Manuel de Réparation MRT-X - 1840

REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
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MOTORISATION
ENGINE DISASSEMBLY 1104D-44T 1-1
TRANSMISSION
DISASSEMBLING HYDROSTATIC MOTOR MRT 1440/1640/1840 EASY 2-1
TRANSMISSION OPERATION (REGULATION) MRT 1440/1640/1840 EASY 2-2
30-disassembly gear-box 2-3
PONT - ESSIEU
DISASSEMBLING FRONT-REAR AXLE AND HYDROSTATIC 3-1
30-disassembly_axle 3-2
FLECHE
DISASSEMBLING AND REASSEMBLING THE TELESCOPIC BOOM MRT 1840 EASY
4-1
DISASSEMBLING AND REASSEMBLING THE TELESCOPIC BOOM MRT 1440-1640
EASY 4-2
50-DISASS BOOM IT-EN-DE 1440-1640 EASY 4-3
50-DISASS BOOM IT-EN-DE MRT1840 EASY 4-4
HYDRAULIQUE
70-COLLECTORS 5-1
HYDRAULIC SYSTEMS 5-2
TANK DISASSEMBLING MRT 1440/1640/1840 EASY 5-3
PRESSURE CONTROL 1440/1640/1840 EASY 5-4
POSITION OF HYDRAULIC COMPONENTS 1440/1640/1840 EASY 5-5
DISASSEMBLING AND REASSEMBLING OUTRIGGERS TILTING CYLINDER
1440/1640/1840 EASY 5-6
CYLINDERS DISASSEMBLY 1440/1640/1840 EASY 5-7
70-CYLIN_ACCELERATOR 5-8
70-HYDRAULIC ROTATION COLLECTOR 5-9
ELECTRICITE
ELECTRICAL SYSTEMS 6-1
CABLES MRT 1440/1640/1840 EASY 6-2
LOGIC BOX MRT 1440/1640/1840 EASY 6-3
BASKET REMOTE CONTROL CABLES MRT 1440/1640/1840 EASY 6-4
RADIO REMOTE CONTROL MRT 1440/1640/1840 EASY 6-5
FREIN
40-BRAKES IT-EN-DE 7-1
UNIT 10
ENGINE
KENR6245
May 2007
Specifications
1104D (Mech) Industrial Engine
NK (Engine)
NL (Engine)
NK (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
KENR6245 3
Table of Contents
Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 5
Fuel Injectors ....................................................... 6
Fuel Transfer Pump ............................................. 6
Lifter Group ........................................................... 7
Rocker Shaft ........................................................ 7
Valve Mechanism Cover ...................................... 8
Cylinder Head Valves ........................................... 8
Cylinder Head ...................................................... 10
Turbocharger ....................................................... 11
Exhaust Manifold ................................................. 12
Camshaft ............................................................. 12
Camshaft Bearings .............................................. 14
Engine Oil Filter ................................................... 14
Engine Oil Cooler ................................................. 15
Engine Oil Pump .................................................. 16
Engine Oil Pressure ............................................. 18
Engine Oil Bypass Valve ...................................... 18
Engine Oil Pan ..................................................... 19
Crankcase Breather ............................................. 20
Water Temperature Regulator and Housing ......... 22
Water Pump ......................................................... 22
Cylinder Block ...................................................... 22
Crankshaft ........................................................... 24
Crankshaft Seals ................................................. 26
Connecting Rod Bearing Journal ......................... 26
Main Bearing Journal ............................................ 27
Connecting Rod ................................................... 27
Piston and Rings .................................................. 29
Piston Cooling Jet ................................................. 30
Front Housing and Covers ................................... 31
Gear Group (Front) ............................................... 31
Flywheel ............................................................... 33
Flywheel Housing ................................................ 34
Crankshaft Pulley ................................................. 34
Fan Drive ............................................................. 35
Engine Lifting Bracket ........................................... 36
Alternator ............................................................. 36
Starter Motor ........................................................ 37
Glow Plugs ........................................................... 38
Index Section
Index ..................................................................... 40
4 KENR6245
Specifications Section When the camshaft is viewed from the front of

the engine, the camshaft rotates in the following
direction: ................................................... Clockwise
i02655068
The front of the engine is opposite the flywheel end.
Engine Design The left side and the right side of the engine are
viewed from the flywheel end. The No. 1 cylinder is
the front cylinder.
i02656438
Fuel Injection Lines
g01333480
Illustration 1
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve
Bore ......................................... 105 mm (4.133 inch)
Stroke ...................................... 127 mm (5.000 inch)
Displacement ...................................... 4.4 L (269 in3)
Cylinder arrangement ..................................... In-line

g01334606
Type of combustion ............................ Direct injection Illustration 2
Typical example
Compression ratio
(1) Tighten the union nuts for the fuel injector nozzles
Naturally aspirated engines ...................... 19.3:1 to the following torque. ............. 30 N·m (22 lb ft)
Turbocharged engines .............................. 18.2:1
Tighten the union nuts for the fuel injection pump (not
Number of cylinders ................................................ 4 shown) to the following torque. ....... 30 N·m (22 lb ft)
Valves per cylinder .................................................. 2
Valve lash
Inlet valve ......................... 0.20 mm (0.008 inch)
Exhaust valve ................... 0.45 mm (0.018 inch)
Firing order ................................................. 1, 3, 4, 2
When the crankshaft is viewed from the front of

the engine, the crankshaft rotates in the following
direction: ................................................... Clockwise
KENR6245 5
i02663071 Unlocking the shaft

Fuel Injection Pump Loosen locking screw (2) and install the washer
(3) to the unlocked position. Tighten the bolt to
the following torque. ................... 12 N·m (9 lb ft)
Note: Before the fuel injection pump is removed from

the engine the fuel injection pump shaft must be
locked. Position the engine to TC compression stroke
of number one cylinder before tightening the locking
screw. The locking screw will prevent the shaft from
rotating. If the fuel injection pump was removed
prior to correctly timing the engine and locking the
shaft, the fuel injection pump will need to be timed by
trained personnel.
g01352239
Illustration 4
Typical example of a support bracket
(4) Tighten the mounting bolt to the following

torque. ...................................... 44 N·m (32 lb ft)
(5) Tighten the mounting bolt and the nut to the

following torque. ....................... 22 N·m (16 lb ft)
Note: The support bracket must be installed after

the coolant pump is installed. In order to stop the
distortion of the timing case, finger tighten the bolt
(4) and then tighten the nut and bolt (5). Tighten the
bolt (4).
Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 N·m (18 lb ft)
g01352237
Illustration 3
Typical example
Note: The solenoid on the fuel injection pump is

a serviceable item. The fuel injection pump is a
nonserviceable item.
(1) O-ring
(2) Locking screw
(3) Washer
Locking the shaft

Loosen locking screw (2) and move the washer
(3) to the locked position. Tighten the bolt to the
following torque. ...................... 17 N·m (12 lb ft)
6 KENR6245
i02662510 i02661897
Fuel Injectors Fuel Transfer Pump
g00908211
Illustration 5
Fuel injector clamp
(1) Tighten the bolt in the clamp for the fuel injector
to the following torque. ............. 35 N·m (26 lb ft)
The fuel injector should be tested at the pressure in

table 1.
Leakage in 10 seconds ................................. 0 drops
Table 1
Service setting for the Fuel Injector g00986823

Illustration 6
Injection Pressure
29.4 + 0.8 MPa (4264 + 116 psi) (1) Retaining bolts
(2) Clip
(3) Spacer
(4) Fuel transfer pump

Type .......................... 12 or 24 volt electric motor
(5) Fuel filter element
(6) O ring
(7) Fuel filter bowl
Note: Tighten the fuel filter bowl by hand. Rotate the

bowl 1/8 of a turn more by hand.
KENR6245 7
i02677369
Lifter Group
g00629433 g01345401
Illustration 7 Illustration 8
The rocker shaft
(1) Diameter of the lifter body .. 18.987 to 19.012 mm
(0.7475 to 0.7485 inch) Note: In order to install the rocker shaft assembly,
Tooling (A) is required.
Clearance of the lifter in the cylinder block
bore ....... 0.038 to 0.095 mm (0.0015 to 0.0037 inch) (1) Snap ring
i02655105
(2) Washer
Rocker Shaft (3) Rocker arm
(4) Rocker arm bore

Diameter of the rocker arm
bore .................................. 25.013 to 25.051 mm
Table 2 (0.9848 to 0.9863 inch)
Required Tools
Rocker arm
Part
Tool Number Part Description Qty Clearance between the rocker arm and the rocker
shaft ...................................... 0.026 to 0.089 mm
A 27610227 Spacing Tool 4
(0.0010 to 0.0035 inch)
Maximum permissible clearance between the
rocker arm and the rocker shaft ............ 0.17 mm
(0.007 inch)
(5) Spring
Note: Install the longest screw at the front of the

rocker shaft assembly.
(6) Tighten the screws evenly. Begin in the center

and work toward the outside. Tighten the screws
(7) Rocker shaft

Diameter of the rocker
shaft .................................. 24.962 to 24.987 mm
(0.9828 to 0.9837 inch)
8 KENR6245
(8) In order to install the rocker shaft assembly, i02662486

ensure that the machined square is to the top of
the rocker shaft. Cylinder Head Valves
(9) Locknut
Torque for the locknut ............... 27 N·m (20 lb ft)
i02551219
Valve Mechanism Cover
g01277221
Illustration 9
Tighten the bolts for the valve mechanism cover

in the sequence that is shown to the following
torque. ................................................. 9 N·m (7 lb ft) g01345407
Illustration 10
Cross section of cylinder head
(1) Valve spring

Naturally aspirated engines
The installed length of the valve
springs .......................... 35.17 mm (1.3846 inch)
The load for the installed valve springs ..... 335 N
(75 lb)
Turbocharged engines
The installed length of the inlet valve springs
(high ratings) ................. 35.17 mm (1.3846 inch)
The load for the installed inlet valve
springs ........................................... 335 N (75 lb)
The installed length of the inlet valve springs (low
ratings) .......................... 36.17 mm (1.4240 inch)
The load for the installed inlet valve
springs ........................................... 312 N (70 lb)
The installed length of the exhaust valve springs
(all ratings) .................... 36.17 mm (1.4240 inch)
The load for the installed exhaust valve
spring ............................................. 312 N (70 lb)
KENR6245 9
Turbocharged aftercooled engines Service limit ........................... 2.06 mm (0.0811 inch)

The installed length of the valve
springs .......................... 36.17 mm (1.4240 inch) Turbocharged aftercooled engines .. 1.55 to 1.81 mm
The load for the installed valve springs ..... 312 N (0.0610 to 0.0713 inch)
(70 lb)
Service limit ........................... 2.06 mm (0.0811 inch)
(2) Valve spring recess
(5) Inlet valve
(3) The finished valve guides Diameter of the inlet valve
Inside diameter of valve stem ...................................... 8.953 to 8.975 mm
guide ..................................... 9.000 to 9.022 mm (0.3525 to 0.3533 inch)
(0.3543 to 0.3552 inch) Clearance of valve in valve
guide .. 0.025 to 0.069 mm (0.001 to 0.0027 inch)
Outside diameter of the valve
guide ................................. 13.034 to 13.047 mm Overall length of the inlet
(0.5131 to 0.5137 inch) valve ................................... 128.838 to 129.288 mm
(5.0724 to 5.0901 inch)
Interference fit of valve guide in cylinder
head ...................................... 0.007 to 0.047 mm The face of the inlet valve is recessed below the
(0.0003 to 0.0019 inch) cylinder head by the following amount.
Length of Valve guide .......... 51.00 to 51.50 mm Naturally aspirated engines ............ 0.60 to 0.85 mm
(2.018 to 2.027 inch) (0.0236 to 0.0335 inch)
Projection of the valve guide above the valve
spring recess (2) ................... 12.35 to 12.65 mm Turbocharged engines (high rating) .. 0.60 to 0.85 mm
(0.486 to 0.498 inch) (0.0236 to 0.0335 inch)
Note: When new valve guides are installed, new Service limit ............................ 1.09 mm (0.043 inch)
valves and new valve seat inserts must be installed.
The valve guides and the valve seat inserts are Turbocharged engines (low rating) .. 1.60 to 1.85 mm
supplied as partially finished parts. The unfinished (0.0630 to 0.0728 inch)
valve guides and unfinished valve seat inserts are
installed in the cylinder head. The guides and inserts Turbocharged aftercooled engines .. 1.60 to 1.85 mm
are then cut and reamed in one operation with special (0.0630 to 0.0728 inch)
tooling. This procedure ensures the concentricity of
the valve seat to the valve guide in order to create a Service limit .......................... 2.09 mm (0.0823 inch)
seal that is tight. Refer to Disassembly and Assembly
for removal and installation procedures. (6) Exhaust valve face angle from the horizontal axis
Valve face angle ............................... 30 degrees
(4) Exhaust valve Valve seat angle ............................... 30 degrees
Diameter of the exhaust valve
stem ...................................... 8.938 to 8.960 mm (7) Diameter of the exhaust
(0.3519 to 0.3528 inch) valve head ............................ 41.51 to 41.75 mm
(1.634 to 1.643 inch)
Clearance of valve in valve
guide ..... 0.040 to 0.062 mm (0.0016 to 0.0024 inch) (8) Diameter of the head of the inlet
valve ..................................... 46.28 to 46.53 mm
Overall length of the exhaust (1.8220 to 1.8319 inch)
valve ................................... 128.184 to 128.634 mm
(5.0466 to 5.0643 inch) (9) Angle of the inlet valve face from the vertical axis
Valve face angle ............................... 45 degrees
The face of the exhaust valve is recessed below the
Valve seat angle ............................... 45 degrees
cylinder head by the following amount.
The valve lash is the following value when the engine
Naturally aspirated engines ............ 0.55 to 0.81 mm
is cold:
(0.0217 to 0.0319 inch)
Inlet valves ........................ 0.20 mm (0.008 inch)
Service limit ............................ 1.06 mm (0.042 inch) Exhaust valves ................. 0.45 mm (0.018 inch)
Turbocharged engines .................... 1.55 to 1.81 mm

(0.0610 to 0.0713 inch)
10 KENR6245
i02662502
Cylinder Head
Table 3
Required Tools
Part
Tool Number Part Description Qty
A 21825607 Angle gauge 1
g00809016
Illustration 11
The maximum distortion of the cylinder head is given
Recess for the valve seat insert in table 4.
(10) Machine the recess in the head for valve seat The cylinder head bolts are two different lengths. The
inserts to the following dimensions. following information provides the proper torque for
the cylinder head bolts.
Recess for Inlet Valve Seat for Naturally Aspirated
Engines and high rated turbocharged engines
(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3953 inch)
(B) ..................................... 47.820 to 47.845 mm
(1.8827 to 1.8837 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch)
Recess for Exhaust Valve Seat for Naturally
Aspirated Engines and high rated turbocharged
engines
(A) ..... 9.84 to 10.04 mm (0.3874 to 0.3953 inch)
(B) ..................................... 42.420 to 42.445 mm
(1.6701 to 1.6711 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch)
Recess for Inlet Valve Seat for low rated
turbocharged engines and turbocharged
aftercooled engines
(A) .... 10.84 to 11.04 mm (0.4268 to 0.4346 inch)
(B) ..................................... 47.820 to 47.845 mm
(1.8827 to 1.8837 inch)
(C) Maximum radius ......... 0.38 mm (0.015 inch) Illustration 12
g00987480
Recess for Exhaust Valve Seat for turbocharged The tightening sequence
engines and turbocharged aftercooled engines
Lubricate the threads and the underside of the head
(A) .... 10.84 to 11.04 mm (0.4268 to 0.4346 inch)
bolts with clean engine oil.
(B) ..................................... 42.420 to 42.445 mm
(1.6701 to 1.6711 inch) Tighten the bolts in the sequence that is shown in
(C) Maximum radius ......... 0.38 mm (0.015 inch) Illustrations to the following torque. ......... 50 N·m
(37 lb ft)
Tighten the bolts again to the following
torque. .................................... 100 N·m (74 lb ft)
KENR6245 11
i02662519
Turbocharger
g00905621
Illustration 13
The head bolts require an additional torque turn

procedure. The numbers (1, 3, 4) are three long
cylinder head bolts. All the other bolts are short bolts.
The tightening sequence is shown in the Illustrations .
Place the angle gauge on the top of each bolt
head. Tighten the short bolts to the additional
amount. ........................................... 225 degrees
Place the angle gauge on the top of each bolt
head. Tighten the long bolts for the additional
amount. ........................................... 270 degrees
g00991357
Illustration 15
Thickness of the cylinder head .. 117.95 to 118.05 mm
Typical turbocharger
(4.643 to 4.647 inch)
(1) Actuator rod
Minimum thickness of cylinder head ........ 117.20 mm
(4.614 inch)
(2) Actuator
Note: The maximum distortion of the cylinder head
(3) Turbocharger
is given in table 4.
(4) Tighten the nuts to the following torque. .. 44 N·m
(32 lb ft)
(5) Tighten the bolt to the following torque. ..... 9 N·m

(80 lb in)
(6) Tighten the bolt to the following torque. ... 22 N·m

(16 lb ft)
The maximum test pressure for the

wastegate ....................................... 205 kPa (30 psi)
The movement for the rod actuator ................. 1 mm

(0.0394 inch)
g01006568
Illustration 14
Table 4
Maximum Permissible
Dimension
Distortion
Width (A) 0.03 mm (0.0012 inch)
Length (B) 0.05 mm (0.0019 inch)
Diagonal Line (C) 0.05 mm (0.0019 inch)
12 KENR6245
Table 5 i02662527
The part number for

the turbocharger
The pressure for the
wastegate
Exhaust Manifold
2674A835 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A841 123 ± 3 kPa
(17.8399 ± 0.4351 psi)
2674A843 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A816 131 ± 3 kPa
(19.0002 ± 0.4351 psi)
2674A817 100 ± 3 kPa
(14.5040 ± 0.4351 psi)
2674A836 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A818 123 ± 3 kPa
(17.8399 ± 0.4351 psi)
2674A844 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
2674A819 131 ± 3 kPa
(19.0002 ± 0.4351 psi)
2674A821 100 ± 3 kPa
(14.5040 ± 0.4351 psi)
g01337856
2674A837 138 ± 3 kPa Illustration 16
(20.0155 ± 0.4351 psi) Typical example
2674A822 123 ± 3 kPa
(17.8399 ± 0.4351 psi) Tighten the exhaust manifold bolts in the sequence
that is shown in illustration 16 to the following
2674A838 138 ± 3 kPa torque. ............................................. 40 N·m (30 lb ft)
(20.0155 ± 0.4351 psi)
2674A825 123 ± 3 kPa
i02662539
(17.8399 ± 0.4351 psi)
2674A845 138 ± 3 kPa Camshaft
(20.0155 ± 0.4351 psi)
2674A826 131 ± 3 kPa
(19.0002 ± 0.4351 psi)
2674A827 100 ± 3 kPa
(14.5040 ± 0.4351 psi)
2674A842 138 ± 3 kPa
(20.0155 ± 0.4351 psi)
g01277351
Illustration 17
Checking the end play of the camshaft
KENR6245 13
(1) End play of a new camshaft ..... 0.10 to 0.55 mm

(0.004 to 0.022 inch)
Maximum permissible end play of a worn

camshaft ................................. 0.60 mm (0.023 inch)
g01277354
Illustration 18
Typical camshaft
(2) Bolt
Tighten the bolt to the following torque. ... 95 N·m
(70 lb ft)
g01345411
(3) Camshaft thrust washer Illustration 19
Typical example
Thickness of the thrust washer .. 5.49 to 5.54 mm
(0.216 to 0.218 inch) (5) Camshaft lobe lift
Depth of the recess in the cylinder block for the
Naturally aspirated
thrust washer ............................ 5.54 to 5.64 mm
(0.218 to 0.222 inch) Inlet lobe ............................... 7.201 to 7.301 mm
(0.2835 to 0.2874 inch)
Tolerance of the thrust washer in cylinder block Exhaust lobe ......................... 7.404 to 7.504 mm
front face ........................... −0.154 to −0.003 mm (0.2914 to 0.2954 inch)
(−0.0006 to −0.0001 inch)
Turbocharged
(4) The diameters of the camshaft journals are given Inlet lobe ............................... 7.527 to 7.627 mm
in the following table. (0.2963 to 0.3003 inch)
Exhaust lobe ......................... 7.363 to 7.463 mm
Table 6
(0.2899 to 0.2938 inch)
Diameters of Camshaft Journals
Turbocharged aftercooled
Camshaft Journals Standard Diameter
Inlet lobe ............................... 7.031 to 7.131 mm
1
50.711 to 50.737 mm (0.2768 to 0.2807 inch)
(1.9965 to 1.9975 inch) Exhaust lobe ......................... 7.363 to 7.463 mm
50.457 to 50.483 mm (0.2899 to 0.2938 inch)
2
(1.9865 to 1.9875 inch)
(6) Camshaft lobe height
49.949 to 49.975 mm
3
(1.9665 to 1.9675 inch) (7) Base circle
Maximum wear on the camshaft journals ... 0.05 mm To determine the lobe lift, use the procedure that
(0.0021 inch) follows:
1. Mount the camshaft between centers.
2. By using a dial indicator in contact with the surface

of the lobe, rotate the camshaft and record the
maximum and minimum lift.
14 KENR6245
Note: There may be two lobes on the camshaft. i02663064

Refer to illustration 19. The surface between the
lobes may not return to the radius of the base circle. Engine Oil Filter
Using a micrometer to measure the diameter of the
base circle may give a inaccurate result.
3. Subtract the smallest dimension from the largest

dimension. The difference is the actual camshaft
lobe lift.
Maximum permissible deviation between the

actual lobe lift and the specified lobe lift of a new
camshaft ................................. 0.05 mm (0.002 inch)
i02656416
Camshaft Bearings
g01338237
Illustration 21
Typical example
(1) Setscrew
Tighten the setscrews to the following
torque. ...................................... 22 N·m (16 lb ft)
(2) Engine oil filter

Tighten the engine oil filter to the following
torque. .................................... 12 N·m (106 lb in)
g01334592
Illustration 20
Typical example
(1) The diameter of the installed camshaft

bearing .............................. 50.787 to 50.848 mm
(1.9995 to 2.0019 inch)
KENR6245 15
i02657143
Engine Oil Cooler
g00952614
Illustration 23
Typical example
(1) Joint
(2) Oil cooler
(3) Housing
(4) Setscrew
(5) Seal
g01338238 (6) Setscrew
Illustration 22
(7) Setscrew
Typical example
(3) Setscrew
Tighten the setscrews to the following
torque. ...................................... 22 N·m (16 lb ft)
(4) Engine oil filter

Tighten the engine oil filter to the following
torque. .................................... 12 N·m (106 lb in)
(5) Plug
Tighten the plug to the following torque. .. 12 N·m
(106 lb in)
g01334858
Illustration 24
Setscrews
Tighten the setscrews (7) to the following
torque. ...................................... 22 N·m (16 lb ft)
Setscrews
Tighten the setscrews (4) and (6) in the
sequence that is in illustration 24 to the following
torque. ...................................... 22 N·m (16 lb ft)
16 KENR6245
i02656269
Engine Oil Pump
Engines with Balancer Group

Type ............................. Gear-driven differential rotor
Number of lobes
Inner rotor ......................................................... 6
Outer rotor ........................................................ 7
g01334410
Illustration 26
Inner rotor
(2) Clearance of inner rotor to outer

rotor ...................................... 0.050 to 0.200 mm
(0.0020 to 0.0079 inch)
g01334408
Illustration 25
The oil pump for the balancer
(1) Clearance of the outer rotor to the

body .. 0.130 to 0.24 mm (0.0050 to 0.0094 inch)
g01334412
Illustration 27
The end play for the rotor
(3) End play of rotor assembly

Inner rotor .................................. 0.04 to 0.11 mm
(0.0016 to 0.0043 inch)
Outer rotor ................................. 0.04 to 0.11 mm
(0.0016 to 0.0043 inch)
KENR6245 17
(6) Tighten the nut to the following torque. .... 95 N·m

(70 lb ft)
Tighten the bolts that hold the balancer to the cylinder

block to the following torque. .......... 54 N·m (40 lb ft)
Engines without Balancer Group

Type ............................. Gear-driven differential rotor
Number of lobes
Inner rotor ......................................................... 5
Outer rotor ........................................................ 6
g01334415
Illustration 28
The end cover
(4) Torque for cover bolts for oil pump .......... 26 N·m
(19 lb ft)
g00938064
Illustration 30
The oil pump
(1) Clearance of the outer rotor to the

body ...................................... 0.152 to 0.330 mm
(0.0059 to 0.0129 inch)
g01334416
Illustration 29
Idler gear and pump gear
g00938061
Illustration 31
Note: Replace the idler gear bolt (5) and the nut for Checking the clearance
the oil pump gear (6).
(2) Clearance of inner rotor to outer
(5) Tighten the idler gear bolt to the following rotor ...................................... 0.040 to 0.127 mm
torque. ...................................... 26 N·m (19 lb ft) (0.0015 to 0.0050 inch)
Note: Set the engine to the TC position. Refer to

Systems Operation, Testing and Adjusting Manual,
“Finding Top Center Position for No. 1 Piston”. Install
the balancer. Refer to Disassembly and Assembly,
“Balancer - Install”. Install the gear for the oil pump
and tighten the nut (6).
18 KENR6245
i02505676
Engine Oil Bypass Valve
Installed in the Oil Pump
g00938799
Illustration 32
Checking the end play
(3) End play of rotor assembly

Inner rotor ............................. 0.038 to 0.089 mm
(0.0014 to 0.0035 inch)
Outer rotor ............................ 0.025 to 0.076 mm
(0.0010 to 0.0029 inch)
g00919893
Illustration 33
Tighten the bolts that hold the front cover of the oil
Typical engine oil pump
pump assembly to the following torque. ........ 10 N·m
(89 lb in)
i02731019
Engine Oil Pressure
The minimum oil pressure at the maximum engine

speed and at normal operating temperature is the
following value. ............................... 280 kPa (41 psi)
g00921377
Illustration 34
Relief valve and spring
(1) Tighten the plug for the relief valve to the

(2) Plunger
Diameter of the plunger ..... 19.186 to 19.211 mm
(0.7554 to 0.7563 inch)
Clearance of plunger in bore .. 0.039 to 0.114 mm
(0.0015 to 0.0045 inch)
(3) Spring
Length of the spring ...... 80.94 mm (3.1866 inch)
KENR6245 19
Installed in the Balancer i02662550
Engine Oil Pan
Table 7
Required Tools
Tool Part Number Part Description Qty
POWERPART
A 21826038 1
Retainer
Illustration 35
g00919890 Front sealant
Plug
g00921379
Illustration 36
The relief valve for the balancer
(1) Tighten the plug for the relief valve to the

g01254690
Illustration 37
(2) Plunger Applying sealant
Diameter of the plunger ........ 14.46 to 14.48 mm If the gasket that is between the front housing and
(0.5692 to 0.5700 inch) the cylinder block is not renewed, apply Tooling (A) to
Clearance of the plunger in the the cylinder block and to the front housing. If a new
bore .... 0.04 to 0.08 mm (0.0015 to 0.0031 inch) gasket is installed, Tooling (A) is not required.
(3) Spring Note: Apply a sealant bead of 3.5 mm (0.1378 inch)

that is shown in illustration 37.
Length of the spring ........... 67 mm (2.6378 inch)
Rear sealant
Note: Install the rear oil seal before sealant is applied
to the bridge.
20 KENR6245
Tighten the remaining bolts to the following

torque. ............................................. 22 N·m (16 lb ft)
(2) Drain plug

Tighten the drain plug for the engine oil pan to
the following torque. ................. 34 N·m (25 lb ft)
i02662638
Crankcase Breather
Table 8
Required Tools
Part
Illustration 38
g01254887 POWERPART red rubber
A 21820221 1
grease
Applying sealant
Apply Tooling (A) to the bridge. The sealant must

not protrude more than 5 mm (0.1969 inch) above
the bridge.
g00926199
Illustration 40
Breather valve
(1) Cover
(2) Cover plate
(3) Screws
Tighten the screws for the cover plate with
a composite valve mechanism cover to the
g01255016
Illustration 39 following torque. ................... 1.3 N·m (11.5 lb in)
Typical example
(4) Diaphragm
(1) Tighten the four front bolts in position (X) to the
following torque. ....................... 22 N·m (16 lb ft) (5) Cap
KENR6245 21
(6) Spring Breather Canister
g00926200
Illustration 41
Typical example
(7) O-ring
Note: Apply Tooling (A) to the O-ring before installing

the breather pipe in the valve mechanism cover. Illustration 42
g01277902
Typical example
(8) Tighten the bolts that secure the breather pipe to
(1) Connection
the cylinder head to the following torque. .. 9 N·m (2) Clamp
(80 lb in) (3) Hose
(4) Filter base
(5) Bolts
(6) Clamp
(7) Hose
(8) Canister
(2) Tighten the clamps to the following

torque. ........................................ 3 N·m (26 lb in)
(5) Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)
(6) Tighten the clamp to the following torque. .. 3 N·m

(26 lb in)
(8) Tighten the canister to the following

torque. .................................... 12 N·m (106 lb in)
22 KENR6245
i02504533 i02363605
Water Temperature Regulator Water Pump

and Housing
Table 9
Required Tools
POWERPART Red
A 21820221 1
Rubber Grease
g01183807
Illustration 44
Tightening sequence
Tighten the setscrews in the numerical sequence

that is shown in illustration 44 to the following
torque. ............................................. 22 N·m (16 lb ft)
i02663067
g01253716
Illustration 43
Cylinder Block
Typical example
Note: Apply Tooling (A) to the O-ring (4) in order to

install the water temperature regulator housing (2).
(1) Tighten the bolts that fasten the housing to the Table 10
following torque. ....................... 44 N·m (32 lb ft) Required Tools
(2) Water temperature regulator housing Tool Part Number Part Description Qty
POWERPART
(3) Water temperature regulator A 21826038 1
Retainer
Opening temperature ........................ 82° to 87°C
(179.6000° to 156.6000°F)
Full opening temperature .... 95 °C (203.0000 °F)
Minimum stroke at full temperature ........... 9 mm
(0.3543 inch)
KENR6245 23
Use the following procedure in order to install the

main bearing cap bolts:
1. Apply clean engine oil to the threads of the main

bearing cap bolts.
2. Put the main bearing caps in the correct position

that is indicated by a number on the top of the
main bearing cap. Install the main bearing caps
with the locating tabs in correct alignment with the
recess in the cylinder block.
3. Evenly tighten the main bearing cap bolts.
Torque for the main bearing cap bolts. .... 245 N·m
(180 lb ft)
g00924764
Illustration 45
Typical example
(1) Cylinder block
(2) Cylinder bore ................ 105.000 to 105.025 mm

(4.1338 to 4.1348 inch)
The first oversize bore

diameter .................................. 105.5 to 105.525 mm g00938203
Illustration 46
(4.1535 to 4.1545 inch)
Use the following procedure in order to install the
The second oversize bore
allen head bolts for the bridge.
diameter .............................. 106.000 to 106.025 mm
(4.1732 to 4.1742 inch)
Note: Install the rear seal before sealant is applied.
The maximum permissible wear for the cylinder bore
1. Use a straight edge in order to ensure that the
................................. 0 to 0.15 mm (0 to 0.0059 inch)
bridge is aligned with the rear face of the cylinder
block.
(3) Camshaft bearings
Diameter of the bore in the cylinder 2. Tighten the allen head bolts (6) for the bridge.
block for the number 1 camshaft
bearing .............................. 55.563 to 55.593 mm Torque for the allen head bolts ... 16 N·m (12 lb ft)
(2.1875 to 2.1887 inch)
3. When the bridge is installed on the cylinder block,
Diameter of the bore in the cylinder apply Tooling (A) into groove (7) at each end of
block for the number 2 camshaft the bridge. Apply the sealant into the groove until
journal ............................... 50.546 to 50.597 mm the sealant is forced through the bottom end of
(1.9900 to 1.9920 inch) the groove in the bridge.
Diameter of the bore in the cylinder Note: The oil pan must be installed within 10 minutes
block for the number 3 camshaft of applying the sealant.
journal ............................... 50.038 to 50.089 mm
(1.9700 to 1.9720 inch) Total height of the cylinder block between the top and
the bottom faces. ................ 441.173 to 441.274 mm
(4) Main bearings (17.3689 to 17.3729 inch)
Bore in the cylinder block for the main
bearings ............................ 80.416 to 80.442 mm
(3.1660 to 3.1670 inch)
(5) Main bearing cap bolts

24 KENR6245
i02663072 Note: All new turbocharged engines and

turbocharged aftercooled engines have crankshafts
Crankshaft that are nitrocarburised. The crankshaft can also
be nitrided for 20 hours, if the nitrocarburised
process is not available. After a crankshaft has
been machined, the crankshaft must be rehardened.
Inspect the crankshaft for cracks before machining
and after machining. Naturally aspirated engines
have induction hardened crankshafts.
g01338264
Illustration 47
Typical example
(1) Crankshaft
The maximum end play of the crankshaft ... 0.51 mm

(0.0201 inch)
(2) Thrust washers

Standard thickness ................... 2.26 to 2.31 mm
(0.089 to 0.091 inch)
Oversize thickness ................... 2.45 to 2.50 mm
(0.097 to 0.098 inch)
(3) The crankshaft gear
Maximum permissible temperature of the gear for

installation on the crankshaft ........... 180 °C (356 °F)
Note: The timing mark is toward the outside of

the crankshaft when the gear is installed on the
crankshaft.
KENR6245 25
g01338265
Illustration 48
Note: Refer to illustration 48 in order to use table 11.
Table 11
The undersize diameter of the Crankshaft Journals
NUMBER 0.25 mm (0.010 inch) 0.51 mm (0.020 inch) 0.76 mm (0.030 inch)
75.905 to 75.926 mm 75.651 to 75.672 mm 75.397 to 75.418 mm
1
(2.9884 to 2.9892 inch) (2.9784 to 2.9792 inch) (2.9684 to 2.9692 inch)
63.216 to 63.236 mm 62.962 to 62.982 mm 62.708 to 62.728 mm
2
(2.4888 to 2.4896 inch) (2.4788 to 2.4796 inch) (2.4688 to 2.4696 inch)
39.47 mm (1.5539 inch)
3 N/A N/A
maximum
37.44 mm (1.4740 inch)
4 N/A N/A
maximum
44.68 mm (1.7591 inch)
5 N/A N/A
maximum
40.55 mm (1.5965 inch)
6 N/A N/A
maximum
7 Do not machine this diameter. N/A N/A
3.68 mm (0.1449 inch) to
8 N/A N/A
3.96 mm (0.1559 inch)
4.36 to 4.60 mm
9 N/A N/A
(0.1717 to 0.1811 inch)
Refer to table 12 for the maximum run out of the

crankshaft journals.
26 KENR6245
Table 12
Journal Excessive run out
(1) Mounting
(2) 0.08 mm (0.0031 inch)
(3) 0.15 mm (0.0059 inch)
(4) 0.08 mm (0.0031 inch)
(5) Mounting
Refer to Specifications, “Connecting Rod Bearing

Journal” for more information on the connecting rod
bearing journals and connecting rod bearings.
Refer to Specifications, “Main Bearing Journal” for

information on the main bearing journals and for
information on the main bearings.
i02658811
g00915076
Crankshaft Seals Illustration 50
(5) Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in the

sequence that is shown in Illustration 50 to the
Remove the alignment tool.
Tighten bolts 8 and 9 in the sequence that is shown

in Illustration 50 to the following torque. ........ 22 N·m
(16 lb ft)
i02504771
Connecting Rod Bearing

Journal
Refer to Specifications, “Crankshaft” for information

on the undersize crankshaft journals.
The original size of the connecting rod bearing

journal ... 63.47 to 63.49 mm (2.4988 to 2.4996 inch)
g01335894
Illustration 49
Typical example Maximum permissible wear of a bearing journal on a
new connecting rod .............. 0.04 mm (0.0016 inch)
(1) Crankshaft
Width of the connecting rod bearing
(2) Crankshaft seal journals ................................... 40.348 to 40.424 mm
(1.5885 to 1.5915 inch)
(3) Plastic sleeve
Radius of the fillet of the connecting rod bearing
(4) Alignment tool journals ......... 3.68 to 3.96 mm (0.145 to 0.156 inch)
Surface finish of connecting rod bearing

journals ............................................. Ra 0.4 microns
KENR6245 27
Surface finish of radii ........................ Ra 1.3 microns i02662161
Connecting Rod
i02656267
Main Bearing Journal
Refer to Specifications, “Crankshaft” for information

on the undersize main bearing journals, and
information on the width of main bearing journals.
The original size of the main bearing

journal ..................................... 76.159 to 76.180 mm
(2.9984 to 2.9992 inch)
Maximum permissible wear of the main bearing

journals ............................... 0.040 mm (0.0016 inch)
Radius of the fillet of the main bearing

journals ..... 3.68 to 3.69 mm (0.1448 to 0.1452 inch)
Surface finish of bearing journals, crank pins and

radii ................................... 0.4 microns (16 µ inches)
The shell for the main bearings Illustration 51

g00907738
The shells for the main bearings are available The mating surfaces of the connecting rod are
for remachined journals which have the following produced by hydraulically fracturing the forged
undersize dimensions. connecting rod.
Undersize bearing shell .... 0.25 mm (0.010 inch)
(1) Tighten the torx screws for the connecting rod to
the following torque. ................. 18 N·m (13 lb ft)
Tighten the torx screws for the connecting rod again
Thickness at center of the shells .. 2.083 to 2.089 mm
to the following torque. .................... 70 N·m (52 lb ft)
(0.0820 to 0.0823 inch)
Tighten the torx screws for the connecting rod for
Width of the main bearing shells .. 31.62 to 31.88 mm
an additional 120 degrees. The torx screws for
(1.244 to 1.255 inch)
the connecting rod (1) must be replaced after this
procedure.
Clearance between the bearing shell and the main
bearing journals ........................... 0.057 to 0.117 mm
Note: Always tighten the connecting rod cap to the
(0.0022 to 0.0046 inch)
connecting rod, when the assembly is out of the
engine. Tighten the assembly to the following torque
20 N·m (14 lb ft).
(2) The bearing shell for the connecting rod

28 KENR6245
g00995584
Illustration 52
Alignment of the bearing shell
Note: The bearing shell for the connecting rod must

be aligned equally from both ends of the connecting
rod. Refer to (A) in figure 52. Refer to Disassembly
and Assembly for information on the alignment tool.
Table 13
Bearing Width for the 31.62 to 31.88 mm

Connecting Rod (1.245 to 1.255 inch)
Bearing Width for the 31.62 to 31.88 mm
Connecting Rod Cap (1.2449 to 1.2551 inch) g00907744
Illustration 53
Thickness of Connecting
1.835 to 1.842 mm
Rod Bearing at the (3) Inside diameter of the small
(0.0723 to 0.0725 inch)
Center bush .................................. 39.723 to 39.738 mm
Thickness of Connecting
(1.5639 to 1.5645 inch)
1.835 to 1.842 mm
Rod Bearing for the Cap
(0.0722 to 0.0725 inch) (4) Distance between the parent
at the Center
bores ................................. 219.05 to 219.10 mm
0.034 to 0.081 mm (8.624 to 8.626 inch)
Bearing Clearance
(0.0013 to 0.0032 inch)
(5) Diameter for the parent bore for the connecting
Table 14 rod bearing ........................... 67.21 to 67.22 mm
(2.6460 to 2.6465 inch)
Undersized Connecting Rod Bearing
0.25 mm (0.010 inch)

0.51 mm (0.020 inch)
0.76 mm (0.030 inch)
g00915056
Illustration 54
KENR6245 29
Connecting rods are color coded. The color code Ring gap ................................... 0.30 to 0.55 mm
is a reference for the length (Y) of the connecting (0.0118 to 0.0217 inch)
rod. Refer to table 15 for the different lengths of
connecting rods. Turbocharged
The shape of the top compression
Table 15 ring ........................... Keystone with a barrel face
Length Grades for Connecting Rods
Width of the top compression ring .......... tapered
Grade Letter Color Code Length (Y)
Ring gap ................................... 0.30 to 0.45 mm
165.728 to 165.761 mm (0.0118 to 0.0177 inch)
F Red
(6.5247 to 6.5260 inch)
165.682 to 165.715 mm Note: When you install a new top compression ring,
G Orange
(6.5229 to 6.5242 inch) make sure that the word “TOP” is facing the top of the
piston. New top piston rings for naturally aspirated
165.637 to 165.670 mm
H White
(6.5211 to 6.5224 inch)
engines have a red identification mark which must
be on the left of the ring end gap when the top
J Green
165.591 to 165.624 mm piston ring is installed on an upright piston. New top
(6.5193 to 6.5206 inch) piston rings for turbocharged engines have a yellow
165.545 to 165.578 mm identification mark which must be on the left of the
K Purple ring end gap when the top piston ring is installed on
(6.5175 to 6.5188 inch)
an upright piston.
165.499 to 165.532 mm
L Blue
(6.5157 to 6.4961 inch) (2) Intermediate compression ring
The shape of the intermediate compression
i02662142 ring .................................. Internal chamfer in the
bottom edge with a tapered face
Piston and Rings
Width of intermediate compression ring for
naturally aspirated engines ....... 2.47 to 2.49 mm
(0.097 to 0.098 inch)
Width of intermediate compression ring for
turbocharged engines ........... 2.470 to 2.495 mm
(0.0972 to 0.0982 inch)
Clearance between the intermediate compression
ring and the piston groove for naturally aspirated
engines ... 0.05 to 0.09 mm (0.002 to 0.003 inch)
Clearance between the intermediate compression
ring and the piston groove for turbocharged
engines .................................. 0.065 to 0.110 mm
(0.0026 to 0.0043 inch)
Ring gap for naturally aspirated
engines ..................................... 0.70 to 0.95 mm
g01363510 (0.0275 to 0.0374 inch)
Illustration 55
Typical example Ring gap for turbocharged
engines ..................................... 0.65 to 0.85 mm
(1) Top compression ring (0.0256 to 0.0335 inch)
Naturally Aspirated Note: When you install a new intermediate
The shape of the top compression compression ring, make sure that the word “TOP”
ring ...................... Rectangular with a barrel face is facing the top of the piston. New intermediate
rings for naturally aspirated engines have a green
Width of the top compression identification mark which must be on the left of the
ring ...... 2.47 to 2.49 mm (0.0972 to 0.0980 inch) ring end gap when the top piston ring is installed
on an upright piston. New intermediate rings for
Clearance between the top compression ring and turbocharged engines have a blue identification mark
the piston groove ...................... 0.09 to 0.13 mm which must be on the left of the ring end gap when
(0.0035 to 0.0051 inch) the top piston ring is installed on an upright piston.
30 KENR6245
(3) Oil control ring Piston pin

Shape of oil control Diameter of a new piston
ring ............ a two-piece coil that is spring loaded pin ..................................... 39.694 to 39.700 mm
(1.5628 to 1.5630 inch)
Width of oil control ring for naturally aspirated
engines ..................................... 3.47 to 3.49 mm Diameter of the bore for the piston
(0.1366 to 0.1374 inch) pin ..................................... 39.703 to 39.709 mm
Width of oil control ring for turbocharged (1.5631 to 1.5633 inch)
engines ..................................... 2.97 to 2.99 mm
(0.1169 to 0.1177 inch)
i02665602
Clearance between the oil control ring and
the groove in the piston for naturally aspirated Piston Cooling Jet
engines ..................................... 0.03 to 0.07 mm
(0.0011 to 0.0027 inch)
Ring gap ................................... 0.30 to 0.55 mm
(0.0118 to 0.0216 inch)
Note: A pin is used in order to hold both ends of the

spring of the oil control ring in position. The ends of
the spring of the oil control ring must be installed
opposite the end gap of the oil control ring.
Note: Ensure that the ring end gaps of the piston

rings are spaced 120 degrees from each other.
Piston
Note: An arrow which is marked on the piston crown
must be toward the front of the engine.
g00942652
The combustion bowl re-entrant angle for the Illustration 56
turbocharged engine ............................... 72 degrees (1) Installed piston cooling jets
The combustion bowl re-entrant angle for the The valve must move freely. Tighten the bolt to the
naturally aspirated engine ....................... 70 degrees following torque. .................................. 9 N·m (7 lb ft)
Piston height above cylinder block .. 0.21 to 0.35 mm Piston Cooling Jet Alignment
(0.008 to 0.014 inch)
Width of top groove in piston for the naturally

aspirated engine ............................. 2.58 to 2.60 mm
(0.1016 to 0.1024 inch)
Width of top groove in piston for the turbocharged

engine .......................................................... Tapered
Width of second groove in piston for naturally

aspirated engines ........................... 2.54 to 2.56 mm
(0.1000 to 0.1008 inch)
Width of second groove in piston for turbocharged

engines ..... 2.56 to 2.58 mm (0.1008 to 0.1016 inch)
g01006929
Illustration 57
Width of third groove in piston for naturally aspirated
(2) Piston cooling jet
engines ..... 3.52 to 3.54 mm (0.1386 to 0.1394 inch) (3) Rod
(4) Cylinder block
Width of third groove in piston for turbocharged
engines ...... 3.02 to 3.04 mm (0.1189 to 0.1197 inch) Use the following procedure in order to check the
alignment of the piston cooling jet.
KENR6245 31
1. Insert rod (3) into the end of the piston cooling

jet (2). Rod (3) has a diameter of 1.70 mm
(0.067 inch). Rod (3) must protrude out of the top
of the cylinder block.
2. Dimension (A) is 50.75 mm (1.9980 inch)

and dimension (B) is 9.35 mm (0.3681 inch).
Dimension (A) and dimension (B) are tangential
to the cylinder bore (4).
3. The position of the rod (3) must be within

dimension (C). Dimension (C) is 10 mm
(0.3937 inch).
Note: Ensure that the rod (3) can not damage the
piston cooling jet when the alignment is checked. The
piston cooling jets can not be adjusted. If a piston
cooling jet is not in alignment the piston cooling jet
must be replaced.
i02662168 g00918672
Illustration 59
Front Housing and Covers Front cover
(2) Tighten the bolts that fasten the water pump to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
The front housing must be aligned to the cylinder Note: Refer to Specifications, “Water Pump” for the
block face. .......................... + 0.05 to minus 0.05 mm correct bolt tightening sequence for the water pump.
(+ 0.0020 to minus 0.0020 inch)
i02662183
Gear Group (Front)
g01337594
Illustration 58
Alignment
(1) Tighten the bolts that fasten the front cover to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
g00995886
Illustration 60
Gear train
32 KENR6245
(1) Fuel injection pump drive gear Maximum permissible end play ............ 0.38 mm
(0.015 inch)
Tighten the nut to the following torque. ... 24 N·m
(18 lb ft) Number of teeth .............................................. 73
Release the lock on the fuel injection pump shaft.
Torque the nut to the following torque. .... 90 N·m
(66 lb ft)
Number of teeth .............................................. 68
Note: Refer to Specifications, “Fuel Injection Pump”

for the locking torque for the fuel injection pump shaft.
(2) Camshaft gear

Tighten the bolt for the camshaft gear to the
Bore diameter of the camshaft
gear ...................................... 34.93 to 34.95 mm g00996214
Illustration 61
(1.3750 to 1.3760 inch)
The gear train for the oil pump
Outside diameter of the camshaft
hub .. 34.90 to 34.92 mm (1.3741 to 1.3747 inch) (4) Crankshaft gear
Clearance between the camshaft gear and the Bore diameter of crankshaft gear
camshaft hub ........................ 0.003 to 0.048 mm .... 47.625 to 47.650 mm (1.8750 to 1.8760 inch)
(0.0001 to 0.0019 inch)
Outside diameter of crankshaft
Number of teeth .............................................. 68 hub .................................... 47.625 to 47.645 mm
(1.8750 to 1.8758 inch)
(3) Idler gear and hub
Clearance of gear on
Tighten the bolts for the idler gear to the following crankshaft ......................... −0.020 to +0.020 mm
torque. ...................................... 44 N·m (33 lb ft) (−0.0008 to +0.0008 inch)
Bore diameter of the idler gear Number of teeth .............................................. 34
........ 57.14 to 57.18 mm (2.2495 to 2.2512 inch)
Bore diameter of the idler gear with roller (5) Oil pump idler gear
bearings ................................ 72.35 to 72.36 mm
(2.8484 to 2.8488 inch) Inside diameter of oil pump idler gear
bearing .............................. 16.012 to 16.038 mm
Width of idler gear and split bearing (0.6304 to 0.6314 inch)
assembly .............................. 30.14 to 30.16 mm
(1.186 to 1.187 inch) Outside diameter of oil pump idler gear
shaft .................................. 15.966 to 15.984 mm
Inside diameter of idler gear bearings with (0.6286 to 0.6293 inch)
flanges .................................. 50.78 to 50.80 mm
(1.999 to 2.000 inch) Clearance of oil pump idler gear bearing on
shaft ...................................... 0.028 to 0.072 mm
Outside diameter of idler gear (0.0011 to 0.0028 inch)
hub .. 50.70 to 50.74 mm (1.9961 to 1.9976 inch)
Outside diameter of idler gear hub with roller End play of the oil pump idler
bearings ............................ 49.975 to 49.988 mm gear ...................................... 0.050 to 0.275 mm
(1.9675 to 1.9680 inch) (0.0019 to 0.0108 inch)
Clearance of idler gear bearing on (6) Oil pump gear

hub ...... 0.04 to 0.10 mm (0.0016 to 0.0039 inch)
The number of teeth on the oil pump gear ..... 17
Idler gear end play .................... 0.10 to 0.20 mm
(0.004 to 0.008 inch) Backlash values
Idler gear end play with roller Backlash between the idler gear (5) and the oil
bearings .................................... 0.10 to 0.75 mm pump drive gear (6) .............. 0.046 to 0.106 mm
(0.0039 to 0.0295 inch) (0.0018 to 0.0041 inch)
KENR6245 33
Backlash between the oil pump idler gear (5) and i02503254
the crankshaft gear (4) ......... 0.095 to 0.160 mm
(0.0037 to 0.0063 inch) Flywheel
Backlash between the idler gear (3) and the
crankshaft gear (4) ............... 0.064 to 0.124 mm
(0.0025 to 0.0049 inch)
Backlash between the camshaft gear (2) and the
idler gear (3) ......................... 0.052 to 0.107 mm
(0.0020 to 0.0042 inch)
Backlash between the fuel injection pump gear
(1) and the idler gear (3) ....... 0.054 to 0.109 mm
(0.0021 to 0.0043 inch)
Backlash between the water pump gear (not
shown) and the fuel injection pump gear
(1) ... 0.073 to 0.133 mm (0.0028 to 0.0052 inch)
Backlash between the power take-off
drive (if equipped) and the idler gear
(3) .... 0.112 to 0.172 mm (0.0044 to 0.0068 inch)
Engines that have a Balancer
g00584712
Illustration 63
Typical example
(1) Flywheel ring gear

Heat the flywheel ring gear to the following
temperature. .............................. 250 °C (480 °F)
Note: Do not use an oxyacetylene torch to heat the

flywheel ring gear.
g00996003
Illustration 62 (2) Flywheel
Balancer gears
(3) Bolt
(7) Idler gear for the oil pump that has a balancer
Tighten the flywheel bolts to the following
The number of teeth on the gear .................... 44 torque. ..................................... 115 N·m (85 lb ft)
The bore diameter of the idler
gear .................................. 37.197 to 37.212 mm
(1.4644 to 1.4650 inch)
The hub diameter for the idler
gear .................................. 37.152 to 37.162 mm
(1.4627 to 1.4631 inch)
The end play for the idler gear .. 0.12 to 0.27 mm
(0.0047 to 0.0106 inch)
(8) Gear for the oil pump that has a balancer

The number of teeth on the gear .................... 17
Backlash between the oil pump gear (8) and the idler
gear (7) ... 0.097 to 0.17 mm (0.0038 to 0.0067 inch)
34 KENR6245
i02663068 i02662798
Flywheel Housing Crankshaft Pulley
g00915497
Illustration 65
A standard pulley
(1) Tighten the three bolts for the crankshaft pulley

to the following torque. ............ 115 N·m (85 lb ft)
Note: Recheck the torque of the bolts (1) once.
(2) Thrust block
Note: The chamfers on the bolt holes must face

toward the front of the engine.
g01338247
Illustration 64 (3) Crankshaft pulley
Typical example
(1) Bolt
Tighten the bolts for the cast iron flywheel
housing to the following torque:
M10 “8.8” .................................. 44 N·m (33 lb ft)
M10 “10.9” ................................ 63 N·m (47 lb ft)
M12 “8.8” .................................. 75 N·m (55 lb ft)
M12 “10.9” ............................... 115 N·m (85 lb ft)
KENR6245 35
Crankshaft Pulley for the Poly Note: The marks (1 and 2) on the pulley must be
vertical when the pulley is installed on the engine.
V-Belt Number one piston of the engine must be at top dead
center.
i02663070
Fan Drive
g01337951
Illustration 66
Typical example
(1) Bolt
(2) Thrust block
(3) Crankshaft adapter
(4) Crankshaft pulley
(5) Bolt
(1) Tighten the three bolts for the thrust block to the
following torque. ...................... 115 N·m (85 lb ft)
Note: Recheck the torque of the bolts (1) once.
Note: The chamfers on the bolt holes must face

toward the front of the engine.
(5) Tighten the three bolts for the crankshaft pulley g01338248
Illustration 68
Typical example
Non - Standard Pulley (1) Tighten the bolts to the following torque. .. 22 N·m
(16 lb ft)
Fan drive housing

Tighten the bolts (2) that secure the fan drive
housing (3) to the cylinder head to the following
torque. ............................................. 44 N·m (32 lb ft)
Maximum permissible end play of the shaft .. 0.20 mm

(0.0079 inch)
g01337945
Illustration 67
(1) T Mark
(2) Alignment mark
36 KENR6245
i01721280 (2) Terminal “D+”

Engine Lifting Bracket Tighten the terminal nut to the following
torque. ..................................... 3.7 N·m (33 lb in)
(3) Terminal “B+”

Tighten the terminal nut to the following
All engines are equipped with two engine lifting torque. ........................................ 7 N·m (62 lb in)
brackets.
Tighten the two bolts on each engine lifting The 12 Volt and 24 Volt Iskra
bracket to the following torque. .. 44 N·m (32 lb ft) Alternator
12 volt output
i02656398
Alternator Two alternators are

available. ....................... 150 Amp and 175 Amp
24 volt output
The 24 volt alternator ............................ 100 Amp
The 12 Volt and 24 Volt Denso

Alternators
Three types of alternator are available.
Output
Two 12 volt alternators are
available. ....................... 100 Amp and 120 Amp
One 24 volt alternator ............................. 80 Amp
g01332519
Illustration 70
Typical example
(1) Terminal “B+”

torque. ...................................... 11 N·m (97 lb in)
(2) Terminal “D+”

g01332517 torque. ........................................ 3 N·m (26 lb in)
Illustration 69
Typical example (3) The terminal “W” is spade-type.
(1) Terminal “W”
torque. ..................................... 3.7 N·m (33 lb in)
KENR6245 37
i02656404
Starter Motor
24 Volt Starting Motor
g00974968
Illustration 71
The 24 volt starting motor which shows the electrical connections
(1) Tighten the negative terminal nut to the following

torque. ...................................... 16 N·m (12 lb ft)
(2) Tighten the positive terminal nut to the following

torque. ...................................... 21 N·m (15 lb ft)
(3) Tighten the solenoid terminal to the following

torque. ..................................... 3.6 N·m (32 lb in)
Rated voltage ................................................ 24 volts

38 KENR6245
g00977365
Illustration 72
The 12 volt starting motor which shows the electrical connections
(1) Tighten the solenoid terminal to the following i02656374

torque. ....................................... 8 N·m ( 70 lb in)
Glow Plugs
(2) Tighten the positive terminal nut to the following
torque. ....................................... 6 N·m ( 53 lb in)
(3) Tighten the negative terminal nut to the following

torque. ....................................... 8 N·m (70 lb in)
Rated voltage ................................................ 12 volts
g01334536
Illustration 73
Typical example
(1) Tighten the glow plugs (3) in the cylinder head to

the following torque. .................. 15 N·m (11 lb ft)
KENR6245 39
Tighten the nuts (2) for the bus bar (1) that is
installed on top of the glow plugs to the following
torque. ............................................... 2 N·m (18 lb in)
Voltage ................................................. 12 or 24 volts
Note: Glow plugs are not installed on all engines.

