COMPANYPOLICY
Companypolicy,whichisoneofcontinuousimprovement,reservestherighttomakechangesindesignand specification,withoutnoticeandwithoutobligationtomodifyunitspreviouslybuilt.
Alldatagiveninthisbookissubjecttoproductionvariations.Dimensionsandweightsareapproximateonlyand theillustrationsdonotnecessarilyshowmachinesinstandardcondition.Forexactinformationaboutany particularmachinepleaseconsultyourdealer.
PARTSANDACCESSORIES
Genuinepartsandaccessorieshavebeenspecificallydesignedforthesemachines.
Wewouldliketopointoutthatnon--genuinepartsandaccessorieshavenotbeenexaminedandreleasedby Builder.Theinstallationoruseofsuchproductscouldhavenegativeeffectsuponthedesigncharacteristicsof yourmachine,andtherebyaffectitssafety.TheBuilderisnotliableforanydamagecausedbytheuseof non--genuinepartsandaccessories.
MODELCODES
Thecompleterangeoftelescopichandlers(Telehandler)describedinthismanualisidentifiedinthetextby referencetothemaximumextensionofthetelescopicarm.
Thevehicleslistedbelowmaynotbeavailableinallcountriesormarkets,thereforeforthelatestinformation consultyourauthoriseddealer.
SECTION21--POWERSHIFTGEARBOX
SECTION27--REARAXLE
SECTION33--BRAKES
SECTION35--HYDRAULICSYSTEM
SECTION55--ELECTRICALSYSTEM
DescriptionPage
Chapter1Electricalsystemgeneral
Electricalequipmentspecifications1 ...............................................................
Electricalsystemandfuse2
Controlsandinstruments6
Useofthetip--overpreventionsystem16 ...........................................................
Bulbreplacement23 .............................................................................
Protectingtheelectricalsystemsduringchargingorwelding26 ........................................ Startingthemachineusingjumpleads27 Temporarywiringrepair28
Chapter2Circuitdiagrams
Listofconnectors48
Listofcomponents49
Howtousethecircuitdiagrams50 ................................................................
Diagram1:Starting/Recharge/Warninglights/Indicator51
Diagram2:Transmission55
Diagram3:Wheelalignment/Hydraulicsolenoids/Brakesystem57
Diagram4:Armcontrol59 ........................................................................
Diagram5:Stabiliser61 ..........................................................................
Diagram6:Lights/Windscreenwiper63
Diagram7:Worklamps/Roofbeaconlight65
Diagram8:Tiltingpreventionsystem/Roofwiper67 ..................................................
Diagram9:Soundsystemheating/Electricsocket/Rooflamp69 .......................................
Diagram10:Airconditioner71
Chapter3--Wiringlist
Instrumentpanelwiring75 Cabwiring81 Frontwiring82 Rearwiring83 .................................................................................. Enginewiring85
GENERALINSTRUCTIONS
IMPORTANTNOTICE
AllmaintenanceandrepairinterventionslistedinthisManualmustbeperformedexclusivelybytheService NetworkoftheManufacturer,complyingstrictlywiththeindicationshereinandusing,whenrequired,the prescribedspecialtools. Whoeverperformsserviceoperationsdescribedhereinwithoutcomplyingstrictlywiththeinstructionsbecomes solelyresponsibleforanyconsequentialdamagethatcouldoccur.
ADJUSTINGSHIMS
Foreachadjustmentselecttheadjustingshims,measuringthemonebyonewithamicrometerandaddingto gethersubsequently,thevaluesmeasured.Donotrelyonthemeasurementoftheentirepack,thatcouldbe wrong,orthenominalvalueindicatedoneachring.
SEALSFORROTATINGSHAFTS
Forcorrectinstallationofthesealsforrotatingshafts,pleasecomplywiththefollowingprecautions:
--priortoinstallation,keepthesealssoakingforatleasthalfanhourinthesameoiltheyaregoingtoseal; --cleanthoroughlytheshaftandmakesurethatitsworkingfaceisundamaged;
--directthesealingliptowardthefluid;intheeventthelipisofthehydrodynamictype,thegroovesmustbe directedsothat,inrelationtotherotatingdirectionoftheshaft,theytendtoreturnthefluidtowardtheinside ofthesealingdevice;
--smearthesealinglipwithafilmoflubricant(oiltobepreferredtogrease)andfillwithgreasethegapbetween sealinglipanddustlipintwinlipseals;
--insertthesealinitsseat,pressingitwithapunchwithaflatface;neverstrikeitwithahammerormallet; --whenpressingintheseal,makesurethatitisinsertedperpendicularlyinrelationtotheseatand,oncein position,makesurethat,whenrequired,itcontactstheshoulder;
--topreventthesealinglipofthesealbeingdamagedbytheshaft,insertappropriateprotectionduringthe installationofthetwoparts.
