING TORQUES..................................................................................................................................7

30.1.5

MAINTENANCE...........................................................................................................................................................................8 MAINTENANCE POINTS...........................................................................................................................................................8

30.1.6

OIL DRAINING MANDATORY PROCEDURE........................................................................................................................9 CENTRAL HOUSING...................................................................................................................................................................9 PLANETARY GEAR REDUCTION.............................................................................................................................................9

30.1.7

MAINTENANCE INTERVALS................................................................................................................................................. 10

30.1.8

LUBRICANT & SEALANT SPECIFICATIONS....................................................................................................................... 11

30.2.

SAFETY PRECAUTIONS..................................................................................................................................... 12

30.3.

CHECKING WEAR AND REPLACING THE BRAKING DISCS............................................................................... 13 30.3.1

EXPLODED VIEW...................................................................................................................................................................... 13

30.3.2

DISASSEMBLY........................................................................................................................................................................... 13

30.3.3

ASSEMBLY.................................................................................................................................................................................. 15

30.3.4

SPECIAL TOOLS........................................................................................................................................................................ 17 T1.................................................................................................................................................................................................. 17 T2.................................................................................................................................................................................................. 17

30.4.

30.5.

COMPLETE STEERING CASE.............................................................................................................................. 18 30.4.1

EXPLODED VIEW...................................................................................................................................................................... 18

30.4.2

DISASSEMBLY........................................................................................................................................................................... 19

30.4.3

ASSEMBLY.................................................................................................................................................................................. 20

DOUBLE U-JOINT.............................................................................................................................................. 22 30.5.1

EXPLODED VIEW...................................................................................................................................................................... 22

30.5.2

DISASSEMBLY........................................................................................................................................................................... 23

30.5.3

ASSEMBLY.................................................................................................................................................................................. 24

30.5.4

SPECIAL TOOLS........................................................................................................................................................................ 26 T1.................................................................................................................................................................................................. 26 T2.................................................................................................................................................................................................. 26

30.6.

PLANETARY REDUCTION GEAR........................................................................................................................ 27 30.6.1

EXPLODED VIEW...................................................................................................................................................................... 27

30.6.2

DISASSEMBLY........................................................................................................................................................................... 28

30.6.3

ASSEMBLY.................................................................................................................................................................................. 31

30.6.4

SPECIAL TOOLS........................................................................................................................................................................ 34 T1.................................................................................................................................................................................................. 34 T2.................................................................................................................................................................................................. 34 T3.................................................................................................................................................................................................. 35 T4.................................................................................................................................................................................................. 36 T5.................................................................................................................................................................................................. 36 2

30.7.

STEERING CYLINDER......................................................................................................................................... 37 30.7.1

EXPLODED VIEW...................................................................................................................................................................... 37

30.7.2

OPTICAL SENSOR AND MAGNETIC SENSOR................................................................................................................. 38

30.7.3

DISASSEMBLY........................................................................................................................................................................... 39

30.7.4

ASSEMBLY.................................................................................................................................................................................. 41 ADJUSTING THE STEERING ANGLE................................................................................................................................... 46

30.7.5

SPECIAL TOOLS........................................................................................................................................................................ 47 T1.................................................................................................................................................................................................. 47 T2.................................................................................................................................................................................................. 48

30.8.

DIFFERENTIAL UNIT.......................................................................................................................................... 49 30.8.1

EXPLODED VIEW...................................................................................................................................................................... 49

30.8.2

DISASSEMBLY........................................................................................................................................................................... 50

30.8.3

ASSEMBLY.................................................................................................................................................................................. 52

30.8.4

SPECIAL TOOLS........................................................................................................................................................................ 54 T1.................................................................................................................................................................................................. 54 T2.................................................................................................................................................................................................. 54

30.9.

BEVEL PINION.................................................................................................................................................... 55 30.9.1

EXPLODED VIEW...................................................................................................................................................................... 55

30.9.2

DISASSEMBLY........................................................................................................................................................................... 56

30.9.3

ASSEMBLY.................................................................................................................................................................................. 58

30.9.4

SPECIAL TOOLS........................................................................................................................................................................ 64 T1.................................................................................................................................................................................................. 64 T2.................................................................................................................................................................................................. 65 T3.................................................................................................................................................................................................. 65 T4.................................................................................................................................................................................................. 66 T5.................................................................................................................................................................................................. 66 T6.................................................................................................................................................................................................. 67 T7.................................................................................................................................................................................................. 68 T8.................................................................................................................................................................................................. 69 T9.................................................................................................................................................................................................. 69

30.10. MANUAL EMERGENCY RELASE........................................................................................................................ 70 30.10.1

EXPLODED VIEW...................................................................................................................................................................... 70

30.10.2

RELEASE..................................................................................................................................................................................... 71

30.10.3

ADJUST....................................................................................................................................................................................... 71

30.11. MECHANICAL PARKING BRAKE........................................................................................................................ 72 30.11.1

EXPLODED VIEW...................................................................................................................................................................... 72

30.11.2

DISASSEMBLY........................................................................................................................................................................... 73

30.11.3

ASSEMBLY.................................................................................................................................................................................. 75

30.12. NORMAL DIFFERENTIAL UNIT.......................................................................................................................... 77 30.12.1

EXPLODED VIEW...................................................................................................................................................................... 77

30.12.2

DISASSEMBLY........................................................................................................................................................................... 78

30.12.3

ASSEMBLY.................................................................................................................................................................................. 80

30.12.4

SPECIAL TOOLS........................................................................................................................................................................ 83 T1.................................................................................................................................................................................................. 83 T2.................................................................................................................................................................................................. 83 T3.................................................................................................................................................................................................. 84 T4.................................................................................................................................................................................................. 84

3

30.13. LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%)....................................................................................... 85 30.13.1

EXPLODED VIEW...................................................................................................................................................................... 85

30.13.2

DISASSEMBLY........................................................................................................................................................................... 86

30.13.3

ASSEMBLY.................................................................................................................................................................................. 88

30.13.4

SPECIAL TOOLS........................................................................................................................................................................ 91 T1.................................................................................................................................................................................................. 91 T2.................................................................................................................................................................................................. 91 T3.................................................................................................................................................................................................. 92 T4.................................................................................................................................................................................................. 92

30.14. HYDRAULIC DIFFERENTIAL LOCK.................................................................................................................... 93 30.14.1

EXPLODED VIEW...................................................................................................................................................................... 93

30.14.2

DISASSEMBLY........................................................................................................................................................................... 94

30.14.3

ASSEMBLY.................................................................................................................................................................................. 96

30.14.4

SPECIAL TOOLS........................................................................................................................................................................ 98 T1.................................................................................................................................................................................................. 98 T2.................................................................................................................................................................................................. 98

4

30.1 SPECIFICATIONS 30.1.1 DEFINITION OF VIEW POINTS LEFT SIDE

RIGHT SIDE

30.1.2 DATA PLATE

2

1 3

MFG. BY CLARK-HURTH COMPONENTS S.P.A. 38062 Arco (Trento) MADE IN ITALY

1.

2.

3.

Model number Serial number Lubricant

30.1.3 CONVERSION TABLES UNITS OF PRESSURE Atm

Bar

MPa

Pa

PSI

Atm

1

1

0.1

10

14.4

Bar

1

1

0.1

10

14.4

MPa

10

10

1

10

144

Pa

0.00001

0.00001

10-6

1

-

-

-

-

-

1

N

daN

kN

kg

lbs

1

0.1

0.001

0.102

0.225

PSI UNIT OF WEIGHT 1N

5 5 6

1daN

10

1

0.01

1.02

2.25

1kN

1000

100

1

102

225

1kg

9.81

0.981

0.00981

1

2.205

N·m

daN·m

kN·m

kg·m

lb·in

UNITS OF TORQUE 1N·m

1

0.1

0.001

0.102

8.854

1daN·m

10

1

0.01

1.02

88.54

1kN·m

1000

100

1

102

8854

1kg·m

9.81

0.981

0.00981

1

86.8

1 lb·in

0.1129

0.01129

0.0001129

0.01152

1

5

30.1.4 TORQUE SPECIFICATIONS COARSE PITCH SIZE OF BOLT

TYPE OF BOLT 8.8

8.8 + Loctite 270

10.9

10.9 + Loctite 270

12.9

12.9 + Loctite 270

M6 x 1 mm

9.5 – 10.5 N·m

10.5 – 11.5 N·m

14.3 – 15.7 N·m

15.2 – 16.8 N·m

16.2 – 17.8 N·m

18.1 – 20 N·m

M8 x 1.25 mm

23.8 – 26.2 N·m

25.6 – 28.4 N·m

34.2 – 37.8 N·m

36.7 – 40.5 N·m

39 – 43 N·m

43.7 – 48.3 N·m

M10 x 1.5 mm

48 – 53 N·m

52 – 58 N·m

68 – 75 N·m

73 – 81 N·m

80 – 88 N·m

88 – 97 N·m

M12 x 1.75 mm

82 – 91 N·m

90 – 100 N·m

116 – 128 N·m

126 – 139 N·m

139 – 153 N·m

152 – 168 N·m

M14 x 2 mm

129 – 143 N·m

143 – 158 N·m

182 – 202 N·m

200 – 221 N·m

221 – 244 N·m

238 – 263 N·m

M16 x 2 mm

200 – 221 N·m

219 – 242 N·m

283 – 312 N·m

309 – 341 N·m

337 – 373 N·m

371 – 410 N·m

M18 x 2.5 mm

276 – 305 N·m

299 – 331 N·m

390 – 431 N·m

428 – 473 N·m

466 – 515 N·m

509 – 562 N·m

M20 x 2.5 mm

390 – 431 N·m

428 – 473 N·m

553 – 611 N·m

603 – 667 N·m

660 – 730 N·m

722 – 798 N·m

M22 x 2.5 mm

523 – 578 N·m

575 – 635 N·m

746 – 824 N·m

817 – 903 N·m

893 – 987 N·m

974 – 1076 N·m

M24 x 3 mm

675 – 746 N·m

732 – 809 N·m

950 – 1050 N·m

1040 – 1150 N·m

1140 – 1260 N·m

1240 – 1370 N·m

M27 x 3 mm

998 – 1103 N·m

1088 – 1202 N·m

1411 – 1559 N·m

1539 – 1701 N·m

1710 – 1890 N·m

1838 – 2032 N·m

M30 x 3.5 mm

1378 – 1523 N·m

1473 – 1628 N·m

1914 – 2115 N·m

2085 – 2305 N·m

2280 – 2520 N·m

2494 – 2757 N·m

FINE PITCH SIZE OF BOLT M8 x 1 mm

TYPE OF BOLT 8.8

8.8 + Loctite 270

10.9

10.9 + Loctite 270

12.9

12.9 + Loctite 270

25.7 – 28.3 N·m

27,5 – 30,5 N·m

36,2 – 39,8 N·m

40 – 44 N·m

42,8 – 47,2 N·m

47,5 – 52,5 N·m

M10 x 1,25 mm

49.4 – 54.6 N·m

55,2 – 61 N·m

71,5 – 78,5 N·m

78 – 86 N·m

86 – 94 N·m

93 – 103 N·m

M12 x 1,25 mm

90 – 100 N·m

98 – 109 N·m

128 – 142 N·m

139 – 154 N·m

152 – 168 N·m

166 – 184 N·m

M12 x 1,5 mm

86 – 95 N·m

94 – 104 N·m

120 – 132 N·m

133 – 147 N·m

143 – 158 N·m

159 – 175 N·m

M14 x 1,5 mm

143 – 158 N·m

157 – 173 N·m

200 – 222 N·m

219 – 242 N·m

238 – 263 N·m

261 – 289 N·m

M16 x 1,5 mm

214 – 236 N·m

233 – 257 N·m

302 – 334 N·m

333 – 368 N·m

361 – 399 N·m

394 – 436 N·m

M18 x 1,5 mm

312 – 345 N·m

342 – 378 N·m

442 – 489 N·m

485 – 536 N·m

527 – 583 N·m

580 – 641 N·m

M20 x 1,5 mm

437 – 483 N·m

475 – 525 N·m

613 – 677 N·m

674 – 745 N·m

736 – 814 N·m

808 – 893 N·m

M22 x 1,5 mm

581 – 642 N·m

637 – 704 N·m

822 – 908 N·m

903 – 998 N·m

998 – 1103 N·m

1078 – 1191 N·m

M24 x 2 mm

741 – 819 N·m

808 – 893 N·m

1045 – 1155 N·m

1140 – 1260 N·m

1235 – 1365 N·m

1363 – 1507 N·m

M27 x 2 mm

1083 – 1197 N·m

1178 – 1302 N·m

1520 – 1680 N·m

1672 – 1848 N·m

1834 – 2027 N·m

2000 – 2210 N·m

M30 x 2 mm

1511 – 1670 N·m

1648 – 1822 N·m

2138 – 2363 N·m

2332 – 2577 N·m

2565 – 2835 N·m

2788 – 3082 N·m

TORQUESPECIFICATIONS

6

WHEEL NUT TIGHTENING TORQUES Wheel nut tightening torques recommended from rim’s O.E.M. with reference the the quality of the rim’s material.

WHEEL NUT TIGHTENING TORQUES RECOMMENDED WHEEL NUTS TORQUE CHARACTERISTICS

WHEEL NUTS WITH INTEGRATED SPHERICAL COLLAR

FLAT COLLAR WHEEL NUTS WITH SEPARATE SPHERICAL LOCK WASHER

WHEEL NUTS WITH INTEGRATE SEAT CAPTIVE WASHER

ILLUSTRATION

WHEEL STUD THREAD

RIM MATERIAL QUALITY ST 37

**ST 52

M18X1,5 mm

330 N-m

460 N-m

M20X1,5 mm

490 N-m

630 N-m

M22X1,5 mm

630 N-m

740 N-m

M18X1,5 mm

270 N-m

360 N-m

M20X1,5 mm

360 N-m

450 N-m

M22X1,5 mm

460 N-m

550 N-m

M18X1,5 mm

260 N-m

360 N-m

M20X1,5 mm

350 N-m

500 N-m

M22X1,5 mm

450 N-m

650 N-m

**RIM’S MATERIAL ST 52 IS RECOMMENDED BY DANA ON AXLE APPLICATION. IT IS THE OPTIMUM MATERIAL FOR TIGHTENING THE RIM TO THE HUB.

!

NOTE

The wheel nut tightening torque is related only on nut thread and stud thread dry (without oil or any lubricant).

!

NOTE

The wheel nut tightening torque takes into consideration not only the nut + stud characteristics, but also the quality of the rim material.

7

30.1.5 MAINTENANCE MAINTENANCE POINTS

3

1

2

4

2

1 3

1.

2.

3.

4.

4

3

4

2

Oil fill plug Oil drain plug Check level plug Grease zerk

8

30.1.6 OIL DRAINING MANDATORY PROCEDURE !

WARNING Do not attempt any maintenance if the axle is hot (40-50°C / 104-122°F). Hot oil and components can cause personal injury. Avoid skin contact. Wear protective gloves and glasses.

Make sure all fluids are contained during inspection, maintenance, tests, adjustment and repair of the product. Prepare a suitable container to collect the fluid before removing any component containing fluids.Dispose of all fluids following legal and local regulations.

CENTRAL HOUSING Before draining oil it is mandatory to loosen the oil filling plug or the breather ( if present ), and wait until the internal pressure is completely released. Remove the oil draining plug and drain oil only when the pressure is completely released.

PLANETARY GEAR REDUCTION Before draining oil it is mandatory to rotate the planetary gear reduction in order to move the oil plug in filling position, then loosen the oil plug and wait until the internal pressure is completely released. Remove the oil plug and drain oil only when the pressure is completely released.

9

30.1.7 MAINTENANCE INTERVALS OPERATION

COMPARTMENT 1ST CHANGE FREQUENCY (whs) / CHECK (whs)

Oil level check

All

10 whs

Oil Change

Differential

100 - 250 whs max. *

Hub Reduction

100 - 250 whs max.*

Dropbox (if any)

100 - 250 whs max.*

Monthly

1000 whs

LUBRICANTS

REMARKS

For details see below

Clean carefully oil plug magnet

Central body standard bevel gears - UTTO (API GL4), or gear: J20/C, MF M1143, or gear: SAE80W/90 (API GL4 or GL5)

If with limited slip differential, and/or wet brakes, use LS additivated oils. Clean carefully oil plug magnet.

Central body hypoid bevel gears - SAE80W/90 (API GL5) UTTO (API GL4) J20/C; Clean carefully oil or gear: SAE80W/90 (API plug magnet.

GL4 or GL5) Gears with wet discs Clean carefully oil clutch - ATF GM Dexron plug magnet. * in accordance with IIE, Dexron III Machine Service reOnly gears - UTTO J20/C, quirements or gear: SAE80W/90 (API GL4 or GL5)

Adjustment

Negative brake (SAHR)

100 whs

Every 500 whs

For hydraulic actuations Not applicable (brakes, SAHR, 100% diff. lock, etc.) use ATF oil e.g. DOTbrakefluidsoilGM Dexron IIE, Dexron III s a r e N O Tc o m p a t ible w/stdoils

Every 200 whs

No lubricant allowed

Service brake Tightening

Wheel nuts

10 whs

Greasing

King Pin Tapered Bearings

10 whs

Seals

10 whs

King Pin Bushings

10 whs

Trunnion Bushings

10 whs

Check for any damage or corrosion of treads or mating surfaces

Normal work – NLGI2 EP or NLGI3 EP Weekly or Severe duty – Daily

Supply grease until clean grease is visible from outside.

Grease performance level acc. to: Ac- cordNLGI2 EP or NLGI3 EP ing to DIN 51825 levwith Moly Addittive el KP2K-30 (NLGI2) or KP3K-20 (NLGI3); ASTM D4950 NLGI2 GC-LB

In case of severe duty, half oil change intervals must be applied.

In case of extreme enviroments, chatter noise, reduce oil change intervals accordingly.

In case of extremely low ambient temperatures (<-20°C), use appropriate oils w/ low viscosity: UTTO J20/D (std Bevel Gears), SAE 75W/90 API GL5 LS (Hypoid Bevel Gears: models 192, 193, 194).

API GL5: Acc. To MIL L-2105-B See PSB 00279 (latest update) for more info regarding lubricants and viscosity grades.

10

30.1.8 LUBRICANT & SEALANT SPECIFICATIONS 1.

2.

Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.

The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar products marketed by different brand names with different trademarks.

LOCTITE 242 Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength locking. Before using it, completely remove any lubricant by using the specific activator.

LOCTITE 243 The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.

LOCTITE 270 Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any lubricant by using the specific activator.

To remove parts, it may be necessary to heat them at 80° C approximately.

LOCTITE 275 Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts, for pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a maximum diametrical clearance of 0.25 mm.

LOCTITE 510 Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can seal clearances between flanges up to 0.2 mm.

LOCTITE 577 Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather difficult, so heating may be necessary for larger diameters.

LOCTITE 638 Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue together parts with clearance ranging between 0.1 and 0.25 mm.

LOCTITE 648 Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue together parts with radial clearance below 0.1 mm.