Engines that do not have glow plugs are installed
with threaded plugs.
40 KENR6245
Index Section
Index
A G
Alternator ............................................................... 36 Gear Group (Front)................................................ 31

The 12 Volt and 24 Volt Denso Alternators ........ 36 Engines that have a Balancer ............................ 33
The 12 Volt and 24 Volt Iskra Alternator ............ 36 Glow Plugs ............................................................ 38
C I
Camshaft ............................................................... 12 Important Safety Information ................................. 2

Camshaft Bearings ................................................ 14
Connecting Rod..................................................... 27
Connecting Rod Bearing Journal........................... 26 L
Crankcase Breather............................................... 20
Breather Canister............................................... 21 Lifter Group............................................................ 7
Crankshaft ............................................................ 24
Crankshaft Pulley .................................................. 34
Crankshaft Pulley for the Poly V-Belt................. 35 M
Non - Standard Pulley........................................ 35
Crankshaft Seals ................................................... 26 Main Bearing Journal............................................. 27
Cylinder Block........................................................ 22 The shell for the main bearings.......................... 27
Cylinder Head........................................................ 10
Cylinder Head Valves ............................................ 8
P
E Piston and Rings ................................................... 29

Piston ................................................................. 30
Engine Design ....................................................... 4 Piston Cooling Jet.................................................. 30
Engine Lifting Bracket............................................ 36 Piston Cooling Jet Alignment ............................. 30
Engine Oil Bypass Valve ....................................... 18
Installed in the Balancer..................................... 19
Installed in the Oil Pump .................................... 18 R
Engine Oil Cooler .................................................. 15
Engine Oil Filter ..................................................... 14 Rocker Shaft.......................................................... 7
Engine Oil Pan....................................................... 19
Front sealant ...................................................... 19
Rear sealant....................................................... 19 S
Engine Oil Pressure............................................... 18
Engine Oil Pump.................................................... 16 Specifications Section ........................................... 4
Engines with Balancer Group ............................ 16 Starter Motor.......................................................... 37
Engines without Balancer Group ....................... 17 12 Volt Starting Motor ........................................ 38
Exhaust Manifold ................................................... 12 24 Volt Starting Motor ........................................ 37
F T
Fan Drive ............................................................... 35 Table of Contents................................................... 3

Fan drive housing .............................................. 35 Turbocharger ......................................................... 11
Flywheel ................................................................ 33
Flywheel Housing .................................................. 34
Front Housing and Covers..................................... 31 V
Fuel Injection Lines................................................ 4
Fuel Injection Pump............................................... 5 Valve Mechanism Cover........................................ 8
Fuel Injectors ......................................................... 6
Fuel Transfer Pump ............................................... 6
W
Water Pump........................................................... 22
KENR6245 41
Index Section
Water Temperature Regulator and Housing .......... 22

42 KENR6245
Index Section
KENR6245 43
Index Section
Copyright © 2007 Perkins Engine Company Limited
All Rights Reserved Printed in U. K.
KENR6246
June 2007
Systems Operation
Testing and Adjusting
NK (Engine)
NL (Engine)
NM (Engine)

this publication.

replacement parts.
death.
KENR6246 3
Table of Contents
Table of Contents Battery - Test .........................................................

Electric Starting System - Test ..............................
43
43
Glow Plugs - Test .................................................. 45
V-Belt - Test .......................................................... 46
Systems Operation Section
Engine Design ....................................................... 4 Index Section
General Information ................................................ 4
Fuel System ........................................................... 7 Index ..................................................................... 48
Air Inlet and Exhaust System ................................. 9
Lubrication System .............................................. 12
Cooling System .................................................... 14
Basic Engine ......................................................... 15
Electrical System ................................................. 15
Testing and Adjusting Section

Fuel System
Fuel System - Inspect ........................................... 18
Air in Fuel - Test .................................................... 18
Finding Top Center Position for No. 1 Piston ........ 19
Fuel Injection Pump Timing - Check ..................... 20
Fuel Injection Pump Timing - Adjust ..................... 20
Fuel Quality - Test ................................................. 20
Fuel System - Prime ............................................. 20
Fuel System Pressure - Test ................................. 21
Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ................. 22
Turbocharger - Inspect .......................................... 22
Compression - Test ............................................... 25
Engine Valve Lash - Inspect/Adjust ...................... 25
Valve Depth - Inspect ............................................ 26
Valve Guide - Inspect ............................................ 27
Lubrication System
Engine Oil Pressure - Test .................................... 28
Engine Oil Pump - Inspect .................................... 28
Excessive Bearing Wear - Inspect ........................ 29
Excessive Engine Oil Consumption - Inspect ....... 29
Increased Engine Oil Temperature - Inspect ........ 30
Cooling System
Cooling System - Check (Overheating) ................ 31
Cooling System - Inspect ...................................... 32
Cooling System - Test ........................................... 32
Engine Oil Cooler - Inspect ................................... 34
Water Temperature Regulator - Test ..................... 34
Basic Engine
Piston Ring Groove - Inspect ................................ 36
Connecting Rod - Inspect ..................................... 36
Connecting Rod Bearings - Inspect ...................... 37
Main Bearings - Inspect ........................................ 37
Cylinder Block - Inspect ........................................ 37
Cylinder Head - Inspect ........................................ 38
Piston Height - Inspect .......................................... 38
Flywheel - Inspect ................................................. 39
Flywheel Housing - Inspect ................................... 40
Gear Group - Inspect ............................................ 41
Electrical System
Alternator - Test .................................................... 42
4 KENR6246
Systems Operation Section i02680006
General Information
i02680003
Engine Design
Engine Description
Note: When you are ordering new parts, refer
to the engine identification number in order to
receive the correct parts. Refer to the Operation
and Maintenance Manual, “Product Identification
Information” for the correct numbers for your engine.
The engine cylinders are arranged in-line. The

engines are controlled by a mechanically governed
fuel injection pump.
The cylinder head assembly has one inlet valve and

one exhaust valve for each cylinder. Each valve has
one valve spring. The pistons have two compression
rings and an oil control ring.
g01346235
Illustration 1
It is important to ensure the correct piston height so
Typical example of the layout of the valves
that the piston does not contact the cylinder head.
(A) Inlet valve The correct piston height also ensures the efficient
(B) Exhaust valve
combustion of fuel.
1104D Engine Specification The 1104D engine crankshaft has five main journals.
End play is controlled by thrust washers that are
Industrial located on both sides of the center main bearing.
Type ............................ Four cylinder and four stroke The timing case has a hole that corresponds with
a hole in the crankshaft. Use an alignment pin to
Type of combustion ............................ Direct injection find TC. The camshaft gear has a timing hole that
corresponds with a timing hole in the timing case.
Bore ......................................... 105 mm (4.134 inch) The timing holes ensure that the camshaft and the
crankshaft are in time with each other.
Stroke ........................................ 127 mm (5.00 inch)
The crankshaft gear rotates the idler gear. The idler
Displacement ...................................... 4.4 L (268 in3) gear rotates the camshaft gear and the fuel injection
pump gear. The idler gear for the engine oil pump is
Compression ratio rotated by the crankshaft gear. This idler rotates the
engine oil pump.
Naturally aspirated .......................................... 19.3:1
The fuel injection pump is a gear-driven pump that
Turbocharged .................................................. 18.2:1 is mounted to the back of the front housing. The
fuel transfer pump is electrically operated. The fuel
Turbocharged, aftercooled .............................. 18.2:1 transfer pump has an integral fuel filter. The fuel
transfer pump is usually located on the left hand side
Number of cylinders ................................................ 4 of the cylinder block. Some applications may have
the fuel transfer pump and the water separator (if
Cylinder arrangement ..................................... In-line equipped) relocated off the engine.
Firing order ................................................. 1, 3, 4, 2 The oil pump is driven by an idler gear. The engine
oil pump sends lubricating oil to the main oil gallery.
The front of the engine is opposite the flywheel end The oil relief valve is internal to the oil pump.
of the engine. The left side of the engine and the right
side of the engine are determined from the flywheel Coolant from the bottom of the radiator passes
end. Number 1 cylinder is the front cylinder of the through the water pump. The water pump is driven
engine. by the idler gear.
KENR6246 5
Lifting the Engine

NOTICE
Failure to follow recommended procedures for han-
dling or transporting engines can lead to engine dam-
age.
To avoid possible engine damage, use the following

procedure.
When you are lifting or moving the engine, use the

following procedures in order to prevent engine
damage.
1. Do not tilt the engine to an extreme angle unless

the lubricating oil is first drained from the oil pan.
2. Do not turn the engine onto a side or an end

surface unless the lubricating oil is first drained
from the oil pan.
3. If the oil is not drained prior to tilting the engine or

turning the engine onto a side or an end surface,
the lubricating oil from the oil pan can flow into
the intake manifold and the cylinder bores. This
situation could cause a hydraulic lock in the
engine. Hydraulic lock can severely damage the
engine.
4. The engine oil should be refilled to the correct

level before the engine is started.
6 KENR6246
1104D Engine Model Views
g01351713
Illustration 2
(1) Pulley (5) Valve Mechanism Cover (9) Fuel Injection Pump
(2) Alternator (6) Rear Lifting Eye (10) Oil Filter
(3) Front Lifting Eye (7) Air Intake (11) Crankshaft Pulley
(4) Water Outlet (8) Secondary Fuel Filter (12) Water Pump
KENR6246 7
g01352705
Illustration 3
(13) Flywheel (17) Turbocharger (21) Oil Drain Plug
(14) Flywheel Housing (18) Oil Gauge (22) Primary Fuel Filter
(15) Oil Filler Cap (19) Oil Pan
(16) Exhaust Manifold (20) Starting motor
i02680048 The fuel transfer pump draws fuel from the fuel tank
and through the water separator. When the fuel goes
Fuel System through the water separator, any water in the fuel will
go to the bottom of the bowl. The fuel transfer pump
sends the fuel at a low pressure to the fuel filter. From
the fuel filter, the fuel goes through the supply line to
The Delphi DP310 fuel injection pump is installed on the fuel injection pump.
the 1104D engine.
8 KENR6246
The fuel injection pump sends fuel through the high Cold Start Advance Unit
pressure fuel line to each of the fuel injectors. The
fuel injector sprays the fuel into the cylinder. Fuel that The cold start advance unit holds the timing of the
is not injected flows through the fuel return line to the fuel injection pump in an advance position when the
top of the fuel filter, back to the fuel tank. engine is cold.
The engine must not be started until the fuel injection The coolant switch for the cold start advance unit is
pump is full of fuel that is free of air. The fuel injection on the water temperature regulator housing on the
pump requires fuel for lubrication. The precision parts left side of the engine.
of the pump are easily damaged without lubrication.
When the engine is cold, the sender unit is
The fuel system must be primed when any of the energized in order to advance the fuel injection
following conditions occur: pump timing for the cold start operation. When the
correct temperature is achieved the sender unit is
• The fuel filter is changed. de-energized and the fuel injection pump timing is
returned to the normal operating position.
• The fuel line is removed.
If the switch fails in the closed position, the engine
• The fuel injection pump is removed. will run with advanced fuel injection timing. The
engine will have higher cylinder pressure and engine
damage may result.
Fuel System Components
If the switch fails in the open position the engine
Fuel Injection Pump will run with the fuel injection timing in the normal
operating position. The engine will be more difficult
General Operation to start. When the engine is cold the engine might
emit white smoke.
The fuel injection pump is a pressurized system
that is totally enclosed. The pump sends the correct
amount of fuel under high pressure at the correct time
through the fuel injectors to the individual cylinders.
The fuel injection pump regulates the amount of fuel
that is delivered to the fuel injectors. This action
controls the engine rpm by the governor setting or
the position of the throttle control.
The fuel lines to the fuel injectors are equal lengths.

This ensures even pressure and correct injection
timing at each fuel injector.
During operation, extra fuel is used as coolant and

lubricant for moving parts of the pump. The extra fuel
is circulated through the pump housing. The extra
fuel is then returned to the fuel tank.
The Delphi DP310 fuel injection pump must be

serviced by an authorized Delphi technician. For
repair information, contact your Perkins dealer or
contact your Perkins distributor.
High idle and low idle of the fuel injection pump are
factory set. Idle adjustments can not be made to the
fuel pump. The Delphi DP310 fuel injection pump
has a boost control. The Delphi DP310 fuel injection
pump has an engine stop solenoid and a feature that
vents air from the pump.
The Delphi DP310 fuel injection pump has a cold

starting aid. The cold starting aid advances the
timing of the pump when the engine is cold. The cold
starting aid is electrically operated.
KENR6246 9
i02678936
g01355169
Illustration 4
Air inlet and exhaust system (typical example)
(1) Exhaust manifold (5) Aftercooler core (if equipped) (9) Air inlet from the air cleaner
(2) Injector (6) Exhaust outlet (10) Inlet valve
(3) Glow plug (7) Turbine side of turbocharger (11) Engine cylinder
(4) Intake manifold (8) Compressor side of turbocharger (12) Exhaust valve
Engines which are naturally aspirated pull outside 3. Power

air through an air cleaner directly into the intake
manifold (4). The air flows from the intake manifold 4. Exhaust
to the engine cylinders (11). The air mixes with the
fuel and leads to combustion. After combustion, the The sequence of the strokes by all of the pistons in
exhaust gases flow directly to the outside air through all of the engine cylinders provide constant air flow
the exhaust manifold (1). through the inlet system during the engine operation.
Turbocharged engines pull outside air through an air Toward the end of the compression stroke, fuel is
cleaner into the air intake (4) of the turbocharger. injected into the cylinder. The mixture of fuel and air
The suction is caused by the rotating turbocharger ignites and combustion takes place.
compressor wheel (5). The compressor wheel
compresses the air which flows through the intake The exhaust stroke and the timing of the valve
manifold (2). This directs an even distribution of the mechanism pushes combustion gases through the
air to each engine cylinder (3). Air is pulled into the open exhaust valve into the exhaust manifold (1).
engine cylinder (3) during the intake stroke of the The exhaust gases flow through the blades of the
piston. turbocharger turbine wheel (6) which causes the
turbine wheel and the compressor wheel to rotate.
Each piston makes four strokes: The exhaust gases flow through the exhaust outlet
(7) of the turbocharger to atmosphere.
1. Intake
2. Compression
10 KENR6246
Turbocharger A turbocharger is installed between the exhaust

and intake manifolds. The turbocharger is driven by
Note: The turbocharger is not serviceable. exhaust gases which flow through the exhaust inlet
(11). The energy of the exhaust gas turns the turbine
A turbocharger increases the temperature and the wheel (8). Then, the exhaust gas flows out of the
density of the air that is sent to the engine cylinder. turbine housing (7) through the exhaust outlet (9).
This condition causes a lower temperature of ignition
to develop earlier in the compression stroke. The The turbine wheel and the compressor wheel (3) are
compression stroke is also timed in a more accurate installed on the same shaft. Therefore, the turbine
way with the fuel injection. Surplus air lowers the wheel and the compressor wheel rotate at the same
temperature of combustion. This surplus air also speed. The compressor wheel is enclosed in the
provides internal cooling. compressor housing (2). The compressor wheel
compresses the intake air (1). The intake air flows
A turbocharger improves the following aspects of into the engine cylinders through the inlet valves of
engine performance: the cylinders.
• Power output is increased. The oil from the main gallery of the cylinder block
flows through the oil inlet port (5) in order to
• Fuel efficiency is improved. lubricate the turbocharger bearings (4) and (6). The
pressurized oil passes through the bearing housing
• Engine torque is increased. of the turbocharger. The oil is returned through the oil
outlet port (10) to the oil pan.
• Durability of the engine is improved.
The turbocharger has a wastegate which is controlled
• Emissions from the engine are reduced. by boost pressure. This allows some of the exhaust
to bypass the turbocharger at higher engine speeds.
The wastegate is a valve that automatically opens
at a preset level of boost pressure in order to allow
excess exhaust gas to bypass the turbine at high
engine speeds. The wastegate allows the design of
the turbocharger to be more effective at lower engine
speeds.
The wastegate is controlled by a diaphragm. One

side of this diaphragm is open to the atmosphere.
The other side of this diaphragm is open to intake
manifold boost pressure.
Cylinder Head And Valves

The valves and the valve mechanism control the
flow of the air and the exhaust gases in the cylinder
during engine operation. The cylinder head assembly
has two valves for each cylinder. Each valve has one
valve spring. The ports for the inlet valves are on
the left side of the cylinder head. The ports for the
g00302786
Illustration 5 exhaust valves are on the right side of the cylinder
Components of a turbocharger (typical example) head. Sintered valve seat inserts are installed in
(1) Air intake
the cylinder head for both the inlet and the exhaust
(2) Compressor housing valves. The valve seat inserts can be replaced.
(3) Compressor wheel
(4) Bearing The valves are installed in valve guides. The valve
(5) Oil inlet port guides can be replaced. A groove is machined into
(6) Bearing
(7) Turbine housing the exhaust valve stem in order to prevent a deposit
(8) Turbine wheel of carbon forming under the head of the valve.
(9) Exhaust outlet
(10) Oil outlet port The inlet and the exhaust valves are opened and
(11) Exhaust inlet
closed by the rotation and movement of the following
components:
KENR6246 11
• Crankshaft
• Camshaft
• Valve lifters
• Pushrods
• Rocker arms
• Valve springs
The camshaft gear is driven by the crankshaft gear.
The camshaft and the crankshaft are timed together.
When the camshaft turns, the valve lifters and the
pushrods are moved up and down. The pushrods
move the rocker arms. The movement of the rocker
arms open the valves. The opening and closing of
the valves is timed with the firing sequence of the
engine. The valve springs push the valves back to
the closed position.
12 KENR6246
i02680107
Lubrication System
g01009682
Illustration 6
Flow diagram of the lubrication system for the 1104D engine
Lubricating oil from the oil pan flows through a The lubricating oil flows from the outlet side of the oil
strainer and a pipe (9) to the suction side of the pump (10) through a passage to the oil filter head
engine oil pump (10). Pressure for the lubrication (7). The oil then flows from the oil filter head through
system is supplied by the oil pump . The crankshaft a passage to a plate type oil cooler for the 1104D
gear (13) drives a lower idler gear (12). The lower engine (3). The oil cooler is located on the left side of
idler gear drives the oil pump gear (11). The pump the cylinder block.
has an inner rotor and an outer rotor. The axis of
rotation of the rotors are off-center relative to each From the oil cooler, the oil returns through a passage
other. There is an interference fit between the inner to the oil filter head. The oil then flows through a
rotor and the drive shaft. bypass valve that permits the lubrication system
to function if the oil filter becomes blocked. Under
The inner rotor has five lobes which mesh with the six normal conditions, the oil then flows to the oil filter (8).
lobes of the outer rotor. When the pump rotates, the
distance increases between the lobes of the outer
rotor and the lobes of the inner rotor in order to create
suction. When the distance decreases between the
lobes, pressure is created.
KENR6246 13
The oil flows from the oil filter through a passage that
is drilled across the cylinder block to the oil gallery
(4). The oil gallery is drilled through the total length
of the left side of the cylinder block. If the oil filter is
on the right side of the engine, the oil flows through
a passage that is drilled across the cylinder block to
the pressure gallery.
Lubricating oil from the oil gallery flows through

high pressure passages to the main bearings of
the crankshaft (5). Then, the oil flows through the
passages in the crankshaft to the connecting rod
bearing journals (6). The pistons and the cylinder
bores are lubricated by the splash of oil and the oil
mist.
Lubricating oil from the main bearings flows through

passages in the cylinder block to the journals of the
camshaft. Then, the oil flows from the front journal of
the camshaft at a reduced pressure to the cylinder
head. The oil then flows through the center of the
rocker shaft (1) to the rocker arm levers. The valve
stems, the valve springs and the valve lifters are
lubricated by the splash and the oil mist.
The hub of the idler gear is lubricated by oil from the

oil gallery. The timing gears are lubricated by the
splash from the oil.
An external line from the cylinder block supplies oil to

the turbocharger. The oil then flows through a return
line to the oil pan.
Engines have piston cooling jets that are supplied

with oil from the oil gallery. The piston cooling jets
spray lubricating oil on the underside of the pistons in
order to cool the pistons.
14 KENR6246
i02680899
Cooling System
g00985481
Illustration 7
Flow diagram of the cooling system for the 1104D engine
The coolant flows from the bottom of the radiator to The main flow of the coolant passes from the rear of
the centrifugal water pump. The water pump assists the cylinder block into the rear of the cylinder head.
in the flow of the coolant through the system. The The coolant flows forward through the cylinder head
water pump is installed on the front of the timing and into the water temperature regulator housing. If
case. The water pump is gear-driven by the fuel the water temperature regulator is closed, the coolant
injection pump gear. goes directly through a bypass to the inlet side of
the water pump. If the water temperature regulator
The water pump forces the coolant through a is open, the bypass is closed and the coolant flows
passage in the front of the timing case to the water to the top of the radiator.
jacket in the top left side of the cylinder block. The
coolant continues to the rear of the cylinder block. 1104D engines
From the rear of the cylinder block, some of the

coolant passes into the oil cooler. The oil cooler is
located on the left side of the cylinder block with no
external lines. The coolant flows around the element
of the oil cooler before being returned to the rear of
the cylinder block.
KENR6246 15
i02680926 The connecting rod is matched to each cylinder.

The piston height is controlled by the length of the
Basic Engine connecting rod. Six different lengths of connecting
rods are available in order to attain the correct piston
height. The different lengths of connecting rods are
made by machining the small end bearing off-center
Cylinder Block and Cylinder Head in order to form an eccentric bearing. The amount of
the eccentricity of the bearing creates the different
The cylinder block for the 1104D engine has four lengths of the connecting rods.
cylinders which are arranged in-line.
Crankshaft
The cylinder block for the 1104D engine has five
main bearings which support the crankshaft. Thrust The crankshaft changes the linear energy of the
washers on both sides of the center main bearing pistons and connecting rods into rotary torque in
control the end play of the crankshaft. order to power external equipment.
A cylinder head gasket is used between the A gear at the front of the crankshaft drives the timing
engine block and the cylinder head in order to seal gears. The crankshaft gear turns the idler gear which
combustion gases, water, and oil. then turns the following gears:
The engine has a cast iron cylinder head. The inlet • Camshaft gear
manifold is integral within the cylinder head. An inlet
valve and an exhaust valve for each cylinder are • Fuel injection pump
controlled by a pushrod valve system. The ports for
the inlet valves are on the left side of the cylinder • Lower idler gear which turns the gear of the
head. The ports for the exhaust valves are on the lubricating oil pump
right side of the cylinder head.
Dynamic seals are used on both the front of the
Pistons, Rings, and Connecting crankshaft and the rear of the crankshaft.
Rods
Camshaft
The pistons have a combustion chamber in the top of
the piston in order to provide an efficient mix of fuel The engine has a single camshaft. The camshaft
and air. The piston pin is off-center in order to reduce is driven by an idler gear in the front housing. The
the noise level. camshaft uses only one bearing on the front journal.
The other journals rotate in the bore of the cylinder
The pistons have two compression rings and an oil block. The front bearing and the camshaft bores
control ring. The groove for the top ring has a hard in the cylinder block support the camshaft. As the
metal insert in order to reduce wear of the groove. camshaft turns, the camshaft lobes move the valve
The skirt has a layer of graphite in order to reduce system components. The valve system components
wear. move the inlet and exhaust valves in each cylinder.
The camshaft gear must be timed to the crankshaft
The correct piston height is important in order to gear. The relationship between the lobes and the
ensure that the piston does not contact the cylinder camshaft gear causes the valves in each cylinder
head. The correct piston height also ensures the to be opened and closed at the correct time. The
efficient combustion of fuel which is necessary in relationship between the lobes and the camshaft
order to conform to requirements for emissions. gear also causes the valves in each cylinder to close
at the correct time.
Engines are equipped with connecting rods that have
bearing caps that are fracture split. The bearing caps i02680940
on fracture split connecting rods are retained with
torx screws. Connecting rods with bearing caps that Electrical System
are fracture split have the following characteristics:
• Higher integrity for the rod

The electrical system is a negative ground system.
• The splitting produces an accurately matched
surface on each side for improved strength. The charging circuit operates when the engine
is running. The alternator in the charging circuit
• Modern design produces direct current for the electrical system.
16 KENR6246
Starting Motor
g00954820
Illustration 8
(1) Terminal for connection of the battery cable
(2) Terminal for connection of the ignition switch
g00956095
Illustration 9
(1) Terminal for connection of the ignition (2) Terminal for connection of the battery
switch cable
The starting motor turns the engine flywheel. The

rpm is high enough in order to initiate a sustained
operation of the fuel ignition in the cylinders.
KENR6246 17
The starting motor has a solenoid. When the ignition The alternator converts the mechanical energy
switch is activated, voltage from the electrical system and the magnetic energy into electrical energy.
will cause the solenoid to engage the pinion in the This conversion is done by rotating a direct current
flywheel ring gear of the engine. When the pinion electromagnetic field on the inside of a three-phase
gear is engaged in the flywheel ring gear, the stator. The electromagnetic field is generated by
electrical contacts in the solenoid close the circuit electrical current flowing through a rotor. The stator
between the battery and the starting motor. This generates AC electrical power.
causes the starting motor to rotate. This type of
activation is called a positive shift. The alternating current is changed to direct current
by a three-phase, full-wave rectifier. Direct current
When the engine begins to run, the overrunning flows to the output terminal of the alternator. The
clutch of the pinion drive prevents damage to the rectifier has three exciter diodes. The direct current
armature. Damage to the armature is caused by is used for the charging process.
excessive speeds. The clutch prevents damage by
stopping the mechanical connection. However, the A regulator is installed on the rear end of the
pinion will stay meshed with the ring gear until the alternator. Two brushes conduct current through two
ignition switch is released. A spring in the overrunning slip rings. The current then flows to the rotor field. A
clutch returns the clutch to the rest position. capacitor protects the rectifier from high voltages.
The alternator is connected to the battery through

Alternator the ignition switch. Therefore, alternator excitation
occurs when the switch is in the ON position.
g00303424
Illustration 10
(1) Shaft for mounting the pulley
The alternator produces the following electrical

output:
• Three-phase
• Full-wave
• Rectified
The alternator is an electro-mechanical component.
The alternator is driven by a drive belt from the
crankshaft pulley. The alternator charges the storage
battery during the engine operation.
18 KENR6246
Testing and Adjusting 2. Install a suitable fuel flow tube with a visual sight
gauge in the fuel return line. When possible, install
Section the sight gauge in a straight section of the fuel line
that is at least 304.8 mm (12 inches) long. Do not
install the sight gauge near the following devices
that create turbulence:
Fuel System
• Elbows
i01804057
• Relief valves
Fuel System - Inspect • Check valves
• Connections
A problem with the components that send fuel to
the engine can cause low fuel pressure. This can Observe the fuel flow during engine cranking.
decrease engine performance. Look for air bubbles in the fuel. If there is no fuel
that is present in the sight gauge, prime the fuel
1. Check the fuel level in the fuel tank. Ensure that system. Refer to Testing and Adjusting, “Fuel
the vent in the fuel cap is not filled with dirt. System - Prime” for more information. If the engine
starts, check for air in the fuel at varying engine
2. Check all fuel lines for fuel leakage. The fuel lines speeds. When possible, operate the engine under
must be free from restrictions and faulty bends. the conditions which have been suspect.
Verify that the fuel return line is not collapsed.
3. Inspect the fuel filter for excess contamination. If

necessary, install a new fuel filter. Determine the
source of the contamination. Make the necessary
repairs.
4. Service the primary fuel filter (if equipped).
5. Remove any air that may be in the fuel system.

Refer to Testing and Adjusting, “Fuel System -
Prime”.
i02780600
Air in Fuel - Test
This procedure checks for air in the fuel system. This

procedure also assists in finding the source of the air. g00578151
Illustration 11
1. Examine the fuel system for leaks. Ensure that (1) A steady stream of small bubbles with a diameter of
the fuel line fittings are properly tightened. Check approximately 1.60 mm (0.063 inch) is an acceptable amount
of air in the fuel.
the fuel level in the fuel tank. Air can enter the (2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
fuel system on the suction side between the fuel are also acceptable if there is two seconds to three seconds
transfer pump and the fuel tank. intervals between bubbles.
(3) Excessive air bubbles in the fuel are not acceptable.
Work carefully around an engine that is running.

Engine parts that are hot, or parts that are moving,
can cause personal injury.
KENR6246 19
3. If excessive air is seen in the sight gauge in the

fuel return line, install a second sight gauge at
the inlet to the fuel transfer pump. If a second
sight gauge is not available, move the sight gauge
from the fuel return line and install the sight gauge
at the inlet to the fuel transfer pump. Observe
the fuel flow during engine cranking. Look for air
bubbles in the fuel. If the engine starts, check for
air in the fuel at varying engine speeds.
If excessive air is seen at the inlet to the fuel

transfer pump, air is entering through the suction
side of the fuel system.
To avoid personal injury, always wear eye and face

protection when using pressurized air.
NOTICE
g00923080
To avoid damage, do not use more than 55 kPa (8 psi) Illustration 12
to pressurize the fuel tank. (1) Hole for crankshaft pin
(2) Hole for camshaft pin
4. Pressurize the fuel tank to 35 kPa (5 psi). Do not 1. Remove the valve mechanism cover, the glow
use more than 55 kPa (8 psi) in order to avoid plugs, and the cover for the front housing.
damage to the fuel tank. Check for leaks in the
fuel lines between the fuel tank and the fuel Note: The crankshaft timing pin can be inserted with
transfer pump. Repair any leaks that are found. the crankshaft pulley still on the engine.
Check the fuel pressure in order to ensure that
the fuel transfer pump is operating properly. For 2. Rotate the crankshaft in the normal direction of
information about checking the fuel pressure, see the engine until the inlet valve of the No. 4 cylinder
Testing and Adjusting, “Fuel System Pressure - has just opened and the exhaust valve of the No.
Test”. 4 cylinder has not completely closed.
5. If the source of the air is not found, disconnect 3. Carefully rotate the crankshaft in the normal
the supply line from the fuel tank and connect an direction of the engine in order to align the hole
external fuel supply to the inlet of the fuel transfer in the crankshaft with the hole in the cylinder
pump. If this corrects the problem, repair the fuel block and the timing case. Insert the 27610211
tank or the stand pipe in the fuel tank. Crankshaft Timing Pin fully into the hole in the
crankshaft web.
i01893344
4. Insert the 27610212 Camshaft Timing Pin
Finding Top Center Position through the hole in the camshaft gear and into the
body of the timing case. The engine is set at the
for No. 1 Piston top center position for No. 1 piston.
Note: The camshaft gear can rotate a small amount

Table 1
when the pin is installed.
Required Tools 5. Remove the timing pins from the camshaft gear
Part and the crankshaft web.
Part Description Qty
Number
27610211 Crankshaft timing pin 1
27610212 Camshaft timing pin 1
20 KENR6246
i02681015 2. Determine if contaminants are present in the

fuel. Remove a sample of fuel from the bottom
Fuel Injection Pump Timing - of the fuel tank. Visually inspect the fuel sample
Check for contaminants. The color of the fuel is not
necessarily an indication of fuel quality. However,
fuel that is black, brown, and/or similar to sludge
can be an indication of the growth of bacteria or
oil contamination. In cold temperatures, cloudy
Delphi DP310 Fuel Injection Pump fuel indicates that the fuel may not be suitable for
the operating conditions. Refer to Operation and
Note: The Delphi DP310 fuel injection pump timing Maintenance Manual, “Fuel Recommendations”
cannot be checked. If you suspect that the fuel for more information.
injection pump timing is incorrect, contact your
Perkins dealer or your Perkins distributor for further 3. If fuel quality is still suspected as a possible
information. cause of problems regarding engine performance,
disconnect the fuel inlet line, and temporarily
Delphi DP310 fuel injection pumps must be serviced operate the engine from a separate source of
by an authorized Delphi technician. For repair fuel that is known to be good. This will determine
information, contact your Perkins dealer or your if the problem is caused by fuel quality. If fuel
Perkins distributor. The internal adjustment for the quality is determined to be the problem, drain the
pump timing is tamper proof. High idle and low idle fuel system and replace the fuel filters. Engine
are factory set. Idle adjustments cannot be made to performance can be affected by the following
the fuel pump. characteristics:
i02681476 • Cetane number of the fuel

Fuel Injection Pump Timing - • Air in the fuel
Adjust • Other fuel characteristics
i02681497
Delphi DP310 Fuel Injection Pumps Fuel System - Prime

The Delphi DP310 fuel injection pumps must be
serviced by an authorized Delphi technician. For
repair information, contact your Perkins dealer or If air enters the fuel system, the air must be purged
your Perkins distributor. The internal adjustment for before the engine can be started. Air can enter the
the pump timing is tamper proof. High idle and low fuel system when the following events occur:
idle are factory set. Idle adjustments cannot be made
to the fuel pump. • The fuel tank is empty or the tank has been partially
drained during normal operation.
i01944302
• The low pressure fuel lines are disconnected.
Fuel Quality - Test
• A leak exists in the low pressure fuel system during
engine operation.
Use the following procedure to test for problems • The fuel filter or the fuel pump is replaced.
regarding fuel quality:
• The high pressure fuel lines are disconnected.
1. Determine if water and/or contaminants are
present in the fuel. Check the water separator (if Delphi DP310
equipped). If a water separator is not present,
proceed to Step 2. Drain the water separator, if The Delphi DP310 fuel injection pumps will eliminate
necessary. A full fuel tank minimizes the potential the air from the fuel system automatically. Position
for overnight condensation. the starting switch to the RUN position for three
minutes. Air in the fuel and the fuel lines will be
Note: A water separator can appear to be full of fuel purged from the system.
when the water separator is actually full of water.
KENR6246 21
i02780603 Check the Function of the Pressure

Fuel System Pressure - Test Regulator
1. Remove the fuel line from the outlet for the supply
for the fuel injection pump (B).
2. Install a pipe with a tap for a pressure gauge.

Connect a 0 to 80 kPa (0 to 12 psi) pressure
gauge.
3. Start the engine and run the engine at idle for two
minutes in order to remove any trapped air.
4. Record the pressure reading at idle and at rated

speed. The minimum pressure reading should be
the following values:
All Fuel Injection Pumps
Illustration 13
g00928705 Idle ........................................ 25 kPa (3.6 psi)
(A and B) Fuel outlet Rated speed ......................... 23 kPa (3.3 psi)
(1) Fuel transfer pump
(2) Fuel filter
Note: The maximum pressure for the fuel injection
pump at idle speed or rated speed is 75 kPa
The pressure test measures the output pressure of
(10.9 psi).
the fuel transfer pump. Low fuel pressure and starting
difficulty may be indications of problems with the fuel
5. Reconnect the fuel line. Turn the key to the RUN
priming pump.
position for three minutes in order to energize the
fuel priming pump. Do not start the engine. Then
Check the Function of the Fuel turn the key to the OFF position.
Transfer Pump Check for the following issues if the pressures are
1. Make a note of the location of the fuel lines from outside of the above specifications.
the fuel transfer pump. Remove the two lines from
the outlets (A) and (B). • All electrical connections are installed correctly.
2. Connect two lengths of 5/16 inch rubber hose to • There are no leaks in the fuel lines or connections.
outlets (A) and (B). Place the hoses into a suitable
container that is capable of holding 3 L (3.17 qt) • The O-ring on the fuel filter housing (2) does not
of fuel. leak.
3. Energize the fuel transfer pump until a constant

flow of fuel is running from the outlet for the supply
for the fuel injection pump.
Note: The flow from the outlet for the return for the
fuel tank will have a slower flow rate.
4. Measure the combined flow of both outlets with

a stopwatch. Fuel flow should be a minimum of
2 L/min (0.53 US gpm).
5. If the combined flow is less than 2 L/min

(0.53 US gpm), repair the pump or replace the
pump.
6. Reconnect the outlet lines in the correct positions.
7. Start the engine and check for any leakage of fuel

or air from the fuel lines.
22 KENR6246
Air Inlet and Exhaust i02755777
System Turbocharger - Inspect
i02281171

- Inspect Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
Do a general visual inspection of the air inlet and
exhaust system. Make sure that there are no signs of
leaks in the system. NOTICE
Keep all parts clean from contaminants.
There will be a reduction in the performance of the
engine if there is a restriction or there is a leak in the Contaminants may cause rapid wear and shortened
air inlet system or the exhaust system. component life.
NOTICE
Care must be taken to ensure that fluids are contained
Hot engine components can cause injury from during performance of inspection, maintenance, test-
burns. Before performing maintenance on the ing, adjusting and repair of the product. Be prepared to
engine, allow the engine and the components to collect the fluid with suitable containers before open-
cool. ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and

mandates.
Making contact with a running engine can cause
burns from hot parts and can cause injury from Before you begin inspection of the turbocharger,
rotating parts. be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the
When working on an engine that is running, avoid exhaust system restriction is within the specifications
contact with hot parts and rotating parts. for your engine. Refer to Testing and Adjusting, “Air
Inlet and Exhaust System - Inspect”.
1. Inspect the engine air cleaner inlet and ducting
in order to ensure that the passageway is not The condition of the turbocharger will have definite
blocked or collapsed. effects on engine performance. Use the following
inspections and procedures to determine the
2. Inspect the engine air cleaner element. Replace a condition of the turbocharger.
dirty element with a clean element.
• Inspection of the compressor and the compressor
3. Check for dirt tracks on the clean side of the housing
engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the • Inspection of the turbine wheel and the turbine
element. housing
• Inspection of the wastegate

KENR6246 23
Inspection of the Compressor and d. If Steps 3.a through 3.c did not reveal the
source of the oil leakage, the turbocharger has
the Compressor Housing internal damage. Replace the turbocharger.
Inspection of the Turbine Wheel

and the Turbine Housing
Remove the air piping from the turbine housing.
1. Inspect the turbine for damage by a foreign object.

If there is damage, determine the source of the
foreign object. Replace turbocharger (2). If there
is no damage, go to Step 2.
2. Inspect the turbine wheel for the carbon and

other foreign material. Inspect turbine housing
(1) for carbon and foreign material. Replace the
turbocharger, if necessary. If there is no buildup of
carbon or foreign material, go to Step 3.
3. Turn the rotating assembly by hand. While you

turn the assembly, push the assembly sideways.
The assembly should turn freely. The turbine
Illustration 14
g01278821 wheel should not rub turbine wheel housing (1).
Typical example of a turbocharger Replace turbocharger (2) if turbine wheel rubs
turbine housing (1). If there is no rubbing or
(1) Turbine housing
(2) Compressor housing scraping, go to Step 4.
1. Inspect the compressor wheel for damage from 4. Inspect the turbine and turbine housing (1) for oil
a foreign object. If there is damage, determine leakage. Inspect the turbine and turbine housing
the source of the foreign object. Replace the (1) for oil coking. Heavy oil coking may require
turbocharger. If there is no damage, go to Step 2. replacement of the turbocharger. If the oil is
coming from the turbocharger center housing go
2. Turn the rotating assembly by hand. While you to Step 4.a. Otherwise go to “Inspection of the
turn the assembly, push the assembly sideways. Wastegate”.
The assembly should turn freely. The compressor
wheel should not rub the compressor housing. The a. Remove the pipe for the oil drain. Inspect the
turbocharger must be replaced if the compressor drain opening. Inspect the area between the
wheel rubs the compressor wheel housing. If there bearings of the rotating assembly shaft. Look
is no rubbing or scraping, go to Step 3. for oil sludge. Inspect the oil drain hole for oil
sludge. Inspect the oil drain line for oil sludge.
3. Inspect the compressor and the compressor If necessary, clean the drain line.
wheel housing for oil leakage. An oil leak from the
compressor may deposit oil in the aftercooler. If oil b. If crankcase pressure is high, or if the oil drain
is found in the aftercooler, then drain and clean is restricted, pressure in the center housing
the aftercooler. may be greater than the pressure of turbine
housing (1). Oil flow may be forced in the wrong
a. Check the oil level in the crankcase. If the oil direction and the oil may not drain. Check the
level is too high, adjust the oil level. crankcase pressure and correct any problems.
b. Inspect the engine crankcase breather. Clean c. If the oil drain line is damaged, replace the oil
the engine crankcase breather or replace drain line.
the engine crankcase breather if the engine
crankcase breather is plugged. d. Check the routing of the oil drain line. Eliminate
any sharp restrictive bends. Make sure that
c. Remove the pipe for the oil drain. Inspect the the oil drain line is not too close to the engine
drain opening. Inspect the oil drain line. Inspect exhaust manifold.
the area between the bearings of the rotating
assembly shaft. Look for oil sludge. Inspect the e. If Steps 4.a through 4.d did not reveal the
oil drain hole for oil sludge. Inspect the oil drain source of the oil leakage, turbocharger (3) has
line for oil sludge in the drain line. If necessary, internal damage. Replace turbocharger (3).
clean the oil drain line.
24 KENR6246
Inspection of the Wastegate

The wastegate controls the amount of exhaust gas
that is allowed to bypass the turbine side of the
turbocharger. This valve then controls the rpm of the
turbocharger.
When the engine operates in conditions of low

boost (lug), a spring presses against a diaphragm
in the canister. The actuating rod will move and the
wastegate actuator will close. The turbocharger can
then operate at maximum performance.
When the boost pressure increases against the

diaphragm in the canister, the wastegate will open.
The rpm of the turbocharger becomes limited. The
rpm limitation occurs because a portion of the
exhaust gases bypass the turbine wheel of the
turbocharger.
The following levels of boost pressure indicate a

problem with the wastegate:
• Too high at full load conditions

• Too low at all lug conditions
The boost pressure controls the maximum rpm of the g01289484
turbocharger, because the boost pressure controls Illustration 15
the position of the wastegate. The following factors Typical example
also affect the maximum rpm of the turbocharger:
Note: The turbocharger is a nonserviceable item.
• The engine rating The pressure for the wastegate can be checked, but
not adjusted.
• The horsepower demand on the engine
1. Remove the boost line (6) from the wastegate
• The high idle rpm actuator (5). Connect an air supply to the
wastegate actuator that can be adjusted
• Inlet air restriction accurately.
• Exhaust system restriction 2. Install Tooling (A) to the turbocharger so that

the end of the actuator rod (1) is in contact with
Check the Wastegate for Proper Tooling (A). This will measure axial movement of
the actuator rod (4).
Operation
Table 2
3. Slowly apply air pressure to the wastegate so that
the actuator rod (4) moves 1.0 mm (0.039 inch).
Required Tools The air pressure should be within 107 to 117 kPa
Part (15.5 to 17.0 psi). Ensure that the dial indicator
Tool Number Part Description Qty returns to zero when the air pressure is released.
Repeat the test several times. This will ensure that
A 21825617 Dial Gauge 1 an accurate reading is obtained.
4. If the air pressure is correct, remove the air supply.

Remove Tooling (A). Reinstall the boost line (6).
5. If the operation of the wastegate is not correct,

the actuator rod (4) cannot be adjusted. The
turbocharger must be renewed.
KENR6246 25
i02675596 Valve Lash Setting

Compression - Test Valve lash setting
Inlet valve ........................... 0.2 mm (0.008 inch)
Exhaust valve ................... 0.45 mm (0.018 inch)
The cylinder compression test should only be used
in order to compare the cylinders of an engine. Refer to Systems Operation, “Engine Design” for the
The pressure in the cylinder should be between location of the cylinder valves.
300 to 500 kPa (43.5120 to 72.5200 psi). If one or
more cylinders vary by more than 350 kPa (51 psi),
the cylinder and related components may need to
Valve Lash Adjustment
be repaired.
If the valve lash requires adjustment several times
in a short period of time, excessive wear exists in
A compression test should not be the only method
a different part of the engine. Find the problem and
which is used to determine the condition of an engine.
make necessary repairs in order to prevent more
Other tests should also be conducted in order to
damage to the engine.
determine if the adjustment or the replacement of
components is required.
Not enough valve lash can be the cause of rapid
wear of the camshaft and valve lifters. Not enough
Before the performance of the compression test,
valve lash can indicate that the seats for the valves
make sure that the following conditions exist:
are worn.
• The battery is in good condition. Valves become worn due to the following causes:
• The battery is fully charged. • Fuel injectors that operate incorrectly
• The starting motor operates correctly. • Excessive dirt and oil are present on the filters for
the inlet air.
• The valve lash is set correctly.
• All fuel injectors are removed. • Incorrect fuel settings on the fuel injection pump.
• The fuel supply is disconnected. • The load capacity of the engine is frequently
exceeded.
1. Install a gauge for measuring the cylinder
Too much valve lash can cause broken valve stems,
compression in the hole for a fuel injector.
springs, and spring retainers. Too much valve lash
can be an indication of the following problems:
2. Operate the starting motor in order to turn the
engine. Record the maximum pressure which is
indicated on the compression gauge. • Worn camshaft and valve lifters
3. Repeat Steps 1 and 2 for all cylinders. • Worn rocker arms

• Bent pushrods
i02696124
• Broken socket on the upper end of a pushrod
Engine Valve Lash -
Inspect/Adjust • Loose adjustment screw for the valve lash
If the camshaft and the valve lifters show rapid wear,
look for fuel in the lubrication oil or dirty lubrication
oil as a possible cause.
The valve lash is measured between the top of the

To prevent possible injury, do not use the starter valve stem and the rocker arm lever.
to turn the flywheel.
Note: An adjustment is not necessary if the
Hot engine components can cause burns. Allow measurement of the valve lash is in the acceptable
additional time for the engine to cool before mea- range. Inspect the valve lash while the engine is
suring valve clearance. stopped and when the engine is cold.
Note: When the following procedures are performed,

the front housing must be installed.
26 KENR6246
3. Rotate the crankshaft in a clockwise direction that

is viewed from the front of the engine. When the
inlet valve of the No. 2 cylinder has opened and
the exhaust valve of the No. 2 cylinder has not
completely closed measure the valve lash of the
inlet valve and the exhaust valve of the No. 3
cylinder.
If adjustment is necessary, refer to Steps 2.a, 2.b,

and 2.c above.

inlet valve and the exhaust valve of the No. 4
cylinder.
If adjustment is necessary, refer to Steps 2.a, 2.b,

and 2.c above.
g01016764
Illustration 16
Setting the valve lash
(1) Adjustment screw
(2) Feeler gauge
Valve Lash Adjustment for the inlet valve and the exhaust valve of the No. 2
1104D (Mechanical) engine cylinder.
1. Remove the valve mechanism cover. Refer to If adjustment is necessary, refer to Steps 2.a, 2.b,
Disassembly and Assembly, “Valve Mechanism and 2.c above.
Cover - Remove and Install”.
6. Install the valve mechanism cover. Refer to
2. Rotate the crankshaft in a clockwise direction that Disassembly and Assembly, “Valve Mechanism
is viewed from the front of the engine. When the Cover - Remove and Install”.
the exhaust valve of the No. 4 cylinder has not i01889422
inlet valve and the exhaust valve of the No. 1 Valve Depth - Inspect
cylinder. If necessary, make adjustment.
a. Loosen the valve adjustment screw locknut

that is on adjustment screw (1). Table 3
b. Place the appropriate feeler gauge (2) between Required Tools

the rocker arm and the valve. Turn adjustment
screw (1) while the valve adjustment screw Part Part Description Qty
locknut is being held from turning. Adjust the Number
valve lash until the correct specification is
achieved. 21825617 Dial gauge 1
21825496 Dial gauge holder 1
c. After each adjustment, tighten the valve
adjustment screw locknut to a torque of 27 N·m
(19.9 lb ft) while adjustment screw (1) is being
held.
KENR6246 27
g00983531
Illustration 17
Measurement of the valve depth
(1) 21825617 Dial gauge
(2) 21825496 Dial gauge holder
1. Use the dial gauge (1) with the dial gauge holder
(2) to check the depths of the inlet valves and Illustration 18
g00986821
the exhaust valves below the face of the cylinder
(1) Valve guide
head. Use the cylinder head face (3) to zero the (2) Radial movement of the valve in the valve guide
dial gauge (1). (3) Valve stem
(4) Dial indicator
2. Position the dial gauge holder (2) and the dial (5) Valve head
gauge (1) in order to measure the valve depth.
Measure the depth of the inlet valve and the 1. Place a new valve in the valve guide.
exhaust valve before the valve springs are
removed. 2. Place a suitable dial indicator with the magnetic
base on the face of the cylinder head.
Refer to Specifications, “Cylinder Head Valves”
for the minimum, the maximum, and the service 3. Lift the edge of the valve head to a distance of
wear limits for the valve depth below the cylinder 15.0 mm (0.60 inch).
head face.
4. Move the valve in a radial direction away from
If the valve depth below the cylinder head face the dial indicator. Make sure that the valve moves
exceeds the service limit, use a new valve to away from the dial indicator as far as possible.
check the valve depth. If the valve depth still Position the contact point of the dial indicator on
exceeds the service limit, renew the cylinder head the edge of the valve head. Set the position of the
or renew the valve seat inserts (if equipped). If the needle of the dial indicator to zero.
valve depth is within the service limit with a new
valve, renew the valves. 5. Move the valve in a radial direction toward the dial
indicator as far as possible. Note the distance of
3. Inspect the valves for cracks and other damage. movement which is indicated on the dial indicator.
Check the valve stems for wear. Check that the If the distance is greater than the maximum
valve springs are the correct length under the clearance of the valve in the valve guide, replace
test force. Refer to Specifications, “Cylinder Head the valve guide.
Valves” for the dimensions and tolerances of the
valves and the valve springs. When new valve guides are installed, new valves
and new valve seat inserts must be installed.
Valve guides and valve seat inserts are supplied
i01938952 as an unfinished part. The unfinished valve guides
and unfinished valve seat inserts are installed in
Valve Guide - Inspect the cylinder head. Then, the valve guides and
valve inserts are cut and reamed in one operation
with special tooling.
Perform this inspection in order to determine if a
Refer to Specifications, “Cylinder Head Valves” for
valve guide should be replaced. the maximum clearance of the valve in the valve
guide.
28 KENR6246
Lubrication System i02696150
Engine Oil Pump - Inspect

i01854908
Engine Oil Pressure - Test

If any part of the oil pump is worn enough in order to
affect the performance of the oil pump, the oil pump
must be replaced.
Low Oil Pressure Perform the following procedures in order to inspect
the oil pump. Refer to the Specifications Module,
The following conditions will cause low oil pressure.
“Engine Oil Pump” for clearances and torques.
• The oil level is low in the crankcase.
• A restriction exists on the oil suction screen.
• Connections in the oil lines are leaking.
• The connecting rod or the main bearings are worn.
• The rotors in the oil pump are worn.
• The oil pressure relief valve is operating incorrectly.
A worn oil pressure relief valve can allow oil to leak
through the valve which lowers the oil pressure.
Refer to the Specifications Module, “Engine Oil Relief
Valve” for the correct operating pressure and other
information.
When the engine runs at the normal temperature for

operation and at high idle, the oil pressure must be
a minimum of 280 kPa (40 psi). A lower pressure is
g01334408
normal at low idle. Illustration 19
Clearance for the outer rotor body
A suitable pressure gauge can be used in order to
test the pressure of the lubrication system. 1. Remove the oil pump from the engine. Refer to
the Disassembly and Assembly, “Engine Oil Pump
High Oil Pressure - Remove”. Remove the cover of the oil pump.
High oil pressure can be caused by the following 2. Remove the outer rotor. Clean all of the parts.
conditions. Look for cracks in the metal or other damage.
• The spring for the oil pressure relief valve is 3. Install the outer rotor. Measure the clearance of
installed incorrectly. the outer rotor to the body (1).
• The plunger for the oil pressure relief valve

becomes jammed in the closed position.
• Excessive sludge exists in the oil which makes the

viscosity of the oil too high.
KENR6246 29
i01126690
Excessive Bearing Wear -

Inspect
When some components of the engine show bearing

wear in a short time, the cause can be a restriction in
an oil passage.
An engine oil pressure indicator may show that there

is enough oil pressure, but a component is worn
due to a lack of lubrication. In such a case, look at
the passage for the oil supply to the component.
A restriction in an oil supply passage will not allow
enough lubrication to reach a component. This will
result in early wear.
i02487769
g01334410
Illustration 20
Excessive Engine Oil
Clearance for the inner rotor body
Consumption - Inspect
4. Measure the clearance of the inner rotor to the
outer rotor (2).
Engine Oil Leaks on the Outside of

the Engine
Check for leakage at the seals at each end of the
crankshaft. Look for leakage at the gasket for the
engine oil pan and all lubrication system connections.
Look for any engine oil that may be leaking from
the crankcase breather. This can be caused by
combustion gas leakage around the pistons. A dirty
crankcase breather will cause high pressure in the
crankcase. A dirty crankcase breather will cause the
gaskets and the seals to leak.
Engine Oil Leaks into the

