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SHOP MANUAL

XDXG25 30

4415 8047 601GB


Ed: 05/2007
Chapter 00
Introduction

Chapter 10
Technical operating data

Chapter 20
Checks and adjustments

Chapter 30
Removal and installation of parts

Chapter 31
Mast
Chapter 00
INTRODUCTION

CONTENTS

00.1 - HOW TO USE THE SHOP MANUAL. ................................................................ 2

00.2 - GENERAL SAFETY INSTRUCTIONS. ............................................................... 3


Avoiding accidents .............................................................................................. 3
Safety instructions ............................................................................................... 3
Electrical system ................................................................................................. 6
Hydraulic system ................................................................................................. 6
Detaching and reattaching parts ......................................................................... 6

00.3 - SAFETY WARNINGS FOR OPERATING THE TRUCK. ................................... 7


Check safety belts anchorages and buckle ......................................................... 7
Safety instructions if the truck tips over ............................................................... 8
Safety instructions for operating the truck ........................................................... 8
Safety instructions for topping up ........................................................................ 9
Safety instructions for inflating tires ..................................................................... 9
Maintenance safety advice ................................................................................ 10
Maintenance preliminary operations ................................................................. 10

00.4 - LOCATION OF THE WARNING PLATES. ....................................................... 11


Description of the plates .................................................................................... 12

00.5 - TRUCK SAFETY. .............................................................................................. 14


Safety device when opening the engine hood ................................................... 14
Safety device start-up with engaged speed ...................................................... 14

00.6 - TRANSPORTING AND LIFTING THE TRUCK. .............................................. 14


Transporting the truck ....................................................................................... 14
Environmental conditions for transporting and storing the truck ....................... 14
Loading and unloading the truck ....................................................................... 14

00 - Ed. 05/2007 1
00.1 - HOW TO USE THE SHOP MANUAL

• This manual is divided into chapters covering different topics. There is a table of contents at the beginning of
each chapter for ease of consultation, and the chapter, version, revision, and page numbers are repeated on
each page.
• The following symbols are used to indicate the safety warnings contained in the manual:

DANGER TO PEOPLE
Not observing some or all of the instructions indicated by this symbol might seriously compro-
mise the safety of the driver or maintenance personnel.

DANGER TO THE TRUCK


Not observing some or all of the instructions indicated by this symbol might cause serious
damage to the truck, and in some cases void the warranty.

IMPORTANT INFORMATION
This symbol indicates important information for the driver.

2 Ed. 05/2007
00.2 - GENERAL SAFETY INSTRUCTIONS

PAY ATTENTION TO THIS SYMBOL

This symbol indicates that the health and safety of people are at risk;
it provides warning that safety precautions must be taken to prevent accidents.
It means “ATTENTION – BE CAREFUL – YOUR SAFETY IS AT RISK”

AVOIDING ACCIDENTS
The majority of mishaps or accidents occur in the shop as a result of someone failing to observe the basic, simple
safety precautions and standards in place. Most accidents and their consequences can be avoided by exercising
the necessary caution and good sense to prevent them from happening in the first place.

No matter how well a machine has been engineered or built, it is impossible to eliminate all the causes of accidents,
but a careful and prudent mechanic can offer the best guarantee against mishaps.

Simply observing a single, basic safety precaution with scrupulous attention is often enough to avoid many serious
accidents.

SAFETY INSTRUCTIONS
General description.
Follow all maintenance and repair procedures carefully.

ATTENTION
Never clean, lubricate, or maintain a vehicle while the battery is still connected.

• Do not wear rings, wristwatches, jewelry, or loose and dangling clothing such as ties, torn clothing, scarves,
unbuttoned or unzipped jackets that could become caught in moving parts.

• Wear approved, protective clothing such as hard hats, non-slip shoes, gloves, and safety glasses.

• Do not service the machine if someone is in the operator’s seat unless it is a qualified technician helping with
the maintenance operations.

• Do not operate the machine or its equipment from anywhere except the operator’s seat.

• Stop the engine and make sure that the pressure has been released from all hydraulic systems before removing
caps or covers.

• Refer to the appropriate instructions in this manual.

• Take all the necessary precautions when performing any service operation.

• Make sure that ladders and service platforms used in the shop or at the site comply with current safety standards.

00 - Ed. 05/2007 3
• Label all the controls to indicate that the vehicle is being serviced. Place blocks under the machine or any part
that must be lifted.

• Do not smoke while checking or topping up the fuel tank, hydraulic oil tank, or the battery due to the flammability
of the fluids.

• Stabilize the machine with blocks or other similar devices because the brakes become inactive when released
manually for the purposes of servicing the machine.

• Connect trailers carefully by means of the fixed hitch points only, and make sure that the pins and/or bolts are
firmly in place before towing. Do not stand near tow bars, cables, or chains that are under strain.

• Use a trailer or lowered flatbed truck, if available, to transport a broken down machine.

• Load and unload the machine onto or from the transport vehicle on a flat area that firmly supports the wheels of
the trailer or the truck.

• Secure the machine firmly to the flatbed of the truck or trailer and block the wheels.

• Use only ancillary sources of power that are adequately grounded to avoid electric shocks when using electric
heaters, battery chargers, or other similar equipment.

• Lift or transport heavy parts by means of a crane or other similar equipment that is capable of handling the
weight, and make sure that no one is in the vicinity.

• Be alert if people are in the vicinity.

• Never pour gasoline or diesel fuel into open, wide and low containers to prevent spillage or inflammable fumes
from collecting.

• Never use gasoline, diesel, or other inflammable liquids as detergents. Use commercial, non-toxic, non-flammable
solvents instead.

• Wear wrap-around safety glasses when using compressed air to clean parts.

• Limit pressure to a maximum of 2.1 bars, in accordance with current local or national regulations.

• Do not smoke or use an open flame or cause sparks when working near or handling inflammable materials.

• Do not use an open flame as a means of illumination when performing operations or to look for “leaks” from the
machine.

• Leave all the safety devices in place when operating the machine

• Do not leave a machine with moving parts unattended.

• Always apply the parking brake and switch off the engine before leaving the operator’s seat. Remove the
ignition key.

• Switch off the engine before freeing a part that has become stuck for some reason.

• Move around very carefully when performing work under, on, or near the machine.

• Wear appropriate safety clothing, such as hard hats, glasses, and safety shoes.

• Take the machine to a flat area and place blocks under the wheels if it needs to be serviced outside the shop.
If servicing the machine on a slope cannot be avoided, place blocks under the wheels then move it to a flat area
as soon as it is safe to do so.

4 Ed. 05/2007
• Do not use dented or bent chains or cables to lift or pull machinery. Always wear safety gloves to handle this
type of equipment.

• Attach chains securely, making sure that the attachment is capable of supporting the load and that no one is in
the vicinity of the attachment, the chains, or cables.

• Keep the maintenance area clean and dry. Clean up water puddles or oil stains immediately.

• Do not pile up rags soaked in grease or oil because they pose a serious fire hazard.

• Keep them in a closed, metal container.

• Check, adjust, and lock the operator’s seat in place before starting the machine or other equipment.

• Make sure that no one is within the radius of action of the machine or equipment.

• Do not carry objects in your pockets that may fall unnoticed into the machine.

• Wear wrap-around glasses, hard hats, safety shoes and gloves if there is a danger of being struck by metal
parts or similar objects.

• Wear protective clothing such as dark glasses, hard hats, overalls, gloves and shoes when operating a welder.
Even individuals who are not actually welding but are in the vicinity should also wear dark glasses. Never look
at the welding arc without wearing adequate eye protection.

• Always wear safety clothing, such as gloves, glasses, etc., to handle metal cables because they become frayed
with use.

• Handle all parts carefully. Keep hands and fingers away from cracks, gears, and similar areas.

• Always wear approved safety clothing, such as safety shoes and glasses.

• Use a pit or a vehicle lift that can support the weight of the truck when working underneath it.

• Remove all tools from the machine after every maintenance operation; check that there are no loose parts or
screws.

• Check that the lights are in the correct position and working properly before driving on the road at night.

00 - Ed. 05/2007 5
ELECTRICAL SYSTEM
Remember that when working with batteries, the ends of the cables must be connected to the terminals as follows:
(+) with (+) and (-) with (-).

Do not short-circuit the terminals. The fumes emitted from the battery are highly flammable. When recharging the
battery, leave the battery compartment open to ventilate the area more effectively and remove the caps. Never
check the status of the battery charge by the “sparks” that occur when metal objects are placed on the terminals.
Avoid creating sparks or flames near the battery.

Do not smoke near the battery to avoid the risk of explosions.


Check for electrolyte leaks and eliminate them if necessary before performing any operation.

Check for short-circuits and eliminate them if necessary before performing any operation.

Do not recharge the battery in a closed environment; make sure that there is adequate ventilation to avoid accidental
explosions from fumes that have accumulated while the battery is recharging.

HYDRAULIC SYSTEM
Fluid trickling from a tiny hole may be almost invisible and have enough force to penetrate the skin, in which case,
always use a piece of cardboard to check for leaks rather than your hands. If the fluid does come into contact with
the skin, seek emergency medical help immediately to prevent a possible infection or skin disease that may result.

Use the appropriate instruments to check the pressure of the hydraulic system.

DETACHING AND REATTACHING PARTS


Lift and handle heavy parts with a lifting means that is capable of handling the weight. Use the appropriate hooks
and slings to support the parts, and use the ringbolts provided for this purpose.
Be alert if people are in the vicinity of the load being lifted.

Handle all parts very carefully. Do not put your hands or fingers between parts. Wear approved safety clothing
such as safety glasses, gloves, and shoes.

Avoid twisting the chains or metal cables.

Always wear safety gloves to handle the cables and chains.

6 Ed. 05/2007
00.3 - SAFETY WARNINGS FOR OPERATING THE
TRUCK

IMPORTANT:
Below is a partial list of safety instructions that must be observed. These rules form part of, and do not
replace, the standards described in the “Safety Instructions for Industrial Forklift Trucks” manual provided
with the truck.

• Do not allow the truck to be used by unqualified, untrained, or unauthorized persons.


• Do not install attachments on the truck unless they have been supplied or approved by the manufacturer.
• Always maintain the truck in good condition, a prerequisite for minimizing risks.
• Keep the warning notices on the truck in good condition, and replace them if they are damaged.
• Carefully read and observe all the safety instructions on the truck.
• Make sure that there is enough free space above the truck.
• Do not park the truck in front of fire extinguishers, emergency exit stairs, or anywhere where it can block traffic.
• Do not use the truck if it shows signs of damage or breakage and cannot be used safely, in which case stop the
vehicle, park it, and notify the maintenance supervisor.
• Pay attention to the distance that must be maintained when working near overhead high-tension wires. Observe
the safe distances established by the responsible authorities.
• Never lift loads with only one fork.
• Lift loads by inserting the forks in the load center. Driving with off-center loads at the side or front may compro-
mise the stability of the truck.
• Make sure that the surface supporting the load can carry the weight.
• Always use protective clothing in accordance with current regulations.
• Do not drive over uneven or obstructed terrain or steps.
• Do not drive with loads elevated more than 300 mm from the ground and with the mast NOT tilted backward.
• Do not turn around or stack on slopes.
• Do not exceed the carrying capacity limits indicated on the appropriate plates.
• Always use the operator safety devices (for example, safety belt, etc.).

CHECK SAFETY BELTS ANCHORAGES AND BUCKLE


Carry out accurate visual and functional inspection of the reel locking device and buckle, the tightnes of fixing
bolts, of the belts to the bonnet.

Seat belts exposed to extreme climatic conditions (e.g. high temperatures, aggressive atmosphere, etc. must be
checked more frequently.

00 - Ed. 05/2007 7
SAFETY INSTRUCTIONS IF THE TRUCK TIPS OVER
Carefully follow the instructions below if the truck starts
to tip over due to incorrect maneuvers:
c
a) Do not abandon the truck.
b) Remain securely in the seat, grasp the steering wheel,
and keep your feet firmly on the floor.
c) Bend your head forward and move your body in the
b
opposite direction to which the truck is tilting.
d) If the truck tips over, wait until it has reached a stable d
position before climbing out.

b OM0060

SAFETY INSTRUCTIONS FOR OPERATING THE TRUCK


• Be confident that the truck is safe and reliable.
• Become familiar with the truck so that you can
accurately describe malfunctions and thus be of
assistance to the maintenance technicians. Trained
and authorized drivers must be familiar with the
controls and functions of the truck.
• Report any malfunctions (unusual noises, leaks, etc.)
OK
immediately because they could result in damage of
a much larger scale if ignored.
• Perform the inspections described in the chapter
“Daily inspections”.

IMPORTANT:
Report any oil and/or battery liquid leaks because
they are dangerous and highly polluting substances.
OM0192

ATTENTION:
If there is a smell of burning, stop the truck and
switch off the engine.

8 Ed. 05/2007
SAFETY INSTRUCTIONS FOR TOPPING UP
Hydraulic oil and motor oil
• Avoid contact with the skin.
• Do not inhale oil fumes.
• NEVER dispose of oils in the environment because they will pollute water. Collect them and take them in
legally approved containers to a collection center.
• Always wear protective clothing when performing maintenance operations on the truck (gloves, glasses, etc.),
to prevent oil from coming into contact with the skin.

DANGER:
It is extremely dangerous if hydraulic oil leaks under pressure and penetrates the skin. Consult a doctor
immediately if this occurs.

DANGER:
Oil squirting at high pressure can penetrate the skin. Identify leaks with a piece of cardboard.

SAFETY INSTRUCTIONS FOR INFLATING TIRES


• Inspect tires in accordance with the scheduled maintenance operations chart provided by the manufacturer.
Check the pressure and wear and tear of the tires.
Never exceed the pressure indicated.
Always stand to the side, never in front, while tires are being inflated due to the risk of explosion.

00 - Ed. 05/2007 9
MAINTENANCE SAFETY ADVICE

DANGER:
Maintenance operations must be carried out by trained personnel possibly trained by the manufacturer.
Always work in respect of regulations in force respecting all requirements concerning the handling of
materials necessary in the operation.
Work in areas set aside for maintenance operations and isolate and mark the area around the truck.

MAINTENANCE PRELIMINARY OPERATIONS


Before commencing maintenance operations do the following:
• Place truck on a flat surface and ensure that it cannot move accidentally.
• Lower lifting forks tio the ground.
• Activate hand brake.
• Switch trock off and remove keys from ignition lock.

DANGER:
Before carrying out any operation on the electrica circuit, disconnect the battery .

CAUTION:
When the truck is used in dusty areas and at temperatures below zero and in heavy applications, the
periods between each maintenance operation must be reduced.

There are two types of maintenance operations :


- NECESSARY MAINTENANCE
- PROGRAMMED MAINTENANCE

The various maintenance operations are contained in the “MANITENANCE TABLES” reported in yhe USE AND
MAINTETANCE” manual.

For all necessary lubricants, please refer to the “REPLENISHMENT TABLE” on the “USE AND MAINTENANCE”
manual.

10 Ed. 05/2007
00.4 - LOCATION OF THE WARNING PLATES

1
2

WARNING
I

GB

10 D

4
3

8 9

LWA LWA

84 dB 86.2dB OMM3000-2

Legend
1 Fork safety
2 Fasten the seat belt
3 Point for lifting the truck
4 Driving with load
5 Prohibited use
6 Warning to check the wheel nuts
7 Attention! Do not overload
8 Noise level plate (LPG Model) 84dB
9 Noise level plate (Diesel Model) 86.2 dB
10 Warning sticker

00 - Ed. 05/2007 11
DESCRIPTION OF THE PLATES

This symbol indicates that it is not permitted to remain or step under elevated forks
or carry passengers.
Plate with white background, red prohibition symbol, black graphic.

This symbol indicates that the seat belt must be fastened while driving.
Plate with yellow background, black graphic.

This symbol indicates that the seat belt must be fastened while driving.
Plate with yellow background, black graphic.

This symbol indicates that the seat belt must be fastened while driving.
Plate with black background, yellow graphic.

This symbol indicates that it is not permitted to drive with an elevated load.
Plate with white background, black border and graphic, red x-sign.

This label is removed by the technician after putting the truck into operation.
It warns the user not to operate the truck until it has been put into operation by a
technician from the manufacturer.
Plate with red background, black wording.

12 Ed. 05/2007
This label is removed by the technician after putting the truck into operation, and
contains the following information:
The wheel nuts must be tightened in accordance with the following schedule:
Before the truck is put into operation
Every 10 operating hours until the first tune-up
Every 100 operating hours after the tune-up
(See the service instructions for the torque values.)
Plate with white background, red wording.

This plate indicates the maximum level of noise power.


LWA
IMPORTANT:

86.2dB
Value shown is for illustration only, for the appropriate level please refer to
plate on truck.

This plate indicates that the forks must not be overloaded.


Refer to the carrying capacity table.
Plate with black background, white border and wording.

WARNING
I PRIMA DI MONTARE LA BOMBOLA VERIFICARE LA COMPATIBILITA’
DELLE FILETTATURE BOMBOLA/VALVOLA LIMITATRICE DI FLUSSO.
This plate indicates that the cylinder/valve threads must be checked for
GB
(VEDI MANUALE USO E MANUTENZIONE)
BEFORE MOUNTING THE LPG BOTTLE, CHECK THE COMPATIBILITY
compatibility (see Use and Mantenance manual).
OF LPG BOTTLE THREAD/PIPE BURST VALVE.
(SEE MAINTENANCE MANUAL) Plate with orange background at the top and white at the bottom, with black
border and lettering.
D VOR LPG FLASCHENMONTAGE ÜBERPRÜFE DIE ÜBEREINSTIMMUNG
VON DEM GEWINDE LPG-FLASCHE/ROHRBRUCHSICHERUNG.
(SIEHE WARTUNGSHANDBUCH)
F AVANT DE MONTER LA BOUTEILLE IL FAUT VERIFIER LA
COMPATIBILITE DES FILETAGES DE LA BOUTEILLE ET DE LA
SOUPAPE QUI LIMITE LE FLEUX.
(VOIR LE MANUEL D’ENTRETIEN)

00 - Ed. 05 /2007 13
00.5 - TRUCK SAFETY

The truck has been designed to provide maximum safety to the driver and minimum risk of damage to the truck.
The truck includes the following safety devices:

SAFETY DEVICE WHEN OPENING THE ENGINE HOOD


The truck is equipped with a safety device that switches off the engine if the hood is opened while the engine is
running.

The newest truck has made changes, without this device.

SAFETY DEVICE START-UP WITH ENGAGED SPEED


The truck is equipped with a safety device which enables starting up the engine with a speed engaged.

00.6 - TRANSPORTING AND LIFTING THE TRUCK


TRANSPORTING THE TRUCK
The truck is usually transported by road or rail complete
with mast. If the truck is bigger than the permissible limits,
it must be disassembled and reassembled by the dealer.
Make sure that the truck is adequately secured during
transport, with blocks placed under the wheels to prevent
any chance movements.

OM0075

ENVIRONMENTAL CONDITIONS FOR TRANSPORTING AND STORING THE TRUCK


Transport and store the truck protected from the weather, and make sure that it is adequately protected in salty
environments.

LOADING AND UNLOADING THE TRUCK


Load and unload the truck by means of a ramp or mobile platform. If the truck is not operational, follow the
instructions below to lift the truck.

DANGER:
Use a crane that is big enough to handle the weight of the truck, indicated on the information plate.

14 Ed. 05/2007
Make sure that the truck is lifted by qualified personnel only.
Do NOT stand within the radius of action of the crane or under the raised truck.
Use NON-METALLIC cables. Make sure the cables can support the weight of the truck.

Lift the truck as follows:


• Remove the caps (1) and insert two ringbolts (2) in the points indicated on the counterweight and secure them
completely.
• Attach two cables to the ringbolts located on the counterweight.
• Insert two cables (3), one for each side, through the upper crossbar (4) of the fixed mast section.
• Attach the ends of the cables to the crane hook and lift the truck without jolting it.

ATTENTION:
The cables should be long enough that they do not touch the overhead guard or other equipment while the
truck is being lifted. Use a swinging bar if necessary.

1
3

OM0195

00 - Ed. 05/2007 15
Chapter 10
TECHNICAL OPERATING DATA

CONTENTS

10.1 - TRUCK OVERALL DIMENSIONS . .................................................................... 3


10.2 - STANDARD MODEL TECHNICAL DATA. ........................................................ 4
10.3 - LPG MODEL TECHNICAL DATA. ..................................................................... 5
10.4 - PNEUMATIC TYRES DATA. .............................................................................. 6
10.5 - VERTICAL MAST CARRYING CAPACITIES - FORKS UP TO 1400 mm,
TRUCK WITH A CARRYING CAPACITY OF 2500 KG, SUPERELASTIC WHEELS. ... 7
10.6 - VERTICAL MAST CARRYING CAPACITIES - FORKS UP TO 1400 mm,
TRUCK WITH A CARRYING CAPACITY OF 2500 KG, PNEUMATIC WHEELS. ...........8
10.7 - VERTICAL MAST CARRYING CAPACITIES - FORKS UP TO 1400 mm,
TRUCK WITH A CARRYING CAPACITY OF 3000 KG, SUPERELASTIC WHEELS....... 9
10.8 - VERTICAL MAST CARRYING CAPACITIES - FORKS UP TO 1400 mm,
TRUCK WITH A CARRYING CAPACITY OF 3000 kg, PNEUMATIC WHEELS. ........ 10
10.9 - MASTS DATA. .................................................................................................. 11
10.10 - GRADIENTS. .................................................................................................... 12
10.11 - TIRE INFLATION PRESSURE. ........................................................................ 12
10.12 - LIGHTS. ............................................................................................................ 12
10.13 - NOISE. .............................................................................................................. 12
10.14 - TRUCK IDENTIFICATION. ............................................................................... 13
Location of the plates ........................................................................................ 13
Engine serial number plate ................................................................................ 14
Gearbox serial number plate ............................................................................. 15
Mast serial number plate ................................................................................... 15
Chassis punching .............................................................................................. 16
10.15 - DISPLACEMENT OF THE HYDRAULIC ASSEMBLIES........................................... 17
10.16 - HYDRAULIC SYSTEM CHART. ....................................................................... 18
Hydraulic pump ................................................................................................. 19
Hydraulic pump data for Standard and LPG models with capacity 2,5t and
for Heavy Duty model capacity 2,5t and 3,0t. .................................................... 19
Imported Hydraulic oil tank ............................................................................... 20
China-made Hydraulic Oil Tank Assembly........................................................ 21
国产液压油箱安装及拆卸 ................................................................................. 22
Lift distributor .................................................................................................... 23
China-made three-element distributor............................................................... 24
China-made three-element distributor............................................................... 25
Imported salami three-element distributor......................................................... 26
Imported salami four-element distributor........................................................... 27
Steering distributor............................................................................................ 28
Manual steering pressure .................................................................................. 29
Pressure relief valve .......................................................................................... 29
Anti-cavitation valve .......................................................................................... 29
Non-return valve ................................................................................................ 29

10 - Ed. 05/2007 1
CONTENTS
Double anti-shock valve .................................................................................... 29
Descent control valve (VRD) ............................................................................. 30
Safety valve (or load descent stop valve) (VBDC) ............................................ 31
Position of the safety valves on a standard mast............................................... 32
Position of the safety valves on a duplex mast......................................................
. .... 33
Position of the safety valves on a triplex mast.......................................................
. .... 34
Standard and triplex lift cylinders (of the same model)...................................... 35
Duplex lift cylinders ........................................................................................... 36
Tilt cylinders ...................................................................................................... 38
10.17 - STEERING AXLE. ............................................................................................ 39
Steering axle. .................................................................................................... 39
10.18 - WIRING DIAGRAM (FOR STANDARD - LPG -
HEAVY DUTY MODELS). ................................................................................. 41
Truck harness. ................................................................................................... 41
灯光原理图........................................................................................................... 42
DEUTZ 引擎线线束图. ....................................................................................... 44
nissan 引擎线线束图. ........................................................................................ 45
Backlighted dashboard. ..................................................................................... 46
Technical features. ............................................................................................ 46
Dashboard. ........................................................................................................ 47
Lock-up switch and starting the engine. ............................................................ 50
Manual reverse unit (Standard). ........................................................................ 51
10.19 - BRAKES. .......................................................................................................... 52
Left brake explanation. ...................................................................................... 53
Automatic clearance adjustment. ...................................................................... 54
Master cylinder or brake pump. ......................................................................... 55
Technical features. ............................................................................................ 55
Air bleeding from the brake piping. .................................................................... 56
Low pressure bleeding. ..................................................................................... 56
High pressure bleeding. .................................................................................... 56

2 Ed. 05/2007
10.1 - TRUCK OVERALL DIMENSIONS

10 - Ed. 05/2007 3
10.2 - STANDARD MODEL TECHNICAL DATA
DESIGN VALUE
POS ITEM DESCRIPTION UNIT
XD25 XD30
Linde(Chain) Forklift Linde(Chain) Forklift
1.1 Manufacturer
Truck Co. Ltd Truck Co. Ltd
1.2 Model designation XD25 XD30
Specification

1.3 Type of drive: Electric-Diesel-Petrol-LPG-Network Diesel Diesel


1.4 Operation Type: Hand-Stand on-Driver seated Driver seated Driver seated
1.5 Load Capacity Q(t) 2.5 3.0
1.6 Load Barycenter Distance c(mm) 500 500
1.8 Axle centre to fork face x(mm) 485 1)2) 485 1)2)
1.9 Wheel Base y(mm) 1620 1620
2.1 Service Weight kg 4082 3) 4520 3)
Weights

2.2 Axle Weight with Rated Load, front/rear kg 5901/681 ( backward) 6772/757 ( backward)
2.3 Axle Weight without Rated Load, front/rear kg 1823/2259 ( backward) 1850/2679 ( backward)
4) 4)
3.1 Tyres: SE=Superelastic PN=Pneumatic Pneumatic Tyre PN Pneumatic Tyre PN
Wheels and Tyres

3.2 Front Tyres Size 7.00-12 4) 27×10-12 4)


3.3 Rear Tyres Size 6.50-10 4) 6.50-10 4)
3.5 Tyres: Number of Front/Rear Tyres (×=drive) 2×/2 2×/2
3.6 Front Track Width b10(mm) 1007 7) 1057
3.7 Rear Track Width b11(mm) 940 940
5) 5)
4.1 Mast lift, forward/backward Grad 4°30′/9° 4°30′/9°
6) 6)
4.2 Mast Minimum Overall Height h1(mm) 2335 2343
4.3 Free Lift h2(mm) 60 6) 60 6)
6) 6)
4.4 Lift Height h3(mm) 3050 3050
4.5 Mast Maximum Overall Height h4(mm) 3829 6) 3832 6)
Dimensions and Overall Sizes

4.7 Overhead Guard Height h6(mm) 2170 2175


4.8 Seat Height h7(mm) 1145 1150
4.12 Drawbar Height h10(mm) 400 395
4.19 Overall Length (including forks arms 1000mm) l1(mm) 3595 1)2) 3685 1)2)
1)2)
4.20 Length to Face of Forks l2(mm) 2595 2685 1)2)
4.21 Overall Width b1/b2(mm) 1116 8) 1320
4.22 Fork Arms Dimensions s/e/l(mm) 45×100×1000 45×122×1000
4.23 Fork Carriage in Compliance with ISO 2328 Class/Form A,B 2A 3A
4.24 Fork Carriage Width b3(mm) 1150 1150
4.31 Ground Clearance Below Mast (with load) m1(mm) 106 9) 114 9)
4.32 Ground Clearance Below Mast m2(mm) 150 160
4.33 Aisle Width with Pallet 1000×1200 and Fork Arms Pitch 1200 Ast(mm) 3939 4025
4.34 Width with Pallet 800¡Á1200 and Fork Arms Pitch 1200 Ast(mm) 4139 4225
4.35 Turning Radius Wa(mm) 2257 2338
4.36 Turning Point Minimum Distance from the Truck Center Line b13(mm) 563 563
5.1 Drive Speed with/without load km/h 20/21 22/22.5
5.2 Lifting speed with/without load m/s 0.45/0.50 0.45/0.50
Performance

5.3 Lowering speed with /without load m/s 0.49/0.43 0.49/0.44


5.5 Drawbar Pull Tractive Effort (at 2km/h) with /without load N 17000/9200 16000/9000
5.7 * Gradeability (at 2km/h) with /without load % 27/23 22/20.5
5.9 Acceleration Time (15m) with /without load s 4.7/4.2 5.2/4.4
5.10 Service Brake Mechanical/Hydraulic Mechanical/Hydraulic
7.1 Engine Manufacturer / Engine Type DEUTZ F4M2011 DEUTZ F4M2011
7.2 Engine Power in compliance with ISO 1585 KW 46.5 46.5
Engine

7.3 Rated Number of Revolutions min-1 2600 2600


7.4 Cylinder Number/ Displacement cm3 4/3108 4/3108
7.5 Fuel Consumption in compliance with VDI-Cycle l/h 3.3 3.6
8.1 Drive Control Type Hydrodynamic Transm. Hydrodynamic Transm.
8.2 Service Pressure for Attachments bar 160 175
Others

8.3 Oil Flow rate for Attachments (max. available) l/min 60 60


8.4 Noise at Operator’s Ear dB(A) 86.2 86.2
8.5 Drawbar, model/Type DIN - -
Note:
1) With Tx mast=25mm
2) With Side Shifter hook-on: 2.5T+60mm,3.0T+67mm
3) Detail refer to 44158041105
4) Refer to table 44158041100-03
5) 4°30′/6°(SX/DX mast with h3≥4450 and TX mast)
6) Other dimension and specification can be chosen. (Refer to 44738041100,44748041100,44758041100)
7) XD25/XG25: 1057mm(27x10-12)
8) XD25/XG25: 1305mm(27x10-12)
9) XD25/XG25:96 mm (TX mast), XD30/XG30: 106 mm (TXmast)
* Testing on slope 17.5% grade XG25:4.7/8.8, XG30:3.5/7.7

4 Ed. 05/2007
10.3 - LPG MODEL TECHNICAL DATA
DESIGN VALUE
POS ITEM DESCRIPTION UNIT
XG25 XG30
Linde(Chain) Forklift Linde(Chain) Forklift
1.1 Manufacturer
Truck Co. Ltd Truck Co. Ltd
1.2 Model designation XG25 XG30
Specification

Liquefied petroleum gas(LPG) Liquefied petroleum gas(LPG)


1.3 Type of drive: Electric-Diesel-Petrol-LPG-Network
LPG LPG
1.4 Operation Type: Hand-Stand on-Driver seated Driver seated Driver seated
1.5 Load Capacity Q(t) 2.5 3.0
1.6 Load Barycenter Distance c(mm) 500 500
1.8 Axle centre to fork face x(mm) 4851)2) 4851)2)
1.9 Wheel Base y(mm) 1620 1620
2.1 Service Weight kg 3917 3) 4364 3)
Weights

2.2 Axle Weight with Rated Load, front/rear kg 5797/620 ( backward) 6554/810 ( backward)
2.3 Axle Weight without Rated Load, front/rear kg 1727/2190 ( backward) 1684/2680 ( backward)
Pneumatic Pneumatic
3.1 Tyres: SE=Superelastic PN=Pneumatic
Wheels and Tyres

PN 4) PN 4)
3.2 Front Tyres Size 7.00-12 4) 27×10-124)
3.3 Rear Tyres Size 6.50-10 4) 6.50-10 4)
3.5 Tyres: Number of Front/Rear Tyres(×=drive) 2×/2 2×/2
3.6 Front Track Width b10(mm) 1007 7) 1057
3.7 Rear Track Width b11(mm) 940 940
4.1 Mast lift, forward/backward Grad 4°30?/9°5) 4°30?/9°5)
6)
4.2 Mast Minimum Overall Height h1(mm) 2335 2343 6)
4.3 Free Lift h2(mm) 60 6) 60 6)
6)
4.4 Lift Height h3(mm) 3050 3050 6)
6)
4.5 Mast Maximum Overall Height h4(mm) 3829 3832 6)
Dimensions and Overall Sizes

4.7 Overhead Guard Height h6(mm) 2170 2175


4.8 Seat Height h7(mm) 1145 1150
4.12 Drawbar Height h10(mm) 400 395
4.19 Overall Length (including forks arms 1000mm) l1(mm) 3595 1)2) 3685 1)2)
1)2)
4.20 Length to Face of Forks l2(mm) 2595 2685 1)2)
8)
4.21 Overall Width b1/b2(mm) 1180 1305
4.22 Fork Arms Dimensions s/e/l(mm) 45×100×1000 45×122×1000
4.23 Fork Carriage in Compliance with ISO 2328 Class/Form A,B 2A 3A
4.24 Fork Carriage Width b3(mm) 1150 1150
4.31 Ground Clearance Below Mast (with load) m1(mm) 106 9) 114 9)
4.32 Ground Clearance Below Mast m2(mm) 150 160
4.33 Aisle Width with Pallet 1000×1200 and Fork Arms Pitch 1200 Ast(mm) 3939 4025
4.34 Aisle Width with Pallet 800×1200 and Fork Arms Pitch 1200 Ast(mm) 4139 4225
4.35 Turning Radius Wa(mm) 2257 2338
4.36 Turning Point Minimum Distance from the Truck Center Line b13(mm) 563 563
5.1 Drive Speed with/without load km/h 19.2/20 19.2/20
5.2 Lifting speed with/without load m/s 0.45/0.50 0.45/0.50
Performance

5.3 Lowering speed with /without load m/s 0.46/0.43 0.46/0.43


5.5 Drawbar Pull Tractive Effort (at 2km/h) with /without load N 15090/10960 14100/10680
5.7 * Gradeability (at 2km/h) with /without load % 24/24 20/21
5.9 Acceleration Time (15m) with /without load s 5.0/4.4 5.3/4.6
5.10 Service Brake Mechanical/Hydraulic Mechanical/Hydraulic
7.1 Engine Manufacturer / Engine Type NISSAN K25 NISSAN K25
7.2 Engine Power in compliance with ISO 1585 KW 35 35
Engine

7.3 Rated Number of Revolutions min-1 2400 2400


7.4 Cylinder Number/ Displacement cm3 4/2488 4/2488
7.5 Fuel Consumption in compliance with VDI-Cycle l/h 8.6 9.4
8.1 Drive Control Type Hydrodynamic Transm. Hydrodynamic Transm.
8.2 Service Pressure for Attachments bar 160 175
Others

8.3 Oil Flow rate for Attachments (max. available) l/min 50 50


8.4 Noise at Operator’s Ear dB(A) 84 84
8.5 Drawbar, model/Type DIN - -
Note:
1) With Tx mast=25mm
2) With Side Shifter hook-on: 2.5T+60mm,3.0T+67mm
3) Detail refer to 44158041105
4) Refer to table 44158041100-03
5) 4°30?/6°(SX/DX mast with h3≥4450 and TX mast)
6) Other dimension and specification can be chosen.(Refer to 44738041100,44748041100,44758041100)
7) XD25/XG25: 1057mm(27x10-12)
8) XD25/XG25: 1305mm(27x10-12)
9) XD25/XG25:96 mm (TX mast), XD30/XG30: 106 mm (TXmast)
* Testing on slope 17.5% grade XG25:4.7/8.8, XG30:3.5/7.7

10 - Ed. 05/2007 5
10.4 PNEUMATIC TYRES DATA

XD/XG25-30 Wheels

Wheel
Superelastic Pneumatic
Type
Front Rear Front Rear
7.00-12 single (SX-DX) 6.50-10 7.00-12/16pr single (SX-DX) 6.50-10/14 p.r.
2500kg
27x10-12 single (TX) 6.50-10 27x10-12/14pr single (TX) 6.50-10/14 p.r.
3000kg 27x10-12 single (SX-DX-TX) 6.50-10 27x10-12/14pr single (SX-DX) 6.50-10/14 p.r.