AREXONS (REPOSITIONABLE JOINTING COMPOUND FOR SEALS) Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer diameter of sealing rings for rotating shafts with outer metal reinforcement.

SILICONE Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and physical elements.

Polymerises with non-corrosive dampness.

TECNO LUBE/101 (SILICONE-BASED GREASE) Highly adhesive synthetic grease, with silicone compounds added.

Applied to adjustment screws with hole communicating with oil-type fluids. Used when frequent adjusting is required.

MOLIKOTE (DOW CORNING) Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent sticking and oxidation of parts that are not lubricated on a regular basis.

(LITHIUM-BASED) GREASE Applied to bearings, sliding parts and used to lubricate seals or parts during assembly.

11

30.2 SAFETY PRECAUTIONS 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

During all operations described in this manual, the axle should be fastened onto a trestle, while the other parts mentioned should rest on supporting benches.

When removing one of the arms, an anti-tilting safety trestle should be placed under the other arm.

When working on an arm that is fitted on the machine, make sure that the supporting trestles are correctly positioned and that the machine is locked lengthways.

Do not admit any other person inside the work area; mark off the area, hang warning signs and remove the ignition key from the machine.

Use only clean, quality tools; discard all worn, damaged, lowq uality or improvised wrenches and tools. Ensure that all torque wrenches have been checked and calibrated.

During maintenance operations, always wear protective glasses, safety footwear, protective gloves and all P.P.E. (Personal Protective Equipment) in function of the risks which the workers may be exposed to.

Should you stain a surface with oil, remove marks straight away.

Dispose of all lubricants, seals, rags and solvents once work has been completed. Treat them as special waste anddispose of them according to the relative law provisions obtaining in the country where thea xles are being overhauled.

Make sure that only weak solvents are used for cleaning purposes; avoid using turpentine, dilutants and toluol, xylolbasedorsimilar solvents; use light solvents such as Kerosene, mineral spirits or water-based, environment friendly solvents.

For the sake of clarity, the parts that do not normally need to be removed have not been reproduced in some of the diagrams.

For agricultural axles, the terms RIGHT and LEFT refer to the position from operator’s seat. For construcition axle,the terms RIGHT and LEFT refer to the position outside facing the machine (with the input drive facing forward).

After repair work has been completed, accurately touch up any coated part that may have been damaged.

Follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle.

Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE.

12

30.3 CHECKING WEAR AND REPLACING THE BRAKING DISCS 30.3.1 EXPLODED VIEW 10

15 17

9 8

17

1

11

2

14

MAXIMUM 10°

16 3

13

12

6

18 7 5

4

30.3.2 DISASSEMBLY !

!

CAUTION Replace the braking disks and the intermediate disks on both sides if necessary.

CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE.

! CAUTION Perform all operations on both arms.

2

17 A

1

Remove the swinging support (2) on the side opposite the drive.

Remove the oil-level plug (1).

!

NOTE If the bushing (17) is worn and needs replacing, write down the assembly side of the connection notch “A”.

T1

S

Apply the brakes and, keeping them under pressure, check the linings “S” between the disks using tool T1 (See drawing T1, pg. 17).

Minimum “S”: 4.5 mm.

13

!

1.

2.

NOTE If the disks do not need replacing, avoid switching their position.

Extract the u-joint (18).

3 8

9

Disconnect the pins of the steering bars from the steering case (See STEERING CYLINDER).

Sling the arm (3) to be removed and put the rod under slight tension.

8

Remove the reversal springs (8) from the piston (9).

4 5

6

!

NOTE If the springs (8) are weak or deformed they must be replaced.

9 3 Loosen and remove the screws (4) and the washers (5) that fix the arm (3) to the central body (6).

10

Remove the pin screws (10) guiding the piston (9).

7

!

CAUTION If the screws are to be replaced, write down the different colors for the different brake gap.

3

Remove the arm (3) together with the pack of the braking disks (7). Place the arm on a bench

9

Slowly introduce compressed air through the connection of the braking circuit in order to extract the entire piston.

18 7

!

CAUTION Hold on to the piston as it may be suddenly ejected and damaged.

Remove the braking disks (7) and write down their order of assembly.

14

30.3.3 ASSEMBLY

14 12 11 13

9

3

9

Accurately clean the piston (9) and the seats of slide and seal.

Replace the o-rings (11) and (12) and the anti-extrusion rings (13) and (14); make sure that the assembly side is correct.

Assist the insertion of the piston (9) by lightly hammering around the edge with a plastic hammer.

! CAUTION Accurately check the positioning of the anti-extrusion rings (13) and (14).

10

15 15

Fit the pin screws (10) making sure that they are all of the same color.

See Service Part List “Brake” section for bolt color detail.

Apply Loctite 270 to the thread.

Torque wrench setting: 5 - 7 N·m.

9

Insert the stroke automatic regulation springs (15); place them in line with the piston (9).

8

9 A A

9

8

Fit the reversal springs (8) on the piston (9).

Lubricate the seals (11) and (12) and fit the piston (9) into the arm (3).

! CAUTION Pay attention not to deform the connections of the springs.

! CAUTION Make sure that the piston seat fits into the stop pin (A) inside the arm.

15

SPECIALTOOLS

BB

7

Slightly lubricate the braking disks (7) and fit them in the arm following the correct sequence; orient them so that the oil circulation holes and the marks “B” are perfectly lined up.

!

NOTE When installing the steel discs, the slot corresponding to the oil level cap should always be kept free.

16

Check that the positioning of the sealing ring (16) on the arm is intact; install the complete arm.

Lock it into position using two screws (4) and washers (5).

T2

Check the flatness of the arms using tool T2 (See drawing T2 ) and finally lock the arms with the screws (4) and the washer (5) using the criss-cross method.

Torque wrench setting: 298 N·m

16

30.3.4 SPECIAL TOOLS T1 P/N : 2313

10

1

1

32

32

8

45

4.3

4.5

32

32

45

°

110

25

°

25

160

T2

=

200

=

20

P/N : 2305

= =

120±0.1

120±0.1

50

90

840 930

17

30.4 COMPLETE STEERING CASE 30.4.1 EXPLODED VIEW

6 8

5 4

9 3 10

2 1

18

12

13

10 14

15 16 17

18

30.4.2 DISASSEMBLY

SASSEMBLY !

CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE

3

4

15

4

19

8

19

1

Loosen and remove the capscrews (15)(8) from the articulation pin (19)(4)

9

4

Remove the complete steering case (1).

3 Using two levers, remove the top articulation pin (4) complete with front seal (9) and shims (3).

! CAUTION Pay attention not to damage the surfaces.

10

19 Using two levers, remove the top articulation pin (4) complete with front seal (9) and shims (3).

19

30.4.3 ASSEMBLY

1

Lubricate the terminal of the u-joint and install the steering case (1).

Lubricate steering case.

!

CAUTION Pay due attention not to damage the dust cover rings and the sealing rings.

12 10 19

4 1

Fit the unit (19) in the steering case (1). Position the screws (15) and tighten.

Check for the correct assembly side of the seal (10).

3

Prepare a series of shims (3) of 0,85 mm. To be assembled under the upper pin (4).

140 N·m

15

140 N·m

3

4

Tighten the new capscrews (15) of top and bottom articulation pins in sequence using the criss-cross method.

Torque wrench setting: 140 N·m Fit a new seal (3) onto the top articulation pin (4). Lubricate and install the unit in the steering case.

Position the screws (8) and tighten with torque wrench 140N·m.

Check the correct assembly side of the seal (3).

20

Check with a lever that there is no vertical gap. In case there is any gap, determine the width and reduce it by removing shims.

30 - 60 N·m

Check the torque of the pins, which has to be between 30 and 60 N·m.

If the preliminary measured value is too high, the shims have to be increased.

21

30.5 DOUBLE U-JOINT 30.5.1 EXPLODED VIEW

1

3 2

9 2

10

11

12

4

13

3

14

22

30.5.2 DISASSEMBLY ASSEMBLY !

CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE

4 13

2

3

Using two levers, remove the top articulation pin (4) complete with front seal (9) and shims (3).

Loosen and remove the capscrews (15)(8) from the articulation pin (19)(4)

11

4

10

11

12

Using two levers, remove the top articulation pin (4) complete with front seal (9) and shims (3).

Using two levers, remove the top articulation pin (4) complete with front seal (9) and shims (3).

!

NOTE When installing the steel discs, the slot corresponding to the oil level cap should always be kept free.

!

NOTE When installing the steel discs, the slot corresponding to the oil level cap should always be kept free.

13

9

Using two levers, remove the top articulation pin (4) complete with front seal (9) and shims (3).

23

30.5.3 ASSEMBLY

14

T2

T1

12

11

13

13

13

9

Using tools T1 (See drawing T1 p. 33) and T2 (See drawing T2), insert the sealing ring (12) and the bearing (11) in the bushing (13).

Fit the check ring (9) on the bushing unit (13); also put the o-ring (14) into position.

!

NOTE Carefully check the assembly side of the seal (12).

2

10

11

Insert the u-joint and tighten the top and bottom studs (2).

Torque wrench setting: maximum 15 N·m.

!

NOTE For u-joint coming with a bushing, center the point of the check studs in the slot.

Fit the snap ring (10) on the bearing (11).

2 13 4

Heat the bearing in oil at an approximate temperature of 100°C and fit the entire bushing (13) on the u-joint (4).

Apply Loctite 242 to the jutting parts of the studs (2).

24

ASS 3

Install the nuts (3) on the studs (2) and tighten them using a torque wrench.

Torque wrench setting: 122 N·m

25

30.5.4 SPECIAL TOOLS T1 P/N : 3342 Ø54,5

0 -- 0.1

Ø30

10

70

46

0.8

R5

0 -- 0.2

2,5

0 + 0.1

7

3 x15 °

0.8

0.8

Ø54

14

0.8

0.8

Ø79 Ø90

-- 0.15

T2 P/N

10 1.5 x45 ° Proteggere da cementazione

R1

0.8

30

Ø30

49.5

89

0 R1 3 x45 °

0.8

130 155

26

30.6 PLANETARY REDUCTION GEAR 30.6.1 EXPLODED VIEW

19

16 18

3

17

7 14

12 15

5 9

10

8

20 13 6

11 4 9 10 2

27

1

30.6.2 DISASSEMBLY ! CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE 9 1

2 1

Remove the snap rings (9).

Disconnect the steering bars from the steering case (3). For details, see COMPLETE STEERING CASE. Remove the securing screws (1) from the planetary carrier cover (2).

10

3

With the help of a puller, remove the planetary wheel gears (10).

2

!

NOTE Write down the assembly side of planetary wheels.

Disjoint the planetary carrier cover (2) from the steering case (3) by alternatively forcing a screwdriver into the appropriate slots.

5

2

4

Loosen and remove the tightening nuts (4) from the crown flange (5).

Remove the complete planetary carrier cover (2).

28

6

7

Partially extract the hub (7) using a plastic hammer.

Remove the safety flange (6).

!

NOTE Alternately hammer on several equidistant points.

5 8

Using a puller, remove the complete crown flange (5) by acting on the stud bolts.

Remove the external bearing (8).

7 12

13

Remove the snap ring (12) from the crown (13).

Remove the complete hub (7).

5

14

Remove the crown flange (5).

Remove the sealing ring from the hub (14).

29

3

15

Remove the internal bearing (15).

Remove the pins and remove the steering case (3).

For details, see COMPLETE STEERING CASE.

7

Remove the external thrust blocks from the bearings (8) and (15) force a pin-driver into the appropriate slots on the hub (7).

!

NOTE Hammer in an alternate way so as to avoid clamping or deformation of the thrust blocks.

16 17 18

16 17 18

3

Use a puller to remove the centering ring (16), the sealing ring (17) and the bearing (18) from the steering case (3).

!

NOTE Write down the orientation of both centering ring (16) and sealing ring (17).

30

30.6.3 ASSEMBLY T1

3

15

T3A

18

Lubricate the bushing (18) and the seat of the steering case (3).

Install the bushing (18), using tool T1 (See drawing T1).

Lubricate the seats of the bearings and position the hub (7) on tool T3A (See drawing T3 ); position the thrust block of the internal bearing (15).

!

NOTE Check that the thrust block is correctly oriented.

16 17

T2

T3B 7

Lubricate the outer surface of the sealing ring (17) and centering ring (16); fit them into their seat using tool T2 (See drawing T2).

Position the upper part of tool T3B (See drawing T3 ) and press the thrust blocks into the hub (7) all the way down.

3

15

19

Fit the steering case (3) onto the U-joint (19) and install the articulation pins.

For pin assembly details, see COMPLETE STEERING CASE Fit the bearing (15) into the internal thrust block

8 T3A T9 A

Position the lower part of tool T3A (See drawing T3) and the thrust block of the external bearing (8) under the press.

31

!

NOTE Using a plastic hammer, drive the bearing to the limit stop by lightly hammering around the edge.

14 7

5 Apply a repositionable jointing compound for seals to the outer surface of the sealing ring (14).

Position the sealing ring (14) in the hub (7).

13

!

NOTE Check that the ring (14) is correctly oriented.

Insert the flange (5) in the crown (13).

T4 12

14

13 5

Insert the snap ring (12) in order to fix the flange (5) in the crown (13).

Position tool T4 (See drawing T4 ) and press the sealing ring (14) into its seat.

!

NOTE Carefully check that ring (12) is properly inserted in the slot of the crown (13)

7

5

Install the hub (7).

8

Fit the complete crown flange (5).

!

NOTE In order to fasten the flange (5), use a plastic hammer and alternately hammer on several equidistant points.

Install the external bearing (8).

32

6

9

5

10

Apply Tecnolube Seal 101 grease to the surface of the safety flange (6) which touches the crown flange (5).

Fit the safety flange (6).

Lock the gears (10) into position by fitting the snap rings (9).

20

3

2 Fit the planetary carrier cover (2) onto the hub (3).

! CAUTION Check that the o-ring (20) is in good condition and in position.

Apply Loctite 242 to the studs and fit on the nuts (4).

4

1

1 2 Tighten the nuts (4) using criss-cross method in two stages.

Initial torque wrench setting: 120 N·m Final torque wrench setting: 255 - 285 N·m

Lock the planetary carrier cover (2) by tightening the screws (1).

Torque wrench setting for screws: 40 - 50 N·m

T5

2 10

With the help of tool T5 (See drawing T5) insert the planetary wheel gears (10) into the cover (2).

Accurately check the orientation.

Connect the steering bars. For details, see COMPLETE STEERING CASE. 33

30.6.4 SPECIAL TOOLS T1 P/N : 2303

Proteggere da cementazione

52 2 x45 °

R1

50

.5

R1

0

Ø64

Ø25

Ø35

-- 0.1

Ø50 -- 0.2

0.8 0.8

5 x15 °

3 x15 °

0

3 -- 0.2 150

13

50

213

T2 P/N : 3363

75 0.8

0.8

Proteggere da cementazione

50

3x45°

0

0.8

5x15° 70

3-- 00.2 13

150 233

34

Ø75

Ø25

Ø35

0.1 Ø50 ---- 0.2

Ø56

Ø64

R1

T3 P/N : 3354

Ø158.5 20°

Ø50 H7

Ø35 16

Ø30

Ø158.5

0.8

Ø40 Ø50---- 0.08 0.12

Ø150 Ø200 ±0.03

Ø95

35

129

117

20°

8x15°

Ø140

102

R3

113 148

--

R3

25

100

R5

Ø132 -- 0.3 0.5

R3

0.8

T4 P/N : 3502

0.8

0.8

Ø139.5

0 -- 0.1

Ø153

5x15°

0.8

0.8

5.5

19

26

41

1

-- 0.2 -- 0.3

1x45°

120

2x45°

Ø40

Ø168 Ø180

T5 P/N : 2304

2 x15° 2 x45°

R3

0.8

Ø35

Ø39

Ø50

10 15 0.8

25 175

36

30.7 STEERING CYLINDER 30.7.1 EXPLODED VIEW 7

15

5

9

11

2

10

1

15

4

8

6 14

7 12

4

12 14

13 13

6

OLD

NEW

6

3

37

6

30.7.2 OPTICAL SENSOR AND MAGNETIC SENSOR

38

30.7.3 DISASSEMBLY ! CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE. 4

7 1

5

2

Disconnect the tapered pins of the articulation (4) from the steering case (7) by means of a puller.

Remove the centering sensor (1) of the steering piston (2), if supplied.

13

5 3

6 4

If the connection of the steering bars includes a safety collar (13), raise the border.

OLD VERSION Remove the safety cotter pins (3) from the articulation pins (4) of the steering bars (5). Remove the castellated nuts (6) that lock the articulation pins (4).

2

! CAUTION Dispose of used cotter pins.

4 Disconnect left and right steering bars(5) from the piston (2).

9

8

NEW VERSION Remove the nuts (6) that lock the articulation pins (4).

Remove the securing screws (8) from the steering cylinder (9).

39

3 9

4

With the help of a drift, apply pressure to the stop ring (4) that is placed inside the cylinder (3) and extract the ring using a screwdriver.

Extract the cylinder (9) using a plastic hammer.

!

NOTE For cylinder disassembly, refer to STEERING CYLINDER.

2

2

1

3

5

Hammer the piston (5) on the rear of the head (2) using a plastic hammer.

Continue hammering until the head (2) is ejected from the cylinder (3).

Remove the snap ring (1) from the cylinder head (2).

5

3

2 2

3 A A

Disassemble the cylinder unit (3) by extracting first the head (2), then the piston (5).

With the help of a plastic hammer, push the head (2) inside the cylinder (3).

! CAUTION Write the assembly side of the piston (5). The beveled part “A” of the piston is oriented towards the head (2).

!

NOTE The head should line up with the edge of the cylinder.

Remove all seals, anti-extrusion rings and scraper rings from head (2), cylinder (3) and piston (5).

1.

2.

40

!

NOTE All seals must be replaced every time the unit is disassembled.

Particular attention must be paid not to damage the seats of both seals and piston slide.

30.7.4 ASSEMBLY

6

7

8

11

13

10

12

After applying grease, install the sealing ring (6) of the shaft, the anti-extrusion ring (7) and the scraper ring (8) inside the cylinder (3).

Prepare the piston (5) by fitting it with the guide ring (10), the magnetic ring (11), the o-ring (12) and the seal (13).

!

!

CAUTION Thoroughly check that positioning of the anti-extrusion ring (7) is correct.

8

7

5

1.

2.

CAUTION In order to facilitate assembly, apply grease.

If a centering sensor is not fitted, then the magnetic ring (11) should be replaced by another guide ring (10).

6 T1

55

33

After applying grease, install the sealing ring (6) of the shaft, the anti-extrusion ring (7) and the scraper ring (8) in the head (2).

Apply tool T1 (See drawing T1 p. 59) to the shaft on the opposite side of the head (2) and center it on the cylinder (3) so that it fits into the piston (5).

! CAUTION Thoroughly check that positioning of the anti-extrusion ring (7) is correct.

!

NOTE Apply a little grease to seals and cylinder.

9 5

3

Push the piston (5) into the cylinder for 100 mm using a plastic hammer.

Fit the seal (9) onto the outside of the head (2).

1.

2.

! CAUTION In order to facilitate assembly, apply grease to the outer surface of the piston.