Combustion Area of the Cylinders
Engine oil that is leaking into the combustion area of
the cylinders can be the cause of blue smoke. There
are several possible ways for engine oil to leak into
g01334412
Illustration 21 the combustion area of the cylinders:
End play measurement of the rotor
• Leaks between worn valve guides and valve stems
5. Measure the end play of the rotor with a straight
edge and a feeler gauge (3). • Worn components or damaged components
(pistons, piston rings, or dirty return holes for the
6. Clean the top face of the oil pump and the bottom engine oil)
face of the cover. Install the cover on the oil pump.
Install the oil pump on the engine. • Incorrect installation of the compression ring and/or
the intermediate ring
• Leaks past the seal rings in the turbocharger shaft

• Overfilling of the crankcase
30 KENR6246
• Wrong dipstick or guide tube

• Sustained operation at light loads
Excessive consumption of engine oil can also
result if engine oil with the wrong viscosity is used.
Engine oil with a thin viscosity can be caused by fuel
leakage into the crankcase or by increased engine
temperature.
i01945015
Increased Engine Oil

Temperature - Inspect
Look for a restriction in the oil passages of the oil

cooler (if equipped). The oil temperature may be
higher than normal when the engine is operating. In
such a case, the oil cooler may have a restriction.
A restriction in the oil cooler will not cause low oil
pressure in the engine.
KENR6246 31
Cooling System 6. Check the filler cap. A pressure drop in the

cooling system can cause the boiling point to
be lower. This can cause the cooling system to
i02696567 boil. Cavitation (air bubbles in the system) will
be present in the system. Refer to Testing and
Cooling System - Check Adjusting, “Cooling System - Test”.
(Overheating) 7. Check the cooling system hoses and clamps.
Damaged hoses with leaks can normally be
seen. Hoses that have no visual leaks can soften
Above normal coolant temperatures can be caused during operation. The soft areas of the hose
by many conditions. Use the following procedure can become kinked or crushed during operation.
to determine the cause of above normal coolant These areas of the hose can cause a restriction
temperatures: in the coolant flow. Hoses become soft and/or get
cracks after a period of time. The inside of a hose
1. Check the coolant level in the cooling system. If can deteriorate, and the loose particles of the
the coolant level is too low, air will get into the hose can cause a restriction of the coolant flow.
cooling system. Air in the cooling system will
cause a reduction in coolant flow and bubbles 8. Check for a restriction in the air inlet system. A
in the coolant. Air bubbles will keep the coolant restriction of the air that is coming into the engine
away from the engine parts, which will prevent the can cause high cylinder temperatures. High
transfer of heat to the coolant. Damage will be cylinder temperatures require higher than normal
caused to internal components within the coolant temperatures in the cooling system.
pump. Low coolant level is caused by leaks or
incorrectly filling the expansion tank. 9. Check for a restriction in the exhaust system.
A restriction of the air that is coming out of the
2. Check the mixture of antifreeze and water. The engine can cause high cylinder temperatures.
mixture should be 50 percent water and 50
percent 21825166 POWERPART antifreeze. a. Make a visual inspection of the exhaust system.
3. Check for air in the cooling system. Air can enter b. Check for damage to exhaust piping. Check for
the cooling system in different ways. The most damage to the exhaust elbow. If no damage
common causes of air in the cooling system is found, check the exhaust system for a
are not filling the cooling system correctly and restriction.
combustion gas leakage into the cooling system.
Combustion gas can get into the system through 10. Check the water temperature regulator. A water
inside cracks, a damaged cylinder head, or a temperature regulator that does not open, or a
damaged cylinder head gasket. Air in the cooling water temperature regulator that only opens part
system causes a reduction in coolant flow and of the way can cause overheating. Refer to Testing
bubbles in the coolant. Air bubbles keep the and Adjusting, “Water Temperature Regulator -
coolant away from the engine parts, which Test”.
prevents the transfer of heat to the coolant.
Damage will be caused to internal components 11. Check the water pump. A water pump with a
within the coolant pump. damaged impeller does not pump enough coolant
for correct engine cooling. Remove the water
4. Check the sending unit. In some conditions, the pump and check for damage to the impeller.
temperature sensor in the engine sends signals to
a sending unit. The sending unit converts these 12. Consider high outside temperatures. When
signals to an electrical impulse which is used by a outside temperatures are too high for the rating
mounted gauge. If the sending unit malfunctions, of the cooling system, there is not enough of
the gauge can show an incorrect reading. Also if a temperature difference between the outside
the electric wire breaks or if the electric wire shorts air and coolant temperatures. The maximum
out, the gauge can show an incorrect reading. temperature of the ambient air that enters the
engine should not exceed 50 °C (120 °F).
5. Check the radiator for a restriction to coolant flow.
Check the radiator for debris, dirt, or deposits on 13. When a load that is applied to the engine is too
the inside of the core. Debris, dirt, or deposits will large, the engine rpm does not increase with an
restrict the flow of coolant through the radiator. increase of fuel. This lower engine rpm causes
a reduction in coolant flow through the system.
This combination of less air and less coolant flow
during high input of fuel will cause above normal
heating.
32 KENR6246
i01889427 i01964006
Cooling System - Inspect Cooling System - Test
This engine has a pressure type cooling system. A Remember that temperature and pressure work
pressure type cooling system gives two advantages: together. When a diagnosis is made of a cooling
system problem, temperature and pressure must
• The pressure type cooling system can operate be checked. The cooling system pressure will have
safely at a higher temperature than the boiling an effect on the cooling system temperature. For
point of water at a range of atmospheric pressures. an example, refer to Illustration 22. This will show
the effect of pressure on the boiling point (steam) of
• The pressure type cooling system prevents water. This will also show the effect of height above
cavitation in the water pump. sea level.
Cavitation is the sudden generation of low pressure

bubbles in liquids by mechanical forces. The
generation of an air or steam pocket is much more
difficult in a pressure type cooling system.
Regular inspections of the cooling system should be

made in order to identify problems before damage
can occur. Visually inspect the cooling system before
tests are made with the test equipment.
Visual Inspection Of The Cooling

System
g00286266
1. Check the coolant level in the cooling system. Illustration 22
Cooling system pressure at specific altitudes and boiling points
2. Look for leaks in the system. of water
3. Inspect the radiator for bent fins and other

restriction to the flow of air through the radiator.
Personal injury can result from hot coolant, steam
4. Inspect the drive belt for the fan. and alkali.
5. Inspect the blades of the fan for damage. At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
6. Look for air or combustion gas in the cooling to heaters or the engine contain hot coolant or
system. steam. Any contact can cause severe burns.
7. Inspect the radiator cap for damage. The sealing Remove filler cap slowly to relieve pressure only
surface must be clean. when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
8. Look for large amounts of dirt in the radiator core.
Look for large amounts of dirt on the engine.
The coolant level must be to the correct level in order
9. Shrouds that are loose or missing cause poor air to check the coolant system. The engine must be
flow for cooling. cold and the engine must not be running.
After the engine is cool, loosen the pressure cap

in order to relieve the pressure out of the cooling
system. Then remove the pressure cap.
KENR6246 33
The level of the coolant should not be more than • Seal

13 mm (0.5 inch) from the bottom of the filler pipe. If
the cooling system is equipped with a sight glass, • Surface for seal
the coolant should be to the correct level in the sight
glass. Remove any deposits that are found on these
items, and remove any material that is found on
these items.
Checking the Filler Cap
3. Install the pressure cap onto a suitable
One cause for a pressure loss in the cooling system
pressurizing Pump.
can be a faulty seal on the radiator pressure cap.
4. Observe the exact pressure that opens the filler
cap.
5. Compare the pressure to the pressure rating that

is found on the top of the filler cap.
6. If the filler cap is damaged, replace the filler cap.
Testing The Radiator And Cooling

System For Leaks
Use the following procedure to test the radiator and
the cooling system for leaks.
g00296067
Illustration 23
Typical schematic of filler cap
(1) Sealing surface between the pressure cap and the radiator
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot

Personal injury can result from hot coolant, steam and under pressure. The radiator and all lines
and alkali. to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines Remove filler cap slowly to relieve pressure only
to heaters or the engine contain hot coolant or when engine is stopped and radiator cap is cool
steam. Any contact can cause severe burns. enough to touch with your bare hand.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool 1. When the engine has cooled, loosen the filler cap
enough to touch with your bare hand. to the first stop. Allow the pressure to release from
the cooling system. Then remove the filler cap.
To check for the amount of pressure that opens the 2. Make sure that the coolant covers the top of the
filler cap, use the following procedure: radiator core.
1. After the engine cools, carefully loosen the filler 3. Put a suitable pressurizing Pump onto the radiator.
cap. Slowly release the pressure from the cooling
system. Then, remove the filler cap. 4. Use the pressurizing pump to increase the
pressure to an amount of 20 kPa (3 psi) more than
2. Inspect the pressure cap carefully. Look for the operating pressure of the filler cap.
damage to the seal. Look for damage to the
surface that seals. Remove any debris on the cap, 5. Check the radiator for leakage on the outside.
the seal, or the sealing surface.
6. Check all connections and hoses of the cooling
Carefully inspect the filler cap. Look for any system for leaks.
damage to the seals and to the sealing surface.
Inspect the following components for any foreign The radiator and the cooling system do not have
substances: leakage if all of the following conditions exist:
• Filler cap
34 KENR6246
• You do NOT observe any leakage after five If necessary, clean the outside and clean the inside
minutes. of the cooling plates. Use a solvent that is not
corrosive on copper. Ensure that no restrictions for
• The dial indicator remains constant beyond five the flow of lubricating oil exist in the cooling plates.
minutes.
Dry the cooling plate with low pressure air. Flush
The inside of the cooling system has leakage only the inside of the cooling plate with clean lubricating
if the following conditions exist: oil.
• The reading on the gauge goes down. 5. Refer to Disassembly and Assembly, “Engine Oil
Cooler - Install” for installation of the engine oil
• You do NOT observe any outside leakage. cooler.
Make any repairs, as required. 6. Ensure that the cooling system and the oil system
of the engine are filled to the correct level. Operate
the engine. Check for oil or coolant leakage.
i02696569
Engine Oil Cooler - Inspect i01889428
Water Temperature Regulator

- Test
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to Note: Do not remove the water temperature regulator
contact the skin. from the water temperature regulator housing in
order to perform the test.
Engine oil cooler for the 1104D 1. Remove the water temperature regulator housing
engine which contains the water temperature regulator
from the engine. Refer to Disassembly and
Perform the following procedure in order to inspect Assembly, “Water Temperature Regulator -
the engine oil cooler (if equipped): Remove and Install”.
1. Place a container under the oil cooler in order to 2. Heat water in a pan until the temperature of
collect any engine oil or coolant that drains from the water is equal to the fully open temperature
the oil cooler. of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator”
2. Refer to Disassembly and Assembly, “Engine Oil for the fully open temperature of the water
Cooler - Remove” for removal of the engine oil temperature regulator. Stir the water in the pan.
cooler. This will distribute the temperature throughout the
pan.
3. Thoroughly clean the flange face of the cover
plate and the cylinder block. 3. Hang the water temperature regulator housing in
the pan of water. The water temperature regulator
housing must be below the surface of the water.
The water temperature regulator housing must be
away from the sides and the bottom of the pan.
Personal injury can result from air pressure.
4. Keep the water at the correct temperature for ten
Personal injury can result without following prop- minutes.
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing. 5. After ten minutes, remove the water temperature
regulator housing. Immediately measure the
Maximum air pressure at the nozzle must be less opening of the water temperature regulator.
than 205 kPa (30 psi) for cleaning purposes. Refer to Specifications, “Water Temperature
Regulator” for the minimum opening distance of
the water temperature regulator at the fully open
4. Inspect the cooling plates for cracks and dents.
temperature.
Replace the cooling plates if cracks or dents exist.
KENR6246 35
If the distance is less than the amount listed in the

manual, replace the water temperature regulator.
Refer to Disassembly and Assembly, “Water
Temperature Regulator - Remove and Install”.
Install the water temperature regulator. Refer to

Disassembly and Assembly, “Water Temperature
Regulator - Remove and Install”.
36 KENR6246
Basic Engine Note: Some pistons have a tapered top groove and
the piston ring is wedged. The clearance for the top
piston ring cannot be checked by the above method
i01889476 when this occurs.
Piston Ring Groove - Inspect Inspect the Piston Ring End Gap
Inspect the Piston and the Piston

Rings
1. Check the piston for wear and other damage.
2. Check that the piston rings are free to move in the

grooves and that the rings are not broken.
Inspect the Clearance of the Piston

Ring
1. Remove the piston rings and clean the grooves
and the piston rings.
g00983549
Illustration 25
(1) Piston ring
(2) Cylinder ring ridge
(3) Feeler gauge
1. Clean all carbon from the top of the cylinder bores.
2. Place each piston ring (1) in the cylinder bore just

below the cylinder ring ridge (2).
3. Use a suitable feeler gauge (3) to measure the

piston ring end gap. Refer to Specifications,
“Piston and Rings” for the dimensions.
Note: The coil spring must be removed from the oil

control ring before the gap of the oil control ring is
measured.
g00905732
Illustration 24
(1) Feeler gauge i01946425
(2) Piston ring
(3) Piston grooves Connecting Rod - Inspect
2. Fit new piston rings (2) in the piston grooves (3).
3. Check the clearance for the piston ring by placing

a suitable feeler gauge (1) between the piston
groove (3) and the top of piston ring (2). Refer
to Specifications, “Piston and Rings” for the
dimensions. This procedure determines the following
characteristics of the connecting rod:
• The distortion of the connecting rod

KENR6246 37
• The parallel alignment of the bores of the i01748770

connecting rod
Connecting Rod Bearings -
Inspect
Check the connecting rod bearings and the

connecting rod bearing journal for wear or other
damage.
Connecting rod bearings are available with a smaller

inside diameter than the original size bearings. These
bearings are for crankshafts that have been ground.
i01748792
g00927038
Illustration 26
Inspection of the connecting rod parallel alignment.
Main Bearings - Inspect
(1) Measuring pins
(2) Connecting rod
(L) Measure the distance between the center of the bore for the
piston pin bearing and the center of the connecting rod bearing Check the main bearings for wear or other damage.
bore. Replace both halves of the bearings and check the
(K) Measure the distance 127 mm (5.0 inch) from the connecting condition of the other bearings if a main bearing is
rod.
worn or damaged.
1. Use the appropriate tools in order to measure the
Main bearings are available with a smaller inside
distances for the connecting rod (2). diameter than the original size bearings. These
bearings are for main bearing journals that have
• Appropriate gauges for measuring distance been ground.
• Measuring pins (1)
i01946424
Note: The connecting rod bearings should be
removed before taking the measurements. Cylinder Block - Inspect
2. Measure the connecting rod for distortion and
parallel alignment between the bores.
1. Clean all of the coolant passages and the oil
The measurements must be taken at distance (K). passages.
Distance (K) has a value of 127 mm (5.0 inch)
from both sides of the connecting rod. 2. Check the cylinder block for cracks and damage.
Measure length (L). 3. The top deck of the cylinder block must not be
machined. This will affect the piston height above
The total difference in measurements of length the cylinder block.
(L) from each side should not vary more than
± 0.25 mm (± 0.010 inch). 4. Check the camshaft bearing for wear. If a new
bearing is needed, use a suitable adapter to press
If the piston pin bearing is not removed, the limits the bearing out of the bore. Ensure that the oil hole
are reduced to ± 0.06 mm (± 0.0025 inch). in the new bearing faces the front of the block.
The oil hole in the bearing must be aligned with
3. Inspect the piston pin bearing and the piston pin the oil hole in the cylinder block. The bearing must
for wear and other damage. be aligned with the face of the recess. Refer to
Disassembly and Assembly, “Camshaft Bearings
4. Measure the clearance of the piston pin in - Remove and Install”.
the piston pin bearing. Refer to Specifications,
“Connecting Rod” for clearance dimensions.
38 KENR6246
i02707805 Refer to Specifications, “Cylinder Head” for the

requirements of flatness.
Cylinder Head - Inspect
Resurfacing the Cylinder Head
1. Remove the cylinder head from the engine. The bottom face of cylinder head can be resurfaced if
any of the following conditions exist:
2. Remove the water temperature regulator housing.
• The bottom face of the cylinder head is not flat
3. Inspect the cylinder head for signs of gas or within the specifications.
coolant leakage.
• The bottom face of the cylinder head is damaged
4. Remove the valve springs and valves. by pitting, corrosion, or wear.
5. Clean the bottom face of the cylinder head Note: The thickness of the cylinder head must not be
thoroughly. Clean the coolant passages and less than 117.20 mm (4.614 inch) after the cylinder
the lubricating oil passages. Make sure that the head has been machined.
contact surfaces of the cylinder head and the
cylinder block are clean, smooth and flat. If the bottom face of the cylinder head has been
remachined, the recesses in the cylinder head for
6. Inspect the bottom face of the cylinder head for the valve seat inserts must be machined. The valve
pitting, corrosion, and cracks. Inspect the area seat inserts must be ground on the side which is
around the valve seat inserts and the holes for the inserted into the cylinder head. Grinding this surface
fuel injectors carefully. will ensure that no protrusion exists above the bottom
face of the cylinder head. Refer to Specifications,
7. Test the cylinder head for leaks at a pressure of “Cylinder Head Valves” for the correct dimensions.
200 kPa (29 psi).
i01889496
Piston Height - Inspect
Table 4
Required Tools
Part Part Description Qty

Number
21825617 Dial gauge 1
g01012606
21825496 Dial gauge holder 1
Illustration 27
Flatness of the cylinder head (typical example)
If the height of the piston above the cylinder block
(A) Side to side
(B) End to end
is not within the tolerance that is given in the
(C) Diagonal Specifications Module, “Piston and Rings”, the
bearing for the piston pin must be checked. Refer to
8. Measure the cylinder head for flatness. Measure Testing and Adjusting, “Connecting Rod - Inspect”.
the flatness of the cylinder head with a straight If any of the following components are replaced or
edge and with a feeler gauge. remachined, the piston height above the cylinder
block must be measured:
• Measure the cylinder head from one side to the
opposite side (A). • Crankshaft
• Measure the cylinder head from one end to the • Cylinder head
opposite end (B).
• Connecting rod
• Measure the cylinder head from one corner to
the opposite corner (C). • Bearing for the piston pin
KENR6246 39
The correct piston height must be maintained in order i01897548

to ensure that the engine conforms to the standards
for emissions. Flywheel - Inspect
Note: The top of the piston should not be machined.
If the original piston is installed, be sure that the
original piston is assembled to the correct connecting Alignment of the Flywheel Face
rod and installed in the original cylinder.
Six grades of length of connecting rods determine

the piston height above the cylinder block. The grade
of length of a connecting rod is identified by a letter or
a color. The letter or the color is marked on the side
of the connecting rod. Refer to Testing and Adjusting,
“Connecting Rod - Inspect” and Specifications,
“Connecting Rod” for additional information.
g00987751
Illustration 29
1. Install the dial indicator. Refer to Illustration 29.
2. Set the pointer of the dial indicator to 0 mm

(0 inch).
3. Turn the flywheel. Read the dial indicator for every

g00983585
90 degrees.
Illustration 28
(1) Dial gauge Note: During the check, keep the crankshaft pressed
(2) Dial gauge holder toward the front of the engine in order to remove any
end clearance.
1. Use the dial gauge (1) and the dial gauge holder
(2) in order to measure the piston height above 4. Calculate the difference between the lowest
the cylinder block. Use the cylinder block face to measurement and the highest measurement of the
zero the dial gauge (1). four locations. This difference must not be greater
than 0.03 mm (0.001 inch) for every 25 mm
2. Rotate the crankshaft until the piston is at the (1.0 inch) of the radius of the flywheel. The radius
approximate top center. of the flywheel is measured from the axis of the
crankshaft to the contact point of the dial indicator.
3. Position the dial gauge holder (2) and the dial
gauge (1) in order to measure the piston height
above the cylinder block. Slowly rotate the
crankshaft in order to determine when the piston
is at the highest position. Record this dimension.
Compare this dimension with the dimensions that
are given in Specifications, “Piston and Rings”.
40 KENR6246
Flywheel Runout
g01199468
Illustration 31
g00987752 Typical example
Illustration 30
1. Install the dial indicator. Refer to Illustration 30. 1. Install Tooling (A). See illustration 31.
2. Set the pointer of the dial indicator to 0 mm 2. Set the pointer of the dial indicator to 0 mm
(0 inch). (0 inch).
3. Turn the flywheel. Read the dial indicator for every 3. Check the concentricity at intervals of 45 degrees
90 degrees. around the flywheel housing.
4. Calculate the difference between the lowest 4. Calculate the difference between the lowest
measurement and the highest measurement of measurement and the highest measurement. This
the four locations. This difference must not be difference must not be greater than the limit that
greater than 0.30 mm (0.012 inch). is given in Table 6.
Note: Any necessary adjustment must be made on

i02406200 the flywheel housing. Then, recheck the concentricity.
Flywheel Housing - Inspect
Alignment of the Flywheel Housing
Note: This check must be made with the flywheel
Table 5 and the starter removed and the bolts for the flywheel
Required Tools housing tightened to the correct torque.
Part
A 21825617 Dial Gauge 1
Concentricity of the Flywheel

Housing
Note: This check must be made with the flywheel
and the starter removed and the bolts for the flywheel
housing tightened lightly.
KENR6246 41
i01958093
Gear Group - Inspect
g01199467
Illustration 32
Typical example
1. Install Tooling (A). See illustration 32.

g00918708
Illustration 33
2. Set the pointer of the dial indicator to 0 mm
(0 inch). (1) Fuel pump drive gear
(2) Camshaft drive gear
(3) Idler gear
3. Check the alignment at intervals of 45 degrees
around the flywheel housing. Remove the front timing cover and inspect the gears.
The timing marks on the gears indicate the front side
4. Calculate the difference between the lowest of the gears. Inspect the gears for broken teeth or
measurement and the highest measurement. This worn teeth.
difference must not be greater than the limit that
is given in Table 6.
Note: Any necessary adjustment must be made on

the flywheel housing.
Table 6
Limits for Flywheel Housing Runout and Alignment
(Total Indicator Reading)
Bore of the Housing Maximum Limit (Total
Flange Indicator Reading)
410 mm (16.14 inch) 0.25 mm (0.010 inch)
448 mm (17.63 inch) 0.28 mm (0.011 inch)
42 KENR6246
Electrical System 4. Turn the ignition switch to the ON position. Check

the voltage between terminal (B) and ground. If
the voltage is more than 2 Volts the alternator
i02757133 needs to be replaced.
Alternator - Test Warning Light is On When the

Engine is Running
1. Start the engine and run the engine at fast idle.
2. Measure the voltage between terminal (A) and

ground.
3. Measure the voltage between terminal (B) and

ground.
4. The measured voltage for terminal (A) and

terminal (B) should be 13 to 15 volts for a 12 volt
system. The measured voltage for terminal (A)
and terminal (B) should be 26 to 30 volts for a 24
volt system.
5. If the voltages do not match replace the alternator.
6. Increase the engine to high idle. Turn an electrical

load ON.
7. Measure the voltage between terminal (A) and

Illustration 34
g00931045 ground.
Typical wiring schematic for an alternator
8. Measure the voltage between terminal (B) and
(A) Terminal “B+”
(B) Terminal “D+”
ground.
(C) Terminal “W”
(D) Ground 9. The measured voltage for terminal (A) and
(1) Electrical switch terminal (B) should be 13 to 15 volts for a 12 volt
(2) Dash light system. The measured voltage for terminal (A)
(3) Ignition switch
(4) Battery and terminal (B) should be 26 to 30 volts for a 24
volt system.
Warning Lamp Does Not Illuminate 10. Replace the alternator if the voltage does not
match.
The warning lamp for the charging system should
illuminate when the ignition switch is in the ON
position. Follow the steps below in order to test the
system.
1. Check the light bulb. Replace the light bulb if the

element is broken.
2. Use a suitable Multimeter to check the battery

voltage. Check the battery voltage with the ignition
switch OFF.
3. Check the voltage between the terminal (A) and

ground. The measured voltage should equal the
battery voltage.
KENR6246 43
Intermittent Charging 7. If the voltage does not meet the specification then
the Alternator should be changed.
i01899136
Battery - Test
Most of the tests of the electrical system can be done

on the engine. The wiring insulation must be in good
condition. The wire and cable connections must be
clean, and both components must be tight.
Never disconnect any charging unit circuit or bat-

tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo-
sion from the flammable vapor mixture of hydro-
gen and oxygen that is released from the elec-
trolyte through the battery outlets. Injury to per-
sonnel can be the result.
The battery circuit is an electrical load on the charging

unit. The load is variable because of the condition of
the charge in the battery.
g01380690
Illustration 35
NOTICE
Intermittent charging may occur. if the cable The charging unit will be damaged if the connections
connected to the terminal “B+” (A) has a faulty between the battery and the charging unit are broken
connection. while the battery is being charged. Damage occurs
because the load from the battery is lost and because
1. Check that the connection is secure. there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
2. If the connection is not secure, then remove the electrical components.
upper nut (1). Remove the cable (2). Check that
the lower nut (3) that secures the collar (4) to the The correct procedures to test the battery can be
terminal “B+” is secure and undamaged. If the found in the manual that is supplied by the OEM.
lower nut (9) is damaged then renew the nut.
Tighten the nut to a torque of 4 N·m (2.9502 lb ft)
to 5 N·m (3.6878 lb ft). i01945632
3. Check the connector on the end of the cable (2) Electric Starting System - Test
for damage. If the connector is damaged, renew
the connector.
4. Replace the cable (2) and the connector onto the General Information
terminal “B+” and tighten the upper nut (1) to a
torque of7.0 ± 1.0 N·m (5.1629 ± 0.7376 lb ft). All electrical starting systems have four elements:
5. Reconnect the battery. Ensure that the polarity is • Ignition switch
correct.
• Start relay
6. Run the engine. Measure the voltage between
terminal “B+” and the body of the alternator. • Starting motor solenoid
The correct reading should be between 13.5 to • Starting motor
14.7 volts.
44 KENR6246
Start switches have a capacity of 5 to 20 amperes. Table 8

The coil of a start relay draws about 1 ampere Maximum Acceptable Voltage Drop In The Starting
between test points. The switch contacts of the start Motor Circuit During Cranking
relay for the starting motor are rated between 100
and 300 amperes. The start relay can easily switch Circuit 12 Volt 24 Volt
the load of 5 to 50 amperes for the starting motor System System
solenoid. Battery post “-” to 0.7 volts 1.4 volts
the starting motor
The starting motor solenoid is a switch with a capacity terminal “-”
of about 1000 amperes. The starting motor solenoid
Drop across the 0.5 volts 1.0 volts
supplies power to the starter drive. The starting motor
disconnect switch
solenoid also engages the pinion to the flywheel.
Battery post “+” 0.5 volts 1.0 volts
The starting motor solenoid has two coils. The to the terminal of
pull-in coil draws about 40 amperes. The hold-in coil the starting motor
requires about 5 amperes. solenoid “+”
Solenoid terminal 0.4 volts 0.8 volts
When the magnetic force increases in both coils, “Bat” to the solenoid
the pinion gear moves toward the ring gear of the terminal “Mtr”
flywheel. Then, the solenoid contacts close in order
to provide power to the starting motor. When the
Voltage drops that are greater than the amounts
solenoid contacts close, the ground is temporarily
in Table 8 are caused most often by the following
removed from the pull-in coil. Battery voltage is
conditions:
supplied on both ends of the pull-in coil while the
starting motor cranks. During this period, the pull-in
coil is out of the circuit. • Loose connections
Cranking of the engine continues until current to the • Corroded connections

solenoid is stopped by releasing the ignition switch.
• Faulty switch contacts
Power which is available during cranking varies
according to the temperature and condition of the Diagnosis Procedure
batteries. The following chart shows the voltages
which are expected from a battery at the various The procedures for diagnosing the starting motor
temperature ranges. are intended to help the technician determine if a
starting motor needs to be replaced or repaired. The
Table 7 procedures are not intended to cover all possible
Typical Voltage Of Electrical System During Cranking problems and conditions. The procedures serve only
At Various Ambient Temperatures as a guide.
Temperature 12 Volt 24 Volt Note: Do not crank the engine for more than 30
System System seconds. Allow the starter to cool for two minutes
−23 to −7°C 6 to 8 volts 12 to 16 volts before cranking the engine again.
(−10 to 20°F)
If the starting motor does not crank or cranks slow,
−7 to 10°C 7 to 9 volts 14 to 18 volts
(20 to 50°F)
perform the following procedure:
10 to 27°C 8 to 10 volts 16 to 24 volts 1. Measure the voltage of the battery.

(50 to 80°F)
Measure the voltage across the battery posts with
The following table shows the maximum acceptable the multimeter when you are cranking the engine
loss of voltage in the battery circuit. The battery or attempting to crank the engine. Do not measure
circuit supplies high current to the starting motor. the voltage across the cable post clamps.
The values in the table are for engines which have
service of 2000 hours or more. a. If the voltage is equal or greater than the
voltage in Table 7, then go to Step 2.
b. The battery voltage is less than the voltage in

Table 7.
KENR6246 45
A low charge in a battery can be caused by c. The starting motor voltage is less than the
several conditions. voltage specified in Table 7. The voltage drop
between the battery and the starting motor is
• Deterioration of the battery too great. Go to Step 4.
• A shorted starting motor 4. Measure the voltage.
• A faulty alternator a. Measure the voltage drops in the cranking

circuits with the multimeter. Compare the
• Loose drive belts results with the voltage drops which are allowed
in Table 8.
• Current leakage in another part of the
electrical system b. Voltage drops are equal to the voltage drops
that are given in Table 8 or the voltage drops
2. Measure the current that is sent to the starting are less than the voltage drops that are given
motor solenoid from the positive post of the in Table 8. Go to Step 5 in order to check the
battery. engine.
Note: If the following conditions exist, do not perform c. The voltage drops are greater than the voltage
the test in Step 2 because the starting motor has a drops that are given in Table 8. The faulty
problem. component should be repaired or replaced.
• The voltage at the battery post is within 2 volts 5. Rotate the crankshaft by hand in order to ensure
of the lowest value in the applicable temperature that the crankshaft is not stuck. Check the oil
range of Table 7. viscosity and any external loads that could affect
the engine rotation.
• The large starting motor cables get hot.
a. If the crankshaft is stuck or difficult to turn,
Use a suitable ammeter in order to measure the repair the engine.
current. Place the jaws of the ammeter around the
cable that is connected to the “bat” terminal. Refer b. If the engine is not difficult to turn, go to Step 6.
to the Specifications Module, “Starting Motor” for
the maximum current that is allowed for no load 6. Attempt to crank the starting motor.
conditions.
a. The starting motor cranks slowly.
The current and the voltages that are specified
in the Specifications Module are measured Remove the starting motor for repair or
at a temperature of 27°C (80°F). When the replacement.
temperature is below 27°C (80°F), the voltage
will be lower through the starting motor. When b. The starting motor does not crank.
the temperature is below 27°C (80°F), the current
through the starting motor will be higher. If the Check for the blocked engagement of the
current is too great, a problem exists in the starting pinion gear and flywheel ring gear.
motor. Repair the problem or replace the starting
motor. Note: Blocked engagement and open solenoid
contacts will give the same electrical symptoms.
If the current is within the specification, proceed
to Step 3.
i01911231
3. Measure the voltage of the starting motor. Glow Plugs - Test

a. Use the multimeter in order to measure the
voltage of the starting motor, when you are
cranking or attempting to crank the engine.
Continuity Check of the Glow Plugs
b. If the voltage is equal or greater than the
voltage that is given in Table 7, then the battery The following test will check the continuity of the glow
and the starting motor cable that goes to the plugs.
starting motor are within specifications. Go to
Step 5. 1. Disconnect the power supply and the bus bar.
46 KENR6246
2. Use a suitable digital multimeter to check i02730999

continuity (resistance). Turn the audible signal on
the digital multimeter ON. V-Belt - Test
3. Place one probe on the connection for the glow
plug and the other probe to a suitable ground. The
Table 11
digital multimeter should make an audible sound.
Replace the glow plug if there is no continuity. Required Tools
4. Check the continuity on all the glow plugs.
A - Belt Tension Gauge 1
Checking The Operation of The
Glow Plug
The following test will check the operation of the glow
plugs.
1. Disconnect the power supply and the bus bar.
2. Connect the power supply to only one glow plug.
3. Place a suitable ammeter on the power supply

wire.
4. Connect a suitable digital multimeter to the

terminal on the glow plug and to a suitable ground.
5. Turn the switch to the ON position in order to

activate the glow plugs.
Table 9
12 Volt System
Amp Time (sec)
30 Initial
21 4
14 8
10 20
9 60
Table 10
24 Volt System
Amp Time (sec)
12 Initial
8.5 8
7 20
6 60
6. Check the reading on all of the glow plugs.
7. If there is no reading on the ammeter check the

electrical connections. If the readings on the
ammeter are low replace the glow plugs. If there
is still no reading replace the glow plugs.
KENR6246 47
Table 12
Belt Tension Chart
Gauge Reading
Size of Belt Width of Belt
Initial Belt Tension(1) Used Belt Tension(2)
1/2 13.89 mm (0.547 Inch) 535 N (120 lb) 355 N (80 lb)
Measure the tension of the belts.
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
Install Tooling (A) at the center of the longest free If necessary, replace the belt tensioner. Refer
length of belt and check the tension on both belts. to Disassembly and Assembly, “Alternator Belt -
Check and adjust the tension on the tightest belt. Remove and Install”.
To adjust the belt tension, refer to Disassembly and
Assembly, “Alternator - Install”.
Poly V-Belt
NOTICE
Ensure that the engine is stopped before any servicing
or repair is performed.
To maximize the engine performance, inspect the

poly v-belt (1) for wear and for cracking. Replace the
poly v-belt if the belt is worn or damaged.
• If the poly v-belt (1) has more than four cracks per
25.4000 mm (1 inch) the belt must be replaced.
• Check the poly v-belt for cracks, splits, glazing,

grease, and splitting.
g01216014
Illustration 36
Typical example
To replace the poly v-belt, refer to Disassembly and

Assembly, “Alternator Belt - Remove and Install”.
48 KENR6246
Index Section
Index
A Engine Valve Lash - Inspect/Adjust ....................... 25
Valve Lash Adjustment ...................................... 25
Air in Fuel - Test..................................................... 18 Valve Lash Adjustment for the 1104D (Mechanical)
Air Inlet and Exhaust System ............................ 9, 22 engine .............................................................. 26
Cylinder Head And Valves ................................. 10 Valve Lash Setting ............................................. 25
Turbocharger ..................................................... 10 Excessive Bearing Wear - Inspect......................... 29
Air Inlet and Exhaust System - Inspect.................. 22 Excessive Engine Oil Consumption - Inspect........ 29
Alternator - Test ..................................................... 42 Engine Oil Leaks into the Combustion Area of the
Intermittent Charging ......................................... 43 Cylinders .......................................................... 29
Warning Lamp Does Not Illuminate ................... 42 Engine Oil Leaks on the Outside of the Engine.. 29
Warning Light is On When the Engine is
Running............................................................ 42
F
B Finding Top Center Position for No. 1 Piston......... 19

Flywheel - Inspect.................................................. 39
Basic Engine.................................................... 15, 36 Alignment of the Flywheel Face......................... 39
Camshaft............................................................ 15 Flywheel Runout ................................................ 40
Crankshaft.......................................................... 15 Flywheel Housing - Inspect ................................... 40
Cylinder Block and Cylinder Head ..................... 15 Alignment of the Flywheel Housing.................... 40
Pistons, Rings, and Connecting Rods ............... 15 Concentricity of the Flywheel Housing............... 40
Battery - Test ......................................................... 43 Fuel Injection Pump Timing - Adjust...................... 20
Delphi DP310 Fuel Injection Pumps ................. 20
Fuel Injection Pump Timing - Check...................... 20
C Delphi DP310 Fuel Injection Pump ................... 20
Fuel Quality - Test.................................................. 20
Compression - Test................................................ 25 Fuel System....................................................... 7, 18
Connecting Rod - Inspect ...................................... 36 Fuel System Components.................................... 8
Connecting Rod Bearings - Inspect....................... 37 Fuel System - Inspect............................................ 18
Cooling System ............................................... 14, 31 Fuel System - Prime .............................................. 20
Cooling System - Check (Overheating) ................. 31 Delphi DP310..................................................... 20
Cooling System - Inspect....................................... 32 Fuel System Pressure - Test ................................. 21
Visual Inspection Of The Cooling System.......... 32 Check the Function of the Fuel Transfer Pump.. 21
Cooling System - Test............................................ 32 Check the Function of the Pressure Regulator .. 21
Checking the Filler Cap...................................... 33
Testing The Radiator And Cooling System For
Leaks................................................................ 33 G
Cylinder Block - Inspect......................................... 37
Cylinder Head - Inspect ......................................... 38 Gear Group - Inspect............................................. 41
Resurfacing the Cylinder Head .......................... 38 General Information................................................. 4
1104D Engine Model Views ................................. 6
Engine Description............................................... 4
E Lifting the Engine ................................................. 5
Glow Plugs - Test................................................... 45
Electric Starting System - Test............................... 43 Checking The Operation of The Glow Plug ....... 46
Diagnosis Procedure.......................................... 44 Continuity Check of the Glow Plugs................... 45
General Information ........................................... 43
Electrical System ............................................. 15, 42
Alternator ........................................................... 17 I
Starting Motor .................................................... 16
Engine Design ......................................................... 4 Important Safety Information ................................... 2
Engine Oil Cooler - Inspect.................................... 34 Increased Engine Oil Temperature - Inspect ......... 30
Engine oil cooler for the 1104D engine .............. 34
Engine Oil Pressure - Test..................................... 28
High Oil Pressure............................................... 28 L
Low Oil Pressure................................................ 28
Engine Oil Pump - Inspect..................................... 28 Lubrication System .......................................... 12, 28
KENR6246 49
Index Section
Main Bearings - Inspect......................................... 37
Piston Height - Inspect .......................................... 38

Piston Ring Groove - Inspect................................. 36
Inspect the Clearance of the Piston Ring........... 36
Inspect the Piston and the Piston Rings ............ 36
Inspect the Piston Ring End Gap....................... 36
Systems Operation Section ..................................... 4
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 18
Turbocharger - Inspect .......................................... 22
Inspection of the Compressor and the Compressor
Housing ............................................................ 23
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 23
Inspection of the Wastegate .............................. 24
V-Belt - Test ........................................................... 46

Poly V-Belt ......................................................... 47
Valve Depth - Inspect ............................................ 26
Valve Guide - Inspect ............................................ 27
Water Temperature Regulator - Test ..................... 34

50 KENR6246
Index Section
KENR6246 51
Index Section
©2007 Perkins Engines Company Limited
All Rights Reserved Printed in U. K.
KENR6247
May 2007
Disassembly and
Assembly
NK (Engine)
NL (Engine)
NM (Engine)

this publication.

replacement parts.
death.
KENR6247 3
Table of Contents
Table of Contents Rocker Shaft and Pushrod - Remove ................... 72

Rocker Shaft - Disassemble ................................ 73
Rocker Shaft - Assemble ..................................... 74
Rocker Shaft and Pushrod - Install ....................... 75
Disassembly and Assembly Section Cylinder Head - Remove ...................................... 76
Cylinder Head - Install .......................................... 78
Fuel Priming Pump and Fuel Filter Base - Remove
Lifter Group - Remove and Install ......................... 81
and Install ............................................................. 4
Camshaft - Remove and Install ........................... 82
Fuel Injection Lines - Remove and Install .............. 5
Camshaft Gear - Remove and Install .................. 84
Fuel Injector Cover - Remove and Install ............... 7
Camshaft Bearings - Remove and Install ............ 86
Fuel Injection Pump - Remove .............................. 8
Engine Oil Pan - Remove and Install (Aluminum and
Fuel Injection Pump - Install .................................. 9
Pressed Steel Oil Pans) ...................................... 87
Fuel Injection Pump Gear - Remove ..................... 11
Engine Oil Pan - Remove and Install (Cast Iron Oil
Fuel Injection Pump Gear - Install ........................ 13
Pan) .................................................................... 90
Fuel Injector - Remove ........................................ 14
Balancer - Remove ............................................... 93
Fuel Injector - Install ............................................ 15
Balancer - Install ................................................... 95
Turbocharger - Remove ........................................ 15
Piston Cooling Jets - Remove and Install ............. 97
Turbocharger - Install ............................................ 17
Pistons and Connecting Rods - Remove .............. 99
Exhaust Manifold - Remove and Install ............... 18
Pistons and Connecting Rods - Disassemble ..... 100
Exhaust Elbow - Remove and Install ................... 20
Pistons and Connecting Rods - Assemble ......... 101
Inlet and Exhaust Valve Springs - Remove and
Pistons and Connecting Rods - Install ................ 103
Install ................................................................... 21
Connecting Rod Bearings - Remove (Connecting
Inlet and Exhaust Valves - Remove and Install .... 23
rods in position) ................................................. 105
Engine Oil Filter Base - Remove and Install ........ 26
Connecting Rod Bearings - Install (Connecting rods
Engine Oil Cooler - Remove ................................. 27
in position) ......................................................... 106
Engine Oil Cooler - Install ..................................... 28
Crankshaft Main Bearings - Remove and Install
Engine Oil Relief Valve - Remove and Install (Engines
(Crankshaft in position) ..................................... 108
Without a Balancer Unit) ..................................... 29
Crankshaft - Remove ........................................... 112
Engine Oil Relief Valve - Remove and Install (Engines
Crankshaft - Install ............................................... 114
with a Balancer Unit) ........................................... 30
Crankshaft Gear - Remove and Install ............... 117
Engine Oil Pump - Remove and Install (Engines
Bearing Clearance - Check .................................. 118
Without a Balancer Unit) ..................................... 32
Glow Plugs - Remove and Install ........................ 119
Water Pump - Remove ......................................... 34
V-Belts - Remove and Install (Engines Without an
Water Pump - Install ............................................. 35
Automatic Belt Tensioner ) ................................ 121
Water Temperature Regulator - Remove and Install
Alternator Belt - Remove and Install (Engines With
............................................................................. 36
an Automatic Belt Tensioner) ............................ 122
Flywheel - Remove ............................................... 38
Fan - Remove and Install ................................... 123
Flywheel - Install ................................................... 39
Fan Drive - Remove and Install ......................... 124
Crankshaft Rear Seal - Remove ........................... 40
Alternator - Remove (Engines With an Automatic Belt
Crankshaft Rear Seal - Install ............................... 41
Tensioner) ......................................................... 125
Flywheel Housing - Remove and Install .............. 42
Alternator - Remove (Engines Without an Automatic
Crankshaft Pulley - Remove and Install (Engines
Belt Tensioner) .................................................. 125
With an Automatic Belt Tensioner) ...................... 44
Alternator - Install (Engines With an Automatic Belt
Tensioner) ......................................................... 126
Without an Automatic Belt Tensioner) ................. 45
Alternator - Install (Engines Without an Automatic
Crankshaft Front Seal - Remove and Install ......... 46
Belt Tensioner) .................................................. 127
Crankshaft Wear Sleeve (Front) - Remove and
Electric Starting Motor - Remove and Install ..... 127
Install ................................................................... 47
Air Compressor - Remove and Install ................ 128
Front Cover - Remove and Install ......................... 49
Vacuum Pump - Remove and Install .................. 133
Gear Group (Front) - Remove and Install ............. 50
Idler Gear - Remove ............................................. 53
Idler Gear - Install ................................................. 56 Index Section
Housing (Front) - Remove .................................... 59
Housing (Front) - Install ........................................ 61 Index ................................................................... 135
Accessory Drive - Remove and Install ................. 63
Crankcase Breather - Remove and Install
(Turbocharged Engines with Unfiltered
Breather) ............................................................. 65
Crankcase Breather - Remove and Install
(Turbocharged Engines with Filtered Breather) .. 67
Crankcase Breather - Remove and Install (Naturally
Aspirated Engines) .............................................. 69
Valve Mechanism Cover - Remove and Install ..... 71
4 KENR6247
Disassembly and Assembly Section
Disassembly and Assembly

Section
i02628881
Fuel Priming Pump and Fuel

Filter Base - Remove and
Install
Removal Procedure
NOTICE
Contaminants may cause rapid wear and shortened

component life.
NOTICE
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to g01318612
collect the fluid with suitable containers before open- Illustration 1
ing any compartment or disassembling any compo- Typical example
1. Isolate the fuel supply.
mandates. 2. Isolate the electrical supply.
3. Disconnect plastic tube assemblies (4) and (5)

Note: Put identification marks on all hoses, on all
from fuel priming pump (3).
hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
4. Disconnect plastic tube assembly (2) from fuel
and tube assemblies. This helps to prevent fluid loss
priming pump (3).
and this helps to keep contaminants from entering
the system.
5. Plug all the connections on fuel priming pump (3)
and plastic tube assemblies (4) and (5).
6. Disconnect the harness assembly from fuel

priming pump(3).
7. Support the fuel priming pump. Remove bolts and

washers (1) and remove fuel priming pump (3).
Note: Note the location and the orientation of the

brackets for the tube assemblies.
Installation Procedure
NOTICE

component life.
KENR6247 5
i02628850
Fuel Injection Lines - Remove

and Install
Removal Procedure
NOTICE

component life.
NOTICE
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-

mandates.
g01318612
Illustration 2
Typical example
2. Isolate the electrical supply.
1. Ensure that the fuel priming pump is clean and
free from wear or damage. If necessary, replace 3. If the engine is equipped with a cover over the fuel
the fuel priming pump as a complete assembly. injectors remove the cover. Refer toDisassembly
and Assembly, “Fuel Injector Cover - Remove and
2. Position the fuel priming pump (3) onto the cylinder Install”.
head. Install bolts and washers (1). Ensure that
any brackets that are retained by the bolts are 4. Remove the breather tube from the valve
installed in the correct position. Tighten the bolts mechanism cover. Refer toDisassembly and
to a torque on 9 N·m (80 lb in). Assembly, “Crankcase Breather- Remove and
Install”.
3. Remove all plugs from the fuel priming pump and
from the plastic tube assemblies. Connect plastic
tube assemblies (4) and (5) to fuel priming pump
(3).
4. Connect plastic tube assembly (2) to fuel priming

pump (3).
5. Install the harness assembly to fuel priming pump

(3).
6. Restore the fuel supply.
7. Restore the electrical supply.
8. Remove the air from the fuel system. Refer

to Operations and Maintenance Manual, “Fuel
System - Prime”.
6 KENR6247
10. Plug and cap all open ports, fuel injection lines
and all tube assemblies.
NOTICE

component life.
1. Inspect the fuel injection lines for damage.

Replace any components that are damaged.
g01343040
Illustration 3
5. Loosen the clip and disconnect plastic tube

assembly (3) from fuel priming pump (5).
6. Loosen the clip and disconnect plastic tube

assembly (4) from the fuel return.
7. Remove plastic tube assembly (6).
8. Disconnect fuel injection lines (2) at fuel injectors

(1).
g01343040
Illustration 5
Typical example
g01319327
Illustration 4
Typical example
9. Disconnect fuel injection lines (2) at fuel injection

pump (7). Ensure that connections (8) do not turn. g01319327
Illustration 6
KENR6247 7
2. Remove the caps from fuel injection pump (7) and i02628851
from fuel injectors (1). Remove the caps from fuel
injection lines (2). Fuel Injector Cover - Remove
and Install
3. Install fuel injection lines(2). Loosely connect the
nuts at both ends of the fuel injection lines.
4. Tighten fuel injection lines (2) at fuel injector (1) to

a torque of 30 N·m (22 lb ft). Removal Procedure
5. Tighten fuel injection lines (2) at fuel injection NOTICE
pump (7) to 30 N·m (22 lb ft). Ensure that the Keep all parts clean from contaminants.
connection (8) does not turn.
Note: Ensure that each fuel injection line does not component life.
contact any other fuel injection line or any other
engine component.
6. Remove the caps from fuel priming pump (5) and

from the plastic tube assemblies.
7. Connect plastic tube assembly (4) to the fuel

return. Secure the plastic tube assembly with the
clip.
8. Connect plastic tube assembly (3) to the fuel

priming pump. Secure the plastic tube assembly
with the clip.
9. Install plastic tube assembly (6).
10. Install the breather tube to the valve mechanism

cover. Refer toDisassembly and Assembly,
“Crankcase Breather- Remove and Install”.
11. If the engine is equipped with a cover over the fuel

injectors install the cover. Refer toDisassembly
g01319811
and Assembly, “Fuel Injector Cover - Remove and Illustration 7
Install”. Typical example
12. Restore the fuel supply. 1. Thoroughly clean all of the outer surfaces of cover
(1).
2. Remove bolts (2) from the cover (1).
14. Remove the air from the fuel system. Refer to
the Operations and Maintenance Manual, “Fuel 3. Remove cover (1).
System - Prime”.
NOTICE

component life.
8 KENR6247
Note: Either Tooling (A) can be used. Use the Tooling

that is most suitable.
NOTICE

component life.
NOTICE

mandates.
g01319811
Illustration 8 Note: Put identification marks on all hoses, on all
Typical example hose assemblies, on wires and on all tube assemblies
1. Thoroughly clean all of the inner surfaces of cover and tube assemblies. This helps to prevent fluid loss
(1). and this helps to keep contaminants from entering
the system.
2. Install cover (1).
3. Install bolts (2). Tighten bolts (2) to a torque of
9 N·m (7 lb ft). 2. Isolate the electrical supply.
i02744499
Fuel Injection Pump - Remove
Removal Procedure
Table 1
Required Tools
Part
Tool Number Part Name Qty
A 1
21825576 Crankshaft Turning Tool 1
27610291 Barring Device Housing 1
A2
27610289 Gear 1
B 27610212 Camshaft Timing Pin 1
C 27610211 Crankshaft Timing Pin 1 g01349817
Illustration 9
Typical example
Start By:
3. Disconnect plastic tube assemblies (1) and (8)
a. Remove the front cover. Refer to Disassembly and from the fuel injection pump (4).
Assembly, “Front Cover - Remove and Install”.
4. Disconnect tube assembly (3) from the fuel
injection pump (4).
KENR6247 9
5. Remove the fuel injection lines. Refer to

Disassembly and Assembly, “Fuel Injection Lines
- Remove”.
6. Remove tube assembly (2).
7. Disconnect the harness assembly from solenoid

(7).
8. Disconnect the harness assembly from solenoid

(9).
9. Use Tooling (A) in order to rotate the crankshaft so

that number one piston is at the top center position
on the compression stroke. Refer to Systems
Operation, Testing and Adjusting, “Finding Top
Centre Position for No.1 Piston”.
10. Use Tooling (B) in order to lock the camshaft in

the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
Disassembly and Assembly, “Gear Group (Front) Illustration 10
g01349818
- Remove” for the correct procedure.
13. Remove nut (15). Remove bolt (14).
11. Remove the backlash from the fuel pump gear.
Lock the fuel injection pump in the correct 14. Remove bolt (16) and bracket (13) from the
position and remove the fuel pump gear. Refer to cylinder block.
Disassembly and Assembly, “Fuel Pump Gear -
Remove and Install” for the correct procedure. 15. Remove bolts (10) and washers (11) in order to
remove the fuel injection pump (4).
12. Loosen locking screw (5). Rotate spacer (6) in
order to allow locking screw (5) to tighten against Note: The fuel injection pump should be supported
the shaft of the fuel injection pump. Rotate the by hand as the bolts are removed.
fuel injection pump gear in a counterclockwise
direction in order to remove the backlash. Tighten 16. Remove the fuel injection pump from the front
locking screw (5) to a torque of 17 N·m (13 lb ft). housing. Remove O-ring seal (12).
Note: Locking screw (5) must be tightened in order
to prevent the shaft of the fuel injection pump from i02744500
rotating. The shaft of the fuel injection pump must
not be rotated after the fuel injection pump has been Fuel Injection Pump - Install
removed from the engine.
Table 2
Required Tools
Part
A 1
A2
27610289 Gear 1
C 27610211 Crankshaft Timing Pin 1
POWERPART
D 21820221 1
Rubber Grease
10 KENR6247

NOTICE 25 N·m (18 lb ft).
6. Position support bracket (11) onto the cylinder
Contaminants may cause rapid wear and shortened block. Install bolt (14) finger tight.
component life.
7. Install bolt (12) and nut (13) finger tight.
NOTICE 8. Tighten bolt (14) to a torque of 44 N·m (32 lb ft).