TIRE INFLATION PRESSURE

AXLE MEASUREMENT PRESS


URE
Front 7.00-12/16pr single 10bar
Front 27x10-12/14pr single 7bar
Rear 6.50-10/14 p.r. 10bar

Abbreviations
Soll. = Mast
DX = Duplex mast
SX = Simplex mast
TX = Triplex mast
Sing. = Single wheel
Gem. = Twin wheels
Opt. = Optional
Tutti soll. = All masts
S.E. = Superelastic
S. = Single
PN. = Pneumatic

6 Ed. 05/2007
10.5 - VERTICAL MAST CARRYING CAPACITIES - FORKS
UP TO 1400 mm, TRUCK WITH A CARRYING
CAPACITY OF 2500 KG, SUPERELASTIC WHEELS
Tyres SE Sing(7.00-12)
SE Twin(7.00-12)
Liftmast SE Sing(27×10-12)
Side-Shifter Hook on Fofk Carriage Side-Shifter Hook on Fofk Carriage
Type Liftheight Loadcenter
max. 3050 max. 3050 max. 3050 max. 3050
500 2250 2250 2500 2500
3050 600 1900 1900 2250 2250
1000 1150 1150 1600 1600
500 2250 2250 2500 2500
4050 600 1900 1900 2200 2200
1000 1150 1150 1600 1600
SX
500 2250 2250 2500 2500
4450 600 1900 1900 2200 2200
1000 1150 1150 1600 1600
500 2150 2250 2400 2500
5150 600 1900 1900 2100 2150
1000 1150 1150 1450 1500
500 2250 2500
2750 600 1900 2250
1000 1150 1600
DX
500 2250 2500
2950 600 1600 2250
1000 1150 1600
500 2200 2200 2300 2450
4025 600 1900 1900 2100 2200
1000 1150 1150 1550 1650
500 2100 2200 2300 2450
TX 4325 600 1850 1900 2100 2200
1000 1150 1150 1550 1650
500 2000 2200 2250 2450
4625 600 1800 1900 2000 2200
1000 1150 1150 1500 1650
500 1950 2200 2150 2450
5075 600 1750 1900 1950 2200
1000 1150 1150 1450 1650
500 1350 2150 1550 2400
6125 600 1200 1900 1400 2150
1000 900 1150 1050 1600
NOTE:(1) Mast tiliting angle:SX/DX< 4450: FW.4°3',BW.9°
SX>=4450: FW.4°3',BW.6°
TX: FW.4°3',BW.6°

SX:Simplex mast-DX:Duplex mast with free lift-TX:Triplex mast with free lift
Mast tiliting angle:Forward(Fw)/Backward(Bw)

10 - Ed. 05/2007 7
10.6 - VERTICAL MAST CARRYING CAPACITIES -
FORKS UP TO 1400 mm, TRUCK WITH A
CARRYING CAPACITY OF 2500 KG, PNEUMATIC
WHEELS
Tyres PN Sing(7.00-12/16 pr)
PN Twin(7.00-12/16 pr)
Liftmast PN Sing(27×10-12/14 pr)
Side-Shifter Hook on Fofk Carriage Side-Shifter Hook on Fofk Carriage
Type Liftheight Loadcenter
max. 3050 max. 3050 max. 3050 max. 3050
500 2250 2250 2500 2500
3050 600 1900 1900 2250 2250
1000 1150 1150 1600 1600
500 2250 2250 2500 2500
4050 600 1900 1900 2200 2200
1000 1150 1150 1600 1600
SX
500 2150 2250 2400 2500
4450 600 1900 1900 2150 2200
1000 1150 1150 1450 1550
500 2150 2250 2300 2500
5150 600 1900 1900 2050 2150
1000 1150 1150 1450 1500
500 2250 2500
2750 600 1900 2250
1000 1150 1600
DX
500 2250 2500
2950 600 1600 2250
1000 1150 1600
500 2050 2150 2300 2400
4025 600 1850 1900 2000 2100
1000 1150 1150 1500 1600
500 2050 2150 2300 2400
4325 600 1850 1900 2000 2100
1000 1150 1150 1500 1600
500 2000 2100 2250 2350
TX 4625 600 1800 1900 1900 2000
1000 1150 1150 1450 1550
500 1850 2000 2050 2250
5075 600 1650 1800 1800 1900
1000 1150 1150 1350 1500
500 1250 1950 1400 2200
5075 600 1100 1750 1250 1850
1000 850 1150 900 1450
NOTE:(1) Mast tiliting angle:SX/DX< 4450: FW.4°3',BW.9°
SX>=4450: FW.4°3',BW.6°
TX: FW.4°3',BW.6°

SX:Simplex mast-DX:Duplex mast with free lift-TX:Triplex mast with free lift
Mast tiliting angle:Forward(Fw)/Backward(Bw)

8 Ed. 05/2007
10.7 - VERTICAL MAST CARRYING CAPACITIES - FORKS
UP TO 1400 mm, TRUCK WITH A CARRYING
CAPACITY OF 3000 KG, SUPERELASTIC WHEELS

Tyres
SE Sing(27×10-12) SE Twin(7.00-12)
Liftmast
Side-Shifter Hook on Fofk Carriage Side-Shifter Hook on Fofk Carriage
Type Liftheight Loadcenter
max. 3050 max. 3050 max. 3050 max. 3050
500 2700 2700 3000 3000
3050 600 2450 2450 2700 2700
1000 1650 1650 1950 1950
500 2700 2700 3000 3000
4050 600 2450 2450 2700 2700
1000 1650 1650 1950 1950
sx
500 2700 2700 3000 3000
4450 600 2450 2450 2700 2700
1000 1650 1650 1950 1950
500 2550 2700 2850 3000
5150 600 2300 2450 2450 2550
1000 1650 1650 1800 1850
500 2700 3000
2750 600 2450 2700
1000 1650 1950
DX
500 2700 3000
2950 600 2450 2700
1000 1650 1950
500 2700 2700 3000 3000
4025 600 2450 2450 2700 2700
1000 1650 1650 1950 1950
500 2500 2650 2800 2950
4325 600 2250 2400 2550 2650
1000 1600 1650 1900 1950
500 2400 2650 2700 2950
TX 4625 600 2150 2400 2450 2650
1000 1600 1650 1800 1950
500 2300 2650 2550 2950
5075 600 2100 2400 2300 2650
1000 1550 1650 1700 1950
500 1500 2650 1700 2950
6125 600 1350 2400 1550 2650
1000 1000 1650 1150 1950

NOTE:(1) Mast tiliting angle:SX/DX< 4450: FW.4°3',BW.9°


SX>=4450: FW.4°3',BW.6°
TX: FW.4°3',BW.6°

SX:Simplex mast-DX:Duplex mast with free lift-TX:Triplex mast with free lift
Mast tiliting angle:Forward(Fw)/Backward(Bw)

10 - Ed. 05/2007 9
10.8 - VERTICAL MAST CARRYING CAPACITIES - FORKS
UP TO 1400 mm, TRUCK WITH A CARRYING
CAPACITY OF 3000 kg, PNEUMATIC WHEELS

Tyres
PN Sing(27×10-12/14 pr) SE Twin(7.00-12/16 pr)
Liftmast
Side-Shifter Hook on Fofk Carriage Side-Shifter Hook on Fofk Carriage
Type Liftheight Loadcenter
max. 3050 max. 3050 max. 3050 3050
500 2700 2700 3000 3000 max.
3050 600 2450 2450 2700 2700
1000 1650 1650 1950 1950
500 2700 2700 3000 3000
4050 600 2450 2450 2700 2700
1000 1650 1650 1950 1950
sx
500 2550 2700 2850 3000
4450 600 2300 2450 2550 2650
1000 1650 1650 1850 1900
500 2300 2700 2550 3000
5150 600 2100 2450 2300 2600
1000 1550 1650 1650 1850
500 2700 3000
2750 600 2450 2700
1000 1650 1950
DX
500 2700 3000
2950 600 2450 2700
1000 1650 1950
500 2200 2600 2500 2900
4025 600 2000 2350 2250 2600
1000 1500 1650 1650 1900
500 2200 2550 2450 2850
4325 600 2000 2300 2200 2550
1000 1500 1650 1600 1850
500 2150 2500 2400 2800
TX 4625 600 1950 2250 2150 2500
1000 1450 1650 1550 1800
500 2100 2450 2350 2750
5075 600 1900 2200 2100 2450
1000 1400 1650 1500 1750
500 1250 2400 1450 2700
4625 600 1100 2150 1300 2400
1000 850 1600 950 1700
NOTE:(1) Mast tiliting angle:SX/DX< 4450: FW.4°3',BW.9°
SX>=4450: FW.4°3',BW.6°
TX: FW.4°3',BW.6°

SX:Simplex mast-DX:Duplex mast with free lift-TX:Triplex mast with free lift
Mast tiliting angle:Forward(Fw)/Backward(Bw)

10 Ed. 05/2007
10.9 - MASTS DATA
Standard (Simplex)
Lift Height h3 mm 3050 4050 4450 5150
Fork Carri age
X D25/X G25

6 Rol l ers

Minimum Overall Height h1 mm 2335 2835 3035 3385


Maximum Overall Height h4 mm 3829 4829 5229 5929
Free Lift h2 mm 60 60 60 60
Lift Height h3 mm 3050 4050 4450 5150
Fork Carri age
X D30/X G30

6 Rol l ers

Minimum Overall Height h1 mm 2343 2843 3043 3393


Maximum Overall Height h4 mm 3832 4832 5232 5932
Free Lift h2 mm 60 60 60 60

Duplex
Lift Height h3 mm 2750 2950
Fork Carri age Fork Carri age
X D30/X G30 X D25/X G25

6 Rol l ers

Minimum Overall Height h1 mm 2085 2185


Maximum Overall Height h4 mm 3529 3729
Free Lift h2 mm 1475 1575
Lift Height h3 mm 2750 2950
6 Rol l ers

Minimum Overall Height h1 mm 2095 2195


Maximum Overall Height h4 mm 3532 3732
Free Lift h2 mm 1475 1575

Triplex
Lift Height h3 mm 4025 4325 4625 5075 6125
Fork Carri age
X D25/X G25

6 Rol l ers

Minimum Overall Height h1 mm 2075 2175 2210 2425 2775


Maximum Overall Height h4 mm 4804 5104 5384 5854 6904
Free Lift h2 mm 1475 1575 1580 1825 2175
Lift Height h3 mm 4025 4325 4625 5075 6125
Fork Carri age
X D30/X G30

6 Rol l ers

Minimum Overall Height h1 mm 2085 2185 2220 2435 2785


Maximum Overall Height h4 mm 4807 5107 5387 5857 6907
Free Lift h2 mm 1475 1575 1580 1825 2175

10 - Ed. 05/2007 11
10.10 - GRADIENTS
• See the technical data table for gradeability information.

10.11 - TIRE INFLATION PRESSURE

AXLE MEASUREMENT PRESSURE

Front 7,00 - 12/16 p.r. 10 bar

Front 27x10 - 12/14 p.r. 7 bar

Rear 6,50 - 10/14 p.r. 10 bar

10.12 - LIGHTS

Light 12V45/40W
Mini lamp 12V-4W
Turn and stop lights 12V-21W
End-outline marker lamp 12V-10W

10.13- NOISE

Noise “pressure” level at driver’s ear:


LpAZ= 80dB (A) with uncertainty KpA= 4dB (A).
This value has been taken in a test cycle as per Harmonized European Norm EN 12053 with time weighed
percentages for operations: Traction, Lifting, Idle.
It is useful only as a comparative value against other fork lift trucks.

Sound “Power” Level ensured:


LwAZ= 86.3 dB (A) (XD 25-30).
LwAZ= 103 dB (A)
LwAZ= 84 dB (A) (LPG Model ).
This value is read according to European Directive 2000/14/CE and calculated according to sound power levels for
operations Traction and Lifting.
Also this value is useful only as a comparative value against other fork lift trucks.
This value is not useful to determine the values of acoustic environmental pollution in actual operation as it does
not represent a real working situation where the Minimum revs operation is also present.

ATTENTION:
During the use of the truck there can be higher or lower noise values tha those indicated above due to different
applications, different environmental conditions or additional noise.

12 Ed. 05/2007
10.14 - TRUCK IDENTIFICATION

• The forklift truck and its main components all have serial numbers so they can be identified.
• Chassis number are necessary for maintenance and repairs and when asking for parts.

LOCATION OF THE PLATES

Truck
identification
TIPO / MODELE / MODEL / TYP
PORTATA NOMINALE / CAPACITE NOMINALE

plate
kg
RATED CAPACITY / NENN-TRAGFAEHIGKEIT
MATRICOLA / N° DE SERIE
SERIAL N° / FABRIKNUMMER
ANNO DI COSTRUZIONE / ANNEE DE FABRICATION
YEAR OF MANUFACTURE / BAUJAHR
MASSA A VUOTO (SENZA BATTERIA DI TRAZIONE)
MASSE A VIDE (SANS BATTERIE DE TRACTION) kg
UNLADEN WT. (WITHOUT TRACTION BATTERY)
Mast plate
LEERGEWICHT (OHNE ANTRIEBS-BATTERIE)
BATTERIA DI TRAZIONE / BATTERIE DE TRACTION V TIPO MODELE CON GOMMATURA AVEC ROUES
TRACTION BATTERY / ANTRIEBS-BATTERIE MODEL TYP WITH TYRES MIT BEREIFUNG
MASSA / MASSE MIN kg MAX kg
WEIGHT / GEWICHT
SENZA ATTREZZATURE SANS EQUIPEMENTS WITHOUT ATTACHMENTS OHNE ANBAUGERAET

PORTATE A MONTANTI VERTICALI Kg ALTEZZA SOLLEVAMENTO mm


CAPACITES A MAT VERTICAL Kg HAUTEUR DE LEVEE mm
CAPACITIES WITH VERTICAL MASTS Kg LIFT HEIGHT mm
TRAGFAEHIGKEIT DES MASTES Kg HUBHOEHE mm

Lubricants plate

LUBRIFICANTI/LUBRIFIANTS/LUBRICANTS/SCHMIERMITTEL
VS DIESEL 15W/40
DIESEL (MIL-L-2104 D API CD-DCMP PD1)
MOTORE E FILTRO ARIA (SAE 15W/40)
MOTEUR ET FILTRE AIR
ENGINE AND AIR FILTER
MOTOR UND LUFTFILTER BENZINA VS 15W/40
ESSENCE FL ITALIA
PETROL (MIL-L-46152C-AP SF-CCMC G2)
BENZIN (SAE 15W/40)
IMPIANTO IDRAULICO IDRAULICAR AP 46
CIRCUIT HYDRAULIQUE
HYDRAULIC SYSTEM (MIL-H-24459)
HYDRAULISCHE ANLAGE (DIN 51524/51525)

TRASMISSIONE IDRAULICA TUTELA GI/M


TRASMISSION HYDRAULIQUE
HYDRAULIC DRIVE (ATF Type A Suffix A)
STROEMUNGS GETRIEBE

PONTE ANTERIORE TUTELA W90/M-DA


PONT AVANT
FRONT AXLE (MIL-L-2105 D API GL 5)
VORDERACHSBRUEKE (SAE 80 W/90)

CIRCUITO FRENI TUTELA DOT SPECIAL TRUCK


SYSTEME DE FREIN (FMSS 116 - DOT 4)
BRAKE CIRCUIT (NHTSA 116 - DOT4)
BREMSKREIS (I.S.O. 4925)
(SAE J 1703 - 1704)
INGRASSAGGI TUTELA MR 2
GRAISSAGES
GREASE LUBRICATION (Grasso al sapone di litio
EINFETTEN consistenza N.L.G.I. 2)

FL

OM0186

10 - Ed. 05/2007 13
ENGINE SERIAL NUMBER PLATE Standard Model
The serial n° plate (1) is positioned on the monobloc.

GPL Model
The engine registration plate (2) is located on the left side of
the engine block.

14 Ed. 05/2007
GEARBOX SERIAL NUMBER PLATE
The gearbox serial number plate (3) is located in the
upper part of the axle assembly beneath the operator’s
footboard.

3
OMM0597

MAST SERIAL NUMBER PLATE


The mast serial number plate (4) is located on the middle
part of the mast.

OMM0598

10 - Ed. 05/2007 15
CHASSIS PUNCHING
The chassis number (5) is punched onto the rear left of
the truck chassis.

0MM3058

16 Ed. 05/2007
10.15 - DISPLACEMENT OF THE HYDRAULIC
ASSEMBLIES

10

3
1

5 10 9

EX PL A NA T I O N :
1=Lift distributor
2=Steer cylinder
3=Tilt cylinders
4=Hydraulic oil tank
5=Oil pump
6=Oil strainer
4 7=Hydraulic steering
8=Descent control valve
6

2
10.1
1 0 - E d. 0 5 / 2 0 0 7 17
2
10.16 - HYDRAULIC SYSTEM DIAGRAM
Hydraulic oil tank

Oil pipe Pipe

Oil pipe Straight thread elbow Tilting cylinder, backward

Oil-return joint
Oil feeding bushing Right cylinder fitting

Suction pipe
Right pipe of
Pump outlet manifold tilting cylinder

Pipe from steering column to filter


Left cylinder fitting
Steering valve

Pipe
Pump oil suction pipe Lift cylinder pipe
Circuit distributor
Pipe

Multi-way valve

Steering and lifting pump


Straight thread elbow Left pipe of tilting cylinder

Pipe from distributing valve


to steering column

Tilting cylinder, backward Pump oil delivery joint

Tilting cylinder assembly inspection

18 2
Ed. 05/2007
HYDRAULIC PUMP

Delivery flange
C= 25,5 Nm Nm

C= 46 Nm Nm

Suction flange

Clockwise turning
direction
OMM0378

HYDRAULIC PUMP DATA FOR DIESEL AND LPG MODELS WITH CAPACITY 2,5t
AND 3,0t
Turning direction. .................................................. clockwise
Max. allowed speed ............................................... 3000 rpm
Max. allowed operation pressure ........................... 250 bar
Intermittent pressure ............................................... 280 bar
Peak pressure ........................................................... 300 bar
Displacement. .................................................. 27,6 cm3/rev.
Rated flow ....................................................................25ml/r
Min revolutions at 250 bar ...................................... 600 rpm

10 - Ed. 05/2007 19
IMPORTED HYDRAULIC OIL TANK
2
1
The imported oil tank equipped with oil strainer has 5
capacity 46 litres. 4
The oil reaches a maximum operation temperature of 3
80°C.
7
For detaching the oil tank please refer to the relevant
chapter.

1= Oil inlet.
Note:
Check the union for correct position.
2= Oil strainer.
3= Oil measuring stick.
4= Air outlet.
5= Oil outlet
6= Outlet cap.
7= Filter cartridge.
6
OMM0379

Oil strainer technical specification:


Rated flow: 70 I
Filtering elements in impregnated cellulose: 25 m.
Max. operation pressure: 10 bar.
By-pass valve with setting: 1,75 bar.
Air outlet: 7 m.

20 Ed. 05/2007
China-made Hydraulic Oil Tank Assembly

Pipe union
Oil filter
Filter washer
Oil filter

10 - Ed. 05/2007 21
2
INSTALLATION AND DISASSEMBLE
OF HOME HYDRAULIC OIL TANK

22 2
Ed. 05/2007
LIFT DISTRIBUTOR

Imported Salami three-element


distributor

SL = Side shift.

B = Tilting.

H = Lifting. H
SL
VS = Overpressure valve.
B
T1 = Outlet.

P = Feeding.

T1

H P

B
SL OMM0380

Imported Salami four-element


distributor

SL = Side shift.

B = Tilting.

H = Lifting.

B O
SL

T1

H
P

B
SL OMM0432

10 - Ed. 05/2007 23
China-made three-element distributor

SL = Side shift
B = Side tilting
H = Lifting
VS1 = Main overflow valve
VS2 = Overflow valve
T = Outlet
P = Inlet
PF = Steering inlet

24 Ed. 05/2007
China-made three-element distributor

Detail

Technical requirements
1.Technical data: rating flow 65L/min, max
pressure 25MPa, allowable back pressure
1.5MPa.
2.Usable oil temperature: -20°~80℃.
3.Use H46 hydraulic oil.
Detail Detail 4.Tightening torque: M10×1.25 Nut 50Nm
M8 Nut 50Nm

10 - Ed. 05/2007 25
2
S ecti on A -A
Priority valve
IMPORTED SALAMI THREE-ELEMENT DISTRIBUTOR
P T1
PF B A PF FD
PF
PF GP
1 C= 2 8 Nm Nm

T1

1 C = 28 N m Nm A2 A1
LC V

P MRV
B3 B2 B1 LSV

Tilt distributor element with anti-cavitation


LC V v a lv e i n t e g r a t e d i n t h e pi lo t r od .
M MRV B A
Section B-B

B2 A2

LC V

LCV
VS
VAC

LCV= Load retaining valve. M= Main by-pass pressure intake.


MRV= Main by-pass valve (for setting values please refer PFGP= hydraulic steering circuit pressure intake.
t o t h e re l e v a n t p a r a g r a p h ) . VAC= Anti-cavitation valve
Controlled flow rate:. ........................ 12.5 l/min.
FD= P r i o r i t y fl o w g o v e r n o r . • TE C H N IC A L S P E C I F I C A T I ON
LSV= Load sensing valve for hydraulic steering circuit. Rated flow: .............................................. 70 l/min.
PF= Hydraulic steering feeding. Max. flow: ................................................ 90 l/min.
T1= Outlet. M a x . p r e s s u r e : . . . .. . . .. . .. . . . .. . .. . . .. . . .. . . .. . . .. . . .. . 3 1 5 b a r .
VS= Auxiliary by-pass valve (second and third element) M a x . re t u r n p r e s s u re : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 b a r .
with fixed setting. F l u i d t e m p e r a t u r e r a n g e : . . . . . . . . . f ro m -2 0 t o + 8 5 ° C .
P= Pu m p f ee din g. I n t e r m i t t e n t t e m p e r a tu r e : . .. . . .. . . .. . . .. . . .. . . m a x . 1 0 0 ° C
A1= Side shift or any optional equipment. C o i l a c t u a t i o n e f f o r t a t 7 0 l /m i n a n d 1 7 5 b a r .
B1= Side shift or any optional equipment. In neutral position: ...................................... 108 N.
A2= Tilting. At end stroke: ............................................. 145 N.
B2= Tilting.
B3= Lifting.
10.3
26 2
Ed. 05/2007
Section A-A
IMPORTED SALAMI FOUR-ELEMENT DISTRIBUTOR
Priority valve

PF PF P T1
B A
FD PF
1 C = 28 Nm Nm

PF GP T1

LCV

P
1 C= 28 Nm Nm

MRV
LSV

P
LCV
B A Tilt distributor element with
M LCV anti-cavitation valve integrated
MRV i n t he p i lot r o d.

Section B-B

B3 A3

LC V

LC V
VS
VAC

LCV= Load retaining valve. M= Ma i n b y - p a s s p r e s s u r e i n t a k e .


MRV= Main by-pass valve (for setting values please PFGP= Hydraulic steering circuit pressure intake.
r ef er t o t he r e lev ant pa r ag r aph ) . VAC= Anti-cavitation valve
C o n t r o l l e d fl o w r a t e : . .. . .. . . . .. . .. . . . .. . .. . . 1 2 , 5 l /m i n .
FD= P r io r it y f lo w go v er n or . • TE C H N IC A L S P E C I F IC A T IO N
LSV= Load sensing valve for hydraulic steering circuit. Rated flow: ............................................ 70 l/min.
PF= H y d ra u l i c s t e e r i n g f e e d i n g . Max. flow: .............................................. 90 l/min.
T1= Outlet. Ma x . p r e s s u r e : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1 5 b a r .
VS= Auxiliary by-pass valve (second and third Ma x . re t u r n p re s s u r e : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 b a r .
element) with fixed setting. Fl u i d t e m p e r a t u r e r a n g e : . .. . .. . fr o m - 2 0 to + 8 5 ° C .
P= Pum p f e ed ing . Intermittent temperature: .................. max. 100°C
A1= O p t i o n a l e q u i p me n t . C o i l a c t u a t i o n e f f o r t a t 7 0 l / m i n a n d 1 7 5 b a r.
B1= O p t i o n a l e q u i p me n t . In neutral position: .................................... 108 N.
A2= Si d e S h i f t . At stroke end: ............................................ 145 N
B2= Side shift.
A3= Tilting.
B3= Tilting.
B4= Lifting.

10.4
10 - Ed. 05/2007 27
2
STEERING DISTRIBUTOR

Type OSPR 80.


• Pressure relief valve: VS3 • Anti-cavitation valves: VAC (2 pieces).
Pressure relief valve opening: at 120-125 bar. • Non-return valve in the P-piping.
• Anti-shock valve: VAU • Anti-shock valves (2 pieces): 175-195 bar.

PRESSURE RELIEF VALVE

ANTI-SHOCK VALVES

ANTI-CAVITATION VALVE

NON-RETURN
VALVE
ANTI-SHOCK VALVE

L R

ANTI-CAVITATION VALVE

VAC
PRESSURE
RELIEF VALVE VS3
T P L

P T

OMM0381_1 OMM0381_2 OMM0381_3

NON-RETURN VALVE R ANTI-SHOCK VALVES


OMM0381

28 Ed. 05/2007
The steering unit consists of a rotating valve and a rotating flow rate governor.
The hydraulic steering is connected to the steering wheels of the vehicle by operating the steering column. Whenever
the steering wheel is turning, the oil delivered by the hydraulic system pump is filled into the inlets of the L or R
cylinder, according to the rotation direction, by means of the rotating valve and flow rate governor. The flow rate
governor measures the oil quantity supplied to the steering cylinder proportionally to the rotation angle of the
steering wheel.

MANUAL STEERING PRESSURE


Under normal operation conditions, with the pump supplying the steering unit with a flow adequate to the required
pressure, the torque to be applied onto the steering wheel does not exceed 0.5 daNm.
If the flow rate is insufficient or missing al all, the steering unit will be operated automatically as a manual pump.
In this way the emergency steering of the vehicle is guaranteed.

PRESSURE RELIEF VALVE


The pressure relief valve limits the maximum pressure of the steering unit to the set value, thus protecting the
system. Moreover, it ensures a by-pass, whenever the cylinder reaches its stroke end.
P= 120 ÷ 125 bar.

ANTI-CAVITATION VALVE
The anti-cavitation valves enable the cylinders to suction some oil, whenever, under particular circumstances, a
vacuum is generated inside them (cavitation).

NON-RETURN VALVE
The non-return valve protects the operator against any back-kick from the steering wheel. The non-return valve
prevents the oil coming back towards the pump when the steering counters the pressure inside the cylinder. The
non-return valve is integrated in the hydraulic steering, in the inlet P.

DOUBLE ANTI-SHOCK VALVE


The double anti-shock valve is a direct-action one, thus reacting very rapidly. This concept protects the hydraulic
steering by limiting the pressure loads coming from the cylinders because of external factors. In this way the
pressure drop down between L and T and R and t respectively, is limited as well. The valves are set at 1 l/min. and
the setting value is 175 ÷ 195 bar.

10 - Ed. 05/2007 29
DESCENT CONTROL VALVE (VRD)
The descent control valve (1), used as a braking vale,
enables a constant descent speed, independently of the
load value.
The valve is essentially made of the slider – spring 1
assembly and of the diaphragm bush.
The bush is moved to the operation position though the
fluid flowing through the valve, thus building a ring-
shaped diaphragm inside the slider, the flow resistance
of which defines, together with the spring pre-loading,
the flow rate value.
In the opposite flow direction, the sliding diaphragm
moves completely away from its governor position, thus
taking apart the ring-shaped diaphragm built together
with the governor slider, and reducing the flow resistance
to a minimum, independently of the governing range. OMM0434

The benefit of a mobile diaphragm in comparison to a


valve with fixed diaphragm the flow resistance of which
would cause an unavoidable and unnecessary energy
increase for lifting manoeuvres is evident.

Operation system
Working direction F B (descent) B
F
Flow rate almost constant, since there is a self-creating
balance condition between the inner pressure drop down
and the pre-loading of the spring of the governor slider.
1= Governing edge OMM3061
2= Diaphragm in governor position

F B

1 2
OMM3060

Opposite direction F B (lift)


Free flow without any obstacle with a low resistance
thank to the sliding diaphragm moving away from its
governor position (no diaphragm effect). F B
1= Pin-shaped diaphragm in case of free flow direction.

1 OMM0210

30 Ed. 05/2007
SAFETY VALVE (or load descent stop valve) (VBDC)
It is a protection device against any hose break. It
prevents any uncontrollable and accelerated movement
of a hydraulic user under load, in case the countering
hydraulic pressure is missing in consequence of a bre- (F) (B)
ak f the delivery hose.
The protection device shall be screwed directly into the
oil inlet of the user to be protected; it consists of a plate
raised above its seat through a spring in stand-by
OMM0002
position and allows the oil to pass though a determined
section. F B= Feeding flow
When the flow rate increases, the hydraulic strengths F B= Discharge flow
exceed the effort applied through the spring and the valve
closes instantaneously.
On the valve plate an orifice is provided, which,
independently of the strength and the size of the load,
allows the oil flow constantly back, to ensure the load is
slowly set to the ground.

IMPORTANT:
For the displacement of the valves installed on the
different mast types please refer to the pictured
tables in the following pages.

10 - Ed. 05/2007 31
POSITION OF THE SAFETY VALVES ON A STANDARD MAST

LEFT RIGHT

A A

C= 20 Nm Nm

A= Safety valve

WARNING:
For selecting the valve type to be used
please refer exclusively to the Spare
Parts Catalogue.
OMM0382

32 Ed. 05/2007
POSITION OF THE SAFETY VALVES ON A DUPLEX MAST

C= 20 Nm Nm

LEFT RIGHT

C = 20 Nm Nm

A
A A

B
C= 2 0 Nm Nm

A-B-D =Safety valves


C = A p ply L oc t i t e 2 70 o n t he t h r e a d .

WA RNI N G:
F or s e l e c t i ng t h e v a l v e t y p e t o b e u s e d
please refer exclusively to the Spare
Parts Catalogue.

10.5
10 - Ed. 05/2007 33
2
POSITION OF THE SAFETY VALVES ON A TRIPLEX MAST

LEFT RIGHT

A
C=Apply Loctite 270 on the thread Nm

B
A

C=Apply Loctite 270 on the thread Nm

C=Apply Loctite 270 on the thread.

WA R N I N G:
F or s e l e c t i ng t h e v a l v e t y pe t o be u s e d
please refer exclusively to the Spare
Parts Catalogue.

10.6
34 2
Ed. 05/2007
STANDARD AND TRIPLEX LIFT CYLINDERS (OF THE SAME MODEL)

• RIGHT/LEFT
1= Tighten completely and apply Loctite 243.
(Threads shall be cleaned, degreased and dry).
2= Screw for air bleeding.

2 C=9.5 Nm Nm

OMM0389

10 - Ed. 05/2007 35
DUPLEX LIFT CYLINDERS

• LEFT CYLINDER • RIGHT CYLINDER


1= Tighten completely and apply Loctite 243. 1= Tighten completely and apply Loctite 243.
(Threads shall be cleaned, degreased and dry). (Threads shall be cleaned, degreased and dry).
2= Screw for air bleeding. 2= Screw for air bleeding.
3= APPLY Loctite 275. 3= APPLY Loctite 275.
(Threads shall be cleaned, degreased and dry). (Threads shall be cleaned, degreased and dry).

2 C= 9.5 Nm Nm

2 C= 9.5 Nm Nm

1 1

3
3

OMM0391 OMM0390

36 Ed. 05/2007
• MIDDLE CYLINDER
1= Tighten completely and apply Loctite 243. 2 C= 9.5 Nm Nm
(Threads shall be cleaned, degreased and dry).
2= Screw for air bleeding
3= Apply Loctite 275.
(Threads shall be cleaned, degreased and dry).

OMM0392

10 - Ed. 05/2007 37
TILT CYLINDERS

1 C= 450 ± 25 Nm Nm
A

B
2 C= 450 ± 25 Nm Nm

3 OMM0388

1= Apply Loctite 270.


2= Apply Loctite 270.
3= Apply Loctite 270.
A=Stroke 117.5 – f or Standard lift heights 3250 + 4050 mm and for Duplex lift heights
2750 + 2950 mm.
B=Stroke 92.5 - for Standard lift heights 4450 + 5050 mm and for Triplex lift heights
4025 + 5075 mm.

38 Ed. 05/2007
10.17 - STEERING AXLE

OMM0412

STEERING AXLE
The rear wheels are steered through a double-acting hydraulic cylinder, fitted to the steering axle and to both stub
axles by means of two track rods (with fixed length). The movement of the steering wheel actuates the hydraulic
steering governing the oil flow to the steer cylinder. The feeding is provided through the gears pump operated by
the transmission power takeoff.
The axle body is fitted to the framework by means of elastic bearings allowing the axle to float on rough terrains.
The steer cylinder is fitted to the axle body by means of guide pins and four bolts.
The track rods are equipped with two knuckles, one on each end, provided with a sealing gasket and are connected
to both the piston stem and the stub axles by means of pressed on bolts and spring pins.
These connecting rods have a fixed length, so that no convergency check is needed.

