INFORMATIONONTHISHANDBOOK
Definitions
HandbookisthisWORKSHOPMANUAL.
Vehicleisthemachinerydescribedinthismanual. Manufactureristhecompanymanufacturingthevehicle.
Dealershipisthecompanyororganisationofficially representingtheManufacturer.
Supplierisanycompanysupplyingcomponentsand/or consumablematerialusedbythevehicle.
Useristhepersondirectlyorindirectlyinvolvedinrepairingthevehicle.
Contents
Thismanualcontainstherepairinstructionsforallthevehicleparts.
Somedevicesdescribedinthishandbook maynotbefittedinyourvehicle,according totheoutfitandthemarketforwhichthevehiclewasmade.
Thishandbookisorganisedinseveralsections,which areorganisedinchaptersand,whererequired,paragraphstoensurerapidandeasyretrievalofinformation. Refertothegenerallistofcontentsatthebeginningof thisHandbookforfurtherinformationonhowthevarious topicsaresetout.
Symbols
Youwillfindthefollowingsymbolshighlightingpartsof thehandbook.Theirmeaningis:
procedures,technicalinformationandprecautionswhich,ifnotrespectedand/orincorrectlycarriedout,couldcauseinjuryto users(safetysymbol,alsoseeSECTION 1.2-SAFETYINSTRUCTIONS).
procedures,technicalinformationandprecautionswhich,ifnotrespectedand/orincorrectlycarriedout,coulddamagethevehicle.
procedures,technicalinformationandprecautionswhich,ifnotrespectedand/orincorrectlycarriedout,couldpollutetheenvironment.
veryimportantprocedures,technicalinformationandprecautions.
Purposeofthishandbook
Purposeofthishandbookistoallowuserstogettoknow thevehicleandrepairitasspecified,inasafeandlong-lastingfashion,takingtherequiredactionsandarranginghumanandmaterialresourcesasneeded.
Towhomthismanualisaddressed
Thismanualisaddressedtothosepersonswhoneedto and/orhavebeendelegatedtocarryoutrepairsonthe vehicleand/orwhosejobitistogiveinstructionsonhow tocarryoutsuchrepairs.
Thesepersonsare:
Doperativeunits/site/departmentmanagers;
Dusersdirectlyconcernedinvehiclemaintenance.
Safekeepingofthishandbook
Thishandbookmustbekeptinsidethevehicle,inadry place,andmustbereadilyavailableforconsultation. Youareadvisedtofileacopy.
Keepthehandbookfortheentirelifeofthevehicle,until itisscrapped.Usersarerequiredtopurchaseanew copyifthehandbookiseitherlostordamaged.Copies mustbeexclusivelyorderedfromthemanufacturer.
Updatestothishandbook
Theinformation,descriptionsandillustrationsinthis handbookreflectthestateoftheartatthetimeof marketingofthevehicle.
Themanufacturerreservestherighttoimplement changestovehicles,fortechnicalormarketingreasons, atanytime.Themanufacturerwillnotbeobligedeither toimplementsuchchangesinthevehiclesmarketedbeforeortoconsiderthishandbookobsolete.
Anyadditionalinformationwhichthemanufacturermay deemsuitabletoprovideatalatertimewillbekeptwith thehandbookasanintegralpartofthepublication.
Unitsofmeasure
InternationalSystem(SI)unitsofmeasureasusedin thishandbook.
ImperialSystemvaluesareexpressedinbrackets.
SCHEDULEDUSE
Thevehicledescribedinthishandbookwasdesigned andmadeforthefollowinguse:
Dtohaulexcavationmaterialingeneral;
Dtohaulmaterialresultingfrominterventionsonindustrialorcivilianartefactsingeneral;
Dtohaulmaterialrequiredtomakeinfrastructuresand/ orindustrialorcivilianartefactsingeneral. Thevehiclemustbeusedforsuchpurposes.
Thevehiclemustbeinprovenandcheckedconditions ofefficiencyforsaiduse,fullyrespectingtheenvisaged criteriaandrestrictionsofuse.