Care must be taken to ensure that fluids are contained Tighten bolt (12) and nut (13) to a torque of
during performance of inspection, maintenance, test- 22 N·m (16 lb ft).
collect the fluid with suitable containers before open- Note: Ensure that the fuel injection pump is not
ing any compartment or disassembling any compo- stressed as the bolts for the bracket are tightened.
9. Ensure that the No. 1 cylinder is at top dead center
Dispose of all fluids according to local regulations and on the compression stroke. Refer to Systems
mandates. Operation, Testing and Adjusting, “Fuel Injection
Timing - Check”. If necessary, use Tooling (A)
1. Inspect the bore in the front housing for damage. in order to rotate the crankshaft so that number
If the bore is damaged, replace the front one piston is at the top center position on the
housing. Refer to Disassembly and Assembly, compression stroke. Refer to Systems Operation,
“Housing (Front) - Remove” and Disassembly and Testing and Adjusting, “Finding Top Centre
Assembly, “Housing (Front) - Install”. Position for No.1 Piston”.

10. Use Tooling (B) in order to lock the camshaft in

the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
Disassembly and Assembly, “Gear Group (Front)
- Remove” for the correct procedure.
11. Install the fuel injection pump gear to fuel injection

pump (4). Refer to Disassembly and Assembly,
“Fuel Injection Pump Gear - Install” and refer to
Disassembly and Assembly, “Gear Group (Front)
- Install”.
Note: Ensure that the fuel injection pump is in the

unlocked position after the installation of the fuel
injection pump gear is completed.
g01350306
Illustration 11
Typical example
2. Use Tooling (D) in order to lubricate O-ring seal

(10). Install a new O-ring seal (10) onto the fuel
injection pump (4).
3. Install the new washers (9) to bolts (8).
4. Align the holes in the fuel injection pump with the

holes in the front housing. Install the fuel injection
pump (4) to the housing.
Note: The fuel injection pump should be supported

by hand until the bolts are installed.
KENR6247 11
i02744530
Fuel Injection Pump Gear -

Remove
Removal Procedure
Table 3
Required Tools
Part
A1
A2
27610289 Gear 1
Illustration 12
g01350305 C 27610211 Crankshaft Timing Pin 1
Typical example D - Puller (Three Leg) 1
12. Remove the plugs and caps from ports and tube Start By:
assemblies.
a. Remove the front cover. Refer to Disassembly and
13. Install the fuel injection lines. Refer to Assembly, “Front Cover - Remove and Install”.
- Install”. Note: Either Tooling (A) can be used. Use the Tooling
14. Connect plastic tube assemblies (1) and (6) to
fuel injection pump(4).
NOTICE
15. Connect tube assembly (3) to fuel injection pump Keep all parts clean from contaminants.
(4).
16. Install tube assembly (2). component life.
17. Connect the harness assembly to solenoid (7).

NOTICE
Tighten nut (7) to a torque of 4 N·m (35 lb in).
18. Connect the harness assembly to solenoid (5).
19. Restore the fuel supply.
End By:
mandates.
a. Install the front cover. Refer to Disassembly and
Assembly, “Front Cover - Remove and Install”. Note: Care must be taken in order to ensure that
the fuel injection pump timing is not lost during the
removal of the fuel pump gear. Carefully follow the
procedure in order to remove the fuel pump gear.

12 KENR6247
4. Apply sufficient pressure to fuel injection pump

gear (3) in a counterclockwise direction in order to
remove the backlash. Lock fuel injection pump (4)
in this position. Loosen locking screw (5). Rotate
spacer (6) in order to allow locking screw (5) to
tighten against the shaft of the fuel injection pump.
Tighten locking screw (5) to a torque of 17 N·m
(13 lb ft).
Note: Locking screw (5) must be tightened in order

to prevent the shaft of the fuel injection pump from
rotating. The shaft of the fuel injection pump must
not be rotated after the fuel injection pump has been
removed from the engine.
g01343056
Illustration 13
Typical example
2. Install Tooling (B) through hole (X) in camshaft

gear (1) into the front housing. Use Tooling (B) in
order to lock the camshaft in the correct position.
3. Install Tooling (C) into hole (Y) in the front housing. g01335384
Illustration 15
Use Tooling (C) in order to lock the crankshaft in
the correct position. Alignment of timing marks
Note: Do not use excessive force to install Tooling 5. Mark gears (1), (2) and (3) in order to show
(C). Do not use Tooling (C) to hold the crankshaft alignment. Refer to Illustration 15.
during repairs.
Note: Identification will ensure that the gears can be
installed in the original alignment.
g01335385
Illustration 16
6. Loosen nut (8) on fuel pump gear (3).
7. Install Tooling (D) through two opposite holes in

g01320304
Illustration 14 fuel pump gear (3). Tighten Tooling (D) until the
fuel pump gear is released.
8. Remove Tooling (D) from fuel pump gear (3).

KENR6247 13
9. Remove nut (8) and the washer from fuel pump

gear (3). Remove the fuel pump gear.
i02744534
Fuel Injection Pump Gear -

Install
Table 4
Required Tools g01343058
Illustration 17
Part Typical example
2. Ensure that Tooling (C) is installed in hole (Y) in
A1 21825576 Crankshaft Turning Tool 1 the front housing. Use Tooling (C) in order to lock
27610291 Barring Device Housing 1 the crankshaft in the correct position.
A2
27610289 Gear 1 Note: Do not use excessive force to install Tooling
B 27610212 Camshaft Timing Pin 1 (C). Do not use Tooling (C) to hold the crankshaft
during repairs.
21825617 Dial Indicator Group 1 3. Ensure that Tooling (B) is installed into hole (X) in
D camshaft gear (1).
- Finger Clock 1
4. Ensure that shaft (9) on the fuel injection pump is
NOTICE clean, dry and free from damage.
5. Ensure that the fuel injection pump is locked in
Contaminants may cause rapid wear and shortened the correct position. Refer to Disassembly and
component life. Assembly, “Fuel Injection Pump - Install”.
6. Ensure that the fuel pump gear is clean, dry and

NOTICE free from wear or damage. If necessary, replace
Care must be taken to ensure that fluids are contained the fuel pump gear.

mandates.
Note: The fuel injection pump must remain locked

until the procedure instructs you to unlock the fuel
injection pump.
1. Ensure that number one piston is at the top center

position on the compression stroke. Refer to Illustration 18
g01335384
the Systems Operation, Testing and Adjusting,
Alignment of timing marks
“Finding Top Center Position for No. 1 Piston”.
7. Install fuel pump gear (3) to shaft (9) of the fuel
injection pump. Ensure that the timing marks on
gears (2) and (3) are in alignment and that the
mesh of the gears is correct.
14 KENR6247
10. Tighten nut (8) to a torque of 88 N·m (65 lb ft).
11. Use Tooling (D) to measure the backlash of gears

(2) and (3). Ensure that the backlash for the gears
is within specified values. Refer to Specifications,
“Gear Group (Front)” for further information.
12. Lubricate the teeth of the gears with clean engine

oil.
End By:

g01343060
Illustration 19
Typical example i02628874
Fuel Injector - Remove
Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to

- Remove”.
NOTICE

component life.
NOTICE
Illustration 20
g01320629 Care must be taken to ensure that fluids are contained
Typical example
8. Install a new spring washer (10) and install nut ing any compartment or disassembling any compo-
(8) to shaft (9) of the fuel injection pump. Apply nent containing fluids.
sufficient pressure to the fuel injection pump gear
(3) in a counterclockwise direction in order to Dispose of all fluids according to local regulations and
remove the backlash. Tighten nut (8) to a torque mandates.
of 24 N·m (17 lb ft). Unlock the fuel injection pump
(5).
Note: Put identification marks on all plastic tube
In order to unlock the fuel injection pump, loosen assemblies for installation purposes. Plug all plastic
locking screw (6) on the fuel injection pump. tube assemblies and tube assemblies. This helps to
Rotate spacer (7) in order to allow locking screw prevent fluid loss and this helps to keep contaminants
(6) to tighten against the spacer. Tighten the from entering the system.
locking screw against the spacer to a torque of
17 N·m (13 lb ft). This will prevent the locking 1. Isolate the fuel supply.
screw from tightening against the shaft of the fuel
injection pump.
9. Remove Tooling (B) and (C).

KENR6247 15
g01320676 g01320782
Typical example
1. Ensure that the seat for the fuel injector in the
2. Remove fuel return lines (2) from fuel injector (1). cylinder head is clean and free from damage.
Position a new sealing washer (6) on the seat for
3. Remove bolt (3). Remove clamp (4) from fuel the fuel injector in the cylinder head.
injector (1).
2. Install a new O-ring seal (5) on fuel injector (1).
4. Remove fuel injector (1) from the cylinder head.
Remove O-ring seal (5) from fuel injector (1). 3. Install fuel injector (1) into the cylinder head.
5. Remove seat washer (6). Note: Alignment Pin (7) must be located opposite
clamp (4).
i02628873 4. Position clamp (4) on fuel injector (1). Install bolt

(3). Tighten the bolt to a torque of 27 N·m (20 lb ft).
Fuel Injector - Install
5. Install fuel return lines (2) to fuel injector (1).
End By:
a. Install the fuel injection lines. Refer to Disassembly
NOTICE and Assembly, “Fuel Injection Lines - Install”.
i02628909
component life. Turbocharger - Remove
Removal Procedure
NOTICE

component life.
16 KENR6247
NOTICE

mandates.
Note: Plug and cap all open ports and tube

assemblies.
1. If the turbocharger is equipped with an exhaust

elbow, remove the exhaust elbow. Refer to
Disassembly and Assembly, “Exhaust Elbow -
Remove and Install”.
2. Loosen the hose clamp and disconnect the air

inlet hose from the turbocharger.
3. Loosen the hose clamp and disconnect the air

outlet hose from the turbocharger. If the engine is
equipped with an air pipe, remove the air pipe and
remove the gasket from the cylinder head.
4. If the valve mechanism cover is equipped with a

heat shield, remove the heat shield.
g01343533
Illustration 23
Typical example
5. If the turbocharger is equipped with an adapter

(9), Remove nuts (10) and remove adapter (9)
from turbocharger (5). Remove gasket (11) (not
shown).
6. Remove banjo bolt (1) and disconnect tube

assembly (3) from turbocharger (5). Remove
sealing washers (2) from tube assembly (3).
7. Remove banjo bolt (4) and disconnect tube

assembly (3) from the cylinder block. Remove
sealing washers (2) from tube assembly (3).
Remove tube assembly (3).
8. Remove bolts (13). Disconnect tube assembly

(14) from turbocharger (5). Remove joint (12).
KENR6247 17
If necessary, remove bolts (15) and remove tube

assembly (14) from the cylinder block. Remove
joint (16).
If tube assembly (14) is secured with tube clips,

loosen the fasteners for the tube clips. If the
engine has a top mounted turbocharger, the
exhaust manifold must be removed in order to
remove tube assembly (13). Refer to Disassembly
and Assembly , “Exhaust Manifold - Remove and
Install”.
9. Remove nuts (8) and remove turbocharger (5).
Note: Do not use the actuator rod to lift the

turbocharger.
10. Remove gasket (7).
11. If necessary, remove the studs from the exhaust

manifold.
i02628908
Turbocharger - Install
Table 5
Required Tools
POWERPART
A 21820117 1
Threadlock and Nutlock
NOTICE
g01343533
Illustration 24
Typical example
component life.
2. Test actuator (6) for correct operation. Refer
1. Ensure that the turbocharger is clean and free to Systems Operation, Testing and Adjusting,
from damage. Inspect the turbocharger for “Turbocharger - Inspect”. If the actuator is
wear. Refer to Systems Operation, Testing and damaged or the actuator does not operate within
Adjusting, “Turbocharger - Inspect” for more the specified limits, the complete turbocharger
information. If the turbocharger is worn, the must be replaced.
complete turbocharger must be replaced.
3. Clean the mating surfaces of the exhaust manifold.
If necessary, install the studs to the exhaust
manifold. Tighten the studs to a torque of 18 N·m
(13 lb ft).
4. Install a new gasket (7) to the exhaust manifold.
5. Position turbocharger (5) onto the exhaust

manifold and install nuts (8). Tighten the nuts to a
torque of 44 N·m (32 lb ft).
18 KENR6247
Note: Do not use the actuator rod to lift the Note: If the air outlet hose has a reflective heat
turbocharger. shield, ensure that the reflective heat shield is
installed toward the engine.
6. Position a new joint (12) and tube assembly (14)
onto turbocharger (5). Install bolts (13) finger tight. 17. Connect the air inlet hose to turbocharger (5).
7. The turbocharger has different sized bolts (13). 18. If the valve mechanism cover is equipped with
Tighten M6 bolts to a torque of 9 N·m (80 lb in). a heat shield, install the heat shield. Tighten the
fasteners for the heat shield to a torque of 9 N·m
Tighten M8 bolts to a torque of 22 N·m (16 lb ft). (80 lb in).
8. Position a new joint (16) onto the cylinder block.

i02628843
Install bolts (15) finger tight.
9. Tighten bolts (15) to a torque of 22 N·m (16 lb ft).

Exhaust Manifold - Remove
and Install
If tube assembly (14) is secured with tube clips,
tighten the fasteners for the tube clips to a torque
of 22 N·m (16 lb ft).
10. Lubricate the bearings of turbocharger (5) with

Removal Procedure
clean engine oil through the oil inlet port. Rotate Start By:
the shaft of the turbocharger in order to distribute
the lubricant. a. Remove the turbocharger. Refer to Disassembly
and Assembly, “Turbocharger - Remove”.
11. Position tube assembly (3) onto turbocharger (5).
Install new washers (2) and banjo bolt (1) to tube
assembly (3). Tighten the banjo bolt finger tight.
12. Install new washers (2) and banjo bolt (4) onto
tube assembly (3). Connect the tube assembly to
the cylinder block. Tighten the banjo bolt finger
tight.
13. Tighten banjo bolts (1) and (4) to a torque of

20 N·m (15 lb ft).
Note: Ensure that the tube assembly does not come

into contact with any other engine components.
14. The turbocharger is equipped with a adapter (9).

Install a new gasket (11) (not shown) and position
the adapter (9) onto the turbocharger. Install
nuts (10). Tighten the nuts to a torque of 44 N·m
(33 lb ft).
15. If the turbocharger is equipped with an exhaust

g01343539
elbow, install the exhaust elbow. Refer to Illustration 25
Disassembly and Assembly, “Exhaust Elbow - Typical example
16. Connect the air outlet hose to turbocharger (5).
If the engine is equipped with an air pipe, install

the air pipe and install the gasket to the cylinder
head. Apply Tooling (A) to the fasteners for the air
pipe. Tighten the fasteners to a torque of 22 N·m
(16 lb ft).
Tighten the hose clamps to a torque of 5 N·m

(44 lb in).
KENR6247 19
g01363916
Illustration 26
Sequence for loosening the exhaust manifold
1. Loosen bolts (4) in reverse numerical order to the

sequence that is shown in Illustration 26.
Note: This will help prevent distortion of the exhaust Illustration 27

g01343539
manifold.
Typical example
2. Remove bolts (4) from exhaust manifold (3).

1. Ensure that the exhaust manifold is clean and free
Note: Bolts (4) may be equipped with spacers. from damage. Clean the joint face of the cylinder
Record the position of the spacers. Support the head.
manifold as the bolts are removed.
2. If necessary, install studs (2) to exhaust manifold
3. Remove exhaust manifold (3). (3). Tighten the studs to a torque of 18 N·m
(13 lb ft).
4. Remove exhaust manifold gasket (1).
5. If necessary, remove studs (2) from exhaust

manifold (3).
Table 6
Required Tools
Part
Tool Part Description Qty
Number
- Guide Bolt
A 2
(M10 by 100 mm)
g01363918
Illustration 28
Tightening sequence for the exhaust manifold
3. Install Tooling (A) to the cylinder head in positions

(X). Refer to Illustration 28.
4. Position a new exhaust manifold gasket (1) onto

Tooling (A).
Note: Ensure that the exhaust manifold gasket is

correctly oriented.
5. Align exhaust manifold (3) with Tooling (A). Install

the exhaust manifold to the cylinder head.
20 KENR6247
Note: If the engine has a top mounted turbocharger, Installation Procedure

the tube assembly for the oil drain must be connected
to the cylinder block before the exhaust manifold is
installed.
6. Install new bolts (4) finger tight.
Note: Bolts (4) that were equipped with spacers.

Install the spacer in the original position.
7. Remove Tooling (A). Install the remaining bolts

(4) finger tight.
8. Tighten bolts (4) to a torque of 40 N·m (30 lb ft) in

the sequence that is shown in Illustration 28.
End By:
a. Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Install”.
i02628842
g01343547
Illustration 30
Exhaust Elbow - Remove and Typical example
Install 1. Ensure that the exhaust elbow is clean and free

from wear or damage.
2. Position support bracket (3) to the cylinder block

Removal Procedure and install bolts (5). Tighten bolts (5) to a torque of
44 N·m (33 lb ft).
3. Position exhaust elbow (2).
Note: Ensure the correct orientation of the exhaust

elbow.
4. Install bolts (4) to support bracket (3). Tighten

bolts (4) to a torque of 44 N·m (33 lb ft).
g01343547
Illustration 29
Typical example
1. Remove bolts (4) and remove exhaust elbow (2).

Note the orientation of the exhaust elbow.
2. Remove bolts (5) and remove support bracket (3)

from the cylinder block.
KENR6247 21
i02628893
Inlet and Exhaust Valve

Personal injury can result from being struck by
Springs - Remove and Install parts propelled by a released spring force.
Make sure to wear all necessary protective equip-

ment.
Removal Procedure
Follow the recommended procedure and use all
Table 7 recommended tooling to release the spring force.
Required Tools
Part NOTICE
Tool Part Description Qty Ensure that the valve spring is compressed squarely
Number
or damage to the valve stem may occur.
A1 21825576 Crankshaft Turning Tool 1
A2 1. Follow Steps 1.a through 1.d in order to position
27610289 Gear 1 the appropriate piston at top center.
21825739 Valve Spring Compressor 1
a. Install Tooling (B) in position on the cylinder
B 27610235 Adapter 1 head in order to compress a valve spring for
the appropriate piston.
27610295 Head 1
b. Use Tooling (B) in order to compress valve
Start By: spring (3) and open the valve slightly.
a. Remove the rocker shaft assembly. Refer to Note: Do not compress the spring so that the valve
Disassembly and Assembly, “Rocker Shaft and spring retainer (2) touches the valve stem seal.
Pushrod - Remove”.
c. Use Tooling (A) in order to rotate the crankshaft
Note: Either Tooling (A) can be used. Use the Tooling carefully, until the piston touches the valve.
Note: Do not use excessive force to turn the
NOTICE crankshaft. The use of force can result in bent valve
Keep all parts clean from contaminants. stems.
Contaminants may cause rapid wear and shortened d. Continue to rotate the crankshaft and gradually
component life. release the pressure on Tooling (B) until the
piston is at the top center position. The valve
is now held in a position that allows the valve
Note: The following procedure should be adopted in spring to be safely removed.
order to remove the valve springs when the cylinder
head is installed to the engine. Refer to Disassembly
and Assembly, “Inlet and Exhaust Valves - Remove NOTICE
and Install” for the procedure to remove the valve Do not turn the crankshaft while the valve springs are
springs from a cylinder head that has been removed removed.
from the engine.
Note: Valve springs must be replaced in pairs for the
Note: Ensure that the appropriate piston is at the top inlet valve or the exhaust valve of each cylinder. If all
center position before the valve spring is removed. valve springs require replacement the procedure can
Failure to ensure that the piston is at the top center be carried out on two cylinders at the same time. The
position may allow the valve to drop into the cylinder procedure can be carried out on the following pairs of
bore. cylinders. 1 with 4 and 2 with 3. Ensure that all of the
valve springs are installed before changing from one
NOTICE pair of cylinders to another pair of cylinders.
Plug the apertures for the push rods in the cylinder
head in order to prevent the entry of loose parts into
the engine.
22 KENR6247

NOTICE

component life.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
1. Inspect the valve springs for the correct length.

Refer to Specifications, “Cylinder Head Valves ”
for more information.
2. If necessary, install a new valve stem seal onto

the valve guide.
g01343550
Illustration 31 Note: The outer face of the valve guide must be
Typical example clean and dry before installing the valve stem seal.
2. Apply sufficient pressure to Tooling (B) in order to

allow removal of the valve keepers (1). Remove
valve keepers (1).
Note: Do not compress the spring so that the valve

spring retainer (2) touches the valve stem seal.
3. Slowly release the pressure on Tooling (B).
4. Remove valve spring retainer (2) and remove

valve spring (3).
5. If necessary, remove the valve stem seals.
6. Repeat Steps 2 through 5 in order to remove

the remaining valve spring from the appropriate
cylinder.
7. Remove Tooling (B).
Installation Procedure Illustration 32

g01343550
Typical example
Table 8
Required Tools 3. Install valve spring (3) onto the cylinder head.
Position valve spring retainer (2) onto valve spring
Part
Tool
Number
Part Description Qty (3).

A2
27610289 Gear 1 Improper assembly of parts that are spring loaded
can cause bodily injury.
B 27610235 Adapter 1 To prevent possible injury, follow the established
assembly procedure and wear protective equip-
27610295 Head 1 ment.
KENR6247 23
4. Install Tooling (B) in the appropriate position on Start By:

the cylinder head in order to compress the valve
spring. a. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove”.
NOTICE
Ensure that the valve spring is compressed squarely NOTICE
or damage to the valve stem may occur. Keep all parts clean from contaminants.

5. Apply sufficient pressure to Tooling (B) in order to component life.
install valve keepers (1). Install the valve spring
keepers (1).
1. Clean the bottom face of the cylinder head.
Note: Do not compress the spring so that valve Check the depth of the valves below the face of
spring retainer (2) touches the valve stem seal . the cylinder head before the valve springs are
removed. Refer to Specifications, “Cylinder Head
6. Carefully release the pressure on Tooling (B). Valves” for the correct dimensions.
Note: Ensure that the valve keepers are correctly 2. Place a temporary identification mark on the
seated. heads of the valves in order to identify the correct
position. Inlet valves have a recess in the center
7. Repeat Steps 2 to 6 for the remaining valves. of the head.
Note: Do not stamp the heads of the valve. Stamping

or punching the heads of the valves could cause the
valves to fracture.
The valve spring keepers can be thrown from
the valve when the valve spring compressor is 3. Use a suitable lifting device to position the cylinder
released. Ensure that the valve spring keepers head with the valve springs upward. The weight of
are properly installed on the valve stem. To help the cylinder head is approximately 56 kg (125 lb).
prevent personal injury, keep away from the front
of the valve spring keepers and valve springs Note: Ensure that the cylinder head is kept on a
during the installation of the valves. clean, soft surface in order to prevent damage to the
machined face.
End By:
a. Install the rocker shaft assembly. Refer to parts propelled by a released spring force.
Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”. Make sure to wear all necessary protective equip-
ment.
i02628894
Inlet and Exhaust Valves - recommended tooling to release the spring force.
Remove and Install
Removal Procedure
Table 9
Required Tools
Part
Number
A 27610235 Adapter 1
27610295 Head 1
24 KENR6247
6. Slowly release the pressure on Tooling (A).
7. Remove valve spring retainer (2). Remove valve

spring (3).
8. Repeat Steps 4 to 7 for the remaining valves.
9. Remove Tooling (A).
10. Remove valve stem seals (4).
11. Use a suitable lifting device to carefully turn over

the cylinder head.
12. Remove valves (5).
Table 10
Required Tools
g01343550 Part
Illustration 33
Typical example Number
4. Install Tooling (A) in position on the cylinder head
in order to compress the appropriate valve spring. A 27610235 Adapter 1
27610295 Head 1
NOTICE
Ensure that the valve spring is compressed squarely NOTICE
or damage to the valve stem may occur. Keep all parts clean from contaminants.

component life.
1. Clean all components of the cylinder head

assembly. Ensure that all ports, all coolant
passages and all lubrication passages in the
cylinder head are free from debris. Follow Steps
1.a through 1.e in order to inspect the components
of the cylinder head assembly. Replace any
components that are worn or damaged.
a. Inspect the cylinder head for wear and for

damage. Refer to Systems Operation, Testing
and Adjusting, “Cylinder Head Inspect”.
b. Inspect the valve seats for wear and for

damage. Refer to Specifications, “Cylinder
Head Valves” for further information.
c. Inspect the valve guides for wear and for

g01352229
Illustration 34 damage. Refer to Specifications, “Cylinder
Typical example Head Valves” and Systems Operation, Testing
and Adjusting, “Valve Guide - Inspect” for
5. Apply sufficient pressure to Tooling (A) in order to further information.
remove valve keepers (1).
d. Inspect the valves for wear and for damage.
Note: Do not compress the spring so that valve Refer to Specifications, “Cylinder Head Valves”.
spring retainer (2) touches valve stem seal (4).
KENR6247 25
e. Inspect the valve springs for the correct length.

Refer to Specifications, “Cylinder Head Valves”.
g01343550
Illustration 36
Typical example
g01352229
Illustration 35
6. Install Tooling (A) in the appropriate position on
2. Lubricate the stems of valves (5) with clean engine the cylinder head in order to compress valve
oil. Install valves (5) in the appropriate positions in spring (3).
the cylinder head. Check the depth of the valves
below the face of the cylinder head. Refer to NOTICE
Systems Operation, Testing and Adjusting, “Valve Ensure that the valve spring is compressed squarely
Depth - Inspect” for more information. or damage to the valve stem may occur.
3. Use a suitable lifting device to carefully turn over
the cylinder head. The weight of the cylinder head 7. Apply sufficient pressure to Tooling (A) in order to
is approximately 56 kg (125 lb). install valve keepers (1).
Note: Ensure that all of the valves remain in place. Note: Do not compress the spring so that valve
spring retainer (2) touches valve stem seal (4).
4. Install new valve stem seals (4) onto each of the
valve guides.
Note: The outer face of the valve guides must be

clean and dry before installing the valve stem seals. The valve spring keepers can be thrown from
the valve when the valve spring compressor is
5. Install valve spring (3) onto the cylinder head. released. Ensure that the valve spring keepers
Position valve spring retainer (2) onto valve spring are properly installed on the valve stem. To help
(3). prevent personal injury, keep away from the front
of the valve spring keepers and valve springs
during the installation of the valves.
8. Carefully release the pressure on Tooling (A).

parts propelled by a released spring force.
9. Repeat Steps 5 to 8 for the remaining valves.
10. Remove Tooling (A) from the cylinder head.
ment.
11. Use a suitable lifting device to position the cylinder
head on a support. Ensure that the heads of the
recommended tooling to release the spring force.
valves are not obstructed. Lightly strike the top of
the valves with a soft hammer in order to ensure
that valve keepers (1) are properly installed.
26 KENR6247
End By: 1. Use Tooling (A) to remove engine oil filter (3).
Refer to Operation and Maintenance Manual,
a. Install the cylinder head. Refer to Disassembly “Engine Oil and Filter - Change”.
and Assembly, “Cylinder Head - Install”.
2. If the engine oil pressure sensor is located in
the engine oil filter base, remove the engine
i02628834
oil pressure sensor. Refer to Disassembly and
Engine Oil Filter Base - Assembly, “Engine Oil Pressure Sensor - Remove
and Install”.
Remove and Install
3. Remove bolts (4) and remove engine oil filter base
(2).
Removal Procedure 4. Remove joint (1).
Table 11 5. If the engine oil filter base has a spacer plate,

remove the spacer plate and remove the joint.
Required Tools
Tool Part Number Part Description Qty 6. If necessary, remove plug (6) from engine oil filter
base (2). Remove O-ring seal (5) from the plug.
A - Strap Wrench 1
Note: The oil filter may be installed vertically or the

oil filter may be installed horizontally. Table 12
Required Tools
NOTICE
Keep all parts clean from contaminants. Tool Part Number Part Description Qty
POWERPART
Contaminants may cause rapid wear and shortened A 21820117 1
component life.
NOTICE
NOTICE Keep all parts clean from contaminants.
during performance of inspection, maintenance, test- Contaminants may cause rapid wear and shortened
ing, adjusting, and repair of the product. Be prepared component life.
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.

mandates.
g01343554
Illustration 38
Typical example
1. Ensure that the engine oil filter base is clean.

Clean the mating surfaces of the cylinder block.
g01343554
Illustration 37 2. If necessary, install a new O-ring seal (5) to plug
Typical example (6). Install plug (6) to engine oil filter base (2).
Tighten the plug to a torque of 12 N·m (106 lb in).
KENR6247 27
3. Install bolts (4) to engine oil filter base (2). 3. If necessary, remove the electric starting motor.
Refer to Disassembly and Assembly, “Electric
4. Install a new joint (1) onto bolts (4). If the engine Starting Motor - Remove and Install”.
oil filter base has a spacer plate, install the spacer
plate and a new joint onto the bolts.
5. Apply Tooling (B) to the threads of the bolts. Install

the assembly of the engine oil filter base to the
cylinder block.
7. If the engine oil pressure sensor is located in

the engine oil filter base, Install the engine oil
pressure sensor. Refer to Disassembly and
Assembly, “Engine Oil Pressure Sensor - Remove
and Install”.
8. Install a new engine oil filter (3). If necessary,

fill the engine oil pan to the correct level that is
indicated on the oil level gauge. Refer to Operation
and Maintenance Manual, “Engine Oil Level -
Check”.
g01343557
i02628833 Illustration 39
Typical example
Engine Oil Cooler - Remove
Removal Procedure
NOTICE

component life.
NOTICE
Dispose of all fluids according to local regulations and Illustration 40

g01343558
mandates. Tightening sequence for the engine oil cooler
1. Drain the coolant from the cooling system into 4. Loosen fasteners (7) in reverse numerical order
a suitable container. Refer to Operation and to the sequence that is shown in Illustration 40.
Maintenance Manual, “Cooling System Coolant - Remove fasteners (7). Support the assembly
Change” for the correct procedure. of the engine oil cooler (1) as the fasteners are
removed.
2. Drain the engine lubricating oil into a suitable
container. Refer to Operation and Maintenance Note: fasteners (7) are different lengths. Note the
Manual, “Engine Oil and Filter - Change” for the correct position of the fasteners. Note the position of
correct procedure. any brackets that are secured by the fasteners. Do
not remove fasteners (6) at this time.
28 KENR6247
5. Remove the assembly of oil cooler (1) from the b. Position new joints (4) onto housing (5). Install
cylinder block. cooler matrix (3).
6. Remove joint (2). c. Apply Tooling (A) to the threads of bolts (6).
7. Follow Steps 7.a through 7.c in order to d. Install bolts (6). Tighten the bolts to a torque of
disassemble the engine oil cooler. 22 N·m (16 lb ft).
a. Remove bolts (6). 2. Clean the mating surface of the cylinder block.
b. Remove cooler matrix (3) from housing (5).
c. Remove joints (4).
i02628832
Engine Oil Cooler - Install
NOTICE

component life.
g01347870
Illustration 42
Typical example
3. Position a new joint (2) on the assembly of engine

oil cooler (1). Install fasteners (7) to positions (X)
on the assembly of engine oil cooler (1).
Note: The holes in the joint have serrations that hold

the fasteners captive.
4. Install the assembly of engine oil cooler (1) to the

cylinder block. Tighten bolts (7) finger tight.
Note: The fasteners are different lengths. Ensure

that the different fasteners are installed in the correct
location. Ensure that any brackets that are secured
by the fasteners are installed in the correct location.
5. Apply Tooling (B) to the fasteners (7) at positions

Illustration 41
g01347869 (Y).
Typical example
Note: The fasteners in this position are allen head
screws.
1. Follow Steps 1.a through 1.d in order to assemble
the engine oil cooler.
a. Ensure that cooler matrix (3) is clean and free

from damage. Ensure that housing (5) is clean
and free from damage.
KENR6247 29
Start By:
a. Remove the engine oil pan. Refer to Disassembly

and Assembly, “Engine Oil Pan - Remove and
Install”.
NOTICE

component life.


ment.
g01343558
Illustration 43 Follow the recommended procedure and use all
Tightening sequence for the engine oil cooler recommended tooling to release the spring force.
6. Install the remaining fasteners (7) into the engine

oil cooler (1). Tighten the fasteners to a torque of
22 N·m (16 lb ft). Tighten the bolts in the sequence
that is shown in Illustration 43.
7. If necessary, Install the electric starting motor.

Refer to Disassembly and Assembly, “Electric
Starting Motor - Remove and Install”.
8. Fill the cooling system to the correct level.

“Cooling System Coolant - Change” for the correct
procedure.
9. Fill the engine oil pan to the correct level. Refer to

Operation and Maintenance Manual, “Engine Oil
Filter and Change” for the correct procedure.
i02628841
Engine Oil Relief Valve - Illustration 44

g01343561
Remove and Install Typical example
(Engines Without a Balancer 1. Remove bolts (6) and suction pipe (7).
Unit)
2. Remove the joint from suction pipe (5) (not
shown).
3. Loosen cap (2). Carefully remove cap (2) from the

Removal Procedure housing of engine oil pump (1).
Table 13
Note: The spring force will be released when the cap
Required Tools is removed.
Tool Part Part Description Qty
Number 4. Remove spring (4) from the bore for the relief
valve in the housing of engine oil pump (1).
A - Telescopic Magnet 1
30 KENR6247
5. Use Tooling (A) to remove plunger (3) from the 2. Lubricate plunger (3) with clean engine oil. Use
bore for the relief valve in the housing of engine long nose pliers to install plunger (3) and spring
oil pump (1). (4) into the bore for the relief valve in the housing
of engine oil pump (1).
Installation Procedure Note: The plunger must slide freely in the bore for
Table 14 the relief valve.
Required Tools 3. Apply Tooling (A) to the threads of cap (2). Install
Part cap (2) to engine oil pump (1). Tighten the cap to
Tool Part Description Qty a torque of 35 N·m (26 lb ft).
Number
B - Loctite 577 1
Note: Ensure that the spring is properly located
inside the plunger and the cap. Ensure that Tooling
NOTICE (A) does not contaminate the bore for the relief valve
Keep all parts clean from contaminants. in the housing of engine oil pump.
Contaminants may cause rapid wear and shortened 4. Install suction pipe (7) and a new joint (5) to the
component life. assembly of the engine oil pump.
5. Install bolts (6). Tighten the bolts to a torque to

22 N·m (16 lb ft).
End By:
a. Install the engine oil pan. Refer to Disassembly

Install”.
i02628840
Engine Oil Relief Valve -

Remove and Install
(Engines with a Balancer Unit)
Removal Procedure
g01343561 Table 15
Illustration 45
Typical example Required Tools
1. Ensure that all components are clean and free Number
from wear or damage. If necessary, replace any
A - Telescopic Magnet 1
components that are worn or damaged. If the
bore for the relief valve in the housing of engine
oil pump (1) is worn or damaged, the complete Start By:
assembly of the engine oil pump must be replaced.
and Assembly , “Engine Oil Pan - Remove and
Install”.
Improper assembly of parts that are spring loaded
can cause bodily injury. NOTICE
To prevent possible injury, follow the established
assembly procedure and wear protective equip- Contaminants may cause rapid wear and shortened
ment. component life.
KENR6247 31


ment.

g01343600
Illustration 47
Typical example
1. Ensure that all components are clean and free

components that are worn or damaged. If the
bore for the relief valve in balancer (1) is worn or
damaged, the complete assembly of the balancer
must be replaced.
g01343600
Illustration 46
Typical example
1. Loosen cap (2). Carefully remove the cap from
balancer (1).
Note: The spring force will be released when the cap
ment.
is removed.
2. Remove spring (3) from the bore for the relief 2. Lubricate plunger (4) with clean engine oil. Install
valve in balancer (1). plunger (4) and spring (3) into the bore for the
relief valve in balancer (1).
3. Use Tooling (A) in order to remove plunger (4)
from the bore for the relief valve in balancer (1). Note: The plunger must slide freely in the bore for
the relief valve.
Installation Procedure 3. Apply Tooling (B) to the threads of cap (2). Install
Table 16 cap (2) to balancer (1). Tighten the cap to a torque
of 21 N·m (15.5 lb ft).
Required Tools
Part Note: Ensure that the spring is properly located
Number inside the plunger and the cap. Ensure that Tooling
(B) does not contaminate the bore for the relief valve
B - Loctite 577 1
in balancer (1).
NOTICE End By:

Contaminants may cause rapid wear and shortened and Assembly, “Engine Oil Pan - Remove and
component life. Install”.
32 KENR6247
i02628837
Engine Oil Pump - Remove and

Install
(Engines Without a Balancer
Unit)
Removal Procedure
Start By:

Install”.
Note: This procedure is for the removal of the engine

oil pump on engines that are not equipped with
a balancer. Refer to Disassembly and Assembly, Illustration 48
g01343631
“Balancer Group - Remove” for information on the
Typical example
removal of the engine oil pump for engines that are
equipped with a balancer.
1. Remove bolts (1) and suction pipe (2).
NOTICE 2. Remove the joint from suction pipe (2).
3. Remove bolts (5). Remove the assembly of engine
Contaminants may cause rapid wear and shortened oil pump (3) from the cylinder block.
component life.
4. If necessary, remove pressure relief valve (4)
from the housing of engine oil pump (3). Refer to
NOTICE Disassembly and Assembly, “Engine Oil Relief
Care must be taken to ensure that fluids are contained Vave - Remove and Install”.

mandates.
KENR6247 33
NOTICE

component life.
NOTICE
If any of the parts on the engine oil pump are worn or
damaged, the entire pump must be replaced.
1. Ensure that all components of the engine oil pump

are clean and free from wear or damage. Check
the clearance between the outer rotor of the oil
pump and the oil pump body. Check the clearance
between the outer rotor and the inner rotor. Check
the end play of the rotor. Refer to the Systems
Operation,Testing and Adjusting, “Engine Oil
Pump - Inspect”. Replace the complete assembly
of the engine oil pump if any of the components
are worn or damaged.
g01343633
Illustration 49
Typical example
5. If necessary, remove bolts (9) and front cover

assembly (6). Remove outer rotor (7) from the
housing of engine oil pump (3).
Note: Do not remove dowels (8) and (10) from the

housing of the engine oil pump unless the dowels
are damaged.
Table 17
Required Tools
Part
Tool Part Name Qty
Number
21825617 Dial Indicator Group 1
A
- Finger Clock 1
Note: This procedure is for the installation of the g01343633

Illustration 50
engine oil pump on engines that are not equipped
with a balancer. Refer to Disassembly and Assembly, 2. If necessary, lubricate the internal components of
“Balancer Group - Install” for information on the the assembly of the engine oil pump with clean
installation of the engine oil pump for engines that engine oil. Install outer rotor (7) and front cover
are equipped with a balancer. (6) to the housing of engine oil pump (3). Install
bolts (9). Tighten the bolts to a torque of 9.5 N·m
(84 lb in).
34 KENR6247
i02628917
Water Pump - Remove
Removal Procedure
Start By:
a. Remove the fan and the fan pulley. Refer to

Disassembly and Assembly, “Fan - Remove and
Install”.
NOTICE

component life.
g01343631
Illustration 51 NOTICE
3. If necessary, install pressure relief valve (4). Refer during performance of inspection, maintenance, test-
to Disassembly and Assembly, “Engine Oil Relief ing, adjusting and repair of the product. Be prepared to
Valve - Remove and Install” for further information. collect the fluid with suitable containers before open-
4. Ensure that dowels (8) and (10) are correctly nent containing fluids.
located in the housing of the engine oil pump (3).
Position the assembly of the engine oil pump onto Dispose of all fluids according to local regulations and
the cylinder block. mandates.
Note: Ensure that the dowels in the housing of the 1. Drain the coolant from the cooling system into
engine oil pump are aligned with the holes in the a suitable container for storage or disposal.
cylinder block. Refer to Operation and Maintenance Manual,
5. Install bolts (5). Tighten the bolts to a torque of procedure.
44 N·m (32 lb ft).
2. Loosen the hose clamps and remove the hose
6. Install suction pipe (2) and a new joint to the from the water pump inlet.
assembly of the engine oil pump.

22 N·m (16 lb ft).
8. Use Tooling (A) in order to check the backlash

between the idler gear of the oil pump and the
crankshaft gear. Refer to Specifications, “Gear
Group - Front” for further information.
End By:

Install”.
KENR6247 35
i02628916
Water Pump - Install
Table 18
Required Tools
Part
- Guide Bolt
A 2
(M8 by 80 mm)
NOTICE

component life.
1. Ensure that the water pump is clean and free from

wear or damage. If necessary, replace the water
pump.
g01263054
Illustration 52
Typical example
3. Remove bolts (4). The bolts are different lengths.

Note the positions of the different bolts.
Note: Do not remove bolts (7) at this time.
4. Remove water pump (3) from front cover (1).
Note: If necessary, tap the water pump with a soft

hammer in order to loosen the water pump.
5. Remove joint (2).
6. If necessary, remove the cover (6) from the water

pump. Follow Steps 6.a through 6.c in order to
remove the cover.
a. Remove bolts (7).
b. Remove cover (6).
c. Remove joint (5).
g01269391
Illustration 53
Typical example
2. If necessary, install cover (6) to water pump (3).

Follow Steps 2.a through 2.d in order to install
the cover.
a. Clean the mating surface of cover (6).

36 KENR6247
b. Position a new joint (5) onto water pump (3).
c. Install cover (6) to water pump (3).
d. Install bolts (7) to cover (6). Tighten the bolts

finger tight.
3. Clean the mating surface of front cover (1).
g01269393
Illustration 55
Tightening sequence for the water pump
9. Tighten bolts (4) and bolts (7) to a torque of 22 N·m

(16 lb ft). Refer to Illustration 53. Tighten the bolts
in the sequence that is shown in Illustration 55.
10. Install the hose to the water pump inlet. Tighten

g01269392 the hose clamps.
Illustration 54
4. Install Tooling (A) in position (X). 11. Fill the cooling system with coolant. Refer to
Operation and Maintenance Manual, “Cooling
5. Use Tooling (A) in order to align a new joint (2) to System Coolant - Change” for the correct
front cover (1). Install the joint to the front cover. procedure.
6. Align water pump (3) with Tooling (A). Install the End By:
water pump to front cover (1).
a. Install the fan and the fan pulley. Refer to
Note: Ensure that the gear of the water pump and Disassembly and Assembly, “Fan - Remove and
the gear of the fuel injection pump mesh. Install”.
7. Install bolts (4). Refer to Illustration 53. Tighten

i02628918
the bolts finger tight.
Note: Ensure that bolts of different lengths are

Water Temperature Regulator -
installed in the correct positions. Remove and Install
8. Remove Tooling (A) and install remaining bolts
(4) finger tight.
Removal Procedure
NOTICE

component life.
KENR6247 37
NOTICE

mandates.
1. Drain the coolant from the cooling system to a

level below the water temperature regulator, into
a suitable container for storage or for disposal.
draining procedure.
2. Loosen the hose clamps from the upper radiator

hose and disconnect the upper radiator hose from g01343959
water temperature regulator housing (2). Illustration 57
Typical example
5. Remove O-ring seal (3) from water temperature

regulator housing (2).
Table 19
Required Tools
Part
Number
POWERPART
A 21820221 1
Rubber Grease
NOTICE

component life.
g01343959
Illustration 56
Typical example 1. Ensure that all components of water temperature
regulator are clean and free of wear or damage.
3. Remove bolts (1) from water temperature Check the water temperature regulator for correct
regulator housing (2). operation. Refer to Systems Operation, Testing
and Adjusting, “Water Temperature Regulator
4. Remove water temperature regulator housing (2) - Test” for the procedure to test the water
from the cylinder head. temperature regulator. If any components of the
water temperature regulator are worn or damaged,
Note: Note the orientation of the water temperature the complete assembly must be replaced.
regulator housing.
38 KENR6247
g01343960 g01343959
Typical example Typical example
2. If the original water temperature regulator housing 5. Install bolts (1). Tighten the bolts to a torque of
is installed, position a new O-ring seal (3) into the 22 N·m (16 lb ft).
groove in water temperature regulator housing (2).
6. Connect the upper radiator hose and tighten the
A new water temperature regulator housing is hose clamps.
supplied with a new O-ring seal.
7. Fill the cooling system to the correct level.
3. Use Tooling (A) to lubricate the new O-ring seal. Refer to Operation and Maintenance Manual,
4. Install water temperature regulator housing (2) to procedure.
the cylinder head.
i02628847
Note: Ensure the correct orientation of the water
temperature regulator housing. Flywheel - Remove
Removal Procedure
Table 20
Required Tools
Part
Guide Bolt
A - (1/2 inch - UNF by 4 2
inch)
Start By:
a. Remove the electric starting motor. Refer to

Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
KENR6247 39
6. Inspect flywheel (1) and ring gear (3) for wear or

NOTICE damage. Replace any components that are worn
Keep all parts clean from contaminants. or damaged.
Contaminants may cause rapid wear and shortened 7. To remove the flywheel ring gear, follow Steps 7.a
component life. and 7.b.
a. Place the flywheel assembly on a suitable

support.
Note: Identify the orientation of the teeth on the

flywheel ring gear.
b. Use a hammer and a punch in order to remove

ring gear (3) from flywheel (1).
i02628846
Flywheel - Install
Table 21
Required Tools
g01245126 Part
Illustration 60
Typical example
Guide Bolt
A - (1/2 inch - 20 UNF by 2
1. Remove two bolts from positions (X) on flywheel
4 inch)
(1).
2. Install Tooling (A) to positions (X) on flywheel (1). NOTICE

3. Attach a suitable lifting device to flywheel (1).
Support the weight of the flywheel. The weight of Contaminants may cause rapid wear and shortened
the flywheel is approximately 71 kg (155 lb). component life.
4. Remove remaining bolts (2).
5. Use the lifting device in order to remove the

flywheel from the engine.
g01343963
Illustration 62
Typical example
g01245152
Illustration 61
Typical example Always wear protective gloves when handling
parts that have been heated.
40 KENR6247
1. If the flywheel ring gear was removed, follow 7. Remove Tooling (A) and install remaining bolts
Steps 1.a through 1.c in order to install a new ring (2) to the flywheel (1).
gear to the flywheel.
8. Remove the lifting device from flywheel (1).
a. Identify the orientation of teeth (4) on the new
ring gear (4). 9. Use a suitable tool to prevent the flywheel from
rotating. Tighten bolts (2) to a torque of 115 N·m
Note: The chamfered side of the ring gear teeth must (85 lb ft).
face toward the starting motor when the flywheel is
installed. This will ensure the correct engagement of 10. Check the run out of the flywheel. Refer to
the starting motor. System Operation, Test and Adjusting, “Flywheel -
Inspect” for further information.
b. Heat flywheel ring gear (3) in an oven to a
maximum temperature of 250 °C (482 °F) prior End By:
to installation.
a. Install the electric starting motor. Refer to
Note: Do not use a torch to heat the ring gear. Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
c. Ensure that the orientation of ring gear (3) is
correct and quickly install the ring gear onto
i02628827
flywheel (1).
2. Inspect the crankshaft rear seal for leaks. If there

Crankshaft Rear Seal - Remove
are any oil leaks, replace the crankshaft rear seal.
Refer to Disassembly and Assembly, “Crankshaft
Rear Seal - Remove”.
Removal Procedure
Table 22
Required Tools
Part
Number
A - E12 Torx Socket 1
Start By:
a. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove”.
NOTICE

component life.
g01245126
Typical example Care must be taken to ensure that fluids are contained
3. Install a suitable lifting device to flywheel (1). The ing, adjusting and repair of the product. Be prepared to
flywheel weighs approximately 71 kg (155 lb). collect the fluid with suitable containers before open-
4. Install Tooling (A) to positions (X) on the nent containing fluids.
crankshaft.
5. Use the lifting device in order to position flywheel mandates.
(1) onto Tooling (A).
6. Install bolts (2) to flywheel (1) finger tight.

KENR6247 41
Note: The crankshaft rear seal and the housing

are manufactured as a one-piece assembly. The
assembly is not serviceable. If the crankshaft rear
seal is removed, the assembly must be replaced.
g01258105
Illustration 65
g01269512
Illustration 64
Typical example
1. Use Tooling (A) in order to remove torx screws (1)

from crankshaft rear seal (2).
2. Remove crankshaft rear seal (2) from the cylinder

block. Discard the crankshaft rear seal.
i02628824
Crankshaft Rear Seal - Install Illustration 66

g01255709
Typical example
1. Ensure that crankshaft flange (1) is clean, dry

Installation Procedure and free from damage. It is possible to reclaim a
crankshaft flange that has a worn seal surface,
Table 23 or a damaged seal surface by installing a wear
sleeve. Refer to Disassembly and Assembly,
Required Tools
“Crankshaft Wear Sleeve (Rear) - Remove and
Part Install” for more information.
Number
2. Ensure that the face of the cylinder block and the
bridge piece are clean and dry.
B 27610306 Alignment Tool 1
3. A new crankshaft rear seal is supplied with a
Note: The crankshaft rear seal and the housing are plastic sleeve (3). Ensure that the plastic sleeve is
manufactured as a one-piece assembly. squarely installed within crankshaft rear seal (2).
Note: The plastic sleeve is included in order to

NOTICE protect the lip of the seal as the seal is pushed over
Keep all parts clean from contaminants. the crankshaft flange.
Contaminants may cause rapid wear and shortened Note: Do not lubricate the crankshaft rear seal or
component life. the crankshaft flange. The crankshaft rear seal
must be installed dry.
4. Align plastic sleeve (3) with crankshaft flange (1).

Ensure that the plastic sleeve is engaged onto the
crankshaft flange. Push new crankshaft rear seal
(2) squarely onto the crankshaft flange.
42 KENR6247
During this process, the plastic sleeve will be i02628848

forced out of the crankshaft rear seal. Discard the
plastic sleeve. Flywheel Housing - Remove
and Install
5. Align the two molded locators on crankshaft rear
seal (2) with the holes in the cylinder block. Ensure
that the crankshaft rear seal is seated against the
cylinder block.
Removal Procedure
Start By:
a. Remove the flywheel. Refer to Disassembly and

Assembly, “Flywheel - Remove”.
NOTICE

component life.
1. Install a suitable lifting device to the flywheel

housing in order to support the flywheel housing.
The flywheel housing weighs approximately 30 kg
(66 lb).
g01258357
Illustration 67
Tightening sequence for the crankshaft rear seal
6. Install torx screws (4) finger tight.
Note: Do not install torx screws to positions (X) at

this stage.
7. Install Tooling (B) to crankshaft rear seal (2) and

to crankshaft flange (1).
8. Use Tooling (A) in order to tighten torx screws (4)

to a torque of 22 N·m (16 lb ft). Tighten torx screws
(4) in the sequence that is shown in Illustration 67.
10. Install remaining torx screws (4) to positions (X). g01244050

Illustration 68
Use Tooling (A) in order to tighten the torx screws
to a torque of 22 N·m (16 lb ft). Refer to Illustration Typical example
67.
2. Remove bolts (2) and bolts (3) from flywheel
End By: housing (1).
a. Install the flywheel. Refer to Disassembly and 3. Use the lifting device in order to remove flywheel
Assembly, “Flywheel - Install”. housing (1) from the cylinder block.
KENR6247 43
2. Inspect crankshaft rear seal (6) for leaks. If there

are any oil leaks, replace the crankshaft rear seal.
Rear Seal - Remove” and refer to Disassembly
and Assembly, “Crankshaft Rear Seal - Install”.
3. Clean the rear face of the cylinder block. If

necessary, install dowels (4) to the cylinder block.
4. Install Tooling (A) to the cylinder block.
5. Install dust seal (5).
g01244051
Illustration 69
Typical example
4. If the engine has an aluminum oil pan, remove

dust seal (5).
5. If necessary, remove dowels (4) from the cylinder

block.
Table 24
Required Tools
Part
Number
- Guide Stud
A 2
(M10 by 100 mm)
g01244050
Illustration 71
B 21825617 Dial Indicator Group 1
Typical example
NOTICE 6. Install a suitable lifting device to the flywheel

Keep all parts clean from contaminants. housing. The flywheel housing weighs
approximately 30 kg (66 lb).
component life. 7. Use the lifting device to align flywheel housing (1)
with Tooling (A). Install the flywheel housing to the
cylinder block.
1. Ensure that the flywheel housing is clean and free
from damage. If necessary, replace the flywheel
8. Install the bolts (2) and bolts (3) finger tight.
housing.
9. Remove Tooling (A). Install the remaining bolts (3).
12. Use Tooling (B) to check the alignment of the

flywheel housing with the crankshaft. Refer
to Systems Operation, Testing and Adjusting,
“Flywheel Housing - Inspect”.
End By:
a. Install the flywheel. Refer to Disassembly and

Illustration 70
g01244056 Assembly, “Flywheel - Install”.
Typical example
44 KENR6247
i02674882 b. Remove crankshaft pulley (4) from crankshaft

adapter (3).
Crankshaft Pulley - Remove
and Install Installation Procedure
(Engines With an Automatic
NOTICE
Belt Tensioner) Keep all parts clean from contaminants.

component life.
Removal Procedure
1. Ensure that the crankshaft adapter, the pulley and
Start By:
the thrust block are clean and free from damage.
Replace any components that are damaged. It
a. Remove the Alternator belt. Refer to Disassembly
is possible to reclaim a crankshaft adapter with
and Assembly, “Alternator Belt - Remove and
a worn seal surface by installing a wear sleeve.
Install”.
Wear Sleeve (Front) - Remove and Install”.
NOTICE

component life.
g01367385
Illustration 73
2. If necessary, follow Steps 2.a through 2.b in order

to assemble the crankshaft pulley.
Illustration 72
g01249049 a. Install crankshaft pulley (4) to crankshaft
adapter (3).
1. Use a suitable tool in order to prevent the
crankshaft from rotating. Remove bolts (1). b. Install bolts (5) to the assembly of the
crankshaft pulley, and the crankshaft adapter.
2. Remove thrust block (2). The bolts should be evenly spaced.
3. Carefully remove the assembly of the crankshaft c. Tighten the bolts to a torque of 78 N·m (58 lb ft).
pulley from the crankshaft.
3. Ensure that the front of the crankshaft is clean
4. Follow Steps 4.a through 4.b in order to and free from damage. Install the assembly of the
disassemble the crankshaft pulley. crankshaft pulley to the crankshaft.
a. Remove bolts (5).

KENR6247 45
NOTICE

component life.
g01367392
Illustration 74
4. Align the holes in thrust block (2) with the holes

in the crankshaft.
Note: Ensure chamfered holes (X) in thrust block (2).