Do not roll the seal (9) up.

41

T1

2 2

5

2

Remove tool T1 (See drawing T1 p. 59) and apply it to the opposite side of the piston (5).

Apply pressure to the head using two screwdrivers or levers until the head is fastened onto the stop ring (4).

22

22 T1

1

5

Apply grease to head (2) seals, fit the head onto the piston and push it into the cylinder (3) using a plastic hammer.

Fit the snap ring (1) on the head (2).

! CAUTION Make sure that the snap ring (1) is securely fastened in its seat.

If necessary, force it into its seat using a drift and a hammer.

!

NOTE Insert the head as to line it up with the edge of the cylinder.

44

9

33

Insert the stop ring (4) ensuring that it fits into the seat of the cylinder (3).

Check that the o-rings (15) of the axle unit are in good condition; lubricate the seats of the seals (15) and fit the steering cylinder (9) into its seat.

42

9

8

6

Lock the cylinder by criss-cross method the screws (8).

Torque wrench setting: 116 - 128 N·m

3

OLD VERSION Insert the cotter pins (3) and bend the safety stems.

13

7

A A

Apply Loctite 242 to the thread and connect the steering bars by screwing the terminals onto the piston stem.

Torque wrench setting: 240 - 270 N·m

NEW VERSION Insert the pins (4) in the steering case (7) and lock into position using a torque wrench setting of 260 - 290 N·m.

!

NOTE Versions with coupling require that the rim of the articulation (13) is riveted onto the surfaces of the piston stem.

Use new cotter pins.

!

CAUTION

1 7

A A

Install the centering sensor (1) for checking piston centering - if applicable - and tighten the screws (10).

Torque wrench setting: 5 - 6 N·m

OLD VERSION Insert the pins (4) in the steering case (7) and lock into position using a torque wrench setting of 260 - 290 N·m.

Find the position of the notching in relation to the hole of the cotter pins and tighten the nut (6) further.

! CAUTION Eliminate the action of the negative brake, if fitted.

! CAUTION Check that rubber guards (A) are intact.

43

=

T2

=

T2 B

Apply tools T2 (See drawing T2 p. 60) to the hubs and lock them.

Using a level “B”, check that tools are perfectly flat and parallel to each other.

Center the piston by slowly moving it first in one direction then in the other. Position it half way on the stroke, which is determined by the switching on and off of the signal lamp of the inspection device in the reversal stage.

1

C

Inspect distance “C” on one side of the piston and write down the size for checking later adjustments.

Connect the sensor (1) to the inspection device according to either diagram.

!

NOTE If cylinders come without a sensor, the centering of the piston must be carried out on the basis of the maximum stroke.

I max=0,80 A NERO BLACK

CONNETTORE CONNECTOR 1

2 4

BLU BLUE

3

-BATTERIA BATTERY

MARRONE BROWN

2A

+

T2

Sensor connection card, STANDARD version.

T2 I max=0,80 A

Without moving the piston, check front “B” and rear “A” using tool T1 (See drawing T2) at “R” value.

R = 400 mm (see picture below).

NERO BLACK

CONNETTORE CONNECTOR 1

2 4

BLU BLUE

3

MARRON E BROWN

BATTERIA BATTERY

!

NOTE In order to check the rear size, rotate the bevel pinion and check that tools T2 (See drawing T2 ) are flat.

--

+

Sensor connection card, OPTIONAL version.

44

A

R

R

16

B Adjust the convergence with a difference between “A” and “B” of maximum 2,5 mm.

A ± B = 2,5 mm R = 400 mm

Rotate the ball-and-socket joints (16) until convergency has been obtained.

Check that articulations move easily and lock the collars (12).

Torque wrench setting for nuts: 42 - 52 N·m

5 14

15

If necessary, adjust convergency without moving the centering of the piston and adjust the length of the steering bars (5) or (14).

11

CONVERGENCY ADJUSTMENT ON ALTERNATIVE VERSIONS Loosen the nuts (11) and screw them onto the ball-andsocket joints (15).

!

NOTE With a half turn of screw, the front size is reduced by about 3 mm, whereas the rear one is increased by about 3 mm.

15

11

12

Hold the articulations still and rotate the balland- socket joints (15).

Once the convergency has been adjusted, lock the nuts (11).

Torque wrench setting for nuts: 298 - 328 N·m

CONVERGENCY ADJUSTMENT ON UNITS WITH COLLAR Loosen the nuts on the collars (12).

45

ADJUSTING THE STEERING ANGLE

Pos. 2

Pos. 4

Pos. 3

Pos. 1

Loosen the nut of one of the adjusting screws on cylinder side.

As you hold the adjusted screw in position against the arm stop, adjust the screw opposite, on noncylinder side, until it leans against the arm stop.

Lock into position with nut tightened to 145 - 148 N·m.

!

NOTE Perform the same operations on both sides (see diagram).

! CAUTION The screws must lean against the respective arm stops all at the same time.

Pos. 2

Pos. 4

Pos. 3

Pos. 1

W

Adjust the “W” distance of the screw according to required data setting.

Lock into position with nut tightened to 145 - 148 N·m.

Repeat the operation on both sides.

!

NOTE The screws must lean against the respective arm stops all at the same time.

Perform one full steering operation until the adjusted screw leans against the arm stop.

46

30.7.5 SPECIAL TOOLS T1 P/N : 2724

-- 0.05

Ø45 -- 0.10 0.8

M8 x1.25

R2

5°

14 6 1

7 1 x45

75

44

30

15

.5

30 °

Ø6.5 0

Ø20.4 -- 0.05 Ø43.6

+ 0.05 0

47

T2

P/N : 1867

100 50 17±0.1

R110

27.5±0.2

125

125

55 Ø23

R1 5

500 555

5x45°

48

30.8 DIFFERENTIAL UNIT 30.8.1 EXPLODED VIEW

4 3

5 1 6 7

2

3 1

49

30.8.2 DISASSEMBLY ! CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE. T1

Apply tool T1 (See drawing T1 ) and remove the ring nuts.

!

NOTE Accurately clean the threaded portions on ring nuts of body and cover.

Remove the complete arms.

For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS.

4

5

3

4 1

Remove the capscrews (4) from the middle cover (5).

Mark the position of the ring nuts (1). Remove the capscrews (3) from the ring nuts (1).

5

1

Insert a screwdriver in the opposing slots then force and remove the middle cover (5) and the complete differential unit.

!

NOTE Support the pieces using a rod.

Uniformly heat the ring nuts (1) up to a temperature of 80° C.

50

2

5

6

If the bearings need replacing, extract the external thrust blocks of the bearings (7) and (8) from middle cover and central body.

!

NOTE Accurately check the o-ring (6).

7

Remove the top plug (7).

!

NOTE The cap must be replaced each time the unit is disassembled.

51

30.8.3 ASSEMBLY

2 T1 5

If the bearings are replaced, insert the external thrust blocks in the middle cover (5) and in the central body (2).

1 5

Tighten ring nuts on the crown side until clearance between pinion and crown is zero, then lock the crown; go back 1/4 - 1/2 turn.

!

NOTE If the ring nuts (1) are removed, coat them with Loctite 242.

6

T2

Position the differential unit in the central body (2) with the help of a bar and fit the middle cover (5).

!

NOTE Thoroughly check the state of the o-ring (6) and make sure that the cover is fitted with the oil discharge in the lower position.

4

Pre-set the bearings by means of the ring nut situated on the opposite side of the crown, so as to increase pinion torque up to 140 - 210 N·cm.

! CAUTION If bearings are not new, check the static torque; if bearings are new, check the continuous torque.

5 4

A A

4

Lock the middle cover (5) with screws (4).

Torque wrench setting for screw: 23.8 - 26.2 N·m Introduce a dial indicator with rotary key “A” through the top plug hole (7).

Position the dial indicator on the center of one of the teeth of the crown, pre-set it to 1mm and reset it.

52

7

A A

3

Manually move the crown in both directions in order to check the existing backlash between the pinion and the crown.

Apply Loctite 242 to the screws (3), fit them into one of the two holes and tighten.

Torque wrench setting: 23.8 - 26.2 N·m Fit the top plug (7) after applying repositionable jointing compound for seals to the rims.

T1

Adjust the backlash between the pinion and the crown by loosening one of the ring nuts (1) and tightening the opposite to compensate.

Normal backlash: see table.

Re-install the complete arms.

For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS.

Difference between MIN and MAX clearance for whole circumference should not exceed 0.09 mm.

53

30.8.4 SPECIAL TOOLS T1

P/N : 3333

0

R1

36

-- 0.1

24 17

238

T2

P/N : 3317/4

59

Ø125

Ø75

0.08 Ø55 ---- 0.12

60

35

15

Tornito Ø 32,25

M6 5

1/4”

5x15

48

Ø14

Ø10

Ø20

Ø40H7-n6

Ø44

54

0.8

Ø10

0.8

R5

10 x15 ° 8 25

100 20 125

Ø35.5 -- 0.2

Ø15H7-n6

Ø37H7-n6

14 30

Ø25 Ø35

± 0.1

Ø47

Ø106

R30

2 x15 ° 123 33

0.8

30.9

BEVEL PINION

30.9.1 EXPLODED VIEW

8

14

9

12 10 13 5

6

11 7

3 4

1

2

55

30.9.2 DISASSEMBLY ! CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE. 4

2

Remove the flange (2) complete with guard (4) by means of a puller.

5

Remove the complete arms and the differential unit.

For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS and DIFFERENTIAL UNIT.

2 1 Remove the swinging support (5).

If disassembly is awkward, heat the check nut (1) of the flange (2) at 80°C.

6

!

NOTE Heating is meant to loosen the setting of Loctite on the nut (1).

Remove the sealing ring (6).

T1A (T1B)

7

3

T2

T3

Position tool T1A (See drawing T1 p. 77) (or T1B), so as to avoid pinion rotation.

Loosen and remove the nut (1); also remove the o-ring (3).

Position wrench T3 (See drawing T3) onto the ring nut (7) and apply bar hold T2 (See drawing T2). to the pinion (8).

Stop wrench T3 (See drawing T3) and rotate the pinion so as to release and remove the ring nut (7).

56

!

NOTE If disassembly proves awkward, heat the ring nut to approximately 80°C. 12

T4

13 8

Remove the thrust block of the external bearing (13).

Apply blocks T4 (See drawing T4 ) and, with the help of a puller, extract the pinion (8) complete with the internal bearing (9), the spacer (10) and shims (11).

!

NOTE The thrust blocks of the bearings remain in the central body (12).

14 9

8

10 Insert a drift in the appropriate holes and remove the thrust block of the internal bearing (9) as well as the shim washers (14).

11

Remove the pinion (8), shims (11) and spacer (10).

8 9

Using a puller and a press, remove the inner bearing (9) from the pinion (8).

57

30.9.3 ASSEMBLY

DG

T6B

T5

T6C

T6A

T5

13

Using a surface plate, reset a dial indicator “DG” and place it on the measurement ring T5 (See drawing T5) (with a thickness of 30.2 mm).

Preset the depth gauge to approximately 2 mm.

Install tension rod T6C (See drawing T6 p. 80), measurement ring T5 (See drawing T5 ) and front guide tool T6A (See drawing T6) on the thrust block of the external bearing (13).

DG

9

Bring the internal bearing (9), complete with its thrust block, under dial indicator.

Determine overall thickness “D” of the bearing checking the discrepancy between this size and the size of the measurement ring.

Connect the tension rod to the press and move the thrust block of the external bearing (13) into its seat.

Disconnect the press and remove the tension rod.

!

NOTE Before starting the next stage, make sure that the thrust block has been completely inserted into its seat.

! CAUTION Press the thrust block in the center and take several measurements while rotating the thrust block.

T7C

T5

T7B

13

13 T6C T6A Insert tool T7B (See drawing T7 p. 81) complete with external bearing (13), measurement ring T5 (See drawing T5 p. 79) and gauged ring nut T7C (See drawing T7 p. 81).

Manually tighten.

Partially insert the thrust block of the external bearing (13).

58

8

DG 1

T7A

X

GB

Y GB

Fit a dial indicator “DG1” with long stem into bar T7A (See drawing T7 p. 81); when the bar rests on two sizeblock “GB” of 57 mm, reset the gauge.

Preset the gauge to approximately 2 mm and reset.

Check the nominal size (X) marked on the pinion and add or subtract the indicated variation (Y) so as to obtain size “Z”. e.g.: Z= 118 + 0.1 = 118.1 Z= 118 ± 0.2 = 117.8

T7C

(

D

A

T7A

C=Z+D

Lay bar T7A (See drawing T7 p. 81) on gauged nut T7C (See drawing T7 p. 81) and take the measurement “A” at about 57 mm corresponding to the maximum diameter of arms centering.

T5

S) Z C

Calculate size “C” which represents the second value for calculating the size of the shims “S” that are to be placed under the thrust block of the internal bearing (9).

B-C=S

14

R1 15

T7C

T7B A 30. 2

(61-A)+1 15+30.2=B

61

B

Calculate size “B” which will be the first useful value for calculating the size of the shims (14) that are to be inserted under the thrust block of the internal bearing (9).

Calculate the difference between sizes “B” and “C” so as to obtain the size “S” of the shim (14) that will go under the thrust block of the internal bearing (9).

59

DD G

14 9

Insert the stem of a depth gauge “DDG” in either side hole of tool T7C (See drawing T7 p. 81); reset the gauge with a presetting of approximately 3 mm.

Insert shim “S” (14) and the thrust block of the internal bearing (9) in the central body.

!

NOTE To hold shim “S” (14) in position, apply grease.

T7C

9

10

13

T7B

T6A

T6C

Remove the depth gauge and release tools and bearings from the central body.

Re-install all and insert the spacer (10) between bearings (9) and (13); manually tighten the whole pack.

Position tool T6A (See drawing T6 p. 80) and tension rod T6C (See drawing T6 p. 80). Connect the tension rod to the press, fasten the thrust block and then remove the tools.

!

NOTE Before going on to the next stage, make sure that the thrust block has been completely inserted.

DD G

9

H T7C

13 T7B

T7C

9

13

T7B Insert depth gauge “DDG” into tool T7B (See drawing T7 p.

81) T7C (See drawing T7 p. 81) and measure variation “H” in relation to the zero setting performed back at Figure 28.

Position tools T7C (See drawing T7 p. 81) and T7B (See drawing T7 p. 81) complete with tapered bearings (9) and (13); manually tighten until a rolling torque has been obtained.

60

H+ 0,12 √ 0,13 =S 1

11 S1

9

11

10

13

Insert the external bearing (13) in the central body in order to complete the pack arranged as in the figure.

The variation is to be added to a set value of 0.12 - 0.13 mm., so as to obtain the size of shim “S1” (11) which will be inserted between the external bearing (13) and the spacer (10) and subsequently, to determine the preload for the bearings.

8

8 9 Connect the pinion (8) to the tie rod T8A (See drawing T8 p.

82) and T8B (See drawing T8 p. 82); connect the tie rod T8C (See drawing T8 p. 82) (see special tools) to the press and block.

Position the internal bearing (9) and the pinion (8) under a press; force the bearing onto the pinion.

8

12 8

7

10

11

STANDARD INPUT FLANGE VERSION Apply Loctite 242 to the thread of the ring nut (7) and screw the nut onto the pinion (8).

Fit the pinion (8), shim “S1” (11) and spacer (10) in the main body (12).

T2

!

NOTE The thinner shims must be placed in-between the thicker ones.

T3

STANDARD INPUT FLANGE VERSION 61

Apply special wrench T3 (See drawing T3 p. 78) to the ring nut (7) and bar-hold T2 (See drawing T2 p. 78) to the pinion (8).

Lock the wrench T3 (See drawing T3 p. 78) and rotate the pinion using a torque wrench, up to a minimum required torque setting of 500 N·m.

T2

T3

T2

FLANGED GEARBOX VERSION Apply special wrench T3 (See drawing T3 p. 78) to the ring nut (7) and bar-hold T2 (See drawing T2 p. 78) to the pinion (8).

Lock the wrench T3 (See drawing T3 p. 78) and rotate the pinion using a torque wrench, up to a minimum required torque setting of 900 N·m.

STANDARD INPUT FLANGE VERSION Apply onto the pinion (8) the bar-hold and with the help of a torque wrench, check the torque of the pinion (8).

Torque: 120 - 200 N·cm

!

CAUTION STANDARD INPUT FLANGE VERSION If torque exceeds the maximum value, then the size of shim “S1” (11) between the bearing (13) and the spacer (10) needs to be increased.

If torque does not reach the set value, increase the torque setting of the ring nut (7) in different stages to obtain a maximum value of 570 N·m.

If torque does not reach the minimum value, then the size of shim “S1” (11) needs to be reduced.

When calculating the increase or decrease in size of shim “S1”, bear in mind that a variation of shim (11) of 0.01 mm corresponds to a variation of 60 N·cm in the torque of the pinion (8).

8

T2

FLANGED GEARBOX VERSION Apply onto the pinion (8) the bar-hold and with the help of a torque wrench, check the torque of the pinion (8).

Torque: 120 - 200 N·cm

! CAUTION FLANGED GEARBOX VERSION If torque exceeds the maximum value, then the size of shim “S1” (11) between the bearing (13) and the spacer (10) needs to be increased.

If torque does not reach the set value, increase the torque setting of the ring nut (7) in different stages to obtain a maximum value of 1000 N·m.

If torque does not reach the minimum value, then the size of shim “S1” (11) needs to be reduced.

When calculating the increase or decrease in size of shim “S1”, bear in mind that a variation of shim (11) of 0.01 mm corresponds to a variation of 60 N·cm in the torque of the pinion (8).

7

FLANGED GEARBOX VERSION Apply Loctite 270 to the thread of the ring nut (7) and screw the nut onto the pinion (8).

62

5

T4

Remove blocks T4 (See drawing T4 p. 79) (used for extracting the pinion) and re-install the arms.

For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS p. 19.

Install the swinging support (5).

!

NOTE Check that it is properly oriented.

2

4

Fit the flange (2) complete with the guard (4) and fasten it.

For seating the flange (2), use a plastic hammer if necessary.

!

NOTE Make sure that the guard (4) is securely fastened onto the flange and that it is not deformed.

T1A (T1B)

Apply Loctite 242 to the threaded part of the pinion (8). Position tool T1A (See drawing T1 p. 77) (or T1B) and fasten it in order to avoid rotation. Insert o-ring (3) the nut (1) and tighten it using a torque wrench.