10 - Ed. 05/2007 39
Electri Schematic Diagram (XD/XG25-30)

40 Ed. 05/20072
10.18 - WIRING DIAGRAM (FOR STANDARD - LPG - HEAVY DUTY MODELS)
TRUCK HARNESS

10 - Ed. 05/2007 41
2
Lighting schematic diagram

42 Ed. 05/20072
10 - Ed. 05/2007 43
2
DEUTZ Engine cable

44 2
Ed. 05/2007
NISSAN Engine cable

10 - Ed. 05/2007 45
BACKLIGHTED DASHBOARD
Function description of the 20 pins
Pin Function Signal
1 ..... ..............
2 ..... Battery recharge insufficient .......................
3 ..... Direction lights ............................................... +
4 ..... Battery Minus .............................................. 20
18
17
5 ..... Parking brake .............................................. 9
13
6
6 ..... Brake system failure ................................... 12
10

5
7 ..... ............ 1

8 ..... ...........
9 ..... 12V when key is switched on ......................... +
10 .... Side lights
OMM0422
...... Low-beam lights ............................................. +
A= 20-way-connector
11 .... Spark plugs pre-heating ................................. +
12 .... ..............
13 .... Air filter clogged ..........................................
14 .... Engine oil temperature
too high ......................................................
15 .... Engine oil pressure too low .........................
16 .... Gearbox oil temperature
too high .......................................................
17 .... Gearbox oil pressure too low ......................
18 .... ...........
19 .... Low fuel warning indicator ..........................
20 .... ...........

TECHNICAL FEATURES
• Operation temperature range: –20 / +80°
• Rated supply voltage: 12V ± 3.
• Protection grade. “IP42” (for ensuring a perfect
sealing between glass and housing)
• Protection against polarity reverse

46 Ed. 05/2007
DASHBOARD
8 9 6 11 12
The dashboard is expected to perform a self-check of
each light (switched-on condition) of 31 seconds from
the instant the pin 10 is supplied with voltage
P !
(corresponding to the condition “key switched on” or
“contact”), without exciting the buzzer during the check. HOURS 10
From the instant the engine is started, the 6-figure-hour 1
10
meter shall run; five of the figures indicate the hours, 13 3
whereas the last figure indicates 1/10h with precision
0.1%; in the meantime the lights 2-4-12, still on after the 5 1
check, shall go off; from this moment each light is
expected to go on as soon as it receives the signal
4
indicated in the table, except for the light 4, which is 7
expected to light on with a delay of 7 seconds.
When one of the lights 1-2-3-4 goes on, the integrated 2
buzzer is expected to release an intermittent noise. A
39Ω - 7W resistance, connected in between the pin 9
and the pin 2, is integrated in the dashboard. The output OM0189
of the pin 2 is provided with a cathode of a diode
connected to the alternator by means of the wiring.

1= Engine oil temperature light.


2= Engine oil pressure light.
3= Gearbox oil temperature light.
4= Gearbox oil pressure light.
5= Low fuel warning light.
6= Spark plugs pre-heating unit or thermal starter light.
7= “Air filter clogged” light.
8= Parking brake light.
9= “Brakes oil insufficient” light.
10= Side lights / Low-beam lights (Optional equipment)
11= Direction indicators light.
Emergency indicators light.
12= “Battery recharge insufficient” light.
13= Operation hour indicator.

“ Engine oil temperature” light (1)


(Colour: covering red)
It goes on whenever the engine oil temperature reaches a high value; in such cases stop immediately
and have the engine run at idle-speed for a few minutes. As soon as the temperature decreases, the light (1)
goes off; if it does not, switch the engine off and check the oil level (after the coolant has cooled down).
Should the problem persist, check engine and cooling system for function.

Engine oil pressure light (2)


(Colour: covering red)
It goes on when the engine oil pressure is low; stop and check the oil level.
If level is correct, check the efficiency of engine and lubricating system.

10 - Ed. 05/2007 47
Gearbox oil temperature light (3)
(Colour: covering red)
It goes on whenever the gearbox oil temperature reaches a high value; stop immediately and have the engine
run at idle-speed for a few minutes. As soon as the temperature decreases, the light (3) goes off.
Should the problem persist, check transmission and cooling system for function.

Gearbox oil pressure light (4)


(Colour: covering red)
It goes on when the engine oil pressure is low; stop and check the oil level.
Should the problem persist, check the gearbox for function.

Low fuel warning light (5)


(Colour: covering red)
It goes on whenever the fuel goes down to the minimum reserve level.

Spark plugs pre-heating unit or thermal starter light (6)


(Colour: amber yellow)
It goes on before start up.

“Air filter clogged” light (7)


(Colour: covering red)
It goes on whenever the air filter is clogged. Replace the filter cartridge.

P
Parking brake light (8)
(Colour: covering red)
It goes on whenever the parking brake is engaged.

!
“Brakes oil insufficient” light (9)
(Colour: covering red)
It goes on whenever the brake liquid goes down beneath the minimum level.

Side lights / Low-beam lights (10) Optional equipment


(Colour: covering green)
It goes on only if the side and/or the low-beam lights are on.

48 Ed. 05/2007
“Direction indicators light. Emergency indicators” light (11) – Optional equipment
(Colour: covering green)
It starts blinking whenever the direction lights lever or the emergency lights switch are operated.

“Battery recharge insufficient” light (12)


(Colour: covering red)
It goes on whenever a failure occurs in the battery recharge circuit.

h h/10
Operation hour indicator (13)
It indicated the current operation hours.

10 - Ed. 05/2007 49
LOCK-UP SWITCH AND STARTING THE ENGINE

30
50

15/54

30 30 30

A 0 A 0 A 0
C 50 15/54 C 50 15/54 C 50 15/54
Key in position “0”. Key in position “C” Key in position “A”
(No circuit supplied (Contact) (Start up)
with voltage).

OMM3009

50 Ed. 05/2007
MANUAL REVERSE UNIT (Standard )

Brown / green 1. Reverse lights


B ro w n 1 . F o r w a r d s p e e d
White 1. Reverse speed
Red / yellow 1 for solenoid valves.
Yellow / green 1 • Reverse lights

Securing pin

Brown / green 1 mm2


Yellow/green 1 mm2
Red / yellow 1 mm2
SH EATH
White 1 mm2
Brown 1 mm2

F o r w a rd s p e e d

Reverse speed

NOTE: Whenever depressing the pedal, the micro-switch MB shall be actuated before
t he lev e r 1 op er at e s t h e in j ec t io n p um p B o wd en c a bl e .

10.17
10 - Ed. 05/2007 51
2
10.19 - BRAKES
The service brace is operated through the pedal. The brake force is transferred hydraulically to the pump brakes
located on the wheel hubs.
The brake is equipped with an automatic adjustment of the clearance between the brake shoe and the drum.
The parking brake is operated manually, by means of a dead point lever. The braking effort is transferred mechanically
by means of steel cables; the parking brake operates directly the shoes of the service brake.
Whenever brake oil is missing in the tank or the parking brake is engaged, the light "P" goes on in the dashboard.

Brake technical features:


Drum: ...................................... ø 310,0mm
Brake cylinder: ........................ ø 28,58mm
Brake shoes: ........................... width 60,0mm
Brake shoes: ........................... thickness: 5,67mm
Brake shoes: ........................... surface: 412,0mm2

1
2
2

21 10
28 1

27 16 19

33 5

3 36
20
22
23
22
26
6 25
32
14 31
24
4 30
13

18

29 7 9 11

52 Ed. 05/2007
Section D-D
L E F T B R A K E E X P L A N A TI O N 26
1= Support plate Section C-C
2= Parking brake Bowden cable 33 C= 25,5 ÷ 36,28 Nm Nm
S e c ti o n E - E
3= Brake cylinder 3
25 36
4= Brake shoe.
5= Brake shoe.
6= Ring.
7= Automatic clearance adjustment. 20
18 24
8= Dust cover. 30 28 C= 17,65 ÷ 26,48 Nm
32 Nm
9= Lever. 31
10= Joint.
11= Spring. A
12= Piston. Section A-A
13= Spring and cable. 35
14= Parking brake lever. D R U M r o t a t i o n i n E 1 0 C = 5 ,8 8 ÷ 8 , 8 3 N m Nm
forward speed D 1
15= Spring.
16= Release rod. 16 5
14
17= Cup.
18= Spring. 19
19= Spring. 35
20= Guide. E
21= Pin. C D C
22= Cup. 22
23= Spring. 4 Y
24= Plate.
25= Split pin. X
13
26= Washer. B B
27= Cap. 21
23 Z
28= Cylinder securing screw.
29= Spring.
30= Spring. 29
11
31= Pin.
32= Washer.
33= Nut. 35 7 9
34= Connecting stub. A
35= Apply lubricant on the marked surfaces.
36= Bush 17
• Make sure not to spread oil or grease on the shoes View Z
8 15 Section B-B
surfaces. 34 6
X - Y W h e n a s s e m b l i n g , e n s u r e t h e fo l l o w i n g c l e a r a n c e : 12
T he c l ea r anc e wit h t he dr um 3 10 s h all b e
1.4 ± 0.3 mm
while measuring the maximum distance from Z to Y. 2
C y l i n d e r D e ta i l

27

10.18
10 - Ed. 05/2007 53
2
AUTOMATIC CLEARANCE ADJUSTMENT
In case of excessive clearance between drum and shoe, the brake cylinder is actuated and “pulls” the cable B by
means of the pulley A, fixed together with the shoe, as long as the adjustment lever is put in rotation and the
adjustment device goes apart, while shoe and drum approach each other again.

A
Drum rotation in
REVERSE speed

Automatic clearance adjustment


function scheme
OMM0633

54 Ed. 05/2007
MASTER CYLINDER OR BRAKE PUMP

C= 28-35 Nm Nm

2
THIS JOINT CAN BE 1
SWIVELLED WHEN
ASSEMBLING OMM0430

Pos.. Designation
1 = Master cylinder
2 = 2-way-joint M10x1
3 = Drilled joint M12x1.5
4 = Copper gaskets.

The product can be bled under vacuum 0.5 bar.

TECHNICAL FEATURES
Mechanical stroke: ..................................... max 36mm
Bore: ............................................ ø26.99mm / ø20mm
Max operation pressure ................................... 110 bar
Brake liquid: ................................. Tutela DOT Special

10 - Ed. 05/2007 55
AIR BLEEDING FROM THE BRAKE
PIPING
Air bleeding is necessary whenever operating on the
brakes hydraulic system. Keep strictly to the following
instructions:
1
• Clean carefully the outer parts of the assemblies
especially in the areas of the bleeding screws and
the brake liquid tank cover.
• Remove the rubber cap from the bleeding screw.
• Apply a transparent rubber tube on the bleeding screw
being the opposite end of the tube plunged in a vessel
partially filled with brake liquid.
• Make sure that the feeding tank (1) of the brake is
supplied before and during bleeding.

OMM0634
Follow strictly the instructions below to bleed the brakes
oil circuit.

Low pressure bleeding


1) Open bleed screw (A) on the caliper or shoes. A
2) Push brake pedal fully.
3) Close bleed screw (A).
4) Release brake pedal.
5) Wait for 10 seconds.
6) Carry out again previous operations from point 1 to
5 until there is no more air coming out.

High pressure bleeding (to be carried out


after low pressure bleeding
1) Push brake pedal down.
2) Open bleed screw (A) keeping pedal forced down.
3) After brake fluid has come out, shut bleed screw (A).
4) Release brake pedal. OMM0635
5) Wait for 10 seconds.
6) Repeat above operations from 1 to 5 until:
- no air appears any longer from bleeder.
- simulating a braking operation there is no bounce
in the pedal and its stroke remains short.

NOTE:
To improve servicing time and ensure better results,
it is advisable to do only a high pressure bleed
(bleed pressure about 2 bar).
For procedure and tooling contact your Technical
Area Manager.

56 Ed. 05/2007
• After finishing bleeding, top up the oil level in the tank (1).

WARNING:
Do not re-use the brake liquid bled before.

IMPORTANT:
For the exhaust oil disposal we recommend to observe strictly the applicable law dispositions.

WARNING:
Perform bleeding separately for each brake assembly.

10 - Ed. 05/2007 57
Chapter 20
CHECKS AND ADJUSTMENTS

CONTENTS

20.1 - AIR BLEEDING. .................................................................................................. 2


Air bleeding for Standard masts .......................................................................... 2
Lift cylinders bleeding .......................................................................................... 2
Tilt cylinders bleeding .......................................................................................... 2
Air bleeding for Duplex and Triplex masts ........................................................... 3
Lift cylinders bleeding .......................................................................................... 3
Tilt cylinders bleeding .......................................................................................... 3
20.2 - CHECK AND ADJUSTMENT OF HYDRAULIC PRESSURES. ......................... 4
Imported salami lift distributor’s pressure check and adjustment......................... 4
Main pressure relief valve .................................................................................... 4
Auxiliary pressure relief valve .............................................................................. 5
China-made distributor – pressure check and adjustment................................... 6
Imported salami steering system – pressure check and adjustment.................... 7
20.3 - ENGINE REVS. ..................................................................................................11
20.4 - MAINTENANCE OPERATIONS. ...................................................................... 12
Brake shoes check and adjustment......................................................................12
Brake fluid replacement ..................................................................................... 13
Chains check and maintenance ......................................................................... 13
Frequency of inspections ................................................................................... 15
Greasing and lubrication .................................................................................... 15
Checking and adjusting chain tension ............................................................... 16
Checking forks wear .......................................................................................... 16
Oil replacement for hydraulic circuit ................................................................... 17
Transmission oil replacement ............................................................................ 19
Diesel and LPG models ..................................................................................... 20
Replacement of alternator belt ........................................................................... 22
Replacing engine cooling liquid ......................................................................... 23
Drainage ............................................................................................................ 23
Refill ................................................................................................................... 23
Other maintenance operations .......................................................................... 24

20 - Ed. 05/2007 1
20.1 - AIR BLEEDING

An air bleeding is mandatory after detaching the mast or after any operation in the hydraulic system demanding a
detachment of piping.

AIR BLEEDING FOR STANDARD MASTS


Lift cylinders bleeding
1 - Apply a load on the fork arms (200-300 kg are
enough).
2 - Loosen the air bleeding screw A, located in the upper
part of the lift cylinders (1/2 revolution 1 revolution is
enough; do not loosen too much).
3 - Move carefully the fork arms lift lever in the position
of raising the fork arms.
4 - Re-tighten the screw A with a torque of 9.5Nm, as
soon as no air or no oil-air mixture comes out.

Tilt cylinders bleeding A


5 - Tilt the mast forward and rearward repeatedly,
reaching the end stop bumper every time.
Bleeding occurs automatically.

After finishing, check the oil level.

OMM0630
IMPORTANT:
For the disposal of exhaust oils we recommend to
observe the applicable law dispositions.

2 Ed. 05/2007
AIR BLEEDING FOR DUPLEX AND TRIPLEX MASTS

Lift cylinders bleeding


1 - Apply a load on the fork arms (200-300 kg are
enough).
2 - Loosen the air bleeding screw A, located in the upper
part of the lateral lift cylinders and of the middle
cylinder (loosening by 1/2 revolution 1 revolution is
enough; do not loosen too much).
3 - Move carefully the fork arms lift lever in the position
of raising the fork arms. A
4 - Re-tighten the screw A with a torque of 9.5Nm, as
soon as no air or no oil-air mixture comes out.

Tilt cylinders bleeding


5 - Move in both directions the tilt control lever for the tilt
cylinders to reach their end stop bumpers several
OMM0630
times.
Bleeding occurs automatically.

After finishing, check the oil level.

IMPORTANT:
For the disposal of exhaust oils we recommend to
observe the applicable law dispositions.
A

OMM0630

OMM0631

20 - Ed. 05/2007 3
20.2 - CHECK AND ADJUSTMENT OF HYDRAULIC
PRESSURES

IMPORTED SALAMI LIFT DISTRIBUTOR’S PRESSURE CHECK AND ADJUSTMENT

Main pressure relief valve

Remove the right lateral panel as indicated in the relevant


paragraph.

• With the engine switched off, move the lift and tilt distribu-
tor control lever in both directions as to discharge pressure
out of the circuit.
• Install a manometer with minimum scale value 300 bar
onto the lift distributor at the point (1). 1
• Warm up the oil in the hydraulic system to a tempera-
ture 45 ÷ 50°C
• Press the accelerator pedal fully, and operate the lift
lever to raise the mast to its maximum height. Check
the value read by the pressure meter with that speci-
fied in the relevant tables.
• If it does not, remove the seal from the pressure relief
OMM0607
vale (by-pass), loosen the locknut (2) and tighten or 1= Cap 1/8” G
loosen the screw (3) for increasing or decreasing the
by-pass pressure value.
• After finishing the adjustment, secure the screw 83)
by tightening the locknut (3).
• Reseal the valve.

PFGP

2
3
OMM0397

M= Lift system pressure intake


PFGP= Hydraulic steering system pressure intake

2
3
OMM0415

4 Ed. 05/2007
Pressure relief valve or by-pass valve adjustment

Mast XD - XG 25 XD - XG 30

Standard 190+50 200+50


Duplex 190+50 200+50
Triplex 200+50 215+50

Auxiliary pressure relief valve


• In the (three or four-element) lift distributor, the
second and third elements are controlled through an
auxiliary pressure relief valve with fixed adjustment
at 145 bar.
• For checking such adjustment, connect a manometer
with minimum scale value 300 bar at the same point
and in the same way as illustrated for checking he
main pressure relief valve.
• Operate the users connected to the relevant element
as long as they reach their end stop bumper, and
check the pressure relief valve for correct adjustment. V
OMM0600

V= Auxiliary pressure relief valve with fixed


adjustment (145 bar) for second and third
element.

20 - Ed. 05/2007 5
CHINA-MADE DISTRIBUTOR – PRES-
SURE CHECK AND ADJUSTMENT 1

· Stop the engine, operate the lift and tilt handle on 2


the distributor in both directions, in order to release
the pressure in the oil circuit.
· Place a pressure meter of 300 bar at least on the
distributor (3).
· Heat the hydraulic oil in the hydraulic system to 45-
50℃.
· Press the accelerator pedal fully, and operate the lift
lever to raise the mast to its maximum height. Check
the value read by the pressure meter with that speci-
fied in the relevant tables.
· If the values are not identical, then release the
locking nut on the main overflow valve(1), and
tighten or release the regulating bolt, to increase or
decrease the pressure value.
· After finishing the regulation, tighten the locking nut
and secure the regulating bolt. 3
· Press the accelerator pedal fully, and operate the lift
lever to raise the mast to its maximum height. Check
the value read by the pressure meter with that speci-
fied in the relevant tables.
· If the values are not identical, then release the
locking nut on the overflow valve (2), and tighten or
release the regulating bolt, to increase or decrease
the pressure value.

Valve adjustment pressure


XD/XG-25 XD/XG-30
Distributor Mast
Lift Tilt Lift Tilt
2-element Standard 200 175 210 175
distributor
DUPLEX 200 175 210 175
3-element
distributor TRIPLEX 205 175 220 175

6 Ed. 05/2007
IMPORTED SALAMI STEERING SYSTEM – PRESSURE CHECK AND ADJUSTMENT
• Remove the right lateral panel as indicated in the
relevant paragraph.
• With the engine switched off, move the lift and tilt
distributor control lever in both directions as to
discharge pressure out of the circuit.
• Install a manometer with minimum scale value
150÷200 bar onto the lift distributor at the point (4).
• Warm up the oil in the hydraulic system to a tempera- 4
ture 45÷50 °C
• Turn the steering wheel to the left or to the right, for
the steering cylinder to reach its end stop bumper
and read the maximum pressure, which is expected
to be 120÷125 bar.
• If the pressure does not meet that value, operate on
the by-pass valve (5) of the steering distributor as
OMM0607
follows:
• Remove both lateral guards of the steering column
as indicated the relevant chapter.

OMM0608

Steering control distributor by-pass valve

5
45°±1°

OMM0417 OMM0418

V= By-pass valve
20 - Ed. 05/2007 7
• Loosen and remove the bolts (6) securing the
hydraulic steering distributor and the steering column.
• Take the steering column and the hydraulic steering
distributor apart from the holder as to obtain enough
space and get through to the pressure relief valve.

IMPORTANT: 6
6
Be careful not to deform or damage the pipes
connected to the hydraulic steering. 6
6

OMM0601

• Operate onto the valve by changing the spring pre-


loading through the setscrew (7).
Tightening the screw increases the pressure value;
loosening it decreases the pressure value.
• Recheck the pressure and its adjustment as required,
as long as you get the correct adjustment.
• Reassemble in the reversed sequence.

OMM0602

China-made EATON steering unit needs no pres-


sure adjustment.

8 Ed. 05/2007
STEERING UNIT ASSEMBLY

EXPLANATION
1= Hydraulic steering distributor
2= Steering column holder 4
3= Switch bracket
4= Hydraulic steering stub
5= Steering wheel
6= Axis of the steering column in neutral position 3
7= Switch 2

1
6
C= 3 5 ÷ 4 0 Nm Nm

Supply
7

Left

Right

Bleed
5

20.1
20 - Ed. 05/2007 1
9
CHINA-MADE
STEERING UNEATON
IT ASSESTEERING
M BL Y UNIT

SUPPORT ASSEMBLY
STEERING STUD

STEERING STUD SUPPORT ASSEMBLY

SCREW
WASHER

STEERING WHEEL ASSEMBLY

CONVERSION VALVE

Self-Loking nut HORN BUTTON


pin

WASHER

pin

SPLIT PIN

STEERING LOCKING NUT

Self-Loking nut
PIN SHIFT

PAD
LOCKING BUSHING

10 Ed. 05/20072
20.3 - ENGINE REVS

XD XD LPG LPG
2,5 t 3,0 t 2,5 t 3,0 t
Idle revs minim 1’ 850 850 850 850
Idle revs max 1’ 2820 2820 2780 2780
Revs by-pass Lift. 1’
(at. by-pass pressure) 2600 2600 2420 2420
Stall revs 1’ 1680 1680 1850 1850

20 - Ed. 05/2007 11
20.4 - MAINTENANCE OPERATIONS
BRAKE SHOES CHECK AND ADJUST-
MENT
- Slacken front wheels nuts. A

- Jack up truck resting on stable and solid.

- Remove fully all front wheel nuts.

- Ensurethat the handbrake is released and pull wheels


from axle.

- Slacken and remove dum fixing screws (A) from


hub and pull off drum.

- Check liners thickness “S” on brake shoes. If the


area most worn is equal or less than 2 mm.
replace the brake shoe. OMM3079

- For the correct replacement procedure please read


manual 604.24.175 about the transmission.

- Refit drum, fis with two screws. apply Loctite 242 and S
tighten to 8-9 Nm.

- Ensure that there is no dragging of shoes against


the drum!

- Complete by refitting wheels respecting given


torques of 400Nm for wheel nuts. S

IMPORTANT:
- For a consistent and equal braking behaviour,it
is advisable to replace the entire set of shoes
even when one only has reached the minimum
OMM3080
thickness.

12 Ed. 05/2007
BRAKE FLUID REPLACEMENT
- Apply to both bleeding screws a plastic tube.

- Position under each tube a receptacle. 1

- Remove brake fluid reservoir top (1), open the bleed


screw and let all fluid out (reservoir should be as
high as possible).

- Put new fluid into reservoir and fill it completely until


you see fluid out of the bleed screws. .

- Tighten bleed screws and bleed all air out of system


as per paragraph 10.42.

IMPORTANT:
For fluid type to be used please refer to
“Replenishment Table” on the Use and Maintenance
Manual. OMM3082

When disposing of exhausted oils, please refer to


the local regulations on the matter.

CHAINS CHECK AND MAINTENANCE


IMPORTANT:
To be carried out without fail every 3 months or as per regulations.

Chain wear shows:


1. on joints with a corresponding stretch in chain length.
2. on platelets due to continuous passing ovel pulleys or giude systems.
3. on the sides of outer platelets and on pin rebated heads for contact with pulley flanges and side guides.

1. CHAIN STRETCH MEASUREMENT


As the wear on chain wear is not likely to be uniform, measure must be taken on 10 link stretches each of which
must be suitably identified.

An initial measurement is taken and shall be the reference for all subsequent ones bearing in mind that later
measurements must be done on the same stretches.

Measurement can be taken with a sliding Vernier of sufficient length, a millimetric rule or with the chain gauge
(available from the PARTS DEPARTMENT Ref.n. 9847340).
Measurement must be done with the chain under tension (just the weight of the forks will do).

Maximum admissible stretch is 2% noting that is usually found around the pulley area when the forks carriage
weight is lifted and in travelling position.

20 - Ed. 05/2007 13
P

10 P

P = 25,4 mm OMM3091

Check carefully also the 4 anchor chains: the comb like anchors and the threaded stretchers.

Check also that the chainc do not present kinks, the the end links are not worn, that chains are tensioned equally
that the adjusters seat properly and the thread in good condition.

2. CHECKING PLATELETS PROFILE


After having identified the area where this is more likely to occur, use a Vernier to: measure the actual length
between eyes and compare it with the original sample.

These are the accepted maximum wear limits:

Type of wear Maximum difference in % between initial and measured size

One sided wear


{ (H-H1) /H } x 100 2%
Even wear
{ (H-H2) /H } x 100 3,5%
H2
H1
H

OMM3092

The high pressures applied between platelet edge and pulley may cause the shift of metal, as well as wear, on the
edge of the plateletswich can cause link seizure.
If you spot a seized link, change the chain without delay.

14 Ed. 05/2007
3. CHECKING WEAR ON THE SIDE OF CHAINS
This type of wear is caused by the incorrect interaction between chain and pulleys ansd other side guides.
The side wear on the pulleys may be caused by off centered loads or by pulleys and or misaligned anchrs.

Wear of pin heads must not endanger their position in the platelets with a possible shift sideways.

Wear on the platelet side causes its weakening.

Should you find pin heads worn by 25% or more of their


rebate or 20% wear on the side platelet change the chain
but first find out
the cause of any abnormal or premature wear.

% wera of pin rebate: 100 x u**/r

% wera of side platelet: 100 x u*/s u** u*


r s

OMM3093

Should you need to change one chain, you must also change the other one coupled to it, as well as the two
stretchers, the end pins and split pins, washers and tensioning nuts.

FREQUENCY OF INSPECTIONS
Every3 months or as per regulation of country of operation of truck you must carry out wear checks bearing in
mind that if notice unusuale wear you must increase the inspection frequency. The same applies in situations of
heavy use of the vehicle or in aggressive environments.

GREASING AND LUBRICATION


A chain and all associated sliding elements will work properly if they are kept lubricated.
Lubricants should be applied to the chains with a brush. Slacken the chains to enable lubricant penetration. It
should go between all platelets and joints to reach the wear points between holes and pins.

If the chain is contaminated by abrasive particles (i.e. sand), you should wash the chain accurately by
immersing it in paraffin or suitable solvent.

For normal applications you can use a mineral oil with viscosity ISO VG46-460 such as IDRAULICAR AP46.

If the truck works in a particularly aggressive ambients, it should be lubricated as well as with oil, with adhesive
water repellent grease.
For cold lubricant applications, use our chain spray HUGH QUALITY SYSTEM ref.n. 9844510.

20 - Ed. 05/2007 15
CHECKING AND ADJUSTING CHAIN TENSION
- Check that chains are tensioned equally.

- If necessary, screw nut (1) in to tension chain, slachen


nut to release chain.

OMM3094

CHECKING FORKS WEAR


The minimum admissible thickness is 90% of original. Use vertical section as thickness reference.

Sample section

Section to be measured

Maximum admitted wear 10%


OMM3095

Maximum flexing difference admitted between forks: 3% of their length.

Example: length cm 120 = (120 x 3/100) = 3,6 cm ISO 5057 (5.3)

Viasually checke that fork do not show cracks near the heel, un the vertical section and the hanging hooks.

16 Ed. 05/2007
OIL REPLACEMENT FOR HYDRAULIC CIRCUIT
IMPORTANT:
In all maintenance visits, switch truck off and carry out maintenance preliminary operations (see Chapter
00).

For quality and quality of lubricant, please refer to “REPLENISHMENT TABLE” on the USE and
MAINTENANCE manual.

When disposing of exhausted oils, please refer to the local regulations on the matter.

To replace oil in hydraulic circuit follow this procedure:

1. Place truck over a pit.

2. Engage hand brake and disconnect battery (or use the emergency button if fitted).

3. Bring forks to the ground.

4. Posizion a receptacle under the hydraulic oil tank.

5. Slacken and remove drain plug from tank.

6. Bring the lift control levet in “lowering” position and keep it there for a while to allow oil flow from the cylinders
to the tank.
For FULL FREE LIFT and THREE STAGE masts, position a tray under the cylinder and diconnect supply
hose at bottom of cylinder.

7. Disconnect at mast end the hose coming from the distributor.

8. Bring distributor lift lever in “lowering” position and apply compressed air to the hose.

9. Disconnect pipes between cylinders , empty them and reconnect them again.

10. Disconnect form the cylinder end all supply hoses from distributor, tilt cylinders (disconnect also from the lock
valve).

11. Bring tilt lever firts forward then backward blowing at the ame time compressed air in the hoses just removed.

12. Empty tilt cylinder using a syringe.

13. Reconnect all hoses and pipes.

14. Ripeat the same operation for side shift or similar attachment.

15. Disconnect from the pump side the output hose to the distributor (including the priority valve).

16. Blow in compressed air.

17. Discinnect intake hose from pump to tank.

18. Blow in compressed air.

19. Blow compressed air into the pump intake side.

20. Disconnect from both sides all hoses that connect power steering unit to tank and power steering unit to
priority valve, steering unit and steering cylinder, and oil tank.

20 - Ed. 05/2007 17
21. Blow in compressed air into the hoses.

22. Empty oil cylinder from oil using a syringe.

23. Reconnect al detached hoses.

24. Empty tank completely.

25. Clean metal gauze filter on the suction conduit end remove filter housing from tank placed along the return
hose.

26. Clean and dry the tank.

27. Refit the drain plug to the tank.

28. Refit oil filter housing after having replaced the cartridge.

29. Refill tank with fresh oil (please see REPLENISHMENT TABLE on the Use and Maintenance manual.

30. Carry out air bleeding as described in paragraph 20.1.

31. Carry out some testing manouvres (lift, lower, tilt both ways, side shift, steer) to send oil to all circuit, then
check oil lever and top up as indicated later.

18 Ed. 05/2007
TRANSMISSION OIL REPLACEMENT
(please refer to figures on this page and to the tables in the next pages).

A better and complete oil drainage is achieved if it is carried out when the transmission is hot. After having
brought the truck to the correct temperature, take the truck over a pit or over a lifting frame.

Remove plug (1) (power take of and transmission) and let all oil out.
Lift the dipstick to help oil outflow.
Reapply the two drain plugs fitted with new washers and tighten.
Pour fresh oil in the filler hole (2): for type and quantity please refer to the table at the end of chapter 6 of the Use
and Maintenance manual.

Adjust oil level when cold and with the truck set on an
horizontal surface. 3
- Keep the engine down to idle.
- Open engine bonnet.
- Pull out dipstick (3) and check that oil level is between
minimum (MIN) and maximum (MAX) marks.
- Should you need to top it up, unscrew cap (2) and
introduce oil of the tipe indicated in the replenishment
table, up to the correct level.

IMPORTANT:
Take great care about moving parts
while carrying out this operation.

OMM3106

OMM3107

20 - Ed. 05/2007 19
DIESEL AND LPG MODELS

OMM3084

20 Ed. 05/2007
DIESEL AND LPG MODELS
A better and complete oil drainage is achieved if it is carried out whilst oil is hot.
After having brought the oil to the correct temperature, take the truck over a pit or over a lifting frame.

Slacken and remove drain plug (1) and let oil flow out.
For a more rapid flow remove the top plug and dipstick (2).
When drainage is complete refit and tighten plug (1) with a new seal washer.
Pour fresh oil in the filler hole (2) until you get to the right level that can be read in the plug dipstick (for type of oil
please refer to the relevant the Use and Maintenance manual).
When completed, tighten plug (2).

MAX

MIN

OMM3086

20 - Ed. 05/2007 21
REPLACEMENT OF ALTERNATOR BELT
- Slecken alternator mounting bolts (1) and (2). DIESEL MODEL
- Slacken and remove cooling fan mounting screw and
remove fan.
- Slide off belt (3) off pulleys and remove.
- Fit in the new belt (3) onto the pulleys .
- Force the alternator in the direction of arrow “A” to A
tension the belt.
- Tighten bolts (1) and (2) properly.
- Check tensioning of belt (3). 1
Flexion must be 1 cm.
Pressure applied: about 10 kg.
- Position cooling fan onto flange and refit and tighten
3
screws. 2

NOTE:
An eccessive tensioning of the belt reduces
considerably the life of bearings in the water pump,
OMM3087
alternator and fan carrier.
LPG MODEL

OMM3090

22 Ed. 05/2007
REPLACING ENGINE COOLING LIQUID
3
When engine is cold follow this procedure: 5

DRAINAGE 1
- Remove external water tank (1). holding the cooling
liquid, remove it from its holding bracket (2) and empty
it completely. MAX
- Position two large trays under the front and the
central opening of the truck frame (engine pit).
- Remove plug (3) from the radiator, and detach the
lower hose (4) to drain antifreeze off.
MIN

REFILL 2
- Refit water hose from on the bottom.
- Pour in a fresh antifreeze (for percentage ratios OMM0487

of water and Paraflu see the relevant sectio on the


Use nad Maintenace manual) trough the filler hole LPG MODEL
(3) on the radiator up to the top.
- Refit external water tank (1) onto its support 3
(2);reconnect to radiator, pour in antifreeze
liquid up to the maximum level and close with the
plug.
- Let the engine run fornr about half an hour and let it
cool.
- Check the level in the external water tank and add 1
liquid if necessary from plug (5).