Face toward the front of the engine.
g01255707
Illustration 75
5. Install thrust block (2) to the assembly of the
crankshaft pulley. 1. Use a suitable tool in order to prevent the
crankshaft from rotating. Remove bolts (1).
6. Install bolts (1) to thrust block (2).
2. Remove thrust block (2).
crankshaft from rotating. Tighten the bolts evenly 3. Carefully remove crankshaft pulley (3) from the
to a torque of 115 N·m (85 lb ft). crankshaft.
8. Repeat Step 7 one more times in order to ensure Installation Procedure

correct torque.
End By:
a. Install the alternator belt. Refer to Disassembly

Install”.
i02628822
Crankshaft Pulley - Remove

and Install
(Engines Without an Automatic
Belt Tensioner) Illustration 76
g01255707
1. Ensure that the crankshaft pulley and the thrust

block are clean and free from damage. Replace
Removal Procedure any components that are damaged. It is possible
to reclaim a crankshaft pulley with a worn seal
Start By: surface by installing a wear sleeve. Refer to
Disassembly and Assembly, “Crankshaft Wear
a. Remove the V-Belts. Refer to Disassembly and Sleeve (Front) - Remove and Install”.
Assembly, “V-Belts - Remove and Install”.
2. Ensure that the front of the crankshaft is clean and
free from damage. Install crankshaft pulley (3) to
the crankshaft.
46 KENR6247
Start By:
a. Remove the crankshaft pulley. Refer to

Disassembly and Assembly, “Crankshaft Pulley
- Remove and Install”.
NOTICE

component life.
g01367392
Illustration 77
3. Align the holes in thrust block (2) with the holes

in the crankshaft.
Note: Ensure chamfered holes (X) in thrust block (2).

Face toward the front of the engine.
4. Install thrust block (2) to the assembly of the

crankshaft pulley.
5. Install bolts (1) to thrust block (2).

g01266942
Illustration 78
crankshaft from rotating. Tighten the bolts evenly 1. Install the legs of Tooling (A) behind crankshaft
to a torque of 115 N·m (85 lb ft). front seal (1). Install a suitable spacer (2) between
Tooling (A) and crankshaft (3). Use Tooling (A) in
7. Repeat Step 6 one more times in order to ensure order to pull the crankshaft front seal out of the
correct torque. front housing.
End By: Note: Do not damage the bore for the crankshaft
front seal in the front housing.
a. Install the V-Belts. Refer to Disassembly and
Assembly, “V-Belts - Remove and Install”. Installation Procedure
Table 26
i02628819
Required Tools
Crankshaft Front Seal - Part
Remove and Install Tool
Number
Part Description Qty
21825577 Threaded Bar 1

21825580 Anchor Plate 1
Removal Procedure B 21825579 Sleeve 1
Table 25 21825578 Pressure Plate 1
Required Tools 27610217 Adapter 1
Part
Number NOTICE
A 27610230 Puller 1 Keep all parts clean from contaminants.

component life.
KENR6247 47
1. Ensure that the bore for the crankshaft front seal in

the front housing is clean and free from damage. NOTICE

component life.
Note: Wear sleeves are used to reclaim worn seal

surfaces. Wear sleeves are not original equipment. A
new crankshaft front seal must be installed when a
new wear sleeve is installed.
g01266453
Illustration 79
Typical example
2. Assemble Tooling (B).
3. Align a new crankshaft front seal (1) to the front

housing.
4. Use Tooling (B) to install crankshaft front seal (1).

Ensure that the front face of the seal is installed Illustration 80
g01269535
to a depth of 9 ± 0.2 mm (0.354 ± 0.008 inch) into
Sectional view of the crankshaft pulley and the wear sleeve
the front housing.
5. Remove Tooling (B) from the crankshaft. 1. Use a sharp tool to score a deep line across wear
sleeve (1).
End By:
Note: Take care to avoid damaging to the crankshaft
a. Install the crankshaft pulley. Refer to Disassembly pulley.
and Assembly, “Crankshaft Pulley - Remove and
Install”. 2. Insert a thin blade between wear sleeve (1) and
crankshaft pulley (2) below the scored line. The
wear sleeve will separate along the line.
i02628828
3. Remove wear sleeve (1) from crankshaft pulley
Crankshaft Wear Sleeve (Front) (2).
- Remove and Install
Table 27
Removal Procedure Required Tools

Tool Part Number Part Description
Start By:
POWERPART
A 21820518
a. Remove the crankshaft pulley. Refer to Liquid Gasket
NOTICE
b. Remove the crankshaft front seal . Refer to
Disassembly and Assembly, “Crankshaft Front
Seal - Remove and Install”.
component life.
1. Ensure that the crankshaft pulley is thoroughly

clean and dry. Remove any areas of raised
damage.
48 KENR6247
g01269521
Illustration 81
Sectional view of the wear sleeve
2. Apply a small continuous bead of Tooling (A) to

the inner surface of wear sleeve (1) at position X.
Apply the bead of Tooling (A) 5.00 mm (0.2 inch)
from the flange end of the wear sleeve. Illustration 83
g01258430
Sectional view of the crankshaft pulley, the wear sleeve and the
installation tool
3. Align wear sleeve (1) with crankshaft pulley (2).

Use installation tool (3) that is provided with the
wear sleeve and use a suitable press in order to
install wear sleeve (1) onto crankshaft pulley (2).
Note: Ensure that the wear sleeve is installed

squarely against the shoulder of the crankshaft pulley.
4. Remove installation tool (3) from wear sleeve (1).
5. Ensure that wear sleeve (1) has no rough edges.
End By:
a. Install a new crankshaft front seal. Refer to

Disassembly and Assembly, “Crankshaft Front
Seal - Remove and Install”.
g01258423 b. Install the crankshaft pulley. Refer to Disassembly
Illustration 82
Typical example and Assembly, “Crankshaft Pulley - Remove and
Install”.
KENR6247 49
i02628849
Front Cover - Remove and

Install
Removal Procedure
Start By:
a. If the engine is equipped with a fan, remove the

fan. Refer to Disassembly and Assembly, “Fan
b. Remove the water pump. Refer to Disassembly

and Assembly, “Water Pump - Remove”.
NOTICE
during performance of inspection, maintenance, test- Illustration 84
g01258462
ing, adjusting and repair of the product. Be prepared to Typical example

ing any compartment or disassembling any compo- 1. Remove bolts (3), (4) and (5). Identify the positions
nent containing fluids. of the different bolts.
Dispose of all fluids according to local regulations and 2. Remove front cover (1) from the front housing.
mandates.
3. Remove joint (2) from front cover (1).
NOTICE
Keep all parts clean from contaminants. Installation Procedure
Contaminants may cause rapid wear and shortened Table 28
component life. Required Tools
Part
Note: In order to remove the front cover, it is not Tool Part Name Qty
Number
necessary to remove the crankshaft pulley or the
alternator. - Guide Bolt
A 2
(M8 by 80 mm)
NOTICE

component life.
50 KENR6247
8. Tighten the bolts for the water pump to a torque of

22 N·m (16 lb ft).
End By:
a. If the engine is equipped with a fan, install the

fan. Refer to Disassembly and Assembly, “Fan
i02628883
Gear Group (Front) - Remove

and Install
Removal Procedure
Table 29
Required Tools
Tool Part Number Part Name Qty
A 1
A2
27610289 Gear 1
g01343967
Illustration 85 B 27610212 Camshaft Timing Pin 1
Typical example
1. Thoroughly clean the mating surface of the front
housing. Start By:
2. If the original front cover is installed, follow Steps a. If the engine is equipped with an air compressor,
2.a and 2.b in order to install the joint. remove the air compressor. Refer to Disassembly
and Assembly, “Air Compressor - Remove and
a. Thoroughly clean the front cover. Install”.
b. Install a new joint (2) to front cover (1). Engage b. If the engine is equipped with a vacuum pump,
locators (Y) into the holes in the front cover. remove the vacuum pump. Refer to Disassembly
and Assembly, “Vacuum Pump - Remove and
3. Install Tooling (A) into holes (X) in the front Install”.
housing.
c. If the engine is equipped with an accessory drive,
4. Use Tooling (A) in order to position the front cover remove the accessory drive. Refer to Disassembly
assembly onto the front housing. and Assembly, “Accessory Drive - Remove and
Install”.
5. Install bolts (3), (4) and (5) finger tight. Ensure
that the different bolts are installed in the correct d. Remove the front cover. Refer to Disassembly and
positions. Assembly, “Front Cover - Remove and Install”.
6. Loosely install the water pump assembly and e. Remove the valve mechanism cover. Refer to
remove Tooling (A). Refer to Disassembly and Disassembly and Assembly, “Valve Mechanism
Assembly, “Water Pump - Install” for the correct Cover - Remove and Install”.
procedure.
7. Tighten bolts (3), (4) and (5) to a torque of 22 N·m that is most suitable.
(16 lb ft).
KENR6247 51
Note: Do not use excessive force to install Tooling

NOTICE (C). Do not use Tooling (C) to hold the crankshaft
Keep all parts clean from contaminants. during repairs.

component life.
NOTICE

mandates.
Note: Care must be taken in order to ensure that

the fuel injection pump timing is not lost during
the removal of the front gear group. Carefully
follow the procedure in order to remove the gear
group.
g01322693
Illustration 87
1. Use Tooling (A) in order to rotate the crankshaft so Typical example
on the compression stroke. Refer to Systems 3. Loosen nuts (6) on all rocker arms (7). Unscrew
Operation, Testing and Adjusting, “Finding Top adjusters (5) on all rocker arms (7) until all valves
Centre Position for No.1 Piston”. are fully closed.
Note: Failure to ensure that ALL adjusters are fully

unscrewed can result in contact between the valves
and pistons.
4. Apply sufficient pressure to fuel injection pump

gear (3) in a counterclockwise direction in order
to remove the backlash. Lock the fuel injection
pump in this position. Refer to Disassembly and
Assembly, “Fuel Pump Gear - Remove” for the
correct procedure.
g01247433
Illustration 86
Typical example

gear (1) into the front housing. Use Tooling (B) in g01335384
order to lock the camshaft in the correct position. Illustration 88
Install Tooling (C) into hole (Y) in the front housing. Typical example
Use Tooling (C) in order to lock the crankshaft in
the correct position. Refer to Systems Operation, 5. Mark gears (1), (2) and (3) in order to show
Testing and Adjusting, “Finding Top Centre alignment. Refer to Illustration 88.
Position for No.1 Piston”.
52 KENR6247
Note: Identification will ensure that the gears can be

installed in the original alignment.
6. Remove fuel pump gear (3). Refer to Disassembly

and Assembly, “Fuel Pump Gear - Remove” for
the correct procedure.
7. Remove camshaft gear (1). Refer to Disassembly

and Assembly, “Camshaft Gear - Remove and
Install”.
8. Remove idler gear (2). Refer to Disassembly and

Assembly, “Idler Gear - Remove and Install”.
Table 30
Required Tools
Part
Tool Part Name Qty
Number
g01247433
B 27610212 Camshaft Timing Pin 1 Illustration 89
Typical example
21825617 Dial Indicator Group 1 2. If necessary, install Tooling (C) into hole (Y) in
D the front housing. Use Tooling (C) in order to
- Finger Clock 1 lock the crankshaft in the correct position. Refer
NOTICE “Finding Top Centre Position for No.1 Piston”.
Note: Do not use excessive force to install Tooling
Contaminants may cause rapid wear and shortened (C). Do not use Tooling (C) to hold the crankshaft
component life. during repairs.
3. Ensure that all of the components of the front gear

Note: The fuel injection pump must remain locked group are clean and free from wear of damage. If
until the procedure instructs you to unlock the necessary, replace any components that are worn
fuel injection pump. or damaged.
1. Ensure that number one piston is at the top center

position on the compression stroke. Refer to
g01269928
Illustration 90
Typical example
4. Install camshaft gear (1). Loosely install bolt

(6) and washer (5). Refer to Disassembly and
Assembly, “Camshaft Gear - Remove and Install”
KENR6247 53
5. Install Tooling (B) through hole (X) in camshaft 9. Install fuel injection pump gear (3). Refer to
gear (1) into the front housing. Disassembly and Assembly, “Fuel Injection Pump
Gear - Install” for the correct procedure. Ensure
that timing marks on gears (2) and (3) are in
alignment. See Illustration 92. Ensure that the
mesh of the gears is correct.
11. Use Tooling (D) in order to measure the backlash

for the gears (1), (2) and (3). Ensure that the
backlash for the gears is within specified values.
Refer to Specifications, “Gear Group (Front)” for
further information.
12. Lubricate each gear with clean engine oil.

g01269927
Illustration 91 13. Adjust the engine valve lash. Refer to Systems
Typical example Operation, Testing and Adjusting, “Engine Valve
Lash - Inspect/Adjust”.
End By:

b. Install the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism
c. If the engine is equipped with an air compressor,

install the air compressor. Refer to Disassembly
Install”.
g01335384
Illustration 92
Alignment of timing marks d. If the engine is equipped with a vacuum pump,
install the vacuum pump. Refer to Disassembly
6. Install idler gear (2). Ensure that the timing marks and Assembly, “Vacuum Pump - Remove and
on gears (1) and (2) are in alignment and that the Install”.
mesh of the gears is correct. Refer to Disassembly
and Assembly, “Idler Gear - Remove and Install”. e. If the engine is equipped with an accessory drive,
Check the end play of the idler gear. Refer to install the accessory drive. Refer to Disassembly
Specifications, “Gear Group (Front)” and refer to and Assembly, “Accessory Drive - Remove and
Disassembly and Assembly, “Idler Gear - Remove Install”.
and Install” for further information.
i02628889
7. Remove Tooling (B) and (C). Tighten the bolt
(6) for the camshaft gear to a torque of 95 N·m Idler Gear - Remove
(70 lb ft). Check the end play of the camshaft
gear. Refer to Specifications, “Camshaft” for more
information.
Install Tooling (B) through hole (X) in camshaft Removal Procedure (Standard Idler
gear (1) into the front housing and install Tooling Gear)
(C) into hole (Y) in the front housing.
Table 31
8. Ensure that the fuel injection pump is locked in Required Tools
the correct position. Refer to Disassembly and
Assembly, “Fuel Injection Pump - Install”. Tool Part Number Part Name Qty
A 27610212 Camshaft Timing Pin 1
B 27610211 Crankshaft Timing Pin 1
54 KENR6247
Start By: 2. Ensure that Tooling (B) is installed in hole (Y) in

the front housing. Use Tooling (B) in order to lock
a. If the engine is equipped with an air compressor, the crankshaft in the correct position.
remove the air compressor. Refer to Disassembly
Install”.
b. If the engine is equipped with a vacuum pump,

remove the vacuum pump. Refer to Disassembly
Install”.

remove the accessory drive. Refer to Disassembly
and Assembly, “Accessory Drive - Remove and
Install”.
d. Remove the fuel injection pump gear. Refer to

Disassembly and Assembly, “Fuel Pump Gear
- Remove”.
e. Remove the valve mechanism cover. Refer to

g01348926
Illustration 94
the fuel injection pump timing is not lost during Typical example
the removal of the fuel pump gear. Carefully
follow the procedure in order to remove the fuel 3. Loosen nuts (4) on all rocker arms (5). Unscrew
pump gear. adjusters (3) on all rocker arms (5) until all valves
are fully closed.
NOTICE Note: Failure to ensure that ALL adjusters are fully
Keep all parts clean from contaminants. unscrewed can result in contact between the valves
and pistons.
component life. 4. Mark plate (3) in order to show orientation. Refer
to Illustration 93.
Note: Identification will ensure that the plate can be

installed in the original orientation.
5. Remove bolts (1). Refer to Illustration 93.
6. Remove plate (3).
g01343975
Illustration 93
1. Ensure that Tooling (A) is installed into hole (X) in

the camshaft gear. Use Tooling (A) in order to lock
the camshaft in the correct position.
Note: Ensure that the gears are marked in order to

show alignment. Refer to Illustration 93.
KENR6247 55

the fuel injection pump timing is not lost during the
removal of the fuel pump gear. Carefully follow the
procedure in order to remove the fuel pump gear.
NOTICE

component life.
Note: The assembly of heavy-duty idler gear is not

serviceable. Do not disassemble the heavy-duty idler
g01269930
gear.
Illustration 95
Typical example
7. Remove the assembly of idler gear (2) and hub (7)

from the recess in the front housing.
Note: The idler gear must be tilted during removal.
8. Remove hub (7) from idler gear (2).
Removal Procedure (Heavy-Duty

Idler Gear)
Table 32
g01343977
Required Tools Illustration 96
A 27610212 Camshaft Timing Pin 1 1. Ensure that Tooling (A) is installed into hole (X) in
B 27610211 Crankshaft Timing Pin 1 the camshaft gear. Use Tooling (A) in order to lock
the camshaft in the correct position.
- Bolt
C 1
(M8x80mm) Note: Ensure that the gears are marked in order to
show alignment. Refer to Illustration 96.
Start By:
2. Ensure that Tooling (B) is installed in hole (Y) in
a. If the engine is equipped with an air compressor, the front housing. Use Tooling (B) in order to lock
remove the air compressor. Refer to Disassembly the crankshaft in the correct position.
Install”.
b. If the engine is equipped with a vacuum pump,

remove the vacuum pump. Refer to Disassembly
Install”.

remove the accessory drive. Refer to Disassembly
Install”.
d. Remove the fuel injection pump gear. Refer to

Disassembly and Assembly, “Fuel Pump Gear
- Remove”.
e. Remove the valve mechanism cover. Refer to

56 KENR6247
g01348930 g01348835
3. Loosen nuts (4) on all rocker arms (5). Unscrew 6. If necessary, remove plate (6). Install Tooling (C)
adjusters (3) on all rocker arms (5) until all valves into threaded hole (Z) in order to remove plate (6).
are fully closed.
i02628887
Note: Failure to ensure that ALL adjusters are fully
and pistons.
Idler Gear - Install
4. Remove bolts (1) from the assembly of heavy-duty
idler gear (2). Refer to Illustration 96.
Installation Procedure (Standard
Idler Gear)
Table 33
Required Tools
C
- Finger Clock 1
Illustration 98
g01269933 NOTICE
Typical example
5. Remove the assembly of idler gear (2) from the Contaminants may cause rapid wear and shortened
recess in the front housing. component life.
Note: The idler gear must be tilted during removal. 1. Ensure that number one piston is at the top center
position on the compression stroke. Refer to
“Finding Top Center Postion for No. 1 Piston”.
KENR6247 57
g01343975 g01269935
Alignment of timing marks Typical example
2. Ensure that Tooling (A) is installed into hole (X) in 7. Align the timing mark on idler gear (2) with the
camshaft gear (1). timing mark on the camshaft gear. Refer to the
Illustration 100. Install the assembly of idler gear
3. Ensure that Tooling (B) is installed in hole (Y) (2) and hub (7) into the recess in the timing case.
in the front housing. Use Tooling (B) in order to Ensure that oil hole (Z) is to the top of the hub.
lock the crankshaft in the correct position. Refer
to Systems Operation, Testing and Adjusting, Note: The idler gear must be tilted during installation.
“Finding Top Centre Position for No.1 Piston”. Ensure that the holes in the hub are aligned with the
holes in the cylinder block.
8. Clean plate (3) and inspect the plate for wear or

damage. If necessary, replace the plate.
9. Lubricate plate (3) with clean engine oil. A used

plate should be installed in the original orientation.
If a new plate is installed, ensure that the holes
in plate (3) are aligned with the holes in hub (7).
Install plate (3) to hub (7).

44 N·m (32 lb ft).
g01269934
Illustration 101
4. Clean idler gear (2) and inspect the idler gear for
wear or damage. Refer to Specifications, “Gear
Group (Front)” for more information. If necessary,
replace the idler gear.
5. Clean hub (7) and inspect the hub for wear or

damage. Refer to Specifications, “Gear Group
(Front)” for more information. If necessary, replace
the hub.
6. Lubricate hub (7) with clean engine oil. Slide the

g01269936
hub into idler gear (2). Ensure that the timing Illustration 103
marks are toward the front of the idler gear. Checking end play by using a set of feeler gauge’s
11. Use a set of feeler gauge’s in order to check the

end play for the idler gear. Refer to Specifications,
“Gear Group (Front)” for more information.
58 KENR6247
12. Use Tooling (C) in order to check the backlash

between the idler gear and the camshaft gear.
more information.
13. Use Tooling (C) in order to check the backlash

between the idler gear and the crankshaft gear.
more information.
14. Lightly lubricate all of the gears with clean engine

oil.
End By:
g01343977
a. Install the fuel injection pump gear. Refer to Illustration 104
Disassembly and Assembly, “Fuel Pump Gear - Alignment of timing marks
Install”.
2. Ensure that Tooling (A) is installed into hole (X) in
b. If the engine is equipped with an air compressor, the camshaft gear.
and Assembly, “Air Compressor - Remove and 3. Ensure that Tooling (B) is installed in hole (Y) in
Install”. the cylinder block. Use Tooling (B) in order to
lock the crankshaft in the correct position. Refer
c. If the engine is equipped with a vacuum pump, to Systems Operation, Testing and Adjusting,
install the vacuum pump. Refer to Disassembly “Finding Top Centre Position for No.1 Piston”.
Install”.
d. If the engine is equipped with an accessory drive,

install the accessory drive. Refer to Disassembly
Install”.
Installation Procedure (Heavy-Duty

Idler Gear)
Table 34
Required Tools
C
- Finger Clock 1 g01348946
Illustration 105
Typical example
NOTICE
Keep all parts clean from contaminants. 4. Install plate (6) into the recess in the front housing.
Contaminants may cause rapid wear and shortened Note: Ensure that the identification mark TOP is
component life. upward.
1. Ensure that number one piston is at the top 5. Clean the assembly of idler gear (2) and inspect
center position on the compression stroke. Refer the assembly of the idler gear for wear or damage.
to Systems Operation, Testing and Adjusting, Refer to Specifications, “Gear Group (Front)”
“Finding Top Center Postion for No. 1 Piston”. for more information. If necessary, replace the
assembly of the idler gear.
KENR6247 59
6. Lubricate the bearings in the assembly of idler 12. Lightly lubricate all of the gears with clean engine
gear (2) with clean engine oil. oil.
End By:
a. Install the fuel injection pump gear. Refer to

Disassembly and Assembly, “Fuel Pump Gear -
Install”.
b. If the engine is equipped with an air compressor,

Install”.
c. If the engine is equipped with a vacuum pump,

install the vacuum pump. Refer to Disassembly
g01269933
Illustration 106 Install”.
7. Align the timing mark on idler gear (2) with the d. If the engine is equipped with an accessory drive,
timing mark on the camshaft gear. Refer to install the accessory drive. Refer to Disassembly
Illustration 104. Install the assembly of idler gear and Assembly, “Accessory Drive - Remove and
(2) into the recess in the timing case. Ensure that Install”.
the identification mark TOP is upward.
Note: The idler gear must be tilted during installation. i02628886
Ensure that the holes in the assembly of the idler

gear are aligned with the holes in the cylinder block.
Housing (Front) - Remove
44 N·m (32 lb ft).
Removal Procedure
Start By:
a. Remove the fan. Refer to Disassembly and

Assembly, “Fan - Remove and Install”.
b. Remove the alternator. Refer to Disassembly and

Assembly, “Alternator - Remove”.
c. Remove the crankshaft pulley. Refer to

d. Remove the engine oil pan. Refer to Disassembly

g01269937
Illustration 107 and Assembly, “Engine Oil Pan - Remove and
Checking end play by using a dial indicator group Install”.
9. Use Tooling (C) in order to check the end play e. Remove the timing gears. Refer to Disassembly
of the idler gear. Refer to Specifications, “Gear and Assembly, “Gear Group (Front) - Remove
Group (Front)” for more information. and Install”.
10. Use Tooling (C) in order to check the backlash f. Remove the fuel injection pump. Refer to
between the idler gear and the camshaft gear. Disassembly and Assembly, “Fuel Injection Pump
Refer to Specifications, “Gear Group (Front)” for - Remove”.
more information.
NOTICE
11. Use Tooling (C) in order to check the backlash Keep all parts clean from contaminants.
between the idler gear and the crankshaft gear.
Refer to Specifications, “Gear Group (Front)” for Contaminants may cause rapid wear and shortened
more information. component life.
60 KENR6247
NOTICE

mandates.
1. Ensure that the coolant is drained into a suitable

container for storage or disposal. Refer to
System Coolant - Change” for the correct
procedure.
g01350333
Illustration 109
3. If the engine is equipped with a heavy duty idle

gear. Remove plate (6). Refer to Disassembly and
Assembly, “Idler Gear - Remove” for the correct
procedure.
g01337982
Illustration 108
Typical example
2. Remove bolts (1) that secure bypass tube (2) to

front housing (3). Note the position of any brackets
that are secured by the bolts. Remove bypass
tube (2). Remove O-ring seals (4) and (5) from
bypass tube (2).
g01350336
Illustration 110
Typical example
4. Remove bolts (8), (9) and (10) from front housing

(3).
Note: The bolts are three different lengths. Note the

positions of the different bolts.
5. Remove front housing (3) from the cylinder block.
6. Remove joint (7).

KENR6247 61
2. Check the condition of the crankshaft front seal. If

the front seal is damaged, remove the front seal
from the front housing.
3. Clean the mating surfaces of the cylinder block.
g01350337
Illustration 111
Typical example
7. Remove thrust washer (11) from the cylinder

block.
g01350337
Illustration 112
Typical example
i02628885
Housing (Front) - Install 4. Install thrust washer (11) into the recess in
the cylinder block. Refer to Disassembly
and Assembly, “Camshaft - Install” for more
information.
Table 35
Required Tools
Part
Number
POWERPART
A 21820117 Threadlock and 1
Nutlock
- Guide Stud
B 2
(M8 by 80 mm)
27610216 Alignment Tool 1
C Bolts
- 3
(M10 by 50 mm)
D - Straight Edge 1
POWERPART
E 21820221 1
Rubber Grease
g01350343
Illustration 113
NOTICE Typical example
5. Install Tooling (B) to the cylinder block. Refer to
Contaminants may cause rapid wear and shortened Illustration 113.
component life.
6. Install Tooling (C) to the cylinder block.
1. Ensure that the front housing is clean and free 7. Align a new joint (7) with Tooling (B). Install the
from damage. If necessary, replace the front joint to the cylinder block.
housing.
Note: Ensure that tabs (X) on the joint are engaged
If necessary, install blanking plugs to a new front in the holes (Y) in the cylinder block.
housing. Use Tooling (A) to seal all D-plugs.
62 KENR6247
g01269947
Illustration 114
Typical example
8. Install the front housing over Tooling (B) and over

Tooling (C) onto the cylinder block.
g01269949
Illustration 116
Tightening sequence for the front housing
13. Tighten bolts (8), (9) and (10) to a torque of

28 N·m (20 lb ft). Tighten the bolts in the sequence
that is shown in Illustration 116.
Note: Ensure that the housing and the cylinder block

are correctly aligned.
14. Remove Tooling (C) from the cylinder block.
15. If necessary, install a new crankshaft front seal.

Front Seal - Remove and Install”.
g01350344
Illustration 115
(8) M8 by 20 mm
(9) M8 by 35 mm
(10) M8 by 25 mm
9. Install bolts (10) to front housing (3) finger tight.
11. Loosely install bolts (8) and (9). Refer to

Illustration 115 for the correct position of the bolts.
12. Align the bottom face of front housing (3) to the

lower machined face of the cylinder block. Use a
Tooling (D) and a feeler gauge in order to check
the alignment between the front housing and the
cylinder block. Refer to Illustration 114. Refer to g01350333
Illustration 117
Specifications, “Front Housing and Covers” for
further information.
KENR6247 63
16. If the engine is equipped with a heavy duty idle i02628800

gear. Install plate (6). Refer to Disassembly and
Assembly, “Idler Gear - Install” for the correct Accessory Drive - Remove and
procedure. Install
Removal Procedure
Table 36
Required Tools
Part
Number
- Bearing Puller 1
- Puller 1
A
- Crossblock 1
g01337982
Illustration 118
- Puller Leg 2
Typical example
17. Install new O-ring seals (4) and (5) to bypass tube NOTICE
(2). Use Tooling (E) in order to lubricate O-ring Keep all parts clean from contaminants.
seal (5). Install bypass tube (2) to the cylinder
head. Install bolts (1). Ensure that any brackets Contaminants may cause rapid wear and shortened
that are secured by the bolts are installed in the component life.
correct location. Tighten the bolts to a torque of
22 N·m (16 lb ft).
NOTICE
End By: Care must be taken to ensure that fluids are contained
a. Install the fuel injection pump. Refer to ing, adjusting and repair of the product. Be prepared to
Disassembly and Assembly, “Fuel Injection Pump collect the fluid with suitable containers before open-
- Install”. ing any compartment or disassembling any compo-
b. Install the timing gears. Refer to Disassembly and
Assembly, “Gear Group (Front) - Install”. Dispose of all fluids according to local regulations and
mandates.
c. Install the engine oil pan. Refer to Disassembly
Install”.
d. Install the crankshaft pulley. Refer to Disassembly

and Assembly, “Crankshaft Pulley - Remove and
Install”.
e. Install the alternator. Refer to Disassembly and

Assembly, “Alternator - Install”.
f. Install the fan. Refer to Disassembly and

g01269954
Illustration 119
Typical example
64 KENR6247
1. Remove allen head screw (1) from accessory

drive housing (8). Remove allen head screws (6)
from accessory drive housing (8).
2. Remove accessory drive housing (8) from the

front housing.
3. If necessary, follow Steps 3.a through 3.c in order

to disassemble the accessory drive.
a. Remove circlip (2) from accessory drive

housing (8).
b. Place accessory drive housing (8) onto a

suitable support. Press the assembly of gear
(4) and bearings (3) and (5) out of accessory
drive housing (8). Use a Tooling (A) in order to
remove bearings (3) and (5) from gear (4).
c. Remove O-ring seal (7) from accessory drive

housing (8).
g01264852
Illustration 120
Installation Procedure Typical example
Table 37 1. If necessary, follow Steps 1.a through 1.e in order

Required Tools to assemble the accessory drive.
Part a. Inspect the condition of the teeth and the
Number splines of gear (4) for wear or damage. Inspect
POWERPART bearings (3) and (5), circlip (2), and the front
B 21820603 -
Retainer housing for wear or damage. Replace any
POWERPART
C 21820221 1
Rubber Grease
b. Apply a small continuous bead of Tooling (B)
D 21820117
POWERPART
1
to inner surface (X) of bearing (5). Place the
Threadlock and Nutlock gear shaft on a suitable support. Press on the
inner race of bearing (5) until the bearing (5) is
against the shoulder of gear (4). Remove any
NOTICE excess sealant.
c. Apply a small continuous bead of Tooling (B) to
Contaminants may cause rapid wear and shortened inner surface (Z) of bearing (3). Place the inner
component life. race of bearing (3) onto a suitable support.
Press the shaft of gear (4) into bearing (3) until
the shoulder of the gear is against the bearing.
Remove any excess sealant.
d. Apply a small continuous bead of Tooling (B)

to the outer surface (Y) of bearings (3) and
(5). Place accessory drive housing (8) on a
suitable support. Press the assembly of the
gear into the accessory drive housing. Ensure
that bearing (5) is against the front face of the
recess in accessory drive housing (8). Remove
any excess sealant.
e. Install circlip (2) into the groove in accessory

drive housing (8). Ensure that circlip (2) is
correctly positioned in the groove.
KENR6247 65
2. Lightly lubricate a new O-ring seal (7) with Tooling 1. Loosen clamp (2) and remove hose (3) from
(C). Install the O-ring seal into the groove in breather tube (1). Withdraw hose (3) from clip (4)
accessory drive housing (8). and remove the hose.
3. Inspect the bore in the front housing for damage.

If necessary, replace the front housing. Refer to
Disassembly and Assembly, “Housing (Front)
- Remove” and Disassembly and Assembly,
“Housing (Front) - Install”.
4. Lightly lubricate bearing (3), bearing (5), and

gear (4) with clean engine lubricating oil. Install
the assembly of the accessory drive to the front
housing. Ensure that the flange on the accessory
drive housing is flush with the front housing.
5. Apply Tooling (D) to allen head screws (1) and (6).

Install allen head screws (1) and (6) to accessory g01346677
drive housing (8). Illustration 122
6. Tighten the allen head screws to a torque of 2. Remove bolt (6) and remove breather tube (1)
22 N·m (16 lb ft). from valve mechanism cover (5).
7. Ensure that there is tactile backlash between the 3. Remove O-ring seal (7) from breather tube(1).
idler gear and the accessory drive gear.
Disassembly Procedure
i02628816
Crankcase Breather - Remove

and Install Personal injury can result from parts and/or cov-
ers under spring pressure.
(Turbocharged Engines with
Unfiltered Breather) Spring force will be released when covers are re-
moved.
Be prepared to hold spring loaded covers as the

bolts are loosened.
Removal Procedure
NOTICE

component life.
g01347094
Illustration 121
g01343996 Illustration 123
Typical example
66 KENR6247
1. Remove plastic cover (8) from valve mechanism 4. Use Tooling (A) to tighten screws (9) to a torque of
cover (5). 1.3 N·m (12 lb in).
2. Remove screws (9). Remove plate (10). 5. Install plastic cover (8) to valve mechanism cover
(5).
3. Remove assembly of diaphragm (11) and the cap
(12). Remove spring (13).
Assembly Procedure NOTICE
Table 38
Required Tools Contaminants may cause rapid wear and shortened
component life.
Part
Tool Part Name Qty
Number
A 27610296 Torque Wrench 1
Personal injury can result from parts and/or cov-

Spring force will be released when covers are re-

moved.

bolts are loosened.
g01346677
Illustration 125
1. Install a new O-ring seal (7) to breather tube(1).
2. Install breather tube (1) to valve mechanism cover

(5). Install bolt (6) and tighten the bolt to a torque
of 9 N·m (80 lb in).
g01347094
Illustration 124 g01343996
Illustration 126
1. Ensure that all components of the crankcase Typical example
breather are clean and free from damage. Replace
any components that are damaged. 3. Connect hose (3) to breather tube (1). Tighten
clamp (2). Install hose (3) into clip (4).
2. Install spring (13). Install assembly of diaphragm
(11) and cap (12).
3. Position plate (10) on valve mechanism cover (5)

and install screws (9).
KENR6247 67
i02628815 1. Remove canister (10). Refer to Operation and

Maintenance Manual, “Crankcase Breather
Crankcase Breather - Remove (Canister) - Replace”.
and Install
2. Release spring clamps (8) and remove hose (9).
(Turbocharged Engines with
Filtered Breather) 3. Release spring clamps (2) in order to remove
hose (3). Remove the hose from breather tube (1)
and from filter base (5).
4. Remove bolts (6) and remove filter base (5).

Removal Procedure
5. If necessary, remove bolts (7) and remove bracket
NOTICE (4) from cylinder head.
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.

mandates.
NOTICE

component life. Illustration 128
g01368677
6. Remove bolt (12) and remove breather tube (1)

from valve mechanism cover (11).
7. Remove O-ring seal (13) from breather tube (1).


moved.

bolts are loosened.
g01368198
Illustration 127
Typical example
68 KENR6247
g01368678 g01368678
1. Remove plastic cover (14) from valve mechanism 1. Ensure that all components of the crankcase
cover (11). breather are clean and free from damage. Replace
any components that are damaged.
2. Remove screws (15). Remove plate (16).
3. Remove assembly of diaphragm (17) and the cap (17) and cap (18).
(18). Remove spring (19).
3. Position plate (16) on valve mechanism cover (11)
and install screws (15).
Assembly Procedure
Table 39 4. Use Tooling (A) to tighten screws (15) to a torque
of 1.3 N·m (12 lb in).
Required Tools
Part 5. Install plastic cover (14) to valve mechanism cover
Tool Part Name Qty (11).
Number
NOTICE
ers under spring pressure. Contaminants may cause rapid wear and shortened
component life.
moved.

bolts are loosened.
KENR6247 69
7. Install spring clamps (2) to hose (3). Install hose

(3) to connection (1) on the valve mechanism
cover and to filter base (4).
Note: Ensure that the spring clamps are correctly

positioned in order to secure the hose.
8. Install spring clamp (8) to hose (9). Install hose

(9) to filter base (5).
9. Install a new canister (10) to filter base (5).

“Crankcase Breather (Canister) - Replace”.
g01368677
Illustration 131 i02681626
1. Install a new O-ring seal (13) to breather tube (1). Crankcase Breather - Remove
and Install
(11). Install bolt (12) and tighten the bolt to a (Naturally Aspirated Engines)
torque of 9 N·m (80 lb in).
Removal Procedure
NOTICE

component life.
g01368198
Illustration 132
Typical example
3. If necessary, install bracket (4). Position bracket Illustration 133

g01368193
(4) onto cylinder head and install bolts (7). Tighten Typical example
the bolts to a torque of 22 N·m (16 lb ft).
1. Remove bolts (2) and remove breather tube (4)
4. Install bolts (6) to filter base (5). from valve mechanism cover (1).
5. Install the assembly of the filter base to the engine. 2. Remove O-ring seal (3) and seal (5) from breather
tube(4).
70 KENR6247
ers under spring pressure. Spring force will be released when covers are re-
moved.
moved. Be prepared to hold spring loaded covers as the
bolts are loosened.
bolts are loosened.
g01347463
Illustration 135
Typical example
g01347463
Illustration 134
Typical example 1. Ensure that all components of the crankcase
breather are clean and free from damage. Replace
1. Remove plastic cover (6) from valve mechanism any components that are damaged.
cover (1).
2. Remove screws (7). Remove plate (8). (10) and cap (9).
3. Remove assembly of diaphragm (9) and the cap 3. Position plate (8) on valve mechanism cover (1)
(10). Remove spring (11). and install screws (7).
4. Use Tooling (A) to tighten screws (7) to a torque of

Assembly Procedure 1.3 N·m (12 lb in).
Table 40
5. Install plastic cover (6) to valve mechanism cover
Required Tools (1).
Part
Tool Part Name Qty
Number Installation Procedure
NOTICE

component life.
KENR6247 71
1. If the engine is equipped with a cover for the fuel

injectors, remove the cover for the fuel injectors.
Refer to Disassembly and Assembly, “Fuel
Injector Cover - Remove and Install”.
2. If the engine is equipped with a heat shield,

remove the heat shield.
g01368193
Illustration 136
Typical example
1. Install new O-ring seals (3) and (5) to breather

tube(4).

g01368184
(1). Install bolts (2) and tighten the bolt to a torque Illustration 137
of 9 N·m (80 lb in). Typical example
3. Remove breather tube (2) from valve mechanism

i02628915
cover (1). Refer to Disassembly and Assembly,
Valve Mechanism Cover - “Crankcase Breather - Remove and Install”.
Remove and Install 4. Loosen captive bolts (3). Remove valve

mechanism cover (1).
5. Remove captive bolts (3) and remove joint (4) (not

Removal Procedure shown) from valve mechanism cover (1).
NOTICE

component life.
NOTICE

mandates.
72 KENR6247
Installation Procedure 6. Tighten the captive bolts for the valve mechanism
cover in the sequence that is shown in Illustration
139. Tighten the captive bolts to a torque of 9 N·m
(80 lb in).
7. Install breather tube (3) to valve mechanism

cover (1). Refer to Disassembly and Assembly,
“Crankcase Breather - Remove and Install”.
8. If the engine is equipped with a heat shield, install

the heat shield.
9. If the engine is equipped with a cover for the fuel

injectors, install the cover for the fuel injectors.
Refer to Disassembly and Assembly, “Fuel
Injector Cover - Remove and Install”.
i02628906
Rocker Shaft and Pushrod -

Remove
g01368184
Illustration 138
Typical example
1. Thoroughly clean valve mechanism cover (1). Removal Procedure

Ensure that the groove for the joint in the valve
mechanism cover is clean and dry. Ensure that Table 41
the mating surface on the cylinder head is clean Required Tools
and dry.
Part
Number
2. Check the condition of captive bolts (3). If
necessary, replace the captive bolts. A - E10 Torx Socket 1
B 27610227 Rocker Assembly Tool 4
3. Install a new joint (4) to valve mechanism cover
(1). Ensure that the joint is seated correctly in the
groove in the valve mechanism cover. Start By:
4. Install captive bolts (3) to valve mechanism cover a. Remove the valve mechanism cover. Refer to
(1). Disassembly and Assembly, “Valve Mechanism
5. Position valve mechanism cover (1) onto the
cylinder head. NOTICE

component life.
g01344009
Illustration 139
Sequence for tightening the isolating bolts
KENR6247 73
g01323013 g01359104
1. Use Tooling (A) to progressively loosen torx 5. Place an identification mark on pushrods (3) in
screws (1). Begin at the ends of the rocker shaft order to show the location. Remove the pushrods
assembly and work toward the center. from the cylinder head.
Note: To avoid distortion of the rocker shaft assembly, Note: Identification will ensure that the pushrods
each torx screw should be loosened by a quarter of a can be reinstalled in the original positions. Do not
turn at one time. Repeat the procedure until all torx interchange the positions of used pushrods.
screws are loosened.
i02628903
2. Remove torx screws (1) from rocker shaft
assembly (2). Rocker Shaft - Disassemble
3. If the rocker shaft will not be disassembled, install
Tooling (B) between each pair of rocker arms.
4. Remove rocker shaft assembly (2) from the Disassembly Procedure

cylinder head.
Table 42
Required Tools
Part
Number
A - Circlip Pliers 1
Start By:
a. Remove the rocker shaft assembly. Refer to

Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
NOTICE

component life.
74 KENR6247
6. If necessary, remove nuts (8) and adjusters

(9) from the rocker arms. Make a temporary
identification mark on each adjuster in order to
show the location.
Note: The components must be reinstalled in the
original location. Do not interchange components.
ment.
Follow the recommended procedure and use all i02628901

Rocker Shaft - Assemble
1. Make an identification mark on each rocker arm
assembly in order to show the location.
Note: The components must be reinstalled in the Assembly Procedure

original location. Do not interchange components.
Table 43
Required Tools
Part
Number
NOTICE

component life.

from wear or damage. Refer to Specifications,
“Rocker Shaft” for more information. If necessary,
replace any components that are worn or
damaged.
g01350909
Illustration 142
Typical example
2. Use Tooling (A) to remove circlip (1) and remove

washer (2) from both ends of the rocker shaft
assembly.
Note: The rocker shaft (7) is not symmetrical as there

is a machined flat (6) toward one end of the shaft.
3. Remove rocker arm assembly (3) for the inlet

valve from rocker shaft (7). Remove rocker arm
assembly (4) for the exhaust valve from rocker
shaft (7).
4. Remove spring (5) from rocker shaft (7).
5. Repeat Step3 and Step4 in order to completely

disassemble the rocker shaft assembly.
g01350909
Illustration 143
Typical example
KENR6247 75
2. If necessary, install adjusters (9) and nuts (8) to

rocker arm assemblies (3) and (4). If the original NOTICE
adjusters are reused, ensure that the adjusters Keep all parts clean from contaminants.
are installed in the original positions.
3. Use Tooling (A) to install circlip (1) and washer (2) component life.
to the front end of rocker shaft (7).
4. Lubricate the bores of rocker arm assemblies (3) 1. Clean the pushrods. Inspect the pushrods for
and (4) and rocker shaft (7) with clean engine oil. wear or damage. Replace any pushrods that are
worn or damaged.
5. Install rocker arm assembly (3) for number 1
cylinder inlet valves to the rocker shaft. Install
rocker arm assembly (4) for number 1 cylinder
exhaust valves to rocker shaft (7).


ment.
6. Install spring (5) to rocker shaft (7).
7. Repeat Steps 5 to 6 in order to assemble the

remaining components to rocker shaft (7).
8. Install washer (2) to rocker shaft (7). Use Tooling

(A) to install circlip (1). Illustration 144
g01359104
Typical example
End By:
2. Apply clean engine lubricating oil to both ends of
a. Install the rocker shaft assembly. Refer to pushrods (3). Install the pushrods to the engine
Disassembly and Assembly, “Rocker Shaft and with the cup upward.
Pushrod - Install”.
Note: Ensure that the pushrods are installed in the
i02628904
original location and that the ball end of each pushrod
is correctly seated in the valve lifters.
Rocker Shaft and Pushrod -
3. Ensure that the rocker shaft assembly is clean
Install and free from wear or damage.
4. If the rocker shaft assembly was disassembled,

install Tooling (B) between each pair of rocker
Installation Procedure arms.
Table 44
Required Tools
Part
Number
B 27610227 Rocker Assembly Tool 4
76 KENR6247
8. Use Tooling (A) to progressively tighten torx

screws (1). Begin at the center of the rocker shaft
assembly and work toward the ends.
Note: To avoid distortion of the rocker shaft assembly,

each torx screw should be tightened by a quarter of a
turn at one time. Repeat the procedure until all torx
screws are tightened.
Tighten torx screws (1) to a torque of 35 N·m

(26 lb ft).
9. Check the valve lash. Refer to Systems Operation,

Testing and Adjusting, “Engine Valve Lash -
Inspect/Adjust”. If necessary, adjust the valve
lash. Refer to Systems Operation, Testing and
Adjusting, “Engine Valve Lash - Inspect/Adjust” for
End By:
Illustration 145
g01323445 a. Install the valve mechanism cover. Refer to
Typical example
5. Ensure that the machined flat (X) is facing upward,
and facing the front end of the engine. i02628830
6. Position rocker shaft assembly (2) onto the Cylinder Head - Remove
cylinder head.
Note: Ensure that adjustment screws are properly

seated in the ends of pushrods (3). Removal Procedure
7. Install torx screws (1) to the rocker shaft assembly Start By:
finger tight.
a. Remove the exhaust manifold. Refer to
Disassembly and Assembly, “Exhaust Manifold
b. Remove the injectors. Refer to Disassembly and

Assembly, “Injector - Remove”.
c. Remove the rocker shaft assembly and the

pushrods. Refer to this Disassembly and
Assembly Manual, “Rocker Shaft and Pushrod -
Remove”.
d. Remove the glow plugs. Refer to Disassembly

and Assembly, “Glow Plugs - Remove and Install”.
NOTICE

component life.
g01323447
Illustration 146
Typical example
KENR6247 77
6. Disconnect the harness assembly from sensor (1).

NOTICE
Care must be taken to ensure that fluids are contained 7. Remove the bolts (2). Remove the bypass tube
during performance of inspection, maintenance, test- (3) from the cylinder head. Remove O-ring seals
ing, adjusting and repair of the product. Be prepared to (4) and (5).

mandates.

hose assemblies, on wires and on all tube assemblies
and tube assemblies. This helps to prevent fluid loss
and this helps to keep contaminants from entering
the system.
1. If the alternator bracket is mounted on the cylinder

head, remove the alternator. Refer to Disassembly
and Assembly, “ Alternator - Remove”.
2. If the fuel priming pump and the fuel filter base are
mounted on the cylinder head, remove the fuel
priming pump and the fuel filter base. Refer to
g01323622
Disassembly and Assembly, “Fuel Priming Pump Illustration 148
and Fuel Filter Base - Remove and Install”. Typical example
3. Drain the coolant from the cooling system into

draining procedure.
4. Disconnect the upper radiator hose from the water

temperature regulator housing.
5. If necessary, remove the air hose from the inlet

connection.
g01352264
Illustration 149
Sequence for tightening the bolts for the cylinder head
8. Gradually loosen bolts (6) in the reverse numerical

order to the sequence that is shown in Illustration
149.
Note: Follow the correct sequence in order to help

prevent distortion of the cylinder head.
9. Remove bolts (6) from cylinder head (7).

g01344073
Illustration 147
78 KENR6247
Note: The bolts are two different lengths. Note the

positions of the different bolts.
g01323639
Illustration 151
Typical example
12. Remove cylinder head gasket (10).
13. Note the position of dowels (9) in the cylinder

block. Do not remove the dowels unless the
dowels are damaged.
g01323631
Illustration 150
14. If necessary, remove the sensor from cylinder
Typical example head.
10. Attach a suitable lifting device (8) to cylinder head 15. If necessary, remove the water temperature
(7). Support the weight of the cylinder head. The regulator from the cylinder head. Refer to
weight of the cylinder head is approximately 56 kg Disassembly and Assembly, “Water Temperature
(124 lb). Regulator - Remove and Install”.
Note: It is advisable to use a spreader bar during the
lifting operation in order to distribute the weight of i02628829
the cylinder head .
Cylinder Head - Install
11. Use lifting device (8) to carefully lift cylinder head
(7) off the cylinder block.
Note: Do not use a lever to separate the cylinder Installation Procedure

head from the cylinder block. Take care not to
damage the machined surfaces of the cylinder head Table 45
during the removal procedure. Required Tools
Part
NOTICE Tool Part Description Qty
Number
Place the cylinder head on a surface that will not
scratch the face of the cylinder head. - Guide Bolt
A 2
(M16 by 115mm)
B - Straight Edge 1
C 21825607 Degree Wheel 1
POWERPART
D 21820221 1
Rubber Grease
NOTICE

component life.
KENR6247 79
1. Thoroughly clean the mating surfaces of the

cylinder head and the cylinder block. Do not
damage the mating surfaces of the cylinder head
or the cylinder block. Ensure that no debris enters
the cylinder bores, the coolant passages, or the
lubricant passages.
2. Inspect the mating surface of the cylinder head for

distortion. Refer to Specifications, “Cylinder Head”
g01323631
Illustration 153
Typical example
6. Use a suitable lifting device (8) to lift the

cylinder head. The weight of the cylinder head is
Note: It is advisable to use a spreader bar during

the lifting operation in order to distribute the weight
of the cylinder head.
g01324063
Illustration 152
Typical example 7. Use Tooling (A) to align cylinder head (7) with
the cylinder block. Install the cylinder head to the
3. Inspect dowels (9) for damage. If necessary, cylinder block.
replace the dowels in the cylinder block.
Note: Ensure that the cylinder head is correctly
4. Install Tooling (A) to the cylinder block. Refer to positioned onto dowels (9).
Illustration 152.
5. Align cylinder head gasket (10) with Tooling (A)

and with dowels (9). Install the cylinder head
gasket onto the cylinder block.
g01324064
Illustration 154
8. Clean bolts (6). Follow Steps 8.a and 8.b for the
procedure to inspect the bolts.
a. Check the length of the bolts.

80 KENR6247
b. Use Tooling (B) in order to check the threads of

the bolts. Refer to Illustration 154. Replace any
bolts that show visual reduction in the diameter
of the thread over length (Y).
9. Lubricate the threads and the shoulder of bolts

(6) with clean engine oil.
g01352369
Illustration 157
(A) Short bolts
(B) Long bolts
14. Use Tooling (C) to turn bolts (6) through an

additional angle in the sequence that is shown in
Illustration 156.
Turn the long bolts through 270 degrees.
Turn the short bolts through 225 degrees.
g01323622
Illustration 155
11. Install bolts (6) to cylinder head (7).
Note: There are two different lengths of bolts (6) for

cylinder head (7). Install longer bolts in position (X)
in the cylinder head.
g01344073
Illustration 158
15. Install new O-ring seals (4) and (5) to bypass tube
(3). Use Tooling (D) in order to lubricate the O-ring
seal (5). Install the bypass tube to the cylinder
g01352300
Illustration 156 head. Install bolts (2). Ensure that any brackets
Sequence for tightening the bolts for cylinder head that are secured by the bolts are installed in the
correct position. Tighten the bolts to a torque of
12. Tighten bolts (6) to a torque of 50 N·m (37 lb ft) in 22 N·m (16 lb ft).
the sequence that is shown in Illustration 156.
16. Connect the harness assembly to sensor (1).
13. Tighten bolts (6) to a torque of 100 N·m (74 lb ft)
in the sequence that is shown in Illustration 156.
KENR6247 81
17. If the alternator bracket is mounted on the cylinder Start By:

head, Install the alternator. Refer to Disassembly
and Assembly, “ Alternator - Remove”. a. If the engine is equipped with a balancer, remove
18. Install the injectors. Refer to Disassembly and “Balancer - Remove”. If the engine is not equipped
Assembly, “Injector - Install”. with a balancer, remove the engine oil pump.
Refer to Disassembly and Assembly, “Engine Oil
19. Install the glow plugs. Refer to Disassembly and Pump - Remove”.
Assembly, “Glow Plugs - Remove and Install”.
b. Remove the camshaft. Refer to Disassembly and
20. If the fuel priming pump and the fuel filter base Assembly, “Camshaft - Remove and Install”.
are mounted on the cylinder head, install the fuel
priming pump and the fuel filter base. Refer to NOTICE
Disassembly and Assembly, “Fuel Priming Pump Keep all parts clean from contaminants.
and Fuel Filter Base - Remove and Install”.
21. Install the exhaust manifold. Refer to Disassembly component life.
and Assembly, “Exhaust Manifold - Remove and
Install”.
1. If the crankshaft is installed, use Tooling (A) to
22. If necessary, install the air hose to the inlet rotate the crankshaft in order to gain access to
connection. lifters (1).
23. If necessary, install the water temperature

regulator housing to the cylinder head. Refer to
Disassembly and Assembly, “Water Temperature
Regulator Housing - Remove and Install”.
24. Connect the upper radiator hose to the water

temperature regulator housing .
25. Fill the cooling system with coolant. Refer to

System Coolant - Change” for the correct filling
procedure.
26. If necessary, fill the engine oil pan to the correct

g01340518
level. Refer to Operation and Maintenance Illustration 159
Manual, “Engine Oil Level - Check”. Typical example
2. Use Tooling (B) in order to remove lifters (1).

i02628895
Lifter Group - Remove and Note: Make a temporary identification mark on each
lifter in order to identify the correct location.
Install
3. Repeat Steps 1 and 2 in order to remove the
remaining lifters.
Removal Procedure Installation Procedure

Table 46 Table 47
Required Tools Required Tools
Tool Part Part Description Qty Tool Part Part Description Qty
Number Number
A 21825576 Crankshaft Turning Tool 1 A 21825576 Crankshaft Turning Tool 1
B - Telescopic Magnet 1 B - Telescopic Magnet 1
82 KENR6247
End By:
NOTICE
Keep all parts clean from contaminants. a. Install the camshaft. Refer to Disassembly and
Assembly, “Camshaft - Remove and Install”.
component life. b. If the engine is equipped with a balancer, install
“Balancer - Install”. If the engine is not equipped
NOTICE with a balancer, install the engine oil pump. Refer
It is strongly recommended that all lifters should be to Disassembly and Assembly, “Engine Oil Pump
replaced when a new camshaft is installed. - Install”.
1. Clean the lifters. Follow Steps 1.a through 1.c in i02628809

order to inspect the lifters. Replace lifters that are
worn or damaged. Camshaft - Remove and Install
a. Inspect the seat of the pushrod in the lifter for
visual wear or damage.
Removal Procedure
b. Inspect the shank of the lifter for wear or
damage. Refer to Specifications, “Lifter Group” Start By:
a. Remove the rockershaft and pushrods. Refer to
c. Inspect the face of the lifter that runs on the Disassembly and Assembly, “Rocker shaft and
camshaft for visual wear or damage. Pushrod - Remove”.
2. If the crankshaft is installed, use Tooling (A) to b. Remove the front housing. Refer to Disassembly
rotate the crankshaft. Rotate the crankshaft to and Assembly, “Housing (Front) - Remove”.
access to the cylinder block in order to install
lifters (1).
NOTICE
3. Lubricate lifters (1) with clean engine oil. Keep all parts clean from contaminants.

component life.
1. The engine should be mounted on a suitable

stand and placed in the inverted position.
g01340518
Illustration 160
Typical example
4. Use Tooling (B) to install lifters (1) to the cylinder

block. Ensure that used lifters are installed in the
correct location.
g01266056
Illustration 161
Note: The lifters should be free to rotate. Typical example
5. Repeat Steps 1 and 4 in order to install the 2. Remove thrust washer (1) from the cylinder block.
remaining lifters. Do not remove dowel (2) from the cylinder block
unless the dowel is damaged.
KENR6247 83
Note: The thrust washer can have one or two slots

(X).
g01266057
Illustration 163
Illustration 162
g01266057 4. If necessary, install a new key (4) to camshaft (3).
5. Lubricate the bearing surfaces of camshaft (3)

NOTICE
and lubricate the lobes of the camshaft with clean
Do not damage the lobes or the bearings when the
engine oil.
camshaft is removed or installed.
NOTICE
3. Carefully remove camshaft (3) from the cylinder
Do not damage the lobes or the bearings when the
block.
camshaft is removed or installed.
4. Do not remove key (4) from camshaft (3) unless
the key is damaged. 6. Carefully install camshaft (3) into the cylinder
block.
NOTICE

component life.
1. Clean the camshaft and the thrust washer. Inspect

the camshaft and the thrust washer for wear and
for damage. Refer to Specifications, “Camshaft”
for more information. Replace any components
that are worn or damaged.
g01266056
Illustration 164
2. Clean the camshaft bearing in the cylinder
Typical example
block. Inspect the camshaft bearing for wear
and for damage. Refer to Specifications,
“Camshaft Bearings” for more information. If 7. Lubricate the thrust washer with clean engine oil.
necessary, replace the camshaft bearing. Refer to Align slot (X) in thrust washer (1) with dowel (2) in
Disassembly and Assembly, “Camshaft Bearing the cylinder block. Install thrust washer (1) into the
- Remove and Install”. recess in the cylinder block.
Note: The thrust washer can have one or two slots.