Torque wrench setting: 280 - 310 N·m

63

30.9.4 SPECIAL TOOLS

T1 P/N : 2308

T1A

25

80

Ø105 ± 0.2

120

Ø185 ± 0.2

Ø105 ± 0.2

15

10

125

25

125

Ø34.5--+ 00.2 Ø50

T1B

126 150

Ø32

100

15

10

Ø45

64

73

97

61.5

85

61.5

135 ±0.5

12

T2 P/N : 3317/3

60 15

35 5x15 0.8 0.8

Ø75

0.08 Ø55 –– 0.12

Tornito Ø 32,25

Ø15H7-n6

3/4"

14 34

T3 P/N : 3317/A

Ø85 Ø66

6

10

7

40

20

60 6

15°

20

75

22

0.8

Ø55H7

60 100 275

65

T4 P/N : 2309

25

Ø17

99.5

20

131

T5 P/N : 2310

Ø30.2 ± 0.001

66

± 0.005

Ø88.8

Ø42

5X45°

T6 P/N : 3329/3

T6A

T6C

Ø83

21° 0.8

Ø35 Ø19.5 ---- 0.08 0.12

R2

23

0.8

0.8

73

R5

40 Ø19.55H7 Ø40 Ø88

R2

3x15°

R2

433.5

473.5

T6B

10

Ø20 +-- 00.1

0.8

56

66

0.8

0.8

R2

0.8

21° 0.8

5

Ø55 Ø83 Ø89 ---- 0.08 0.12

45 0.8

5x15° 11

T25C T6c

Ø16.5---- 0.1 0.2 M18x1.5

T25B T6B

30

M18x1.5 Ø40

T6A

67

23

15°

T7

4 x45°

P/N : 2312

15

T7A

14 300

50

30

R5

25 25

20

T7B

M14 x1

0 Ø41.2 +-- 0.03

61-- 0.02

Ø110 Ø65 M14 x1 -- 0.01

Ø20

41

40

Ø9

10 50

Ø80

Ø11

T7C

Ø6.5

68

35

95 195

Ø20

T8 P/N : 3354

59 30

14 0.8

R5

1/4”

5x15

48 15 60

35

T9 P/N : 3327

87

63

5x45 °

Ø50

Ø37.75 Ø55

+ 0.08 + 0.12

-- 0.2 -- 0.3

Ø89 Ø99

69

3x15 °

0.8

0.8

0.8

12

12

2

0 -- 0.2

74

R5

Ø75

0.08 Ø55 ---- 0.12

Tornito Ø 32,25

Ø10

Ø20

Ø40H7-n6

Ø44

M6 5

30.10 MANUAL EMERGENCY RELASE 30.10.1 EXPLODED VIEW

RELEASE

70

30.10.2 RELEASE

30.10.3 ADJUST

! DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle.

29

30

Tecno Lube 101

Remove screws complete with nuts and seals.

Replace seals, apply silicone-based Tecno Lube /101 grease to the screws and install all parts into the arm.

31

Loosen nuts (30) of screws (31) provided for the mechanical and manual release of the braking units, then move the nuts backwards by approximately 8 mm.

34 mm

Adjust screws (31) to obtain a distance of 34 ± 0.5 mm between axle machined surface and screw underhead.

Tighten screws (31) so as to fasten them onto the pressure plate (23).

26

27

Lock into position with nuts (30).

! CAUTION Hold screws (31) into position while locking the nuts (30); after locking, check the distance of screws (31) once more.

Using a wrench, tighten the screws (31) in an alternate sequence by 1/4 turn at a time so as to compress the Belleville washers (1) and disengage the braking disks.

!

CAUTION Tighten maximum by one turn.

71

30.11 MECHANICAL PARKING BRAKE 30.11.1 EXPLODED VIEW

1

16

2 4

15

3 4 6

5 7

12 13 11 10

8

14 9 11

72

30.11.2 DISASSEMBLY !

DANGER Before maintaining brakes, when the axle is installed on the vehicle, follow all safety instructions in the Original Equipment Manufacturer (OEM) manual that came with the vehicle.

6

! CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE 7

!

NOTE Though the photos in this manual refer to a steering and oscillating axle, the operations described apply anyway.

5 Draw out the screws (5) and remove bushing (6) along with o-ring (7).

Disconnect the steering bars from the steering case. For details, see STEERING CYLINDER p. 47.

Connect the whole arm (8) to the hoist and put the rod under light tension.

Remove the whole arm; for details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS p. 19.

1 10 2

3

Draw out the screw (1) locking the washer (2) that stops the lever (3).

9 Remove the braking disks (9) and the whole piston (10).

For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS p. 19.

2

4

12 13

3

Remove washer (2), lever (3) and o-rings (4).

Mark the positions of levers (3) in relation to the thrust levers (12) and (13).

73

10

11

If pins (11) need replacing, block the piston (10) into a vice whose jaws are covered in smooth material and remove the pins.

8 14

12 13

If thrust levers (12) and (13) need replacing, remove the U-joint (14) before removing the arms (8).

For details, see DOUBLE U-JOINT p. 29.

74

30.11.3 ASSEMBLY

12 13

14

Install thrust levers (12) and (13), then install the U-joint (14).

For details, see DOUBLE U-JOINT p. 29.

Install the arms (8) into the main body; check flatness and block arms following the appropriate procedures illustrated in section MECHANICAL PARKING BRAKE p. 87 and HYDRAULIC NEGATIVE BRAKE p. 151.

10

6

11

5 Apply Loctite 270 to the threaded portion of the pins (11) and fit them onto the piston (10).

Block them: torque wrench setting 30 - 35 N·m.

Install the bushing (6) complete with o-ring (7) and block it with screws (5). Tighten screws with a torque wrench setting of 23.8 - 26.2 N·m.

10

1

2

9

3 Re-install the piston (10) and the braking disks (9).

For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS p. 19.

Install in sequence the lower o-ring (4), the lever (3) and the washer (2) with the relative o-ring (4).

Block with screw (1) and tighten using a torque wrench setting of 23.8 - 26.2 N·m.

! CAUTION Refer and keep to the positions marked during disassembly.

75

! CAUTION The idle stroke should be eliminated without preloading thrust levers (12) and (13).

16 15

After connecting the control cable, check that when brakes are released both studs (16) do lean against bushing (6).

3

Connect the braking circuit and apply maximum working pressure to set the disks.

Release the pressure, loosen nut (15) and unscrew stud (16) by a few turns.

6

3

16

8√10 N (0,8 √1 kg)

Apply a force of 8 - 10 N (0.8 - 1 kg) to lever (3).

Direct the force towards the braking direction in order to eliminate the idle stroke.

While the force is being applied, tighten stud (16) until it is caused to rest onto bushing (6).

16 15 3

Lock stud (16) in this position with nut (15).

Torque wrench setting: 20 - 25 N·m.

76

30.12 NORMAL DIFFERENTIAL UNIT 30.12.1 EXPLODED VIEW

11 10 1 9 8

7

9

8

10

11

5

6 3

5 12 7

2

4

8 11

10

9 8 9 10

13 11

77

30.12.2 DISASSEMBLY ! CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE 4 1

12

2

If the bearing need replacing, extract the bearing (4) from the differential carrier (12).

Remove the capscrews (1) from the crown (2).

3 11

2

9

Remove the snap rings (11) from the two pins (9) of the planetary gears (7).

If the bearing needs replacing, extract the bearing (3) and remove the crown (2).

T1

5

7

7

6

Insert tool T1 (See drawing T1 p. 131) between the planetary gears (7).

Remove the shim washer (5) and the planetary gear (6).

78

12

12

9

Force tool T1 (See drawing T1 p. 131) in-between the planetary gears (7) using two pin-drivers.

Remove tool T1 (See drawing T1 p. 131) together with the pin (9) of the planetary gear.

! CAUTION Make sure that tool T1 (See drawing T1 p. 131) is perfectly lined up with the pins (9) when locked.

T3B

T1

7

T2

T3B

7

9 12 Leave the released planetary gear in position and again lock tool T1 (See drawing T1 p. 131).

Repeat the operations for the extraction of the pin of the 2nd planetary gear (9).

Repeat the operations for all other pins.

Place the differential carrier (12) under a press, position guide bushing T2 (See drawing T2 p. 131) and insert press tool T3A (See drawing T3 p. 132). Press T3A (See drawing T3 p. 132) pin to limit position.

6 T2

T3A

5 12

Remove tool T1 (See drawing T1 p. 131) and remove the last two planetary gears (7), the 2nd differential side gear (6) and the relative shim washer (5) from the differential carrier.

Remove press tool T3A (See drawing T3 p. 132) and guide bushing T2 (See drawing T2 p. 131).

!

NOTE In this condition the tool T1 (See drawing T1 p. 131) contains pin (9).

79

30.12.3 ASSEMBLY etary gears (7). Line up the entire unit by pushing bar T3C (See drawing T3 p. 132) all the way down until press tool T3A (See drawing T3 p. 132) is ejected.

6 5

T1

12 7

7

Insert the shim washer (5) and the differential side gear (6) in the differential carrier (12).

Lock tool T1 (See drawing T1 p. 131) behind the planetary gears (7).

After locking, remove bar T3C (See drawing T3 p. 132).

7 8 T3C

10

9

Position the shim washer (8) and the first planetary gear (7).

Hold them in position using bar T3C (See drawing T3 p. 132).

7

Fit the snap rings (11) onto the pins (9).

T3A

12

8

T3C

9

T1

With the help of press tool T3A (See drawing T3 p. 132), position the second planetary gear (7) and the relative shim washer (8).

Place the differential carrier (12) under the press, position guide bushing T2 (See drawing T2 p. 131) and insert the planetary pin (9).

T1

T3C

Insert tool T1 (See drawing T1 p. 131) between the two plan80

T3B

9 T2

T3B

5

9 12

Put press tool T3B (See drawing T3 p. 132) on top of the planetary wheel pin (9).

T3B

Position the second planetary gear (6) in the differential carrier (12).

T1

5

T3B

2

9 12

Position the shim washer (5) on the crown (2).

Press T3B (See drawing T3 p. 132) pin all the way down.

!

NOTE In order to hold the shim washer (5) in position, apply grease to it.

11 9

1

2

12 Remove press tool T3B (See drawing T3 p. 132), bushing T2 (See drawing T2 p. 131) and fit the snap ring (11) on the pin (9).

Position the crown (2) on the differential carrier (12) and lock it with screws (1) applied with Loctite 242.

Torque wrench setting for screws: 128 - 142 N·m

! CAUTION Make sure that the snap ring centers the seat and that it rests on the surface of the differential carrier. Repeat the operations on the other planetary pins.

!

NOTE Secure the screws using the criss-cross method.

81

T4 T4

4

3

Install the bearings (3) and (4) using tool T4 (See drawing T4 p. 132).

82

30.12.4 SPECIAL TOOLS T1 P/N: 3708

36

33 6

9

31

18

5

26 0.8

0.8

1 x45 °

R1

6

Ø5.5 10.5

20

22.5

1 x45 ° Ø5.5

T2 P/N: 3424

24.5

0.0.1

0.8

8.5 5

Ø23

+ 0.08 + 0.12

Ø20

-- 0.1

Ø27 -- 0.2

Ø30

15 °

0.8

83

Ø41

Ø25

0.8

+ 0.2 0

Ø20

M26X1.5

+ 0.2 0

Ø20

Ø25

Ø41

0.8

T3 P/N: 2306

T3A

T3B

± 0.5 10 19.6

56.6

29.6

Ø6

Ø30

+0

+0

Ø28.5

46.45 ± 0.1

10

Ø19.9 - 0 .1

2x30° Ø19.9 - 0 .1

± 0.2

3x30°

0.5x45°

+0

Ø19.9 - 0 1

T3C

1x30°

175

T4 P/N: 3332 0.8

Ø38.5 -- 0.1 -- 0.2

Ø55

Ø63

Ø65

0.8

1

1.5 x45° 3 0.8

38 68

84

30.13 LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) 30.13.1 EXPLODED VIEW

15

3

13

5

10

4

19 17

14

18

16

13

16

11

15

7

14

12 18 11

6

6 14

19 10

15 13

7

16

19

11

7

15

18 11 2

17

8

13

18

16

9

12

10

7

14

19 10

85

1

30.13.2 DISASSEMBLY ! CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE

7

1

6

2

Remove the planetary gear (6) and the whole friction unit (7).

Remove the whole differential unit (2) from the central axle unit (1).

For details, see DIFFERENTIAL UNIT p. 61.

8 9 3 4

If bearing (8) needs replacing, extract it from the differential unit (9).

Remove the check screws (3) of the crown (4).

!

NOTE Write down the position of the notches of the central hole in relation to the protrusions of the friction unit steel discs.

10

11

Remove the snap rings (10) from the pins (11) of the planetary gears (12).

5

T1

4

12

12

If bearing (5) needs replacing, remove it; remove crown (4).

Introduce tool T1 (See drawing T1 p. 140) inbetween the planetary gears (12).

86

9

9

11

Using two pin-drivers, engage tool T1 (See drawing T1 p.

140) in between the planetary gears (12).

Remove tool T1 (See drawing T1 p. 140) and planetary pin (11) with it.

! CAUTION Carefully check that tool T1 (See drawing T1 p. 140) keeps in an aligned position with the pins (11) when locked.

T3A

T1

T2

12

12

T3A

11 9

Leaving the released planetary in its position, lock again tool T1 (See drawing T1 p. 140).

Repeat pin extraction operation on the second planetary pin (11).

Repeat the same operations on the remaining pins.

Place the differential unit (9) under a press, position guide bushing T2 (See drawing T2 p. 140) and insert press tool T3A (See drawing T3 p. 141). Press press tool T3A (See drawing T3 p. 141) to end of stroke.

6 7

T2

T3A

9

Remove tool T1 (See drawing T1 p. 140) and extract from the differential unit (9) the two final planetary gears (12), the 2nd differential side gear (6) and the whole friction assembly concerned (7).

Remove press tool T3A (See drawing T3 p. 141) and bushing T2 (See drawing T2 p. 140).

!

NOTE In this state, the pin (11) is contained within tool T1 (See drawing T1 p. 140).

87

30.13.3 ASSEMBLY

12

6

18

7

T3C

9

Place the friction disc assembly (7) - suitable for the specific type of slipping and differential side gear (6) into the differential unit (9).

The composition of the unit is illustrated in the points below.

Position shim washer (18) and the first planetary gear (12).

Hold in position with bar T3C (See drawing T3 p. 141).

12

13

6

T3A

18, 2 ± 0,1

18

14

9 T3C

17

6 15 16

Using press tool T3A (See drawing T3 p. 141), position the second planetary gear (12) and relative shim washer (18).

25% FRICTION UNIT COMPOSITION Friction ring with inner disc (13), intermediate discs (14) and friction discs (15) alternated, outer disc (16) and spacer (17).

T1

!

CAUTION As to rings (13) and (16), the side without notches must face outwards.

T3C

6

6 13

15

18, 2 ± 0,1

14 Insert tool T1 (See drawing ) in-between the two planetary gears (12).

Align the whole unit, pushing bar T3C (See drawing T3 p.

141) in as far as it will go, until press tool T3A (See drawing T3 p. 141) is expelled.

16

45% FRICTION UNIT COMPOSITION Friction ring with inner disc (13), intermediate discs (14) and friction discs (15) alternated, outer disc (16) and spacer (17).

!

CAUTION As to rings (13) and (16), the side without notches must face outwards.

88

T3A

T1

T2 T25 T1

T3A

6

11

6

9

Lock tool T1 (See drawing T1 p. 140) behind the planetary gears (12).

After locking the tool, remove bar T3C (See drawing T3 p.

141).

19

Press press tool T3B (See drawing T3 p. 141) as far down as it will go.

11 10 11

Fit snap rings (19) onto the pins (11).

11

Remove press tool T3B (See drawing T3 p. 141), bushing T2 (See drawing T2 p. 140) and fit the snap ring (10) onto the pin (11).

! CAUTION Make sure that the snap ring centers seat and positions itself on the differential unit face.

Repeat the operations on the other planetary pins.

T2

9 7 Position the differential unit (9) under the press, position bushing T2 (See drawing T2 p. 140) and insert the planetary pin (11).

T3B T16B T3B T3B

6 9

11 T1 T25

Check that planetary have a light clearance in relation to the first planetary gear.

Position the second differential side gear (6) and the second friction disc assembly (7) into the differential unit (9).

11

Place press tool T3B (See drawing T3 p. 141) on top of the planetary pin (11).

89

3

4

9

Line the lubrication holes up with the slots in the differential carrier. Orient the holes of the crown (4) towards the protrusions of the braking unit. Position the crown (4) on the differential unit (9) and lock it with the screws (3) previously coated with Loctite 242.

Torque wrench setting for screws: 128 - 142 N·m.

!

NOTE Tighten screws using the criss-cross method.

8

T4

5

T4

If bearings (5) and (8) have been removed, install them using tool T4 (See drawing T4 p. 141).

1

2

Install the whole differential assembly (2) into the central body (1).

For details, see DIFFERENTIAL UNIT p. 61.

90

30.13.4 SPECIAL TOOLS T1 P/N : 3708

36

33 6

9

31

18

5

26 0.8

0.8

1 x45 °

R1

10.5

1 x45 °

20

22.5

Ø5.5

T2 P/N : 3424

24.5

0.0.1

0.8

8.5 5

Ø23

+ 0.08 + 0.12

Ø20

-- 0.1

Ø27 -- 0.2

Ø30

15 °

0.8

91

Ø41

6

Ø5.5

Ø25

0.8

+ 0.2 0

Ø20

M26X1.5

+ 0.2 0

Ø20

Ø25

Ø41

0.8

T3 P/N : 2306

T3A

T3B

46.45 ± 0.1

± 0.5 10 19.6

56.6

29.6

Ø6

Ø30

+0

+0

Ø28.5

10

Ø19.9 - 0 .1

2x30° Ø19.9 - 0 .1

± 0.2

3x30°

0.5x45°

Ø19.9

+0 - 01

T3C

1x30°

175

T4 P/N : 3332

0.8

Ø38.5 -- 0.1 -- 0.2

Ø55

Ø63

Ø65

0.8

1

1.5 x45° 3 0.8

38 68

92

30.14 HYDRAULIC DIFFERENTIAL LOCK 30.14.1 EXPLODED VIEW

14

2

13

3 4

23 15

5

12

20

8 7 6 10

11

9

21

1

22 17 19 18 16

93

30.14.2 DISASSEMBLY ! CAUTION Before draining oil, release the internal pressure, for details see OIL DRAINING MANDATORY PROCEDURE

5

4

Loosen the lock nut (4) of selector fork (5) by approximately 2 turns.

Remove the arms.

For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS p. 19.

5 6 1

Using a metal punch and a hammer, disengage selector fork (5) from piston cone (6).

Remove the top cap (1).

!

NOTE The cap must be replaced each time the unit is disassembled.

6

Using two wrenches, lock piston (6) and remove nut (4).

2

14

13

IRemove the security switch (2).

!

NOTE Check the state of the o-ring (3).

Remove screws (14) and remove the intermediate cover (13).

94

!

!

NOTE Support the differential unit with a lever.

NOTE The guide ring (11) and o-ring (10) must be replaced each time the unit is disassembled.

5

6 9

15

7 8 9 Disconnect selector (5) from piston (6). While holding the selector up, remove the differential unit (15).

Remove snap ring (9) and take piston unit (6) apart. Remove all component parts.

5 19 18

16

17

20

Extract selector fork (5).

Remove bearing (16) from the differential carrier (17) as well as the stop ring (18), the sleeve (19) and the spheres (20).

!

NOTE Write down the direction of assembly of the stop ring (18).

6 12

21 15 Remove snap ring (12) and whole piston (6).

11

ONLY IF NECESSARY Remove the key (21) and disassemble the differential unit (15).