XD 25-30 uses oil-cooled engine, and needs no


coolant.
4
OMM3097

20 - Ed. 05/2007 23
Chapter 30
REMOVAL AND INSTALLATION OF PARTS

CONTENTS

30.1 - MAST. ................................................................................................................. 4


Detachment ......................................................................................................... 4
Re-attachment ..................................................................................................... 6

30.2 - TILT CYLINDERS. .............................................................................................. 8


Detachment ......................................................................................................... 8
Re-attachment ................................................................................................... 12

30.3 - COVERS. .......................................................................................................... 14


Detachment ....................................................................................................... 14
Re-attachment ................................................................................................... 16
Rear guard detachment ..................................................................................... 17
Rear guard.re-attachment ................................................................................. 17

30.4 - BATTERY. ........................................................................................................ 18


Detachment ....................................................................................................... 18
Re-attachment ................................................................................................... 18

30.5 - DISTRIBUTOR GUARDS. ................................................................................ 19


Detachment ....................................................................................................... 19
Re-attachment ................................................................................................... 20
Distributor footboard assembly .......................................................................... 21

30.6 - TANKS. ............................................................................................................. 22


Detachment ....................................................................................................... 22
Re-attachment ................................................................................................... 24
Guards and side covers installation sequences (Valid for pre-modification units) .. 25
Guards and side covers installation sequences (Valid for post-modification units) ....... 26
Oil strainer assembly and relevant hoses ......................................................... 27
Diesel fuel strainer assembly and relevant hoses..............................................28
LPG system supply hoses ................................................................................. 29
Bottle cradle (LPG model) ................................................................................. 30

30.7 - COUNTERWEIGHT. ......................................................................................... 31


Detachment ....................................................................................................... 31
Re-attachment ................................................................................................... 35

30.8 - AIR FILTER. ...................................................................................................... 36


Detachment ....................................................................................................... 36
Re-attachment .................................................................................................. 37
Diesel model.......................................................................................................38
LPG model......................................................................................................... 39
Cyclonic filter assembly (on request) ................................................................ 40

30 - Ed. 05/2007 1
CONTENTS

30.9 - RADIATOR. ...................................................................................................... 41


Re-attachment ................................................................................................... 44
Radiator assembly (XD 25-30 Model)................................................................ 45
Radiator assembly (LPG) ...................................................................................46
Engine / transmission assembly ........................................................................ 47

30.10 - SILENCER AND OUTLET PIPING. .................................................................. 48


Detachment (only for models) ........................................................................... 48
Detachment (only for LPG model) ..................................................................... 50
Re-attachment (for XD25/30 models) ............................................................... 51
Re-attachment (for LPG model) ........................................................................ 52

30.11 - LIFTING SYSTEM HYDRAULIC PUMP. .......................................................... 53


Imported salami pump detachment.................................................................... 53
Re-attachment ................................................................................................... 57
Imported salami pump assembly drawing......................................................... 58
China-made gear pump assembly diagram....................................................... 59
Oil pump assembly drawing............................................................................... 60

30.12 - TRANSMISSION OR DRIVE UNIT. ................................................................... 61


Detachment ....................................................................................................... 61
Drive unit disassembly ...................................................................................... 72
Drive unit assembly ........................................................................................... 73
Drive unit assembly (XD 25-30 model) ............................................................. 74
Drive unit assembly (LPG model) ...................................................................... 75
Driving unit reassembly...................................................................................... 76
Driving unit reassembly (lpg model)................................................................... 77

30.13 - ENGINE. ............................................................................................................ 78


Detachment ....................................................................................................... 78
Re-attachment ................................................................................................... 89

30.14 - REAR AXLE. ..................................................................................................... 90


Detachment ....................................................................................................... 90
Assembly ........................................................................................................... 92
Axle assembly drawing ...................................................................................... 93

30.15 - STEERING AXLE. ............................................................................................ 94


Description ........................................................................................................ 94
Detachment ....................................................................................................... 94
General fitting instructions ................................................................................. 95
Steering axle assembly drawing ........................................................................ 97

30.16 - STEER CYLINDER. .......................................................................................... 99


Detachment ....................................................................................................... 99
Re-attachment ..................................................................................................100
30.17 - REPLACING THE STEER CYLINDER GASKETS. ........................................101

30.18 - STUB AXLE. ....................................................................................................102


30.19 - WHEEL BEARINGS REPLACEMENT. ...........................................................103
30.20 - ADJUSTING THE STEERING BUMP STOPS. .............................................. 104

2 Ed. 05/2007
CONTENTS

30.21 - DETACHING RIMS AND TYRES. .................................................................. 105


Replacing tyres ................................................................................................ 105
Rims and wheels ............................................................................................. 105
Wheels detachment ......................................................................................... 106
Wheels attachment .......................................................................................... 107
Desassembling and assembling pneus from / onto split-rims ......................... 108
Pneus disassembly ......................................................................................... 108
Pneus assembly .............................................................................................. 109
Front wheel installation.....................................................................................111
Rear wheel installation..................................................................................... 112
30.22 - PROTECTIVE ROOF. ..................................................................................... 113
Braking pump assembly exploded view........................................................... 114
Hand brake assembly drawing.........................................................................115
Operator’s seat framework assembly drawing ................................................ 116
Assembly ......................................................................................................... 116
Accelerator pedal ............................................................................................ 117

30 - Ed. 05/2007 3
CAUTION
Figures given in this section are indicative only and refer to the standard Diesel
engine truck: these are likely to differ from other versions without any
consequence to the operations described.

CAUTION
Before doing any removal or installation, disconnect the battery positive cable
first.

30.1 - MAST

DETACHMENT
Put the mast in vertical position and engage the
handbrake.
Loosen and remove the socket head bolts preventing
the fork arms lateral dislodgement. Slide the fork arms
off the fork carriage.

Use a rope or other suitable means to hook the mast up


to a crane and put it under tension.

Please check the lift equipment you intend to use for


matching the load capacities required for the weights
indicated in the table below.

OMM0435

Masts weights table


Type Lift Heights Weight Type Lift Heights Weight Type Lift Heights Weight
kg kg kg
3050 530 2750 575 4025 700
S t an d ar d

2950 595 4325 750


D u p le x

Triplex

4050 630 5075 960


4450 670
5150 740

Loosen and remove the bolts securing the mast hinge


pins to the framework.

OMM0437

4 Ed. 05/2007
Make sure that the engine is switched off and move the
distributor levers in both directions in order to bleed
pressure off the hydraulic circuit. Detach the lift cylinders
inlet hoses and any side shift, attachment, etc. from the
offtake block.

OMM0436

Drive the safety spring pins out of the bolts connecting


the tilt cylinder to the mast.

OMM0438

DANGER
Do not insert your hands or fingers in between the
parts. Use suitable tools and equipment.

Use a punch driftpin properly dimensioned for driving


the pins out of the cylinders attaching points.
Raise the mast from the lower attaching points and drive
the truck rearwards to slip the mast off.

OMM0439

30 - Ed. 05/2007 5
RE-ATTACHMENT
Perform the same operations described above in the C= 250+5%
-15%
Nm

reversed sequence. Please keep to the correct wrench


setting values and observe the attaching instructions
indicated in the sketch aside.

OMM0448

When finishing, bleed the lift cylinders. Whenever


replacing the mast with a mast of another type, replace
the load capacities plate too and re-adjust the by-pass
valve.
Perform a couple of lifting and lowering operations first
in unladen and then in laden condition for detecting any
sticking or functional failure (perform any necessary
adjustment as indicated in the chapter “Masts”).

6 Ed. 05/2007
IMPORTANT:
When adjusting SX/DX/TX masts and fork carriages
of STD/SX/TX masts apply the following instructions.

SX :
• The inner mast shall be positioned as to obtain the
dimension K by inserting the shims provided, part A.
• Adjust the fork carriage by means of the adjusting
nut provided, part B, as to obtain the dimension R.

DX:
• The inner mast shall be positioned as to obtain the A
dimension K by inserting the shims provided, part A.
• Adjust the fork carriage by means of the adjusting
nut provided, part C, as to obtain the dimension R. B

TX:
• The middle mast shall be positioned as to obtain the C
dimension N by inserting the shims provided, part A.
• Adjust the inner mast by means of the adjusting bolt K
provided, part, B, as to obtain the dimension P. R
• Adjust the fork carriage by means of the adjusting
nut provided, part C, as to obtain the dimension R.

DX/STD Mast

SETTI NG VALUES
IMPORTANT:
Keep strictly to the setting values indicated:
• K = 3 0 + /- 2
• R = 3 0 + /- 2
• N= 15 +/-1
• P= 1 5 + / - 1

The securing block bolted on the roller plate of the


fork carriage may not interfere with the bump stop
located on the upper crossbar of the inner mast
(minimum clearance: 5 mm). B um p s t o p

5 mm
Inner mast
N
P
R

Fork carriage

S e cu r i n g b l o c k
TX M ast 30.1
30 - Ed. 05/2007 72
30.2 - TILT CYLINDERS

DETACHMENT
• Put the mast in vertical position.
• Engage the handbrake for securing the truck.
• Use a rope or other suitable means to hook the mast
up to a crane at the points provided and put it under
tension.

Make sure that the engine is switched off and move the
distributor levers in both directions in order to bleed
pressure off the hydraulic circuit.
OMM0435

Loosen and remove the studs securing the footboard.


Remove it.
Detach the cylinder feeding hoses.

OMM0440

Drive the safety spring pins out of the studs connecting


the cylinder to the mast.

OMM0441

8 Ed. 05/2007
DANGER
Do not insert your hands or fingers in between the
parts. Use suitable tools and equipment.
Do not stay in front of the truck. Keep beside it.

Use a punch driftpin properly dimensioned for driving


the cylinder attaching pins.
Pull the driftpin off. If necessary, fasten the front part of
the cylinder with a wire or a rope for the cylinder not to
drop down.
OMM0439

Remove the dowel securing the connection stud from


the rear attachment area to the framework.

OMM0442

30 - Ed. 05/2007 9
Remove the side covers from both sides by loosening
the relevant bolts.
(3 or 4 screws depending on versions:
3 screws for units before modification
4 screws for units after modification).

OMM3099

OMM0454

Loosen and remove the nut of the dowel securing the


operator’s seat framework to the front elastic bearings.

OMM0443

10 Ed. 05/2007
Slightly raise (4-5 cm) and carefully the front part of the
operator’s seat framework. Make sure not do damage
piping or other components.

OMM0444

DANGER
Do not insert your hands or fingers in between the
parts. Use suitable tools and equipment.
P
Use a driftpin properly dimensioned to drive off the pin
connecting the cylinder to the framework. Recover both
spacers of the ball joint.
Pull the cylinder off.

OMM0445

P= Pin

IMPORTANT:
When detaching the left cylinder it might be
necessary to remove the grease nipple for the pin
to be driven off outwards from the chassis. Make
sure not to damage the thread of the grease nipple
seat.

OMM0446

30 - Ed. 05/2007 11
RE-ATTACHMENT
Perform the same operations described above in the
reversed sequence. Make sure that the pins are facing
properly for the securing dowel to be tightened in its seat.

17
A
Tighten according to the wrench setting values indicated.

OMM0451

A= Installation dimension

1
1 2

10°

20°

OMM0612

1= Tilt cylinder joint


2= Grease nipple

12 Ed. 05/2007
Adjust angles and the check dimension “C” as indicated in the drawing.

B C= 80 Nm Nm

C
OMM0447

IMPORTANT:
For tilting angles please refer to the technical specifications. PLEASE NOTICE THAT THE REFERENCE
DIMENSION “C” MAY NEVER EXCEED 36 mm.

A=Stroke A 117,5 – For STD lift heights 3050+4050 mm and for all DX lift heights.
B=Stroke B 92,5 – For STD lift heights 4450 +5150 mm and for all TX lift heights.
C=Check dimension.

30 - Ed. 05/2007 13
30.3 - COVERS
DETACHMENT
For detaching the two upper lateral covers, loosen and
remove the front securing bolts (two per side) and the
rear bolt located inside the engine compartment.
Remove both covers.

OMM0449

For detaching the front cover, loosen and remove both


front securing bolts after disconnecting the plugs of
the sensor indicating the condition “bonnet open” and
the relevant switch.

OMM0450

The newest truck has omitted the bonnet status sensor


switch.

OMM0455

14 Ed. 05/2007
Loosen and remove from the inside the bolt securing
the front panel to the bracket of the hinged knuckle.

OMM0456

For detaching the upper cover, remove the seat and then
loosen and remove the bolts securing the cover to the
hinged knuckles.

OMM0457

30 - Ed. 05/2007 15
RE-ATTACHMENT
Perform the same operations described above in the
reversed sequence. Make sure to position the bonnet
correctly. Check the lock for proper closing before
tightening the bolts.

7 1

* 5 mm
4 2
3

* 6.4 mm

6
OMM0458

1= Upper bonnet.
2= Push button.
3= Locking rod.
4= Upper bonnet soundproofing.
5= Yoke securing the push button.
6= Upper bonnet lock.
7= Heated seat (if provided).
*= WHENEVER DIFFERENT, RESTORE THE CORRECT DIMENSION.

IMPORTANT:
• Adjust the position of the lock (6) in respect to the push button (2) as to realise the following conditions:
• Whenever the push button (2) is locked with the key, there must be a free stroke by approx. 6.5 mm.
As long as this free stroke is provided, no releasing of the lever of the lock (6) is enabled.
• Whenever the push button (2) is released, check the lock (6) for correct unlocking, after closing the
bonnet (1).

16 Ed. 05/2007
REAR GUARD DETACHMENT
Loosen and remove the four securing bolts and remove
the radiator upper guard.

OMM0459

REAR GUARD.RE-ATTACHMENT
Perform the same operations described above in the
reversed sequence.

30 - Ed. 05/2007 17
30.4 - BATTERY

DETACHMENT
Disconnect the battery terminals.
Loosen the nuts located on the tie rods for fastening the
battery.
Detach the tie rods, remove the securing angle bar and
pull off the battery.

OMM0460

RE-ATTACHMENT
Perform the same operations described above in the
reversed sequence.

18 Ed. 05/2007
30.5 - DISTRIBUTOR GUARDS

DETACHMENT
Remove the distributor levers by loosening from the
inside the securing clamps, after raising the rubber
bellows.

OMM0462

1
1

OMM0465

Loosen and remove the bolts securing the distributor


guard , as indicated by the arrow in the figure.

OMM0463

30 - Ed. 05/2007 19
RE-ATTACHMENT
Perform the same operations described above in the
reversed sequence
• Insert the levers (1) in the bellows (4).
• Insert the levers (1) in the clamps (8) and, after
adjusting their positions, adjust the bellows (4) on
the distributor vessel.
• After installing the levers, check the bonnet for
opening properly.

3
8

6
2

OMM0465

1= Levers.
2= Yoke.
3= Screw for securing the lever.
4= Protection bellows.
5= Pin.
6= Yoke clamps.
7= Tie rod with adjustment nuts.
8= Lever clamps and bushes.
9= Lever holder – distributor.

20 Ed. 05/2007
DISTRIBUTOR SUPPORT ASSEMBLY

STEP 2

STEP 1
249 mm 1
1
1

1
310 mm
405 mm

1 1

123 mm
EX PL A NA T I O N :
1= Grease all sliding surfaces with grease type “Grassofiat MR2” or equivalent.

STEP 1:
• Install bonnet holders.
• Install gas springs. STEP 2:
• Install distributor vessel holder. • Install the bonnet crossbar onto the operator’s seat framework. 30.2
30 - Ed. 05/2007 21
2
30.6 - TANKS

IMPORTANT:
In the following description the Diesel fuel tank is pictured.
Please perform the same operations for the oil tank.

For the LPG version the following operations are applicable only o the oil tank.

DETACHMENT
Loosen and remove the bolts securing the left lower side
panel (1).
Remove the left lower side panel. 1

1
OMM3064

Detach the fuel delivery / return hoses from the tank,


the harness from the level gauge and the tank fill-in hose.

OMM0466

Loosen and remove the bolts securing the tank retaining


bandages (see also picture on the next page).

OMM0467

Rear bandage

22 Ed. 05/2007
OMM0468

Front bandage

IMPORTANT:
A plug provided on the tank bottom allows emptying
the tank for handling it easier.
The same operations can be performed on the right
side where the oil tank for the hydraulic system is
located (please do not consider particulars such as
level gauge etc. which are specific for the fuel tank).

OMM0469

Release the bandages from the bottom part; remove the


bandages and the tank from its lodgement.

Loosen and remove the relevant securing bolts to remove


the lower protective metal sheets of the tanks

The cross pieces supporting the tanks are fixed to the


framework in the middle area of it; inside the engine/
transmission compartment.

OMM0470

30 - Ed. 05/2007 23
RE-ATTACHMENT
Performed the same operations illustrated for the
detachment in the reversed sequence.

Please refer to the following drawings and to the piping


connecting drawings.

OMM0470

24 Ed. 05/2007
GUARDS AND SIDE COVERS INSTALLATION SEQUENCES
Valid for pre-modification units.

1
1
View B
2 Front guards installation
1
View A
Side panel installation D

A
C

View D
Lower guard installation
1 View C
Rear guard installation
OMM0610

1= Bolts securing side covers and tank retaining bandages


2= Tank securing bandage.

30 - Ed. 05/2007 25
GUARDS AND SIDE COVERS INSTALLATION SEQUENCES
Valid for post-modification units.

1
1 View B
Application of front and rear panels
2
1
View A
Side panel installation

A
C

1 View C
Rear guard installation
OMM3112

1= Bolts securing side covers and tank retaining bandages


2= Tank securing bandage.

26 Ed. 05/2007
OIL STRAINER ASSEMBLY AND RELEVANT HOSES

1
5 6
8

3
4

OMM0611

1= Oil inlet hose.


2= Air outlet.
3= Oil filter.
4= Measuring stick.
5= Oil return hose.
6= Pump.
7= Distributor.
8= Hydraulic steering return hose.

Volume: 46 litres.

30 - Ed. 05/2007 27
螺栓: 垫圈: 电池支架组件:

DIESEL FUEL STRAINER ASSEMBLY AND RELEVANT HOSES

SCREW

WASHER

BATTERY RACK ASSEMBLY

OIL WATER SEPARATOR ASSEMBLY


COLLAR
COLLAR

DIESEL FUEL PIPE

DIESEL FUEL PIPE

OIL WATER SEPARATOR DRAIN PIPE

THE PROTECTING HOUSING


OF DIESEL FUEL PIPE

OIL TANK ASSEMBLY

COLLAR

COLLAR

28 2
Ed. 05/2007
LPG SYSTEM SUPPLY HOSES

E X P LA N A T I O N :
1= FUELOCK Filter 3 9
2= Diffuser
3= Mixer
4= Low fuel warning pressostat
5= LPG bottle hose
6= Vacuum warning hose
7= Engine water hose
8= LPG supply to mixer 8
9= Water hose to engine
10= LPG valve cut off hose
11= LPG valve cut off o cut out hose
12= LPG cut off or cut out valve 7
13= LPG reservoir
14= Flow limiting valve 6
15= Hose with one wey valve
16= External overpressure valve
17= Gas venting from safety valve
18= Internal overpressure valve
19= LPG supply hose from diffuser to mixer
4
IMPORTANTE:
Hoses layout shown is the ideal one and ensure their
correct distance from heat sources.

Pay particular attention to the route of diffuser to


engine hose and keep it away from heat sources.

When fitting is completed, che for gas leaks using


soapy water (never open flames).
6
Safety information and maintenance periods are set 3
out in the Use and Maintenance Manual.
13
19
2 1
11 5 2
10 4
18
12
14
15
12 16

1
5
17

30.5
30 - Ed. 05/2007 29
2
BOTTLE CRADLE (LPG MODEL)

30 2
Ed. 05/2007
30.7 - COUNTERWEIGHT

DETACHMENT
WARNING
The operations described in the following shall be
performed with the mast completed lowered and
tilted rearwards.
If you miss to take these precautions you might cau-
se the truck to loose stability and the truck might
tip over.

Slacken and remove the three external bolts of outer


silencer and pull this out off the counterbalance
(applicable to XD25/30 models).

OMM0472

For LPG models remove bottle and its carrier first. 6


Proceed as follows:
- Open bottle cover (1) opening toggle lock (2).
- Close bottle tap (3).
- Disconnect LPG supply hose (4) from bottle tap or
3
from safety valve. (if fitted).
- Remove bottle (5).
- Remove screws (6) and bottle carrier. 5

4
1
2

0MM3053

30 - Ed. 05/2007 31
Apply two eyebolts at the points provided on the
counterweight.

OMM0473

Disconnect the fuel line by slackening the hose tie on


manifolds inside engine housing (valid only for to
XD25/30 models).

OMM0474

Attach a rope to the counterweight and tu a crane or


suitable lifting equipment tension it.

NOTE:
Please check the lift equipment you intend to use
for matching the load capacities required for the
weights indicated in the table below.

Counterweight
Model Weight kg
XD - XG 25 1413 kg
XD - XG 30 1795 kg

OMM0479

32 Ed. 05/2007
Raise the tow hook, loosen and remove the rear bolt
securing the counterweight.

OMM0476

Loosen and remove the two bolts left inside the engine
compartment.

OMM0477

OMM0478

30 - Ed. 05/2007 33
Raise the counterweight and drive rearwards. When lif-
ting, make sure not to bump the lateral radiator bearings.

OMM0479

OMM0480

34 Ed. 05/2007
RE-ATTACHMENT
Perform the same operations described above in the C= 600+5%
-15% Nm
Nm

reversed sequence. Observe strictly the torque wrench


setting for the bolts securing the counterweight to the
framework.

Install the tow hook in the counterweight before fastening


the counterweight to the framework.

C= 600+5%
-15% Nm
Nm

OMM0481

30 - Ed. 05/2007 35
30.8 - AIR FILTER

DETACHMENT
Loosen the clamps securing the inlet and outlet couplings
and detach the couplings.

OMM0483

DIESEL AND LPG MODELS

36 Ed. 05/2007
RE-ATTACHMENT
Perform the same operations described above in the
reversed sequence.

30 - Ed. 05/2007 37
DIESEL MODEL

1= Clamp.
2= Air inlet hose to the filter .
3= Air filter support to the framework .
4= Switch “air filter clogged”.
5= Filter holder .
6= Air inlet hose.
A= Inlet.

38 Ed. 05/2007
LPG MODEL

1 = Clamp.
2 = Air inlet hose to the filter.
3 = Air Filter to mixer hose.
4 = Switch “air filter clogged”.
5 = Air filter support to the framework.
6 = Clamp.
7 = Air inlet hose.
8 = Clamp.
9 = Mixer.
A = Inlet.

30 - Ed. 05/2007 39
CYCLONIC FILTER ASSEMBLY (On request)

90°

5 2

1 2
4

OMM0590

1= Cyclonic filter assembly.


2= Nut.
3= Clamp.
4= Washer.
5= Cyclonic filter.
6= Filter fitting.

40 Ed. 05/2007
30.9 - RADIATOR
Discharge the antifreeze from the place indicated by
the arrow (only applicable to LPG model, near the
starter motor); as to XD 25-30, disconnect the oil pipe
from radiator to motor (as indicated by the arrow).

Figure 1

Remove the outer water tank from the radiator.


(LPG Model)

Figure 2
Release the hose clamp and disconnect the inlet and
outlet hose.

Figure 3
30 - Ed. 05/2007 41
Release and remove the outlet hose clamp, and move
the outlet hose to remove the radiator.

Figure 1

Remove the screw on the cooling air hood.

Figure 2

Remove the transmission oil inlet and outlet hose below


the radiator (Please refer to the figures on the following
sheet).

Figure 3

42 Ed. 05/2007
Figure 1
Remove the nut fixing the radiator to elastic support.

Figure 2
Remove the back pedal of protective roof and the plate
below, as indicated by the arrow.

Figure 3
Lift the radiator, and pull it out of the engine room.

Figure 4

30 - Ed. 05/2007 43
RE-ATTACHMENT
Perform the same operations described above in the
reversed sequence. Please refer to the drawing on next
page for torque wrench settings and installation
instructions.

44 Ed. 05/2007
RADIATOR ASSEMBLY (XD 25-30 MODEL)
Elastic support

Nut

Washer
Washer

Radiator left support assembly Self-locking nut

Screw
Screw

Washer

Washer

Screw
Radiator assembly Radiator
Washer
Nut
Fan protection support assembly

Screw
Collar

Oil pipe

Support clamp

Radiator right support assembly

Oil pipe

Oil pipe fix clamp

30 - Ed. 05/2007 45
2
RADIATOR ASSEMBLY (LPG) Cooling inlet hose
Washer Collar

Compensation box Elastic support

Collar

Collar

Screw

Washe
Inlet hose
Nut Washer

Water pipe Nut


fixing support
Radiator right
support assembly Noise suppressor unit

Screw
Radiator left
support assembly
Outlet hose
Washer

Washer Collar

Fan cowl

Oil pipe fix clamp Washer

Screw

Self-locking nut

Washer

Support

Radiator

Screw

Oil pipe Gasket

Oil pipe fitting

Screw

Screw
Support bottom
rubber washer

Oil pipe

*Ensure the proper connection between engine and transmission before assembly.

30.9
46 2
Ed. 05/2007
EN G I N E / T R AN S M I SS I O N AS SE M B L Y

E X P LA N A T I O N :
1= any shim required shall be inserted in this area.
❊= For Diesel model: L= 160 ±2 mm. Detail A
For LPG model: L = 160±1 mm.
❊❊= For Diesel model: 30 mm.
Fo r L P G m o d e l : 2 9 m m .
1
W h e n t h e d ri v e u n i t i s c o m p l e t e l y a s s e mb l e d , c h e c k t h e d i me n s i o n L
matching the due value. If not, add or remove shims (part A – item 1) a
c e nt r e e n g in e f a n a n d c o n v e y o r t o e a c h ot h e r in t h e b e s t w a y .
for
s to

30.10
30 - Ed. 05/2007 47
2
30.10 - SILENCER AND OUTLET PIPING

DETACHMENT
Loosen and remove the bolts securing the external
silencer. Remove the silencer by slipping it off through
the outlet pipe.

Only for models


XD25/30 OMM0472

Loosen and remove the four bolts securing the rear guard
to remove it.

OMM0459

Loosen and remove the four bolts (1) securing the rear
crossbeam of the radiator guards.
1
1

1
1

OMM0497

48 Ed. 05/2007
Loosen and remove the four bolts (2) securing the
silencer upper guard to remove it.
2 2

2 2

OMM0614

Loosen the hose clamp on the silencer and detach the


hose.

OMM0615

Loosen and remove the nuts securing (3) the radiator to


the elastic bearings.

OMM0616

30 - Ed. 05/2007 49
Loosen and remove the bolts (4) securing the silencer
(5) to the bearings.

4
5

OMM0500

Remove screws (6) from exhaust (this operation applies


only to) LPG modes).

Only for LPG model 0MM3066

Push the radiator forwards as to ensure enough room


for the silencer (5) to slip out of its compartment without
damaging either the radiator or the fan. 5
Swivel the silencer adequately for pulling it off.

OMM0501

50 Ed. 05/2007
RE-ATTACHMENT (FOR XD25/30 MODELS)
Perform the same operations described above in the reversed sequence.

7
4

OMM3102

EXPLANATION:
4= Securing bolts.
5= Silencer.
7= External silencer.

30 - Ed. 05/2007 51
RE-ATTACHMENT (FOR LPG MODEL)
Perform the same operations described above in the reversed sequence.

8
4

0MM3103

EXPLANATION:
4= Securing bolts.
5= Silencer.
8= External silencer.

52 Ed. 05/2007
30.11 - LIFTING SYSTEM HYDRAULIC PUMP

IMPORTED SALAMI PUMP DETACHMENT


Imported Salami pump detachment
Put steady and sturdy chocks under the truck to raise it.
Raising the front part of the truck may be enough.

OMM0502

Loosen and remove the four bolts securing the footboard.


Remove the footboard.

OMM0503

Remove the wheel.

OMM0504

30 - Ed. 05/2007 53
Loosen and remove the bolts securing the left mudguard.
Remove the mudguard.

OMM0505

Loosen and remove the bolts (1) securing the upper


(inlet) flange and remove the pipe (2). 2
1

OMM0506

Detach the hose (3) from the pump delivery pipe.

OMM0507

54 Ed. 05/2007
Use a spanner for hexagonal head socket screws with
ball-shaped end for loosening alternatively both bolts 4
(4) securing the pump (top and bottom bolt).

OMM0508

Loosen and remove the bolt (5) securing the delivery


piping support on the gearbox distributor.
Remove the pump assembly including the delivery pipe.

OMM0509

3 2

4
5

OMM0617

30 - Ed. 05/2007 55
CHINA-MADE GEAR PUMP
DETACHMENT
Unscrew the oil pipe retaining screw (1) securing radiator to gear
pump, and disconnect the oil pipe (2).
Release the fitting of oil pipe (3). 1

Release the two retaining screws (4) of the pump using a ball
hexagonal socket wrench. Remove the pump assembly.

56 Ed. 05/2007
RE-ATTACHMENT
Perform the same operations described above in the
reversed sequence. Make sure to place the O-ring
properly under the flange and tighten both securing bolts
alternatively (please refer to the drawing on next page).

30 - Ed. 05/2007 57
IMPORTED SALAMI PUMP ASSEMBLY DRAWING

E XP L AN AT I O N : Section B-B Suction Section C-C


1= Washer.
2= Washer.
3= Bolts securing the delivery flange
4= Bolts securing the suction flange.
5= Gasket.
6= Gasket.
7= Pipe.
8= Pump suction hose. 5
9= Use the same securing bolt as for the gearbox
di s tr i bu t or .
1
Suction 4 C= 4 7 Nm Nm

3 C= 2 6 Nm Nm 2

Deli very

Del ivery
7

B
C 30.11
58 2
Ed. 05/2007
CHINA-MADE GEAR PUMP ASSEMBLY DIAGRAM

Suction pipe Outlet pipe

30 - Ed. 05/2007 59
O I L P UM P AS SE M B L Y D RA W I N G
E X P LA N A T I O N : 2
1= Hydraulic system pump.
2= Bolt securing the pump.
3= Washer.
4= Pump suction. 4
B e f or e in s t a l l i n g t h e oi l p um p, gr e a s e t h e ge a r b o x
power takeoff with grease “MOLYCOTE type P40”.

30.12
60 2
Ed. 05/2007
CAUTION
The photo sequence illustrating removal of engine,
anly XD25/30 is shown.
For the LPG model, there no material differences
concerning the removal.

30.12 - TRANSMISSION OR DRIVE UNIT


DETACHMENT
WARNING
When dismounting the drive unit from the framework
and counterweight assembly, the truck stability is
not ensured (as the front part of the framework is
raised).
Remove the counterweight. If you cannot remove
the counterweight, put shims under it and hook the
front part of the framework up to a load or to a fixed
and steady attachment point.
• Remove the mast according to the instructions in the
relevant chapter. OMM0632
• Raise the truck and put sturdy and steady chocks
under it.
• Remove bonnet, lateral and front covers, rear guard
according to the instructions in the relevant
paragraph.
• Remove the tank lateral covers (lower lateral covers)
according to the instructions in the relevant
paragraph.
• Dismount the battery (as described above).
• Remove glove compartment, distributor guard and
levers.

Remove the plastic covers of the hydraulic steering


column and the dashboard plastic cover.
Remove the front plastic panel located between
framework and mast.
OMM0513

OMM0515 OMM0514

30 - Ed. 05/2007 61
Loosen and remove the bolts securing the footboard.
Remove the footboard.

OMM0503

Detach the hoses from the hydraulic steering distributor.


Mark each hose properly as to be able to reassemble
each hose in its correct position.

OMM0516

Danfoss steering gear

Detach the hoses from the lifting distributor. Mark each


hose properly as to be able to reassemble each hose in
its correct position.
Eaton steering gear

OMM0619
China-made distributor Salami distributor
62 Ed. 05/2007
Detach the crosspiece supporting the distributor from
the operator’s seat framework. Remove the distributor
and crosspiece assembly.

OMM0620

Detach both inlet hoses to the brake cylinders from the


three-way union.
Insert a plug in the three-way union for preventing the
oil from running out of the pump and the brake oil vessel.

OMM0518

Loosen and remove the bolts securing the handbrake


lever assembly.

OMM0519

30 - Ed. 05/2007 63
Put the handbrake lever assembly on the gearbox.

OMM0520

Detach the inching cable.

OMM0521

Detach the suction and delivery hoses of the lifting


hydraulic system pump.

OMM0522

64 Ed. 05/2007
Detach the gearbox oil delivery and return hoses to the
radiator.

OMM0523

OMM0524

30 - Ed. 05/2007 65
Detach all harnesses between the operator’s seat
framework and the drive unit (some of these harnesses
are pictured in the figures aside).

OMM0525

Horn

OMM0526

Gearbox pressure switch

OMM0527

Gearbox solenoid valve

OMM0621

Spark plug preheating unit

66 Ed. 05/2007
Remove the air filter, detach the holder assembly and
put aside both couplings.

OMM0482

Disconnect the gas hose from engine.

OMM0529

Engine side

OMM0614

Silencer side

30 - Ed. 05/2007 67
Remove the oil feeding pipe and oil return pipe
connecting the engine to fuel tank, as well as the oil
level switch line. (Only applicable to XD 25/30) As
to LPG model, remove the air tank and disconnect
the air feeding hose.

OMM0466

Discharge the antifreeze from the place indicated by


the arrow (only applicable to LPG model, near the
starter motor); as to XD 25-30, disconnect the oil
pipe from radiator to motor (as indicated by the
arrow).

OMM0486

Remove the retaining screw on the cooling air hood.

OMM0490

68 Ed. 05/2007
Loosen and remove the bolts securing the operator’s
seat framework to the four elastic bearings (middle bolt).

OMM0443

Use some ropes to hook the operator’s seat framework


up to a crane or a hoist (a forklift truck may be used for
this purpose as well) and raise the operator’s seat
framework carefully.
Check for interferences and any piping or harness which
might be still connected!

OMM0530

Make sure that the operator’s seat framework can be


lifted freely. Raise it completely out of the truck and put
in on sturdy and steady chocks.

OMM0531

30 - Ed. 05/2007 69
Loosen and remove the bolts securing the front wheels.
Remove the front wheels.

OMM0504

Loosen and remove the bolts securing the mudguards.


Remove the mudguards.

OMM0505

Use some ropes to hook the drive unit up to a crane or


hoist and put under tension.

OMM0532

70 Ed. 05/2007
Loosen and remove the bolts securing the engine to the
elastic bearings.

Loosen and remove the bolts securing the mounting


clamps for attaching the transmission onto the
framework.

DANGER
If the truck has the counterweight and
the rear axle and you remove the
engine, the truck will overturn
backwards. Remove counterweight
and prepare truck as indicated at the
beginning of this chapter.

OMM0622

Raise the drive unit carefully. Make sure that the drive
unit can slip freely out of the framework.
Put the drive unit on sturdy and steady chocks or
workshop stands if you intend to disassemble the unit.
Make sure that each part of the drive unit rests steadily,
even when detached from each other.

OMM3077

30 - Ed. 05/2007 71
DRIVE UNIT DISASSEMBLY
Remove the cover from the opening on the flywheel
housing.

OMM0534

Loosen and remove the four bolts securing the converter


drive flange. Apply a 24er spanner on the drive shaft
pulley (on the distributor’s side) to have the engine turn
more easily.

OMM0535

WARNING
Insert an adequate number of shims in between
engine and transmission for them to rest steadily 1
even when disassembled.

Loosen and remove the bolts (1) attaching the engine to


the gearbox housing.
Use a rope to hook the assembly (either the engine or
the gearbox) up to a crane or a hoist. Disassemble the
drive unit.

OMM0536

72 Ed. 05/2007
DRIVE UNIT ASSEMBLY

Perform the same operations described above in the reversed sequence. Keep strictly to the installation directions
as well as the torque wrench settings indicated in the following drawing.