Specificcaremustbepaidtothefollowingaspects:
Ddonotexceedthepayloadsspecifiedbythe manufacturer;
Ddonotexceedthegradientsspecifiedbythe manufacturer;
Ddonotdrivethevehicleonlooseterrainwhichcan compromisestability;
Ddonotusethevehicletoremoveobjectsorproducts;
Dusethevehiclepayingspecialcaretothesafetyinstructionsandspecifications;
Dcarryouttheordinarymaintenanceinterventions specifiedbythemanufacturer;
Dcarryouttheextraordinarymaintenanceinterventionswhicharerequired,specificallythoserelatedto safetyofuse.
Themanufacturerdeclinesliabilityforinjurytopersonsandfordamagetothevehicle and/ortothetransportedgoodsintheevent ofotheruseoruseinotherconditionsthan thosespecified.
VEHICLEOPERATORS
Thevehiclecanbedrivenexclusivelybyqualifiedpersonnelwiththenecessaryskillsandsuitabletechnical knowledge.
Vehicledriversmust:
Dhavetheskillsrequiredtodrivethevehicleinallenvironmentalandweatherconditions;
Dbepsychologicallyandphysicallyfit;
Dbeveryresponsibleandrespectthesafetyinstructions.
Vehiclemaintenancepersonnelmust:
Dhavetheoperativeskillsrequiredforconstruction sitevehiclemaintenance;
Dbesensitisedtorespectandadoptsafetyinstructionsandprecautions.
Vehicleoperatorsmustbeinconditiontoworkintotal safety,alsobymeansofsuitabletrainingperiodsor courses,toacquirefullknowledgeofinstructionsforvehicleuse.
Thedirectreportingmanagermustensurerespectof generalsafetyinstructions,specificallythosecontained inthishandbook.
Themanagerwillalsoascertainsuitabilityofoperating personnel,intermsoftechnicalskillsandpsychological--physicalconditions.
WASTEDISPOSAL
Collectandproperlydisposeofreplacedmaterial(brake pads,filters,etc.)andwastematerial,resultingfrom maintenanceoperationsandrepairs(materialsoakedin fuel,oil,powder,etc.)accordingtothelawsinforce,separatelyfromnormalwaste.
Collectanddisposeofusedlubricantsandfluids,accordingtothelawsinforce.
Collectanddisposeofusedbatteriesaccordingtothe lawsinforce.
Drainandrechargetheairconditioningsystemusingthe specificdevices,accordingtothelawsinforce.
Furthermore,youareadvisedtoseparateferrousmaterials,lightalloysandwasteplasticmaterialsforseparate recycling.
SCRAPPINGTHEVEHICLE
Thevehiclemustbescrappedaccordingtothelawsin force,attheendofthevehiclesworkinglife. Recycleanddemolishthevehicleaccordingtothelaws inforce.
Thevehiclemustbedemolishedbyexpertpersonnel usingsuitableworkingtoolstoensuretherequiredsafetyconditions.
Demolishthevehiclebyseparatingandcollectingthe variousmaterialsbytypetoallowrecyclinganddisposal.
Pleasenotethatitisforbiddentoabandonanobsolete vehicleataquarry,buildingsite,dumporintheenvironment.
Specificattentionmustbedevotedtocertaincomponentsandsubstanceswhichcanpollutetheenvironmentand/orcauseinjuries,i.e.:
Dpresenceoffuels,coolantfluids,hydraulicoilandlubricatingoilsonboard;
Dpresenceofbatteriesandrespectiveelectrolyte;
Dpresenceofpressurizedgas(tires,suspensioncomponents,airconditioner);
Dpresenceofsolidpollutingmaterials(tires,brake pads,plasticparts,filters)orhazardousmaterials (glass,windows).
Disposeofthesematerialsaccordingtothelawsinforce.