0--RINGTOROIDALSEALS
LubricateO--ringsbeforeinsertingthemintherelevantseatstopreventthembecomingtwistedandrolledduring installation,thusjeopardisingtheirsealingcapacity.
SELAINGCOMPOUNDS
MatingsurfacemarkedXmustbesmearedwithasealingcompoundrecommendedbytheManufactureroran adequateequivalent. Priortoapplyingthecompound,preparethesurfacesinthefollowingmanner: --removeallpossiblescalingwithametalbrush; --degreasethesurfacesthoroughlyusingthedegreesingagentrecommendedbytheManufactureroran adequateequivalent.
BEARINGS
Wheninstallingbearings,itisrecommendedto: --warmthemupto8090C(176194F)beforeinstallingthemontherelevantshafts; --coolthemdownbeforeinsertingthemintherelevantseatswithanouterfitting.
SPLITPINS
Wheninstallingsplitpins,makesurethatthecutispointinginthedirectionoftheloadonthepin. Ontheotherhand,spiralelasticpinsdonotrequireanyinstallationorientation.
NOTESONSPAREPARTS
UsegenuinesparepartsguaranteedbytheManufactureronly. Genuinesparepartsaretheonlyonesensuringthesamequality,thesamelifeandthesamesafetyasthe originallymountedparts,sincetheyarethesameastheonesinstalledinproduction. Onlygenuinepartsfromthemanufacturerensurethisguarantee. Ordersforsparepartsmustincludethefollowingindications: --modelofthevehicle(commercialdesignation)andserialnumber; --typeandnumberoftheengine; --partnumberfortheitemordered,asprovidedbytheMicrofichesortheSparePartCatalogue,onwhich theorderisbased.
NOTESONTOOLING
ThetoolingthattheManufacturerrecommendsandillustratesinthisManualis: --studiedanddesignedspecificallyforservicingvehiclesofthisrange; --requiredtoensureareliablerepair; --accuratelydevelopedandinspectedtoprovideeffectiveandlonglastingworking. Youarealsoremindedthatcorrecttoolingallowsyouto: --tooperateunderoptimisedtechnicalconditions; --toachievethebestresults; --tosavetimeandeffort; --toworkinsaferconditions.
WARNING
Thewearlimitsprovidedforsomeitemsmustbeconsideredasrecommendedvalues,butnotabsolutelybinding. Theindicationsfront,rear,right,leftrefertodifferentpartsasseenseatingfromintheoperatorsseat orientedinthenormaltraveldirectionofthevehicle.
HOWTOMOVEAVEHICLEWITHOUTBATTERIES
Thecablesoftheexternalpowersupplymustbeconnectedexclusivelytotherespectiveterminalsofthepositive andnegativecablesofthevehicle,usingefficientclampsprovidingadequateandsafecontact.Intheeventit isnecessarytochecktheoperationoftheelectricalsystemofthevehicle,doitexclusivelywiththepowersupply connected.Attheendoftheinspection,disconnectallactuatorsanddeactivatethepowersupplybefore disconnectingthecables.
SAFETYRULES
PAYATTENTIONTOTHISSYMBOL
Thisalertsymbolannouncesimportantmessagesinvolvingyoursafety. Readcarefullythesafetyinstructionslistedandfollowtheprecautionsrecommended toavoidpotentialrisksandtosafeguardyourhealthandyoursafety. YouwillfindthissymbolinthetextofthisManualwiththefollowingkeywords:
WARNING--Cautionsintendedtoavoidimproperrepairinterventionsinvolving potentialconsequencesforthesafetyofthepersonnelperformingtherepairs.
DANGER--Thesewarningsqualifyspecificallypotentialdangersforthesafetyofthe operatororotherpersonsdirectlyorindirectlyinvolved.