For details, see DIFFERENTIAL UNIT p. 61.

10

Remove guide ring (11) and o-ring (10).

95

30.14.3 ASSEMBLY

21

11

10

6

15

T1

ONLY IF PREVIOUSLY DISASSEMBLED Assemble the differential unit (15). (For details, see DIFFERENTIAL UNIT p. 61). Position the key (21) in the differential unit (19).

Fit o-ring (10) and guide ring (11) onto the piston (6). Lubricate seals and insert the assembly into tool T1 (See drawing T1 p. 149).

18

22

T1

19

6

20

Insert tool T1 (See drawing T1 p. 149) in the central unit (22) and push the piston (6) into the seat.

Remove tool T1 (See drawing T1 p. 149)

Install spheres (20), sleeve (19) and stop ring (18).

!

NOTE Pay great attention to ring orientation (18).

7

T2

16

8

17

6

Install spring (7) and washer (8) on the piston (6) and install tool T2 (See drawing T2 p. 149).

Install bearing (16) onto the differential carrier (17).

!

NOTE Make sure that the bearing is well set in the differential carrier.

96

14

13

23

6

T2

Screw tool T2 (See drawing T2 p. 149) on the thread of the piston (6) to compress the spring (7) and vacate the seat for installing the snap ring (12).

Install the intermediate cover (13) and lock it with screws (14). Tighten screws using a torque wrench setting of 23.8 - 26.2 N·m.

!

NOTE Carefully check the state of the o-ring (23).

12

4 Install the snap ring (12).

Remove tool T2 (See drawing T2 p. 149) and fit the snap ring (9) of spring (7).

Install the lock nut (4) of the selector fork (5) and lock it with a torque wrench set to a torque of 70 - 75 N·m.

5

22

15 2 1

Insert the selector fork (5) and the differential unit (15) into the central unit (22).

Engage the selector fork (5) in the coupling (19) and on the piston (6).

Install the security switch (2) complete with o-ring; torque wrench setting: maximum 30 N·m.

If necessary, adjust differential unit clearances. (see DIFFERENTIAL UNIT p. 61).

Install the top cap (1) and the arms. (For details, see CHECKING WEAR AND REPLACING THE BRAKING DISCS p. 19).

97

30.14.4 SPECIAL TOOLS T1

10 30

50

Proteggere da cementazione

15

0.8

0.8

Ø24 ---- 0.08 0.12

3x15 °

Ø28 ---- 0.08 0.12

P/N : 3543

5° Ø26 Ø33

T2 P/N : 2316

17

35

18

15

M12x1.25

Ø16.2

0 -- 0.1

Ø17 ++ 0.2 0.1

98

BRAKE

99

Intentionally Left Blank

TABLE OF CONTENTS

40.1

40.2

40.3

BRAKES - SERVICE BRAKE AND PARKING BRAKE............................................................................................. 3 40.1.1

SERVICE BRAKE COMPONENTS..................................................................................................................................... 3

40.1.2

PARKING BRAKE COMPONENTS......................................................................................................................................3

SERVICE BRAKE - REMOVAL AND INSTALLATION............................................................................................. 4 40.2.1

PREPARATION AND SAFETY INSTRUCTIONS.............................................................................................................4

40.2.2

PROCEDURE......................................................................................................................................................................4

BRAKE BLEEDING PROCEDURE......................................................................................................................... 6 40.3.1

40.4

40.5

PROCEDURE......................................................................................................................................................................6

BRAKE ADJUSTMENT PROCEDURE................................................................................................................... 7 40.4.1

PREPARATION AND SAFETY INSTRUCTIONS.............................................................................................................7

40.4.2

PROCEDURE......................................................................................................................................................................7

PARKING BRAKE - REMOVAL AND INSTALLATION........................................................................................... 7 40.5.1

PREPARATION AND SAFETY INSTRUCTIONS.............................................................................................................8

40.5.2

PROCEDURE......................................................................................................................................................................8

2

40.1 BRAKES - SERVICE BRAKE AND PARKING BRAKE The service brake is the system that is designed to slow down the vehicle and bring it to a stop. The service brake is activated everytime you step on the brake pedal and it distributes the braking force hydraulically to the front and rear wheels, 75% front and 25% rear, on average.

The parking brake is the brake that is designed to hold the vehicle. Parking brakes are also referred to as emergency brakes although, in an emergency they would never slow down a vehicle in a safe manner. The parking brake is typically cable operated and applies force to either dedicated brake shoes inside the rear rotor or,through the piston in the caliper. It can be operated by a seperate handle ever, usually located beside the driver’s seat.

40.1.1 SERVICE BRAKE COMPONENTS

8 7

2

11 9 10

1

3 4

5

6

Key: 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Brake Master Cylinder Brake Master Cylinder - Push Rod Hair Pin Weldment Brake Pedal Pin Spring Service Brake Pedal Pump To Brake-Hose Hose-Brake Cylinder To Return Pipe Hose-Brake Fluid Tank To Master Cylinder Hose-Brake Cylinder To Front Axle - T-Fitting Brake Fluid Reservoir.

40.1.2 PARKING BRAKE COMPONENTS

1

2

Key: 1.

2.

Hand Brakeassembly BrakeCable

3

40.2 SERVICE BRAKE - REMOVAL AND INSTALLATION 40.2.1 PREPARATION AND SAFETY INSTRUCTIONS -

Stabilise the machine on level ground, fully retract the boom, place transmission control lever in neutral position.

Ensure the engine is Shut OFF. Disconnect the battery .

40.2.2 PROCEDURE NOTE If the bushing (17) is worn and needs replacing, write down the assembly side of the connection notch “A”.

1

1.

Uninstall and remove the brake cover plate(1) from the inside of the cabin.

2

2.

3

1

4

Disconnect the following Hoses from the Brake Master Cylinder (6): 1.

2.

3.

4.

Hose-Brake master cylinder to tank by removing worm drive clip.

Hose - Pump to brake master cylinder.

Hose-Brake cylinder to return line.

Brake master cylinder to both axle.

4

9

8

3.

4.

Uninstall the split pin(7) and the clevis pin(8).

Disconnect the wiring connectors 9 from brake switch.

10

12

11

9

5.

6.

7.

Uninstall the hair pin(9) and brake pedal pin(10) .

Uninstall the spring(11) by adjusting the brake pedal(12).

Remove the brake pedal(12) from the mount.

6

15 16 15

14 13

8. Uninstall the clevis(13) and the push rod(14).

9. Uninstall the hex head bolts(15) and the washers.

10. Remove the brake master cylinder (6) from the mount (16).

Please carry out the reverse process for installation of the service brake circuit .

After fitment of all the parts brake pedal adjustment should be done as per the procedure given in 40.3 BRAKE ADJUSTMENT PROCEDURE. Brake circuit should be bleed properly as per the instructions given in 40.4 BRAKE BLEEDING PROCEDURE.

5

40.3 BRAKE ADJUSTMENT PROCEDURE 40.3.1 PROCEDURE

0

1.

Adjust the height of brake pedal to 90mm above the cab floor, without the mat .

NOTE Check that the pedal is returned to the correct position by the actuation of the Spring(1).

32mm

2.

3.

Minimum height of the pedal should be 32 mm after pressing the brake pedal.

The height of the pedal can be adjusted by tightening or loosening the clevis(13) on the master cylinder push rod.

6

40.4 BRAKE BLEEDING PROCEDURE Brake bleeding is the procedure performed on hydraulic brake systems whereby the brake lines (the pipes and hoses containing the brake fluid) are purged of any air bubbles.

40.4.1 PREPARATION AND SAFETY INSTRUCTIONS -

Stabilise the machine on level ground, fully retract the boom, place transmission control lever in neutral position.

Ensure the brake pedals are correctly adjusted.

Engage parking brake.

Start the engine.

40.4.2 PROCEDURE

1 1

1.

2.

3.

4.

5.

6.

7.

8.

Check and correct the brake system fluid level.

Connect clear plastic tube to the left and right vent screws(1) of the front axle and position the other end into a suitable container.

Open the left and right side vent screws one by one.

Press and release the brake pedal a few times and allow the brake fluid to drain into the container until an air free flow of brake oil is obtained.

Close the left and right vent screws one by one after ensuring that the fluid do not contain any air bubble.

Repeat this process for rear axle.

Remove the plastic tubes and the container.

Check the brake system fluid level and top up if required.

7

40.5 PARKING BRAKE - REMOVAL AND INSTALLATION 40.5.1 PREPARATION AND SAFETY INSTRUCTIONS -

Stabilise the machine on level ground, fully retract the boom, place transmission control lever in neutral position.

Ensure the engine is Shut OFF. Disconnect the battery.

40.5.2 PROCEDURE NOTE Check the brakes for every 1,000 hours of operation or yearly.

For more information on brake inspection, refer to the maintenance section of the Operator’s Manual.

1.

Release the hand brake and keep it in zero position before starting the dis-assembly .

7

3 1

4

2

5 6

2.

3.

4.

5.

Uninstall the hair pin (1), washer(2) and clevis pin (3).

Disconnect the parking brake cable(4).

Uninstall the 2 hex bolts(5) and the 2 washers (6).

Remove the hand brake assembly(7).

8

1

6.

Remove the chassis front cover (1).

4

7.

Uninstall the lock nuts(8), springs(9) and release the parking brake cable (4).

Installation is the reverse of removal procedure.

10 11

8.

After installation a maximum of 1mm gap to be maintained between stop screw (10 ) and lever (11).

9

Intentionally Left Blank 10

BOOM

TABLE OF CONTENTS

50.1

BOOM CHARACTERISTICS AND SPECIFICATIONS............................................................................................. 3 50.1.1

50.2

BOOM SCHEMATIC DIAGRAMS.......................................................................................................................... 4 50.2.1

50.3

50.4

TRIPLEX (MT 14 METERS)........................................................................................................................................................3 CHAIN BOOM KINEMATIC DIAGRAM..................................................................................................................................4

BOOM COMPONENTS LOCATION....................................................................................................................... 5 50.3.1

INDEX OF COMPONENT CODES...........................................................................................................................................5

50.3.2

TX BOOM MAIN COMPONENT LOCATION (3 ELEMENTS)............................................................................................6

50.3.3

QX BOOM MAIN COMPONENT LOCATION (4 ELEMENTS) ..........................................................................................7

BOOM CONTROL AND ADJUSTMENT................................................................................................................ 8 50.4.1

PREPARATION AND SAFETY INSTRUCTIONS....................................................................................................................8

50.4.2

IMPORTANT INFORMATION...................................................................................................................................................9

50.4.3

CHECK WEAR ON BOOM CHAINS...................................................................................................................................... 10

• EXTERNAL CHAINS................................................................................................................................................................. 10 • INNER CHAINS.......................................................................................................................................................................... 12 50.4.4

DISMANTLING CHAIN BOOM COMPONENTS............................................................................................................... 14

• GENERAL INFORMATION...................................................................................................................................................... 14 • STEPS NEEDED FOR CHANGING CHAINS....................................................................................................................... 15 • “HYDRAULIC KIT” REMOVAL................................................................................................................................................ 16 • “T2 + T3 TELESCOPES ASSEMBLY” REMOVAL................................................................................................................ 22 • “T3 TELESCOPE” REMOVAL.................................................................................................................................................. 28 50.4.5

CHAIN BOOM COMPONENTS REFIT................................................................................................................................. 31

• GENERAL INFORMATION...................................................................................................................................................... 31 • “T3 TELESCOPE” REFIT........................................................................................................................................................... 32 • “T2 + T3 TELESCOPES ASSEMBLY” REFIT......................................................................................................................... 35 •

CHAIN TENSION PRE-SETTINGS DURING REASSEMBLY........................................................................................... 42

•

CHECKING AND SETTING CHAIN TENSIONS................................................................................................................ 45

• “HYDRAULIC KIT” REFIT......................................................................................................................................................... 48 50.5

SPECIFIC BOOM TOOLING................................................................................................................................ 52 50.5.1

CHANNEL LEVER..................................................................................................................................................................... 52

50.5.2

HOSING PATH SUPPORT....................................................................................................................................................... 53

50.5.3

HOSING TENSION SETTING TOOL..................................................................................................................................... 54

50.5.4

CHAIN CHECKING GAUGE.................................................................................................................................................... 54

2

50.1 BOOM CHARACTERISTICS AND SPECIFICATIONS 50.1.1 QUADRUPLEX (MT 18 METERS) Consisting of 4 components : - 1 fixed - 3 mobile Deployment : Deployment of the quadruplex boom is controlled simultaneously.

-

T1, T2 and T3 extend at same time.

Boom weight : -

3092 KG approx.

3

50.2 BOOM SCHEMATIC DIAGRAMS 50.2.1 CHAIN BOOM KINEMATIC DIAGRAM

“HYDRAULIC CIRCUIT” IN INTERMEDIATE POSITION SCHEMATIC DIAGRAM

Hydraulic hosing (inferior ply) Hydraulic hosing (superior ply)

“CHAINS” IN INTERMEDIATE POSITION SCHEMATIC DIAGRAM

Chain exit T2

Chain exit T3

Chain entry T2

Telescope T2

Chain entry T3

Telescope T3

Boom T1

Boom base

4

50.3 BOOM COMPONENTS LOCATION 50.3.1 INDEX OF COMPONENT CODES -

TX boom main component location Item

Designation

CSD

Double safety valve

CSP

Piloted safety valve

T1

Telescope 1

T2

Telescope 2

VT1

Telescope cylinder 1

VT2

Telescope cylinder 2

X134

Retracted boom sensor

X141

ORH panel connector

X194

Intermediate boom outlet inductive sensors

X195

Access retractor socket

X202

Intermediate boom extend sensor 2

X203

Intermediate boom extend sensor 1

-

QX boom main components location Item

Designation

CSD

Double safety valve

VT

Telescope cylinder

B54

Inductive sensor C1 QX boom

B55

Inductive sensor C2 QX boom

B67

Intermediate boom extend sensor 1

B68

Intermediate boom extend sensor 2

S34

Retracted boom sensor

S56

Chain tension contactor 1

S57

Chain tension contactor 2

S58

Chain tension contactor 3

S59

Chain tension contactor 4

X130

Boom extend connector C1

X131

Boom extend connector C2

X134

Retracted boom sensor

X141

ORH panel connector

X195

Access retractor socket

X202

Intermediate boom extend sensor 2

X203

Intermediate boom extend sensor 1

X232

Chain tension contact 1 connector

X233

Chain tension contact 2 connector

X234

Chain tension contact 3 connector

X235

Chain tension contact 4 connector

5

50.3.2 TX BOOM MAIN COMPONENTS LOCATION (3 ELEMENTS)

90°

X141

CSD

CSD X202

X203

X195

X194

VT2

T2

VT1 T1

CSP

X134

6

50.3.3 QX BOOM MAIN COMPONENTS LOCATION (4 ELEMENTS)

180°

X141 X195

X232 X233

S56

S57

X235

X234 VT

S59 S58

X134 / S34 X203 CSD

X202

X131 X130

X195

B55 B54

7

B67 B68

50.4 BOOM CONTROL AND ADJUSTMENT 50.4.1 PREPARATION AND SAFETY INSTRUCTIONS. -

Stabilize the machine on a horizontal floor.

Deactivate battery power supply using a battery cut - off.

Decompress all hydraulic elements.

Whole boom weight = about 3092 Kg Specific tools: -

Lifting system (Hoist +sling) Mallet Presser foot Wooden chock Cord Trestles Channel lever - 50 “Specific tooling” Hose path fittings - 50 “Specific tooling” Hosing tension setting shim - 50 “Specific tooling” Chain checking gauge - 50 “Specific tooling”

8

50.4.2 IMPORTANT INFORMATION Check internal chain wear during dismantling procedure.

“Check wear on boom chains”.

When changing a chain, replace it with a pair and measure the difference in length between the chains.

In the case of a dismantling and reassembly operation without chain exchange (not replacing worn chains with new ones), take the pre-setting dimensions (Item 7 & 8) on the machine before dismantling. These dimensions will be used during reassembly for setting chain tensions. ”Chain tension pre-settings”.

Pre-setting example :

6

5

2 1

4 7

3

XLeft chain 6

5

8

XRight chain

Captions : 1.

2.

3.

4.

5.

6.

7.

8.

Chain Chain tensioner Jib Belleville washers Nut Lock nut Dimension to read on left chain tensioner before dismantling.

Dimension to read on right chain tensioner before dismantling.

9

50.4.3 CHECK WEAR ON BOOM CHAINS EXTERNAL CHAINS Chain wear occurs at a number of locations: 1. On the articulations, which leads to elongation of the chain.

2. On the edge of link plates through contact with the pulleys.

3. On the face of the plates and the extended pins through contact with the pulley flanges.

4. On the alignment of the flats of the extendedpins.

CHAIN ELONGATION We recommend that you perform this operation using the chain checking gauge.

50 - “Specific boom tooling” -

Set the lift truck on its stabilisers, with the boom horizontal.

Fully extend the telescopes and continue operating the control for a few moments to properly tension the chains.

As the chain will likely wear unevenly over its length, divide the chain into 4 equal sections and check with the gauge at the centre of each section.

19,05 mm x 12 = 228,6 mm

25,4 mm x 9 = 228,6 mm

19,05 mm

25,4 mm =

=

=

=

=

=

=

=

If the maximum dimension is exceeded ( 228,6 mm + 2 % = 233,2 mm ), replace the pair of chains.

10

SIDE WEAR OF PLATES

24 mm

15,5 mm

As for chain elongation, perform a check in the middle of each section using a calliper gauge.

If the dimension is less than the minimum dimension (24 mm -2% = 23,5 mm and 15,5 mm -2% = 15,2 mm), replace the pair of chains.

EXTENDED PIN WEAR

53,6 mm

42,25 mm

As for chain elongation, perform a check in the middle of each section using a calliper gauge.

Chain exit T2

Chain exit T3

If the dimension is less than the minimum dimension (53,6 mm -2% = 52,5 mm and 42,25 mm-2% = 41,4mm), replace the pair of chains.

In addition to wear, the high pressures between the side of the plates and the pulleys may force out material, causing the articulations to seize. Replace the pair of chains in this casealso.

ALIGNMENT OF EXTENDED PIN FLATS Check the chains over their entire length.

High friction between the plates and the extended pins may cause the pins to turn in the outer plates and thus come out of their housing.

NOT OK

OK

If the flats are not aligned in the longitudinal direction of the chain, replace the pair of chains.

11

INNER CHAINS The telescopes need to be dismantled to check the boom inner chains.

“Dismantling chain boom components”.

Chain wear occurs at a number of locations: -

On the articulations, which leads to elongation of the chain.

On the edge of link plates through contact with the pulleys.

On the face of the plates and the extended pins through contact with the pulley flanges.

On the alignment of the flats of the extended pins.

CHAIN ELONGATION We recommend that you perform this operation using the chain checking gauge.

50 - “ Specific boom tooling ” As the chain will likely wear unevenly over its length, divide the chaini nto 4 equal sections and check with the gauge at the centre of each section.

19,05 mm x 12 = 228,6 mm

19,05 mm

SIDE WEAR OF PLATES

15,5 mm

As for chain elongation, perform a check in the middle of each section using a calliper gauge.