WARRANTYANDLIABILITYOFTHE MANUFACTURER
Warrantyconditions
Theusermustscrupulouslyobservetheprecautionsillustratedinthishandbooktoensurevalidityofthecontractualwarranty.Specifically,theuserwill:
Drespectrestrictionsofusespecifiedbythemanufacturer;
Dnotimplementchangesorvariantstothevehicle withoutthemanufacturerswrittenapproval;
Dalwayscarryoutthemaintenanceinterventions;
Dalwaysusegenuinespareparts;
Dascertainthatthepersonnelcalledtousethevehicle havethenecessaryrequirementsintermsofskills andtraining.
Thecontractualwarrantywillnotbeapplicableifthe aforesaidconditionsarenotrespected,eveninpart.
Liability
Themanufacturerdeclinesalldirectorindirectliabilities derivingfrom:
Ddisrespectoftheinstructionscontainedinthishandbook;
Duseofthevehiclebyuntrainedorunauthorisedpersonnel;
Dusenoncomplyingwiththeregulationsinforceinthe countrywherethevehiclewasmarketed;
Dunauthorisedchangesand/orrepairs;
Duseofotherthangenuinespareparts.
SERVICE
Warrantycoupons
Themanufacturerprovidesawarrantycardtotheuser witheachvehicle.
Youareadvisedtousethecouponduringthefirsthours ofoperationofthevehicle.
Warrantycoupon:after250hoursofwork.
Differentwarrantyconditionsarevalidonly ifstatedonthevehiclepurchasingcontract.
Service
Dealershipsareavailableforalltypesofinterventions. Equipmentandexpertpersonnelareavailableforoverhaulingandrepairingoperations.
Dealershipscanprovideinformationandadvicetoensurethebestuseofthevehicle.
Spareparts
Usegenuinesparepartsforreplacementswhichcanbe orderedfromdealersandauthorisedworkshops. Pleaserememberthatthefollowinginformationwillbe requiredtoorderspareparts:
Dvehicletype;
Dchassisnumber;
Dreferenceandcataloguenumbersshowninthe SparePartsCatalogue.
Ifthepartbelongstoamainassembly(engine,transmission,axles,motors,etc.),youwillalsoneedtospecifytheassemblymodelandserialnumber.
GENERALOPERATIONRULES
Pre--disassemblypreparation
Cleaningbeforebringingthevehicleintoserviceshop
Removemudanddirtcompletelybeforebringingthevehicleintotheserviceshop.Carryingmudanddirtintothe serviceshopimpedescleaningoperationswhendisassemblingandincreasesthepossibilityofcontamination ofpartsduringreassembly.
Preliminarysurveybeforedisassembly
Beforedisassembly,makeanaccuratepreliminarysurveyandmakeanoteoftheresults.Thiswillsaveunnecessarylabourandcomponentcostsandwillbeuseful togiveadvicetotheusertopreventproblemsinthefuture.
Inparticularly:
DCheckthetypeandnumberofthemachineandservicemeterreading.
DCheckthereasonfordisassembly.
DCheckthesymptom,locationandcauseoftheproblemandmakeanothervisualcheckifnecessary.
DCheckthecontaminationoftheaircleanerandair leakage.
DCheckthecharacteristicsofthefuelbeingused,contaminationofthefuelfilterandforanywaterinthe fuel,lossoffuel,deformedpipes.
DChecktheoillevel,oilcontamination(viscosity,colourandimpurity)presenceofwaterintheoil,oil leakageandcloggedoilfilter.
DCheckthetensionoftheVbelts;
DCheckforanyfaultycomponentsorloosenedconnections.
Disassemblypreparation
Tosaveunnecessarylabour,makesurethattheequipment,areaandspaceontheshelvesisavailable,accordingtothespecifictypeofdisassemblytobecarried out,andcleantheareabeforehand.
Duringdisassembly
Removalofparts
DBeforeremovingparts,checktheassemblyconditionsandfront/rear,left/rightandup/downrelations andtheremovalprocedures
DMakesuretherearetherelevantmatingmarksindicatingthemountingpositionsandifnecessarymark clearlytoavoiderrorsduringreassembly.
