Fiat kobelco t17 telehandlers service repair manual
- 1. T13 T14 T17 TELEHANDLERS Service Manual Print N. 604.02.395.01 (III -- 2004) THIS ALERT SYMBOL SIGNALS IMPORTANT MESSAGES INVOLVING YOUR SAFETY. Read and heed carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to safeguard your health and your safety. You will find this symbol in the text of this Manual referred to the following key words: WARNING -- Cautions directed to avoid improper repair interventions involving potential consequences for the operator’s safety. DANGER -- These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved. IMPORTANT NOTICE All maintenance and repair interventions explained in this Manual must be performed exclusively by the Service Organization of the Manufacturer, observing strictly the instructions explained using, whenever necessary, the recommended specific tools. Whoever performs the operations reported without following exactly the precautions is responsible on his own, for the damages that may result. Neither the Factory nor any Organizations in its Distribution Network, including but not limited to national, regional or local distributors, are responsible for any liability arising from any damage resulting from defects caused by parts and/or components not approved by the Factory for use in maintaining and/or repairing products manufactured or merchandized by the Factory. In any case, no warranty of any kind is made or shall be imposed with respect to products manufactured or merchandized by the Factory, when failures are caused by the use of parts and/or components not approved by the Factory.
- 2. Service manual T13 -- T14 -- T17 TELESCOPIC HANDLERS 604.02.395.01 -- 03 -- 2004 GENERAL LIST OF CONTENTS SECTION 00 -- GENERAL Description Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General instructions 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety rules 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product identification 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental considerations 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance techniques 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 -- ENGINE Description Page Coding of engines of origin 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main specifications of engines 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General engine specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generalities 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description of main mechanical components of the engines 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel and mechanical injection 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection assembly 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of engine transmission group from the vehicle 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine overhaul on bench 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the injectors 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve clearance 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing of setting 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing of injection pump 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical components 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tooling 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Data --mounting – plays 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 3. 4 GENERAL LIST OF CONTENTS 604.02.395.01 -- 03 -- 2004 SECTION 21 -- POWERSHIFT GEARBOX Description Page Gearbox assembly 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Idler gear case assembly 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearbox operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission and Hydraulic oil circuit diagrams 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modulation valve operation 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque converter and heat exchanger hydraulic oil circuit 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting procedures 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure testing clutch and high pressure circuit 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure testing torque converter and cooler circuit 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check points 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly instructions 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 25 -- FRONT AXLE Description Page Specifications 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel toe--in check 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component overhaul 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front axle removal procedure 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front axle overhaul 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle drive pinion bearing adjustment 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to install and adjust the axle drive pinion 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front drive shaft 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 4. GENERAL LIST OF CONTENTS 5 604.02.395.01 -- 03 -- 2004 SECTION 27 -- REAR AXLE Description Page Specifications 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation diagram 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component overhaul 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear axle removal procedure 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 33 -- BRAKES Description Page Power brakes 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking brake 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake disc adjustment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes disassembly 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 35 -- HYDRAULIC SYSTEM Description Page Technical data 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description and operation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering system hydraulic circuit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering valve 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Telescopic boom hydraulic circuit 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic pump 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic scheme 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery side divider valve 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front loader controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power steering (OSPQ) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Telescopic boom distributor 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary controls distributor 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinders 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arms 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom removal 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working platform 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure for the calibration of the personnel carrier platform electronic controller 47. . . . . . . . . . . . . . . . . . . . . Special tools 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 5. 