AVOIDACCIDENTS
Mostaccidents,whethertheyoccurinworkshop,on thefarm,athomeorontheroad,arecausedbythe failureofsomeindividualstofollowsimpleandfundamentalsafetyrulesandprecautions.ForthisreasonMOSTACCIDENTSCANBEPREVENTEDby recognisingtherealcauseanddoingsomething aboutitbeforetheaccidentoccurs.
Regardlessofthecareusedinthedesignandconstructionofanytypeofequipment,therearemany conditionsthatcannotbecompletelysafeguarded againstwithouthinderingreasonableaccessibility andefficientoperation.
Acarefuloperatoristhebestinsuranceagainstan accident.
Thecompleteobservanceofonesimplerulewould preventmanyseriousaccidents.
DANGER.Neverattempttoclean,lubricateormaintainamachinewhileitisinmotion.
SAFETYRULES
SAFETYRULES
Readandheedallsafetyrulesbeforeanyintervention.
Donotwearrings,wristwatches,jewellery,and looseorhangingapparels,suchasties,torn clothing,scarves,unbuttonedorunzipped jacketsthatcancatchonmovingparts.Wear propersafetyequipmentasrecommendedfor thejob.Examples:hardhat,heavygloves,ear protection,safetyglassesorgoggles,reflector vests,respirator.Consultyouremployerforspecificsafetyequipmentrequirements.
Donotperformanyserviceoperationonthe machinewithapersonseatedintheoperators compartment,unlessheisanauthorisedoper-
atorco--operatingintheoperationtobeperformed.
Neverattempttooperatethemachineoritstools fromanypositionotherthanseatedintheoperatorsseat.
Neverperformanyinterventiononthemachine withenginerunningunlessthisisprescribed. Cut--offtheengineandmakesurethatallpressuresinthehydraulicsystemsarereleased beforeremovingcaps,covers,valvesetc.
Allserviceinterventionsmustbeperformedwith theutmostcareandattention.
Shopand/orfieldserviceplatformsorladders mustbeconstructedandmaintainedinaccordancewithlocalandnationalregulations.
Disconnectthebatteriesandtagallcontrolsto signalthataninterventionisinprogress.Block themachineandallequipmentthatmustbe lifted.
Donotchecknorrefillfueltanks,aswellasbatteries,norusestartingfluidwhilesmokingor nearopenflamessincethesefluidsareflammable.
Brakesareinactivewhenmanuallyreleasedfor serviceinterventions.Undersuchcircumstancesitisnecessarytomaintainthecontrolof themachineusingappropriateblocksorsimilar devices.
Thefuel--fillingnozzlemustbekeptconstantly insidethefillingneck.Keepthiscontactfromthe beginningtotheendofthefuellingoperationto avoidthepossibilitythatsparksduetostatic electricityaregenerated.
Useonlydesignatedtowingorattachingpoints. Usecareinmakingattachments.Makesurepins and/orlocksaresecurebeforepulling.Stayclear ofdrawbars,cablesorchainsunderload.
Tomoveadisabledmachine,useatrailerora low--boy,ifavailable.
Toload/unloadamachinefromtransporter, choosealevelsurfaceensuringfirmsupportto thewheelsoftruckortrailer.Anchorthemachine securelytothebedoftruckortrailerandblock wheelsortrackswithappropriatewedges.
Useonlyapprovedgroundedauxiliarypower sourcesforheaters,chargers,pumpsandsimilarequipmenttoreducethehazardsofelectrical shocks.
Liftandhandleheavypartswithaliftingdevice ofpropercapacity.
Bewareofbystanders.
Neverpourgasolineordieselfuelintoopen, wideandlowcontainers.
Neverusegasoline,solventorotherflammable fluidtocleanparts.Useexclusivelyqualified, non--flammable,non--toxiccommercialsolvents.
Whenusingcompressedairforcleaningparts, usesafetyglasseswithsideshieldsorgoggles.
Limitpressureto2.1bar,inaccordancewith localandnationalregulations.
Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaust fumes.
Donotsmokeorpermitanyopenflamesorspark nearwhenre--fuellingorhandlingflammable materials.
Donotuseanopenflameasalightsourceto lookforleaksorforinspectionanywhereonthe machine.
Movewithextremecarewhenworkingunderthe machine,itsattachmentsandoronornear them.Alwayswearprotectivesafetyequipment asrequired,suchashardhat,goggles,safety shoes,earplugs.