If the dimension is less than the minimum dimension (15,5 mm -2% = 15,2 mm), replace the chain or pair of chains.

EXTENDED PIN WEAR

42,25 mm

As for chain elongation, perform a check in the middle of each section using a calliper gauge.

If the dimension is less than the minimum dimension (42,25 mm - 2 % = 41,4 mm), replace the chain or pair of chains.

In addition to wear, the high pressures between the side of the plates and the pulleys may force out material, causing the articulations to seize. Replace the pair of chains in this case also.

12

ALIGNMENT OF EXTENDED PIN FLATS Check the chains over their entire length.

High friction between the plates and the extended pins may cause the pins to turn in the outer plates and thus come out of their housing.

NOT OK

OK

If the flats are not aligned in the longitudinal direction of the chain, replace the chainor pair of chains.

13

50.4.4 DISMANTLING CHAIN BOOM COMPONENTS

GENERAL INFORMATION In order better to understand chain boom operation and dismantling procedure: 50 “ Boom schematic diagrams ” The “Chain boom component dismantling” operation is done in several stages: “ Hydraulic kit ”removal “T2+T3 telescopes assembly ” removal.

The “Hydraulic kit removal” operation should be done “ T3 Telescope ”removal.

The “Hydraulic kit removal” and “T2 + T3 Telescopes assembly removal” operations should be carried out These various stages are detailed below in this chapter.

14

STEPS NEEDED FOR CHANGING CHAINS

The table below shows the various actions to be taken on the chains to be replaced.

Chain descriptions

Action to be taken

Extend T2 Retract T3 Retract T2

Extract T2 + T3 assembly.

Extract T1 + T2 + T3 + hydraulic kit assembly.

Note: It is not obligatory to remove the hydraulic kit to change the “ Retrac tT2 ” chain.

Extend T3

Extract T2 + T3 assembly, the extract T3.

15

“ HYDRAULIC KIT ” REMOVAL 5 1

2

5

4 3

3

-

Remove protection cover (Item 1) by undoing 4 screws (Item 2).

Undo two screws (Item 3) from the “ accessory hydraulic tube support bracket ” (Item 4) ont he right side of the boomhead.

Take out two hydraulic tube flanges (Item 5).

6

7 6

-

Undo the two screws (Item 6) that hold the two hydraulic tubes support bracket (Item 7) on the left side of the boom head.

16

8

-

Disconnect the electrical connector (Item 8).

12

13 13

-

13

13

13

Undo boom head stop (Item 12).

Place an oil container under boom head.

Pull the set of five hydraulic tubes (Item 13) out from the boom head then use 27 mm wrench and 30 mm wrenches to undo them.

Then use stoppers to plug the hydraulic connections to prevent any oil running out.

15

14

-

Pull on the set of five hydraulic hosing pieces (Item 14) so as to extract the bracket (Item 15).

15

16

14

-

Undo the two screws (Item 16) on the bracket.

Remove bracket (Item 15).

17

-

Reposition the hydraulic hosing pieces( Item 14) in boom head so that they do not become caught when the hydraulic kit is extracted.

17

-

Unscrew and remove rear cover (Item 17) attached to frame ( 6 screws ).

18 19

-

19

Remove “ hosing guide ” ( Item 18 ). To do that, undo two screws ( Item 19 ) on each side.

20

-

Unscrew pulley axle grease point ( Item 20 ).

22

21

23

-

21

22

23 24

Unscrew two stops (Item 21) positioned on “ spring suppor t” ( Item 22 ).

Use a 22 mm socket wrench ( Item 24 ) to do up ( turning clockwise ) the screw ( Item 23 ) on each side, to release the hosing tensioning system.

18

26

25

27

-

Use the specific “ channel tool ” ( Item 25 ) to pull channel out ( Item 26 ) to release hosing pieces ( Item 27 ).

29

29

29

28

-

Undo “pulley support bracket” (Item 28) on the right side. Use 15 mm wrench to take out three screws (Item 29) to do that.

28

31

33

-

32

30

First remove only the “pulley support” on the right side (Item 28).

Dislodge right hand pulley (Item 30) from its axle (Item 31).

Do the same for the central pulley (Item 32).

Then remove left hand pulley (Item 33) with its axle (Item 31).

35 35

35

34

-

Undo “ pulley support bracket ” ( Item 34 ) on the left side. Use 15 mm wrench to take out three screws ( Item 35 ) to do that.

19

26

25

-

If possible use “ channel lever ” (Item 25 ) to push channel ( Item 26 ) to gain better accessibility for undoing the two “ spring support ” screws.

37

36

36

-

Use 13 mm wrench to undo two right hand side “ spring support ” (Item 37 ) screws ( Item 36 ).

Carry out the same operation on the left hand side “ spring support ”.

39 38

40

-

Use a tie ( Item 39 ) to attach electrical harness ( Item 38 ) so that it does not get damaged during hydraulic kit ( Item 40 ) extraction.

Pull “ hydraulic kit ” assembly ( Item 40 ) out by some 50 cms o as to gain access for disconnecting five hosing pieces and disconnecting electrical connector.

42

41

41

41 43

-

41 41

Place an oil container under hosing pieces.

20

-

Use 27 mm + 30 mm wrenches to disconnect five hosing pieces ( Item 41 ).

Plug hosing piece ends with stoppers ( Item 42 ).

Disconnect electrical connector (Item 43).

44

-

Use a cord (Item 44) to tie hosing pieces against chassis to that they do not hamper hydraulic kit extraction.

47 46

45

-

Pull “hydraulic kit” assembly ( Item 45 ) out by about 1 meter.

Pull out also the hosing pieces ( Item 46 ) above it so as to ease extraction.

Position sling and hoist ( Item 47 ) to keep assembly together during extraction.

46

45

48

48

-

Pull out “ hydraulic kit ” assembly ( Item 45 ), checking that hosing pieces ( Item 46 ) follow the movement.

Remove “ hydraulic kit ” assembly ( Item 45 ) and place on two trestles ( Item 48 ).

21

“ T2 + T3 TELESCOPES ASSEMBLY ” REMOVAL

4

1 5

3

2 1

5 3

-

Use 24 mm wrench to undo nuts and locknuts ( Items 1 & 2 ) on the “ T3 extend chain tensioners ” ( Item 3 ) attached to T1 telescope ( Item 4 ).

Take out Belleville washers ( Item 5 ).

Remove two T3 telescope chain tensioners ( Item 3 ).

9 10 6

10

8

7 6

8

-

Use 36 mm wrench to undo nuts and locknuts ( Items 6 & 7 ) on the “ T2 extend chain tensioners ” ( Item 8 ) attached to boom foot ( Item 9 ).

Take out Belleville washers ( Item 10 ).

Remove two T2 telescope chain tensioners ( Item 8 ).

8 9

-

10

Take out two “ T2 extend chain tensioners ” ( Item 8 ) by removing pins and axles ( Items 9 & 10 ).

22

12

12

11 4

-

Undo screw ( Item 11 ) of pin that holds chain rollers ( Item 12 ) in place on T1 telescope ( Item 4 ).

13

14

-

Use a tube and mallet (Item 13) to dislodge roller pin ( Item 14 ).

Remove two rollers and their holders.

17

18

-

Take out cylinder rod ( Item 18 ) circlips ( Item 17 ).

20

19 19 21

19

19 21

-

Use 15 mm wrench to take out four telescoping cylinder (Item 20) screws (Item 19) then remove fixing pads ( Item 21 ).

23

22

23

-

Use sling and hoist ( Item 22 ) gently to lift cylinder ( Item 23 ) whilst pulling out cylinder rod ( Item 24 ).

25

24

-

Use a tube and mallet ( Item 25 ) to dislodge cylinder rod.

23

27

28

-

Raise cylinder sufficiently to gain access to four nuts ( Item 26 ).

Put a wooden chock ( Item 27 ) between cylinder ( Item 23 ) and boom foot ( Item 28 ).

26 29 26

26

26

29

-

Loosen four “ T2 chain tensioner ” ( Item 29 ) nuts ( Item 26 ) without taking them out.

24

30 30

31

30 30

-

Loosen four “T2 retract chain blade” (Item 31) screws (Item 30) fixed on rear of T2 telescope.

32 32

33

-

Take off two “ T3 retract chain tensioner ” ( Item33 ) nuts ( Item32 ) on T1 telescope front.

35 35

36 36 34

36

37

37

37

37

37

35

-

37

Take out left and upper pads ( Item 35 ) + shims ( Item 36 ) + screws and nuts ( Item37 ) from T2 telescope foot ( Item34 ).

This operation gives some clearance to facilitate T2 + T3 assembly extraction.

41

39 40

38

-

Remove sealing blade ( Item 38 ) at bottom of boom foot ( Item 39 ).

Remove sealing blade assembly ( Item 40 ) on T1 telescope ( Item 41 ).

25

45

44 43 42

-

Separate “ T3 retraction chain ” ( Item 42 ) from its tensioner ( Item 43 ) by taking out pin ( Item 44 ) and its hinge pin ( Item 45 ).

46

-

Place a cord ( Item 46 ) around the links at the end of the chain.

This operation is necessary so that the chain can be tensioned during T2 + T3 assembly extraction to avoid any possible kinking.

49

47

48

-

Use a presser foot tool ( Item 47 ) to slightly move the T2 + T3 assembly ( Item 48 ) of T1 telescope ( Item 49 ).

50

50

50

-

50

49

Use 19 mm socket wrench to undo sixteen T1 telescope ( Item 49 ) pad nuts ( Item 50 ). Then loosen screws and take out pads + shims.

26

51

52

53

-

Use sling and hoist ( Item 51 ) to pull out “ T2 + T3 telescopes ” assembly ( Item 52 ) whilst using cord ( Item 53 ) to pull on “T3 retraction chain ”.

Check that “ T3 retraction chain ” remains intension during T2 + T3 assembly extraction.

55

54

-

Pull on the “ T2 + T3 telescopes ” assembly but do not pull it out completely.

Place container ( Item 54 ) to collect “ T3 retraction chain ” ( Item 55 ).

58

57 56

-

56

Position temporary chocks (Item 56) between T1 telescope ( Item 57 ) and T2 telescope ( Item 58 ).

This operation protects the right boom and prevents crushing of the “ T3 retraction chain ” when shifting sling to the T2 + T3 assembly centre of gravity.

59

-

Reposition sling (Item 59) to “ T2 + T3 Telescopes ” assembly centre of gravity for balance during removal.

27

-

Take out temporary chocks.

Completely remove “ T2 + T3 telescopes ” assembly and place it on two trestles.

“ T3 TELESCOPE ” REMOVAL 5

5 6

3

6

7 7

7 6

7 7

5

7

The “ Hydraulic kit removal ” and “ T2 + T3 Telescopes assembly removal ” operations should be carried out.

-

Take out left and upper pads ( Item 5 ) + shims ( Item 6 ) + screws and nuts ( Item 7 ) from T3 telescope foot ( Item3 ).

This operation gives some clearance to facilitate T3 telescope extraction.

9

10

10

8

8 11

-

Undo two “ pad support bracket ” ( Item 9 ) nuts ( Item 8 ).

Remove support bracket.

Loosen two “ T3 retract chain blade ” ( Item 11 ) nuts ( Item 10 ) at T3 telescope rear.

Remove blade.

28

13

-

12

Remove sealing blade assembly (Item 12) on T2 telescope ( Item 13 ).

15

16

-

14

Remove the screw ( Item 14 ) from the roller ( Item 16 ) pin ( Item 15 ).

Remove pin ( Item 15 ) then rollers ( Item 16 ).

17 18 19

18

19

18 19

-

18

Undo sixteen T2 telescope ( Item 17 ) pad nuts.

Then loosen screws ( Item18 ) and take out pads + shims ( Item19 ).

20

21

-

Use sling & hoist ( Item 20 ) gently to lift T3 telescope ( Item 21 ) then take out chocks between T2 and T3.

29

20

21

22

-

Pull on T3 telescope ( Item 21) but do not pull it out completely.

Place a wooden chock ( Item 22 ) under boom head.

This operation stabilises the boom during the shifting of the sling to the T3 telescope centre of gravity.

Reposition sling ( Item 20 ) to the T3 telescope centre of gravity for balance during removal.

Fully remove T3 telescope and set it aside.

30

50.4.5 CHAIN BOOM COMPONENTS REFIT

GENERAL INFORMATION In order to better understand chain boom operation and reassembling procedure: 50 “ Boom Schematic Diagram” The “chain boom component reassembly” operation is done in several stages: -

“ T3 Telescope ” refit.

-

“ T2 + T3 Telescopes assembly ” refit.

The “ T3 Telescope refit ” operation should be done.

-

“ Hydraulic kit ” refit.

The “ T3 Telescope refit ” and “ T2 + T3 Telescopes assembly refit ” operations should be carried out.

These various stages are detailed below in this chapter.

During the reassembly procedure: -

Grease each pad sliding face before putting them in place.

Grease telescope sliding faces.

31

“ T3 TELESCOPE ” REFIT

Apply “ Loctite 243 normal thread lock” to all screw / insert and nut / screw interfaces only on boom inside.

-

Replace pad assembly (Item 1) at T3 telescope foot (Item 2).

Put chocks (Item 3) only on T3 telescope lower part (Item2).

2

1 3

3

4 1

-

Use sling and hoist to insert T3 telescope into T2 telescope ( Item 4 ) without putting it in fully. Leave a clearance of about 30 cm.

Use a presser foot tool to butt T3 telescope foot ( Item 2 ) against T2 telescope foot ( Item 4 ) right side.

Measure “ J1 ” clearance between the two telescopes on left hand side. Divide this clearance figure by 2 to find the thickness of the shim to be inserted on each side of the T3 telescope.

5 6

-

1

J2

Shim thickness = J1/2

J1

Insert one shim on each side of the T3 telescope.

32

-

Find the “ J2 ” clearance between upper pad ( Item 5 ) and T3 telescope upper side.

Insert one shim ( Item 6 ) under each pad ( Item 5 ) to fill in this clearance ( between 0 and 0,5 mm ).

9 4 9

J3

7 8 10

-

2

Insert two pads ( Item 7 ) + 2 shims ( Item 8 ) to T2 telescope head ( Item4 ).

Fix them in place by tightening up their rods and nuts.

Insert four side pads + rods ( Item 9 ) to each side of the T2 telescope.

Insert two pads + shims + rods to the T2 telescope upper part.

Use a presser foot tool ( Item 10 ) to butt T3 telescope ( Item 2 ) against T2 telescope ( Item 4 ) right side.

11

-

Measure “ J3 ” clearance between the two telescopes on left hand side. Divide this clearance figure by 2 to find the thickness of the shim to be inserted on each side of the T2 telescope.

Shim thickness = J3/2

-

Insert one shim ( Item 11 ) to each side of the T2 telescope.

Total clearance between 0 and 0,5 mm.

13

14

J4

-

Find “ J4 ” clearance between upper pad and shim ( Item 13 ).

Insert a shim ( Item 14 ) to take up this clearance.

Tighten rods and nuts for each pad, observing the required tightening torque figures.

33

9 mini

C 1 =15 N.m +15% -

-

-

0 +- 0,5

Wedging

C 2 =92 N.m +15% -

Observe tightening torques and assembly recommendations.

C1 = 15 N.m ±15% C2 = 92 N.m ±15% Fully insert T3 telescope into T2 telescope.

Fix “ T3 retract chain blade ” ( Item 15 ) in place. Tighten two screws ( Item16 ) to a 95 N.m. tightening torque.

Put blade stub in place before tightening screws. Then tighten up blade fixing screws.

17

16 15

18

18 16

-

Put “ pad support bracket ” ( Item 17 ) in place then tighten up its two nuts with washers ( Item18 ).

Apply “ Loctite 243 normal thread lock ” to fasteners.

22

22

23

24

22

22 24

-

22

Replace pad assembly ( Item 22 ) at T2 telescope foot ( Item 23 ).

Put chocks ( Item 24 ) only on T2 telescope lower part ( Item 23 ).

34

“T2 + T3 TELESCOPES ASSEMBLY” REFIT

1

2

-

The “T3 Telescope refi t” operation should be done.

Use sling + hoist ( Item1 ) to insert “ T2 + T3 telescopes ” assembly ( Item 2 ) into T1 telescope ( Item3 ).

During this operation, check that the “ T3 retract chain ” goes in smoothly and is always intension.

Put “ T2 extend chains ” in T2 centre to ensure that they do not slide on the sides.

5

4

4 3 1 6

-

Position temporary chocks ( Item 4 ) between T1 telescope ( Item 3 ) and T2 telescope ( Item 5 ).

This operation protects the right boom and prevents crushing of the “ T3 retraction chain ” ( Item6 ) when shifting sling ( Item1 ) to boom head.

1

3

- Reposition sling ( Item 1 ) to boom head then insert “ T2 + T3 telescopes ” assembly into T1 telescope ( Item 3 ).

Comment: - Do not insert T2 + T3 assembly fully into T1. Leave about 30 cm clearance.

- Lift the T2 + T3 assembly and take out temporary chocks (Item 4).

35

3

5

7

8

-

Insert 2 pads ( Item 7 ) + 2 shims ( Item 8 ) between T1 ( Item 3 ) and T2 ( Item 5 ) telescopes.

-

Tighten up their rods + position rings + nuts.

9 mini

Apply “ Loctite 243 normal thread lock ” to all screw/ insert and nut/screw interfaces only on boom inside.

C 1 =15 N.m +15% -

-

0 +- 0,5

Wedging

C 2 =92 N.m +15% -

Observe tightening torques and assembly recommendations.

C1 = 15 N.m ±15% C2 = 92 N.m ±15%

11 10

9

10

10 9 10

-

Insert 2 pads (Item 9) + rods (Item 10) into T1 telescope left side (Item 11).

Carry out same operation on T1 telescope right side.

36

11

13

12

-

Insert 2 pads ( Item12 ) + shims ( Item 13 ) into T1 telescope top ( Item 11 ).

J1

-

Use a presser foot tool to butt up T2 telescope head on T1 telescope right side.

Measure “ J1 ” clearance between the two telescopes on left hand side. Divide this clearance figure by 2 to find the thickness of the shim to be inserted on each side of T1 telescope.

Shim thickness = J1/2

-

Insert one shim on each side of T1 telescope.

Total clearance between 0 and 0,5 mm.

14 13

J2

15 15

15

15

-

Find the “ J2 ” clearance between shim ( Item 13 ) and T3 telescope lower side.

Insert shims ( Item14 )to each pad to take up this clearance.

Tighten up pad nuts ( Item 15 ) to recommended torque.

C1 = 15 N.m ±15% C2 = 92 N.m ±15%

37

17

16

-

18

Fix “ T3 retract chain ” ( Item 16 )to its tensioner ( Item17 ). Replace hinge pin and split pin ( Item18 ).

Then fully insert “ T2 + T3 telescopes ” assembly into T1 telescope.

20 20

T1

21

T J3 2

19

-

J4

21

Use a presser foot tool to butt T2 telescope foot against T1 telescope foot right side.