6 GENERAL LIST OF CONTENTS 604.02.395.01 -- 03 -- 2004 SECTION 55 -- ELECTRICAL SYSTEM Description Page Chapter 1 – Electrical system general Electrical equipment specifications 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical system and fuse 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls and instruments 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Use of the tip--over prevention system 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bulb replacement 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protecting the electrical systems during charching or welding 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting the machine using jump leads 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temporary wiring repair 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical system general fault finding 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working platform 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 2 – Circuit diagrams List of connectors 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of components 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to use the circuit diagrams 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 1: Starting/Recharge/Warning lights/Indicator lights 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 2: Transmission 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 3: Wheel alignment/Hydraulic solenoids/Brake system 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 4: Arm control 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 5: Stabiliser 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 6: Lights/Windscreen wiper 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 7: Work lamps/Roof beacon light 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 8: Tilting prevention system/Roof wiper 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 9: Sound system heating/Electric socket/Roof lamp 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagram 10: Air conditioner 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3 -- Wiring list Instrument panel wiring 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab wiring 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front wiring 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear wiring 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine wiring 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 6. SECTION 00 -- GENERAL 1 604.02.395.01 -- 03 -- 2004 GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair interventions listed in this Manual must be performed exclusively by the Service Network of the Manufacturer, complying strictly with the indications herein and using, when required, the prescribed special tools. Whoever performs service operations described herein without complying strictly with the instructions becomes solely responsible for any consequential damage that could occur. ADJUSTING SHIMS For each adjustment select the adjusting shims, measuring them one by one with a micrometer and adding to gether subsequently, the values measured. Do not rely on the measurement of the entire pack, that could be wrong, or the nominal value indicated on each ring. SEALS FOR ROTATING SHAFTS For correct installation of the seals for rotating shafts, please comply with the following precautions: -- prior to installation, keep the seals soaking for at least half an hour in the same oil they are going to seal; -- clean thoroughly the shaft and make sure that its working face is undamaged; -- direct the sealing lip toward the fluid; in the event the lip is of the hydro dynamic type, the grooves must be directed so that, in relation to the rotating direction of the shaft, they tend to return the fluid toward the inside of the sealing device; -- smear the sealing lip with a film of lubricant (oil to be preferred to grease) and fill with grease the gap between sealing lip and dust lip in twin lip seals; -- insert the seal in its seat, pressing it with a punch with a flat face; never strike it with a hammer or mallet; -- when pressing in the seal, make sure that it is inserted perpendicularly in relation to the seat and, once in position, make sure that, when required, it contacts the shoulder; -- to prevent the sealing lip of the seal being damaged by the shaft, insert appropriate protection during the installation of the two parts. “0--RING” TOROIDAL SEALS Lubricate O--rings before inserting them in the relevant seats to prevent them becoming twisted and rolled during installation, thus jeopardising their sealing capacity. SELAING COMPOUNDS Mating surface marked X must be smeared with a sealing compound recommended by the Manufacturer or an adequate equivalent. Prior to applying the compound, prepare the surfaces in the following manner: -- remove all possible scaling with a metal brush; -- degrease the surfaces thoroughly using the degreesing agent recommended by the Manufacturer or an adequate equivalent. BEARINGS When installing bearings, it is recommended to: -- warm them up to 80° – 90 °C (176 – 194 °F) before installing them on the relevant shafts; -- cool them down before inserting them in the relevant seats with an outer fitting. SPLIT PINS When installing split pins, make sure that the cut is pointing in the direction of the load on the pin. On the other hand, spiral elastic pins do not require any installation orientation.