Whenperformingoperationsrequiringrunningof theengine,haveaqualifiedoperatorintheoperatorsseatatalltimeswiththemechanicon sight.Placethetransmissioninneutralandset thebrakesandsafetylock.
Forfieldservice,movemachinetolevelground, ifpossible,andblockit.Ifworkonaninclineis absolutelynecessary,firstblockmachineandits
attachmentssecurely,thanmoveittolevel groundassoonaspossiblewithacertainmargin ofsafety.
Donottrustwornand/orkinkedchainsand cables:donotusethemforliftingorpullingoperations.Tohandlethem,alwaysuseheavy gloves.
Besurechainsandcablesareanchoredandthe anchorpointsarestrongenoughtohandlethe expectedload.Keepexposedpersonnelclearof anchorpointsandcablesorchains.No bystandersareallowednearthehookingpoints, chainsorcables.
Keeptheareawheremaintenanceoperations areperformedCLEANandDRY.Eliminate immediatelyallwaterandoilspillages.
Donotpileupoilyorgreasyrags;theyrepresent afirehazard.Storeinaclosedmetalcontainer.
Beforestartingmachine,check,adjustandlock theoperatorsseatformaximumcomfortand controlofthemachine.Besureexposed personnelintheareaofoperationareclearofthe machinebeforemovingitoritsattachments. Soundthehorn.
Donotcarrylooseobjectsinpocketsthatmight fallunnoticedintoopencompartments.
Wearproperprotectiveequipmentsuchas safetygogglesorsafetyglasseswithside shields,hardhat,safetyshoes,heavygloves whenmetalorotherparticlesareapttoflyorfall.
Wearweldersprotectiveequipmentsuchas darksafetyglasses,helmets,protectiveclothing,glovesandsafetyshoes,whenweldingor burning.Weardarksafetyglassesnearwelding zones.DONOTLOOKATARCWITHOUT PROPEREYEPROTECTION.
Steelcablesarefrayedafterprolongeduse; alwayswearappropriateprotections(heavy gloves,gogglesetc.).
Handleallpartscarefully.Keephandsand fingersawayfromstructures,gearsormoving parts.Useandwearalwaystheappropriate protections,suchassafetygoggles,glovesand safetyshoes.
STARTING
Donotruntheengineinclosedareaswithout properventilationtoremovedeadlyexhaust fumes.
Donotplacehead,body,limbs,feet,handsor fingers,nearrotatingfansorbelts.Beespecially alertnearpusherfans.
ENGINE
Loosentheradiatorcapveryslowly,torelease pressurefromthesystem,beforeremovingit.All coolantleveltop--upsmustbeperformedwith engineinoperativeoratlowidle,ifwarm
Donotrunenginewhenrefuellingandusecare iftheengineishotduetotheincreasedpossibilityofafireiffuelisspilled.
Neverattempttocheckoradjustfanbeltswhen engineisrunning.Donotadjustenginefuel pumpwhenmachineismoving.
Neverlubricatethemachinewithenginerunning.
ELECTRICALSYSTEM
Shouldboosterbatteriesbeused,rememberto connectbothendsoftheboostercablesinthe propermanner(+)with(+)and(--)with(--).Avoid short--circuitsoftheterminals.Followthoroughly theinstructionsofthisManual. Avoidshortcircuitingtheterminals.BATTERY GASISHIGHLYFLAMMABLE.Leavebattery boxopentoimproveventilationwhenrecharging batteries.Nevercheckchargebyplacingmetal objectsacrosstheposts.Keepsparksoropen flamesawayfrombatteries.Donotsmokenear batterytoguardagainstthepossibilityofcausing anexplosion.
Beforeanyintervention,makesurethatthere arenofuelorelectrolyteleakages;eliminate thembeforeproceedingwithfurtherwork.
Whenrechargingbatteriesinclosedambient, makesurethatthereisappropriateventilationto preventpossibleaccidentalexplosionsdueto theaccumulationofgasesgeneratedduringthe recharge.
Beforeanyintervention,makesurethatthemain switchisOFF.