DUsethespecialdisassemblytoolswherespecified.
DIfitisdifficulttoremoveapartevenafterthemountingscrewshavebeenremoved,donotforceit,but checktheparttofindwheretheproblemlies.
DAllunits,especiallythosewhichlookalike,shouldbe placedinorderandtaggedormarkedwhennecessary.
DStandardpartssuchasnutsandboltsaretobekept, notingtheassemblypositionandthequantity.
DShimsandwashersusedtoadjustclearancesareto bekeptsotheycanbere--assembledinthesame conditions.
DDuringdisassembly,carefullyinspectforanyseizure,interferenceorcontactwithmovingpartstofind thecauseoftheproblem.
DWhenmeasuring,recordallthevalues,suchasend clearances,backlashorprojectionwhichonlyhave significanceifmeasuredduringdisassembly.
DKeepthesameadjustmentvaluesoftherodsasfar aspossible.Ifitisnecessarytodisassembleadjustmentdevices,measurethelengthbeforedisassemblyandmakeanoteofthevaluesoastobeableto reassembleintheidenticalcondition.
DIftaperedorfittedpartsthatshouldfittightlycomeoff easily,inspectthepartsinvolvedtofindthecauseso thatthesameproblemdoesnotoccuragainwhenreassembling.
DUseanappropriatejiganddonottrytoforcethem.
Disconnectinghydrauliclines
Operateeachcontrolleverseveraltimesto relieveanypressureinthelinestoberemoved.
Opentheairbleedercapofthehydraulic tank.
DTodisconnectarigidtubefromanotherone,orarigid tubefromahose,graspthemaleendwithawrench andloosenthefemalenutside.
DPlugtheendoftheremovedtubeorhoseandtheoil portonthepart,topreventforeignmatterfromentering.
DSincethetubeorhosetoberemovedcontainsoil, pourthisoffintoasuitablecontainer.
DCleanupanyoilspillsintheworkingarea.
DAttachatagwithanappropriatemarkingtoeach tube,hoseandhydrauliccomponentlineconnection foreasierreassembly.
Afterdisassembly
Whenusingdetergents,makesureyou fullyunderstandtheuseinstructionsand takecarenottobringthemintocontactwith theeyesorskin.Disposeofuseddetergentscorrectly.
Cleaning
DCleanthedisassembledpartsandarrangethemin order.Completelyremovesludgeanddustfromthe oilportsofeachpart.
DTocleanmoreefficiently,dividethedetergentinto twocontainers;onetoremovethedirtandoneforfinishing.Whencleaningmoreimportantparts,divide thecontainersfurthertoavoidusingdirtydetergent.
DWhencleaninglargecastings,suchasthecylinder headorblock,,immersetheminacontainerfor5to 10minuteswithapH10--12detergent,atatemperatureof50Cand70C(122158F),thenrinse thoroughly.
Rustanddustprevention
DCovercleanpartstoavoidrusting.
DPlacecapsontheendsoftubesandhoses.
DIfitwillbesometimebeforeassembly,userustinhibitor.
Duringassembly Installingtheparts
DBeforestartingtoassemble,cleanallthecomponentsandrepairanydamage.Dirtanddusthaveadverseeffectsonmovingpartsandcanshortenthe machinelife,sotakeallprecautionstolimittheirpenetration.
DBeforeassembly,removethelayerofrustinhibitorif presentonnewparts.
DPartswithmatingmarksaretobemountedsothat themarksarecorrectlyaligned.
DUseapressandappropriatetoolswheninstalling bearings,bushings,oilgasketsetc.Whenmounting specialparts,usethespecificspecialtools.
DCoatthesurfaceofpress--fitpartswithmolybdenum disulphategreaseorotherspecificlubricant,where prescribed.
Screwandnuttightening
DTightennutsandboltsalternatelysothataverage torquecanbeappliedevenly.Thenumbersonthe figureindicatetheorderoftightening.