- 7. 2 SECTION 00 -- GENERAL 604.02.395.01 -- 03 -- 2004 NOTES ON SPARE PARTS Use genuine spare parts guaranteed by the Manufacturer only. Genuine spare parts are the only ones ensuring the same quality, the same life and the same safety as the originally mounted parts, since they are the same as the ones installed in production. Only genuine parts from the manufacturer ensure this guarantee. Orders for spare parts must include the following indications: -- model of the vehicle (commercial designation) and serial number; -- type and number of the engine; -- part number for the item ordered, as provided by the “Microfiches” or the “Spare Part Catalogue”, on which the order is based. NOTES ON TOOLING The tooling that the Manufacturer recommends and illustrates in this Manual is: -- studied and designed specifically for servicing vehicles of this range; -- required to ensure a reliable repair; -- accurately developed and inspected to provide effective and long lasting working. You are also reminded that correct tooling allows you to: -- to operate under optimised technical conditions; -- to achieve the best results; -- to save time and effort; -- to work in safer conditions. WARNING The wear limits provided for some items must be considered as recommended values, but not absolutelybinding. The indications “front”, “rear, “right”, “left” refer to different parts as seen seating from in the operator’s seat oriented in the normal travel direction of the vehicle. HOW TO MOVE A VEHICLE WITHOUT BATTERIES The cables of the external power supply must be connected exclusively to the respective terminals of the positive and negative cables of the vehicle, using efficient clamps providing adequate and safe contact. In the event it is necessary to check the operation of the electrical system of the vehicle, do it exclusively with the power supply connected. At the end of the inspection, disconnect all actuators and deactivate the power supply before disconnecting the cables.
- 8. SECTION 00 -- GENERAL 3 604.02.395.01 -- 03 -- 2004 SAFETY RULES PAY ATTENTION TO THIS SYMBOL This alert symbol announces important messages involving your safety. Read carefully the safety instructions listed and follow the precautions recommended to avoid potential risks and to safeguard your health and your safety. You will find this symbol in the text of this Manual with the following key words: WARNING -- Cautions intended to avoid improper repair interventions involving potential consequences for the safety of the personnel performing the repairs. DANGER -- These warnings qualify specifically potential dangers for the safety of the operator or other persons directly or indirectly involved. AVOID ACCIDENTS Most accidents, whether they occur in workshop, on the farm, at home or on the road, are caused by the failure of some individuals to follow simple and fun- damental safety rules and precautions. For this rea- son MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs. Regardless of the care used in the design and con- struction of any type of equipment, there are many conditions that cannot be completely safeguarded against without hindering reasonable accessibility and efficient operation. A careful operator is the best insurance against an accident. The complete observance of one simple rule would prevent many serious accidents. DANGER. Never attempt to clean, lubricate or main- tain a machine while it is in motion. SAFETY RULES SAFETY RULES ◊ Read and heed all safety rules before any inter- vention. ◊ Do not wear rings, wristwatches, jewellery, and loose or hanging apparels, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can catch on moving parts. Wear proper safety equipment as recommended for the job. Examples: hard hat, heavy gloves, ear protection, safety glasses or goggles, reflector vests, respirator. Consult your employer for spe- cific safety equipment requirements. ◊ Do not perform any service operation on the machine with a person seated in the operator’s compartment, unless he is an authorised oper- ator co--operating in the operation to be per- formed. ◊ Never attempt to operate the machine or its tools from any position other than seated in the oper- ator’s seat. ◊ Never perform any intervention on the machine with engine running unless this is prescribed. ◊ Cut--off the engine and make sure that all pres- sures in the hydraulic systems are released before removing caps, covers, valves etc. ◊ All service interventions must be performed with the utmost care and attention. ◊ Shop and/or field service platforms or ladders must be constructed and maintained in accord- ance with local and national regulations. ◊ Disconnect the batteries and tag all controls to signal that an intervention is in progress. Block the machine and all equipment that must be lifted. ◊ Do not check nor refill fuel tanks, as well as bat- teries, nor use starting fluid while smoking or near open flames since these fluids are flam- mable. ◊ Brakes are inactive when manually released for service interventions. Under such circum- stances it is necessary to maintain the control of the machine using appropriate blocks or similar devices. ◊ The fuel--filling nozzle must be kept constantly inside the filling neck. Keep this contact from the beginning to the end of the fuelling operation to avoid the possibility that sparks due to static electricity are generated. ◊ Use only designated towing or attaching points. Use care in making attachments. Make sure pins and/or locks are secure before pulling. Stay clear of drawbars, cables or chains under load. ◊ To move a disabled machine, use a trailer or a low--boy, if available.