NOTICE
It is strongly recommended that all lifters should be End By:
replaced when a new camshaft is installed.
a. Install the front housing. Refer to Disassembly and
3. Inspect the lifters for wear and for damage. Assembly, “Housing (Front) - Install”.
Refer to Specifications, “Lifter Group” for more
information. Replace any worn lifters or any b. Install the rockershaft and pushrods. Refer to
damaged lifters. Refer to Disassembly and Disassembly and Assembly, “Rocker shaft and
Assembly, “Lifter Group - Remove and install”. Pushrod - Install”.
84 KENR6247
i02628811
Camshaft Gear - Remove and

Install
Removal Procedure
Table 48
Required Tools
A1 21825576 Crankshaft Turning Tool 1 g01255712
Illustration 165
27610291 Barring Device Housing 1 Typical example
A2
27610289 Gear 1
B 27610212 Camshaft Timing Pin 1 gear (1) into the front housing. Use Tooling (B) in
C 27610211 Crankshaft Timing Pin 1 order to lock the camshaft in the correct position.
3. Install Tooling (C) into hole (Y) in the front housing.

Start By: Use Tooling (C) in order to lock the crankshaft in
the correct position.
a. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, “Valve Mechanism Note: Do not use excessive force to install Tooling
Cover - Remove and Install”. (C). Do not use Tooling (C) to hold the crankshaft
during repairs.
b. Remove the front cover. Refer to Disassembly and

NOTICE

component life.
NOTICE

g01350327
mandates. Illustration 166
Typical example
that number one piston is at the top center position 4. Loosen nuts (6) on ALL rocker arms (7). Unscrew
on the compression stroke. Refer to Systems adjusters (5) on all rocker arms (7) until all valves
Operation, Testing and Adjusting, “Finding Top are fully closed.
Note: Failure to ensure that all adjusters are fully
and pistons.
KENR6247 85
Table 49
Required Tools
Part
Tool Part Name Qty
Number
D
- Finger Clock 1
Illustration 167
g01344527 NOTICE

5. Mark gears (1) and (4) in order to show alignment.
component life.
Refer to Illustration 167.
Note: Identification will ensure that the gears can be 1. Ensure that number one piston is at the top center
installed in the original alignment. position on the compression stroke. Refer to
g01340554
Illustration 168
Typical example
g01255712
Illustration 169
6. Remove Tooling (B) and Tooling (C). Remove bolt Typical example
(3) and washer (2) from camshaft gear (1).
2. Install Tooling (C) into hole (Y) in the cylinder block.
7. Remove camshaft gear (1) from the camshaft. Use Tooling (C) in order to lock the crankshaft in
the correct position. Refer to Systems Operation,
Note: If the camshaft gear is a tight fit on the nose Testing and Adjusting, “Finding Top Centre
of the camshaft, use a prybar in order to remove the Position for No.1 Piston”.
camshaft gear.
3. Ensure that the camshaft gear and the key are
8. If necessary, remove the key from the nose of clean and free from wear or damage.
the camshaft.
4. If necessary, install the key into the nose of the
camshaft.
Note: Ensure that the key is squarely seated.

86 KENR6247
12. Adjust the valve lash. Refer to Systems Operation,

Testing and Adjusting, “Engine Valve Lash -
Inspect/Adjust”.
End By:

b. Install the valve mechanism cover. Refer to

i02628810
g01344527
Illustration 170
Camshaft Bearings - Remove
and Install
5. Align the keyway in camshaft gear (1) with the key
in the camshaft. Install the camshaft gear onto the
camshaft. Ensure that the timing marks on gears
(1) and (8) are in alignment and that the mesh of
the gears is correct. Refer to Illustration 170.
Removal Procedure
Table 50
Required Tools
Part
A 27610275 Bearing Puller Group 1
Start By:
a. If the engine is equipped with a balancer, remove

“Balancer - Remove”. If the engine is not equipped
with a balancer, remove the engine oil pump.
g01340554
Illustration 171 Pump - Remove”.
Typical example
b. Remove the camshaft. Refer to Disassembly and
6. Install Tooling (B) through hole (X) in the camshaft Assembly, “Camshaft - Remove and Install”.
gear into the front housing. Install washer (2) and
bolt (3) to camshaft gear (1). NOTICE
8. Tighten bolt (3) to a torque of 95 N·m (70 lb ft). component life.
9. Use Tooling (D) to check the backlash for gears (1)
and (8). Ensure that the backlash for the gears is
within specified values. Refer to the Specifications,
“Gear Group (Front)” for further information.
10. Use Tooling (D) to check the end play for

camshaft gear (1). Ensure that the end play is
within specified values. Refer to the Specifications,
“Camshaft” for further information.
11. Lubricate the teeth of the gears with clean engine

oil.
KENR6247 87
2. Lubricate the bearing housing in the cylinder block

with clean engine oil.
3. Accurately align the two oil holes (X) in camshaft

bearing (1) with the two oil holes in the cylinder
block.
Note: The groove (Y) in the camshaft bearing must

be to the top of the cylinder block.
4. Use Tooling (A) in order to install camshaft bearing

(1) into the cylinder block. Install the camshaft
bearing so that the front edge of the bearing is
flush with the face of the recess in the cylinder
g01270437
block.
Illustration 172
Note: Ensure that all oil holes are correctly aligned.
1. Inspect camshaft bearing (1). Refer to If the oils are not correctly aligned, the camshaft
Specifications, “Camshaft Bearings” for more bearing should be removed.
information.
End By:
2. If camshaft bearing (1) is worn or damaged use
Tooling (A) in order to remove the camshaft a. Install the camshaft. Refer to Disassembly and
bearing from the cylinder block. Assembly, “Camshaft - Remove and Install”.
Note: Remove the camshaft bearing from the front of b. If the engine is equipped with a balancer, install
the cylinder block. the balancer. Refer to Disassembly and Assembly,
Installation Procedure with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, “Engine Oil Pump
Table 51 - Install”.
Required Tools
Part i02628836
Engine Oil Pan - Remove and
A 27610271 Bearing Puller Group 1
Install
NOTICE
(Aluminum and Pressed Steel
Keep all parts clean from contaminants. Oil Pans)
component life.
Removal Procedure
1. Clean the bearing housing in the cylinder block.
Ensure that the oil holes in the bearing housing NOTICE
are free from debris. Keep all parts clean from contaminants.

component life.
NOTICE

g01266512
mandates.
Illustration 173
88 KENR6247
2. Remove O-ring seal (11) from drain plug (5).
3. Disconnect breather hose (1) from clip (6).

Position the breather hose away from the engine
oil pan.
4. If necessary, remove the assembly of dipstick

tube. Loosen nut (3) and remove tube assembly
(2). Remove seal (4) from the tube assembly.
Note: Identify the position and orientation of the tube

assembly.
5. Support the assembly of the engine oil pan.

Mark the position of clip (6). Loosen the bolt that
secures the clip and remove the clip.
6. Remove bolts (9) and (10).
7. Remove engine oil pan (8) and remove joint (7)

g01344541
Illustration 174
Typical example Installation Procedure
1. Place a suitable container below the engine Table 52
oil pan. Remove drain plug (5) and drain the Required Tools
engine lubricating oil. Refer to Operation and
Maintenance Manual, “Engine Oil and Filter - Part
Change” for the correct procedure. Tool Number Part Description Qty
- Guide Stud
A 4
(M8 by 100 mm)
POWERPART -
B 21826038
Silicon Rubber Sealant
POWERPART -
C 21820117
NOTICE

component life.
1. Ensure that the mating surface of the cylinder

block is clean and free from damage.
g01251767
Illustration 175
Typical example
KENR6247 89
g01251766
Illustration 178
Typical example
4. Apply a bead of Tooling (B) to positions (Y) on the

cylinder block.
Illustration 176
g01251768 Note: If the bridge piece for the cylinder block has
just been installed, the engine oil pan must be
Typical example
installed before Tooling (B) has cured.
2. Install Tooling (A) to positions (X) in the cylinder
block.
3. Ensure that the engine oil pan is clean and free

from damage.
g01251763
Illustration 177
Typical example
g01251767
Illustration 179
Typical example
5. Position a new joint (7) onto engine oil pan (8).

90 KENR6247
i02628835
Engine Oil Pan - Remove and

Install
(Cast Iron Oil Pan)
Removal Procedure
Note: In order to remove a cast iron oil pan, the
engine must be removed from the machine. Ensure
that the engine lubricating oil is drained. Refer to
Operation and Maintenance Manual, “Engine Oil and
Filter - Change” for the correct procedure.
NOTICE
g01344541 Contaminants may cause rapid wear and shortened

Illustration 180
component life.
Typical example
6. Align the assembly of the engine oil pan with NOTICE

Tooling (A). Install the assembly of the engine oil Care must be taken to ensure that fluids are contained
pan to the cylinder block. during performance of inspection, maintenance, test-
7. Install bolts (9) finger tight. Install clip (6) in the collect the fluid with suitable containers before open-
correct position. ing any compartment or disassembling any compo-
9. Apply Tooling (C) to bolts (10). Install bolts (10) mandates.
and the remaining bolts (9).
1. The engine should be mounted in a suitable stand
10. Tighten bolts (9) and (10) to a torque of 22 N·m
and placed in the inverted position.
(16 lb ft).
11. Install a new O-ring seal (11) to drain plug (5).

Install the drain plug to engine oil pan (8). Tighten
the oil drain plug to a torque of 34 N·m (25 lb ft).
12. If necessary, follow Steps 12.a through 12.c in

order to install the assembly of the dipstick tube.
a. Install a new seal (4) to tube assembly (2).
b. Apply Tooling (C) to nut (3). Install the tube

assembly to the engine oil pan.
Note: Ensure that the orientation of the tube

assembly is correct.
c. Tighten nut (3) to a torque of 18 N·m (13 lb ft).

Install the dipstick.
13. Fill the engine oil pan to the correct level. Refer to
Operation and Maintenance Manual, “Engine Oil
and Filter - Change” for the procedure.
KENR6247 91
g01344541
Illustration 181
Typical example
2. Disconnect breather hose (1) from clip (6).

Position the breather hose away from the engine
oil pan.
g01251978
Illustration 182
Note: Identify the position and orientation of the tube
Typical example
assembly before removal.
3. Remove the assembly of the dipstick tube. Loosen 4. Mark the position of clip (6). Refer to Illustration
nut (3) and remove tube assembly (2). Remove 181. Loosen the bolt that secures the clip and
seal (4) from the tube assembly. remove the clip.
5. Remove nuts (10) and bolts (9).
Note: The bolts are different lengths. Note the

position of the different bolts.
6. Attach a suitable lifting device to engine oil pan

(8). Support the weight of the engine oil pan. The
engine oil pan weighs approximately 41 kg (90 lb).
7. Use the lifting device to remove engine oil pan (8)

8. Remove joint (7) from the cylinder block.
9. If necessary, remove drain plug (5). Remove

O-ring seal (11) from oil drain plug (5).
92 KENR6247
Table 53
Required Tools
Part
POWERPART -
A 21826038
POWERPART -
B 21820117
C - Straight Edge 1
Note: In order to install a cast iron oil pan, the engine Illustration 184
g01251766
must be removed from the machine. Typical example
NOTICE 3. Apply a bead of Tooling (A) to positions (Y) on the

Keep all parts clean from contaminants. cylinder block.
Contaminants may cause rapid wear and shortened Note: If the bridge piece for the cylinder block has
component life. just been installed, the engine oil pan must be
installed before Tooling (A) has cured.
1. Ensure that the mating surface of the cylinder
block is clean and free from damage. Inspect
the studs in the cylinder block for damage. If
necessary, replace the studs.
2. Ensure that the engine oil pan is clean and free

from damage.
g01251763
Illustration 183
Typical example
g01251978
Illustration 185
Typical example
4. Align a new joint (7) with the studs in the cylinder

block. Install the joint to the cylinder block.
5. Attach a suitable lifting device to engine oil pan

(8). The engine oil pan weighs approximately
41 kg (90 lb).
KENR6247 93
6. Use the lifting device to align engine oil pan (8) 11. Follow Steps 11.a through 11.c in order to install
with the studs in the cylinder block. Install the the assembly of the dipstick tube.
engine oil pan to the cylinder block. Remove the
lifting device from the engine oil pan. a. Install a new seal (4) to tube assembly (2).
7. Install bolts (9) and nuts (10) finger tight. Install b. Apply Tooling (B) to nut (3). Install the tube
the clip (6). assembly to the engine oil pan.
Note: Ensure that the orientation of the tube

assembly is correct.
c. Tighten the nut to a torque of 18 N·m (13 lb ft).

Install the dipstick .
12. Install breather hose (1) to clip (6).
Note: After the engine has been installed, ensure that

the engine oil pan is filled with lubricating oil to the
correct level. Refer to Operation and Maintenance
Manual, “Engine Oil and Filter - Change” for the
correct procedure.
g01251982
Illustration 186
i02628808
Typical example
Balancer - Remove
8. Align the rear face of engine oil pan (8) to the rear
face of cylinder block (12). Use Tooling (C) and
a feeler gauge in order to check the alignment
between the engine oil pan and the cylinder block.
Removal Procedure
9. Tighten bolts (9) and nuts (10) to a torque of
Table 54
22 N·m (16 lb ft).
Required Tools
10. If necessary, install a new O-ring seal (11) to drain Part
plug (5). Install drain plug (5) to engine oil pan Tool Part Name Qty
Number
(8). Tighten the drain plug to a torque of 34 N·m
(25 lb ft). A 21825576 Crankshaft Turning Tool 1
C 27610225 Timing Pin (Balancer) 1
D - Puller (Two Leg) 1
Start By:

Install”.
b. Remove the front cover. Refer to Disassembly

and Assembly, “Front Cover - Remove and Install”.
Note: In order to remove the balancer, the engine

must be removed from the machine. The engine
should be mounted in a suitable stand and placed
in the inverted position.
NOTICE
Illustration 187
g01344541 Keep all parts clean from contaminants.
Typical example
component life.
94 KENR6247
3. Remove bolts (3) and suction pipe (2).

NOTICE
Care must be taken to ensure that fluids are contained 4. Remove the joint from the suction pipe.

mandates.
1. Use Tooling (A) in order to rotate the crankshaft

so that number one piston is at the top center
position.
g01252310
Illustration 190
Typical example
5. Install Tooling (C) into balancer (1). Ensure that

Tooling (C) is engaged into the hole in drive shaft
(5).
6. Attach a suitable lifting device to balancer (1).

Support the weight of the balancer. The balancer
weighs approximately 23 kg (51 lb).
7. Remove bolts (4). Use the lifting device to remove

Illustration 188
g01259627 the balancer.
Typical example
2. Install Tooling (B) through hole (X) in the front

housing. Use Tooling (B) in order to lock the
crankshaft in the correct position.
g01259636
Illustration 191
8. Do not remove dowels (6) and (7) unless the

dowels are damaged.
Note: The balancer unit is not a serviceable item.

The engine oil pump and the engine oil relief valve
are the only serviceable parts of the balancer.
1. Remove the engine oil relief valve. Refer to
g01259635
Illustration 189 Disassembly and Assembly, “Engine Oil Relief
Typical example Valve - Remove and Install”.
KENR6247 95
i02628805
Balancer - Install
Assembly Procedure
Table 55
Required Tools
POWERPART
E 21820117 1
NOTICE

component life.
1. Ensure that all components of the engine oil pump

are clean and free from wear or damage.
g01344542
Illustration 192
2. Remove bolt (8) and hub (9). Remove idler gear

(10) and thrust washer (11).
g01259631
Illustration 193
3. Remove nut (12). Use Tooling (D) in order to

remove gear (13) from the shaft of the oil pump.
Note: Do not use a timing pin to lock the balancer in

g01344542
order to loosen nut (12). Illustration 194
Typical example
4. Remove bolts (14) and remove front cover (15).
5. Remove outer rotor (17) and remove inner rotor

(16).
Note: Mark the direction of rotation of the rotors.

96 KENR6247
2. Install inner rotor (16) and outer rotor (17). Used

rotors should be installed in the original direction
of rotation. Check the clearance between the outer
rotor and the body of the oil pump. Check the
clearance between the inner rotor and the outer
rotor. Check the end play of the rotor assembly.
Refer to Specifications, “Engine Oil Pump” for
more information.
3. Lubricate the assembly of the oil pump with clean

engine oil. Install front cover (15). Install bolts (14).
Tighten the bolts to a torque of 26 N·m (19 lb ft).
4. Ensure that the shaft of the oil pump is clean

and dry. Position gear (13) onto the shaft. Install g01259627
nut (12). Tighten the nut to a torque of 95 N·m Illustration 195
(70 lb ft).
1. Ensure that No. 1 piston is at the top center
Note: Do not use a timing pin to lock the balancer in position and that Tooling (B) is installed to position
order to tighten nut (12). (X) in the front housing.
5. Lubricate hub (9), thrust washer (11) and the bush 2. Clean the mating surfaces of the cylinder block.
of idler gear (10) with clean engine oil. Install hub
(9) and thrust washer (11) to idler gear (10).
Note: Ensure the correct orientation of the idler gear.
6. Install the assembly of the idler gear to balancer

(1).
7. Ensure that the threads of bolt (8) are clean and

dry. Apply Tooling (E) to the threads of the bolt.
Install bolt (8). Tighten the bolt to a torque of
26 N·m (19 lb ft).
8. Check the end play of idler gear (10). Refer to

Specifications, “Engine Oil Pump”. g01252312
Illustration 196
9. Install the engine oil relief valve . Refer to
Disassembly and Assembly, “Engine Oil Relief 3. Install Tooling (G) to the cylinder block.
Valve - Remove and Install” for further information.
Table 56
Required Tools
C 27610225 Timing Pin (Balancer) 1
F
- Finger Clock 1
g01260306
Guide Studs Illustration 197
G - 1
(M10 by 75 mm)
4. Ensure that dowels (6) and (7) are seated in the
housing of balancer (1).
KENR6247 97

22 N·m (16 lb ft).
13. Use Tooling (F) in order to check the backlash

between gears (10) and (13). Refer to Illustration
197. Refer to Specifications, “Engine Oil Pump”.
14. Use Tooling (F) in order to check the backlash

between gear (10) and the crankshaft gear. Refer
to Specifications, “Gear Group - Front” for further
information.
End By:
g01252310
Illustration 198 and Assembly , “Engine Oil Pan - Remove and
Install”.
5. Install Tooling (C) to balancer (1). Ensure that
Tooling (C) is engaged into shaft (5). b. Install the front cover. Refer to Disassembly and
6. Attach a suitable lifting device to the balancer. The
balancer weighs approximately 23 kg (51 lb).
i02628896
7. Use the lifting device to align balancer (1) with
Tooling (G). Install the balancer to the cylinder Piston Cooling Jets - Remove
block. Ensure that dowels (6) and (7) are aligned and Install
with the holes in the cylinder block. Ensure that
gear (10) and the crankshaft gear mesh. Remove
the lifting device.
Removal Procedure
Table 57
Required Tools
Number
A2
27610289 Gear 1
Start By:

Pump - Remove”.
g01259635
Illustration 199
8. Install bolts (4) to balancer (1) finger tight. that is most suitable.
9. Remove the Tooling (G) and install the remaining NOTICE

bolts (4). Tighten the bolts to a torque of 54 N·m Keep all parts clean from contaminants.
(40 lb ft).
10. Remove the Tooling (B) and (C). component life.
11. Install suction pipe (2) and a new joint to balancer

(1).
98 KENR6247
1. If the crankshaft is installed, use Tooling (A) to

rotate the crankshaft in order to gain access to the
piston cooling jet.
g01265615
Illustration 201
1. Clean the piston cooling jets and inspect the

Illustration 200
g01265615 piston cooling jets for damage. Ensure that the
Typical example
valve is free to move within each piston cooling
jet. Replace any damaged piston cooling jets.
2. Remove bolt (1) and piston cooling jet (2) from
the cylinder block. 2. If the crankshaft is installed, use Tooling (A)
to rotate the crankshaft in order to access the
3. Repeat Steps 1 and 2 for the remaining piston mounting flange for the piston cooling jet.
cooling jets.
3. Position piston cooling jet (2) in the cylinder block.
Install bolt (1). Tighten the bolt to a torque of
Installation Procedure 9 N·m (80 lb in).
Table 58 4. Repeat Steps 2 through 3 for the remaining piston
Required Tools cooling jets.
Tool Part Part Description Qty 5. If the cylinder head has been removed, It is
Number
possible to check the alignment of the piston
A1 21825576 Crankshaft Turning Tool 1 cooling jets. Refer to Specifications, “Piston
Cooling Jet Alignment” for more information.
A2
27610289 Gear 1 Note: It is not possible to check the alignment of the
piston cooling jets with the cylinder head in position.
End By:
a. If the engine is equipped with a balancer, install
NOTICE the balancer. Refer to Disassembly and Assembly,
Keep all parts clean from contaminants. “Balancer - Install”. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
Contaminants may cause rapid wear and shortened to Disassembly and Assembly, “Engine Oil Pump
component life. - Install”.
KENR6247 99
i02628900
Pistons and Connecting Rods

- Remove
Removal Procedure
Table 59
Required Tools
A2
27610289 Gear 1
B 27610274 Ridge Reamer 1
Start By: Illustration 202

g01344569
a. Remove the cylinder head. Refer to Disassembly 3. The connecting rod and the connecting rod cap
and Assembly , “Cylinder Head - Remove”. should have an etched number (X) on the side.
The number on the connecting rod and the
b. If the engine is equipped with a balancer, remove connecting rod cap must match. Ensure that the
the balancer. Refer to Disassembly and Assembly, connecting rod and connecting rod cap (2) are
“Balancer - Remove”. If the engine is not equipped marked for the correct location. If necessary, make
with a balancer, remove the engine oil pump. a temporary mark on the connecting rod and the
Refer to Disassembly and Assembly, “Engine Oil connecting rod cap in order to identify the cylinder
Pump - Remove”. number.
c. Remove the piston cooling jets. Refer to Note: Do not stamp the connecting rod assembly.
Disassembly and Assembly , “Piston Cooling Jets Stamping or punching the connecting rod assembly
- Remove and Install”. could cause the connecting rod to fracture.
Note: Either Tooling (A) can be used. Use the Tooling 4. Remove bolts (1) and remove connecting rod cap
that is most suitable. (2) from the connecting rod.
NOTICE

component life.
1. Use Tooling (A) to rotate the crankshaft until the

crank pin is at the bottom center position.
2. Use Tooling (B) to remove the carbon ridge from

the top inside surface of the cylinder bore.
g01244066
Illustration 203
Typical example
5. Carefully push piston (3) and the connecting rod

assembly out of the cylinder bore. Lift the piston
out of the top of the cylinder block.
Note: Do not push on the fracture split surfaces of

the connecting rod as damage may result.
100 KENR6247
6. Temporarily install connecting rod cap (2) and

bolts (1) to the connecting rod when the assembly
is out of the engine. Tighten bolts (1) to a torque
of 20 N·m (14 lb ft).
Note: Fracture split connecting rods should not be left

without the connecting rod caps installed. Ensure that
the etched number on connecting rod cap matches
the etched number on connecting rod. Ensure the
correct orientation of the connecting rod cap.
7. Repeat Steps 1 through 5 for the remaining

pistons and connecting rods.
i02628898

- Disassemble
Table 60
Required Tools
Part g01244067
Tool Number Part Description Qty Illustration 204
B - Piston Ring Expander 1
Start By:
a. Remove the pistons and the connecting rods.

Refer to Disassembly and Assembly, “Piston and
Connecting Rods - Remove”.
NOTICE

component life.
1. Make a temporary mark on the components of

the piston and connecting rod assembly. This
will ensure that the components of each piston
and connecting rod assembly can be reinstalled
in the original cylinder. Mark the underside of the
piston on the front pin boss. Do not interchange
components.
g01253091
Illustration 205
Typical example
KENR6247 101
2. Place the piston and connecting rod assembly on

a suitable surface with the connecting rod upward. NOTICE
Use Tooling (A) in order to remove retaining Removal of the piston pin bushing in the connecting
rings(5). rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
Note: The forged marks (X) identify the front of the information refer to your authorized Perkins distribu-
connecting rod assembly. The forged marks should tor.
be used for the purposes of orientation.
3. Remove piston pin (8) and connecting rod (6) from 7. Inspect the connecting rod for wear or damage. If
piston (4). necessary, replace connecting rod (6) or replace
bush (7) for the piston pin.
Note: If the piston pin cannot be removed by hand,
heat the piston to a temperature of 45 ± 5 °C Note: If the connecting rod or the bush for the piston
(113 ± 9 °F). Do not use a torch to heat the piston. pin are replaced, first identify the height grade of the
Note the orientation of the connecting rod and the connecting rod. Refer to Specifications, “Connecting
piston. Rod”.
4. Place the piston on a suitable surface with the 8. Repeat Steps 1 through 7 in order to disassemble
crown upward. Use Tooling (B) in order to remove the remaining pistons and connecting rods.
compression rings (1) and (2), and oil control ring
(3) from piston (4). i02628897
Note: Identify the position and orientation of Pistons and Connecting Rods
compression rings (1) and (2), and oil control ring (3).
- Assemble
Assembly Procedure
Table 61
Required Tools
Part
Number
B - Piston Ring Expander 1
g01244068
Illustration 206
NOTICE
5. Remove bolts (12) and connecting rod cap (11)
from connecting rod (6). Discard the bolts. Contaminants may cause rapid wear and shortened
component life.
Note: Fracture split connecting rods should not be left
without the connecting rod caps installed. After the
disassembly procedure for the piston and connecting 1. Ensure that all components are clean and free
rod is completed, carry out the assembly procedure from wear or damage. If necessary, replace any
and the installation procedure as soon as possible. components that are worn or damaged.
Connecting Rods - Assemble” and Disassembly and 2. If the original piston is assembled, follow Steps
Assembly, “Piston and Connecting Rods - Install”. 2.a through 2.e in order to install the piston rings.
6. Remove the lower half of connecting rod bearing a. Position the spring for oil control ring (3) into
(10) from connecting rod cap (11). Remove the the oil ring groove in piston (4). The central wire
upper half of connecting rod bearing (9) from must be located inside the end of the spring.
connecting rod (6). Keep the bearing shells
together.
102 KENR6247
g01155119
Illustration 207
b. Use Tooling (B) to install oil control ring (3) over

the spring.
Note: Ensure that the central wire is 180 degrees

from the ring gap.
c. Use Tooling (B) to install intermediate

compression ring (2) into the second groove in
piston (4). The word “TOP” must be upward.
The chamfer on the inner face must be
downward.
g01244067
Illustration 208
d. Use Tooling (B) to install top compression ring
(1) into the top groove in piston (4). The word 4. Lubricate bush (7) and lubricate the bore for the
“TOP” must be upward. piston pin in piston (4) with clean engine oil.
e. Position the piston ring gaps at 120 degrees

away from each other.
Note: A new piston assembly is supplied with new

piston rings.
NOTICE
Removal of the piston pin bushing in the connecting
rod must be carried out by personnel with the correct
training. Also special machinery is required. For more
information refer to your authorized Perkins distribu-
tor.
3. If the connecting rod assembly or the bush for Illustration 209

g01244172
the piston pin have been replaced, ensure that
the height grade of the connecting rod is correct. 5. Place the piston on a suitable surface with the
Refer to Specifications, “Connecting Rod” for crown downward. Install connecting rod (6) and
further information. piston pin (8) to piston (4). Ensure that square
boss (13) on the piston, and forged mark (X) on
the connecting rod are in the correct position. See
illustration 209.
Note: If the piston pin cannot be installed by hand,

heat the piston to a temperature of 45° ± 5°C
(113° ± 9°F).
KENR6247 103
6. Use Tooling (A) in order to install retaining rings Note: Fracture split connecting rods should not be
(5) to the piston pin bore in piston (4). left without the connecting rod caps installed. After
the assembly procedure for the piston and connecting
Note: Ensure that the retaining rings are seated in rod is completed, carry out the installation procedure
the grooves in the piston. as soon as possible. Refer to Disassembly and
Assembly, “Piston and Connecting Rods - Install”.
End By:
a. Install the pistons and the connecting rods.

Connecting Rods - Install”.
i02628899

- Install
g01244068
Illustration 210
Table 62
Required Tools
Number
A2
27610289 Gear 1
B 21825491 Piston Ring Compressor 1
C 21825607 Angle gauge 1
g01001160
Illustration 211
Aligning the connecting rod bearing in the center of the connecting Note: Either Tooling (A) can be used. Use the Tooling
rod that is most suitable.
Note: New connecting rod bearings are supplied with
an alignment tool. If new connecting rod bearings NOTICE
are installed, use the tool to align the bearing in the Keep all parts clean from contaminants.
connecting rod.
7. Install the upper half of connecting rod bearing component life.
(9) to connecting rod (6). Ensure that the bearing
is centralized in the connecting rod. Refer to NOTICE
Illustration 211. Discard all used connecting rod bolts.
8. Install the lower half of connecting rod bearing
(10) to connecting rod cap (11). Ensure that the 1. If the connecting rod caps were temporarily
bearing is centralized in the connecting rod cap. installed, remove the connecting rod caps. If
Refer to Illustration 211. necessary, thoroughly clean all of the components.
9. Repeat Steps 2 through 8 for the remaining piston 2. Apply clean engine oil to the cylinder bore, to the
and connecting rod assemblies. piston rings, to the outer surface of the piston and
to the connecting rod bearings.
104 KENR6247
Note: Install the connecting rod bearings dry

when clearance checks are performed. Refer to
Disassembly and Assembly, “Bearing Clearance -
Check”. Apply clean engine oil to the connecting rod
bearings during final assembly.
3. Use Tooling (A) to rotate the crankshaft until the

crankshaft pin is at the bottom center position.
Lubricate the crankshaft pin with clean engine oil.
g01344572
Illustration 213
Typical example
g01253096
Illustration 212
6. Install connecting rod cap (2) onto the connecting
Typical example rod.
4. Ensure that the gaps for the piston rings are at Note: Ensure that etched number (X) on the
120 degrees away from each other. Install Tooling connecting rod cap matches the etched number on
(B) onto piston (3). the connecting rod. Ensure the correct orientation of
connecting rod cap (2).
Note: Ensure that Tooling (B) is installed correctly
and that the piston can easily slide from the tool. 7. Install new bolts (1) to the connecting rod. Tighten
Ensure that the piston and the connecting rod the bolts evenly to a torque of 18 N·m (13 lb ft).
assembly are installed in the correct cylinder. The
arrow on the top of the piston must be toward the 8. Tighten the bolts evenly to a torque of 70 N·m
front of the engine. (52 lb ft).
5. Carefully push the piston and the connecting rod 9. Use Tooling (B) to turn the bolts through an
assembly into the cylinder bore and onto the additional 120 degrees.
crankshaft pin.
10. Ensure that the installed connecting rod assembly
Note: Do not damage the finished surface of the has tactile side play. Carefully rotate the crankshaft
crankshaft pin. in order to ensure that there is no binding.
11. Repeat Steps 2 through 10 in order to install the

remaining pistons and connecting rods.
Note: If all pistons and connecting rods require

replacement the procedure can be carried out on
two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders. 1
with 4 and 2 with 3. Ensure that both pairs of the
pistons and connecting rods are installed before
changing from one pair of cylinders to another
pair of cylinders..
KENR6247 105
12. Check the height of the pistons above the top face
of the cylinder block. Refer to Systems Operation, NOTICE
Testing and Adjusting, “Piston Height - Inspect” for Discard all used connecting rod bolts.
End By: Note: If all connecting rod bearings require

replacement the procedure can be carried out on
a. Install the piston cooling jets. Refer to Disassembly two cylinders at the same time. The procedure can
and Assembly, “Piston Cooling Jets - Remove be carried out on the following pairs of cylinders.
and Install”. 1 with 4 and 2 with 3. Ensure that both pairs
of the connecting rod bearings are installed
b. If the engine is equipped with a balancer, install before changing from one pair of cylinders to
the balancer. Refer to Disassembly and Assembly, another pair of cylinders.. Refer to Disassembly
“Balancer - Install”. If the engine is not equipped and Assembly, “Connecting Rod Bearings - Install”.
to Disassembly and Assembly, “Engine Oil Pump 1. Use Tooling (A) to rotate the crankshaft until the
- Install”. crank pin is at the bottom center position.
c. Install the cylinder head. Refer to Disassembly If necessary, remove the glow plugs. Refer
and Assembly, “Cylinder Head - Install”. to Disassembly and Assembly, “Glow Plugs -
i02628814 Note: Removal of the glow plugs aids removal of the

connecting rod bearings. It is not essential.
Remove
(Connecting rods in position)
Removal Procedure
Table 63
Required Tools
A1
A2
27610289 Gear 1
Start By:
a. If the engine is equipped with a balancer, remove g01344569

the balancer. Refer to Disassembly and Assembly, Illustration 214
Pump - Remove”.

NOTICE

component life.
g01253101
Illustration 215
106 KENR6247
2. The connecting rod and the connecting rod cap Note: Either Tooling (A) can be used. Use the Tooling
should have an etched number (X) on the side. that is most suitable.
The number on the connecting rod and the
connecting rod cap must match. If necessary, NOTICE
make a temporary mark on connecting rod (5) Keep all parts clean from contaminants.
and connecting rod cap (2) in order to identify the
cylinder number. Contaminants may cause rapid wear and shortened
component life.
Note: Do not punch identification marks onto fracture
split connecting rods. Do not stamp identification
marks onto fracture split connecting rods. NOTICE
Discard all used connecting rod bolts.
3. Remove bolts (1) and connecting rod cap (2) from
connecting rod (5). Discard the bolts.
1. Inspect the pins of the crankshaft for damage.
4. Remove the lower half of connecting rod bearing If the crankshaft is damaged, replace the
(3) from connecting rod cap (2). Keep the crankshaft or recondition the crankshaft. Refer
connecting rod bearing and the connecting rod to Disassembly and Assembly, “Crankshaft
cap together. - Remove” and Disassembly and Assembly,
“Crankshaft - Install”. Ensure that the connecting
5. Carefully push the piston and connecting rod rod bearings are clean and free from wear or
assembly into the cylinder bore until connecting damage. If necessary, replace the connecting rod
rod (5) is clear of the crankshaft. Remove the bearings.
upper half of connecting rod bearing (4) from
connecting rod (5). Keep the bearings together.
Note: Do not push on the fracture split surfaces of the

connecting rod as damage may result. Do not allow
the connecting rod to contact the piston cooling jet.
Fracture split connecting rods should not be left

without the connecting rod caps installed. After the
removal procedure for the connecting rod bearings
is complete, carry out the installation procedure
as soon as possible. Refer to Disassembly and
Assembly, “Connecting Rod Bearings - Install”.
g01260354
i02744541 Illustration 216

Install
(Connecting rods in position)
Table 64
Required Tools
A 1
21825576 Crankshaft Turning Tool 1 Illustration 217
g01001160
27610291 Barring Device Housing 1 Aligning the bearing in the center of the connecting rod
A2
27610289 Gear 1 Note: New connecting rod bearings are supplied with
B 21825607 Angle Gauge 1 an alignment tool. If new bearings are installed, use
the tool to align the bearing in the connecting rod.
KENR6247 107
2. Install the upper half of connecting rod bearing Note: Ensure that etched number (X) on connecting
(4) to connecting rod (5). Ensure that the bearing rod cap (2) matches etched number (X) on
is centralized in the connecting rod. Refer to connecting rod (5). Ensure the correct orientation of
Illustration 217. the connecting rod cap. The forged marks (Y) on the
connecting rod and the connecting rod cap should be
The ends of the bearing must be centered in the on the same side. Refer to Illustration 216.
connecting rod. The ends of the bearing must be
equally positioned in relation to the mating faces 9. Install new bolts (1). Tighten the bolts evenly to a
of the connecting rod. torque of 18 N·m (13 lb ft).
3. Clean the connecting rod cap. Install lower Note: Do not reuse the old bolts in order to secure
connecting rod bearing (3) to connecting rod cap the connecting rod cap.
(2). Ensure that the connecting rod bearing is
centralized in the connecting rod cap. Refer to 10. Tighten the bolts evenly to a torque of 70 N·m
Illustration 217. (52 lb ft).
The ends of the lower connecting rod bearing 11. Use Tooling (B) to turn the bolts through an
must be centered in the connecting rod cap. The additional 120 degrees.
ends of the lower connecting rod bearing must be
equally positioned in relation to the mating faces 12. Ensure that the installed connecting rod assembly
of the connecting rod cap. has tactile side play. Carefully rotate the crankshaft
in order to ensure that there is no binding.
4. Lubricate upper connecting rod bearing (4) with
clean engine oil. 13. Repeat Steps 2 through 12 for the remaining
connecting rod bearings.
5. If necessary, use Tooling (A) in order to rotate the
crankshaft until the crankshaft pin is at the bottom Note: If all connecting rod bearings require
dead center position. replacement the procedure can be carried out on
two cylinders at the same time. The procedure can
6. Carefully pull connecting rod (5) against the be carried out on the following pairs of cylinders.
crankshaft pin. 1 with 4 and 2 with 3. Ensure that both pairs of
the connecting rod bearings are installed before
Note: Do not allow the connecting rod to contact the changing from one pair of cylinders to another
piston cooling jet. pair of cylinders..
7. Lubricate the pin of the crankshaft and lubricate 14. If the glow plugs were removed, install the glow
lower connecting rod bearing (3) with clean engine plugs. Refer to Disassembly and Assembly, “Glow
oil. Plugs - Remove and Install”.
End By:

- Install”.
g01344572
Illustration 218
8. Install connecting rod cap (2) to connecting rod

(5).
108 KENR6247
i02628821
Crankshaft Main Bearings -

Remove and Install
(Crankshaft in position)
Removal Procedure
Table 65
Required Tools
Tool Part Number Part Description Qty g01253717
Illustration 219
A 1
21825576 Crankshaft Turning Tool 1 Typical example
A2 1. Remove allen head screws (1). Remove bridge
27610289 Gear 1 piece (2).
Start By: 2. Ensure that the main bearing cap is marked for
the correct location and orientation.
Pump - Remove”.
b. Remove the crankshaft rear seal. Refer to

Disassembly and Assembly, “Crankshaft Rear
Seal - Remove”.

NOTICE Illustration 220

g01253719
This procedure must only be used to remove and in-
Typical example
stall the main bearing shells with the crankshaft in po-
sition.
3. Remove bolts (3). Remove main bearing cap (4)
The removal procedure and the installation procedure from the cylinder block.
must be completed for each pair of main bearing shells
before the next pair of main bearing shells are re-
moved.
NOTICE

component life.
g01253146
Illustration 221
Typical example
KENR6247 109
4. Remove lower main bearing (5) from main bearing

cap (4). Keep the main bearing and the main
bearing cap together. Take care not to displace
dowels (6).
Note: The lower main bearing is a plain bearing that

has no oil holes. The dowels may remain in the main
bearing cap or in the cylinder block.
g01253145
Illustration 224
7. Push out upper main bearing (9) with a suitable

tool from the side opposite the locating tab.
Carefully rotate the crankshaft while you push on
the bearing . Remove upper main bearing (9) from
the cylinder block. Keep the bearings together.
Illustration 222
g01253137 Note: Do not damage the machined surfaces of the
Typical example
crankshaft during removal of the upper main bearing.
The upper main bearing has a groove and two oil
5. For number three main bearing cap, remove thrust holes.
washers (7).
Table 66
Required Tools
Part
Number
C - Straight Edge 1
D - 5 mm Allen Socket 1
POWERPART -
E 21826038
g01253142
Typical example This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in po-
6. For number three main bearing, remove thrust sition.
washers (8) from the cylinder block. In order to
remove the thrust washers, push the crankshaft The removal procedure and the installation procedure
toward the front of the engine or push the must be completed for each pair of main bearing shells
crankshaft toward the rear of the engine. Use before the next pair of main bearing shells are re-
Tooling (A) in order to rotate the crankshaft. If moved.
necessary, use a suitable tool to free the thrust
washers.
NOTICE
Note: Do not damage the machined surfaces of the Keep all parts clean from contaminants.
crankshaft during removal of the thrust washers.
component life.
110 KENR6247
1. Ensure that the main bearings are clean and free

from wear or damage. If necessary, replace the
main bearings.
2. Clean the journals of the crankshaft. Inspect

the journals of the crankshaft for damage. If
necessary, replace the crankshaft or recondition
the crankshaft.
g01253146
Illustration 227
Typical example
5. Install lower main bearing (5) into main bearing

cap (4). Ensure that the locating tab for the lower
main bearing is correctly seated into the slot in
the bearing cap.
g01253145
Illustration 225 Note: The lower main bearing is a plain bearing that
Typical example has no oil holes.
3. Lubricate the crankshaft journal and the upper

main bearing (9) with clean engine oil. Slide the
upper main bearing (9) into position between the
crankshaft journal and the cylinder block. Ensure
that the locating tab for the upper main bearing is
correctly seated in the slot in the cylinder block.
Note: The upper main bearing has a groove and two

oil holes.
g01253137
Illustration 228
Typical example
6. For number three main bearing cap, ensure that

thrust washers (7) are clean and free from wear or
damage. If necessary, replace the thrust washers.
Lubricate thrust washers (7) with clean engine
oil. Place the thrust washers into position on the
main bearing cap. Ensure that the locating tab is
correctly seated in the main bearing cap.
g01261200
Illustration 226
Typical example
4. For number three main bearing, ensure that thrust

washers (8) are clean and free from wear or
damage. If necessary, replace the thrust washers.
Lubricate thrust washers (8) with clean engine oil.
Slide the thrust washers into position between the
crankshaft and the cylinder block. The grooves in
the thrust washers must be located against the
crankshaft.
KENR6247 111
11. Check the crankshaft end play. Push the

crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face
of the crankshaft. Push the crankshaft toward the
rear of the engine. Use Tooling (B) to measure the
crankshaft end play. The permissible crankshaft
end play is 0.17 mm (0.007 inch) to 0.41 mm
(0.016 inch).
g01253719
Illustration 229
Typical example
7. Lubricate the crankshaft journal and the lower

main bearing with clean engine oil. Install main
bearing cap (4) to the cylinder block.
Note: Ensure the correct orientation of the main

bearing cap. The locating tab for the upper and the g01253836
Illustration 231
lower bearing should be on the same side of the Typical example
engine.
12. Follow Steps 12.a through 12.d in order to install
8. Lubricate the threads of bolts (3) with clean engine the bridge piece.
oil. Lubricate the underside of the heads of the
bolts with clean engine oil. a. Ensure that the recess in the cylinder block
and the bridge piece are clean, dry and free
9. Install bolts (3) to main bearing cap (4). Evenly from old sealant.
tighten the bolts in order to pull cap (5) into
position. Ensure that the cap is correctly seated. b. Install bridge piece (2) and allen head screws
(1). Tighten the allen head screws finger tight.
Note: Do not tap the main bearing cap into position
as the bearing may be dislodged. c. Use Tooling (C) in order to align the rear face
of the bridge piece with the rear face of the
10. Tighten bolts (3) to a torque of 245 N·m (180 lb ft). cylinder block.
d. Use Tooling (D) to tighten allen head screws

(1) to a torque of 16 N·m (12 lb ft).
13. Install the crankshaft rear seal. Refer to

Disassembly and Assembly, “Crankshaft Rear
Seal - Install”.
g01253186
Illustration 230 g01344584
Illustration 232
Typical example
Typical example
112 KENR6247
14. Apply Tooling (E) to cavities (Y) in bridge piece

(2). Continue to apply Tooling (E) until sealant NOTICE
extrudes from cavities (X). Keep all parts clean from contaminants.
Note: If the oil pan will not be installed immediately, Contaminants may cause rapid wear and shortened
ensure that the joint face of the bridge piece. and the component life.
cylinder block are left free of sealant.
End By: 1. The engine should be mounted on a suitable

stand and placed in the inverted position.
the balancer. Refer to Disassembly and Assembly, 2. If necessary, remove the cylinder head. Refer
“Balancer - Install”. If the engine is not equipped to Disassembly and Assembly, “Cylinder Head -
with a balancer, install the engine oil pump. Refer Remove”. Remove the pistons and connecting
to Disassembly and Assembly, “Engine Oil Pump rods. Refer to Disassembly and Assembly,
- Install”. “Pistons and Connecting Rods - Remove”.
If the cylinder head, the pistons and the

i02628818 connecting rods have not been removed, remove
the connecting rod caps. Refer to Disassembly
Crankshaft - Remove and Assembly, “Connecting Rod Bearings -
Remove”.
Removal Procedure
Table 67
Required Tools
Part
Number
A - Lifting Strap 1
Start By:
a. Remove the rocker shaft and pushrods. Refer to

Disassembly and Assembly, “Rocker Shaft and g01253717
Illustration 233
Pushrod - Remove”. Typical example
b. Remove the front housing. Refer to Disassembly 3. Remove allen head screws (1). Remove bridge
and Assembly, “Housing (Front) - Remove”. piece (2).
c. Remove the crankshaft rear seal. Refer to 4. Ensure that the bearing caps are marked for the
Disassembly and Assembly, “Crankshaft Rear location and orientation.
Seal - Remove”.
d. If the engine is equipped with a balancer, remove

Pump - Remove”.
NOTICE
If the crankshaft has been reground or if the crankshaft
has been replaced, the height of the piston above the
cylinder block must be inspected. It is necessary to
remove the cylinder head in order to inspect the height
of the piston above the cylinder block.
KENR6247 113
Note: The lower bearings are plain bearings that

have no oil holes. The dowels may remain in the
bearing cap or in the cylinder block.
g01253719
Illustration 234
Typical example
g01254099
5. Remove bolts (3) and bearing caps (4) from the Illustration 237
cylinder block. Typical example
7. Attach Tooling (A) and a suitable lifting device to

crankshaft (8). Carefully lift the crankshaft out of
the cylinder block. The weight of the crankshaft is
Note: Do not damage any of the finished surfaces

on the crankshaft, when the crankshaft is removed
from the engine.
g01253146
Illustration 235
Typical example
g01254104
Illustration 238
Typical example
8. Remove upper bearings (9) from the cylinder

block. Keep the upper bearings with the respective
bearing caps.
g01253137 Note: The upper bearings have a groove and two

Illustration 236
oil holes.
Typical example
9. Remove thrust washers (10) from number three
6. Remove lower bearings (5) from bearing caps (4). bearing in the cylinder block.
Take care not to displace dowels (6). For number
three bearing cap, remove thrust washers (7). 10. If necessary, remove the crankshaft gear. Refer
Keep the lower bearing and the thrust washers to Disassembly and Assembly, “Crankshaft Gear
with the respective bearing caps. - Remove and Install”.
114 KENR6247
i02628817 Note: If the crankshaft bearings are replaced, check

whether oversize bearings were previously installed.
Crankshaft - Install If the thrust washers are replaced, check whether
oversize thrust washers were previously installed.
Table 68
Required Tools
A - Lifting Strap 1
C - Straight Edge 1
D - 5 mm Allen Socket 1
POWERPART - g01253240
E 21826038 Illustration 239
Typical example
NOTICE 5. Install upper bearings (9) to the cylinder block.

Keep all parts clean from contaminants. Ensure that the locating tabs for the upper
bearings are seated in the slots in the cylinder
Contaminants may cause rapid wear and shortened block.
component life.
Note: The upper bearings have a groove and two
oil holes.
NOTICE
If the crankshaft has been reground or if the crankshaft 6. Lubricate upper bearings (9) with clean engine oil.
has been replaced, the height of the piston above the
cylinder block must be inspected. It is necessary to
remove the cylinder head in order to inspect the height
of the piston above the cylinder block.
1. Clean the crankshaft and inspect the crankshaft

for wear or damage. Refer to Specifications,
“Crankshaft” for more information. If necessary,
replace the crankshaft or recondition the
crankshaft.
2. If necessary, install the crankshaft gear. Refer to

Disassembly and Assembly, “Crankshaft Gear -
g01254099
Illustration 240
Note: The engine should be mounted on a suitable
stand and placed in the inverted position. Typical example
3. Ensure that the parent bores for the crankshaft 7. Attach Tooling (A) and a suitable lifting device to
bearings in the cylinder block are clean. Ensure crankshaft (8). Carefully lift the crankshaft into
that the threads for the bearing bolts in the cylinder the cylinder block. The weight of the crankshaft is
block are clean and free from damage. approximately 30 kg (66 lb). Remove Tooling (A).
4. Clean the crankshaft bearings and the thrust Note: Do not damage any of the finished surfaces on
washers. Inspect the bearings and the thrust the crankshaft. Do not damage the bearing.
washers for wear or damage. If necessary, replace
the bearings and the thrust washers.
KENR6247 115
9. Install lower bearings (5) into bearing caps (4).