Installation directions:
• Prior to attaching the gearbox to the engine, check the torque converter to be properly located in its seat in the
gearbox.
It this is not the case, turn the converter by hand while gently pushing it as long as it is located properly.
To check this situation see that distance “D” is:
66.5 mm per XD25-30 models;
64.5 mm for LPG models;
wich must be kept during the assembly operations that follow.
• Gently couple engine and gearbox to each other, by fastening the flywheel housing to the gearbox flange by
means of the bolts (2) to be tightened at the torque wrench setting indicated.
• Secure the converter drive plate to the engine flywheel by means of the bolts (1) to be tightened at the torque
wrench setting indicated. For tightening use the slot applied on the flywheel housing.
• Refit the locking cover “E” on the slot of the engine flywheel housing (4).

Torque wrench settings:


• The torque wrench settings indicated apply for bolts and bolt dies as originally manufactured, without any
lubricant.

30 - Ed. 05/2007 73
DRIVING UNIT ASSEMBLY (XD 25-30 MODEL)

Screw Washer

Screw

Screw

Membrane

Washer

Washer

30.13
74 2
Ed. 05/2007
DRIVING UNIT ASSEMBLY (LPG MODEL)

Engine
Screw assembly

Washer

Flywheel
housing

Screw Gearbox
converter
Gearbox converter flange
hole plate

Driving axle
Nut

Washer

Hexagon screw
Washer

Screw

Hexagon screw

Washer

30.15
30 - Ed. 05/2007 75
2
DRIVING UNIT REASSEMBLY

76 Ed. 05/20072
DRIVING UNIT REASSEMBLY (LPG MODEL)

Engine right support

THE LEFT RACK OF ENGINE

THE SHOCK ABSORBER OF ENGINE

THE SPACER SHIM OF ENGINE

30 - Ed. 05/2007 77
CAUTION
The photo sequence illustrating removal of engine, Only the Standard is shown,
there could be differences in the appearance for LPG and Heavy Duty engine
but there are differences in the operations described.

30.13 - ENGINE
DETACHMENT
WARNING
Whenever performing the following operations on
counterweight-free trucks, please make sure to lower
the mast fully down and to tilt it rearwards before
detaching the engine.
Moreover, sturdy and steady chocks shall be put
under the mast attaching points or under the outer
masts.

• Engage the handbrake to lock up the truck safely.


• Remove the engine bonnet as well as the lateral and
front covers as explained in the relevant chapter.

OMM0543

WARNING
Do not perform this operation with warm engine. Wait
as long as the liquid in the system has cooled down
before loosening the radiator and water tank (LPG
model).

Drain coolant from radiator by slackening and removing


the plug fitted to the engine block (valid only for LPG
model).

Collect the liquid (which may not be reused) by putting


two large and low-edged containers under the framework

OMM0544

OMM0545

78 Ed. 05/2007
Loosen the hose clamps to detach and remove the
cooling system couplings. (LPG model).

OMM0488

OMM0546

Loosen the bolts of *** (as indicated by the arrow).

OMM0626

30 - Ed. 05/2007 79
Release the oil cooling pipe of engine (XD 25/30 model).

80 Ed. 05/2007
Remove the distributor guards as explained in the
relevant chapter. Detach all hoses from the hydraulic
distributor. While detaching mark each hose properly
as to be able to reassemble each hose in its correct
position.

OMM0548

Loosen and remove the four bolts securing the front


footboard. Remove the footboard.

OMM0550

30 - Ed. 05/2007 81
Loosen and remove the bolts (1) securing the distributor
crossbeam and remove the distributor and crossbeam
assembly after detaching all harnesses.

OMM0620

OMM0627

Remove the cover from the opening in the flywheel


housing.

OMM0551

82 Ed. 05/2007
Slacken the four holding screws from converter drive
flange. To access all screws, rotate crankshaft with a
spanner acting on the pulley .

OMM0535

OMM0552

30 - Ed. 05/2007 83
Detach each engine-connected harness (alternator,
starter, spark plugs, etc.), accelerator pedal cable, fuel
piping.

Starter motor OMM0553

Alternator OMM0554

Glow plugs OMM0555

OMM0557 OMM0556

Fuel hoses Fuel Hoses

84 Ed. 05/2007
Unscrew the countersunk head screw (1), and discon-
nect the oil-water separator support.

Remove the air filter.

Disconnect the air outlet pipe from the engine.

30 - Ed. 05/2007 85
Loosen and remove the nuts from the bolts securing the
engine from the elastic bearings (middle bolt 1).

Re-insert the bolt from the upper side in order to retain


the engine in its position.

OMM0559

OMM3041

Use a band or a bracket to hook the engine up to the


crane by the lifting attachments provided on the engine
and put under tension (use hooks or lifting bracket).

The bracket pictured allows picking up the engine by


the truck fork arms after raising it by the crane.

OMM0561

86 Ed. 05/2007
Insert shims in between the bottom part of the gearbox
casing and the framework as to prevent the transmission
from “dropping” downwards when detached from the
engine.

Insert shims.
OMM0562

30 - Ed. 05/2007 87
It might be useful to detach the inlet and delivery hoses
of the hydraulic system pump located on the right side,
as to operate more comfortably.

OMM0563

Loosen and remove the bolts connecting engine and


gearbox. Begin with the bolts located on the lower side
operating either from the opening in the lower side of
the framework or from the upper side by using a reduced-
length (approx. 130 mm) spanner (17 mm).

OMM0564

Remove the middle bolts of the engine bearings you


have inserted before for retaining temporarily the engine.

OMM0559_1

88 Ed. 05/2007
NOTICE:
A forklift truck equipped with suitable lifting devices
(brackets and hooks) is recommended for working
and moving under the overhead guard more
comfortably and freely.

Operate the crane smoothly, thus detaching the engine


from the gearbox before raising it.
As soon as the engine is detached from the gearbox,
you can raise it. When lifting, be careful not to hurt or
damage the overhead guard.
Put aside the shims you have used to adjust the engine
bearings, making sure to mark their locations (right or
left) for reattaching them in case you do not replace the
engine.

OMM0565

RE-ATTACHMENT
Perform the same operations described above in the
reversed sequence. Apply strictly the torque wrench
settings indicated and adjust the engine bearings, if
required, by inserting shims as explained for the drive
unit (please refer to the drawing “Drive Unit Assembly”).

30 - Ed. 05/2007 89
30.14 - REAR AXLE
DETACHMENT
The pictures illustrating the operations described in the
following apply for an axle detached from a
counterweight-free truck.
The same description applies for a counterweighted
truck.

Engage the handbrake and put some chocks under the


front wheels as to prevent the truck from any
displacement.

IMPORTANT:
Lower the mast fully down and tilt it throughout
rearwards.

Loosen the bolts securing the rear wheels, staying the


rear wheels on the ground.
Put sturdy and steady chocks under the rear part of the
truck to raise it.

OMM0566

Remove the bolts securing the rear wheels.


Remove the wheels.

OMM0567

90 Ed. 05/2007
Detach the steering cylinder inlet hoses.

OMM0568

Put either a car jack or a pallet truck under the axle and
adjust it to the axle as for both surfaces to contact each
other.
Loosen and remove the bolts securing the front U-bolt
and the rear plate fastening the axle to the framework.

OMM0569

Rear plate

OMM0570

Front U-bolt

Remove plate and U-bolt, lower the pallet truck and go


rearwards for pulling the axle off the truck.

OMM0571

30 - Ed. 05/2007 91
ASSEMBLY

2 Rear side
3

4 C= 211-15%
+5%
Nm Nm

2
6

5 4 C= 211-15%
+5%
Nm Nm

Front side

OMM0578

6= Centring bushes

• Insert both rubber bumpers (2) on the axle.


NOTICE. The rubber bumpers are not symmetrically shaped: the thicker side shall be placed facing upwards.
• Insert the steering axle (1) in the framework from the lower side; raise it smoothly as long as both rubber
bumpers (2) reach their positions.
• Apply Loctite 243 on the securing bolts (4).
• Displace the plate (3) and the bracket (5) in their correct position by tightening the bolts (4).
• Tighten the bolts (4) with 211-15%
+5%
Nm.
• Screw the oil pipes on both steering cylinder joints.
• Bleed the steering system by turning the steering wheel as to perform approx. 10 complete revolutions.
• Refit the wheels and tighten the securing bolts.
• Lower the truck.
• Tighten the wheel nuts with the torque wrench setting and in the sequence indicated in the relevant paragraph.

92 Ed. 05/2007
AXLE ASSEMBLY DRAWING

6
5

3
9 4 C= 211-+155%% Nm Nm

8
7 C= 211-+155%% Nm Nm

10 1

10.5

E X P L A N A TI O N :
1= Axle.
2= Front axle bracket.
3= Rear axle bracket.
4= Bolt securing axle.
5= Elastic bumpers.
6= Centring bush.
7= Bolt securing axle.
8= When assembling check this dimension on both sides with the axle installed horizontally.
9= Forwards drive direction.
10= Axle inclination (swivelling): 3°.
• T h e t o r q u e w r e n c h s e t t i n g s i n d i c a t e d a p p l y f o r b o l t s a n d b o l t d i e s a s o ri g i n a l l y m a n u f a c t u r e d , w i t h o u t a n y l u b ri c a n t .

30.19
30 - Ed. 05/2007 93
30.15 - STEERING AXLE

DESCRIPTION

5
4

1 2 3 3 OMM0576

. Wheel hub
1=
2= Stub axle.
3= Track rod stud.
4= Knuckle.
5= Track rod or connecting rod.

OMM0577

The rear wheels are steered through a double acting hydraulic cylinder fitted to the steering axle and tilt cylinder
by means of two track rods (with fixed length). The hydraulic steering governing the oil flow to the steer cylinder
is actuated through the steering wheel. The oil is delivered through a gear pump operated through the gearbox
power takeoff.
The axle body is fitted to the framework by means of elastic bearings, allowing the axle to swivel and perform
angular movements when driving on rough terrains.
The steer cylinder is fitted to the axle body by means of guide pins and four bolts.
The track rods are equipped with two knuckles, one on each end, provided with a sealing gasket and are connected
to both the piston stem and the stub axles by means of pressed on bolts and spring pins.
The track (or connecting) rods have a fixed, so that no convergency check is needed.

DETACHMENT
For detaching the axle from the truck please refer to the instructions in the relevant paragraph.

94 Ed. 05/2007
GENERAL FITTING INSTRUCTIONS:
(Please refer to the following drawing)
• Tighten the safety nuts (4) (wheel bearing), by turning the wheel hub continuously.
• Handle the shaft radial retaining rings carefully, as to prevent damaging.
• Use the bump stop bolts for adjusting the wheel inner full bump position right and left at 82°-2°.
Warning: the wheel inner full bump position is restricted exclusively through the bump stop bolts M 12x40.

Press-on coupling strengths:


• Pin – track rod on the stub axle side: 4000-38000 N treated with Mo S 2 (molybdenum bisulfide).
• Pin – track rod on cylinder side: 5000-50000 N treated with Mo S 2 (molybdenum bisulfide).
• Stub axle pin – middle axle. 60000 N oiled.

Greasing instructions:
Grease to be used: MR2 grease for wheel bearings, shaft radial retaining rings, stub axle bearings and ball-shaped
knuckles.

Greasing before assembling:


Wheel bearings: taper roller bearings between inner ring and retainer – Spaces in between the sealing lips of each
shaft radial retaining ring =fill up with MR2 grease.
The stub axle bearings shall be greased preventively when assembling; have the stub axle is turned repeatedly
before press it on the relevant pin.

Greasing during assembly:


Wheel bearings: fill up the inner spaces of the taper roller bearing with grease MR2 as explained. After assembling
have the wheel hub turned repeatedly in both directions.
Grease all resting points. Grease is expected to come out of the stub axle and the track rods.

Greasing during operation:


Grease each knuckle point as long as some fresh grease comes out.
Grease interval: 200 h.

1= Cylinder centring bush.

2= Torque wrench setting: 210 Nm.

3= Nut securing the wheel.


Torque wrench setting: 400 Nm.

4= Nut securing the wheel hub.


Torque wrench setting: 225 Nm.
Turn the wheel hub while tightening as to reach the torque wrench setting indicated.

5= Convergency: 0 ± 1 mm.

6= The torque wrench setting indicated applies for any assembly carried out during service operations without
pre-assembling the components on the press.
Lubricate each component.
When assembling by means of a press (on the assembly line) the torque wrench setting is 185 Nm.

7= Steering angles to be obtained by means of the bump stop bolt (12) and the nut (11).

8= Lubricate during assembly.

9= Grease with grease MR2 before assembling.

10= Forwards drive direction.

11= Hexagonal nut.

30 - Ed. 05/2007 95
12= Steering angle adjust screw

13= Every 200 operation hours grease the knuckles as long as some lubricant comes out off the grease nipples.

14= Axle body.

15= Bumper.

16= Steer cylinder.

NOTE:
• Convergency: 0 +/- 1 mm.
• Stub axle and lever assembly reaction torque:
• For 2.5 t truck: min 12Nm / max. 30Nm.
• For 3.0t truck: min. 12Nm / max. 35Nm.

96 Ed. 05/2007
S T EE RI N G A XL E AS S EM B L Y D RA W I NG

6 C = 2 90 Nm Nm

13
16
A
13 8 8

8
C C

13
A 13
14 V i ew B - B
10
7 2 C= 21 0 Nm Nm
1

°
-2
°
82 15
V i e w A- A
12
11
61°

13
-2°

7 15
13

5
3 C= 40 0 Nm Nm

5+1

4 C = 22 5 Nm Nm

V i ew C - C 30.20
30 - Ed. 05/2007 97
EX PL A NA T I O N:
Section A-A 1= Grease the parts marked with grease MR2
2= Adjust steering angles with the screw specified.
3= When assembling check this dimension on both sides with the axle
A i n s t a l l e d h o ri z o n t a l l y .
1
4= No lubricant added.
5 5 5= Grease the knuckles as long as lubricant comes out from the grease
n i p p l e s e v e r y 2 0 0 o p e ra t i o n h o u r s .
AV= FORWARD drive direction.
Convergency: 0 ± 1 mm.

B B
1
5 5
A

( 82 ° -2 ° ) AV

2
2
(61
° -
2 °)

5
4 C = 21 1 + 5 % -1 5 % N m Nm

5 4 C= 21 1 + 5 % - 15 % Nm Nm

10.5 3

Section B-B
30.21
98 Ed. 05/20072
30.16 - STEER CYLINDER
NOTICE:
The following operations may be carried out without
detaching the steering axle from the truck; in this
case you are expected to operate from the bottom
side.

DETACHMENT 1
• Bring the steering wheel in the straight position. 4 2
• Raise the rear part of the truck so that the wheels
can turn freely. Lock up the truck safely (by placing
sturdy chocks under it and engaging the handbrake).
• Loosen the four bolts (3) securing the steer cylinder
(1).
• Pull the steer cylinder (1) rearwards by taking it apart
from the elastic centring bushes.
• Remove the spring pins (5) from the bolt (6).
• Place the extractor (9) on the bolt shoulder (6); put a
car jack (8) (with load capacity 6-8 t) on the extractor
bottom plate; put an expeller bolt (7) on the car jack
piston and align it to the bolt (6).
• Operate the car jack (8) and extract the bolt (6).
• Insert a screw or something similar in the hole of the 3 OMM0581

bolt you have just removed to prevent the cylinder


from dropping down.
• Remove the extractor and place it on the opposite
bolt.
• Extract the second bolt. Insert a screw or a bolt with
a diameter smaller than the bolt you have just
removed in the hole. 5
• Remove the extractor and car jack assembly.
• Detach both inlet pipes (2 and 4) from the steer 6
cylinder (1). 7
• Remove the steer cylinder (1).
8
WARNING
Do not insert your hands or fingers in between the
parts. Use suitable tools and equipment.

9
OMM0580

OMM0582

30 - Ed. 05/2007 99
RE-ATTACHMENT
4 2
• Place the steer cylinder (1) of the steering axle on
the centring bushes and secure it by tightening two 10
bolts (3) only. 11
• Insert and adjust the track rod (10) into the yoke (11)
of the steer cylinder (1).
• Drive a centring bolt through the yoke (11) and the
track rod (10) to keep the two of them aligned to each
other.
• Place the extractor and car jack assembly previously 1 6
used on the bolt seat (6).
• Insert the bolt (6) from the bottom into the yoke (11)
hole of the steer cylinder 81).
• Operate the car jack (8) and insert the bolt (6).
• Remove the car jack (8) and the centring bolt.
3 C= 210 Nm Nm
• Insert both spring pins (5) onto the bolt (6). OMM0584
• Proceed in the same way to insert the second bolt
and secure it by means of the spring pins.
• Screw and tighten the fittings of both pipes (2) and
(4) onto the nipples of the steer cylinder (1).
• Secure the steer cylinder (1) to the steering axle by
means of the four bolts (3). Tighten with 210 Nm.
• Check the steering axle for tightness.

OMM0583

OMM0582

100 Ed. 05/2007


30.17 - REPLACING THE STEER CYLINDER GASKETS

• Detach the steer cylinder as described previously, and lock it up in the bench vice.
• Pull off the stem (1) from one side as long as the maximum bump stop is reached.
• Push the pilot bushing (5) inside by 12 mm.
• Press the spring ring (9) by inserting a pindriver through a hole (3) and remove it by means of a screwdriver.
• Push the piston in the direction of the spring ring you have just removed and tap slightly (by means of a rubber
hammer) on the opposite end of the stem; pull off the pilot bushing (5).

WARNING
You can remove the piston only after loosening the fittings of the hydraulic pipes.

• Pull off the stem and piston assembly from the cylinder and remove the pilot bushing (5) from the stem.
• Remove O-rings (4), sealing ring (7), gasket (8) and pilot rings (6) from the pilot bushing.
• Insert new O-rings, new grooved ring, gasket and pilot rings making sure to match the correct positions of each
component (see detail A).
• Remove the sealing ring (2) from the piston and replace it by a new one.
• Remove the second spring ring (9) on the opposite side.
• Disassemble the pilot bushing (5) and replace the sealing elements.
• Grease slightly the pilot bushing (5) and the cylinder and insert the bushing making sure to match its correct
position (the beveling on the outer diameter shall face against the outer part of the cylinder).
• Insert the spring ring (9).
• Insert carefully the stem and piston (1) assembly in the cylinder from the opposite side; drive the stem and
piston assembly through the pilot bushing (5) as long as it reaches the bump stop. Take care not to damage the
sealing elements.
• Insert the second pilot bushing (5) greased, push it as long as the spring ring seat (9) gets free. Insert the spring
ring.

2
A
1
3

4
9

8
3
7 6

Detail A
OMM0585

30 - Ed. 05/2007 101


30.18 - STUB AXLE

1 C= 290 Nm Nm

2
3

5
6
7

8
9

10

11
OMM0586

1= Nut, torque wrench setting 290 Nm.


2= Shim.
3= Axle body.
4= Sealing ring.
5= Taper roller bearing.
6= Spindle pin.
7= Spindle.
8= Spacer.
9= Taper roller bearing.
10= Sealing ring.
11= Spacer.

102 Ed. 05/2007


30.19 - WHEEL BEARINGS REPLACEMENT
• Loosen the wheel nuts.
• Raise the rear part of the truck, put sturdy and steady chocks under it; engage the handbrake. If required, put
some chocks under the front wheels for preventing any truck displacement.
• Remove the wheel.
• Remove the grease cover (7).
• Loosen and remove the nut (6).
• Tap from the inside to the outside with a hammer while turning the hub to pull off the wheel hub (1).
• Replace the outer ring of the taper roller bearings (2) and (5) and the sealing ring on the wheel pin (3).
• Remove the taper roller bearing (3) from the stub axle (4) and replace it.
• Fill in with grease the spaces surrounding the taper roller bearings (as pictured).
• Drive the wheel hub into the stub axle and insert a new bearing (5), insert the shim (8) and the pin; tighten the
nut (6) applying a torque wrench setting of 225 Nm while turning the hub.
• Fill approximately half the cover (7) with lithium soaped grease (see Operation and maintenance) and fit the
cover on the hub tapping with the rubber hammer.

3
9
1
2 4

8
7

OMM0587

1= Wheel hub.
2= Inner taper roller bearing.
3= Shaft retaining ring.
4= Stub axle.
5= Outer taper roller bearing.
6= Crown-shaped nut
7= Grease cover.
8= Shim.
9= Elastic dowel.

30 - Ed. 05/2007 103


30.20 - ADJUSTING THE STEERING BUMP STOPS

1
2
3

OMM0588

1= Setscrew.
2= Locknut.
3= Axle body.
4= Steer cylinder.
For preventing any damage to the hydraulic steer cylinder after repairing the stub axle, a tie rod, or a steer cylinder,
the steering bump stops right and left shall be check and adjusted if required.

• Loosen the locknut (2) and let the setscrew M12x60 (1) turn by approx. 10 revolutions.
• Start the engine and steer as long as the steer cylinder has completely come out.
• Tighten the setscrew on the axle body (3) up to the end stroke stop.
• Steer the cylinder (4) to the middle position and tighten the setscrew (1) by 2-3 revolutions more, then lock the
nut (2).

IMPORTANT:
Adjust the steer bump stop on the opposite side in the same way.

104 Ed. 05/2007


30.21 - DETACHING RIMS AND TYRES
- WARNING - In case of split-rim wheels, the inadvertent detachment
of joint nuts being the wheels yet forced over the wheels
REPLACING TYRES hubs is prevented through appropriate precautions.
A periodical check of the tyres operation pressure for When handling twin-tyres loosen the securing bolts by
matching the values indicated in the Operation and a couple of rotations only, raise the wheels from the
Maintenance Manual as well as of the tread height is soil and check them for rotating without any interference
recommended for using properly and appreciating fully referable to structural decays.
the steadiness and safety features of the tyres the Prior to any further operation, deflate the pneu
forklift trucks are equipped with. completely (if you have not deflated it yet), and remove
No aqua-planing is normally expected because of the also the valve middle body as to allow an exhaustive
peculiar application conditions of both pneus and other and safer air bleeding.
tyres, in respect of the loads applied and the drive
speeds driven.
Replacing pneus and full tyres is recommended
whenever damages caused through shocks occur or
for improving safety, whenever the tread is reduced to ATTACHMENT PRECAUTIONS
a value of 1.6mm which is the minimum requirement When assembling, check the components you intend
through the Motor Vehicles Circulation on Public Roads to used for integrity and suitability, When handling rims
Code. with detachable rings, make sure that the detachable
As far as superelastic full tyres are concerned, the rings are reassembled again to the same rim which
wear grade may not exceed the line applied on the they have been previously detached from. Moreover,
tyre side being either 60J (Joule) or SAFETY LINE with the rim located horizontally, check that the rings
(depending on the suppliers). are concentric and placed properly in their seats by
inflating briefly some air (approx. 0.3-0.5 bar).
When inflating the tyre up to the final pressure required
– which may not be exceeded – provide a sturdy cage
or any safety devices as a protection against any
RIMS AND WHEELS inadvertent accident, which might occur very seldom,
but cannot be excluded.
SAFETY PRECAUTIONS WHEN HANDLING RIMS When detaching a pneu from split-rims, using a
AND WHEELS protection case is a recommended safety precaution.
There is a good reason for constant and careful checks,
DANGER
especially under heavy-duty application conditions;
The user of wheels and rims, which are significant reliability and safety margin, originally designed, might
components for the vehicle safety, is expected to be endangered through severe corrosion phenomena,
care for proper use, periodical checks and regular deformations caused through shocks, incorrect use or
maintenance. Particularly when attaching and disregarding the safety precautions.
detaching tyres some basic safety precautions
should be taken for preventing any failure or
carelessness which might cause severe injuries. DANGER
For your safety do not use wheels or securing
• Never mend or use for operation damaged or elements different from the components provided
deformed wheels. originally.
• Never mend by welding rims for any reason. Do not lubricate bolts and nuts securing wheels
• Replace failing components with components of for facilitating detaching and reattaching.
the same type with the same pattern and After each attachment check periodically the
dimensions. wheels nuts for tightening every 10 hours, as long
• Clean carefully and protect against rust each as the nuts have set and every 100 hours after the
coupling surface. settlement. It is recommended to use matched rims
and tyres (same supplier and same design) for each
DANGER
axle.
Prior to detaching a wheel from the truck, check
the pneu casing or the rim for damage. In any case
deflate the pneu completely.

30 - Ed. 05/2007 105


WHEELS DETACHMENT
• Park the truck on a plain surface and lock it up by
means of the handbrake.
• Place some wooden chocks under the wheels to keep
them in contact with the soil.
• Loosen partly the bolts or nuts respectively securing
the wheel to be replaced, being the wheel in contact
with the ground.
• Raise the truck as long as the wheel is detached from
the ground and secure the truck by adequate and
steady bearings (stands, wooden chocks, etc.).
DANGER
Handle each component carefully. Do not insert your
hands or fingers in between the parts. Wear
approved safety working clothing such as safety
glasses, gloves and shoes.
Make sure that the tyre is completed deflated.

• Remove the bolts or nuts, respectively, securing the


wheel and pull the wheel off.
When handling large dimensioned wheels use a tiller
1
truck for pulling the wheels off (see fig. 1) or a tool as
pictured in fig. 2, to be applied to a crane or hoist.

OMM0096

OMM0097

106 Ed. 05/2007


WHEELS ATTACHMENT
DANGER
Handle each component with care. Do not insert your
hands or fingers in between the parts. . Wear
approved safety working clothing such as safety
glasses, gloves and shoes.

• It is recommended to use matched rims and tyres


(same supplier and same design) for each axle.
• Use an appropriate device (tiller truck for pulling the
wheels off or tool) to raise and handle the wheel (this
precaution is not required for small dimensioned
wheels) and slip the wheel onto the hub.
• Put the wheel in such a way that any inflating valve
would face towards the outside and any space
engraved in the drum.
• Tighten the bolts or nuts, respectively, crosswise
(examples hereof are pictured in fig. 3 and 4) in three
steps.
• Tighten slightly the bolts or nuts, respectively, as long
as the wheel stays steadily on the drum.
• Tighten the bolts or nuts, respectively, up to approx.
50% of the torque wrench setting required.
3
• Lower the truck and tighten the securing bolts or nuts,
respectively, with the torque wrench setting required.
4
2 5
DANGER
When adjusting the tyre pressure stay aside from 9 7
the tyre.
10 8
• Check the inflating pressure and adjust it, if required.
6 1
3

OMM0098

2 5

6 1

OMM0099

30 - Ed. 11/2002 • Rev. 02-05/2004 107


Series 4141 - 4159 - 4257

DESASSEMBLING AND ASSEMBLING PNEUS FROM / ONTO SPLIT-RIMS

For this operation a press is required.


Check all components for integrity and conformity.

PNEUS DISASSEMBLY 3
IMPORTANT:
When detaching mark or distinguish the detachable B
rings, to make sure that they are reassembled again
3
to the same rim which they have been previously
detached from.
2
• Place under the wheel-pneu assembly the bearing 2
shaped ring (A);
• Use the press and the shaped ring (B) to push the
outer ring (2) towards outside as long as the locking
ring (3) gets free and can be pulled off.

A
OMM0103

• Place the rim on a bearing ring (F) and pull the pneu P
off the rim by means o a pressing ring (G) and the
press.

OMM0104

108 Ed. 05/2007


PNEUS REASSEMBLY
IMPORTANT:
B
Make sure that the detachable rings are reassembled
again to the same rim, which they have been øD+8
previously detached from.
Spread a water-soap solution (1:20) or some grease
specific for pneus assembly over the rim groove and the
pneu edge.
Never use lubricants.

• Force the pneu including air tube on the rim ad locate


the inflating valve in the opening provided in the rim.
• Press downwards the pneu bead.

A
OMM0105

WARNING 3
2
Do not put the ring 1 upside down when assembling.

• Put the shoulder ring (1) around the rim bead and øD+2
press it by means of the shaped ring (C) as long as a
room (“f”) can be create for lodging the outer ring 1 C
1
and the locking ring.

“f”

OMM0106

30 - Ed. 05/2007 109


• Place the outer ring (2).
• Apply a taper shaped ring (D) and force the locking 3
ring (3) over it. B
• Push the ring (3) by means of the shaped ring (B).
15°
IMPORTANT: 3
In some rims types shoulder ring (1) and outer ring
D
(2) are one piece.
2
1

OMM0107

• Use a hammer and some irons (E) for driving the


locking ring (3) in the rim groove so as to secure the B
E
outer ring (2).

3 2

OMM0108

• Inflate briefly some air (approx. 0.3÷0.5 bar) and


check that the rings are concentric and placed
properly in their seats with the rim staying horizontally.

DANGER
When adjusting the tyre pressure stay aside from
the tyre.

• As soon as the wheel is completely assembled,


proceed with inflating, provided the wheel is located
in a sturdy cage as provided through the accident
prevention rules.
• Do not exceed the maximum pressure indicated.

110 Ed. 05/2007


FRONT WHEEL INSTALLATION

6 2

5 3

C= 450 Nm Nm
0MM3056
OMM0595

30 - Ed. 05/2007 111


REAR WHEEL INSTALLATION

C= 400 Nm Nm

OMM0594

5 4

1
3

0MM3057

112 Ed. 05/2007


30.22 - Protective roof

Inching and braking panel adjustment

Inching and brake pedal setting


For adjusting the brake pedal and the inching
pedal.
1)First check if there is enough oil and no air in
the system.
2)The movability of the brake pedal and the inch-
ing pedal has to be circa 1mm before it stress.For
brake pedal adjust the Rod (R) to get the
range,For the inching pedal,adjust the bolt (B).
3)Both pedals are on the same heigth and move
down when the inching pedal got pressed.If
not,use the screw (S) to adjust the right height
and movement.But when pressing the brake
pedal only the brake pedal goes down.

30 - Ed. 05/2007 113


BRAKING PUMP ASSEMBLY EXPLODED VIEW
Washer
Braking panel assembly

Washer
Hand brake assembly

Brake oil cup

Screw
Threaded pin

Brake oil cup fixing clamp

Brake oil support

Brake return spring Brake return spring

Pipe

Pipe Pipe Inching cable

General brake
pump

Assembly step 1: Assembly step 2:


● Pedal pre-assembly ● Fitting the footboard inside the protective roof.
● Brake oil cup assembly ● Fitting the brake oil cup inside the protective roof.
● Brake pump pre-assembly ● Fitting the inching cable onto the transmission unit.
● insideprotective roof        

114 2
Ed. 05/2007
HAND BRAKE ASSEMBLY DRAWING

30 - Ed. 05/2007 115


2
OPERATOR’S SEAT FRAMEWORK ASSEMBLY DRAWING
EXPLANATION:
1= Bolt securing the elastic
bearing.
2= Nut.
3= Bottom washer.
4= Top washer.
5= Elastic bearing.
6= Front bearing bracket.
Engine supports may be bolted or welded.
7= Operator’s eat bearing framework.
8= Bolt securing the front bearing bracket.
9= Nut (for bolt no. 8).
10= Bolt.
11= Shim.

ASSEMBLY
• Pre-assemble both front bearings (5) on the bracket
(6); then install the bracket onto the framework (view
K).
• Pre-assemble both rear bumpers (5) onto the
framework (view K). Sink the cab onto the
framework; then secure the whole assembly by
inserting and tightening the four bolts (12) (view
K).
• The torque wrench settings indicated apply for bolts
and bolt dies as originally manufactured, without
any lubricant.
• After assembling the protective roof completely,
check the dimension L and insert shims, if required
(detail G).

NOTE:
Supports may be welded rather than bolted.

116 Ed. 05/2007


AC C E L E R A T O R P E D A L

Description:
A=Stroke
B=REGULATING ANGLE

30 - Ed. 05/2007 1172


Chapter 31
MASTS

CONTENTS

31.1 - MAST TYPES. ................................................................................................... 3


Simplex mast description ................................................................................... 3
Simplex hydraulic system ................................................................................... 4
Simplex hydraulic system unit ............................................................................ 5
Adjusting the Simplex load chain ....................................................................... 6
Adjustng the Simplex fork carriage assembly and mast sections ...................... 7
Simplex mast assembly ...................................................................................... 8
Duplex mast description ..................................................................................... 9
Duplex hydraulic system .................................................................................. 10
Duplex hydraulic system unit............................................................................ 11
Adjusting the Duplex load chains ..................................................................... 12
Adjusting the Duplex fork carriage assembly and mast sections ..................... 13
Duplex mast assembly ..................................................................................... 14
Triplex mast description ................................................................................... 15
Triplex hydraulic system ................................................................................... 16
Triplex hydraulic system unit ............................................................................ 17
Adjusting the Triplex load chains...................................................................... 18
Adjusting the Triplex fork carriage assembly and mast sections ..................... 19
Triplex mast assembly...................................................................................... 20

31.2 - LOAD CHAIN SECURITY. ............................................................................... 21

31.3 - FORK CARRIAGE ASSEMBLY ANTI-SLIP DEVICE. .................................... 21

31.4 - DISTRIBUTOR/TOOLS HYDRAULIC SYSTEM . ................................................ 22

31.5 - ASSEMBLING THE MAST SECTION/FORK CARRIAGE ASSEMBLY


SUPPORT ROLLERS. ..................................................................................... 24
Fork carriage assembly - Internal mast section................................................ 24
Internal mast section (intermediate mast section) - External mast section ...... 26

31.6 - CHECK. ..................................................................................................... 27


Determining the amount of radial play with a thickness gage .......................... 27

31.7 - DISASSEMBLING THE SIMPLEX CYLINDER. .............................................. 28


Assembly ..................................................................................................... 28
Disassembling the cylinder............................................................................... 28

31.8 - DISASSEMBLING THE DUPLEX SIDE CYLINDERS. ................................... 29


Reassembling the duplex side cylinders .......................................................... 29

31.9 - DISASSEMBLING THE TRIPLEX SIDE CYLINDERS. ................................... 31


Assembly .......................................................................................................... 33

31 - Ed. 05/2007 1
CONTENTS

31.10 - DUPLEX / TRIPLEX MIDDLE CYLINDER. ..................................................... 34


Disassembling the Duplex middle cylinder ....................................................... 34
Assembling the Duplex middle cylinder ............................................................ 34
Disassembling the Triplex middle cylinder ....................................................... 36
Assembling the Duplex middle cylinder ............................................................ 36

31.11 - DISASSEMBLING THE DUPLEX / TRIPLEX CYLINDER. ............................. 38

31.12 - DUPLEX / TRIPLEX STROKE END DAMPERS. ............................................ 39


Method of operation ......................................................................................... 39

31.13 - DISASSEMBLING THE FORK CARRIAGE ASSEMBLY. .............................. 40


Assembly .......................................................................................................... 40

31.14 - TILT CYLINDER. ............................................................................................. 41


Disassembly ..................................................................................................... 41
Assembly .......................................................................................................... 42

2 Ed. 05/2007
31.1 - MAST TYPES
SIMPLEX MAST DESCRIPTION
The mast is always higher than the load when lifting. 1
The mast consists of two lift cylinders and two mast
sections (fixed and movable).