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- 10. 4 SECTION 00 -- GENERAL 604.02.395.01 -- 03 -- 2004 ◊ To load/unload a machine from transporter, choose a level surface ensuring firm support to the wheels of truck or trailer. Anchor the machine securely to the bed of truck or trailer and block wheels or tracks with appropriate wedges. ◊ Use only approved grounded auxiliary power sources for heaters, chargers, pumps and simi- lar equipment to reduce the hazards of electrical shocks. ◊ Lift and handle heavy parts with a lifting device of proper capacity. ◊ Beware of bystanders. ◊ Never pour gasoline or diesel fuel into open, wide and low containers. ◊ Never use gasoline, solvent or other flammable fluid to clean parts. Use exclusively qualified, non--flammable, non--toxic commercial sol- vents. ◊ When using compressed air for cleaning parts, use safety glasses with side shields or goggles. ◊ Limit pressure to 2.1 bar, in accordance with local and national regulations. ◊ Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes. ◊ Do not smoke or permit any open flames orspark near when re--fuelling or handling flammable materials. ◊ Do not use an open flame as a light source to look for leaks or for inspection anywhere on the machine. ◊ Move with extreme care when working under the machine, its attachments and or on or near them. Always wear protective safety equipment as required, such as hard hat, goggles, safety shoes, ear plugs. ◊ When performing operations requiring runningof the engine, have a qualified operator in the oper- ator’s seat at all times with the mechanic on sight. Place the transmission in neutral and set the brakes and safety lock. ◊ For field service, move machine to level ground, if possible, and block it. If work on an incline is absolutely necessary, first block machine and its attachments securely, than move it to level ground as soon as possible with a certain margin of safety. ◊ Do not trust worn and /or kinked chains and cables: do not use them for lifting or pulling oper- ations. To handle them, always use heavy gloves. ◊ Be sure chains and cables are anchored and the anchor points are strong enough to handle the expected load. Keep exposed personnel clear of anchor points and cables or chains. No bystanders are allowed near the hooking points, chains or cables. ◊ Keep the area where maintenance operations are performed CLEAN and DRY. Eliminate immediately all water and oil spillages. ◊ Do not pile up oily or greasy rags; they represent a fire hazard. Store in a closed metal container. Before starting machine, check, adjust and lock the operator’s seat for maximum comfort and control of the machine. Be sure exposed personnel in the area of operation are clear of the machine before moving it or its attachments. Sound the horn. ◊ Do not carry loose objects in pockets that might fall unnoticed into open compartments. ◊ Wear proper protective equipment such as safety goggles or safety glasses with side shields, hard hat, safety shoes, heavy gloves when metal or other particles are apt to fly or fall. ◊ Wear welders protective equipment such as dark safety glasses, helmets, protective cloth- ing, gloves and safety shoes, when welding or burning. Wear dark safety glasses near welding zones. DO NOT LOOK AT ARC WITHOUT PROPER EYE PROTECTION. ◊ Steel cables are frayed after prolonged use; always wear appropriate protections (heavy gloves, goggles etc.). ◊ Handle all parts carefully. Keep hands and fingers away from structures, gears or moving parts. Use and wear always the appropriate protections, such as safety goggles, gloves and safety shoes.