HYDRAULICSYSTEM
Fluidescapingunderpressurefromaverysmall holecanbealmostinvisibleandcanhavesufficientforcetopenetratetheskin.Useapieceof cardboardorwoodtosearchforsuspectedpressureleaks.donotusehands.Ifinjuredbyescapingfluid,seeadoctoratonce.Seriousinfection orreactioncandevelopifpropermedicaltreatmentisnotadministeredimmediately.
Incasepressuresmustbemeasured,use instrumentsofadequatecapacity.Alwaysfollow therecommendedprocedures.
WHEELSANDTYRES
Makesurethattheinflationpressureofthetyres isaccordingtothespecificationsissuedbythe Manufacturerandcheckitperiodically.
Shouldthepressurebechanged,standonthe sideofthetyreatasafedistance.
Pressurecheckoperationsmustbeperformed withunloadedmachineandcoldtyres.Never usereconditionedtyrerims,sinceeventual weldings,heat--treatmentsorrepairsnotperformedcorrectlycanweakenthewheel,thus causingsubsequentdamagesordangers.
Donotperformtorchcuttingorweldingoperationsonrimswithinflatedtyresinstalled.
Beforeoperatingontyres,blockallwheels,front andrear.Afterjackingthemachine,blockitwith standsaccordingtocurrentsafetyrulesand regulations.
Beforeremovingobjectsfromthetyretread, deflateit.
Neverinflatetyreswithflammablegas; explosionsandseriousbodilyinjuriesmay result.
REMOVALSANDINSTALLATIONS
Liftandhandleallheavypartswithliftingdevices ofadequatecapacity.Makesuethattheparts areattachedtoliftingdevicesareproperly slinged.Usetheliftingeyesprovided.Bewareof personsinthevicinity.
Handleallpartscarefully.Keephandsand fingersawayfromstructures,gearsormoving parts.Useandwearalwaystheappropriate protections,suchsgoggles,glovesandsafety shoes.
Preventchainsandcablesfromkinking.To handlethem,alwaysuseheavygloves.
PRODUCTIDENTIFICATION
TheTelehandleranditsmaincomponentsareidentifiedbyvariousnumbersandlettersprovidingits identificationbytheServicenetwork.Thefollowing informationgivesthelocationoftheidentification plates,ofthenumbersstampedonthemachineand variousexamplesofwhatcanbefoundonthe machine.
VEHICLESERIALNUMBER
Theserialnumberisstampedonthefrontpartofthe machine,ontheuppersideofthemainframe,right side.
NOTE:Theserialnumberandtheidentification numberofthecomponentscanberequestedbythe DealerwhenSparePartsareorderedorinterventionsarerequired.Thesenumbersarealsorequired ashelpinidentifyingthemachineintheeventoftheft. Keeptheminasafeplace.
VEHICLEIDENTIFICATIONPLATES
Thevehicleidentificationplateislocatedontheleft sideoftheseatlocation.Recordherebelowthedata foryourmachine.
TECHNICALTYPE/MODEL
SERIALNO.OFVEHICLE
IDENTIFICATIONOFENGINE
Theidentificationdataoftheengineareontheleft sideoftheenginecylinderblock.Pleaserecordhere belowthesedataforeasierconsultation,when required.
IDENTIFICATIONOFFRONTAXLE
Theserialnumberandtheaxletypeareindicatedon plate(1)locatedonthefrontsideoftheaxlehousing. Pleaserecordherebelowthedataindicatedfor fasterconsultationwhenrequired.
AXLETYPE
SERIALNO.
DATECODE
IDENTIFICATIONOF4x3POWERSHIFT TRANSMISSION
Theserialnumberandthemodelareindicatedon plate(1)locatedonthelowersideofthetransmission.Pleaserecordherebelowthedataindicated forfasterconsultationwhenrequired.
MODELNO.
SERIALNO.
DATECODE
IDENTIFICATIONOFREAR TRANSMSSION
Theserialnumberisindicatedonplate(1)locatedon thelowersideofthereartransmission.Please recordherebelowthedataindicatedforfasterconsultationwhenrequired.
AXLETYPE
SERIALNO.
DATECODE
IDENTIFICATIONPLATESINTHECAB
Thecabidentificationplatecontainsaseriesof furtherdetailsanditislocatedontheleftrearsideof theseat.Pleaserecordherebelowthedataindicated forfasterconsultationwhenrequired.
SERIALNO.