The two cylinders are located inside the external mast


section profile and are supplied by a pipe that branches
from the speed reduction valve.

The two pistons are connected at the top to the


crossbeam of the internal mast section.

Supplying the cylinders, the two pistons extend and lift


the internal mast section.
1
The end of stroke stop is located inside the cylinder.

The load chains are attached at one end to the external


mast section and pass around the internal mast
section by means of load rollers. The other end of the
load chains are connected to the fork carriage assembly.

The mast thus extends by a ratio of 1:2 with respect to


the fork carriage assembly.

A lower function brake (speed reduction valve)


incorporated inside the rigid pipe limits the lowering
speed to a maximum of 0.49/0.43 meters/second.

Two safety valves incorporated inside the lift cylinders


(at the bottom) prevent the load from being lowered in OMM0647-1

an uncontrolled manner if the delivery lines break.

1= Anti-slip device.

The anti-slip device prevents the fork carriage assembly


from accidentally slipping out of the movable mast
section (see the relevant paragraph).

IMPORTANT:
Keep wear and tear to a minimum by greasing the
roller tracks as necessary with a high pressure
adhesive lubricant.

31 - Ed. 05/2007 3
SIMPLEX HYDRAULIC SYSTEM

OMM0650-1

1= Speed reduction valve.


2= Safety valve.
3= Simplex hydraulic system shut-off valve.

The hydraulic oil enters through the speed reduction valve (1), from where it flows to the two cylinders through the
pipes.

IMPORTANT:
It is not permitted to adjust or repair the valves if they malfunction, in which case they must be replaced.
Refer exclusively to the Spare Parts Catalog for the type of valve required.

4 Ed. 05/2007
SIMPLEX HYDRAULIC SYSTEM UNIT

5 6
1

2 Section A-A 3 C= 26 Nm Nm

Section B-B

4 C= 26 Nm Nm

B B

A A

7
OMM0648

1= Pressure reduction valve.


2= Straight connector.
3= Screw.
4= Screw.
5= Free flow (to distributor).
6= Controlled flow (to mast lift cylinder).
7= Side shifter hydraulic delivery system.

31 - Ed. 05/2007 5
ADJUSTING THE SIMPLEX LOAD CHAIN
Adjust the load chain evenly by means of the coupler tie
rod (1).

Never compensate for wear on the tires by adjusting


the tension of the load chains.

IMPORTANT:
Check for wear, damage, and lengthening of the load
chain in accordance with the safety requirements
and as described in the Use and Maintenance
manual. 1

OMM0339

6 Ed. 05/2007
ADJUSTNG THE SIMPLEX FORK CARRIAGE ASSEMBLY AND MAST SECTIONS

B
K
R

OMM0452_4

IMPORTANT:
Follow the instructions below when adjusting the Simplex mast sections and fork carriage assembly.

• Adjust the internal mast section by inserting shims A as necessary until the mast section reaches height K.
• Adjust the fork carriage assembly by means of the adjustment nut B until it reaches height R.
IMPORTANT:
The adjustments indicated in the figure must be strictly observed:
• K= 30 +/- 2
• R= 30 +/- 2

Make sure that the safety stop on the side of the fork carriage assembly does not touch the stroke end
stop on the upper crossbeam of the internal mast section (minimum clearance: 5 mm)

31 - Ed. 05/2007 7
SI M PL EX M A ST A SS E M BL Y A

Part
X

View A rotated 90°

R ig h t a nd le f t

KEY:
1= Plug tightened with Loctite 270.

31.1
8 2
Ed. 05/2007
DUPLEX MAST DESCRIPTION
The Duplex mast consists of three lift cylinders (two side 1
cylinders and one middle cylinder), and two mast
sections (fixed and movable).
The movable mast section never extends higher than
the raised load when lifting.

The middle cylinder performs the high free lift function


due to the telescopic effect inside the movable mast
section.

One end of the chain is fastened to the movable mast


section and is passed around the middle cylinder by
means of a roller, while the other end is fastened to the
fork carriage assembly. 1

This allows the fork carriage assembly to lift without


increasing the height of the mast.

The two side cylinders are located inside the double “T”
profile of the external (fixed) mast section.

The side cylinder piston rods are connected to the


internal (movable) mast section.

When the cylinders fill with oil, the middle cylinder piston
rod is the first to extend because it has the greatest
surface area.

The side cylinder piston rods then extend and lift the
internal mast section.

A speed reduction valve limits the lowering speed to a OMM0649-1


maximum of 0.49/0.43 meters/second.

Two safety valves incorporated inside the lift cylinders


prevent the load from being lowered too quickly and in
an uncontrolled manner if the oil delivery lines break.

1= Fork carriage assembly anti-slip device

This device prevents the fork carriage assembly from


accidentally slipping out of the movable mast section
(see the relevant paragraph for adjustment information).

IMPORTANT:
Keep wear and tear to a minimum by greasing the
roller tracks as necessary with a high pressure
adhesive lubricant.

31 - Ed. 05/2007 9
DUPLEX HYDRAULIC SYSTEM

6 3

OMM0651-1

The hydraulic oil enters through the speed reduction valve (1), from where it flows to the side cylinders through the
side pipes. On the Duplex mast, the oil flows to the middle cylinder through the side cylinders and the vertical
pipes. The middle cylinder piston rod is the first to extend because it has the greatest surface area.

If one of the pipes breaks, the safety valves located inside the cylinders prevent the load from being lowered too
quickly and in an uncontrolled manner.

1= Speed reduction valve.


2= Safety valve.
3= Safety valve.
4= Safety valve.
5= Safety valve.
6= Safety valve.

IMPORTANT:
It is not permitted to adjust or repair the valves if they malfunction, in which case they must be replaced.
Refer exclusively to the Spare Parts Catalog for the type of valve required.

10 Ed. 05/2007
DUPLEX HYDRAULIC SYSTEM UNIT

5 1 6

2 3 C= 26 Nm Nm
Section A-A

Section B-B

4 C= 26 Nm Nm

B B

A A

OMM0648

1= Speed reduction valve.


2= Straight connector.
3= Screw.
4= Screw.
5= Free flow (from the distributor).
6= Controlled flow (from the mast).
7= Side shifter hydraulic delivery system.

31 - Ed. 05/2007 11
ADJUSTING THE DUPLEX LOAD CHAINS
Adjust the load chains evenly by means of the coupler
tie rods (1).

Never compensate for wear on the tires by adjusting the


tension of the load chains.

IMPORTANT:
Check for wear, damage, and lengthening of the load
chain in accordance with the safety requirements
and as described in the Use and Maintenance
manual.

OMM0342

12 Ed. 05/2007
ADJUSTING THE DUPLEX FORK CARRIAGE ASSEMBLY AND MAST SECTIONS

K
R

OMM0452_2

IMPORTANT:
Follow the instructions below when adjusting the Duplex mast sections and fork carriage assembly.

• Adjust the internal mast section by inserting the shims A as necessary until the mast section reaches height K.
• Adjust the fork carriage assembly by means of the adjustment nut C until it reaches height R.
IMPORTANT:
The adjustments indicated in the figure must be strictly observed:
• K= 30 +/- 2
• R= 30 +/- 2

Make sure that the safety stop on the side of the fork carriage assembly does not touch the stroke end
stop on the upper crossbeam of the internal mast section (minimum clearance: 5 mm)

31 - Ed. 05/2007 13
DUPLEX MAST ASSEMBLY A

Part Y

Part X
View A rotated 90°
R ig h t a nd le f t

Part
Z

Ri g ht an d l e f t

4 C= 1 3 ± 1 , 3 N m Nm
5

KEY:
1= Tightened with Loctite 270.
Y 2= Cylindrical plug. Tightened with Loctite 270.
3= Right and left. Tightened with Loctite 243.
4= Hexagon nut. Tightened with Loctite 270.
5= Right + left. Tightened with Loctite 270.

31.2
14 2
Ed. 05/2007
TRIPLEX MAST DESCRIPTION
1
The Triplex mast consists of three lift cylinders (two side
cylinders and one middle cylinder), and three mast
sections (fixed, intermediate, and internal).
Similar to the Duplex mast, the movable mast section
never extends higher than the raised load when lifting.

The middle cylinder performs the high free lift function


due to the telescopic effect inside the internal mast
section but without exceeding the external height.

The two side cylinders are located inside the double “T”
profile of the external or fixed mast section.

The side cylinder piston rods are connected to the


intermediate mast section. 1

One end of the fork carriage assembly load chain is


fastened to the internal mast section and is passed
around the middle cylinder by means of a chain roller,
while the other end is fastened to the fork carriage
assembly.

The internal mast section load chains are fastened to


the top of the external (fixed) mast section and the bottom
of the internal (movable) mast section, and are passed
around the chain roller which is fastened to the upper
end of the intermediate mast section.

When the cylinders fill with oil, the middle cylinder piston
rod is the first to extend because it has the greatest
surface area. OMM0652-1

The two side cylinder piston rods then extend and lift
the intermediate mast section. The intermediate mast
section lifts the internal mast section by a ratio of 1:2
because it is fastened to the chain.

A speed reduction valve limits the lowering speed to a


maximum of 0.49/0.43 meters/second.

1= Fork carriage assembly anti-slip device

This device prevents the fork carriage assembly from


accidentally slipping out of the internal mast section (see
the relevant paragraph for adjustment information).

IMPORTANT:
Keep wear and tear to a minimum by greasing the
roller tracks as necessary with a high pressure
adhesive lubricant.

31 - Ed. 05/2007 15
TRIPLEX HYDRAULIC SYSTEM

OMM0653-1

The hydraulic oil enters through the speed reduction valve (1), from where it flows to the side cylinders through the
side pipes.
The hydraulic oil flows to the middle cylinder through the pipes connected to the hydraulic system unit. The middle
cylinder piston rod is the first to extend because it has the greatest surface area. As soon as it reaches the end of
its stroke, the side cylinder piston rods will extend.

If one of the pipes breaks, the safety valves located inside the cylinders prevent the load from being lowered too
quickly and in an uncontrolled manner.

1= Speed reduction valve.


2= Safety valve.
3= Safety valve.

IMPORTANT:
It is not permitted to adjust or repair the valves if they malfunction, in which case they must be replaced.
Refer exclusively to the Spare Parts Catalog for the type of valve required.

16 Ed. 05/2007
TRIPLEX HYDRAULIC SYSTEM UNIT

3 C= 26 Nm Nm

5 1 6

2 Section B-B

Section A-A

4 C= 26 Nm Nm

8
7

B B
A A

OMM0655

1= Speed reduction valve.


2= Straight connector.
3= Screw.
4= Screw.
5= Free flow (from the distributor).
6= Controlled flow (from the mast).
7= Middle cylinder hydraulic delivery system.
8= Side shifter hydraulic delivery system.

31 - Ed. 05/2007 17
ADJUSTING THE TRIPLEX LOAD CHAINS

External chains:
Adjust the load chains evenly by means of the coupler
tie rods (1).

Middle chain:
Adjust the chain by means of the coupler tie rod (2).

Never compensate for wear on the tires by adjusting


the tension of the load chains.
1
IMPORTANT:
Check for wear, damage, and lengthening of the load
chains in accordance with the safety requirements OMM0344

and as described in the Use and Maintenance


manual.

2
OMM0345

18 Ed. 05/2007
ADJUSTING THE TRIPLEX FORK CARRIAGE ASSEMBLY AND MAST SECTIONS

OMM0452_5

IMPORTANT:
Follow the instructions below when adjusting the Triplex mast sections and fork carriage assembly.

• Adjust the intermediate mast section by inserting the shims A as necessary until the mast section reaches
height N.
• Adjust the internal mast section by means of the adjustment screw B until it reaches height P.
• Adjust the fork carriage assembly by means of the adjustment nut C until it reaches height R.

IMPORTANT:
The adjustments indicated in the figure must be strictly observed:
• R= 30 +/- 2
• N= 15 +/-1
• P= 15 +/- 1

Make sure that the safety stop on the side of the fork carriage assembly does not touch the stroke end
stop on the upper crossbeam of the internal mast section (minimum clearance: 5 mm)

31 - Ed. 05/2007 19
TR IP L EX MA S T A S S E MB LY A

LEGENDA: 1
1= Push the bracket up until the last oval hole stop.
2= Tightened with Loctite 270.
3= Tightened with Loctite 243.
4= Cylindrical plug. Tightened with Loctite 270.
5= Hexagon nut. Tightened with Loctite 270.

Part X

View A rotated 90°

Part Y

Ri g ht o nl y

5 C = 13 ±1 , 3 N m Nm Z

Part Z
4

3
X

31.3
20 2
Ed. 05/2007
31.2 - LOAD CHAIN SECURITY
The middle chain on the Duplex and Triplex masts and
the external chains on the Simplex and Triplex masts
are secured with a nut and lock nut as shown in the
diagram at side.

1
2

OMM0654

1= Nut.
2= Lock nut.

31.3 - FORK CARRIAGE ASSEMBLY ANTI-SLIP DEVICE


When adjusting the load chains, make sure that when
the mast is fully extended the stroke end stop does not
2
exceed the lift cylinder stroke; in other words, the safety
stop (1) on the fork carriage assembly and the anti-slip
device (2) on the mast must not touch. 4
There must be at least 5 mm of clearance between the
safety stop (1) and the anti-slip device (2).
5 mm

IMPORTANT: 1
3
The clearance on high lift masts can be determined
quite easily by sticking a piece of Plasticine onto
OMM0452
the safety stop (1), lifting the fork carriage assembly
up to the safety stop and then measuring the 1= Safety stop.
thickness of the Plasticine with a caliper. 2= Stroke end stop (anti-slip device).
3= Fork carriage assembly.
4= Internal mast section.

31 - Ed. 05/2007 21
31.4 - DISTRIBUTOR/TOOLS HYDRAULIC SYSTEM

Throttle plate 1.5


diameter hole
Throttle plate 2.5
Side
diameter hole
shifter

Lift

Tilt

Throttle plate 1.5 Possible 4-way;


diameter hole free connectors
Throttle plate 1.5
diameter hole
OMM0705

22 Ed. 05/2007
Solution applicable for Triplex

C
S o l u t i o n ap p l i c a b l e f o r S i m p l e x / D u p l e x S o l u t i o n a p p l i c a b l e f o r S i m p l e x / D u p l e x / Tr i p l e x

C= 26 Nm Nm

From
the distributor
B S ect io n E -E

From the distributor C= 2 6 Nm Nm

T o ol s or s i d e s hi f t e r

T o o l s o r si d e
s hi f te r

Side
Side
cylinder
C entral cylinder
From the cylinder
d i s t r i bu t or Section D-D

O-Ring

E E C= 8 Nm
D D E E
Nm
Section C-C
D D

From
the distributor
Side Side
cylinder cylinder C= 8 Nm Nm

A dd i t i o n a l
tools
C= 8 Nm Nm

From the distributor A d d i t i o n al


tools

C= 8 Nm Nm

Section B-B
From the distributor

31.4
31 - Ed. 05/2007 23
2
31.5 - ASSEMBLING THE MAST SECTION/FORK
CARRIAGE ASSEMBLY SUPPORT ROLLERS

FORK CARRIAGE ASSEMBLY - INTERNAL MAST SECTION


Adjusting the radial play (Gr):

Height “A” Support Rollers Gl


Diameter rollers 1 and 2 Diameter roller 3 (refer
(refer to Spare to Spare Parts Catalog) Gr
Above Up to Parts Catalog)
- 90.3 ø 89.9 ø 89.9
90.3 90.6 ø 90.2 ø 89.9
90.6 - ø 90.5 ø 90.2

“A”
Permissible lateral play (Gl):
IMPORTANT:
Adjust the lateral play by inserting shims onto the
roller pin.

Return within the limits of permissible lateral play in terms


of thickness as necessary with support washer: 0.3 /
0.5 / 1 mm.

Support roller 1 and 2:


Min. 0 max. 0.2 at the narrowest point, otherwise max.
OMM0657-2
1.0.

24 Ed. 05/2007
Assembly instructions for the support roller safety
washer: 1
• Clean the M12 threads on the support pin and the
safety washer (4) to remove all traces of oil or grease.
Dry the parts thoroughly to remove all traces of
solvent on the threads.
• Apply Loctite 243 adhesive to the first two or three
spirals of the M12 threads on the safety washer. Do
4 C= 20 Nm Nm
not use activators!
• Screw the safety washer with a hexagon head wrench
and tighten to 20 Nm of torque.
• Wait at least 6 hours before operating the truck to
allow the adhesive to harden. 3

OMM0656-1

1= Upper rollers torque.


Tightening torque: 20 Nm; sealed with Loctite 243.
2= Support roller.
3= Support roller.
4= Safety washer.

31 - Ed. 05/2007 25
INTERNAL MAST SECTION (INTERMEDIATE MAST SECTION) -
EXTERNAL MAST SECTION
Adjusting the radial play (Gr):
Gl
Height “A” Support Rollers
Diameter roller Gr
Above Up to (refer to Spare Parts Catalog)
- 90.3 ø 89.9
90.3 90.6 ø 90.2
90.6 - ø 90.3

“A”
Permissible lateral play (Gl):
Adjustment of the play at the narrowest point 0 + 0.2,
otherwise maximum 1.0.

IMPORTANT:
Adjust the lateral play by inserting shims onto the
roller pin.

OMM0657-2

26 Ed. 05/2007
31.6 - CHECK

DETERMINING THE AMOUNT OF


RADIAL PLAY WITH A THICKNESS
GAGE
The value of 0.4 mm is a guideline for inserting a support
roller of the next size during the running-in period; in
other words, the material of the new profile will compress
at the points where the support rollers slide up and down
the track.

After the running-in period, which varies depending upon


the use of the truck, the radial play will stabilize until
there is practically no more variation.

Keep wear and tear to a minimum by cleaning the dirt


from the roller tracks and greasing them with an adhesive
lubricant.
OMM0352

The figures at right show how to determine the amount


of radial play in the fork carriage assembly support
rollers.

• Lift the fork carriage assembly.


• Insert wooden blocks under the forks.
• Lower the fork carriage assembly.

The support rollers will touch the side opposite the slide
track.

• The amount of radial play “Gr” can now be measured.

OMM0353

“Gr”

OMM0354

31 - Ed. 05/2007 27
31.7 - DISASSEMBLING THE SIMPLEX CYLINDER

• Bring the mast into the vertical position.


• Apply the hand brake.
• Extend the lift piston rod (approximately 20 cm) until
the upper fastening can be easily accessed to remove
the safety ring.
• Hook the upper crossbeam of the internal mast to a
crane with a strap or cable and keep the mast section
in this position. 2 C= 9.5Nm Nm

• Remove the safety ring from the upper fastening of 4


the piston rod.
• Completely lower the mast (the piston rods will lower
by extending from the crossbeam). Use a screwdriver
if necessary. 5
• Switch off the engine and operate the distributor in
both directions to release the pressure from the
hydraulic system.
• Unscrew the lower delivery connector from the
cylinder. 6
• Lift the cylinder from its support and remove it from 7
the mast.
8
1
ASSEMBLY
Reassemble the cylinder by following the above proce- 9
dure in reverse.

DISASSEMBLING THE CYLINDER


• Clamp the cylinder in a vise.
• Unscrew the cylinder head with a tooth wrench used
for lock nuts, heating it with a blowtorch if it does not
come off. 10
The cylinder head is sealed with Loctite 243.

1= Apply Loctite 243 and screw tightly


(threads cleaned, degreased, and dry) 11
2= Air bleed screw
3= Safety valve
4= Gasket
5= Seal
6= Cylinder head
7= O-ring
8= Piston rod
9= Cylinder
10= Rubber ring
11= Guide bushing.

After reassembling the cylinder, bleed the hydraulic


system as described in the relevant paragraph.
3 C= 20 Nm Nm
OMM0389-1

IMPORTANT:

Apply Loctite 243 around the perimeter of the threads and screw the cylinder head (6) tightly.

28 Ed. 05/2007
31.8 - DISASSEMBLING THE DUPLEX SIDE CYLINDERS

• Bring the mast into the vertical position.


• Apply the hand brake.
• Hook the upper crossbeam of the movable mast section to a crane with a strap or cable.
• Switch off the engine and operate the distributor levers in both directions to release the pressure from the
hydraulic system.
• Disconnect the middle cylinder delivery pipe from the upper rod connector and disconnect the lower side cylinder
connector.
• Remove the rubber rings fastening the piston rods to the crossbeam.
• Lift the movable mast section with the crane until the piston rods extend from the crossbeam (use a screwdriver
if necessary).
• Remove the rubber anti-vibration cover from its housing at the top of the cylinder.
• Lift and remove the cylinder from the lower support.

REASSEMBLING THE DUPLEX SIDE CYLINDERS


Reassemble the side cylinders by following the above procedure in reverse.

1= Upper rod connector (right and left sealed with Loctite 243).
2= O-ring (reinsert it with grease).
3= Cylinder head.
4= Piston.
5= Safety valve.
6= Air bleed screw.
7= Apply Loctite 243.
8= Apply Loctite 275.
9= Safety valve (right and left sealed with Loctite 270).

IMPORTANT:
Observe the warnings below when disassembling the cylinder.
Proceed as follows when reassembling the upper rod connector (1), the cylinder head (3), and the piston
(4):

• Upper rod connector (1):


Apply Loctite 243 and screw tightly.
• Cylinder head (3):
Apply Loctite 243 onto the threads and screw tightly.

After reassembling the cylinder, bleed the hydraulic system as described in the relevant paragraph.

31 - Ed. 05/2007 29
• LEFT • RIGHT

1
1

9 C= 20 Nm Nm

9 C= 20 Nm Nm

6 C= 9.5 Nm Nm 6 C= 9.5 Nm Nm

3
3

2 2

7
7

4
8 8
4

5 C= 20 Nm Nm
5 C= 20 Nm Nm

C= 35 Nm Nm
OMM0658 OMM0659-1

30 Ed. 05/2007
31.9 - DISASSEMBLING THE TRIPLEX SIDE CYLINDERS

• Apply the hand brake to block the truck.


• Operate the lift distributor until the side cylinder head
extends approximately 20 cm beyond the upper part
of the fixed mast section.
• Place solid, stable supports under the internal and
intermediate mast sections to keep them in position.

OMM0668-2

• Remove the chain anti-slip device from the side


cylinder head.
• Remove the rubber ring fastening the cylinder to the
mast section crossbeam.

OMM0669

• Operate the distributor to completely lower the mast;


the cylinder rod will extend from the crossbeam (use
a screwdriver if necessary).
• Switch off the engine and operate the distributor lever
in both directions to release the pressure from the
hydraulic system.

31 - Ed. 05/2007 31
• Place a container under the cylinder and disconnect
the cylinder delivery pipe from the bottom.

OMM0700

• Remove the anti-vibration device.

OMM0701

32 Ed. 05/2007
• Hook the cylinder to a crane with a strap or other
suitable means and lift it.

OMM3078
• Lift the cylinder to free it from the lower support, then
lower it to free it from the upper support.

ASSEMBLY

Reassemble the side cylinders by following the above


procedure in reverse.

The side cylinders of Triplex and Simplex are of the same


type. Please refer to the Simplex cylinder for disassembly.

After reassembling the cylinder, bleed the hydraulic system as described in the relevant paragraph.

31 - Ed. 05/2007 33
31.10 - DUPLEX / TRIPLEX MIDDLE CYLINDER
DISASSEMBLING THE DUPLEX MIDDLE
CYLINDER 1
4
• Apply the hand brake to block the truck.
• Operate the distributor and lift the fork carriage
assembly to access the lower part of the cylinder.
• Place a solid, stable support under the fork carriage 2
assembly and lower it onto the support.
• Switch off the engine and operate the distributor
levers in both directions to release the pressure from 5
the hydraulic system.
• Remove the safety screw from the hook fastening
the chain to the fork carriage assembly. 3 C= 9.5 Nm Nm

• Remove the chain anti-slip device from the pulley,


unhook the chain from the fork carriage assembly
7 6
and move it to the side (together with any pipes
connected to it) to free the pulley.
• Place a container under the cylinder and remove the
three screws fastening the lower part of the cylinder
to the bottom plate.
• Hook the cylinder to a crane with a strap or other
suitable means and lift it, keeping it taut.
• Remove the clamp from the cylinder and remove the
cylinder.

ASSEMBLING THE DUPLEX MIDDLE


CYLINDER
Reassemble the Duplex middle cylinder by following the
above procedure in reverse.

1= Double gasket.
2= Sealing ring.
3= Air bleed screw. A
4= Cylinder head.
5= O-ring.
6= Plunger.
7= Cylinder.
8= Piston rod piston.
9= Gasket. 9
10= Guide ring. 10
11= Safety valve.

8 C= 950+50 Nm Nm

11 C= 20 Nm Nm

OMM0392-2

34 Ed. 05/2007
IMPORTANT:
Observe the warnings below when reassembling the cylinder:

• Cylinder head (4):


Apply Loctite 243 around the perimeter of the threads and screw tightly.
• Piston (8):
Apply Loctite 275 to the entire surface of the threads (A) and tighten to 950 + 50 Nm of torque.

After reassembling the cylinder, bleed the hydraulic system as described in the relevant paragraph.

IMPORTANT:
Do not disassemble the piston rod when replacing the gasket set.

31 - Ed. 05/2007 35
DISASSEMBLING THE TRIPLEX
MIDDLE CYLINDER
• Apply the hand brake to block the truck.
• Operate the distributor and lift the fork carriage
assembly to access the lower part of the middle
cylinder.

OMM0703

• Place solid, stable supports under the internal and


intermediate mast sections and under the fork
carriage assembly.
• Operate the distributor to lower the mast sections
and fork carriage assembly onto the supports.
• Hook the fork carriage assembly to a crane with a
strap or cable so that it can be moved as necessary.
• Remove the safety screw from the hook fastening
the chain to the fork carriage assembly.
• If the chain is still taut or not loose enough, lift the
fork carriage assembly with the crane to loosen the
chain.
• Place another support under the fork carriage
assembly.
• Remove the chain anti-slip device from the middle
cylinder, free the chain from the fork carriage
assembly hook and move the chain away from the
pulley, being careful not to damage any flexible hoses
connected to the chain.
• Operate the distributor levers in both directions to
release the pressure from the hydraulic system.
• Place a container under the cylinder and remove the
three screws fastening the lower part of the cylinder
to the bottom plate.
• Hook the cylinder to a crane with a strap or other
suitable means and lift it, keep it taut.
• Remove the clamp from the cylinder and remove the
cylinder.

ASSEMBLING THE DUPLEX MIDDLE


CYLINDER
Reassemble the Triplex middle cylinder by following the
above procedure in reverse.

36 Ed. 05/2007
1= Double gasket.
2= Sealing ring. 1
4
3= Air bleed screw.
4= Cylinder head.
5= O-ring.
6= Piston rod. 2
7= Cylinder.
8= Piston rod piston.
9= Gasket.
5
10= Guide ring.
11= Safety valve.
3 C= 4 Nm Nm

7 6
IMPORTANT:
Observe the warnings below when reassembling the
cylinder:

• Cylinder head (4):


Apply Loctite 243 around the perimeter of the threads
and screw tightly.
• Piston (8):
Apply Loctite 275 to the entire surface of the threads
(A) and tighten to 950 + 50 Nm of torque.

After reassembling the cylinder, bleed the hydraulic


system as described in the relevant paragraph.

IMPORTANT:
Do not disassemble the piston rod when replacing
the gasket set.
A

9
10

8 C= 950+50 Nm Nm

11 C= 20 Nm Nm

OMM0392-2

31 - Ed. 05/2007 37
31.11 - DISASSEMBLING THE DUPLEX / TRIPLEX CYLINDER

• Clamp the cylinder in a vise in the bottom plate area 1 3 C= 4 Nm Nm


4
(12) to prevent it from becoming misshapen.
• Unscrew the cylinder head (4) with a tooth wrench,
heating it with a blowtorch if it is difficult to remove.
• Remove the piston rod (6) from the cylinder. 2
• BClamp the piston rod in a vise using protective jaws
and unscrew the pulley support fork for the chain.
• The fork is sealed with Loctite 270.
5
• Remove the cylinder head (4) from the piston rod
(6).

1= Double gasket. 7 6
2= Sealing ring.
3= Air bleed screw.
4= Cylinder head.
5= O-ring.
6= Piston rod.
7= Cylinder.
8= Piston rod piston.
9= Gasket.
10= Guide ring.
11= Safety valve.
12= Bottom plate.
A= Apply Loctite 275.

The middle cylinder is equipped with a stroke end


damper (holes B and C).

Observe the warnings on the previous pages when


reassembling the cylinders. B A

9
10

12

8 C= 950+50 Nm Nm

11 C= 20 Nm Nm

OMM0392-3

38 Ed. 05/2007
31.12 - DUPLEX / TRIPLEX STROKE END DAMPERS
The purpose of the stroke end dampers is to hydraulically brake the side cylinder piston rod just before it reaches
the end of its stroke as the mast is being lowered and at the moment of transition from the side cylinder stroke to
the middle cylinder stroke.This prevents metal from bumping into metal.

METHOD OF OPERATION
When the cylinder is supplied with oil under pressure during the lifting process, the bushing (2) is pushed by the
elastic force of the compression spring (4) toward the bottom plate of the cylinder until the rubber ring (5) touches
it. The oil under pressure flows through the hole (3) from chamber A to chamber B until the pressure equalizes.
Before the piston rod reaches the end of its stroke during the lowering process, the bushing (2) will touch the
bottom plate of the cylinder.
The bushing (2) is pushed toward the piston rod while the oil under pressure flows through the hole (3) from
chamber B to chamber A. This change in pressure causes the mast to brake hydraulically as it is being lowered.

1 2 5 6
3

A B

4
OMM0660

1= Piston rod piston.


2= Bushing.
3= Throttle hole.
4= Compression spring.
5= Rubber ring.
6= Piston rod.

31 - Ed. 05/2007 39
31.13 - DISASSEMBLING THE FORK CARRIAGE ASSEMBLY

• Apply the hand brake to block the truck.


• Bring the mast into the vertical position.
• Disconnect the pipes from the side shifter or other
tools if any.
• Disassemble the forks or other tools if any. The fork
carriage assembly will remain in the vertical position
if the forks are not removed.
• Lift the fork carriage assembly slightly and place it
on a solid, stable support.
• Completely lower the internal mast section using the
hydraulic system.
• Unhook the load chains from the fork carriage
assembly.
• Remove the fork carriage assembly anti-slip device
from the mast section.
• Lift the mast section to free the fork carriage 2
assembly.
IMPORTANT:
Be careful during this operation because the 1
chain is loose.

OMM0661-1

Adjusting the support rollers:


• See the functional unit in the relevant paragraph.

Adjusting the fork carriage assembly anti-slip device:


• See the functional unit in the relevant paragraph.

1= Safety screw to prevent the forks from slipping out.


2= Safety screw to prevent the end shackle of the load
chain from becoming loose.

ASSEMBLY
Reassemble the fork carriage assembly by following the
above procedure in reverse.

40 Ed. 05/2007
31.14 - TILT CYLINDER

DISASSEMBLY
Clamp the cylinder in a vise in the bottom plate area.
Unscrew the threaded connector on the cylinder head
side (the threaded connector protrudes into the cylinder
chamber).
Remove the protective cover (13).
Lightly push the cylinder head back (9).
With the aid of a pin driver, push the rubber ring (11)
through the hole in the cylinder rod and lift it out with a
screwdriver (see figure A).
OMM0363
Pulling firmly on the piston rod, remove the cylinder head
from the cylinder. Fig. A

IMPORTANT:
When disassembling the piston rod, use protective
jaws to clamp it in the vise.

A/B= Apply Loctite 270.


1= Piston lock nut (apply Loctite 270).
2= Piston lock bushing (apply Loctite 270).
3= Piston guide ring.
4= Piston seal.
5= Piston.
6= Piston rod.
7= Seeger ring.
8= Sealing ring.
9= Cylinder head.
10= O-ring.
11= Rubber ring.
12= Oil seal.
13= Protective cover
C= Stroke 117.5 For Simplex height: 3050 - 4050 mm;
For Duplex height: 2750-2950 mm;
C1= Stroke 92.5 For Simplex height: 4450 - 5150 mm;
For Triplex height: 4025-5075 mm.
L= Distance between the two pins.

1 C= 450±25 Nm Nm
C C= 80 Nm Nm
5 7
C1 8 9
3 A
12

B 4 6 13
10
11
X
L

2 C= 450±25 Nm Nm
OMM0662

31 - Ed. 05/2007 41
ASSEMBLY
Check the parts for signs of wear. The piston (5) is
sealed onto the piston rod (6) with Loctite 270 applied
to the surface A.
The hexagon nut (1), or in some cases the spacer
bushing (2), is sealed with Loctite 270 applied to the
threads B.

When assembling the piston guide ring, the seals, and


the gasket set for the cylinder head, make sure that the
cavity on the cylinder head faces the threaded connector
hole when inserting the cylinder head in the cylinder.

Check that height X = 36 mm during assembly.

Before assembling the bolts for the tilt cylinder, grease


the holes that will house the bolts.

X
IMPORTANT:
When mounting the cylinders onto the truck, make
sure that the stroke end and tilt angles correspond
to the values in the Specifications table (see chapter
10), and that height X does not exceed 36 mm.