Ensure that the locating tabs for the lower bearings
are correctly seated into the slots in the bearing
caps. For number three bearing cap, ensure that
thrust washers (7) are clean and free from wear
or damage. If necessary, replace both the thrust
washers. Lubricate thrust washers (7) with clean
engine oil. Place the thrust washers into position
on the bearing cap. Ensure that the locating tab is
correctly seated in the bearing cap.
Note: The lower bearing is a plain bearing that has

no oil holes.
g01254100
10. Lubricate lower bearings (5) and lubricate the
Illustration 241 journals of crankshaft (8) with clean engine oil.
Typical example Install bearing caps (4) to the cylinder block.
8. For number three bearing, ensure that thrust Note: Ensure the correct location and orientation of
washers (10) are clean and free from wear or the bearing caps. The locating tabs for the upper
damage. If necessary, replace the thrust washers. and the lower bearings should be on the same side
Lubricate thrust washers (10) with clean engine of the engine.
oil. Slide the thrust washers into position between
the crankshaft and the cylinder block.
Note: The grooves in the thrust washers must be

located against the crankshaft.
g01253719
Illustration 244
11. Lubricate the threads of bolts (3) with clean

engine oil. Lubricate the underside of the heads
of the bolts with clean engine oil.
g01253146
Illustration 242
12. Install bolts (3) to bearing caps (4). Evenly tighten
the bolts in order to pull the caps into position.
Ensure that the caps are correctly seated.
Note: Do not tap the bearing caps into position as

the bearing may be dislodged.
14. Rotate the crankshaft in order to ensure that there

is no binding.
g01253137
Illustration 243
116 KENR6247
g01254102
Illustration 246
Typical example
18. Follow Steps 18.a through 18.d in order to install

the bridge piece.
Illustration 245
g01253186 a. Ensure that the cylinder block and the bridge
piece are clean, dry and free from old sealant.
Typical example
b. Install bridge piece. (2) and allen head screws

15. Check the crankshaft end play. Push the (1). Tighten the allen head screws finger tight.
crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face c. Use Tooling (C) in order to align the rear face
of the crankshaft. Push the crankshaft toward the of the bridge piece with the rear face of the
rear of the engine. Use Tooling (B) to measure the cylinder block.
crankshaft end play. The permissible crankshaft
end play is 0.17 mm (0.007 inch) to 0.41 mm d. Use Tooling (D) in order to tighten the allen
(0.016 inch). head screws to a torque of 16 N·m (12 lb ft).
16. If the piston and connecting rods have been 19. Install the crankshaft rear seal. Refer to
removed , install the piston and connecting rods. Disassembly and Assembly, “Crankshaft Rear
Refer to Disassembly and Assembly, “Piston and Seal - Install”.
Connecting Rods - Install”.
If the piston and connecting rods have not been

removed , install the connecting rod caps. Refer
to Disassembly and Assembly, “Connecting Rod
Bearings - Install”.
17. If the crankshaft has been replaced or the

crankshaft has been reconditioned, inspect the
height of the piston above the cylinder block. Refer
“Piston Height - Inspect” for more information.
g01344593
Illustration 247
Typical example
20. Apply Tooling (E) to cavities (Y) in the bridge

piece (2). Continue to apply Tooling (E) until
sealant extrudes from cavities (X).
KENR6247 117
Note: If the oil pan will not be installed immediately,

ensure that the joint face of the bridge piece and the NOTICE
cylinder block are left free of sealant. Keep all parts clean from contaminants.
End By: Contaminants may cause rapid wear and shortened

component life.
a. If the engine has a balancer, install the balancer.
Refer to Disassembly and Assembly, “Balancer -
Install”. If the engine does not have a balancer, Note: The crankshaft gear may be a sliding fit on the
install the engine oil pump. Refer to Disassembly crankshaft or an interference fit on the crankshaft.
and Assembly, “Engine Oil Pump - Install”.
b. Install the front housing. Refer to Disassembly and

Assembly, “Housing (Front) - Install”.
c. If necessary, install the cylinder head. Refer to

Disassembly and Assembly, “Cylinder Head -
Install”.
d. Install the rockershaft and pushrods. Refer to

Disassembly and Assembly, “Rockershaft and
Push Rods - Install”.
i02628820
g01367358
Illustration 248
Crankshaft Gear - Remove and Typical example
Install
Removal Procedure
Table 69
Required Tools
Part
Number
- Bearing Puller 1
- Puller 1
A
- Crossblock 1
- Puller Leg 2
Start By:
a. Remove the front housing. Refer to Disassembly g01270549

and Assembly, “Housing (Front) - Remove”. Illustration 249
Typical example
b. If the engine is equipped with a balancer, remove
the balancer. Refer to Disassembly and Assembly, 1. If the crankshaft gear is a sliding fit on the
“Balancer - Remove”. If the engine is not equipped crankshaft, remove crankshaft gear (1) from
with a balancer, remove the engine oil pump. crankshaft (2).
Pump - Remove”. If the crankshaft gear is an interference fit on the
crankshaft, use Tooling (A) in order to remove
crankshaft gear (1) from crankshaft (2).
2. If necessary, remove key (3) from crankshaft (2).
Note: Do not remove the key from the crankshaft

unless the key is damaged.
118 KENR6247
Installation Procedure b. If the engine is equipped with a balancer, install

NOTICE “Balancer - Install”. If the engine is not equipped
Keep all parts clean from contaminants. with a balancer, install the engine oil pump. Refer
Contaminants may cause rapid wear and shortened - Install”.
component life.
i02748526
Bearing Clearance - Check
Measurement Procedure
Table 70
Required Tools
Part
Plastic Gauge (Green)
- 0.025 to 0.076 mm 1
(0.001 to 0.003 inch)
Plastic Gauge (Red)
- 0.051 to 0.152 mm 1
g01367359 (0.002 to 0.006 inch)
Illustration 250 A
Typical example Plastic Gauge (Blue)
- 0.102 to 0.229 mm 1
(0.004 to 0.009 inch)
2. If necessary, install a new key (3) to crankshaft (2).
Plastic Gauge (Yellow)
Note: The crankshaft gear may be a sliding fit on the - 0.230 to 0.510 mm 1
crankshaft or an interference fit on the crankshaft. (0.009 to 0.020 inch)
NOTICE
Hot parts or hot components can cause burns or
personal injury. Do not allow hot parts or compo- Contaminants may cause rapid wear and shortened
nents to contact your skin. Use protective clothing component life.
or protective equipment to protect your skin.
Note: Perkins does not recommend the checking of
3. If the crankshaft gear is a sliding fit on the the actual clearances of the bearing shells particularly
crankshaft, align the keyway in crankshaft gear (1) on small engines. This is because of the possibility
with key (3) in the crankshaft. Install crankshaft of obtaining inaccurate results and of damaging the
gear (1) to crankshaft (2). bearing shell or the journal surfaces. Each Perkins
bearing shell is quality checked for specific wall
If the crankshaft gear is an interference fit on the thickness.
crankshaft, heat crankshaft gear (1) in an oven to
150° ± 50°C (302° ± 90°F). Align the keyway in Note: The measurements should be within
crankshaft gear (1) with key (3) in the crankshaft. specifications and the correct bearings should
Install crankshaft gear (1) to crankshaft (2). be used. If the crankshaft journals and the bores
for the block and the rods were measured during
Ensure that shoulder (4) on crankshaft gear (1) is disassembly, no further checks are necessary.
toward the front of the engine. However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable
End By: method. Tooling (A) is less accurate on journals with
small diameters if clearances are less than 0.10 mm
a. Install the front housing. Refer to Disassembly and (0.004 inch).
Assembly Manual, “Housing (Front) - Install”.
KENR6247 119
Note: When Tooling (A) is used, the readings can

NOTICE sometimes be unclear. For example, all parts of
Lead wire, shim stock or a dial bore gauge can dam- Tooling (A) are not the same width. Measure the
age the bearing surfaces. major width in order to ensure that the parts are
within the specification range. Refer to Specifications
Manual, “Connecting Rod Bearing Journal” and
The technician must be very careful to use Tooling (A) Specifications Manual, “Main Bearing Journal” for the
correctly. The following points must be remembered: correct clearances.
• Ensure that the backs of the bearings and the

bores are clean and dry. i02628884
• Ensure that the bearing locking tabs are properly Glow Plugs - Remove and
seated in the tab grooves. Install
• The crankshaft must be free of oil at the contact
points of Tooling (A).
1. Put a piece of Tooling (A) on the crown of the Removal Procedure

bearing that is in the cap.
NOTICE
Note: Do not allow Tooling (A) to extend over the Keep all parts clean from contaminants.
edge of the bearing.
2. Use the correct torque-turn specifications in order component life.
to install the bearing cap. Do not use an impact
wrench. Be careful not to dislodge the bearing 1. Isolate the electrical supply.
when the cap is installed.
2. If the engine is equipped with a cover over the fuel
Note: Do not turn the crankshaft when Tooling (A) injectors remove the cover. Refer toDisassembly
is installed. and Assembly, “Fuel Injector Cover - Remove and
Install”.
3. Carefully remove the cap, but do not remove
Tooling (A). Measure the width of Tooling (A) 3. Remove the breather tube from the valve
while Tooling (A) is in the bearing cap or on the mechanism cover. Refer toDisassembly and
crankshaft journal. Refer to Illustration 251. Assembly, “Crankcase Breather- Remove and
Install”.
g01152855
Illustration 251
Typical Example
4. Remove all of Tooling (A) before you install the

bearing cap.
120 KENR6247
g01346250 g01346250
4. Disconnect harness assembly from bus bar (1). 2. Install glow plugs (3) into the cylinder head.
Tighten the glow plugs to a torque of 15 N·m
5. Remove nuts (2) that secure bus bar (1) to glow (132 lb in).
plugs (3).
3. Position bus bar (1) onto glow plugs (3). Install
6. Remove bus bar (1) from glow plugs (3). nuts (2) onto the glow plugs. Use Tooling (A) in
order to tighten the nuts to a torque of 2 N·m
7. Remove glow plugs (3) from the cylinder head. (17 lb in).
4. Connect harness assembly to bus bar (1).

Table 71 5. Install the breather tube to the valve mechanism
cover. Refer toDisassembly and Assembly,
Required Tools “Crankcase Breather- Remove and Install”.
Part
Tool Part Name Qty 6. If the engine is equipped with a cover over the fuel
Number
injectors install the cover. Refer toDisassembly
and Assembly, “Fuel Injector Cover - Remove and
Install”.
NOTICE
Keep all parts clean from contaminants. 7. Restore the electrical supply to the engine.

component life.
1. Ensure that the threads of the glow plugs are clean

and free from damage. Replace any damaged
glow plugs.
KENR6247 121
i02628912
V-Belts - Remove and Install

(Engines Without an Automatic
Belt Tensioner )
Removal Procedure
g01254466
Illustration 255
Typical example
1. Install V-belts (3) onto the correct pulleys.
Note: Used V-belts should be installed in the original

position and direction of rotation.
2. Adjust the tension on the V-belts by moving the

alternator away from the engine. Use Tooling
Illustration 254
g01254466 (A) in order to achieve the correct belt tension.
Typical example Refer to System Operation, Testing and Adjusting,
“V-Belt -Test” for more information. Tighten bolt (4)
1. If the engine is equipped with fan guards, remove to a torque of 22 N·m (16 lb ft).
the fan guards.
3. Tighten bolt (2) to a torque of 44 N·m (32 lb ft).
2. Loosen nut (1), bolt (2) and bolt (4). Slide the
alternator toward the engine. 4. Tighten nut (1) to a torque of 22 N·m (16 lb ft).
3. Remove V-belts (3). 5. If the engine is equipped with fan guards, install
the fan guards.
Note: Mark the position and direction of rotation if the
V-belts will be reused. Never replace single V-belts.
Always replace V-belts as a pair.
Table 72
Required Tools
Number
A - Belt Tension Gauge 1
122 KENR6247
i02589352 5. From the front of the engine, turn the square drive
tool in a clockwise direction. Release the pressure
Alternator Belt - Remove and on Tooling (A). Remove Tooling (A) from hole (Y).
Install
6. Release the pressure on the square drive tool and
(Engines With an Automatic remove the tool from hole (X).
Belt Tensioner) 7. If necessary, follow Steps 7.a and 7.b in order to
remove tensioner (3) from mounting bracket (2).
a. Remove bolt (4) that secures tensioner (3) to

Removal Procedure mounting bracket (2).
Table 73
b. Remove tensioner (3) from mounting bracket
Required Tools (2).
Number Installation Procedure
- Locking Pin Table 74
A 1
(Ø 8mm by 85 mm)
Required Tools
1. If the engine has fan guards, remove the fan Tool Part Part Description Qty
guards. Number
- Locking Pin
A 1
(Ø 8mm by 85 mm)
g01260739
Illustration 256
Typical example
g01270907
Illustration 257
2. Install a suitable square drive tool into hole (X) in Typical example
tensioner (3). From the front of the engine, turn
the tool in a clockwise direction. 1. If the tensioner was previously removed, follow
Steps 1.a through 1.c in order to install the
3. Insert Tooling (A) into hole (Y). Release the tensioner.
pressure on the square drive tool.
a. Align the dowel in the back of tensioner (3) with
4. Remove alternator belt (1). the hole in mounting bracket (2).
Note: Mark the direction of rotation if the belt will b. Install tensioner (3) to mounting bracket (2).
be reused.
KENR6247 123
c. Install bolt (4). Tighten the bolt to a torque of

45 ± 5 N·m (33 ± 3 lb ft).
2. Install a suitable square drive tool into hole (X) in

tensioner (1). From the front of the engine, turn
the tool in a clockwise direction.
3. Insert Tooling (A) into hole (Y). Release the

pressure on the square drive tool.
4. Install alternator belt (1). Ensure that the alternator

belt is centered on pulley (5). A used alternator
belt should be installed in the original direction of
rotation.
Note: The ribs on the alternator belt must be located

into the ribs of all pulleys.
5. From the front of the engine, turn the square drive

tool in a clockwise direction. Release the pressure
on Tooling (A). Remove Tooling (A) from hole (Y).
g01270917
Illustration 258
6. Release the pressure on the square drive tool until Typical example
the alternator belt is tensioned. Remove the tool
from hole (X). 1. Remove locking nuts (1).
Note: The tensioner should be at the nominal 2. Remove fan (2).
position.
Note: Note the orientation of the fan.
7. If the engine has fan guards, install the fan guards.
3. Remove fan adapter (3).
i02628844
4. Remove fan pulley (4).
Fan - Remove and Install
5. If necessary, remove studs (5) from fan drive (6).
Removal Procedure
1. Ensure that all the components are free from wear
Start By: or damage. If necessary, replace any components
that are worn or damaged.
a. If the engine is equipped with an automatic belt
tensioner, remove the Alternator Belt. Refer to
Disassembly and Assembly, “Alternator Belt -
Remove and Install”. If the engine is not equipped
with an automatic belt tensioner, remove the
V-Belts. Refer to Disassembly and Assembly,
“V-Belts - Remove and Install”.
124 KENR6247
g00944500
Illustration 260
Typical example
1. Remove bolts (1) from fan drive (2).
Note: Identify the orientation and the position of the

Illustration 259
g01270917 fan drive.
Typical example
2. Remove fan drive (2).
2. If necessary, install studs (5) to fan drive (6).
3. Install fan pulley (4).
4. Install fan adapter (3).
5. Install fan (2).
Note: Ensure that the fan is correctly oriented.
6. Inspect the condition of locking nuts (1). If

necessary, replace the locking nuts. Install locking
nuts (1) and tighten to a torque of 22 N·m (16 lb ft).
End By:
a. If the engine is equipped with an automatic belt g00944500

Illustration 261
tensioner, install the Alternator Belt. Refer to
Disassembly and Assembly, “Alternator Belt - Typical example
Remove and Install”. If the engine is not equipped
with an automatic belt tensioner, install the 1. Check the fan drive for wear or damage. The fan
V-Belts. Refer to Disassembly and Assembly, drive is not a serviceable item. If the fan drive is
“V-Belts - Remove and Install”. worn or damaged, replace the fan drive.
2. Install fan drive (2).

i02628845
Note: Ensure the correct orientation of the fan drive.
Fan Drive - Remove and Install
3. Install bolts (1). Tighten the bolts to a torque of
44 N·m (32 lb ft).
Removal Procedure End By:
Start By: a. Install the fan. Refer to Disassembly and

a. Remove the fan. Refer to Disassembly and
KENR6247 125
i02725803 a. Hold the shaft of alternator (3) with an allen

wrench. Use a cranked ring spanner (box
Alternator - Remove wrench) in order to loosen nut (7).
(Engines With an Automatic
b. Remove nut (7) and pulley (8) from alternator
Belt Tensioner) (1).
i02628804
Removal Procedure Alternator - Remove

Start By: (Engines Without an Automatic
Belt Tensioner)
a. Remove the alternator belt. Refer to Disassembly
Install”.
NOTICE
Removal Procedure
Keep all parts clean from contaminants. Start By:
Contaminants may cause rapid wear and shortened a. Remove the V-belts. Refer to Disassembly and
component life. Assembly, “V-belts - Remove and Install”.
1. Isolate the electrical supply to the engine. NOTICE

2. Make temporary identification marks on the
connections of the harness assembly. Contaminants may cause rapid wear and shortened
component life.
Note: The incorrect connection of the harness
assembly can result in damage to the alternator or
failure. 1. Isolate the electrical supply to the engine.

connections of the harness assembly.
g01271317
Illustration 262
Typical example
3. Disconnect the harness assembly from alternator

(3).
4. Remove bolt (5) from alternator (3).
5. Remove nut (1) and washer (2). Remove bolt (6)

from alternator (3). Remove the alternator from Illustration 263
g01255718
alternator bracket (4).
Typical Example
6. If necessary, follow Steps 6.a and 6 in order to
remove pulley (8) from alternator (1). 3. Disconnect the harness assembly from alternator
(1).
126 KENR6247
4. Remove bolt (6) from alternator (4). Note: Different types of alternator have different
sizes of nut. Ensure that the correct torque value is
5. Remove nut (1) and washer (2). Remove bolt (5) used for the nut.
from alternator (4). Remove alternator (4) from
alternator bracket (3). Tighten M16 and M17 nuts to a torque of 80 N·m
(59 lb ft). Tighten 5/8 inch - 18 UNF nuts to a
6. If necessary, remove pulley (8) from alternator (4). torque of 102 N·m (75 lb ft).
Follow Steps 6.a and 6.b for the method in order
to remove the pulley from the alternator. 2. Position alternator (3) on alternator mounting
bracket (4).
Note: This method may not be suitable for some
configurations of pulley. 3. Install bolt (6) to alternator (3). Install washer (2)
and nut (1) to bolt (6).
a. Hold the shaft of alternator (4) with an allen
wrench. Use a cranked ring spanner (box 4. Install bolt (5) to alternator (3).
wrench) in order to loosen nut (7).
5. Tighten nut (1) and bolt (5) to a torque of 22 N·m
b. Remove nut (7) and pulley (8) from alternator (16 lb ft).
(4).
6. Connect the wiring harness assembly to alternator
(3).
i02725802
Alternator - Install Note: The incorrect connection of the harness

assembly can result in damage to the alternator or
(Engines With an Automatic failure.
Belt Tensioner) 7. Install the alternator belt. Refer to Disassembly
Install”.
Installation Procedure 8. Restore the electrical supply.
NOTICE

component life.
g01271317
Illustration 264
Typical example
1. If necessary, install pulley (8) and nut (7) to

alternator (3). Hold the shaft of the alternator with
an allen wrench. Use a cranked ring spanner (box
wrench) in order to tighten nut (7).
KENR6247 127
i02628802 6. Tighten nut (1) and bolt (6) to a torque of 22 N·m

(16 lb ft).
Alternator - Install
(Engines Without an Automatic 7. Connect the harness assembly to alternator (4).
Belt Tensioner) 8. Restore the electrical supply.
i02628831
Installation Procedure Electric Starting Motor -

Remove and Install
Removal Procedure
Accidental engine starting can cause injury or

death to personnel working on the equipment.
To avoid accidental engine starting, disconnect

the battery cable from the negative (−) battery ter-
minal. Completely tape all metal surfaces of the
disconnected battery cable end in order to prevent
contact with other metal surfaces which could ac-
tivate the engine electrical system.
Place a Do Not Operate tag at the Start/Stop switch

g01263045
location to inform personnel that the equipment is
Illustration 265 being worked on.
Typical example
1. If necessary, install the pulley to the alternator. 1. Disconnect the battery.

Follow Steps 1.a and 1.b for the method in order
to install the pulley to the alternator. 2. If necessary, remove the hose for the crankcase
breather. Refer to Disassembly and Assembly,
Note: This method may not be suitable for some “Crankcase Breather - Remove”.
configurations of pulley.
a. Install pulley (8) and nut (7) to the shaft of harness assemblies that are connected to the
alternator (4). electric starting motor and to the solenoid.
b. Hold the shaft of the alternator with an allen

wrench. Use a cranked ring spanner (box
wrench) in order to tighten nut (7). Tighten the
nut to a torque of 80 N·m (59 lb ft).
2. Install alternator (4) to bracket (3) and install bolt

(5) to alternator (4).
3. Install washer (2) and nut (1) to bolt (5) finger tight.
4. Install bolt (6) through adjusting link (9) to

alternator (4) finger tight.
5. Install the V-belts. Refer to the Disassembly and g01261155

Illustration 266
assembly, “V-belts - Remove and Install” for the
correct procedure. Typical example
4. Disconnect the harness assemblies from the

electric starting motor and from the solenoid.
128 KENR6247
5. Remove nuts (3) from electric starting motor (1). i02628801
Note: Support the weight of the electric starting Air Compressor - Remove and
motor as the nuts are removed. Install
6. Remove electric starting motor (1).
7. If necessary, remove studs (2).

Removal Procedure
Installation Procedure Table 75
Required Tools
Part
Tool Part Name Qty
Number
A2
27610289 Gear 1
C - Puller (Three Leg) 1

g01261155
Illustration 267
Typical example NOTICE
1. If necessary, install studs (2). during performance of inspection, maintenance, test-
2. Align electric starting motor (1) to studs (2). Install collect the fluid with suitable containers before open-
the electric starting motor. ing any compartment or disassembling any compo-
3. Install nuts (3). Different types of starting motor
have different sized nuts. Dispose of all fluids according to local regulations and
mandates.
Tighten M10 nuts to a torque of 44 ± 11 N·m
(32 ± 8 lb ft).
NOTICE
Tighten M12 nuts to a torque of 78 ± 19.5 N·m Keep all parts clean from contaminants.
(57 ± 14 lb ft).
4. Connect the harness assemblies to the electric component life.
starting motor and the solenoid.
5. If necessary, install the hose for the crankcase hose assemblies and on all tube assemblies for
breather. Refer to Disassembly and Assembly, installation purposes. Plug all hose assemblies and
“Crankcase Breather - Install”. tube assemblies. This helps to prevent fluid loss and
this helps to keep contaminants from entering the
6. Connect the battery. system.
Do not disconnect the air lines until the air pres-

sure in the system is at zero. If hose is disconnect-
ed under pressure it can cause personal injury.
1. Release the pressure from the air system.

KENR6247 129
2. Drain the coolant from the cooling system into

draining procedure.
3. Remove the front cover. Refer to Disassembly and

4. If the engine is equipped with a hydraulic pump

on the rear of the air compressor, remove the
hydraulic pump.

Note: The air compressor must be timed with the

engine in order to minimize engine vibration.
g01250794
Illustration 269
Typical example
7. Disconnect coolant hoses (1) and (2) from air

compressor (4).
8. Disconnect the air lines from ports (3) and (5).

g01272266
Illustration 268 9. Remove tube assembly (7) from air compressor
Typical example (4) and from the cylinder block.
6. Install Tooling (B) through hole (X) in the front 10. Remove bolts (8) and (10) from support bracket
housing. Use Tooling (B) in order to lock the (9) and remove the support bracket.
crankshaft.
130 KENR6247
g01250816 g01250889
11. Support air compressor (4). Remove nuts (13) 12. Remove O-ring seal (18) from air compressor (4).
and remove the air compressor from front housing
(6). 13. If necessary, remove bolts (15) and remove plate
(14). Remove O-ring seal (11) from plate (14).
Refer to Illustration 270.
14. If necessary, remove nut (17) and remove

the spring washer. Use Tooling (C) in order to
remove gear (16) from the crankshaft of the air
compressor.
Table 76
Required Tools
Part
Tool Part Name Qty
Number
POWERPART -
D 21826051
High Strength Retainer
POWERPART -
E 21820221
Rubber Grease
KENR6247 131
c. Apply Tooling (D) to the threads of the shaft.

NOTICE Install nut (17) to the shaft of air compressor
Keep all parts clean from contaminants. (4). Tighten the nut to a torque of 120 N·m
(89 lb ft).
component life. 2. Install the O-ring seal to air compressor (4). Use
Tooling (E) in order to lubricate the O-ring seal.
NOTICE 3. Ensure that number one piston is at the top center

Care must be taken to ensure that fluids are contained position on the compression stroke. Refer to
during performance of inspection, maintenance, test- the Systems Operation, Testing and Adjusting,
ing, adjusting and repair of the product. Be prepared to “Finding Top Center Position for No. 1 Piston”.
ing any compartment or disassembling any compo- Note: The air compressor must be timed with the
nent containing fluids. engine in order to minimize engine vibration.

mandates.
g01272266
Illustration 273
Typical example
4. Ensure that Tooling (B) is installed in hole (X) in

the front housing. Use Tooling (B) in order to lock
the crankshaft in the correct position.
g01250889
Illustration 272
Typical example
1. If necessary, follow Steps 1.a through 1.b in order

to install the gear to the air compressor. g01250968
Illustration 274
a. Ensure that the shaft of air compressor (4) is Typical air compressor with a SAE drive
clean and dry. Ensure that gear (16) is clean
and free from damage.
b. Install gear (16) and a new spring washer to

the shaft of the air compressor.
132 KENR6247
Note: Ensure that timing mark (X) is aligned with

the timing mark A4. Refer to Illustration 274 for air
compressors with a SAE drive. Refer to Illustration
275 for air compressors with a DIN drive.
7. Install nuts (13). Tighten the nuts to a torque of

78 N·m (58 lb ft).
8. If necessary, follow Steps 8.a through 8.c in order

to install cover (14).
a. Install a new O-ring seal (11) to cover (14). Use

Tooling (E) in order to lubricate the O-ring seal.
g01251223
b. Install cover (14) to air compressor (4).
Illustration 275
Typical air compressor with a DIN drive c. Install bolts (15). Tighten the bolts to a torque
of 13 N·m (9.5 lb ft).
5. Rotate the crankshaft of the air compressor until
the timing mark (X) is aligned with the timing mark
A4 on the rear face of air compressor (4). Refer
to Illustration 274 for air compressors with a SAE
drive. Refer to Illustration 275 for air compressors
with a DIN drive.
g01250794
Illustration 277
Typical example
9. Position support bracket (9) onto air compressor

(4). Install bolts (8) finger tight.
g01250816
Illustration 276
10. Install bolts (10) finger tight.
Typical example
11. Tighten the bolts (8) to a torque of 22 N·m
6. Align the air compressor (4) with studs (12). (16 lb ft). Tighten the bolts (10) to a torque 22 N·m
Install the air compressor to the front housing. (16 lb ft).
If necessary, rotate the crankshaft of the air
compressor in a clockwise direction in order to Note: Ensure that the air compressor is not stressed
align the gears. as the bolts are tightened.
KENR6247 133
12. Install tube assembly (7) to air compressor (4)

and to the cylinder block. Tighten the nuts to a
torque of 9 N·m (80 lb in).
13. Remove Tooling (B) from hole (X) in the front

housing.
14. Install the front cover. Refer to Disassembly and

15. If the engine is equipped with a hydraulic pump

on the rear of the air compressor, install the
hydraulic pump.
16. Connect the air lines to ports (3) and (5) in the g01254510
air compressor. Illustration 278
Typical example
17. Connect coolant hoses (1) and (2) to air
compressor (4). 1. Remove tube assembly (4) from vacuum pump
(1) and from the cylinder block.
18. Fill the cooling system with coolant to the correct
level. Refer to the Operation and Maintenance 2. Disconnect the vacuum line from connector (3) on
Manual. the vacuum pump.
3. Remove bolts (2). Remove vacuum pump (1) from

i02628914 the front housing.
Vacuum Pump - Remove and 4. Remove the joint.
Install
NOTICE
Removal Procedure Keep all parts clean from contaminants.
NOTICE Contaminants may cause rapid wear and shortened

Keep all parts clean from contaminants. component life.

component life.

hose assemblies and on all tube assemblies for
installation purposes. Plug all hose assemblies and
tube assemblies. This helps to prevent fluid loss and
this helps to keep contaminants from entering the
system.
g01254510
Illustration 279
Typical example
1. Ensure that the vacuum pump is clean and free

from damage. If necessary, replace the vacuum
pump.
2. Clean the mating surfaces on the front housing.
3. Install a new joint to vacuum pump (1).

134 KENR6247
4. Install vacuum pump (1) to the front housing. If

necessary, rotate the shaft of the vacuum pump in
order to align the gears.
5. Install bolts (2).
Tighten M8 bolts to a torque of 22 N·m (16 lb ft).
Tighten M10 bolts to a torque of 44 N·m (32 lb ft).
6. Connect the vacuum line to connector (3).
7. Install tube assembly (4) to vacuum pump (1) and

to the cylinder block. Tighten the nuts on the tube
assembly to a torque of 9 N·m (80 lb in).
KENR6247 135
Index Section
Index
A Crankcase Breather - Remove and Install (Naturally
Aspirated Engines) .............................................. 69
Accessory Drive - Remove and Install................... 63 Assembly Procedure.......................................... 70
Installation Procedure ........................................ 64 Disassembly Procedure ..................................... 70
Removal Procedure ........................................... 63 Installation Procedure ........................................ 70
Air Compressor - Remove and Install.................. 128 Removal Procedure ........................................... 69
Installation Procedure ...................................... 130 Crankcase Breather - Remove and Install
Removal Procedure ......................................... 128 (Turbocharged Engines with Filtered Breather) ... 67
Alternator - Install (Engines With an Automatic Belt Assembly Procedure.......................................... 68
Tensioner) .......................................................... 126 Disassembly Procedure ..................................... 67
Installation Procedure ...................................... 126 Installation Procedure ........................................ 68
Alternator - Install (Engines Without an Automatic Removal Procedure ........................................... 67
Belt Tensioner)................................................... 127 Crankcase Breather - Remove and Install
Installation Procedure ...................................... 127 (Turbocharged Engines with Unfiltered
Alternator - Remove (Engines With an Automatic Belt Breather).............................................................. 65
Tensioner) .......................................................... 125 Assembly Procedure.......................................... 66
Removal Procedure ......................................... 125 Disassembly Procedure ..................................... 65
Alternator - Remove (Engines Without an Automatic Installation Procedure ........................................ 66
Belt Tensioner)................................................... 125 Removal Procedure ........................................... 65
Removal Procedure ......................................... 125 Crankshaft - Install................................................ 114
Alternator Belt - Remove and Install (Engines With Installation Procedure ....................................... 114
an Automatic Belt Tensioner)............................. 122 Crankshaft - Remove............................................ 112
Installation Procedure ...................................... 122 Removal Procedure .......................................... 112
Removal Procedure ......................................... 122 Crankshaft Front Seal - Remove and Install.......... 46
Installation Procedure ........................................ 46
Removal Procedure ........................................... 46
B Crankshaft Gear - Remove and Install ................. 117
Installation Procedure ....................................... 118
Balancer - Install.................................................... 95 Removal Procedure .......................................... 117
Assembly Procedure.......................................... 95 Crankshaft Main Bearings - Remove and Install
Installation Procedure ........................................ 96 (Crankshaft in position)...................................... 108
Balancer - Remove................................................ 93 Installation Procedure ...................................... 109
Disassembly Procedure ..................................... 94 Removal Procedure ......................................... 108
Removal Procedure ........................................... 93 Crankshaft Pulley - Remove and Install (Engines
Bearing Clearance - Check .................................. 118 With an Automatic Belt Tensioner)....................... 44
Measurement Procedure .................................. 118 Installation Procedure ........................................ 44
C Without an Automatic Belt Tensioner).................. 45
Camshaft - Remove and Install ............................. 82 Removal Procedure ........................................... 45
Installation Procedure ........................................ 83 Crankshaft Rear Seal - Install................................ 41
Camshaft Bearings - Remove and Install .............. 86 Crankshaft Rear Seal - Remove............................ 40
Installation Procedure ........................................ 87 Removal Procedure ........................................... 40
Removal Procedure ........................................... 86 Crankshaft Wear Sleeve (Front) - Remove and
Camshaft Gear - Remove and Install .................... 84 Install ................................................................... 47
Installation Procedure ........................................ 85 Installation Procedure ........................................ 47
Removal Procedure ........................................... 84 Removal Procedure ........................................... 47
Connecting Rod Bearings - Install (Connecting rods Cylinder Head - Install ........................................... 78
in position) ......................................................... 106 Installation Procedure ........................................ 78
Installation Procedure ...................................... 106 Cylinder Head - Remove ....................................... 76
Connecting Rod Bearings - Remove (Connecting Removal Procedure ........................................... 76
rods in position) ................................................. 105
Removal Procedure ......................................... 105
D
Disassembly and Assembly Section........................ 4

136 KENR6247
Index Section
E Fuel Injection Pump - Install .................................... 9

Installation Procedure .......................................... 9
Electric Starting Motor - Remove and Install ....... 127 Fuel Injection Pump - Remove ................................ 8
Installation Procedure ...................................... 128 Removal Procedure ............................................. 8
Removal Procedure ......................................... 127 Fuel Injection Pump Gear - Install ......................... 13
Engine Oil Cooler - Install...................................... 28 Installation Procedure ........................................ 13
Installation Procedure ........................................ 28 Fuel Injection Pump Gear - Remove ...................... 11
Engine Oil Cooler - Remove.................................. 27 Removal Procedure ............................................ 11
Removal Procedure ........................................... 27 Fuel Injector - Install .............................................. 15
Engine Oil Filter Base - Remove and Install.......... 26 Installation Procedure ........................................ 15
Installation Procedure ........................................ 26 Fuel Injector - Remove .......................................... 14
Engine Oil Pan - Remove and Install (Aluminum and Fuel Injector Cover - Remove and Install ................ 7
Pressed Steel Oil Pans)....................................... 87 Installation Procedure .......................................... 7
Installation Procedure ........................................ 88 Removal Procedure ............................................. 7
Removal Procedure ........................................... 87 Fuel Priming Pump and Fuel Filter Base - Remove
Engine Oil Pan - Remove and Install (Cast Iron Oil and Install .............................................................. 4
Pan) ..................................................................... 90 Installation Procedure .......................................... 4
Installation Procedure ........................................ 92 Removal Procedure ............................................. 4
Engine Oil Pump - Remove and Install (Engines
Without a Balancer Unit)...................................... 32 G
Removal Procedure ........................................... 32 Gear Group (Front) - Remove and Install.............. 50
Engine Oil Relief Valve - Remove and Install (Engines Installation Procedure ........................................ 52
with a Balancer Unit)............................................ 30 Removal Procedure ........................................... 50
Installation Procedure ........................................ 31 Glow Plugs - Remove and Install ......................... 119
Removal Procedure ........................................... 30 Installation Procedure ...................................... 120
Engine Oil Relief Valve - Remove and Install (Engines Removal Procedure .......................................... 119
Without a Balancer Unit)...................................... 29
Removal Procedure ........................................... 29 H
Exhaust Elbow - Remove and Install..................... 20
Installation Procedure ........................................ 20 Housing (Front) - Install ......................................... 61
Exhaust Manifold - Remove and Install ................. 18 Housing (Front) - Remove ..................................... 59
I
F
Idler Gear - Install .................................................. 56
Fan - Remove and Install .................................... 123 Installation Procedure (Heavy-Duty Idler Gear).. 58
Installation Procedure ...................................... 123 Installation Procedure (Standard Idler Gear) ..... 56
Removal Procedure ......................................... 123 Idler Gear - Remove .............................................. 53
Fan Drive - Remove and Install ........................... 124 Removal Procedure (Heavy-Duty Idler Gear) .... 55
Installation Procedure ...................................... 124 Removal Procedure (Standard Idler Gear) ........ 53
Removal Procedure ......................................... 124 Important Safety Information ................................... 2
Flywheel - Install.................................................... 39 Inlet and Exhaust Valve Springs - Remove and
Installation Procedure ........................................ 39 Install ................................................................... 21
Flywheel - Remove................................................ 38 Installation Procedure ........................................ 22
Flywheel Housing - Remove and Install ................ 42 Inlet and Exhaust Valves - Remove and Install ..... 23
Installation Procedure ........................................ 43 Installation Procedure ........................................ 24
Front Cover - Remove and Install.......................... 49
Fuel Injection Lines - Remove and Install................ 5
Installation Procedure .......................................... 6
Removal Procedure ............................................. 5
KENR6247 137
Index Section
L Water Temperature Regulator - Remove and

Install ................................................................... 36
Lifter Group - Remove and Install.......................... 81 Installation Procedure ........................................ 37
Piston Cooling Jets - Remove and Install.............. 97

Pistons and Connecting Rods - Assemble .......... 101
Assembly Procedure........................................ 101
Pistons and Connecting Rods - Disassemble ..... 100
Disassembly Procedure ................................... 100
Pistons and Connecting Rods - Install................. 103
Installation Procedure ...................................... 103
Pistons and Connecting Rods - Remove............... 99
Rocker Shaft - Assemble....................................... 74

Assembly Procedure.......................................... 74
Rocker Shaft - Disassemble .................................. 73
Disassembly Procedure ..................................... 73
Rocker Shaft and Pushrod - Install........................ 75
Rocker Shaft and Pushrod - Remove.................... 72
Table of Contents..................................................... 3
Turbocharger - Install ............................................ 17
Turbocharger - Remove ........................................ 15
V-Belts - Remove and Install (Engines Without an

Automatic Belt Tensioner )................................. 121
Vacuum Pump - Remove and Install ................... 133
Valve Mechanism Cover - Remove and Install...... 71
Water Pump - Install .............................................. 35

Water Pump - Remove .......................................... 34
138 KENR6247
Index Section
KENR6247 139
Index Section
Copyright © 2007 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.
SMONTAGGIO DEL MOTORE IDROSTATICO
DISASSEMBLING HYDROSTATIC MOTOR
AUSBAU DES HYDROSTATISCHEN MOTORS
MRT 1440-1640-1840 EASY

IT-EN-DE
75 MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO DEL MOTORE DISASSEMBLING HYDROSTATIC AUSBAU DES HYDROSTATISCHEN

IDROSTATICO MOTOR MOTORS
Posizionare la macchina su una superficie Position the vehicle on level ground. The Die Maschine auf einer ebenen Fläche
piana. Il motore termico deve essere spen- engine must be switched off. abstellen. Der Verbrennungsmotor muss
to. abgestellt sein.
Unscrew the connecting screws of the half-
Svitare le viti di collegamento delle semi- flange (Fig. 1-Ref. A and Fig. 2-Ref. B) Die Verbindungsschrauben der
flange (Fig. 1-Rif. A e Fig. 2-Rif. B) posizio- positioned on the two sides of the hydro- Flanschhälften (Abb. 1-Bez. A und Abb. 2-
nate ai due lati del motore idrostatico e static motor and disconnect the pipes. Bez. B) auf den beiden Seiten des
scollegare i tubi. hydrostatischen Motors losschrauben und
Disconnect the hydraulic pipes (Fig. 2-Ref. die Leitungen abtrennen.
C and Fig. 3-Ref. D).
Scollegare i tubi idraulici (Fig. 2-Rif. C e Die hydraulischen Leitungen (Abb. 2-Bez.
Fig. 3-Rif. D). Disconnect the two pipes (Fig. 2-Ref. E) C und Abb. 3-Bez. D) abtrennen.
from the “T” coupling and disconnect the
Scollegare i due tubi (Fig. 2-Rif. E) dal rac- electric wiring (Fig. 2 - Ref. F). Die beiden Leitungen (Abb. 2 - Bez. E)
cordo a “T” e staccare il collegamento elet- vom “T”-Teil abtrennen und den elektri-
trico (Fig. 2 - Rif. F). schen Anschluss abklemmen (Abb. 2 -
Bez. F).
Prendere adeguate precauzioni per soste- Take suitable precautions to support the
nere il motore idrostatico (es: carrello all’al- hydrostatic motor (e.g.: trolley at motor Angemessene Vorsichtsmaßnahmen tref-
tezza del motore) e svitare le quattro viti di height) and unscrew the four fixing screws fen, um den hydrostatischen Motor abzu-
fissaggio (Fig. 3-Rif. G). (Fig. 3-Ref. G). stützen (z.B.: Gabelstapler auf der Höhe
des Motors) und die vier
Smontare il motore idrostatico. Befestigungsschrauben losdrehen (Abb. 3-
Disassemble the hydrostatic motor. Bez. G).
Den hydrostatischen Motor ausbauen.

MONTAGGIO DEL MOTORE
IDROSTATICO ASSEMBLING HYDROSTATIC
MOTOR
Posizionare la macchina su una superficie EINBAU DES HYDROSTATISCHEN
piana. Il motore termico deve essere Position the vehicle on level ground. The MOTORS
spento. engine must be switched off.
Die Maschine auf einer ebenen Fläche
abstellen. Der Verbrennungsmotor muss
Montare il motore idrostatico nella sua abgestellt sein.
posizione originaria avvitando le quattro Fit the hydrostatic motor in its original posi-
viti di serraggio (Fig. 1-Rif. A). tion, tightening the locking screws (Fig. 1- Den hydrostatischen Motor in seiner
Ref. A). ursprünglichen Position einbauen und die vier
Befestigungsschrauben anziehen (Abb. 1-
Bez. A).
N.B. : quando viene rimontato il motore
idrostatico può essere opportuno sostituire N.B.: when the hydrostatic motor is
reassembled, it is advisable to replace the Anm.: Wenn der hydrostatische Motor wieder
le rondelle accoppiate alle viti. eingebaut wird, kann es richtig sein, die
screw washers.
Unterlegscheiben der Schrauben zu erset-
zen.
Rimontare i due tubi con le relative semi-
flange ai lati del motore idrostatico (Fig. 2- Refit the two pipes with the relative half- Die beiden Leitungen mit den entsprechen-
Rif. B e Fig. 3-Rif.C). flange to the sides of the hydrostatic motor den Flanschhälften wieder an den Seiten des
(Fig. 2-Ref. B and Fig. 3-Ref.C). hydrostatischen Motors anbringen (Abb. 2-
Ricollegare i tubi idraulici (Fig. 2-Rif. D e Bez. B und Abb. 3-Bez. C).
Fig. 1-Rif. E). Reconnect the hydraulic pipes (Fig. 2-Ref.
D and Fig. 1-Ref. E). Die hydraulischen Leitungen wieder ansch-
Ricollegare i due tubi (Fig. 2-Rif. F) e ripri- ließen (Abb. 2-Bez. D und Abb. 1-Bez. E).
stinare il collegamento elettrico (Fig. 2-Rif. Reconnect the two pipes (Fig. 2-Ref. F)
and restore the electric wiring connections Die beiden Leitungen wieder anschließen
G).
(Fig. 2-Ref. G). (Abb. 2-Bez. F) und den elektrischen
Anschluss wieder anklemmen (Abb. 2-Bez.
G).
In caso di sostituzione motore idrostatico To replace the hydrostatic motor, check to Beim Ersetzen des hydrostatischen Motors
verificare che la testa del tappo M18x1,5 ensure that the M18x1.5 plug head (Fig. 4- sicherstellen, dass der Kopf des Stopfens
(Fig. 4-Rif. H) sporga di circa 2 mm. Ref. H) projects by about 2 mm. M18x1,5 (Abb. 4-Bez. H) circa 2 mm über-
In caso la sporgenza sia di circa 5 mm If it projects by about 5 mm replace with a steht. Wenn er circa 5 mm übersteht, ist er
sostituirlo con un tappo rif. 584569 plug Ref. 584569 durch einen Stopfen Bez. 584569 zu erset-
ed utilizzare del teflon per la tenuta and use Teflon to seal the threading. zen und Teflon für die Abdichtung auf dem
sul filetto. Gewinde zu benutzen.
2
MRT 1440-1640-1840 EASY 75
SMONTAGGIO DEL MOTORE DISASSEMBLING HYDROSTATIC AUSBAU DES HYDROSTATISCHEN

IDROSTATICO MOTOR MOTORS
E
F
E
A
B
1
C
MONTAGGIO DEL MOTORE ASSEMBLING HYDROSTATIC EINBAU DES HYDROSTATISCHEN

IDROSTATICO MOTOR MOTOR
A
F
G
F
A
E B
1
D
2
3 4
3
FUNZIONAMENTO (REGOLAZIONI) DELLA TRASMISSIONE
TRANSMISSION OPERATION (REGULATION)
FUNKTION (EINSTELLUNGEN) DES GETRIEBES
MRT 1440-1640 EASY

IT-EN-DE
MRT 1440-1640-1840 EASY 75
IT EN DE
REGOLAZIONE E CONTROLLO SPECIFIC ADVANTAGES OF EINSTELLUNG UND PRÜFUNG DES
TRASMISSIONE HYDROMATIK TRANSMISSION UNITS GETRIEBES
VANTAGGI SPECIFICI DELLE TRASMIS- In addition to the traditional features of SPEZIFISCHE VORTEILE DER
SIONI HYDROMATIK hydrostatic transmission systems (freedom HYDROMATIK-GETRIEBE
of transmission installation, minimum
Oltre alle caratteristiche classiche delle tra- space requirements, instant drive reversal, Neben den klassischen Eigenschaften der
smissioni idrostatiche (libertà no clutches, dynamic braking), HYDRO- hydrostatischen Getriebe
d’installazione della trasmissione, ingom- MATIK transmission units have the follow- (Installationsfreiheit des Getriebes, mini-
bro minimo, inversione istantanea del ing advantages: maler Platzbedarf, sofortige Wendung der
senso di marcia, soppressione delle Fahrtrichtung, Unterdrückung der
frizioni, frenatura dinamica), le trasmissioni 1) Specific output of A 4 VG pumps is the Kupplungen, dynamisches Bremsen) besit-
HYDROMATIK possiedono i vantaggi highest on the market. zen die Getriebe HYDROMATIK die fol-
seguenti: 2) High speed A 4 VG pumps and A 6 VM genden Vorteile:
motors.
1) Potenza delle pompe A 4 VG la più ele- 3) Bent axis design of A 6 VM motors, the 1) Die Leistung der Pumpe A 4 VG ist
vata del mercato. pistons have no shoes, this allows die höchste am Markt.
2) Velocità di rotazione elevata delle 90% of rated load torque to be trans- 2) Hohe Drehgeschwindigkeit der
pompe A 4 VG e dei motori A 6 VM. mitted on start-up and produces a Pumpen A 4 VG und der Motoren A 6
3) Costruzione a corpo inclinato dei moto- wide control range. VM.
ri A 6 VM, i pistoni non possiedono dei 4) Continuos automatic variation of trans- 3) Konstruktion mit schrägem Gehäuse
pattini,questo permette di trasmettere mission ratio, controlled by the opera- der Motoren A 6 VM, die Kolben
in partenza già il 90% della coppia tor (accelerator pedal) or according to besitzen keine Gleitschuhe, dadurch
nominale e la possibilità di un grande the load, and consequently a better kann schon beim Anfahren 90 % der
campo di variazione di cilindrata. use of the installed capacity. Nenndrehmoments übertragen wer-
4) Variazione automatica continua del rap- 5) Conventional drive with accelerator den und der Verstellbereich des
porto di trasmissione, guidato a secon- pedal and brake and inching pedal. Hubraums ist sehr groß.
da dell’esigenza dell’operatore (pedale 6) The DA control acts as a “maximum 4) Automatische stufenlose Variation
accelleratore) o in funzione del carico e load power control”.Pumps with DA des Übersetzungsverhältnisses, je
migliore utilizzo della potenza installata. control are used universally on diesel nach den Erfordernissen des Fahrers
5) Comando convenzionale con pedale engines and do not require any power (Gaspedal) oder je nach der Last,
accelleratore, pedale freno e di taglio calibration,thus making the corre- und bessere Ausnutzung der instal-
trasmissione (inching). sponding settings easier. lierten Leistung.
6) La regolazione DA agisce come una Tha DA control allows peak pressure 5) Herkömmliche Bedienung mit
"regolazione di potenza a carico limita- and maximum displacement to be Gaspedal, Bremspedal und
to". La pompacon regolazione DA é reached well befor the maximum Getriebeschnitt (Inching).
normalmente montata sul diesel e non diesel engine speed (1600÷2000 rpm), 6) Die DA-Einstellung wirkt wie eine
necessita di tarature di potenza, facili- and therefore maximum machine "Leistungsregelung bei beschränkter
tando così le regolazioni power or 75% of the travel speed are Last". Die Pumpe mit DA-Einstellung
corrispondenti. achieved within a favourable fuel con- ist in der Regel auf dem Diesel mon-
La regolazione DA permette di ottenere sumption range and a restricted noise tiert und verlangt keine Eichungen
la pressione massima e la cilindrata level range. der Leistung, was die entsprechen-
massima ancora prima il regime massi- 7) When used on loaders, a high average den Einstellungen vereinfacht.
mo del diesel (1600/2000 min-1) e quin- travel speed and maximum propulsive Die DA-Einstellung gestattet es, dem
di facendo sì che la forza del motore al force for a favourable diesel engine is Höchstdruck und den max. Hubraum
75% della velocità di spostamento per- possible. The efficiency of the machine zu erhalten, noch bevor der Diesel
metta un basso consumo specifico di (hourly capacity:hourly consumption) is die max. Drehzahl erreicht
carburante ed un basso livello di also very high. (1600/2000 min-1). Dies führt dazu,
rumorosità. dass die Motorkraft bei 75 % der
7) Nel caso di una applicazione sotto cari- Fahrgeschwindigkeit einen niedrigen
co, la velocità media di spostamento é spezifischen Spritverbrauch und
elevata e la forza di trazione massima einen geringen Lärmpegel gestattet.
per un regime diesel favorevole. Il ren- 7) Im Fall einer Anwendung unter Last
dimento del motore (cubatura ora- ist die durchschnittliche
ria/consumo orario) é molto elevato. Fahrgeschwindigkeit hoch und die
Zugkraft maximal für eine günstige
Drehzahl des Dieselmotors. Der
Wirkungsgrad des Motors
(Stundenrauminhalt/Stundenverbrauc
h) ist sehr hoch.
1
75 MRT 1440-1640-1840 EASY
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8) La valvola inching fissata per il primo 8) The inching valve coupled up to the 8) Das Inching-Ventil, das an der ersten
tratto di corsa al pedale del freno per- brake pedal clearance stroke allows Stecke des Hubs des Bremspedals
mette di diminuire la velocità di trasla- the driver to reduce the machine befestigt ist, gestattet es, die
zionedella macchina aumentando il speed whilst increasing the IC engine Fahrgeschwindigkeit der Maschine
regime del motore termico,e, di conse- speed, and, consequently, the delivery zu verringern und die Drehzahl des
guenza, la portata della pompa per dif- of the pump supplying the various Verbrennungsmotors zu steigern, und
ferenti movimenti idraulici. hydraulic movements. It is therefore folglich auch die Fördermenge der
Il conseguimento della velocità massi- possible to achieve maximum lifting Pumpe für unterschiedliche hydrauli-
ma di sollevamento é dunque possibile speed at low travel speed, hence more sche Bewegungen.
a velocità ridotta, e quindi si ottiene un efficient handling. Das Erreichen der max.
Thanks to the inching valve, when the
migliore rendimento lavorativo. Hubgeschwindigkeit ist daher bei
driver brakes,firstly hydrostatic braking
Grazie alla valvola inching nel momen- reduzierter Geschwindigkeit möglich
of the machine occurs, then the brakes
to in cui il conduttore frena, si ha inizial- und man erhält demgemäß eine bes-
are activated, giving economy and
mente una frenatura idrostatica, poi dei sere Arbeitswirkleistung.
long life to the braking system.
freni, quindi si ha economia e longevità 9) Limited negative impact on diesel Dank des Inching-Ventils gibt es in
del sistema di frenatura. engine speed at full load. dem Augenblick, in dem der Fahrer
9) Debole abbassamento del regime 10) No diesel engine overload. bremst, zu Beginn eine hydrostati-
diesel a pieno carico. 11) When immobilized, diesel power is not sche Bremsung, dann der Bremsen,
10) Nessun sovraccarico del motore diesel. transformed into heat; the HP relief folglich erhält man lange Haltbarkeit
11) All’abbassamento del regime, la valves are not activated due to the und sparsamen Gebrauch des
potenza del diesel non é trasformata in combined restoring force-DR valve Bremssystems.
calore; i limitatori: HP non si aprono system. 9) Bescheidene Senkung der Drehzahl
grazie al doppio sistema congiunto: 12) Displacement of the A 6 VM variable des Diesels bei voller Last.
forze di richiamo e valvola DR. motor controlled by the same pilot 10) Keine Überlastung des Dieselmotors.
12) Controllo della cilindrata del motore pressure as the pump (still the only 11) Beim Senken der Drehzahl wird die
variabile A 6 VM attraverso la stessa system of this type on the market). Leistung des Dieselmotors nicht in
pressione di pilotaggio della pompa 13) The installation of the DA controlled Wärme verwandelt. Die Begrenzer
(sistema ancora unico sul mercato). variable motor allows the pump mod- HP öffnen sich dank des doppelt ver-
13) Il montaggio del motore variabile regolato DA ule to be better adapted to the power bundenen Systems nicht:
permette di adattare in modo migliore la of the IC engine (and not to the Rückholkräfte und Ventil DR.
cilindrata della pompa in rapporto alla apparent power of the machine) 12) Steuerung des Hubraums des
potenza termica (e non alla potenza Thus, the constant power delivery Verstellmotors A 6 VM durch den
apparente del motore). In questo modo, il range of the pump is maximized and gleichen Druck, bei dem die Pumpe
flusso a potenza costante della pompa é is still satisfactory with the transfer of vorgesteuert wird (noch einzigartiges
power to the working hydraulics.
ottimale e resta ancora soddisfacente con il System auf dem Markt).
14) HP locking system on the A 6 VM 13) Die Montage des DA-geregelten
trasferimento della potenza sull’idraulica dei
motor permitting detection of the Verstellmotors gestattet es, den
movimenti del carrello. Hubraum der Pumpe auf die best-
torque direction in relation to the
14) Sistema di blocco della HP sul motoreA6 VM mögliche Weise an die
direction of travel, thus avoiding
che gli permette di rivelare il senso della untimely braking in stoppage. Wärmeleistung anzupassen (und
coppia in rapporto al senso di marcia nicht an die Scheinleistung des
Motors). Auf diese Weise ist der
evitando così delle frenate brusche ed Leistungsfluss der Pumpe optimal
intempestive. und bleibt auch zufriedenstellend,
wenn die Leistung auf die Hydraulik
der Staplerbewegungen übertragen
wird.
14) Sperrsystem der HP auf dem Motor A
6 VM, was es ihm gestattet, die
Richtung des Drehmoments im
Bezug zur Fahrtrichtung zu erfassen
und dadurch plötzliches und zu star-
kes Bremsen zu vermeiden.
2
MRT 1440-1640-1840 EASY 75
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CIRCUITO PRINCIPALE DELLE BASIC DIAGRAM OF HAUPTKREISLAUF DER
TRASMISSIONI IDROSTATICHE HYDROSTATIC TRANSMISSION HYDROSTATISCHEN GETRIEBE
SYSTEMS
3
1 2 4
6 6
5
Regolazione
e Inversione
Regulation and
Reversal
Regelung und
Wenden
FIG. 1
1) Motore PERKINS serie 1104C.44T 1) PERKINS engine type 1104C.44T 1) Motor PERKINS Serie 1104C.44T
2) Pompa idrostatica a cilindrata variabile 2) Variable displacement hydrostatic pump 2) Hydrostatische Verstellpumpe
serie A4VG56DA type A4VG56DA Serie A4VG56DA
3) Motore idrostatico a cilindrata variabile 3) Variable displacement hydrostatic engine 3) Hydrostatischer Verstellmotor
serie A6VM80DA type A6VM80DA Serie A6VM80DA
4) Pompa ad ingranaggi sovralimentazione 4) Booster pump gear 4) Zahnradpumpe Aufladung
5) Valvola di massima sovralimentazione 5) Booster relief valve 5) Überdruckventil Aufladung
6) High pressure valves 6) Hochdruckventil