DATECODE
Thedatarelativetotheengineareindicatedonthe conformityplatesinstalledtogetherwiththeCab Plate.Pleaserecordherebelowtheserialnumber indicatedforfasterconsultationwhenrequired.
SERIALNO.
DATECODE
ENVIRONMENTALCONSIDERATIONS
Thefollowingrecommendationscanbeuseful:
Becomefamiliarandmakesureyouhavewell understoodtherelevantlegislationineffectin yourcountry.
Intheeventnoregulationsexist,askforspecific informationwiththesuppliersoflubricants,antifreezeanddetergentsregardingtheireffectson humansandtheenvironmentandhowtostore, handleanddisposeofthesesubstancessafely.
4.Avoidspillagewhendrainingusedcoolantmixtures,engineoils,transmissionandhydraulic fluids,brakefluid.Afterdraining,donotmix brakefluidorfuelwithlubricants.Storethemina riskfreemanneruntilwhentheycanbedisposed ofinanadequateway,inaccordancewithlocal regulationsandtheresourcesavailable.
5.Moderncoolingmixtures,suchasantifreezeand otheradditives,mustbechangedeverytwo years.Maximumattentionmustbepaidtopreventthattheyspillovertheground.Theymustbe collectedanddisposedofsothatdonotcreate anydanger.
6.Donotunsealairconditioningsystembyyourselves,sincetheycancontaingasesthatmust notbereleasedintotheatmosphere.Thepersonnelspecialisedinairconditionersuses specialequipmenttochargeanddischargeair conditioningsystems.
Usefulindications
1.Donotfilltankswithinadequatecanistersordispensingpressurisedsystemsthatcouldcause considerablespillage.
2.Ingeneral,avoidthecontactoftheskinwithany fuel,oil,acid,solventetc.Themajorityofthem containsubstancedangerousforyourhealth.
3.Modernlubricantscontainadditives.Donotburn contaminatedfuelsand/orwedoilsinnormal heatingburners.
7.Repairatonceanyleakageordefectofthe enginecoolingsystemorhydraulicsystem.
8.Donotincreasethepressureofanypressurised system,sincethiscouldcauseseriousproblems tothecomponentsofthesystem.
9.Protecthoseswhenperforminganywelding, sinceasplashofweldingmaterialscouldpenetrateandburnthem,causingaholeorweakeningthewallwithsubsequentleakagesofoil, coolantetc.
MAINTENANCETECHNIQUES
GENERALNOTICES
Cleantheoutsideofallthecomponentspriortoperforminganytypeofrepair.Dirtandabrasivedustcan reducetheefficientlifeexpectancyofacomponent andresultinexpensiverepairs.
Thetimespentinpreparingandcleaningworking surfacesisgivingresults,makingworkeasierand safer,andthecomponentsoverhauledwillbemore reliableandoperatebetter.
Usecleaningfluidsproventobesafe.Sometypesof fluidcancauseseriousproblemstoO--Ringsandirritatetheskin.Itisnecessarytocheckthatthesolventsaresuitabletocleanthecomponentsandthat oftheyarefreeofrisksforthehealthofworkers. ReplaceO--Rings,sealingringsandsealseverytime theyaremoved.NeveruseoldO--Ringsorsealsand newonestogether,independentlyfromtheirconditions.AlwayslubricatenewO--Ringsandsealswith hydraulicoilbeforeinstallingthem.
Whenreplacingcomponents,alwaysusethetooling requiredbythistypeofwork.
HOSESANDSTEELPIPES
Alwaysreplacehosesandsteelpipeswhenthetaper endorconnectionsaredamaged.
Whenanewhoseisinstalled,connectitwithout tighteningtheendsandmakesurethatitisroutedin thecorrectmanner,beforetighteningtheends.Fixturesmustbetightenedjustenoughtoholdthehose withoutsqueezingit,avoidingrubbingaswell.
Afterreplacingahoseofmovingcomponents,make surethatthehoseisnotdisturbedbythemovement ofthecomponentinanyposition.
Makesurethatallhosesinstalledarenotchokedor bent.
Ifhoseconnectionsaredamaged,dented,chokedor leaking,decreasetheflowofoilandtheproductivity oftherelevantactuators.Connectionsshowing signsofdisplacementfromtheiroriginalpre-pressedpositionmustbeconsideredasalready broken,sincetheyaregoingtofailorseparatesoon.