OMM0663-1

42 Ed. 05/2007
Chapter 32
TECHNICAL OPERATING DATA

CONTENTS
SAFETY RULES v
32.1- TECHNICAL DATA - TRANSMISSION TXL 30/ST 1
Transmission TXL 30/ST 1
Circuitry 2
Kinematic diagram of the transmission 2
General description 3
TXL 30/ST General views 5
TXL 30 - TXL 30/ST General section 7
32.2- TRANSMISSION HYDRAULIC SYSTEM - SUPERMODULATING DISTRIBUTOR 9
Hydraulic diagram - Supermodulating Distributor 10
SCHEME A of hydraulic diagram - Gear in neutral position - Supermodulating Distrib. 11
SCHEME B of hydraulic diagram - Reverse gear, Started lift truck - Supermod. Distrib. 12
SCHEME C of hydraulic diagram - Inching Reverse gear - Supermodulating Distrib. 13
32.3- DISASSEMBLING AND RE-ASSEMBLING OF TRANSMISSION 14
General instructions 14
Storage and service instructions 15
Specific tools 16
Disassembling and assembling transmission 19
Converter case overhauling 21
Dismantling andre-assembling of Supermodulating Distributor 24
Dismantling andre-assembling Wheel hubs - Brakes (1st Version) 38
Shoes replacement 39
Shoes setting procedure 44
Brakes disassembly 46
Wheel re-assembling - (1st Version) 48
Brake reassembly 49
Wheel hubs reassembling - Bearings adjustment specifications 50
Dismantling and re-assembling Wheel hubs - Brakes (2nd Version) 52
Wheel hubs reassembling 55
Bearings adjustment specifications 56
Dismantle transmission 58
Oil pump and transmission cover overhaul 59
Clutches overhauling 63
Differential overhauling 71
Differential reassembly and bevel gear set positioning with relevant adjustment 77
Transmission reassembly 78
Bevel pinion-and-ring gear set inspection 83
Control inching - assy 88

32 - Ed. 05/2007 iii


CONTENTS

32.4- OIL SPECIFICATIONS 89


DATA FOR COUPLING TO ENGINE - Assembling instructions 99
Engine with P. T. O. coupling 90
Engine gearbox coupling check-up 92
TECHNICAL DATA - Supermodulating Distributor pressure measurement 93
32.5- RUNNING-IN 94
PERIODIC SERVICING 94
32.6- TROUBLE SHOOTING PROCEDURE 95
A- General information 95
B- Problems hints 95
C- Diagnosis 95
Common running faults in all gears 96
Running faults with gears engaged 97
Further problems 97
Fault finding in bad working in idle 97
Transmission overheating 98
32.7- SPECIFIC TOOLS - DRAWINGS 99

iiii Ed. 05/2007


! WATCH FOR THIS SIGN !
This sign identify important messages devoted to your safety.
Read carefully safety rules reported here and follow with the greatest care all recommended sugge -
stion to avoid potential dangers and protect your health and personal safety.

AVOID CAUSALITIES

Most of all injuries and accidents that are encountered in workshops are caused by disre-
garding some simple and basic caution and safety rule.
For this reason most of these events can be avoided. To anticipate possible causes will suffice and
acting accordingly with proper care and caution.
Each kind of operating machine, even if correctly planned and assembled, cannot be absolutely safe.
A cautious and careful operator is the best warrant against injuries.
Following scrupulously safety rule will be sufficient to prevent many dangerous injuries.

DANGER! Don’t clean, lubricate or service with engine running.

SAFETY RULES
GENERAL

! Follow strictly directions reported for servicing and repair operations.

Don’t wear rings, wrist watches, loose clothes, i.e.: neckties, torn clothing, scarves, unbuttoned
! jackets or overall with open zip that could be entangled in moving parts.
It is recommended use of proper accident preventing clothing, i.e.: anti-slip shoes, gloves, gog -
gles helmets, etc.

Don’t start any servicing operation on machine with anyone on driver seat, except for authorized
! operator that cooperate for the work to be done.

Don’t operate machine or use relevant equipment from position other than driver’s seat.
!
! Don’t service machine with engine running, if not specified by repair instructions.

Stop engine and make sure there is no pressure when disconnecting piping, caps, covers,
! valves, etc.

! All servicing operations must be performed with best attention and car e.

Disconnect batteries and mark all controls to point out that servicing operations are on course.
! Block machine, all equipment must be lifted up, and mechanically secured accordingly, with the
appropriate device.

Brakes are inoperative when hand released for servicing operations: in such a condition machine
! control should be provided by proper blocks or similar equipment.

Should heavy components be displaced or moved, use proper hoist or similar equipment.
!

32 - Ed. 05/2007 V
! Care for people near operation areas.

! Never pour gasoline or diesel fuel in open, large and low vessels.

Never use gasoline, diesel fuel or other inflammable fluids as detergent. Use only commer-
! cial non toxic, uninflammable cleaning compounds.

! When using compressed air for cleaning purposes wear goggles with side shields.

! Pressure must be limited to 2.1 bar max., according current safety rules.

! Never use free flame for illumination when operations are devoted to repair or locate leaks.

Caution when repair shall be carried out working under machine, wear safety equipment:
! helmets, goggles and safety shoes.

Area where servicing operations are carried out must be always kept CLEAN and DRY.
! Clean and dry immediately any oil or water puddle.

In case of problem, towing of vehicle is only allowed for a distance of less than 2 km with
! maximum towing speed of 10 km/h. It is not possible to start the engine through towing
the vehicle, this can cause damage to the transmission.

VI Ed. 05/2007
32.1 - TECHNICAL DATA

Transmission TXL 30/ST


Powershift transmission clutches: operational pressure min. 8.5 bar, max 9.5 bar
Converter: ■ input pressure min. 4 bar, max. 5 bar
■ output pressure min. 2 bar, max. 3 bar

Lubrication: pressure 0.8 - 1 bar


Note:the above mentioned data refer to an operative temperature of 100°C and a engine speed of about 2000 r.p.m.
Temperature: ■ normal operation: 80 - 100°C
■ peak: 120°C

Oil type, quality and quantity: see page 94


Oil filter: ■ pump mesh intake filter, filtering capacity 25 µm

Electrical installation: ■ voltage: 12 V d.c. (24 V d.c.)


■ power: 26 W

32 - Ed. 05/2007 1
Circuitry

Supermodulating distributor 2

1
+ -

Forward Clutch Reverse Clutch

1 - Commutator
3 3
2 - Fuse
3 - Electric Bulb
4 - Valves body
5 - Solenoid valve
Voltage 12/24 V CC/DC
Power 26 W

5 Forward Clutch

Reverse Clutch

Kinematic diagram of the transmission

Power take off

Brake

Input

Pump

2 Ed. 05/2007
General description
The transmission is equipped with a single-stage converter with free wheel. Thus a high efficiency over
the whole range of operation is achieved. It has two hydraulic clutches (one for Forward Gear and
one for Reverse Gear) with multiple wet disks, while the constant mesh gears have the same ratio in
Forward and Reverse Gear. The selection of direction is effected by hydraulic selectors, which are
controlled electrically.

Connection engine - converter


The converter is connected to the engine flywheel via flexible drive plate (see page 96 ).

Torque converter
The single-stage converter has been designed to obtain maximum flexibility when being connected
to different engines with different performances. It is able to transmit considerable torque and gua -
rantees maximum reliability. The converter-pump, integral with the converter housing, rotates gene -
rating sufficient fluid flow inside the converter to drive the turbine and transmit drive to the transmis -
sion gears as shown in the diagrams

Converter schemas - TXL 30/ST

Forward Gear Reverse Gear

32 - Ed. 05/2007 3
Operation
1) Gear shifting: an electrically actuated solenoid controls the corresponding valve for releasing oil pressure
on the clutch piston, while an valve regulate the pressure increase to the clutch gradually, allowing
direction changes and soft gear shifts.
2) Inching control: the Inching valve, which is actuated mechanically, allows truck movement at a very low
speed with constant speed of the engine. Inching control works on drive off.
3) Capacity: the dynamic torque transmissible by the clutches is higher than the transmission input torque
after the converter. Thus a long service life of the clutches is guaranteed.

Clutches
These are hydraulically operated. The drive is transmitted via force-lubricated, force-cooled plates (12
active friction surfaces). In addition to high static and dynamic transmissible torque capacity, they also have
a high kinetic energy absorption capacity during gearchanges. Clutch engagement is through piston displaced
axially under fluid pressure. A spring pushes the piston back and the plates are then released.

Power take-off
It is driven by the thermic motor and by a silent chain. The rotating direction as well as the speed corresponds
to that of the engine. The hydraulic pump for the lifting and steering system is flan ged to the PTO.

Pump
A gear oil pump that rotates at the same speed as the engine, is mounted coaxially with the direct drive
shaft. Oil is sucked from the sump via a duct in the transmission case casting, and passes through a mesh
filter.

Control distributor
The distributor is situated on the outside of the transmission case. It receives the oil delivered by the pump
and incorporates devices that control the flow and pressure of the oil to ensure that the converter, the clutches
and the lubrication system all operate correctly. It is provided with a modulator valve, which ensure gradual,
shock-free gear changes and start-ups.

4 Ed. 05/2007
TXL 30/ST General views

H M G P

D U D

A. Filler plug, gear box oil


B. Forward gear solenoid valve
C. Reverse gear solenoid valve
D. Oil drain plugs
E. Oil filter
F. Drive axle oil level plug
G. Mechanical Inching control
H. Converter
L. Dipstick with breather
M. Exchanger return
N. Exchanger delivery
P. Inching drive control (optional)
R. Additional oil level rod (optional)
S. Supermodulating Distributor
T. Pressure switch (optional)
U. Temp. switch 125° ± 3°C
V. Power take-off
Z. Hydraulic Inching control

32 - Ed. 05/2007 5
TXL 30/ST General views

S P L V R

E T A

B
Z C

F
E MA

6 Ed. 05/2007
TXL 30 /ST General section

14 2
11
3
1 17
4 5 16
13

10 9 8 6 7

1. Converter
2. Gear driven by power take-off
3. Power take-off
4. Pump
5. Forward clutch
6. Reverse clutch
7. Pinion drive gear
8. Pinion Gear
9. Driving gear, for power take-off
10. Turbine shaft
11. Chain
12. Brake Assembly
13. Differential Unit
14. Converter case
15. Wheel Assembly
16. Lubrication safety valve
17. Distributor with Hydraulic Inching control

32 - Ed. 05/2007 7
TXL 30/ST General section

12 15

13

8 Ed. 05/2007
32.2 - TRANSMISSION HYDRAULIC SYSTEM - SUPERMODUL ATING DISTRIBUTOR

The whole transmission system relies for its trouble-free operation on the various components of thehydraulic
system which perform the following functions:
- Ensure a given pressure inside the converter.
- Ensure a continuous exchange of converter oil and cooling through heat exchanger.
- Provide oil pressure to forward and reverse clutch pack.
- Lubricate clutch plates.

The main components of the hydraulic system are:


a. TRANSMISSION OIL PUMP
An internal-tooth oil pump is fitted inside the transmission and has the same speed as the engine. Oil suction
from the sump is through a line incorporating a gauze filter.
b. OIL FILTER
Fitted in the inlet duct, it filters the oil for various utilities. Its net size is 25 micr on.

c. HYDRAULIC TORQUE CONVERTER


Fitted between engine and reverser the converter uses the dynamic action of the oil to multiply engine output
torque in line with truck work requirements.
d. HEAT EXCHANGER
Located on circuit in exit at the converter the exchanger dissipates the heat produced during gearbox
operation.
e. REVERSER
The reverser unit consists of two oil bath, multiplate clutch packs controlled hydraulically through the
electrovalves.
f. SUPERMODULATING VALVE BLOCK
This unit is fitted on the gearbox and incorporates:
Max pressure valve (regulator)
This valve regulates clutch pressure.
Modulating valve
Located on the clutch supply circuit, this valve controls the increase in clutch pressure so that the clutch
in question is fed gradually regardless of speed of manoeuvre.
Inching valve
It cloke clutch pack pressure and gradually disengages the engaged clutch. Running speed isconstantly
reduced without changing engine speed so that the vehicle can be moved forward
Electrodistributor selector
Situated on the feeding ducts of the clutch units, allows to convey oil to gears and to let it flow to exhaust.
Converter safety valve
Located on converter inlet line, this valve settles the input pressure and protects the converter from
accidental over pressure.
Lubrication safety valve
Located on the lubrication circuit this valve checks increases in pressure in this circuit.

32 - Ed. 05/2007 9
Hydraulic diagram description - Supermodulating Distributor

LUBRICATION
2.5 bar
11

PRESSURE DROP 1.5 b ar max.


10
FORWARD GEAR

REVERSE GEAR

8
7 4

5 3

CONTROL VALVE BLOCK

1- SUCTION FILTER
2- PUMP
3- SHIFT PRESSURE VALVE
4- PRESSURE CONTROL VALVE
5- ORIFICE
6- TORQUE CONVERTER
7- HEAT EXCHANGER (COOLER)
8- CONVERTER SAFETY VALVE
9- INCHING VALVEL
10 - FORWARD AND REVERSE SPEED VALVEL
11 - LUBRICATION SAFETY VALVE

10 Ed. 05/2007
Supermodulating Distributor - Gear in neutral position / SCHEME A

Neutral position
The oil sucked by the pump, after filtration, is conducted to the pressure control valve and the, by way of the
orifice (5), to the converter. From there, after having passed through cooler, the oil reaches the clutch for forward
and reverse Gear through the lubrification circuit and then oil sump. The oil flow, regulated by the main valve,
is conveyed to exhaust by the selection valve.
The exceeding oil reaching the main valve feeds the converter. The converter pressure is regulated by the converter
pressure control valve that diverts the exceeding flow to the lubrication circuit.

LUBRICATION
2.5 bar
11

PRESSURE DROP 1.5 b ar max.


10
FORWARD GEAR

REVERSE GEAR

8
7 4

5 3
Exhaust

9
Clutch pressure

2 Converter inlet

CONTROL VALVE BLOCK Exchanger inlet


1
Lubrication

32 - Ed. 05/2007 11
Supermodulating Distributor - Reverse gear, Started lift truck / SCHEME B

Running
During this stage the clutches are supplied at maximum pressure. This value is regulated by valve (3).

LUBRICATION
2.5 bar
11

PRESSURE DROP 1.5 b ar max.


10
FORWARD GEAR

REVERSE GEAR

8
7 4

5 3 Exhaust

9 Clutch pressure

Converter inlet
2
Exchanger inlet
CONTROL VALVE BLOCK
1
Lubrication

12 Ed. 05/2007
Supermodulating Distributor - Inching reverse gear / SCHEME C

Inching manoeuver
The Inching control allows precise movement of the vehicle, irrespective of engine speed. The oil
feed to the clutch is controlled, lowering the operating pressure, allowing slipping
- to occur accor
ding to pedal position.

LUBRICATION
2.5 bar
11

PRESSURE DROP 1.5 b ar max.


10
FORWARD GEAR

REVERSE GEAR

8
7 4

5 3 Exhaust

9 Clutch pressure

Converter inlet
2
Exchanger inlet
CONTROL VALVE BLOCK
1
Lubrication

Inching

32 - Ed. 05/2007 13
32.3 - DISASSEMBLING AND RE-ASSEMBLING OF TRANSMISSION - GENERAL INSTR UCTIONS

General instructions
Prior to starting work on the dismantling or assembing of the transmission, bear in mind the following points:
1) When working on the transmission observe high standards of cleanliness. All parts should be cleaned
throughly prior to assembly.
2) The location where the work is to be carried out should be dust-free clean.
3) Make sure that all the necessary tools are available, particularly those mentioned in this manual. Parts fitted
incorrectly can cause serious damage to the transmission, in the same way as metal chips or foreign
bodies.
4) During the transmission overhaul, you are advised tu substitute the following with new parts: oil sealing
rings, gaskets, retaining rings and any parts damaged during dismantling.
5) If breakage occurs inside the transmission, all lines, casing and heat echanger should be cleaned thoroughly
to prevent damage caused by residues left inside the system.

SHIMS
All adjustments shall be carried out after all adjustment shims have been selected measuring them one by
one with a micrometer gauge and, then, summing up all values measured; don’t trust incorrect measure -
ment of pack as a unit or sum of nominal value printed on each shim.

SEALS FOR REVOLVING SHAFTS


Proceed as follows for proper fitting of captioned seals:
▲ prior assembly, seals should be kept, for at least half an hour, in a bath with the same oil to be sealed;
▲ clean thoroughly shaft and make that working surface be not damaged;
▲ position sealing lip against the fluid to be sealed; in case of hydrodynamic lip lines should be oriented so
as that, considering direction of revolving shaft, they lead fluid inside of sealing means;
▲ smear sealing lip with a film of lubricant (oil is better than grease) and fill up with grease the space
between sealing lip and dust shield lip, if using double sealing lip type seals;
▲ press seal in relevant seat or use a proper fitter with flat contact surface; never use hammer or mallet to
mount seal;
▲ when press fitting seal make sure that it be correctly driven in relevant seat, i.e., perpendicular with res -
pect to its seat, as fitting is completed make sure, if required, that seal itself be in contact with relevant
shoulder;
▲ to prevent damage of seal lip when inserting shaft, duly protect component during assembly.

O-RING SEALS
Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.

SEALING COMPOUNDS
For matching surfaces identified by X use compound LOCTITE 510 or similar one.
Clean matching surface as follows prior, smearing compound:
▲ remove old deposits using a metal brush;
▲ degrease surfaces by one the following cleaners: trichloroethylene, kerosene or a warm water and
soda solution.

BEARINGS
When assembling them it is advisable to proceed as follows:
▲ heat them at 80 to 90 °C before fitting on relevant shafts;
▲ cool them before inserting in relevant external seats.

SPRING PINS
When using split pins be sure that lengthwise cleft be positioned toward stress on pin.
Coil pins don’t require specific position.

IMPORTANT: Dispose of worn and replaced materials according to local regulation.

14 Ed. 05/2007
GENERAL INSTRUCTIONS / Storage and service instructions

In order to assure the right condition, handling and utilization of the product, perform the following
instruction:

TEMPERATURE CONDITIONS

• Storage - 40 + 60° C
• Working - 30 + 60° C

During the handling of the product avoid any collision in order not to damage the external
! and internal components.

In case of long inactivity of the product, before installing or starting, beware that the product
! has not suffered any damage.

! Do not energize the electrical components with incompatible voltage.

Never use petrol, solvents or other inflammable fluids, use only approved commercial solven-
! ts that are both non-inflammable and not-toxic.

! In case of stopping and before living the vehicle, make sure the parking brake is engaged.

Failing to follow these instructions or an unproper use of the product may result in harm to
persons and objects damages.

32 - Ed. 05/2007 15
DISASSEMBLING AND RE-ASSEMBLING OF TRANSMISSION - Specific tools

1 - Bearing fitting tool

2 - Tool for Q-Ring assembly

3 - Fixture for diassembling of clutch plates

4 - Bearing fitting tool

5 - Bearing fitting tool

6 - Bearing fitting tool

7 - Bearing fitting tool

8 - Spanner for slotted nut of wheel hub spindle (1st version) see page 22

9 - Locking spanner for slotted nut of hub bearing adjusting (2nd version) see page 22

10 - Forcing seal ring tool on spindle of axle (1st version) see page 22

11- Forcing seal ring tool on spindle of axle (1st version) see page 22

12 - Locking spanner for slotted nut of Differential see page 22

13 - Forcing seal ring tool on spindle of axle (2nd version) see page 22

14 - Forcing seal ring tool on spindle of axle (2nd version) see page 22

16 Ed. 05/2007
1 2 3

4902166

48A17092 PTO SAE "A"


48A17127 SAE "A"-"B"

4A41377

4 5 6 7

4902648 4902174 4902172 4902302

32 - Ed. 05/2007 17
DISASSEMBLING AND RE-ASSEMBLING OF AXLE - Specific tools

12 13 14

48A19118

48A19394

48A19120

10 9

48A19119

8 12.
70 m
m

48A13533

11

48A13164

"
3/4

48A13511
48A12542

18 Ed. 05/2007
Dismantle and assemble transmission

! GENERAL SAFETY !
Before undertaking any repair, follow safety rules indicated in chapter “Safety rules” in accordan-
ce with specific local regulation about safety on work places.

Oil draining: Drain oil through plug (a) of axle


casing and plugs (b) of PTO case and transmission
case.

a
1

b
b
1a

The picture shows the filter placed on the pump


suction duct. This filter, compulsorily with the plug
o.ring, must be replaced at recommended inter -
vals ( see maintenance operation ) or whenever an
overhaul is performed.

32 - Ed. 05/2007 19
Torque converter removal
Remove converter unit by pulling it in axial direc-
tion.

Removal of torque converter case


Remove the screws securing the converter.

Remove the converter case.

20 Ed. 05/2007
Converter case overhauling

Unhook lock ring retaining driven gear.

Lift driven gear by proper lever and remove chain.

Release screws securing cover retaining driving


gear bearing.

Remove driving and driven gears, complete with


bearings.

32 - Ed. 05/2007 21
Remove bearing lock rings, respectively on driving
and driven gears. Clean thoroughly all componen-
ts, check and replace as required.

10

Should the replacement of the Q-Ring fitted on


the driving and driven gears be necessary, use
specific tool:
48A17127 for TXL30/ST SAE “A” and SAE “B”
48A17092 for TXL30/ST PTO SAE “A”.

11

12

Replace the seal on converter case by using a


proper installer.
Note: Lubricate the seal prior installation following
specific general instructions.

13

22 Ed. 05/2007
Refit bearings on driving and driven gears and
relevand lock rings.
Refit driving and driven gear assembly in relevant
seats on converter case.
Install and secure the bearing retaining cover,
smear a medium locking compound on screws
and tighten with a torque of 3 Nm.

14

Assemble chain on drive and driven gears.

15

Insert into its seat the lock ring retaining driven


gear.

16

32 - Ed. 05/2007 23
Dismantling and re-assembling of Supermodulating Distributor

Removal of the inching control mechanism


(according to various configuration)
17

Unhook the spring from pin


18

Distributor removal
19 Unscrew the fixing screws and dismantle the
complete distributor.
Remove the paper gasket

24 Ed. 05/2007
Supermodulating distributor overhauling

fig. 20 INCHING IDRAULICO INCHING MECCANICO


HYDRAULIC INCHING MECHANICAL INCHING
Hydraulic
HYDRAULIK Inching
INCHING Mechanical Inching
MECHANISCHES INCHING

The figure shows from top to bottom the four


distributor axis:
1) forward-reverse shifting axle
2) Inching control axle
3) main valve - converter valve axle
4) Modulating Axle.

Disassembly of forward-reverse shifting shaft


Undo nut securing electrovalve.

21

32 - Ed. 05/2007 25
Remove the electrovalves complete with O-Rings.
22 Check components, clean full each component,
replace if required (if there are metallic residues,
replace the electrovalve complete).
Reassemble components locking solenoid nut
with a torque of 1 daNm.

Inching Axle dismantling - Mechanical Inching


23 Version
Undo the four screws securing cover.

Remove Inching control components.


24

Note: To dismantle Inching axle it isn’t necessary


to dismantle regulating nut: if required, unscrew
nut complete and relevant rubber seal.

25

26 Ed. 05/2007
! WARNING! To not prejudice right working of
Inching axle, don’t tamper and don’t dismantle
regulating plug of nut.

25a

Remove and replace O-Ring seal (a).

26

Clean full each component, check them, replace if


required.

27

Dismantling of main valve - converter valve


axle
Unscrew plug and remove small piston of - conver
ter pressure regulating valve with relevant spring
and possible shims.

28

32 - Ed. 05/2007 27
Undo rear plug, extract small piston from main
29 pressure valve with relevant spring and shims.

To remove central bush of axle, undo screw placed


30 under distributor.

Components of converter valve - main valve axle


31 Clean full each component, check them, replace if
required.

Dismantling and re-assembling Modulating Axle


Push bushing and unhook front lock ring.

32

28 Ed. 05/2007
Extract bushing and remove O-Ring seal.
33

Remove piston and the two springs.

34

Unhook rear lock ring, remove O-Ring seal and


Modulating Axle cover.

35

Components of Modulating Valve Axle


Clean full each component, check them, replace if
required.

36

32 - Ed. 05/2007 29
Special care is required for bushing complete:
37 37a unscrew plug, check inside of the same and on
the ball that there aren’t impurities, clean full and
reassemble.

Assemble the O-Ring seal into its seat, insert


38 cover and positionning it, take care not to overtake
lock ring seat.

Insert lock ring.


39

30 Ed. 05/2007
Reassemble springs and piston.

40

Assemble into its seat O-Ring seal.

41

Assemble the bushing complete, taking care not


to damage the O-Ring seal, push bushing and
insert lock ring.

42

32 - Ed. 05/2007 31
Reassembling of Main Valve - Converter Valve
43 Axle
- Position the central bushing (a):
- smear locking screw (b) with Loctite 242;
- lock bushing;
- reassemble shims (c);
- insert spring and small piston of Main Pressure
Valve (d);
- lock plug with rubber seal (e).
Follow the same procedure to assemble front part
of converter valve (fig. 43b).
43a

c
e

a b
d

43b c

e
d

32 Ed. 05/2007
Reassembling Inching Axle - Mechanical Drive
Version
Reassemble regulating nut with relevant rubber
seal and lock.

44

! WARNING! To not prejudice right working of


Inching axle, don’t tamper and don’t dismantle
regulating plug of nut.

44a

Insert components of Inching Axle.

45

Smear the four screws with Loctite 242 and lock


the cover with a torque of 0.5 daNm. 46

32 - Ed. 05/2007 33
Inching Axle Dismantling - Hydraulic Inching
Version
Undo fixing screws of Inching body to distributor.

47

Remove components of Inching axle.


IMPORTANT : The inching control assy is not
repairable. In case of wear or malfunction a
new assy must be fitted.
!

48

48a

34 Ed. 05/2007
Note: To dismantle Inching axle it isn’t necessary
to dismantle regulating nut: if required, unscrew
nut complete and relevant rubber seal.

49

! WARNING! To not prejudice right working of


Inching axle, don’t tamper and don’t dismantle
regulating plug of nut.

49a

Clean full each component, check them, replace if


required. 50

Remove and replace O-Ring seal (a).

51

32 - Ed. 05/2007 35
Reassembling Inching Axle - Hydraulic Drive
Version
Reassemble regulating nut with relevant securing
washer and lock.

52

! WARNING! To not prejudice right working of


Inching axle, don’t tamper and don’t dismantle
regulating plug of nut.

52a

Insert components of Inching Axle.

53

36 Ed. 05/2007
Smear the four screws with Loctite 242 and lock
Inching body to distributor with a torque of 5 Nm. 54

Re-assembling of front - back selection valve


Insert electrovalve with relevant seals (righting
smeared).
Lock nut with a torque of ~ 70 Nm.

55

Check conditions of safety valve of lubrication


system and relevant seat on distributor adaptor.

56

32 - Ed. 05/2007 37
Wheel hubs dismantling and re-assembling - 1st Version

! WARNING !
Handle all heavy parts with the appropriate
equipment and with the utmost care. Never
put your hands and fingers in between parts

Undo screws securing brake drum to wheel hub.


57 Remove brake. Check diameter and wear condi-
tions of shoes lining.

Wheel shaft disassembly


57a Undo screws securing shaft to wheel hub on both
side.

Unscrew the two fixing screws, unlock and remove


the half shaft.

58 58a

38 Ed. 05/2007
! IMPORTANT : Use only genuine spare parts
Shoes replacement
Unhook shoe return spring on automatic brake
clereance take-up device side.

59

Unhook the two shoe return spring on side of


wheel brake cylinder. 60

Remove brake shoes retaining springs, brake


shoes, return fulcrum, hand brake drive and lever
cable.
Should hand control cable be replaced, remove
fork washer backing cable return spring.

61

61a

32 - Ed. 05/2007 39
Should brake cylinder be replaced, undo the two
a screws (a) retaining small plate of spring hooking
a of shoes return.
Unscrew brake oil bleeder (b), connector (c) and
the two screws (d) retaining small cylinder placed
behind brake plate, with relevant washers (see fig.
62a).

62

c
b
d

fig. 62a

40 Ed. 05/2007
! IMPORTANT : Don’t dismantle the brake cylin-
der to repair it, in case of malfunction, change.

- Position brake cylinder into relevant seat (fig.62a);


- screw in the two screws ( d) with washers with a
torque of 20 ÷ 25 Nm;
- mount and screw in oil bleeder ( b) with a torque
of 4 ÷ 6 Nm;
- mount and screw connector ( c) with copper seal
with a torque of 30 ÷ 36 Nm;
- reassemble small plate hooking springs and
screw in the screws (a) with washers with a torque
of 20 ÷ 25 Nm.

63

a
a

64

32 - Ed. 05/2007 41
Should automatic adjusting be replaced, screw in
and lock screw with relevant washers with a torque
of 90 ÷ 100 Nm.

! IMPORTANT : Don’t dismantle the automatic


adjusting to repair it, in case of malfunction,
changed.

65

65a

Before mounting the shoes adjust width “ a” at


65b 81±0.5 mm for brake size 310x60. Be careful to
operate evenly on both adjusting screws. For other
brake sizes, please refer to the table underneath.

a Brake size

54 170 x 40
60 200 x 40
60/79 203 x 40/60
79 230 x 50
85 245 x 60
79 250 x 45/50
84/80 270 x 60
81±05 310 x 60

42 Ed. 05/2007
Refit right shoe, hook brake hand control cable on
lever and insert retaining spring.

66

Refit left shoe and retaining spring fitting in the


strut of hand brake control. 67

Hook the two shoe return spring on side of wheel


brake cylinder. 68

Hook shoe return spring on automatic brake cle -


reance take-up device side (A).

69

32 - Ed. 05/2007 43
Shoes setting procedure.
Brake size Presetting width - Release the parking brake and relieve the cables
tension.
170 x 40 169,2 - 0.2 - Measure the diameter of the shoes and of the
200 x 40 199 - 0.4 drum. The correct gap is 1,2-1,8, for brake
310x60 (for different brake size see table); If not
203 x 40/60 201.8 +/- 0.2 within limit adjust it acting evenly on both adju -
230 x 50 228.7 +/- 0.2 sting wheels (A).
245 x 60 243.6 +/- 0.3 Remark: Precise adjustment of the brake shoes
diameter is vital to the correct functioning of the
250 x 45/50 248.6 +/- 0.3 automatic adjuster.
270 x 60 268.6 +/- 0.3
! WARNING! A too small diameter could damage
310 x 60 308.5+/- 0.3 permanently the automatic adjuster.

Check the brake efficiency


Carry out approximately 10 braking moderate
manoeuvres ( no emergency braking ) at a speed
of 10 Km/h forth and back. This will ideally set the
automatic adjuster and enable to check the brake
Drum fig. 70 efficiency.

Gap Gap

Ø Presetting

44 Ed. 05/2007
Wheel hub dismantly
Straighten up the tab of the locking washer.

71

Undo and unscrew completely ring nut securing


wheel hub (with special tool dwg. 48A13164).

72

Remove the tab washer, distance washer, bearing


and hub.

73

Pull out the inner race of wheel inner bearing.


Note: hook up spacer edge with puller to prevent
damage on seal.

74

32 - Ed. 05/2007 45
Brakes disassembly
To disassemble brakes follow the procedure from step 59 to 65, page 39 - 40 - 41 - 42.

Should hand control cable be replaced. remove


fork washer backing cable return spring.

75

Undo screws securing brake back plate to frame


mounting support and remove it.
Note: same procedure should be followed for
brake on the opposite side.

76

46 Ed. 05/2007
Frame mount support disassembly
Release frame mount support.

77

Remove frame mount support.


Note: same procedure should be followed for sup -
port on opposite side.

78

32 - Ed. 05/2007 47
Wheel re-assembling - 1st Version
In case of spindle installation, the mating area has
to be smeared with “loctite 510”. Coat the screws
with medium grade fastener. Fit the washer and
tighten to torque of 266÷294 Nm.

79

Frame mount support reassembly


Remove grease seal and replace.

80

Lubricate with Molikote P40 axle sleeve and install


frame mount support. Check that support rotation
be smooth and free from friction or play.

81

Remount brake back plate, smear medium locking


compound on screws fixing plate to frame mount
support.
Tighten screws M14x1.5x35 with a torque of 181
÷ 200 Nm.

82

48 Ed. 05/2007
Brake reassembly
To reassemble brakes follow the procedure from step 62 to 70, from page 44 to 48.

Apply oil to the shaft seal (a) before wheel hub


assembly, by using special tool dwg. 48A13533 for
assembly.
Note: Respect assembling quota to avoid possible
damage to seal ring, see figure 84.
Remove and replace seal ring (b) on spindle of
axle; apply oil to the shaft ring before wheel hub
assembly, by using special tool dwg. 48A12542 for
assembly, see figure 84a.

83

48A13533

0,5 mm

84

b 84a
48A12542

0,7 mm

32 - Ed. 05/2007 49
Wheel hubs reassembling

Bearings adjustment specifications


1) Wash the bearings with hot petroleum and dry
them lubricate them by immersion in melted grea - b
se.
2) Assemble the bearings with the related hub,
after filling with grease (FIAT MR2 or similar) each
internal cavity (a).
! Attention! Too much grease can cause the over-
turning of the lip of the seal (b). Assemble the
toothed washer and the screw the ring nut.
3) Rotated and hammer the hub to make easier
the bedding of the conical rollers on the tracks,
and at the same time screw gradually the ring nut
to the driving torque of 147 Nm.
4) Loosen the ring nut and then screw it increasing
gradually the driving torque to 1 daNm.
5) Loosen again the ring nut in a way to assure a
max. play on the bearings of 0.05 mm, correspon - a
dent to about 1/32 of turn of the ring nut. Lock 85
then the ring nut in the way explained in step 6.
6) If no tab mates the slot, tighten slightly the nut
to match the nearest tab (see photo 87).

86

87

50 Ed. 05/2007
Wheel shaft reassembly
Install the half shaft, taking care not to damage the
seal ring.

88

Apply Loctite 242 or similar to the bolts and lock


with a torque of 8 ÷ 9 Nm.

89

Screw in twelve bolts with spring washer and


tighten with 130 ÷ 136 Nm.

90

Install the brake drum using Loctite 242 for the


two fixing bolts and screw in with a torque of 8 ÷
9 Nm.
Note : Make sure that the brake shoes are not in
contact with the drum.

91

32 - Ed. 05/2007 51
Wheel hubs dismantling and re-assembling - 2nd Version

! WARNING !
Handle all heavy parts with the appropriate
equipment and with the utmost care. Never
put your hands and fingers in between parts

Undo screws securing brake drum to wheel hub.


92 Remove brake. Check diameter and wear condi-
tions of shoes lining.
Note: Please refer to specific manufacturer instruc-
tion to overhaul brake or to replace the shoes.

Wheel shaft disassembly


93 Undo screws securing shaft to wheel hub on both
side, unlock and remove the half shaft.

Remove the spring pin holding the nut.

94

52 Ed. 05/2007
Unscrew completely ring nut securing wheel hub
(with special tool dwg. 48A19119).
Remove the bearing and hub.

95

Pull out the inner race of wheel inner bearing.

96

Remove the lip seal with spacer (a).

97

32 - Ed. 05/2007 53
Complete brake dismantly
Undo screws securing brake back plate to frame
mounting support and remove it.
Note: same procedure should be followed for
brake on the opposite side.

98

Frame mount supports and spindle disassembly


To disassemble follow the procedure from step 77 to 78, page 51.
To reassemble from step 80 - 81, page 52.

Brake reassembly
Remount brake back plate, smear medium locking
compound on screws fixing plate to frame mount
support; screw in and lock with a torque of 181 ÷
200 Nm.