DUnlessindicatedotherwise,applylubricanttothe threadedpartofthebolts,soastoobtaineven tightening.
a:correctassembly
b:incorrectassembly
DThenutsandboltsthatcannotbeinspectedexternally,orthoseformoreimportantpartsaretobeinstalledandlockedwithanappropriatedevicetopreventloosening(lockwire,splitpin,bentwasher).
DBoltsonwhichathreadstophasbeenapplied(residuecanbeseenwhenremoved)aretobecleaned withlightoilanddriedbeforetightening.Apply2or 3dropsofthreadstoptothethreadedpartofthe bolts,thentighten.
Connectinghydrauliclines
DCleanallrigidtubeswithasuitabledetergentand blowdrywithcompressedair.
DDonotusecouplingliquids(threecomponents).
DWheninstallinghighpressurehoses,donotallow anytorsion.Avoidthatotherpartsinterferewiththe hosesiftheyhavenoprotectivespring.
DInstallcorrectly,checkingthetagsoneachrigidtube orhoseandonhydrauliccomponentconnections.
DWhenconnectingthelines,slightlytightenthenuts atbothends,thentightenalternately.
DAftercompletingthelineconnections,runtheengine atlowspeedandfromtheoperatorsseatmoveeach hydrauliccomponentthroughthecontrollevers. Makeafurtherinspectionthentopuptheoilinthehydraulictank
DPointssuchasendclearances,endplates,projections,stepsandbacklashthatcannotbecheckedexceptduringtheassemblyprocess,aretobechecked andmeasuredbeforepassingontothenextstep.
DShimsandwashersusedtoadjustclearancesareto berefittedinthesameconditionastheywerebefore disassembly,unlesswornordamaged.
DAfterreassembly,checktheadjustmentvalues.
DAssemblethelinkagewiththerodadjustmentvalue identicaltothatbeforedisassembly.
DIfpartsfittedbypressureareeasilyinserted,check theinsertiondimensionsagainandcorrectanyflaws beforeassembling.
Interchangeableparts
Gaskets
DAsarule,replaceallgasketswithnewones.
DApplysealingliquidtothesealinggasketsofcertain parts.
DRemoveallflaws,dust,paint,oilorpreviouslyused sealliquids.
DApplyanevencoatingofthespecifiedsealingliquid andallowtodryforafewminutes.
DWhentheliquidisdrytothetouch,matethegaskets.
O--rings
DIftheO--ringshavebecomehardenedafterlong storage,discardthemeveniftheyhaveneverbeen used.
DUseonlytheO--ringsindicatedinthespareparts lists.Fortheengine,inparticular,O--ringsofspecial material,likesiliconerubberareusedfortheirresistancetoheatanddeterioration.Donotusesubstitutes.
DBeforeinstallation,applyacoatingofoiltotheO--ring topreventcracking.Siliconerubbertearseasilyand mustthereforebehandledwithcare.
Oilsealgaskets(oilsealrings)
A:innerside(possiblepressure)
B:outerside
a:mainlip(seal)
b.dustprotectionlip
DPayattentiontothedirectionoftheoilsealgasket lips.
DTakecarethatnodustsettlesontheoilsealgasket, andascertainthatthereisnorustorcracking(especiallyonthelipsurfaces).
DWhenassemblingoilsealgaskets,applysome greasetopreventinitialdryfriction.
a.Singleliptypeoilsealgasket
Applythegreaseevenlyovertheentireexternal borderofthesideoppositetothesealingpartofthe lip(arrow),takingcarethatthereisnobuildup.
b.Doubleliptypeoilsealgasket Applygreaseto40--60%oftheexternalborderof thesectionbetweenthelips(arrow).
DMakesurethatthecontactsurface(shaftarea)ofthe oilsealgasketisfreeofdust,cracksorrustandapply lubricanttofacilitatetheinstallation.
DToinstall,useaguideandanassemblyjigtoavoid damagingtheoilsealgasketlip.
DAfterinsertingtheoilsealgasketandpushingitinto itsseat,thegasketshouldhavenoinclination.