Measure “J3 ” clearance between the two telescopes on left hand side. Divide this clearance figure by 2 to find the thickness of the shim to be inserted on each side of the T2 telescope.

Shim thickness = J3/2 Insert one shim ( Item 19 ) to each side of the T2 telescope.

Find the “ J4 ” clearance between upper pad ( Item 20 ) and T2 telescope upper side.

Insert a shim ( Item 21 ) to each pad ( Item 20 ) to take up this clearance.

Tighten up their rods + position rings + nuts ( Item 22 ).

9 mini

Apply “Loctite 243 normal thread lock” to all screw/ insert and nut/screw interfaces only on boom inside.

22 22

0 +- 0,5

Wedging

C 2 =92 N.m +15% -

22

-

C 1 =15 N.m +15% -

Observe tightening torques and assembly recommendations.

C1 = 15 N.m ±15% C2 = 92 N.m ±15%

38

24 23 25

-

23

Insert “ T2 + T3 ” assembly completely into T1.

Fix two “ T2 retract chain plates ” ( Item 23 ) to T2 telescope foot ( Item 24 ). To do that, do up 4 screws ( Item 25 ) to a 95 N•m. tightening torque.

Apply “ Loctite 243 normal threadlock ” to fasteners.

Put blade stub in place before tightening screws. Then tighten up blade fixing screws.

29 27 28 26

-

Before repositioning two rollers ( Item 26 ) on the T1 telescope, place a temporary rag ( Item 27 ) between T2 telescope ( Item 28 ) and T1 telescope ( Item 29 ) to prevent any washer falling into the boom.

26

30

-

Put roller (Item 26) + its washer (Item 30) in place.

31

29

-

Insert “ roller pin ” ( Item 31 ). Take out rag and place it on the other side.

39

-

Carry out same operation for the second roller.

After putting the second roller + its washer in place, use a mallet to fully insert “ roller pin ” ( Item 31 ).

Remove the rag then screw and tighten the pin locking screw on T1 telescope ( Item 29 ).

33

32

34

-

Put rollers ( Item 32 ) in place on T2 telescope ( Item 33 ) then insert their pins ( Item 34 ).

Screw and tighten the pin locking screw ( Item 34 ) on T2 telescope.

-

36 35

36

35

Fix two “ T2 extend chain tensioners ” ( Item 35 ) with pins and split pins ( Item 36 ).

39

40

37

40 39 37

-

38

Put “ T3 extend chain tensioners ” ( Item 37 ) in place on T2 telescope ( Item 38 ).

Insert Belleville washers ( Item 39 ) then nuts ( Item 40 ).

Carry out “ T2 retract chains ” tension pre-setting in order to obtain dimension X1. “ Chain tension pre-settings during reassembly ”

40

41 42

43

-

Use sling + hoist ( Item41 ) to put cylinder ( Item42 ) in place on T1 telescope ( Item43 ).

Use a mallet to insert its hinge pin in T1 telescope ( Item 43 ) then put its circlips in place.

45

45 44

45 44 45

-

Replace and tighten up plates ( Item 44 ) on each side of cylinder ( Item 42 ) by screwing in 4 screws ( Item45 ).

48

47 46

-

Put “ T2 extend chain tensioners ” ( Item 46 ) in place on T1 telescope.

Insert Belleville washers ( Item 47 ) then nuts ( Item 48 ).

Pay attention to the stacking direction of the Belleville washers (Item 47).

41

CHAIN TENSION PRE-SETTINGS DURING REASSEMBLY STEP 1: “ T2 RETURN CHAINS ” PRE - SETTINGS Adjust “ X1 ” dimension by turning nut ( Item 1 ).

With no worn chain replacement: 1

X1 Right 1

X1 Left X1Left

=

Dimension read on “ left chain tensioner ” before dismantling.

X1Right

=

Dimension read on “right chain tensioner” before dismantling.

With worn chain replacement with new: 1.

Measure the difference in length ( ∆ L ) between the chains.

∆L

2.

Position the “left chain tensioner”at: X1Left = 65 mm.

3.

Position the “right chain tensioner”at: X1Right = 65 mm - ∆ L X1Right = 65 mm + ∆ L

⇒ if LRight chain < ⇒ if LRight chain >

LLeftchain LLeftchain 42

STEP 2 : “T3 RETRACT CHAINS ” PRE - SETTING

2

8

X2

Adjust “X2” dimension by turning nut (Item 2).

With no worn chain replacement : = measured machine dimension before dismantling operation.

X2 With worn chain replacement with new : X2 = 90 mm.

STEP 3 : “ T2 EXTEND CHAINS ” PRE - SETTING 3

X3 Left

3

X3 Right

Before tightening nuts ( Item 3 ), protect the cylinder rod ( Item 8 ).

Adjust “ X3 ” dimension by turning nut ( Item 3 ).

With no worn chain replacement : X3 = measured machine dimension before dismantling operation.

With worn chain replacement with new : X3 = 40 mm.

STEP 4 : “ T3 EXTEND CHAINS ” PRE - SETTING

4

X4 Left

4

X4 Right

Adjust “ X4 ” dimension by turning nut ( Item 4 ).

With no worn chain replacement : = measured machine dimension before dismantling operation.

X4 43

With worn chain replacement with new : = 55 mm.

X4 -

Carry out a full boom extend/retract cycle.

With boom extended, “ extend chains ”should quickly be tensioned and there tract chains should take up a little slack.

With boom retracted, “ extend chains ” should take a little slack and the retract chains should quickly be tensioned.

44

CHECKING AND SETTING CHAIN TENSIONS The procedure is carried out with boom in horizontal position and in 2 situations:

⇒ ⇒

During reassembly procedure of boom components or During regular checks

T3

Lower chain

T2

H2

Lower chain Above T2 0 75 - 10

T1

H1

1.

2.

Fully extend boom than retract it by a total of 200 mm.

Monitor “extend chains”slack:

⇒

H1

=

75-100

mm

⇒

H2

=

107-100

mm

Turn their nuts to obtain dimensions “ H1 ” and “ H2 ”.

The left and right chains must have the same dimension or within 2 mm.

6

T3

T2 7

T1 6

(05/06/2012)

3. Fully and carefully retract the telescopes.

4. Check that the telescopes are at the mechanical stop. If they are not, measure the following clearances : ⇒ Clearance between T1 and T2 ( Item 6 ) ⇒ Clearance between T2 and T3 ( Item 7 ) Acceptable clearance = less than 3 mm 45

107 -010

Above T1

Where clearance is greater than 3 mm, carry out the following procedure:

No

Clearance T1/T2 Clearance T2/T3

Clearance T1/T2 Clearance T2/T3

Yes

No

Yes

Loosen T2 chain exit by clearance value T1/T2

erence in clearances T1/T2 and T2/T3

Tighten T2 chain retraction by clearance value T1/T2

Loosen T2 chain exit by clearance value T1/T2

Tighten T2 chain retraction by clearance value T1/T2

erence in clearances T1/T2 and T2/T3

Carefully retract the boom

No

No

Clearance T1/T2 is zero Yes Measure clearance between T2/T3

No

Clearance T2/T3

3 mm

Clearance T2/T3

Yes

≤ 3 mm

No

Yes

Loosen T3 exit chains by clearance value

Tighten T3 retraction chain by clearance value

Checking tension of exit chains

Fully extend boom than retract it by approx. 200 mm.

Tighten T2 exit chains: 0

dimension 107-10 mm above T1

If chains are too highly tensioned chains breaking.

Tighten T3 exit chains: 0

dimension 75-10 mm above T2

Carefully extend and retract boom

End of procedure

No

Clearance > 3 mm

46

Yes

Note : Where there is a difference in tensioner length on a pair of chains, keep the difference, do not adjust the tensioners to the same dimensions.

5.

Tighten up lock nuts for each “ chain tensioner ”once all chain tensioner settings have been done. Apply tightening torque to lock nuts: C = 85 N.m

6.

Refit split pins to each “chain tensioner”.

47

“HYDRAULIC KIT” REFIT

1

-

The “ T3 Telescope refi t” operation should be done.

Put special “ hosing path support ” tool ( Item 1 ) inside T3 telescope. This tool helps insert hosing pieces into the hosing channel.

Use sling + hoist to position “Hydraulic kit” at rear of truck.

-

Apply a layer of grease to channel in pad support areas between channel and T3 fixed pads.

-

2 1

-

Lay hosing + electrical harness ( Item 2 ) into channel by sliding them in using special tool ( Item 1 ).

Insert “ Hydraulic kit ” into boom by about 20 cm.

48

-

Take out special tool ( Item 1 ).

Insert“ Hydraulic kit ” by inclining it so that it passes over the “T3 retract chain”.

3

-

Connect up hosing pieces and electrical connector ( Item3 )at boom foot.

Place an oil container to recover any oil coming out of hosing pieces.

Fully insert “Hydraulic kit” into boom.

6

6

4

5

Fix “ spring support bracket ” ( Item 4 ) to T2 telescope ( Item 5 ). To do that, do up two screws ( Item 6 ) on each side of T2 telescope.

Apply “ Loctite 243 normal thread lock ” to fasteners.

“Spring support” should be fixed in an upper position in the orifices as shown in the photo.

9

7

9

8

Fix “ left pulley support bracket ” ( Item 7 ) on T1 telescope ( Item 8 ). Spread “ Loctite 243 normal thread lock ” on three screws ( Item 9 ) then screw them in.

49

10 10

11

-

Pre-assemble two pulleys ( Item 10 ) with pin ( Item 11 ).

13

-

12

Position “pulley + pin” assembly ( Item 12 ) with hosing pieces ( Item 13 ).

Then insert third pulley on pin.

8

15 15

15

14

-

Fix “ right pulley support bracket ” ( Item 14 ) on T1 telescope ( Item 8 ). Spread “ Loctite 243 normal thread lock ” on three screws ( Item 15 ) then screw them in.

18

16

17 18

-

Screw in grease point ( Item 16 ).

Replace “ hosing guide ” ( Item 17 ). Screw in two screws ( Item 18 ) on each side. Apply “ Loctite 243 normal thread lock ”.

50

HOSING PIECE TENSION SETTING

19

-

19

Loosen the 2 nuts ( Item 19 ).

22 19

22

21

21

19 20

-

Use “ hosing tension setting wedge ” special tool ( Item 20 ) to set the two “ spring supports ” ( Item 21 ) to 120 mm by turning nuts ( Item 19 ).

1.

2.

Clockwise Anti-clockwise

-

Tighten up stop screw (Item 22) on each “ spring support ”.

Remove special tool.

-

Reassemble the hosing at the top of the boom.

Connect up hosing pieces and reconnect electrical connector.

Refit sealing blades to telescopes.

Do a complete boom extend/retract test to test the correct rolling out of the hosing. Carry out operation twice.

Carry out same test under load.

= =

reduce dimension increase dimension

51

50.5 SPECIFIC BOOM TOOLING 50.5.1 CHANNEL LEVER

690 mm

90°

100 mm

52

50.5.2 HOSING PATH SUPPORT

630

mm

45 mm

53

70 mm

124 mm

600 mm

170

mm

120°

50.5.3 HOSING TENSION SETTING TOOL

m 60 m

m

30 m 120

mm

50.5.4 CHAIN CHECKING GAUGE

CHAIN CHECKING GAUGE

1 6 1 5 8 3

54

HYDRAULICS

55

Intentionally Left Blank

TABLE OF CONTENTS 70.1

70.2

70.3

CYLINDER ASSEMBLY AND DISASSEMBLY........................................................................................................ 3 70.1.1

REMOVAL AND REASSEMBLY OF THE COMPLETE STEM..............................................................................................3

70.1.2

REMOVAL AND REASSEMBLY OF THE PISTON AND LOCKING RING........................................................................5

70.1.3

REMOVAL AND REASSEMBLY OF THE PISTON SEALS AND RING..............................................................................7

70.1.4

REMOVAL AND REASSEMBLY OF THE LOCKING RING SEALS AND RING................................................................8

70.1.5

APPLICATION OF THE THREAD LOCKING MATERIAL.................................................................................................. 10

CYLINDERS DRAWINGS.................................................................................................................................... 11 70.2.1

LIFT CYLINDER......................................................................................................................................................................... 11

70.2.2

COMPENSATION CYLINDER................................................................................................................................................ 12

70.2.3

TELESCOPIC CYLINDER......................................................................................................................................................... 13

70.2.4

TILT CYLINDER.......................................................................................................................................................................... 14

70.2.5

STABILZER CYLINDER............................................................................................................................................................ 15

HYDRAULIC SCHEMATIC DIAGRAM................................................................................................................. 16

2

70.1 CYLINDER ASSEMBLY AND DISASSEMBLY 70.1.1 REMOVAL AND REASSEMBLY OF THE COMPLETE STEM REMOVAL

Locking ring 2 Stem 1

Body 3

Piston 4

1

-

Place the cylinder in a vice fitted with false jaws.

Tighten the vice, ensuring that the body does not get distorted.

Free locking ring 2 (Fig. 1) using a spanner wrench.

If you find it difficult to free the ring, see subsection “REMOVAL” in section 70.1.5.

Completely unscrew locking ring 2 (Fig. 1).

Extract the complete stem from the cylinder body.

2

NOTE : VERY LONG CYLINDERS Take out the stem over 200 mm maximum.

Give a half turn to the locking ring to loosen it (ver y slowly and evenly).

Take out the stem by about 2500 mm.

Support the stem end to prevent it from weighing on the locking ring (Fig. 2).

Carry on unscrewing the locking ring. If the effort is excessive, lift and lower the stem to reduce the friction.

!

NOTE Never force the ring when unscrewing it as this could cause it to seize.

INSPECTION -

Degrease and clean the cylinder chamber.

Visually inspect the cylinder chamber, there should be no scratches, burrs, oxidisation,etc...

3

REASSEMBLY Locking ring Loctite

Stem

Seal 3

LOCKING RING TIGHTENING TORQUE 450 400 350

Torque in N.m

300 250 200 150 100 50 0

M40

M50

M60

M70

M80

M90

M100

Thread

4

-

Apply hydraulic oil on the piston seals and ring, using a brush.

Reassemble the complete stem inside cylinder body 3 (Fig. 1).

Ensure that the seals are not damaged while passing through the inside thread in the cylinder body.

Apply hydraulic oil to the outside seals on the locking ring.

Apply Loctite 222 (See section 70.1.5) on the locking ring (Fig. 3).

Screw the ring in.

Block using a spanner wrench and a torque wrench, see table for the tightening torque (Fig. 4).

Give one turn to the screw to ensure that the seals are correctly positioned.

REMARK -

We advise completing a hydraulic test of the cylinder before reassembling it on the machine.

Operate the stem several times in both directions.

4

70.1.2 REMOVAL AND REASSEMBLY OF THE PISTON AND LOCKING RING REMOVAL

Locking ring 2 Stem 1

Piston 4 Nut 5

Piston 7 Screw 6

1

-

Place the stem in a vice fitted with false jaws.

Tighten so as to stop it turning.

Loosen nut 5 (Fig. 1) and unscrew it completely using a box wrench. Or, depending on the version, remove locking screw 6 (Fig. 1) using a hexagonal wrench.

NOTE : Locking ring 6 (Fig. 1) is fitted using Loctite, then blocked by striking it with a chisel.

Locking ring 2

Locking ring 2 Stem 1

Piston 4

Stem 1

2

-

3

Remove piston 4 (Fig. 2) by pulling it out manually or, depending on the version, by unscrewing piston 7 (Fig. 1) using a hook wrench.

Remove locking ring 2 (Fig. 3) by sliding it along the stem.

INSPECTION

Comparator Stem 1

4

-

Check that the stem is straight over its whole length, using a comparator (Fig. 4).

Check that the stem is not scaling, corroded or scratched.

5

REASSEMBLY

PISTON TIGHTENING TORQUE

Locking ring 2

1400

Torque in N.m

1200

Stem 1

1000 800 600 400 200 0

M20

M30

M40

M50

M60

M70

Thread

5

-

6

Reassemble locking ring 2 (Fig. 5) on stem 1 (Fig. 5).

Reassemble piston 4 (Fig. 1) on the stem.

Screw and lock nut 5(Fig. 1) using a box wrench and a torque wrench. See the table for the tightening torque (Fig. 6). Or, depending on the version, screw piston 7 (Fig. 1) using a spanner wrench (see tightening torque Fig. 6) and block it with locking screw 6 (Fig. 1).

NOTE : • 1.

2.

3.

The locking screw should be fitted using Loctite 243, see section 70.1.5.

Tightening torque for the screw : 20 Nm. Strike with a chisel to drive the screw into the metal.

6

70.1.3 REMOVAL AND REASSEMBLY OF THE PISTON SEALS AND RING !

NOTE Never use cutting or sharp tools (screw drivers, blades, etc.) when assembling and removing seals. Ensure that there are no chippings on the work bench.

REMOVAL

Seals

Seals

O-ring

O-ring

1

-

2

Remove the piston seals and ring (Fig. 1 or 2).

Take care not to damage the edges or the bottom of the grooves.

INSPECTION -

Degrease and clean the piston.

Check that the groove bottoms and sides are smooth, and without scratches.

There should be no extraneous bodies in the grooves.

REASSEMBLY -

Fit the seals and ring as in Fig. 1 or 2.

When fitting the outside seals, open them sufficiently to slip them into the grooves while ensuring that they do not break.

The inside ring should be fitted by hand.

7

70.1.4 REMOVAL AND REASSEMBLY OF THE SEALS AND RINGS ON THE LOCKING RING !

NOTE Never use cutting or sharp tools (screw drivers, blades, etc.) when assembling and removing seals. Ensure that there are no chippings on the work bench.

REMOVAL -

Remove the locking ring seals and rings.

Take care not to damage the edges or the bottom of the grooves.

INSPECTION -

Degrease and clean the locking ring.

Check that the groove bottoms and sides are smooth, and without scratches.

There should be no extraneous bodies in the grooves.

Thread the bare ring on the stem and slide it over its whole length.

The gap should not be excessive, but it should not grip either.

REASSEMBLY Extrusion proof ring 2 Seal 3

Seal 1

Scraper ring 4 Stem seal 5

1

-

Fit the seals and rings as in Fig. 1. The lips of the stem seal should face the pressure side.

Seal

Bit 1 2

-

When fitting the stem seal, first introduce it in the groove, holding it back either with your thumb or a bit (item 1) with no sharp edges (Fig. 2).

8

Plug 2

Seal

Bit 1

3

-

Push it into the groove with the other hand or a smooth die (item 2) (Fig. 3). If the seal is too tight, dip it into hydraulic oil heated to 50°C. Fit scraper ring 4 (Fig. 1) using a plug and a mallet. O-rings 1 and 3 (Fig. 1) and extrusion proof ring 2 (Fig. 1) will be fitted by hand.

9

70.1.5 APPLICATION OF THE THREAD LOCKING MATERIAL CHARACTERISTICS Light thread locking material (Loctite 222) Application on the locking ring threads.

Without activation agent Handling time

10 - 30 minutes

Use time ( Placing of the cylinder under pressure)

3 - 6 hours

Shearing strength

15.4 - 4 N/mm2

With N Loctite activation agent Handling time

10 - 20 minutes

Use time (Placing of the cylinder under pressure)

2 - 4 hours

Shearing strength

15.4 - 4 N/mm2

Medium thread locking material (Loctite 243) Application on the M8 screws to lock the pistons.