99

54 Ed. 05/2007
Wheel hubs reassembling
Should hub bearings be replaced use genuine
spare parts only to warrant trouble free operations
of the whole system.

100

Apply oil to the seal ring (a) before assembly on


spacer (b), by using special tool dwg. 48A19120. 101
Note: Respect assembling quota to avoid possible
damage to seal ring.

48A19120/01

48A19120/02

0,5 mm
a
b

Mount spacer lip seal complete on wheel hub sleeve


and mount inner race of bearing.

101a

32 - Ed. 05/2007 55
Remove and replace seal ring (c) on spindle of
101b c axle; apply oil to the shaft ring before wheel hub
assembly, by using special tool dwg. 48A19394 for
48A19394 assembly.
Note: Respect assembling quota to avoid possible
damage to seal ring, see figure 101b.

21,5 mm

Bearings adjustment specifications


102 1) Assemble the bearings with the related hub,
b after filling with grease (FIAT MR2 or similar) each
internal cavity (a).

! Attention! Too much grease can cause the over-


turning of the lip of the seal (b). Assemble the
toothed washer and the screw the ring nut.
2) Rotated and hammer the hub to make easier
the bedding of the conical rollers on the tracks,
and at the same time with tool 48A19119 screw
gradually the ring nut to the driving torque of 147
Nm.
3) Loosen the ring nut and then screw it until the
“ZERO CLEARANCE” condition..
4) After the adjustment, lock the ring nut by means
of the pin. If this is not possible, rotated the ring
nut clockwise until the nest slot, then fit the pin.
The preload must be in the range of 0.00-0.10
mm.
a

102a

56 Ed. 05/2007
Wheel shaft reassembly
Install the half shaft, taking care not to damage the
seal ring (a).

103 a

Screw in 10 bolts and tighten with 130 ÷ 136 Nm.

104

Install the brake drum using Loctite 242 for the


two fixing bolts and screw in with a torque of 19 ÷
21 Nm.
Note: Make sure that the brake shoes are not in
contact with the drum.

105

32 - Ed. 05/2007 57
Dismantle transmission
The wheel side assays can be removed complete,
106 if necessary.
To remove them, undo the screws holding the
spindle to rear case.

Transmission cover Dismatling


- To unscrew and remove screws securing the
bevel pinion cover.
- Remove bevel pinion cover.

107

Lift up notches on bevel pinion ring nut collar.

108

Undo ring nut after both clutches have been pac -


ked up with compressed air.

109

58 Ed. 05/2007
Release and remove screws securing transmission
cover.

110

Remove the cover, complete with oil pump, from


transmission case.

111

Oil pump and transmission cover overhaul


Undo screws retaining pump and remove the
pump complete .

112

Disassermble the pump. Clean full all components,


check wear of parts and of relevant seats.

113

32 - Ed. 05/2007 59
Check bearing, on pump shell, and replace, if
required

114

Reassemble the pump unit, fit driving and driven


gears set in pump shell, then, the pump cover sta
tor sleeve, take care to avoid damage on driving
gear bushing

115

Use a proper tool to remove seal from P.T.O. outlet


seat, then, remove needle roller casing.

116

Remove the outer race, of bevel pinion bearing, by


117 a driff punch.

60 Ed. 05/2007
If the tapered bearings have to be replaced, remo-
ve the outer race them with a normal extractor and
re-assemble hot or with the appropriate tool.

118

Refit needle roller casing, seal and outer race of


bevel pinion bearing.
Note: the press fitting strength exerted to drive
needle roller casings, in relevant seats, should be
applied evenly and bumpless, on the marked side,
by a proper tool resting on the casing and suitably
aligned to seat.

119

Reinstall pump on transmission cover, smear


medium locking compound on screws.
Tighten with a torque of 23 to 25 Nm.

120

32 - Ed. 05/2007 61
Transmission disassembly
Pull out the upper clutch unit complete.

121

Pull out the lower clutch unit complete.

122

Remove the spacer and bearing pre-load adjust-


ment shims of bevel pinion.
Unscrew the 3 retaining screws and remove the
gear guard.
Pull out the driven gear on bevel pinion.

123

62 Ed. 05/2007
Clutches overhauling

Unhook and remove, with particular care, rings


from clutch shaft.

124

Remove bearing from shaft on constant mesh gear


side.

125

Remove bearing inner race and thrust washers of


gear.

126

32 - Ed. 05/2007 63
Remove gear and relevant roller cages along and
spacer with inner thrust washers.

127

Remove from its seat the circlip which holds the


reaction plate. The circlip must be pressed upwards
with a screwdriver fitted in one of the holes of the
clutch housing.
Simultaneously with another screw driver pry the
circlip out, then remove all the components of the
clutch pack.

128

Pull out driving and driven disks from clutch bell


housing.

129

64 Ed. 05/2007
! WARNING !
Use the proper tools.
NEVER USE FINGERS OR HANDS
or incorrect tools

Compress the reaction spring by a proper tool


(4A41377) and pull out the retaining ring.

130

131

Remove cup and spring.

132

32 - Ed. 05/2007 65
Push out piston from clutch bell housing by injec -
ting compressed air into ducting. Clean full all
components, check, replace as required and reas-
samble after O-Rings have been duly lubricated.

133

Replace the outer and inner seal rings of piston.


Lubricate O-Rings according to instructions.

134

Insert piston, reaction spring and relevant seat cup


into clutch bell housing.

135

66 Ed. 05/2007
! WARNING !
Use the proper tools.
NEVER USE FINGERS OR HANDS
or incorrect tools

Compress the reaction spring and insert the retai-


ning spring into the seat on shaft.

136

136a

Remount the 6 clutch driving ( b) and the 6 driven


disks (a);
Note: when packing clutch disk bear in mind that
a steeldriven disk (a) must face the piston.

137

a b

32 - Ed. 05/2007 67
Fit the circlip on the reaction plate, then insert the
138 assy as shown in photo 138, then press on the cir-
clip in order to fit it in its seat, photo 139 and 140.
Note: check clereance as figure 141 and verify it
in three points, every 120°.

139

140

141

68 Ed. 05/2007
Insert thrust washers of gear roller cages on inner side.

142

Mount roller cages with relevant spacer and gear positioning the
hub true on toothing of clutch disks.

143

Mount thrust washers and bearing inner race on gear side.

144

32 - Ed. 05/2007 69
Verify clereance between gear and thrust washer
(see fig. 145).

145

Mount bearing on shaft, constant mesh gear side.

146

Mount rings in relevant seats.


Note: smear cast rings with grease, after installa-
tion, to keep them centered and steady in relevant
seat when shafts are inserted, so as to prevent
failures or damages.

147

70 Ed. 05/2007
Differential overhauling

Remove the spring pin holding the nut and unscrew


the nut with tool 48A19118

148

Central case diisassembly


Undo screws fixing cover to central casing and
remover cover.

149

Undo and remove screws securing differential


support caps, mind to mark reference for reas -
sembly.

150

32 - Ed. 05/2007 71
Take off caps.

151

Remove differential unit complete.

152

Take off bevel pinion complete with roller cage, of


pinion under head bearing, and spacer.

153

72 Ed. 05/2007
Differential unit disassembly and overhauling
Roller cages of differential bearing can be taken
off by a proper puller.

154

Undo and remove screws securing the ring gear


and pull it out from casing

155

Mark both half-casings for reference at reassem-


bly.

156

32 - Ed. 05/2007 73
Separate differential half casings by undoing the
fixing screws.

157

Check differential components. Clean thoroughly


all parts, check and replace as required.

158

Remount differential positioning components in


relevant seats.

159

74 Ed. 05/2007
Use a suitable equipment to heat differential
bearing roller cage and install in its seat. Smear
medium locking compound on screws fixing half-
casing.

160

Tighten screws with a torque of 75 to 83 Nm.

161

Heat up, by proper equipment, and refit roller cage


of bearing on ring gear side.

162

32 - Ed. 05/2007 75
Should bevel gear set be replaced it is necessary
to smear medium locking compound on screws
fixing the ring gear and tighten them with torque
of 210 to 230 Nm.

163

Central case overhaul


Pull out bearings from relevant seats on case and
refit new ones.

164

Fit inner bearing race, under head of pinion, using


proper heating equipment of a specific installer.
Fit a new OR on the pinion shaft.

165

76 Ed. 05/2007
Differential reassembly and bevel gear set
positioning with relevant adjustment:
BEVEL GEAR
1) Positioning bevel pinion (fig. 166)
COMPUTING SHIMS THICKNESS:
- Record dimension A (if not printed on housing)
housing measure from differential center line to
distance seat of bevel pinion bearing.
e. g.: recorded dimension A = 190.47 mm A
- Determine true dimension B algebrically adding
the correction factor
printed on pinion head to theoretical dimension B. 166
e. g.: B = 149.50 mm; correction shown (in tenth
of millimeter) = -1, true dimension B will
be: 149.50-0.1=149.40 mm
- Determine dimension C measuring thickness of
the pinion head bearing assy. fig. 166a
e. g.: dimension C = 36.6 mm
- Add dimensions B and C. Resulting value
must of S shim thickness to be fitted under the
pinion bearing.
e. g.: S = A - [(B±K)+C]
S = 190,5[(149,50±K)+36,6]

S
B = dimension to be rectified according to value
reported on pinion head.
K = correction value reported on pinion head.

(190.50)
A
K

(36.6)
C
(149.50)
B
32 - Ed. 05/2007 77
Prior positioning shim S, mont the seal (suitably
greased) and fit outer race of pinion underhead
bearing.

167

Insert pinion in its seat with housing.

168

Transmission reassembly
Fit gear on pinion splined shaft and fit spacer.
Fit the guard. Smear the 3 holding screws with
medium grade fastener, and tighten at the torque
of 9.5÷10.5 Nm.

169

78 Ed. 05/2007
Replace O-Ring seals on oil delivery ducts.

170

Refit lower clutch assembly complete.

171a

Refit upper clutch assembly complete.

171b

Smear sealing compound on contact surface and


reassembly transmission cover complete with oil
pump, smear medium screw locking compound
and lock with a tightening torque of 62 to 69 Nm.

172

32 - Ed. 05/2007 79
- Measure shim thickness for pre-load of pinion
bearings, said value should be suitably increased
so as to have no pre-load.
- Insert spacers, then, fit bearing inner race on
pinion shaft and screw in ring nut.
- Pack up clutches by compressed air.
Lock nut with a torque of 665 to 735 Nm.
- Check system passive torque less pinion bearing
pre-load.

173

Check end play, remove inner race of bearing fit-


ted on pinion shaft; remove spacer, vary thickness
to eliminate the whole play and reach a pre-load of
0.05 mm. Reassembly all components, lock ring
nut at the specified torque, check that increasing
of revolving torque be included within 1.5 to 4.0
Nm than the passive torque that was previously
checked.
Notch ring nut collar.

174

Replace O-Ring and mount cover, smear medium


screw locking compound and tighten.

175

80 Ed. 05/2007
2) Adjustment of bevel gear set
- Mount differential assy, complete with ring gear
and bearings, on central body. Screw in partially
ring nuts.
- Mount caps. Smear the 4 fixing screws with
medium grade fastener ( loctite 242 )and tighten
them at the torque of 132 to 146 Nm.
- Tighten up progressively ring nuts (a) and, at the
same time, rotate differential unit to set bearing
eliminating bearing play, until end play is com-
pletely taken up. 176
- Rest a dial gauge on central body and check that
differential end play be equal to 0 mm
- Block rotation of pinion and, then, check that
backlash between ring gear (a) and pinion be of fig. 176a
0.18 to 0.23 mm
- Should this value not be approached, release
ring nut on one side and tighten the other of the
same amount up to reach the specified value.
- Smear some teeth of ring gear with red lead
and rotate ring gear in both directions. Rotation
should be performed with no load and contact
area be as shown (fig. 180).
- Should this result not be approached it is neces -
sary increase or reduce thickness of adjustment
shim to displace bevel pinion and act on ring
nuts to reset backlash displacing ring gear.
- Readjust end play of pinion bearings and of dif -
ferential support bearings. Finally readjust back-
lash of ring gear-and-pinion teeth. Check again
the contact area pattern.
Note : should lug of lock plate not match with slot
of nut, ring nut must be tightened slightly more.
As assembling and adjustment have been
completed, check that : a a
- pinion taper roller bearings preload be of 0,15 to
0,40 Nm;
- pinion-ring gear backlash be of 0.18 to 0.23 mm;
- differential support taper roller bearing preload be
of 0,25 to 0,40 Nm;
- contatct area of unloaded pinion-ring gear teeth
be as shown in the bevel pinion-and-ring gear
set inspection page 88.

177

00 - Ed. 05/2007 81
Differential reassembly
Mount differenhal unit on relevant support, position
caps according to reference marked at disassembly.
Smear medium screw locking compound and lock
with a torque of 132 to 146 Nm.

178

Check for backlash between pinion and ring gear.


It must be within 0.18 to 0.23 mm Should it be
outside said value, operate on both ring nuts by
slackening one and tightening the otherof the
same angle (notches quantity), (fig.167a).

179

82 Ed. 05/2007
Bevel pinion-and-ring gear set inspection

Spread red lead on some tooth of ring gear, mesh gears in both directions many times, so to make evident tooth
contact. Proper and correct tooth contact is visible on ring gear and said marks indicate the optimum contact
approached on a tester, therefore, a proper axial position of pinion will emphasize remarking of previous contact.

Bevel drive tooth contact


Tooth contact should be as shown in the figure. 180a
Correct contact
Distance of pinion from ring gear centerlines is
correct.

Concave side (crown wheel)

180b

Convex side (crown wheel)

32 - Ed. 05/2007 83
Incorrect tooth contact
181a Distance of pinion from ring gear centerline must
be reduced.

Concave side (crown wheel)

181c
181b

(—)
Convex side (crown wheel)

Incorrect tooth contact


182a Distance of pinion from ring gear centerline must
be increased.

Concave side (crown wheel)

182c
182b

(+)

Convex side (crown wheel)

84 Ed. 05/2007
Fit the spring pin to lock the nut.
183

Spread sealing compound on housing edge and


mount cover.
Smear medium locking compound on cover
screws and lock washer complete, with a tighte -
ning torque of 47.5 to 52.5 Nm.

184

Install the wheel assies , smear the butting, faces


moistening by means “loctite 510”. Coat the
screws with medium grade fastener. Fit the washer
and tighten to torque of 266÷294 Nm.

185

32 - Ed. 05/2007 85
Converter carter reassembly
Spread sealing compound on P.T.O. cover edge.
Mount converter carter, smear medium locking
compound on fixing screws and lock with a torque
of 62 to 69 Nm.de serrage de 62 ÷ 69 Nm.

186

Fit converter unit on input shaft.

187

Install and tighten the filter placed on the pump


intake.

188

86 Ed. 05/2007
After having placed the paper gasket in position, fit
the distributor, smear medium locking compound
on fixing screws, lock with a torque of 22 to 24 Nm
from center to esternal side.

189

Inching control assay assemly (accordino to


configuration) a
The spring hooking pins (a) must be tightened to a
torque of 22 ÷ 24 Nm. If a new pin/lever kit is fitted
coat all the parts with grease, check both wheel
(b) and lever (c) must be rotate freely on their own
center pivot. c
Fit the support assay to the valve control and
tighten the screws to the torque of 22 ÷ 24 Nm.
Hook the spring (d) to pins.
Refer to picture for end play adjustement page b
119. 190 a

191

32 - Ed. 05/2007 87
Control inching - assy

30 13°
6 1

100 38
OVERALL DIMENSION
23.4
Section “A-A” KE E
TRO OK
X. S STR
3 MA
A
2 02

0.2-0.6 42° 25°


CLEARANCE BAUDEN

137
5

11 4

52.5
7

9
0.1-0.3
CLEARANCE 8
12 1
A
6 10 20 STROKE
1
03

03

45.5`0.2

fig. 192

1 REACTION BRACKET
- THREADS MOISTENING BY MEANS OF LOCTITE 242
1 OR SIMILAR
2 SUPPORT FOR LEVER

2 3 LEVER ASSY
2 - DURING THE ASSEMBLY MOISTEN BY GREASE

4 INCHING REACTION SPRING


- BOTH WEEL AND LEVER MUST BE ROTATE FREELY
5 KNUCKLE PIN ON THEIR OWN CENTER PIVOT

24.15
1 6 PIN FOR SPRING C.S.
21.85
Nm

2 7 PIVOT

2 8 WHEEL

9 LOCK PIN

10 SCREW

11 LOCK PIN

12 NUT

88 Ed. 05/2007
32.4 - OIL SPECIFICATIONS

Transmission oil specification:


ATF oils corresponding to specifications DEXRON II D or TYPE “A” SUFFIX A of General Motors orC3 of Detroit
Diesel Allison (e.g. MOBIL ATF 220 and FIAT TUTELA GI/A and GI/M) or correspon ding to specifications
MIL-L2104B and API CC (e.g. MOBIL DELVAC 1110) or to the specifications MIL-L2104C and API CD
(e.g. MOBIL DELVAC 1310) viscosity 10W20.
Quantity: 1st filling of ~ 10 liters; oil change of ~ 9 liters.
Axle oil specifications: By specifications: MIL-L2105B or API GL5 in the gradation SAE90 or 80W90.

Quantity: oil change of ~ 6 liters.


Brake circuit plus hydraulic Inching: By specifications: SAE J1703, FMVSS 116 DOT 3,
LUNA DOT 3 AB, FORD SAM 6C 9101A,
ISO 4925.

DATA FOR COUPLING TO ENGINE

Assembling instructions
a. Assemble drive plate to converter with reinforcemente plate on flywheel side.
Ensure that concentricity of outer bolt circle with converter pilot be within 0.38 mm (0.15 in)
T.I.R. (Total Indicator Reading). Torque M10 × 18 bolts to 47.5/52.5 Nm (0.34 - 0.38 Ibs. ft).
b. Assemble converter to flywheel. Maintain concentricity of hub (diameter 55 mm) to flywheel housing. Tighten
bolts to torque depending on quality of the bolts.
c. Field service: concentricity must be maintained within 0.30 mm (0.012 in) T.I.R.
Recommended gauge size of flywheel housing SAE 3 Ø 409.58 F8 U.D. (16.125 in).

32 - Ed. 05/2007 89
Engine with P. T. O. coupling diagram

159 +0,3
- 0,93

66,5±0,5 92,5

6 5
FLYWHEEL 2

r3 MINIMUM
1

4
3

232
A

Engine with P. T. O. coupling


1 - Converter drive plate
2 - Converter reinforcing plate
3 - Bolts - drive plate to converter
4 - Spring washer
5 - Bolts - drive plate to flywheel - supplied by customer
6 - Special washer (see page 98)
0
A Suggested dimension for flywheel hole: 19.063 + 0.025
/ Pilot : 19,037 - 0,025 + 0.020
A Suggested dimension for flywheel hole: 20 + 0.041
- 0,007
/ Pilot : 20 - 0,040

90 Ed. 05/2007
Special washer to fix drive plate to flywheel

17 +00.50
15° 15°

+0.30
9 - 0.20

R5 R5

1.5
1.5
Drawing Nr. 3.16475.3

24± 0.65

13± 0.27
15°
15°

R5

1.5
R5

2.5±0.22
Drawing Nr. 3.17113.3

10.2 +00.20
15°
15°

22
R5

1.5
R5
2

Drawing Nr. 3.20489.3

32 - Ed. 05/2007 91
Engine gearbox coupling check-up

01

2 MIN DIMENSION

SEATING FACE FOR DRIVE PLATE

B
01 SAE 3 AND 4 FLANGE APPLICATION
66.5±0.5

Dial gauge mounted on flywheel cover Dial gauge mounted on flywheel

A Total reading ≤ 0,1 mm C Total reading ≤ 0,23 ÷ 0,25

B Total reading ≤ 0,2 mm D Total reading ≤ 0,23 ÷ 0,25

92 Ed. 05/2007
TECHNICAL DATA - Supermodulating Distributor pressure measurement

D
C
6
20
2 5 max. Pressure Zero Pressure
stroke

Pressure operating time diagram - Mechanical Inching travel

Pressure
0.5 ÷ 0.7 max.
P / P max.
Pressure
bar
Apply brakes (brake operating time)

Stroke mm
0 2 5 10 15 18 20

F
F / F = 13 + 02 Kg

32 - Ed. 05/2007 93
Supermodulating distributor pressure measurement
1 - Main pressure intake M10x1
2 - Converter pressure intake M10x1
3 - TXL 30/ST Reverse pressure intake M10x1
4 - TXL 30/ST Forward pressure intake M10x1
5 - Lubrication pressure
6 - Inching brake oil bleeder vent
A - REVERSE electrovalve
B - FORWARD electrovalve.
C - Hydraulic Inching.
D - Mechanical Inching.
If the fixing bolts of the control valve on the transmission are used to locate other elements, please
contact GRAZIANO Trasmissioni S.p.A. (Projects Technical Office) for approval. Bolts have to be
tightened with torque of 1.9 ÷ 2.1 Nm.

RUNNING-IN
Hydraulic transmission
The running-in time is 60-80 hrs., during which it is necessary to perform the following operations: check
the transmission frequently to make sure that there are no oil leaks.
Every 10 hrs.
Check the oil level in the transmission and, if required, top up (for oil brand pls. refer to the supply list).
Oil level check must be performed at engine idle speed, transmission in neutral and with oil at rated
temperature (minimum 40°C).
At the end of the running-in period
a. change the oil
b. replace the oil filter
Above rules must be observed even after an overhaul of the hydraulic transmission.

PERIODIC SERVICING
Every 200 hrs.:
Transmission: check oil level with oil dipsticks. If necessary, top up through the inlet plug. The oil level check
must be performed with engine at idle speed, transmission in neutral and oil at operating temperature
(minimum 40°C).
Every 500 hrs.:
Transmission oil filter: change the filtering cartridge and o-ring on plug.
Note: As two cartridges have been replaced it is necessary to replacetransmission oil,
drain thru plug. When oil is renewed clean also oil suction filter. Oil replacement should
be performed not over a year or 1000 hours.
Brake At least every 500 hours the automatic adjuster bolt threads and sliding bushes are to
be greased with heat resistance grease. Also the cylinders and shoe lining must be
inspected, check also for plugs installation, if missing or loose must be replaced.
Care must be taken for water tightness of the brake compartment if steam cleaner has
to be used.
Henges: Grease the frame mount support.

Every 1500 hrs.:


Axle: oil change.

94 Ed. 05/2007
32.6 - TROUBLESHOOTING PROCEDURE

A. General information
Before locating any fault, it is necessary to act as follows:
• check oil level and oil condition. For details, pls. see servicing section.
• Check transmission, oil cooler and oil cooler pipes to find any damage or leak. Repair if necessary.
• Make sure that the problem is not due to the engine and/or to the axle assy.
Proceed on all pressure checks at normal working temperature. The pressure gauges must have a range of
0-15 bar and must be accurate.
Warning:never stall converter for more than 10 seconds with high engine r.p.m.. Select neutral and let
! transmission cool. Failure of this precaution can cause serious damage to the transmission.

B. Problems hints
During the diagnosis, switch the selector into all positions and try to find out in which position the problems
or noises appear. Determine which parts are in motion. This will be a useful point to determinate the cause.
Use the following as a guide in case of problems.
Converter
Some transmission problems are related to the converter. Check and/or replace the converter inthe following
cases:
• weak acceleration with reduced max. speed and overheating (normal stall speed): it can indicate that the
one way clutch wheel is sticking.
• A metallic noise from the converter can indicate converter vane damage.
• Increased stall speed may indicate that the one way clutch is broken.
Clutches
Check and/or replace the clutches if the following abnormalties appear.
• High stall speed. This can indicate that the clutch is slipping. A slipping clutch generally squeals.
Note: generally a slipping clutch overheats. This can cause the disks to warp. In case of overheating,the disks
can stick together. This can stall the transmission if another clutch is engaged.
• If the truck moves in neutral this can indicate clutch damage. Clutch plates warped.

C. Diagnosis

Problems Causes Remedies


LEAKS

1. Pump output shaft gasket or - Faulty gasket Replace


PTO shaft leaks - Bad alignement Rectify
- Damaged shaft Replace.

2. Leaks between the outside of - Damaged seal seat in housing Change seal and apply sealant on
the gasket and its seating the outside diameter.

3. Leaks from the case sealing - Fixing screws loosened Tighten the screws.
gasket

4. Leaks from the drain plug - Copper gasket damaged Replace.

5. Not easy to locate oil leaks on - Oil leaks from the cooler or from Replace the faulty cooler or the faulty
the transmission the oil cooling circuit components of the circuit.

6. Oil leaks from the breather - High or low oil level Rectify the oil level.

32 - Ed. 05/2007 95
Common running faults in all gears

Problems Causes Remedies


1. Low oil pressure - Regulating valve sticked Clean and polish the valve
- Internal leakage Replace the faulty seal rings
- Low oil level Add oil
- Faulty pump Replace the pump
- Suction filter clogged Replace
- Misadjusted Inching control Adjust.

2. No oil pressure - Internal leakage Replace the faulty parts


- Damaged pump Replace the pump
- Damage in the regulating valve Clean and polish the valve.

3. Hard clutch engagement - Locked high pressure, regulating Clean and polish
valve
- Engine idling speed too high Rectify
- Faulty modulating valve Overhaul
- Sticking or unset anti-shock valve Reset or replace
- Impurity or foreign particles in Disassemble and clean.
the distributor

4. Slow clutch engagement - Low clutch pressure See “Low oil pressure”
- Too low idling speed engine Adjust
- Faulty modulating valve Overhaul
- Sticking or unset anti-shock valve Reset or replace.

5. High pressure - Sticking regulating valve Clean and polish.

6. High oil temperature - Faulty cooling circuit Replace the faulty parts
- Choke in the cooling circuit Remove
- Faulty cooler Replace
- Damaged converter Replace
- High oil level Restore the level.

7. Noises in Forward and Reverse - Bad alignment of the converter Align the converter group and the
housing or of the converter with case
the engine
- Damaged gears Replace the damaged gears
- Damaged converter vane Replace the converter.

8. No drive when gears are - Pressure lack See “Oil pressure lack”
engaged - Broken input shaft Replace
- Broken converter drive plate Replace
- Failure of the electric system Repair.

9. Bad Inching working - Sticking valve Repair or replace.

96 Ed. 05/2007
Running faults with gears engaged
Forward and Reverse Gear

Problems Causes Remedies

1. The clutch drags or does not - Warped clutch disks Replace the faulty parts
release (the truck moves at idle) - Mechanical failures Replace the faulty parts
- Absence of clearance in the Increase the clearance as per
clutch pack descriptions
- Sticking electrovalve Repair or replace
- Sticking selector Clean and polish
- Electric failure Repair
- Impurity or foreign particles in the Disassemble and clean.
distributor

2. The clutch does not engage - Low pressure See “Low oil pressure”
(the truck does not move) - Locked electrovalve Repair or replace
- Sticking selector Clean and polish
- Electric failure Repair
- Impurity or foreign particles in the Disassemble and clean.
distributor

3. The truck does not move or it - Low pressure See “Low oil pressure”
moves weakly - Broken or worn seal rings Replace the faulty parts.

Further problems

Problems Causes Remedies


1. Hydraulic noises or valve hums - Air in the hydraulic circuit or low Check the oil level and add if failing.
oil level Make the engine run at 1200 r.p.m.
to eliminate the air.

2. Noises in Forward and Reverse - Broken, cracked or worn gear Replace the damaged parts
Gear teeth
- Worn or damaged bearings Replace.

Bad working in idle

Problems Causes Remedies


1. Truck moving Forward and - Warped clutch plates or clutch Replace the faulty parts
Reverse Gears at idle mechanical failure

2. The Forward and Reverse Gears - Electric breakdown Repair


remain engaged - Sticking electrovalve Repair or replace
- Sticking selector Clean and polish
- Impurities or foreign bodies in valve Dismantle and clean.

32 - Ed. 05/2007 97
Transmission overheating

GB Problems Causes Remedies


Overheating - Too small cooler or oil hoses All the external oil lines and the
cooler must allow the passage of
the oil and have an adequate
exchange capacity
- Faulty cooler Replace
- Damaged converter Replace
- Low oil level Restore the level
- Obstructed suction filter Clean
- Improper use of equipment Do not use the engine in extended
stall
- Low pump pressure, pump worn Check the pressures. Inspect the
or damaged pump if pressures are low. Replace
the pump if worn or damaged
- Slipping clutches Check the seal rings and pressures
- Low pressure See “Low oil pressure”
- Emulsified oil Check the type of oil or low oil level
- Faulty temperature sensor Replace.

98 Ed. 05/2007
SPECIFIC TOOLS - DRAWINGS

INDEX

Drawing. Description page

114
4A41377/00 Fixture for diassembling of clutch plates
115
116
48A17092/00 Q-Ring assembling tool PTO SAE “A”
117
118
48A17127/00 Q-Ring assembling tool SAE “A” -”B”
119
120
48A19118 Locking spanner for slotted nut of Differential

121
48A19119 Locking spanner for slotted nut of hub bearing adjusting (2nd version)

122
48A19120/00 Forcing seal ring tool on spindle of axle (2nd version)

123
48A19394 Forcing seal ring tool on spindle of axle (2nd version)

32 - Ed. 05/2007 99
Fixture for diassembling of clutch plates

8 x 130

Notch

22 x 250

3x3 Weldings

01

02

Thread Rod M12 L = 240 mm

Tool 4A41377/00

Scale : 1:2.5

100 Ed. 05/2007


Tool 4A41377/01
22
40 sm 2x45 8 12
= = 01

65
15
45
30

3x30
180

122
80
66
=
Saldature 3x3
Weldings

14
Weldings
Schweinßnaht 7 30'

118
25
Soudures
Soldaduras

Scale: 1:2,5

Tool 4A41377/02

20

=
40
=
sm 2x45
02 12

50
Saldature 3x3
Weldings
Weldings sm 1
Schweinßnaht
Soudures
Soldaduras
sm 1

=
150
110

180
=
M12
Scale : 1:2,5

32 - Ed. 05/2007 101


Q-Ring assembling tool PTO SAE “A”

3
N

3/N 3/N CACCIASPINA


PIN PUNCH 1 1 7502
UNI UNI Ø5
7502 5

2 2 BASE
BASE 1 1 ALUMINUM
ALLUMINIO

1 1 PUNCH
PUNZONE 1 ALLUMINIO
1 ALUMINUM
N.Part Denom.particolare Quant Materiale o normale Trattam. Dimens.
Part.No Part. No Description Q.ty Material/ Standard Heat treatment Dimension

ELEMENTO DIS. N. 3350283

Scala : 1:2
Scale
Tool 48A17092/00

102 Ed. 05/2007


Tool 48A17092/01

145

95.2

15

2x45
88
132.7+0.1

Quantita
' Mater.
*ZONA PER MARCATURA 1 ALLUMINIO
3.2 N. ATTREZZO 48A17092/1 1 N.Dis. Trattam.
DIS.ELEMENTO 335028 -
Scala
Scale : 1:2

Tool 48A17092/02

95

54.2

1.6
R20

15
65
R20

85
13

1.6

15
R20

7.8
129.7

1.6
132.5+0.1
3.2 1.6

Quantita
' Mater.
*ZONA PER MARCATURA 1 ALLUMINIO
N. ATTREZZO 48A17092/2 2 N.Dis. Trattam.
DIS.ELEMENTO 335028 -

Scala
Scale : 1:2

32 - Ed. 05/2007 103


Q-Ring assembling tool SAE “A” -”B”

3
N

3/N PIN PUNCH 1 UNI 7502 Ø5


3/N CACCIASPINA 1 UNI 7502 5
2 BASE 1 ALUMINUM
2 BASE 1 ALLUMINIO
1 PUNCH 1 ALUMINUM
1 PUNZONE 1 ALLUMINIO
Part.No N.Part
Part. No Description
Denom.particolare
Material/
Q.ty Quant Standard Heat treatment Dimens.
Materiale o normale Trattam.
Dimension

ELEMENTO DIS. N. 3289943-3289933-3290003

Tool 48A17127/00 Scala : 1:2

104 Ed. 05/2007


Tool 48A17127/01

140

95.2

15
85
126.2+0.1

Quantita
' Mater.
*ZONA PER MARCATURA 1 ALLUMINIO
N. ATTREZZO 48A17127/1 1 N.Dis. Trattam.
3.2
DIS.ELEMENTO328993-94
329000 -

Scale : 1:2

Tool 48A17127/02

95

R15

15
R15

75
R15

15
7.7
54.2
123

1.6
126+0.1

Quantita
' Mater.
*ZONA PER MARCATURA 1 ALLUMINIO 3.2 1.6
N. ATTREZZO 48A17127/2 2 N.Dis. Trattam.
DIS.ELEMENTO328993-94
329000 -

Scala
Scale : 1:2

32 - Ed. 05/2007 105


45 °

45°
45 °
elettricamente
N.Part
MONTAGGIO

45°
Ø 64

Ø 74

Ø 85

Ø 106

Ø 112

Ø 125

6.3

106 Ed. 05/2007


32 - Ed. 05/2007 107
108 Ed. 05/2007
109

110
50
Proteggere dalla cmt
R 10
26
6

ZONA PER MARCATURA


N° ATTREZZO 48A19394
DIS.ELEMENTO 3353383
R 10
50 (ZIGRINATO)
184
135

R 10
6.3
21.5`0.05

0.8
0.8
42.5

Punzone 1 18NiCrMo5 cmt/tmp HRC 60`2


d

b
a
c

0.8 N.Part Denom.particolare Quant Materiale o normale Trattam. Dimens. MODIFICHE


Tolleranze generali per DENOMINAZIONE ELEMENTO Tolleranze di forma e posiz
dimensioni di parti
lavorate senza indicazioni
secondo tab. UNI 7226-73
a disegno:
Proteggere le filettature
11

FORI H13 ASSALE TXL30/ST


30 ALBERI h1 3
QUOTE LINEARI J/j13
dalla cementazione
ELEMENTO DIS. N. Raggi e smussi non
ANGOLI `30'
3353383 quotati = 0.5
presente disegno a norma delle vigenti leggi

FILETTATURE 6H/6g
E' vietato riprodurre o comunicare a terzi il

-0.05 ATTREZZATURA
42 Punzone per piantaggio
0.8

-0.10 CAD
DRAWING
anello di tenuta dis.71482 su
32 - Ed. 05/2007

GRAZIANO Trasmissioni S.p.A. NO HANDLING


-0.05 WITHOUT CAD SYSTEM
55 - 0 .1 0 BARI manicotto scatola ponte
Macchina operatrice MONTAGGIO N. GT OP.N.
Disegnato Scala Foglio
77 CAPORALE DIS. N.
Visto Data 1di1 48A19394
11/02/04