Ahosewitharaggedoutersleeveallowswaterto penetrate.Thus,hiddencorrosionofthereinforcing wirewilldevelopalongtheentirelengthofthehose, withthesubsequentfailureofthehoseitself.
Ifahoseswells,thisindicatesthatthereisaninternal leakageduetoastructuralfailure.Thiscondition deterioratesveryquicklyandcausesthefailureof thehose.
Clogged,squeezed,excessivelytensionedor deformedhosesaregenerallyeasilysubjecttoflow reduction,decrementoftheoperationalspeedofthe fluidandthefinalfailureofthehose.
Loosehosesmovefreelyandmustbeprevented fromtouchingeachotherandnearbysurfaces.This causesarubbingactionshorteningtheusefullifeof thehose.
CONNECTIONSWITHFRONTSEALING O--RINGS
Whenrepairingconnectionswithfrontsealing O--Rings,pleasecomplywiththefollowingprocedures.
WARNING:NEVERDISCONNECT,NOR TIGHTENAHOSEORASTEELPIPEUNDER PRESSURE.IFINDOUBT,MOVETHECONTROL LVERSSEVERALTIMESWITHTHEENGINE INOPERATIVEBEFOREDISCONNECTINGA HOSEORASTEELPIPE.
1.Loosentheconnectionsandseparatethehose orsteelpipe,thenremoveandeliminatethe O--Ringsfromtheconnection.
2.DipanewO--Ringinclean,hydraulicoilbefore installingit.InstallthenewO--Ringintheconnectionand,ifnecessary,holditinitsposition withvaseline.
3.Installanewhoseorsteelpipeandtightenmanuallytheconnectionholding,atthesametime, thepipestilltopreventitfromturning.
4.Usetwowrenchestotightentheconnectionto thetorqueprescribedforitssize.Pleasereferto thetabletofollowforthetighteningtorques.
NOTE:toensurethatajointdoesnotleak,itis importantthattheconnectionsareneither excessivelytightenednortoolittle.
SPECIFICSEALINGCOMPOUNDS
Thefollowingsealingcompoundsmustbeused,complyingwiththeindicationsprovidedbytheManual:
SEALANTSCOMMERCIALNAME
AnaerobicsealantLOCTITE518(liquidgasket)
RTVsiliconsealantLOCTITESUPERFLEX593,595or596 LOCTITEULTRABLUE587DOWCORNINGSILASTIC 732GENERALELECTRICRTV103or108
PipesealantPST592(pipesealantwithteflon)
Lockingcompoundfor threads LOCTITE271/RED(sealant/lockingforthreads)
TIGHTENINGVALUESFORFASTENERS
Checkperiodicallythatthefastenersareproperly tightened.
Baseduponthetablestofollow,determinethecorrecttighteningtorquewhenpartsofthefastening componentsarechecked,adjustedorreplaced.
IMPORTANT:DONOTusethevalueslistedinthe tableswhentheManualindicatesadifferenttorque
ortighteningprocedureforaspecificapplication.The torquevaluesareprovidedforgeneraluseonly. Makesurethatthethreadsofthefastenersareclean andundamaged.
NOTE:useatorquewrenchtotightenfastenerscorrectly.
GRADESAE2GRADESAE5GRADESAE8
GRADEIDENTIFICATION
GRADEA:NOCUTS
GRADEB:ONEPERIMETERCUT
GRADEC:TWOPERIMETERCUTS
GRADEIDENTIFICATION
GRADEIDENTIFICATION
GRADEA:NEWMARK
GRADEB:THREEMARKS
GRADEC.SIXMARKS
THEMARKSARENOTCOMPULSORILY LOCATEDINTHECORNERS
GRADEA.NOMARKS
GRADEB:LETTERB
GRADEC:LETTERC
GENERAL
NOTE:TheManufacturerpursuesapolicyofconstantimprovements,thusreservestherighttomodifyatany momenttechnicalanddesigndata,withoutnotice,andwithoutanyobligationtomodifythemachinespreviously manufactured.
AllthedataprovidedinthisManualaresubjecttovariationsinproduction.Dimensionsandweightsare approximateandtheillustrationsdonotnecessarilyshowthemachinesinnormalconditions.Inordertohave specificinformationaboutadeterminedmachine,pleaseconsultanAuthorisedDealer.