Without activation agent Handling time

10 - 20 minutes

Use time (Placing of the cylinder under pressure)

3 - 6 hours

Shearing strength

5 - 7.5 N/mm2

With N Loctite activation agent Handling time

5 - 15 minutes

Usetime (Placing of the cylinder under pressure)

2 - 4 hours

Shearingstrength

5 - 7.5 N/mm2

REMOVAL If the parts fitted with locking material cannot be removed using standard tools, we recommend heating the glued area to T = 250°C, preferably using a hot air pistol rather than a blow pipe.

REMARK If the temperature is near 0°C, we recommend using a Loctite activation agent for the assembly, in addition, this will limit the polymerisation time.

10

70.2 CYLINDER DRAWINGS 70.2.1 LIFTING CYLINDER

11

70.2.2 COMPENSATION CYLINDER

12

70.2.3 TELESCOPIC CYLINDER

13

70.2.4 TILT CYLINDER

14

70.2.5 STABILIZER CYLINDER

15

70.3 HYDRAULIC SCHEMATIC DIAGRAM

A : to rear axle B : to rear axle T : to front axle

350b

350b

To front axle

Aggravating. cut-off

To axle brake

260 bar

6 cc

45 cc

16

Intentionally Left Blank 17

ELECTRICITY

27

Intentionally Left Blank

TABLE OF CONTENTS

80.1

ELECTRICAL SCHEMATIC.................................................................................................................................... 3 80.1.1

BOOM AND STABILIZER...........................................................................................................................................................3

80.1.2

COMPENSATION LOCKING VALVE........................................................................................................................................4

80.1.3

FORWARD/REVERSE SOLENOID VALVE..............................................................................................................................5

80.1.4

FRONT AND REAR WORK LIGHT...........................................................................................................................................6

80.1.5

FRONT WIPER MOTOR..............................................................................................................................................................7

80.1.6

HAZARD INDICATOR.................................................................................................................................................................8

80.1.7

HEAD LIGHT LH & RH................................................................................................................................................................9

80.1.8

HORN, CABIN LIGHT AN CABIN FAN................................................................................................................................. 10

80.1.9

HVAC SYSTEM.......................................................................................................................................................................... 11

80.1.10

RADIO......................................................................................................................................................................................... 12

80.1.11

REAR WIPER MOTOR.............................................................................................................................................................. 13

80.1.12

SIDE INSTRUMENT PACK...................................................................................................................................................... 14

80.1.13

STARTING SYSTEM.................................................................................................................................................................. 15

80.1.14

WHEEL ALIGNMENT SENSOR.............................................................................................................................................. 16

2

80.1

ELECTRICAL SCHEMATIC

80.1.1 BOOM AND STABILIZER

3

80.1.2 COMPENSATION LOCKING VALVE

4

80.1.3 FORWARD/REVERSE SOLENOID VALVE

5

80.1.4 FRONT AND REAR WORK LIGHT

6

80.1.5 FRONT WIPER MOTOR

7

80.1.6 HAZARD INDICATOR

8

80.1.7 HEAD LIGHT LH & RH

9

80.1.8 HORN, CABIN LIGHT AND CABIN FAN

10

80.1.9 HVAC SYSTEM

11

80.1.10

RADIO

12

80.1.11

REAR WIPER MOTOR

13

80.1.12

SIDE INSTRUMENT PACK

14

80.1.13

STARTING SYSTEM

15

80.1.14

WHEEL ALIGNMENT SENSOR

16

DRIVER'S CAB

4

Intentionally Left Blank

TABLE OF CONTENTS

85.1

85.2

DRIVER’S CAB - REMOVAL AND INSTALLATION................................................................................................ 3 85.1.1

PREPARATION AND SAFETY INSTRUCTIONS......................................................................................................... 3

85.1.2

PROCEDURE.................................................................................................................................................................................3

DRIVER’S SEAT REMOVAL AND INSTALLATION............................................................................................... 5

2

85.1

DRIVER’S CAB - REMOVAL AND INSTALLATION

85.1.1 PREPARATION AND SAFETY INSTRUCTIONS -

2.

Stabilise the machine on level ground place transmission control lever in neutral position.

Fully retract boom, lower boom, engage park brake and shut engine OFF. Disconnect battery.

Open tank cover and allow system fluids to cool down.

Disconnect, label and cap all hydraulic hoses attached to the Service Brake Master Cylinder(2). Cap all fittings and openings to keep dirt and debris from entering the hydraulicsystem.

Push all hydraulic hoses through opening in cab.

3

!

NOTE Remove and label cab components as needed before removing the cab from the machine. Label, disconnect and cap hydraulic hoses.

! CAUTION Block all four wheels to help prevent the machine from moving. Assure that there is sufficient overhead and side clearance for driver’s cab removal.

3. Disconnect the throttle cable (3) from the throttle assembly.

!

NOTE Remove necessary dash panels to gain access to electrical wiring connections. Label and disconnect harnesses.

Push harness connectors through opening in the cab.

2

4

4

2

Remove Cab interior trim. Refer Cab Interior Trim removal procedure.

Remove Driver’s Seat. Refer Driver’s Seat removal procedure.

6

85.1.2 PROCEDURE

4

7

4

5

8

4.

1

Remove the hydraulic control lever knobs 4 &5 and boots 6, 7 & 8.

11

1.

Disconnect, Label and cap all hydraulic hoses attached to the steering orbitrol valve(1). Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

10

9

5.

2

3

12

Uninstall the gear lever knob 9, steering selector knob 10, engine stop cable knob 11. Remove the boot 12.

13

19

13

20

6.

Uninstall the 4 Hex Bolts - Washers(13).

10. Uninstall the silent block nuts(20) on all four silent blocks (19).

21

21

14 21

7.

Disconnect all electrical connectors(14).

11. Attach sling to the four lifting points (21) provided on the driver’s cab.

12. Carefully begin to lift the cab. Stop and check that all wiring, hydraulic hoses and fasteners are disconnected or removed.

13. When the cab is completely clear of the machine, carefully lower it to the ground. Block up ors upport the cab so that it does not move or fall.

! WARNING Ensure nobody enters the cab while it is being removed from the machine.

15

8.

-

Disconnect the parking brake cable(15) from the lever.

7

8

9.

21

6

Loosen the jubilee clip 17 and disconnect AC duct hose 16 from recirculation box 18.

4

Installation is the reverse of removal procedure.

85.2

DRIVER’S SEAT REMOVAL AND INSTALLATION

1 1

1.

Uninstall the 4 Hex Bolts - Washers (1).

2

2.

Remove the seat (2).

-

Installation is reverse of the removal.

5

FRAME-BODY

10

Intentionally Left Blank

TABLE OF CONTENTS

90.1

TANK COVER REMOVAL AND INSTALLATION.................................................................................................... 3 90.1.1

PREPARATION AND SAFETY INSTRUCTIONS....................................................................................................................3

90.1.2

PROCEDURE.................................................................................................................................................................................3

2

90.1

TANK COVER REMOVAL AND INSTALLATION

90.1.1 PREPARATION AND SAFETY INSTRUCTIONS -

!

NOTE Take help of an assistant to perform the tank cover reStabilize the machine on level ground, fully retract the moval/installation procedure and/or use proper lifting boom, place transmission control lever in neutral position. aid.

Put both the stabilizers on the ground.

Installation is the reverse of removal procedure.

Ensure the engine is Shut OFF. Disconnect the battery. !

CAUTION Hot oils and fluids must be left to cool down before performing any disassembly procedure.

90.1.2 PROCEDURE

1

2

1.

Unlock the latch(1) and open the Tank Cover (2) .

3

2. Hold the Tank Cover open with the help of the bonnet strut(3).

2 4

4

3. Unscrew the hinges(4) and remove the tank cover(2).

3

Intentionally Left Blank 6

OPTIONS-ATTACHMENTS

17

Intentionally Left Blank

TABLE OF CONTENTS

110.1

110.2

AIR CONDITIONING OPTION - CHARACTERISTICS AND SPECIFICATIONS...................................................... 3 110.1.1

DESCRIPTION OF OPERATION....................................................................................................................................... 3

110.1.2

OPERATING PRINCIPLE............................................................................................................................................................4

110.1.3

DESCRIPTION OF COMPONENTS...................................................................................................... 5

AIR CONDITIONING LOCATION......................................................................................................................... 6 110.2.1

110.3

CONDENSER COMPONENTS..................................................................................................................................................6

AIR CONDITIONING CONTROLS & ADJUSTMENTS........................................................................................... 7 110.3.1

GENERAL CHECK POINTS...............................................................................................................................................7

110.3.2

AIR - CONDITIONING ELECTRICAL SYSTEM CHECK POINTS................................................................................7

110.3.3

ASSEMBLY INSTRUCTIONS FOR AIR - CONDITIONING CIRCUIT........................................................................7

110.3.4

SAFETY MEASURES FOR HANDLING R134A...................................................................................................................8

110.3.5

REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT..................................................................8

110.4

AIR CONDITIONING BELTS - REMOVAL.............................................................................................................. 8

110.5

AIR CONDITIONING TROUBLE SHOOTING......................................................................................................... 9 110.5.1

PRESSURE TROUBLE SHOOTING..................................................................................................................................9

110.5.2

ABNORMAL NOISE ON A/C SYSTEM...........................................................................................................................9

110.5.3

UNPLEASANT SMELL.......................................................................................................................................... 9

2

110.1 TIONS

AIR CONDITIONING OPTION - CHARACTERISTICS AND SPECIFICA! WARNING Only operators who are certified to handle refrigerant fluids may work on the air conditioning system, otherwise please contact a specialist air-conditioning company.

110.1.1

DESCRIPTION OF OPERATION

The air - conditioning system reduces the atmospheric pressure in the cab interior by extracting and dispersing the heat to the exterior. This heat exchange is possible thanks to theuse of a refrigerant fluid, R134a whose properties are to obtain very low temperature at low pressures by dilating it and inversely high temperatures at average pressure by compressing it.

The use of the properties of this fluid is done following the closed circuit cycle whose principle is: PHASE 1: COMPRESSION The fluid in the gaseous state at low pressure and at low temperature is drawn in and compressed by the compressor which sends it at high pressure and high temperature to the condenser.

PHASE 2: CONDENSATION The fluid passes through the condenser to transmit its heat to the outside of the vehicle, by means of the fan. As it passes through the condenser the fluid liquifies while maintaining a high temperature and pressure. It is then filtered in a drier (or desiccator).

PHASE 3: EXPANSION The fluid enters a pressure reducing valve (or expansion valve) so as to lower its pressure and temperature considerably while remaining in liquid state.

PHASE 4: EVAPORATION The fluid passes through the evaporator to absorb the cab interior heat and vaporises while maintaining a low temperature and pressure. In this way, the cab interior air propelled by the fan motor cools and releases its moisture when in contact with the evaporator. The condensation of the air is then drained and evacuated to the outside of the vehicle.

The high and low pressures in the system are monitored by a HP and LP pressure switch attached directly on the drier filter.

It has the following safety functions: Complete shut down of the air - conditioning system if the pressure is lower than 2 bars or greater than 27bars.

3

110.1.2

OPERATING PRINCIPLE

Engine Electromagnetic clutch Compressor

Alternator

Low pressure steam circuit

High pressure steam circuit

External air

Axial fan

Condenser

Hot air discharge

Drier Filter Binary pressure switch Indicator lamp High pressure liquid circuit

Warm air Filters Centrifugal fan (Turbine)

Pressure reducing valve Low pressure liquid circuit

Evaporator Thermostat Condensation water drainage

4

110.1.3

DESCRIPTION OF COMPONENTS

THE COMPRESSOR The compressor circulates the fluid through the circuit, drawing it in as a low pressure and low temperature gas from the evaporator and sending it to the condenser as a high pressure, high temperature gas.

THE CONDENSER The condenser is a thermal exchanger that transmits the heat recuperated from the evaporator to the outside air by means of the fan and causes the condensation of the fluid at highpressure.

THE DRIER FILTER The filter is the main protective component in the system. It performs the following functions: Filtering any solid particles carried by the fluid that could damage the compressor or obstruct the reducing valve, for example Dehumidifying the fluid and the oil to protect all the components to protect all parts of the circuit from corrosive substances and freezing moisture at the outlet of the pressure reducing valve. Storing the fluid in liquid state and thus constituting a buffer tank to compensate for pressure variations. It therefore helps to absorb pressure differences generated by the compressor.

THE “ BINARY ” PRESSURE SWITCH Mounted on the drier filter, the pressure switch is the system’s safety device which is sensitive to pressure variations. It protects the system against both excessively low pressures and excessively high pressures by directly controlling the compressor clutch. Acts against low pressures (below 2 bars) due to a lack of refrigerant, a leak or a downstream circuit blockage. Acts against high pressures (greater than 27 bars) due to incorrect compressor cooling, an excess of refrigerant or an upstream circuit blockage.

THE REDUCING VALVE The pressure reducing valve is mounted on the evaporator inlet. By expansion, it lowers the pressure and thus the temperature of the fluid in such a way as to cool the air passing through the evaporator. It adjusts the flow to calibrate the quantity of fluid in such a way that it is completely vaporised at the evaporator outlet.

THE EVAPORATOR The evaporator is a heat exchanger fitted with a pressure reducing valve and a fan. The fan draws air across the cold evaporator fins.

As the air passes across the fins the moisture it contains condenses and the air leaves the evaporator cooled. This heat exchange allows the coolant to evaporate at low pressure.

ANTI - FROST THERMOSTAT The electric thermostat is connected to a sensor located between two evaporator fins. Temperature variations in the evaporator lead to changes in the resistance of the potentiometer in the preset thermostat and this controls the compressor clutch relay.

5

110.2

AIR CONDITIONING LOCATION

Condenser

Evaporator

Compressor

110.2.1

CONDENSER COMPONENTS

Condensor Fans

Hot air discharge

Relay block

Machine connectors

Pressure Sensor

6

Reciever drier

Coolant connctions

110.3

AIR CONDITIONING CONTROLS AND ADJUSTMENTS

110.3.1

GENERAL CHECK POINTS !

WARNING Only operators who are certified to handle refrigerant fluids may work on the air conditioning system, otherwise please contact a specialist air-conditioning company.

Before repairing or diagnosing the A/C system, first check the following points: -

Check the positions of all control buttons referred to in the operator’s manual.

Visual inspection of A/C Checking the condenser cooling fins to ensure that there are no obstructions, such as insects, leaves or grass.

The condenser fans are operating and turning in the correct direction.

Check the condition and the tension of the compressor’s drive belt and repair if necessary.

Compressor operates in on/off cycles.

Evaporator hoses are not obstructed.

Fan runs at all operating speeds.

Water valve fully closed.

Air vent opens and closes fully.

110.3.2 -

AIR-CONDITIONING ELECTRICAL SYSTEM CHECK POINTS

Fan is switched on and working.

Voltage from condenser to connectors.

Voltage from relay block to at least 1 fan (fans switched from series to parallel when medium pressure (switch is closed).

The two condenser fans are working.

Compressor clutch voltage via condenser connector.

Signal voltage to compressor.

Compressor clutch engagement.

Compressor housing is constant or there is an electrical ground connection to the compressor.

110.3.3

ASSEMBLY INSTRUCTIONS FOR AIR - CONDITIONING CIRCUIT

!

WARNING Only operators who are certified to handle refrigerant fluids may work on the air conditioning system, otherwise please contact a specialist air-conditioning company.

Carry out the assembly operations in a dry and dust free area. Use PAG ISO SP20 oil for lubricating all seals and seal surfaces before assembly.

7

110.3.4 1.

2.

3.

4.

5.

6.

SAFETY MEASURES FOR HANDLINGR134A

Individual protection: protective goggles and rubber gloves.

Perform the operations in a ventilated space.

First aid: After inhalation, breathe clean air, give oxygen or perform mouth-to-mouth resuscitation according to the degree of urgency (medication contraindication). Consult a doctor. In the event of contact with the eyes, rinse thoroughly for 15 minutes and see a doctor. In the event of contact with the skin, rinse thoroughly and remove contaminated clothing.

Storage conditions: keep R134a in a sealed container in a dry, cool and well ventilated place.

Handling: only in ventilated areas.

Measures to be taken in case of accident: wear a self-contained breathing apparatus if R134a is exposed to fire.

110.3.5 -

REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT

Refrigerant fluid : R134a Charging equipment : Charging station Quantity of fluid : 1500 g ± 50 g and 245 ml of PAG ISO SP20 oil.

110.4

AIR - CONDITIONING BELT -REMOVAL

110 - 1

2

4 1

3

Fix the special wedge (1) on ribbed pulley (2).

Lock the wedge with the nut (3).

Make the rotation movement on the pulley shaft (4). This will drive the tool and lift the belt.

110 - 2 5

Pull the belt(5) by hand to release it, continue turning and remove the belt and the tool.

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110.5

AIR CONDITIONING TROUBLE SHOOTING

110.5.1

PRESSURE TROUBLE SHOOTING

Problem.

Low pressure manometer

Low pressure manometer

Normal

Normal

Hot air infiltration into the appliance or evaporator block.

Hot water infiltration at the heating water valve position or faulty water valve.

Low

Normal situation if ambient temperature is very low. Obstruction in the HP hose connected between the compressor and the condenser-filter- evaporator. Before the HP reading point. Check for leaks.

Very low quantity of coolant.

Faulty compressor

Normal or low

Little or no cool- Normal or high ing

110.5.2

High

Probable cause

Normal situation if the ambient temperature is very high. Excess coolant load. 5 - 35% of condenserobstructed Air present in the A/C system Obstruction in the HP hose connected between the compressor and the condenser-filter-evaporator. After the HP reading point.

Check for leaks. Compressor belt has jumped, probably due to poor pulley alignment. Compressor clutch not engaged, compressor damaged

High

Normal or low

Hose suction and discharge inverted on the compressor clutch.

Clutch not engaging.

Pressure reducing valve blocked in open position.

Compressor damaged.

Low

Normal or high

Drier filter saturated with moisture

ABNORMAL NOISE ON A/C SYSTEM

Sometimes, for a variety of reasons, the A/C system may produce an abnormal noise. The following are possible examples Causes

-

Solution

1

The belt is worn or slipping.

Check belt wear and tension

2

Noise of belt on the pulley.

Replace

3

Electric clutch plate slippage.

Check that the clearance between the compressor pulley and the clutch is 0.3-0.5 mm

4

Compressor support plate vibration and reso- Ensure that the bolts are properly tightened and the plate is correctly positioned. nance.

5

Whistling expansion valve.

110.5.3 -

Problem

If the noise persists, replace the valve.

UNPLEASANT SMELL

Under certain conditions, mould and bacteria (normally present in the air) may form on the surface of the evaporator core, producing an unpleasant smell inside the cab.

Treat the evaporator with an anti-bacterial product. Keep the evaporator clean.

Switch off the A/C system a few minutes before switching off the machine, while leaving the fan running (this will dry the moisture from the evaporator core which encourages bacteria growth).

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