- 11. SECTION 00 -- GENERAL 5 604.02.395.01 -- 03 -- 2004 STARTING ◊ Do not run the engine in closed areas without proper ventilation to remove deadly exhaust fumes. ◊ Do not place head, body, limbs, feet, hands or fingers, near rotating fans or belts. Be especially alert near pusher fans. ENGINE ◊ Loosen the radiator cap very slowly, to release pressure from the system, before removing it. All coolant level top--ups must be performed with engine inoperative or at low idle, if warm ◊ Do not run engine when refuelling and use care if the engine is hot due to the increased possibil- ity of a fire if fuel is spilled. ◊ Never attempt to check or adjust fan belts when engine is running. Do not adjust engine fuel pump when machine is moving. ◊ Never lubricate the machine with engine run- ning. ELECTRICAL SYSTEM ◊ Should booster batteries be used, remember to connect both ends of the booster cables in the proper manner (+) with (+) and (--) with (--). Avoid short--circuits of the terminals. Follow thoroughly the instructions of this Manual. Avoid short circuiting the terminals. BATTERY GAS IS HIGHLY FLAMMABLE. Leave battery box open to improve ventilation when recharging batteries. Never check charge by placing metal objects across the posts. Keep sparks or open flames away from batteries. Do not smoke near battery to guard against the possibility of causing an explosion. ◊ Before any intervention, make sure that there are no fuel or electrolyte leakages; eliminate them before proceeding with further work. ◊ When recharging batteries in closed ambient, make sure that there is appropriate ventilation to prevent possible accidental explosions due to the accumulation of gases generated during the recharge. ◊ Before any intervention, make sure that the main switch is OFF. HYDRAULIC SYSTEM ◊ Fluid escaping under pressure from a very small hole can be almost invisible and can have suffi- cient force to penetrate the skin. Use a piece of cardboard or wood to search for suspected pres- sure leaks. do not use hands. If injured by escap- ing fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treat- ment is not administered immediately. ◊ In case pressures must be measured, use instruments of adequate capacity. Always follow the recommended procedures. WHEELS AND TYRES ◊ Make sure that the inflation pressure of the tyres is according to the specifications issued by the Manufacturer and check it periodically. ◊ Should the pressure be changed, stand on the side of the tyre at a safe distance. ◊ Pressure check operations must be performed with unloaded machine and cold tyres. Never use reconditioned tyre rims, since eventual weldings, heat--treatments or repairs not per- formed correctly can weaken the wheel, thus causing subsequent damages or dangers. ◊ Do not perform torch cutting or welding oper- ations on rims with inflated tyres installed. ◊ Before operating on tyres, block all wheels, front and rear. After jacking the machine, block it with stands according to current safety rules and regulations. ◊ Before removing objects from the tyre tread, deflate it. ◊ Never inflate tyres with flammable gas; explosions and serious bodily injuries may result. REMOVALS AND INSTALLATIONS ◊ Lift and handle all heavy parts with lifting devices of adequate capacity. Make sue that the parts are attached to lifting devices are properly slinged. Use the lifting eyes provided. Beware of persons in the vicinity. ◊ Handle all parts carefully. Keep hands and fingers away from structures, gears or moving parts. Use and wear always the appropriate protections, such s goggles, gloves and safety shoes. ◊ Prevent chains and cables from kinking. To handle them, always use heavy gloves.
- 12. 6 SECTION 00 -- GENERAL 604.02.395.01 -- 03 -- 2004 PRODUCT IDENTIFICATION The Telehandler and its main components are identi- fied by various numbers and letters providing its identification by the Service network. The following information gives the location of the identification plates, of the numbers stamped on the machine and various examples of what can be found on the machine. VEHICLE SERIAL NUMBER The serial number is stamped on the front part of the machine, on the upper side of the main frame, right side. Example: *ZEFK1740AXXXXXXXX* NOTE: The serial number and the identification number of the components can be requested by the Dealer when Spare Parts are ordered or interven- tions are required. These numbers are also required as help in identifying the machine in theevent of theft. Keep them in a safe place. TH100040 1 VEHICLE IDENTIFICATION PLATES The vehicle identification plate is located on the left side of the seat location. Record here below the data for your machine. TECHNICAL TYPE/MODEL SERIAL NO. OF VEHICLE YEAR TH001050 ϒ 2 IDENTIFICATION OF ENGINE The identification data of the engine are on the left side of the engine cylinder block. Please record here below these data for easier consultation, when required. MODEL NO. SERIAL NO. DATE CODE TH001029 3