6) Valvole alta pressione
3
75 MRT 1440-1640-1840 EASY
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DESCRIZIONE FUNZIONAMENTO DESCRIPTION OF HYDROMATIK A BESCHREIBUNG DER FUNKTION
DELLA TRASMISSIONE HYDROMATIC 4 VG..DA/A 6 VM..DA TRANSMIS- DES GETRIEBES HYDROMATIC
A 4 VG..DA/A6 VM..DA SION UNIT OPERATION A4 VG..DA/A6 VM..DA
ALLGEMEINES
GENERALITA’ GENERAL
By its principle, hydrostatic transmission Das hydrostatische Getriebe optimiert das

La trasmissione idrostatica ottimizza la Drehmoment des Verbrennungsmotors bis
adapts the torque provided by the IC
coppia disponibile del motore termico fino zu den Rädern, je nach dem vom Motor
engine to the wheels according to the
alle ruote, a seconda della resistenza festgestellten Widerstands,und im
resistance by the vehicle and the speed at
incontrata dal motore, ed in rapporto alla which the driver wishes to travel. Verhältnis zu der vom Fahrer gewünschten
velocità desiderata dall’operatore. Geschwindigkeit.
The transmission ratio varies continuosly
Il rapporto della trasmissione varia di Das Übersetzungsverhältnis ändert sich
and automatically.
continuo e in maniera automatica. stufenlos und automatisch.
The agent enabling the power to be
Il sistema permette di trasmettere la poten- Das System gestattet es, die Leistung zu
za in quanto l’olio minerale, praticamente transmitted is mineral oil which is pratically übertragen, weil das Mineralöl praktisch
incomprinibile e di sopportare forti carichi. incompressible and which is able to nicht komprimierbar ist und starke
withstand substantial loads. Belastungen aushält.
La trasmissione HYDROMATIK A 4
VG..DA/A 6 VM..DA si compone di due Das Getriebe HYDROMATIK A 4 VG..DA/A
organi separati. The HYDROMATIK A 4 VG.. DA/A 6 6 VM..DA setzt sich aus zwei getrennten
VM..DA transmission system consists of Organen zusammen.
1° Una pompa A 4 VG del tipo a two separate organs.
1) Eine Pumpe A 4 VG vom Axialkolbentyp
pistoni assiali costruzione a
mit Plattenkonstruktion, die auf dem
piattello, flangiata sul 1° An A 4 VG axial piston pump of a plate Dieselmotor aufgeflanscht ist und direkt
diesel e trascinata direttamente design, flange-mounted on to the diesel vom Schwungrad mittels einer elastischen
dal volano per mezzo di un engine and driven directly by the flywheel Kupplung mitgenommen wird.
giunto elastico. by means of a flexible coupling.
2) Ein Hydromotor A 6 VM vom
2° Un motore idraulico A 6 VM del 2° An A 6 VM hydraulic axial piston motor Axialkolbentyp, Konstruktion mit
tipo a pistoni assiali costruzio- of a bent axis design, flange-mounted on Schräggehäuse, aufgeflanscht auf einem
ne a corpo inclinato, flangiato Untersetzungsgetriebe mit zwei
to a coupling case and a transfer case and
ad un riduttore a due velocità Geschwindigkeiten, das auf einer
driving the two axle shafts via a differential.
posizionato su di un ponte dif- Differentialachse sitzt, das die Bewegung
ferenziale che trasferisce il bis zu den Rädern überträgt.
moto fino alle ruote.
La pompa e il motore idraulico sono colle- The pump and the hydraulic motor are Die Pumpe und der Hydromotor sind mit-
gate tra loro tramite dei tubi flessibili così linked together by a series of hoses, as einander über hydraulische Leitungen ver-
come i diversi accessori necessari per il are various accessories required for opera- bunden, so wie auch mit verschiedenen
tion of the system: reservoir,filter,drain and Zubehörteilen, die für den Betrieb erforder-
funzionamento: serbatoio, flltro, ritorno del
lich sind: Tank, Filter, Rücklauf des Öls
drenaggio nel radiatore, etc. return to the cooler, etc.
zum Kühler etc.
La pompa assorbe la potenza limite dispo- The pump absorbs the maximum power Die Pumpe nimmt die verfügbare
nibile del motore termico e la trasforma in supplied by the IC engine and converts it Grenzleistung des Verbrennungsmotors
potenza idraulica (prodotto di pressione into hydraulic power (product of the pres- auf und setzt sie in hydraulische Leistung
generata e del flusso). sure generated and the delivery rate). um (Produkt aus erzeugtem Druck und
Durchfluss).
Il motore idraulico che é l’organo ricevitore The hydraulic motor receives the hydraulic
assorbe integralmente la potenza idraulica. power and absorbs it completely. The out- Der Hydromotor ist das Organ, das die
Risulta allora sull’albero di uscita, una cop- hydraulische Leistung ganz aufnimmt. Auf
put shaft is then given a torque and speed
pia e una velocità di rotazione ripresa da der Ausgangswelle liegt daher ein
which is transferred to the axle and distrib-
un ponte e distribuita alle ruote. Drehmoment und eine
uted to the wheels. Drehgeschwindigkeit vor, die von einer
La variazione del rapporto della trasmissio- Achse übernommen und auf die Räder
ne si ottiene per variazione della cilindrata The variation in the transmission ratio is verteilt wird.
della pompa e del motore idraulico. obtained by the variation in the displace-
ment of the pump and the hydraulic motor. Die Variation des Übersetzungsverhältnis-
ses erhält man durch die Variation des
La pressione di pilotaggio agisce contro
The pilot pressure acts against the high Hubraums von Pumpe und Hydromotors.
l’alta pressione sul servo-posizionatore in
un rapporto fisso determinato (1/3). pressure on the servo positioner in a set
Der Vorsteuerdruck wirkt gegen den
ratio (1/3). Hochdruck auf dem Servo-Positionierer mit
La preponderanza di una in rapporto all’al- einem vorgegebenen festen Verhältnis
tra fanno sì che il motore entri o non entri The preponderance of one in relation to (1/3).
in regolazione. the other determines whether the motor is
controlled or not. Das Überwiegen des einen im Bezug zum
La cilindrata minima del motore é limitata anderen führt dazu, dass der Motor in
da una vite di arresto. The minimum motor displacement is limit- Regulierung geht oder nicht.
ed by a butt screw.
Un sistema di regolazione controlla il Der kleinste Hubraum des Motors wird
tempo di commutazione del motore. durch eine Feststellschraube begrenzt.
A control system sets the motor switching
time. Die Umschaltzeit des Motors wird durch
ein Regelsystem gesteuert.
4
MRT 1440-1640-1840 EASY 75
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CATENA CINEMATICA DELLA CINEMATIC CHAIN OF THE KINEMATISCHE KETTE DES
TRASMISSIONE TRANSMISSION GETRIEBES
FRENI PONTE DIFFERENZIALE FRENI

BRAKE FINAL TRANSMISSION BRAKE
BREMSEN DIFERENTIALACHSE BREMSEN
RIDUTTORE A 2 VELOCITÀ
2 SPEED REDUCER
2-STUFIGES UNTERSET-
ZUNGSGETRIEBE MOTORE A CILINDRATA VARIEBILE
VARIABLE DISPLACEMENTMOTOR
VERSTELL-MOTOR
RADIATORE OLIO
OIL COOLER
ÖLKÜHLER
SERBATOIO
TANK
RESERVOIR
TUBI FLESSIBILI AD ALTA PRESSIONE TUBI FLESSIBILI AD ALTA PRESSIONE

HIGH PRESSURE HOSE HIGH PRESSURE HOSE
HOCHDRUCKLEITUNGEN HOCHDRUCKLEITUNGEN
FILTRO
FILTER
FILTER
POMPA DI
SOVRALIMENTAZIONE
BOOSTER PUMP
AUFLADEPUMPE
POMPA A CILINDRATA VARIABILE

VARIABLE CAPACITY PUMP
VERSTELL-PUMP
MOTORE TERMICO
IC ENGINE
VERBRENNUNG-
SMOTOR
5
75 MRT 1440-1640-1840 EASY
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TRASMISSIONE IDROSTATICA TRANSMISSION HYDROSTAIC HYDROSTATISCHES GETRIEBE
6
TRASMISSIONE
IT
SISTEMA IDRAULICO
VALVOLA INCHING
INCHING VALVE
INCHING-VENTIL
DISTRIBUTORE
DISTRIBUTOR
STEUERGERÄT
MRT 1440-1640-1840 EASY
R T1 T2 b a PS MB
MOTORE PERKINS
PERKINS ENGINE T A
MOTOR PERKINS B
1104C-44T
EN
HYDRAULIC SYSTEM
A MOTORE A CILINDRATA VARIABILE

A6VM 80 DA
X1 X2 G S MA VARIABLE DISPLACEMENT
POMPA A CILINDRATA VARIABILE A4VG 56 DA ENGINE A6VM 80 DA
VARIABLE DISPLACEMENT A4VG 56 DA VERSTELLMOTORA6VM 80 DA
VERSTELLPUMPE A4VG 56 DA X1 X2 B
SERBATOIO
TANK
SERBATOIO IDRAULICO
HYDRAULIC TANK
GETRIEBE
HYDRAULIKBEHÄLTER
DE
HYDRAULISCHER SCHALTPLAN
7
75
75 MRT 1440-1640-1840 EASY
IT EN DE
POMPA A4 VG / DA PUMP A 4 VG / DA PUMPE A4 VG / DA
Come nella serie A 4 V, questa pompa é Wie bei der Serie A 4 V ist diese Pumpe
Like the A 4 VG series, this pump is fitted
munita: with: ausgestattet mit:
di una regolazione tachimetrica, a tachometric control device, einer Drehzahlregelung,

a plate restoring force control device,
di una regolazione tramite di richiamo del einer Regelung mittels Plattenrückruf,
piattello,
but also: hat aber zusätzlich:
ma in più:
eine DR-Regelung, genannt "ANNULLIE-
a DR control known as a "flow cut-off
di una regolazione DR detta "VALVOLA DI valve" with pressure hold. RUNGSVENTIL" des Durchflusses mit
ANNULLAMENTO" di flusso con Beibehaltung des Drucks.
mantenimento della pressione.
VALVOLA HP
HP VALVE
VENTIL HP
ZERO MECCANICO
ZERO MECHANICAL SET
MECHANISCHE NULL USCITA VALVOLA INCHING
INCHING VALVE OUTLET
AUSGANG INCHING-VENTIL
PS
VALVOLA DR
DR VALVE
VENTIL DR
VITE DI FINE REGOLAZIONE

FINE TUNING SCREW
SCHRAUBEN FÜR REGELENDE
VALVOLA DI MASSIMA SOVRALIMENTAZIONE

MAXIMUM BOOSTER VALVE
VENTIL FÜR MAX. AUFLADUNG
CARTUCCIA DI REGOLAZIONE “DA”

“DA” REGULATION CARTRIDGE
REGELPATRONE “DA”
VALVOLA HP
HP VALVE
VENTIL HP
8
MRT 1440-1640-1840 EASY 75
IT EN DE
SEZIONE POMPA 4 VG / DA SECTIONAL VIEW OF PUMP QUERSCHNITT PUMPE 4 VG / DA

A 4 VG / DA
9
75 MRT 1440-1640-1840 EASY
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MOTORE A6 VM / DA MOTOR A 6 VM / DA MOTOR A6 VM / DA

Motore a cilindrata variabile serie 6 - per Series 6 variable displacement motor - for Verstellmotor Serie 6 - für offene und
circuiti aperti e chiusi - costruzione: a open and closed circuits - design: axial geschlossene Kreisläufe - Konstruktion:
pistoni assiali conici con segmenti a tenuta tapered pistons with sealing rings and bent Axialkegelkolben mit hermetisch abdich-
stagna e asse inclinato. Cilindrata 28 a axis. Size 28 to 200 - nominal pressure: tenden Kolbenringen und schrägstehender
200 - pressione nominale: 400 bar - pres- 400 bar - peak pressure: 450 bar. Achse. Hubraum von 28 bis 200 -
sione massima: 450 bar. Nenndruck: 400 bar - Höchstdruck: 450
bar.
Adatto ad installazioni mobili e fisse. Adapted to mobile and stationary applica- Geeignet für stationäre und bewegliche
Il suo grande campo di regolazione per- tions. Installationen.
mette a questo motore di soddisfare le esi- Its wide control range allows this motor to Der große Einstellbereich gestattet es die-
genze di meet high speed and torque requirements. sem Motor, den Ansprüchen hinsichtlich
velocità e di coppia elevate. Its displacement is continuosly variable in hoher Geschwindigkeiten und
La cilindrata é variabile nel rapporto: the ratio: Drehmomente gerecht zu werden.
Der Hubraum ist mit dem folgenden
Verhältnis variabel:
Vg max / Vg min = 4,85 di continuo. V g max / V g min = 4,85.
Vg max / Vg min = 4,85 stufenlos.
La velocità di uscita é proporzionale al The output speed is proportional to the
flusso assorbito e inversamente proporzio- flow absorbed and inversely proportional to Die Ausgangsgeschwindigkeit ist dem
nale alla the displacement. The output torque varies absorbierten Fluß proportional und dem
cilindrata. La coppia di uscita varia in fun- according to the difference in pressure Hubraum umgekehrt proportional. Das
zione della differenza di pressione tra le between the high and low pressure outlets, Ausgangsdrehmoment ändert sich je nach
uscite di alta e bassa pressione, lo stesso and according to the displacement. der Druckdifferenz zwischen den
che in funzione della cilindrata. Ausgängen mit Niederdruck und
Hochdruck, ebenso wie im Bezug zum
Hubraum.
Particolarità: Special features: Besonderheiten:
- Grande campo di regolazione per - Wide control range for hydrostatic - Großer Regelbereich für hydrosta-
trasmissioni idrostatiche. transmission systems. tische Getriebe.
- Diversi dispositivi di regolazione di - Various displacement control - Verschiedene Vorrichtungen zur
cilindrata. devices. Einstellung des Hubraums.
- Riduzione del costo delle trasmis- - Reduced cost due to the elimina- - Verringerung der Getriebekosten
sioni grazie alla soppressione del tion of the gearbox or the use of dank der Unterdrückung des
cambio di velocità o all’utilizzo di smaller pumps. Schaltgetriebes oder der
pompe di più piccola cilindrata. - Compact, robust tapered bearings. Benutzung von Pumpen mit klei-
- Supporti a rulli conici robusti e di - High specific output. nem Hubraum.
piccolo ingombro. - Good start-up characteristics. - Robuste Kegelrollenlager mit
- Potenza massima elevata. geringem Platzbedarf.
- Buone caratteristiche in partenza - Große Höchstleistung.
- Gute Anlaufeigenschaften.
10
MRT 1440-1640-1840 EASY 75
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FUNZIONAMENTO CARTUCCIA DI “DA” CONTROL CARTRIDGE FUNKTION DER REGELPATRONE “DA”
REGOLAZIONE “DA” OPERATION
La pressione di pilotaggio viene prelevata The pilot pressure is drawn via the control Der Vorsteuerdruck wird durch den
tramite il cursore della cartuccia di regola- cartridge slide valve into the booster cir- Schieber der Regelpatrone des
zione del circuito di sovralimentazione. Al cuit. At maximum IC engine speed, the Aufladekreislaufs entnommen. Bei max.
regime massimo del motore termico, la pilot pressure is a few bars lower than the Drehzahl des Verbrennungsmotors ist der
pressione di pilotaggio é inferiore di qual- booster pressure. Vorsteuerdruck um ein paar Bar kleiner als
che bar alla pressione di sovralimentazio- der Aufladedruck.
ne.
Al minimo (850 min-1), il flusso di sovrali- On idling (850 rpm) the booster flow which Bei der Mindestdrehzahl (850 min-1) reicht
mentazione, che attraversa il foro calibrato passes through the calibrated opening in der Aufladefluß, der durch das kalibrierte
dell’elemento della cartuccia di regolazio- the control cartridge slide valve is sufficient Loch des Elements der Regelpatrone
ne, non é sufficiente per creare una perdita to create a drop in pressure capable of dis- strömt, nicht aus, um einen
di carico capace di spostare il cursore Rif. placing the slide valve 1 against the force Strömungsverlust zu schaffen, der in der
1 a causa della forza della molla Rif. 2. La of the spring 2. The pilot pressure is there- Lage ist, den Schieber Bez. 1 durch die
pressione di fore nil. Kraft der Feder Bez. 2 zu bewegen. Der
pilotaggio é allora nulla. Vorsteuerdruck ist dann Null.
Quando l’operatore accelera il regime del When the operator accelerates in order to Wenn der Bediener die Drehzahl des
motore termico per avanzare (a circa 1050 move forward (to approximately 1050 Verbrennungsmotors zum Fahren erhöht
min-1), il flusso di sovralimentazione rpm), the booster flow increases; the drop (auf circa 1050 min-1), nimmt der
aumenta; la perdita di carico davanti al in pressure before the calibrated opening Aufladefluß zu; der Strömungsverlust vor
foro calibrato diventa is now sufficient to move the slide valve to dem kalibrierten Loch wird dann ausrei-
sufficiente per spostare il cursore verso the left, against the spring, thus revealing chend groß, um den Schieber nach links
sinistra, schiacciando la molla, scoprendo the pilot opening. zu bewegen, wobei die Feder zusammen-
così il foro di pilotaggio. gedrückt und das Vorsteuerloch freigege-
ben wird.
Quando la pressione di pilotaggio arriva a When the pilot pressure reaches approxi-
circa 6 ÷ 7 bars, il cilindro di servocoman- mately 6 to 7 bar, the servocontrol cylinder Wenn der Vorsteuerdruck bei circa 6 - 7
do comincia a spostarsi inclinando il piat- begins to move, tilting the plate of the vari- bar ankommt, beginn der Zylinder der
tello della pompa a portata variabile. able capacity pump. The pump begins to Servosteuerung sich zu bewegen und die
Questa comincia ad erogare (inizio di discharge (start of control). The greater the Platte der Verstellpumpe zu neigen. Diese
regolazione). Più il regime del motore engine speed, the more the booster flow beginnt zu fördern (Beginn der Regelung).
aumenta, più il flusso di increases thus increases thus leading to a Je stärker die Drehzahl des Motors
sovralimentazione aumenta così come rise in the pilot pressure and therefore zunimmt, desto mehr nimmt der
aumenta la pressione di pilotaggio, e dun- increased influence on the pump and Aufladungsfluß zu, wie auch der
que un greater machine speed. Vorsteuerdruck, und folglich eine umfang-
pilotaggio più ampio della pompa e, di con- reichere Vorsteuerung der Pumpe und
seguenza, una velocità più elevata della daher eine höhere Geschwindigkeit der
macchina. Maschine.
Per fermarsi, I'operatore non accelera più, To halt this process, the operator stops Um anzuhalten, gibt der Fahrer kein Gas
il flusso di sovralimentazione cade, la per- accelerating, the booster flow drops, the mehr, der Aufladefluß nimmt ab, der
dita di carico diminuisce e la molla Rif. 2 pressure drop is reduced and the spring 2 Strömungsverlust nimmt ab und die Feder
respinge il cursore Rif. 1 fermando anche il pushes back the slide valve 1 thus closing Bez. 2 schiebt den Schieber Bez. 1
passaggio della sovralimentazione verso la the booster passage to the pilot conduit. zurück, wobei auch der Durchstrom des
canalizzazione di pilotaggio. La pressione The residual pilot pressure is discharged Aufladeöls zum Vorsteuerkanal aussetzt.
residua di pilotaggio viene evacuata verso towrads the housing. Der restliche Vorsteuerdruck wird zum
il carter. Gehäuse abgeleitet.
11
75 MRT 1440-1640-1840 EASY
IT EN DE
FUNZIONAMENTO CARTUCCIA DI “DA”CONTROL CARTRIDGE FUNKTION REGELPATRONE “DA”

REGOLAZIONE “DA” OPERATION
POMPA A FLUSSO VARIABILE

VARIABLE CAPACITY PUMP
VERSTELLPUMPE
CILINDRO SERVOCOMANDO
SERVOCONTROL CYLINDER
ZYLINDER SERVOSTEUERUNG
ELETTROVALVOLA MAV_N.MAR.
M A V _ N. M A R. ELETTROVALVE
MAGNETVENTIL M A V _ N. M A R.
LIMITATORE DI PRESSIONE
SOVRALIMENTAZIONE
BOOSTER PRESSURE
RELIEF VALVE
DRUCK-BEGRENZER
AUFLADUNG
RIF. 2
REP. 2 RIF. 1
BEZ. 2 REP. 1
BEZ. 1
CARTUCCIA DI REGOLAZIONE
CONTROL CARTRIDGE
REGELPATRONE
ACCELERATORE
ACCELERATOR
GASPEDAL
VITE DI CALIBRAZIONE INIZIO REGOLAZIONE

START OF CONTROL ADJUSTING SCREW
KALIBRIERSCHRAUBE REGELBEGINN
12
MRT 1440-1640-1840 EASY 75
IT EN DE
CIRCUITO INCHING PILOT CIRCUIT INCHING-KREISLAUF
Serbatoio
Tank
PS
Valvola inching
inching valve
Inching-Ventil
P
A T
Valvola inching
inching valve MB
b a PS
Inching-Ventil
13
75 MRT 1440-1640-1840 EASY
IT EN DE
FUNZIONAMENTO VALVOLA OPERATION OF THE INCHING FUNKTION INCHING-VENTIL (VEN-

INCHING (VALVOLA TH7 SUL VALVE (TH7 VALVE ON BRAK TIL TH7 AUF BREMSPEDAL)
PEDALE DEL FRENO) EPEDAL)
REF. A “START CONDITION” BEZ. A “FAHRZUSTAND”

RIF. A “CONDIZIONE DI MARCIA” When the brake pedal is released; pusher Wenn das Bremspedal losgelassen wird,
Quando il pedale del freno è rilasciato; lo spinto- “1” is ist der Stößel “1” ganz in seinen Sitz ein-
re “1” è completely retracted into its seat: the pas- gefahren: Der Öldurchfluß ist integral zwi-
completamente rientrato all’interno della sua sage of oil is entirely between orifice “P” schen der Öffnung “P” (Ankunft des
sede : il passaggio (pilot pressure inlet) and orifice “A” (pilot Vorsteuerdrucks) und der Öffnung “A”
d’olio è integralmente fra l’orifizio “P” (arrivo della pressure outlet). (Ausgang des Vorsteuerdrucks).
pressione di The oil circulates freely through orifice “3” Das Öl läuft frei zur Öffnung “3” des
pilotaggio) e l’orifizio “A” (uscita di pressione di of cursor “2”. Schiebers “2”.
pilotaggio). The pilot pressure, injected in the pump Der Vorsteuerdruck, der in den
L’olio circola liberamente per l’orifizio “3” del cur- pad control cylinder is therefore identical to Steuerzylinder der Pumpenplatte einge-
sore “2”. that with an assembly without Inching spritzt wird, ist daher identisch mit dem
La presione di pilotaggio, iniettata nel cilindro di valve TH7. Druck, den wir bei einer Montage ohne
comando del Inching-Ventil TH7 haben.
piattello della pompa, è dunque identico a quella
che noi abbiamo con un montaggio senza valvo-
la Inching TH7. BEZ. B “ZUSTAND FÜR LANGSAME
ANNÄHERUNG”
Drückt man auf die ersten cm Hub des
RIF. B “CONDIZIONE PER L’AVVICINAMENTO REF. B “CONDITION FOR SLOW Bremspedals, können wir eine langsame
LENTO” APPROACH” Annäherung ausführen; der Stößel “1” ist
Push on the brake pedal on the first cm of teilweise aus seinem Sitz ausgefahren.
Spingendo sul pedale del freno sui primi cm di travel, for a slow approach; pusher “1” is Der Öldurchfluß ist für die Öffnung “3” des
corsa, possiamo fare l’avvicinamento lento; lo partially drawn out of its seat; the oil pas- Schiebers “2” kalibriert.
spintore “1” è parzialmente uscito dalla sua sage is calibrated for orifice “3” of cursor Der Ausgangsdruck der Vorsteuerung am
sede; il passaggio d’olio è calibrato per l’orifizio “2”. Ausgang “A” ist daher auf den Wert des
“3” del cursore “2”. The pilot output pressure at outlet “A” will letzteren geregelt.
La pressione d’uscita del pilotaggio all’uscita “A” therefore be regular at the latter value. Wenn nämlich die Ankunft des
sarà pertanto regolare al valore di questa ultima. In fact, if the arrival of the pilot pressure Vorsteuerdrucks am Eingang “P” zunimmt,
In effetti se l’arrivo della pressione di pilotaggio increases at inlet “P”, with this pressure entsteht dieser Druck auf dem Querschnitt
aumenta all’entrata “P”, questa pressione creata- created on section “S” of cursor “2”, “S” des Schiebers “2”, die Federn “4” und
si sulla sezione “S” del cursore “2”, le molle “4” e springs “4” and “5” will be compressed and “5” werden zusammengedrückt und der
“5” verranno compresse ed il cursore “2” si spo- cursor “2” will move in the direction of Schieber “2” bewegt sich in der Richtung
sterà nel senso della freccia “F” : così ridurrà il arrow “F”: thus the passage of oil through von Pfeil “F”: So wird der Öldurchlauf
passaggio d’olio attraverso l’orifizio “3” creando orifice “3” will be reduced, creating a load durch die Öffnung “3” verringert, was einen
una perdita di carico fra l’entrata “P” e l’uscita “A”. loss between inlet “P” and outlet “A”. Strömungsverlust zwischen dem Eingang
Così la pressione di uscita al pilotaggio “A” sarà The pilot pressure at outlet “A” will thus be “P” und dem Ausgang “A” schafft.
proporzionale al valore di pressione in entrata proportional to the pilot pressure value at So wird der Ausgangsdruck der
del pilotaggio “P”. inlet “P”. Vorsteuerung “A” proportional zum Wert
Così vuol dire che la pressione iniettata nel cilin- This means the pressure injected in the des Eingangsdrucks der Vorsteuerung “P”
dro di comando del piattello della pompa sarà pump pad control cylinder will be constant; sein.
costante; l’inclinazione del piattello sarà anche lui the pad inclination will also be constant. Das bedeutet, dass der in den
costante. This makes it possible to have a slow Steuerzylinder der Pumpenplatte einge-
Questo ci permette sul carrello un avvicinamento approach on the carriage with millimetre spritzte Druck konstant sein wird. Auch die
lento con un avanzamento millimetrico; questa progress; this speed will be selected Neigung der Platte wird konstant sein.
velocità sarà selezionata in depending on the push on the brake pedal. Dies gestattet auf dem Stapler die langsa-
funzione della spinta sul pedale del freno. me Annäherung mit einem millimeterwei-
sen Vorwärtsfahren; diese Geschwindigkeit
wird je nach dem Druck auf das
RIF. C “STACCO TRASMISSIONE” REF. C “TRANSMISSION DETACHMENT” Bremspedal gewählt.
On pressing the brake pedal all the way
Spingendo a fondo il pedale del freno, lo spintore down, pusher “1” will be completely BEZ. C “GETRIEBEABTRENNUNG”
“1” sarà completamente uscito e finchè il pedale extended outwards; as long as the pedal Drückt man das Bremspedal ganz durch,
resterà premuto, lo spintore rimarrà in tale posi- remains pressed, the pusher will remain in tritt der Stößel “1” ganz aus und bleibt in
zione. this position. dieser Position, solange das Pedal durch-
Dunque in questa posizione dello spintore “1” Thus, in this position, of pusher “1” the getreten bleibt.
non ha più la pressione di pilotaggio all’uscita pilot pressure is no longer available at out- In dieser Position hat der Stößel “1” keinen
“A”; pertanto mancando la pressione al cilindro di let “A”; therefore, in the absence of pres- Vorsteuerdruck mehr am Ausgang “A”; da
comando del piattello della pompa, la pompa sure at the pump pad control cylinder, the der Druck am Steuerzylinder der
avrà la cilindrata annullata pertanto la macchina pump displacement will be annulled, and Pumpenplatte fehlt, wird der Hubraum der
sarà frenata. therefore the vehicle will be braked. Pumpe gleich Null und die Maschine wird
N.B. è chiaro che la pressione di pilotaggio N.B. it is clear that the pilot pressure out- gebremst.
uscendo dalla “A” è tuttavia diretto : put from “A” is however directed as fol- Anm.: Es ist klar, dass der Vorsteuerdruck,
- una parte verso il cilindro di comando dell lows: der aus “A” austritt, auf jeden Fall
pompa - one part towards the pump control gerichtet ist zu:
- l’altra parte verso il dispositivo di comando della cylinder - ein Teil zum Steuerzylinder der
cilindrata del motore. - the other part towards the motor Pumpe
displacement control device. - der andere Teil zur
Steuervorrichtung des Hubraums
des Motors.
14
MRT 1440-1640-1840 EASY 75
Rif. A
Rif. B
Rif. C
15
75 MRT 1440-1640-1840 EASY
IT EN DE
VALVOLA DR DR VALVE VENTIL DR
Cursore di regolazione DR
DR Control Slide Valve
Regelschieber DR
Sede
Seat
Sitz Molla
Sprin
Selettore HP Feder
HP Selector
Wähler HP
Foro per evacuazione dei trafilamenti

Cursore
Hole in Collar for Leakes
Bronze Slide Valve
Loch für Ablauf des durchsickernden Öls
Schieber
Spillo di pilotaggio
Pilot Needle
Vorsteuernadel
Vite di regolazione
DR Adjusting
Stellschraube
In caso di grande caduta del regime del In the event of a considerable drop in Bei einem starken Abfall der Drehzahlen
motore termico, controllare che lo the IC engine speed, check that the des Verbrennungsmotors sicherstellen,
spillo di pilotaggio non sia “grippato” pilot needle has not become stuck in dass die Vorsteuernadel nicht im
nel cursore the slide valve Schieber festgefressen ist.
16
MRT 1440-1640-1840 EASY 75
IT EN DE
VALVOLA DR DR VALVE VENTIL DR
1°) RUOLO 1) ROLLE
1°) FUNCTION
Aufhebung des Flußes unter Beibehaltung
Annullamento del flusso con mantenimento To cut off flow while maintaining pressure. des Drucks. Dies entspricht einer
della pressione. Questo corrisponde ad un This corresponds to a return of the pump Rückkehr des Hubraums des Pumpe zu
ritorno della cilindrata della pompa verso la displacement to the “O” before the HP "O", bevor die Eichung der Ventile HP
"O" prima che la taratura delle valvole HP valve calibration is reached. erreicht ist.
sia ragguinta.
Questa valvola previene l’attivazione dei This valve anticipates HP relief valve acti- Dieses Ventil beugt der Aktivierung der
limitatori HP al momento dei fenomeni di Begrenzer HP bei Erscheinungen wie
vation on acceleration and deceleration
accelerazione e di decelerazione (aumento Gasgeben und Abbremsen vor (schnelle
(rapid rise in pressure). Druckzunahme).
rapido della pressione). The peak pressure is reduced by the HP Der Höchstdruck wird von den Begrenzern
La pressione massima viene tagliata dai relief valves which also protect the circuit HP geschnitten, die den Kreislauf dennoch
limitatori HP che proteggono ugualmente il against ultra-rapid fluctuations. The cali- gegen extrem rasche Druckschwankungen
circuito contro le fluttuazioni estremamente bration range for cutting off the flow while schützen. Die Eichung mit Aufhebung des
rapide. La taratura in annullamento del maintaining pressure covers the whole Durchflußes unter Beibehaltung des
flusso con mantenimento di pressione si working pressure range. The correspond- Drucks dehnt sich auf die ganze
estende su tutta la superficie di pressione Betriebsdruckfläche aus. Die entsprechen-
ing calibration values should however be
di servizio. I valori della taratura corrispon- den Eichungswerte müssen auf jeden Fall
20 to 30 bar lower than those of the HP um 20 bis 30 bar unter denen der
denti dovranno tuttavia essere da 20 a 30 relief valves. Begrenzer HP liegen.
bar inferiori a quelli dei limitatori HP.
- Reduced transmission noise. - Getriebe mit geringerem
- Trasmissione meno rumorosa. - Wider control range. Betriebsgeräusch.
- Campo di regolazione più grande. - Größerer Regelbereich.
Composition of the DR Valve Aufbau des Ventils DR

Composizione della Valvola DR
1) Fördermengenwähler Kreislauf
1) HP circuit sensor flow selector.
1) Selettore di portata circuito HP. HP.
2) A slide valve which connects the 2) Ein Schieber, der den
2) Un cursore che mette in
pilot circuit to the tank in order Vorsteuerkreislauf mit dem Tank
comunicazione il circuito di
to release the pump from the in Verbindung setzt, um die
pilotaggio al serbatoio per
pilot control while maintaining Pumpe vorzusteuern und bei
pilotare la pompa e mantenere i
the 400 bar level (control starts 400 bar zu halten (Beginn der
400 bars (inizio regolazione di 6 Regelung bei 6 - 7 bar, 20 bar
at 6 to 7 bar, control ends at 20
÷ 7 bar, 20 bar fine regolazione Ende der Regelung mit max.
bar with maximum flow).
con portata max). Fördermenge).
The DR valve allows the flow to be Das Ventil DR gestattet es, die
La valvola DR permette di ridurre
reduced while retaining maximum torque. Fördermenge aufgrund der max.
la portata in base alla coppia max.
Drehmoments zu verringern.
2°) OPERATION 2) FUNKTION

2°) FUNZIONAMENTO
Der HP MA oder MB geht durch den
The HP or MB pushes the HP circuit selec- Wähler Kreislauf HP nach oben oder nach
La HP MA o MB passa per il selettore cir-
tor upwards or downwards thus closing the unten und schließt auch die gegenüberlie-
cuito HP verso l’alto o verso il basso chiu-
opposite low pressure port (in a HP direc- gende Öffnung mit Niederdruck (im Sinne
dendo anche l’orifizio opposto in bassa
tion of A to B, the HP traverses the centre einer HP von A nach B, HP geht zum
pressione (nel senso di una HP da A verso
of the selector through a small channel). Mittelpunkt des Wählers durch einen klei-
B, la HP passa per il centro del selettore nen Durchlauf).
attraverso un piccolo passaggio).
In all cases, the HP then pushes the nee-
In allen Fällen schiebt der HP die Nadel
dle 4 which in turn raises the control slide
In tutti i casi, la HP spinge lo spillo Rif. 4 Bez. 4, die gleichzeitig den Regelschieber
valve 3 which creates a partial connection Bez. 3 hebt, wobei die Vorsteueröffnung
che, allo stesso tempo solleva il cursore
between the control opening and return teilweise mit dem Ablauf in Verbindung
della regolazione Rif. 3 mettendo parzial-
thuis reducing the pilot pressure. gesetzt wird, was den Vorsteuerdruck ver-
mente in comunicazione l’orifizio di pilotag-
ringert.
gio con lo scarico, riducendo così la pres-
The effect of this is to reduce the pump
sione di pilotaggio. Das bringt als Wirkung zur Verringerung
displacement, thus reducing the flow while
maintaining the 400 bar HP (flow reduction des Hubraums der Pumpe, was die
Questo porta all’effetto di diminuire la cilin- Fördermenge reduziert, um den HP bei
for a maximum torque).
drata della pompa, riducendo così la porta- 400 bar zu halten (Verringerung der
ta per mantenere la HP a 400 bar (diminu- Fördermenge bei einem max.
This action of removing the pilot control Drehmoment).
zione della portata per una coppia max).
from the pump acts in the same way as
the restoring forces generated by the HP Diese Vorsteuerung der Pumpe wirkt in der
Questa azione di pilotaggio della pompa
and the adjustment of the control plate. gleichen Richtung wie die Rückholkräfte,
agisce nello stesso senso che le forze di die von der HP erzeugt werden, und wie
richiamo generate dalle HP e il bloccaggio die Sperre der Verteilerplatte.
della piastra di distribuzione.
17
75 MRT 1440-1640-1840 EASY
IT EN DE
VISTA IN SEZIONE DELLA “DR” SECTIONAL VIEW OF THE ANSICHT AUF QUERSCHNITT DES
VALVOLA DR DR VALVE VENTILS DR
Controdado Vite di regolazione

Locknut 14 9 DR Adjusting
Gegenmutter Stellschraube
Distanziale Boccola di contenimento

Collar 1 End cap
Distanzstück 8 Haltebuchse
Guarnizione Cursore in bronzo

Seal 10 2 Bronze slide valve
Dichtung Bronzeschieber
Cursore per la registrazione DR

Molla
Spring 7 3 DR control slide valve
Regelschieber DR
Feder
Pilotaggio
Pilot
Vorsteuerung
Distanziale 8
Collar 4 Spillo
Distanzstück Needle
Nadel
Selettore HP
MB 5 HP selector
Wähler HP
MA 6
Sede
Seat
Sitz
18
MRT 1440-1640-1840 EASY 75
IT EN DE
PUNTI DI REGOLAZIONE TRANSMISSION ADJUSTMENT GETRIEBEREGELSTELLEN

TRASMISSIONE POINTS
POMPA A 4VG PUMP A 4VG PUMPE A 4VG
Registro del “0” meccanico del piattello

Swashplate zero position Valvola HP
Einstellung der mechanischen “0” der Platte HP Valve
Ventil HP
Eccentrico registrazione della piastra fine regolazione

Eccentric for valve plate adjustement
Stellnocken der Platte für Regelende
Valvola della sovralimentazione

Boost of valve
Aufladeventil
Registro inizio regolazione “DA”

Start of regulation
Einstellung Regelbeginn “DA”
Valvola HP
HP Valve
Ventil HP
Valvola DR
Valve DR Valvola di regolazione “DA”
Ventil DR Control valve
Regelventil “DA”
MOTORE A 6VM MOTOR A 6VM MOTOR A 6VM
Vite registro cilindrata minima (non sregolare)

Minimum displacement stop (do not readjust)
Stellschraube kleinster Hubraum (nicht verstellen)
Vite registrazione rego-
lazione commutazione
A6VM DA Regulation screw
Stellschraube
Einstellung
Umschaltung
19
75 MRT 1440-1640-1840 EASY
IT EN DE
CONTROLLO E REGISTRAZIONI CHECKING AND REGULATING PRÜFUNG UND EINSTELLUNGEN
TRASMISSIONE TRANSMISSION DES GETRIEBES
1 CONTROLLO E REGISTRAZIONE 1 CHECKING AND REGULATING 1 PRÜFUNG UND EINSTELLUNG

PRESSIONE DELLA BOOSTER DES AUFLADEDRUCKS
SOVRALIMENTAZIONE
3
6
“G”
Limitatore sovralimentazione Booster limiter Begrenzer Aufladung
20
MRT 1440-1640-1840 EASY 75
IT EN DE
Osservare le regole di sicurezza! Observe the safety rules! Die Sicherheitsregeln beachten!
N.B.: Registrare solamente a temperatura N.B.: Adjust only the operating tempera- Anm.: Nur bei Betriebstemperaturen ein-
di esercizio. ture. stellen.
Connettere il manometro in “G”. Connect the pressure gauge in “G”. Das Manometer an “G” anschließen.
Registrazione della pressione della sovrali- Adjusting booster pressure Einstellung des Ausladedrucks
mentazione Nominal Pressure Nenndruck
Pressione Nominale PH - 18 bar PH - 18 bar
PH - 18 bar Pressure at maximum speed Druck bei max. Geschwindigkeit
Pressione alla massima velocità PH - 40 bar PH - 40 bar
PH - 40 bar
The A4VG56 series pump is equipped with Die Pumpe - Serie A4VG56 - ist mit einem
La pompa - serie A4VG56 - è equipaggiata a limiter that can be adjusted from the out- von außen einstellbaren Druckbegrenzer
di un limitatore regolabile dall’esterno. side. versehen.
Per aumentare la pressione di sovralimen- To increase the booster pressure, it is nec- Um den Aufladedruck zu erhöhen, ist es
tazione, é necessario aumentare lo spes- essary to increase the thickness between erforderlich, die Stärke zwischen dem
sore fra il distanziale 6 e la molla 3. spacer 6 and spring 3. Distanzstück 6 und der Feder 3 zu
Al max regime motore termico, Pmax. = 32 At maximum engine rpm, Pmax. = 32 bar erhöhen.
bar (utilizzare manometri di piccola scala (use pressure gauges with small scale Bei der max. Drehzahl des
(40÷100 bar)). (40÷100 bar)). Verbrennungsmotors Pmax. = 32 bar
La temperatura dell’olio non deve superare The oil temperature must not exceed 40 (Manometer mit kleiner Skala benutzen:
i 40 °C. °C. (40-100 bar)).
La pompa deve essere equipaggiata di The pump must be equipped with a pres- Die Öltemperatur darf nicht über 40 °C
una presa di pressione come in figura. sure intake as shown in the Figure. liegen.
La macchina deve essere completamente The vehicle must be completely braked. Die Pumpe muss mit einem
frenata. Check that there is no entrainment in the Druckanschluss wie in der Abbildung ver-
Controllare che non vi siano trafilamenti inching valve. sehen sein.
nella valvola inching. Die Maschine muss ganz
gebremst werden.
Sicherstellen, dass am Inching-Ventil kein
Öl durchsickert.
Questa operazione deve essere eseguita This operation must be performed with Bei der Durchführung dieses Vorgangs
avendo cura di non sporcare le parti smon- great care to avoid dirtying the dismantled unbedingt darauf achten, dass die ausge-
tate. parts. bauten Teile nicht verschmutzt werden.
21
75 MRT 1440-1640-1840 EASY
IT EN DE
2 REGISTRAZIONE DELLO “0” 2 ADJUSTMENT OF SWASHPLATE 2 EINSTELLUNG DER MECHANI-
MECCANICO DELLA POMPA “O” POSITION SCHEN “0” DER PUMPE
MA
MB
- Raccordare sulle prese di pressione HP due - An den Druckanschlüssen HP zwei

- Install two (40÷100 bar) gauges at the
Manometer mit kleiner Skala anbringen
manometri di piccola scala (40 ÷ 100 bar). HP test points. (40-100 bar).
- Assicurarsi che il freno a mano sia disinnestato - Ensure the parking brake is released, the - Sicherstellen, dass die Handbremse aus-
e che la macchina si trovi su cavalletti (ruote truck supported on blocks (wheels free geschaltet und die Maschine aufgebockt
sospese nel vuoto). to turn). ist (Räder im Leeren hängend).
- Engine running at idle. - Motor bei Mindestdrehzahl.
- Motore al minimo.
- Drive selector in neutral position. - Wendeschalter in der neutralen Stellung.
- Inversore di marcia in posizione neutra. - Die Sperrgegenmutter der
- Unscrew the locknut of the “0” adjuster
- Allentare il controdado di bloccaggio della vite di Einstellschraube der mechanischen “0”
(19 mm ring spanner). Screw in very
registro dello “0” meccanico (chiave lockern (19er Sechskantschlüssel). Die
slowly the screw (6 mm allen key) until
esagonale 19). Agire dolcemente sulla vite Schraube (6er Steckschlüssel) vorsichtig
movement is seen on the pressure im Uhrzeigersinn drehen, bis die kleinste
(chiave a brugola 6) in senso orario fino rileva- gauge. Variation von HP gefunden wird.
re la più bassa variazione del HP. - Make a mark relative to the allen key - In der Richtung des Schlüssels eine
- Fare un segno in direzione della chiave. Agire position, slowly turn the screw in the Markierung anbringen. Im
nell’altro senso antiorario fino far variare la HP opposite direction until movement is Gegenuhrzeigersinn drehen, bis die HP
seen on the other pressure gauge, mark in der anderen Fahrtrichtung variiert. In
nell’altro senso di marcia. Fare un segno in
the position of the allen key. Turn the der Richtung des Schlüssels eine
direzione della chiave. Markierung anbringen.
adjuster back so that the allen key is
- Dopodichè ruotare la vite di registro fino che la - Die Stellschraube danach drehen, bis der
exactly central between the two marks.
chiave si trovi al centro tra i due segni fatti pre- Schlüssel sich in der Mitte zwischen den
Lock the locknut. beiden Markierungen befindet. Die
cedentemente. Bloccare il controdado.
Gegenmutter anziehen.
VERIFICA DELLA REGISTRAZIONE: CHECKING ADJUSTMENT: PRÜFUNG DER EINSTELLUNG:
Remove the low pressure gauges from the 2 Manometer an den Druckanschlüssen
Collegare 2 manometri sulle prese HP scala 600 HP Skala 600 bar anschließen:
bar: HP circuit and install two 600 bar gauges:
1. Regelbeginn beim Vor- und
1° Controllare l’inizio regolazione in marcia 1° Check the start of regulation in Rückwärtsfahren mit einem
avantieretromarciaconuncontagiri. forward and reverse drive using a Drehzahlmesser prüfen.
Accelerare dolcemente il motore termico tachometer. Den Verbrennungsmotor vorsichtig
- selettore in marcia avanti - fino che le Select forward drive, increase the beschleunigen - Wendeschalter auf
ruote incominciano a muoversi. Rilevare engine speed slowly until the wheel Vorwärts - bis die Räder beginnen,
begin to turn-record the engine sich zu bewegen. die Drehzahl des
la velocità di rotazione del motore termi-
speed. Verbrennungsmotors messen. Den
co. Fare la stessa operazione in retro- gleichen Vorgang beim
marcia. Verificare le due velocità di rota- Repeat the same in reverse drive.
Rückwärtsfahren vornehmen.
zione del motore termico che dovranno Compare the two readings; they Die beiden Drehzahlen des
essere identiche. should be identical. Verbrennungsmotors müssen i
dentisch sein.
2° Controllo del HP e della pressione di pilo- 2° Check the pilot and HP readings. 2. Prüfung des HP und des entspre-
taggio corrispondenti - ruote bloccate - Select forward drive, apply foot chenden Vorsteuerdrucks - Räder
selettore inversore di marcia avanti - brake, accelerate progressively to blockiert - Wendeschalter auf
maximum speed. Vorwärtsgänge - Verbrennungsmotor
accelerare progressivamente il
langsam bis zu max. Drehzahl brin-
motore termico fino al regime max. Record the forward HP and forward
gen. Drücke HP Vorwärts und
Rilevare le pressioni HP marcia pilot pressure. Vorsteuerung Vorwärts messen.
avanti e pilotaggio marcia avanti. Repeat the same operation in Gleichen Vorgang bei rückwärts wie-
Ripetere la stessa operazione in reverse. The valves should be the derholen; Werte müssen identisch
retromarcia; i valori dovranno same. sein.
essere identici.
22
MRT 1440-1640-1840 EASY 75
IT EN DE
3A CONTROLLO E REGISTRO 3A TRANSMISSION INSPECTION 3A PRÜFUNG UND EINSTELLUNG
DELL’INIZIO REGOLAZIONE AND ADJUSTMENTS REGELBEGINN
Valvola di regolazione “DA”

“DA” Control valve
Regelbeginn “DA”
Registro inizio regolazione “DA”

“DA” Start of regulation
Einstellung Regelbeginn “DA”
INIZIO DELLA REGOLAZIONE: START OF REGULATION : REGELBEGINN:
• Misurare il regime del motore ter- • Check the engine speed at idle • Die Drehzahl des
mico al minimo il quale dovrà depending on machine type. It Verbrennungsmotors bei der
essere ~ 850 min-1. should be ~ 850 rpm. Mindestdrehzahl messen, die ~
L’inizio della regolazione deve 850 min-1 ausmachen muss.
avvenire a 1050 min-1. Per la regi- It shoud be between 1050 rpm. If Die Regelung muss bei 1050 min-1
strazione agire sulla vite di registro not adjust the screw on the end of einsetzen. Zum Einstellen die
situata all’estremità della valvola the regulation valve. Stellschraube benutzen, die sich
inizio regolazione: • Screw into delay the start am Ende des Ventils für
• Avvitare per ritardare of regulation. Regelbeginn befindet:
l’inizio dell’avanzamento. • Screw out to advance the • für späteren Einsatz des
• Svitare per anticipare start of regulation. Fahrbetriebs anziehen.
l’inizio dell’avanzamento. • für früheren Einsatz des
• Adjustment of the start of regula- Fahrbetriebs losschrauben.
• La modifica dell’inizio regolazione tion outside its specified limits will
del punto d’avanzamento sposta il change the performance curve of • Die Änderung des Regelbeginn
campo di the pump. Check systematically des Anfahrpunktes verschiebt den
regolazione della pompa. Bisogna the end of the regulation “400 bar Regelbereich der Pumpe. Das
sistematicamente verificare la fine for the engine mentioned”. Ende der Regelung "400 bar für
della regolazione "400 bar per il (1600÷1800 rpm). die Drehzahl des fraglichen Motors
regime del motore in questione". " ist systematisch zu prüfen (1600
(1600 ÷ 1800 min-1). • The adjustment control has the - 1800 min-1).
same procedure of the adjustment
• Il controllo della regolazione è of swashplate “0” position - point • De Prüfung der Regelung ent-
uguale alla verifica dello "0 mecca- 2. spricht der Prüfung der “mechani-
nico" - Punto 2. schen 0” - Punkt 2.
23
75 MRT 1440-1640-1840 EASY
IT EN DE
3B CONTROLLO E REGISTRAZIONE 3B CHECK AND ADJUST END OF 3B PRÜFUNG UND EINSTELLUNG
FINE DELLA REGOLAZIONE REGULATION: DES REGELENDES
Fine regolazione
End of regulation
Regelende
CONTROLLO: CHECK: PRÜFUNG:
- La macchina deve essere su cavalletti - - The truck is supported on blocks, inching - Die Maschine muss aufgebockt sein -die
freni bloccati e inching (freno) in by valve by passed, brakes applied (foot Bremsen blockiert und das Inching (Bremse)
pass. and park). im By-pass.
- Inversore in marcia avanti. - Drive reverser in forward drive. - Wendeschalter auf Vorwärtsgänge.
- Motore al minimo, controllare la velocità - Select forward drive. - Motor auf Mindestdrehzahl, die Drehzahl des
di rotazione del motore termico. - Engine at low idle-check rpm. Verbrennungsmotors prüfen.
- Accelerare progressivamente e verificare - Gradually increase the engine speed - Nach und nach Gas geben und die
la velocità del motore termico (1600 ÷ (1600÷1800rpm) until the forward HP Geschwindigkeit des Verbrennungsmotors
1800 min-1) quando la HP marcia avanti reading is 400 bar. At this point check prüfen (1600 - 1800 min-1), wenn die HP
raggiunti 400 bar. engine speed and compare with specifi- Vorwärtsgänge 400 bar erreicht hat.
cations.
FINE DELLA REGOLAZIONE:
REGELENDE:
END OF REGULATION:
La registrazione della fine della regolazio-
ne della pompa si ottiene agendo sulla vite Die Einstellung des Regelendes der Pumpe
The adjustment of the pump end of regula- erhält man durch Benutzung der exzentrischen
eccentrica che fa variare la posizione della
piastra (nel senso di rotazione). Questo tion is obtained using an eccentric screw Schraube, welche die Position der Platte (in der
per avere l’effetto di aumentare o diminuire which restricts the pump flow creating back Drehrichtung) ändert. Dadurch werden die
le forze di richiamo del piattello inclinabile. pressure against the swash plate. Rückholkräfte der schrägstellbaren Platte erhöht
oder verringert.
Questa registrazione si effettua al This adjustment can only be set using a Diese Einstellung wird vom Hersteller auf der
banco da parte del costruttore, non può test bench. Werkbank vorgenommen, sie darf ohne die
It cannot be modified in any way with- spezifische Genehmigung des Herstellers
assolutamente essere ritoccato tranne out prior authorization from the manu-
previa autorizzazione dalla casa madre. facturer. absolut nicht verändert werden.
The slot in the eccentric screw should Die Frässtelle des Exzenters muss zur Seite
La fresatura dell’eccentrico dovrà essere
point towards the boost pump derAufladungspumpe zeigen. Die
orientato verso il lato della pompa di
sovralimentazione. (opposite to A4VG pump where slot Einstellspanne beträgt nur 90 % nach rechts
Il margine della registrazione è solamente al pointed to drive shaft). und 90 % nach links. Diesen Prozentwert
90 % a destra e il 90 % a sinistra. Non The adjustment must not go beyond 90 nicht überschreiten (Gefahr mechanischer
superare questa percentuale (rischio di rottu- to the left or right-Do not exceed Brüche wegen Interferenz zwischen Platte
ra meccanica per l’interferenza tra la piastra und Gehäuse). Wie für die Einstellung des
or damage may occur.
e la carcassa). Come per la registrazione del HP muss auch diese Einstellung mit übe-
HP, questa registrazione deve essere effet- As for the HP adjustment, this adjust-
ment has to be done with the DR valve reichtem Ventil DR vorgenommen werden.
tuata con la valvola DR sovratatrata.
overcalibrated.
24
MRT 1440-1640-1840 EASY 75
IT EN DE
4 CONTROLLO E REGISTRO DEI 4 CHECK AND ADJUST HP 4 PRÜFUNG UND EINSTELLUNG DER
LIMITATORI HP VALVES BEGRENZER HP
• Il controllo e la registrazione dei limitatori • The HP valves are checked with the truck • Die Prüfung und Einstellung der
del HP si effettuano; con il carrello su upported on blocks with the brakes Begrenzer HP wird mit aufgebocktem
cavalletti (ruote sospese nel vuoto) e applied. Stapler
freni bloccati. It is also necessary to by-pass the inch- (Räder im Lereren hängend) und
E’ necessario by passare la valvola ing valve with a flexible hose. blockierten Bremsen vorgenommen.
inching, per eliminare la funzione di Also, if fitted, by-pass the parking brake Das Inching-Ventil muss umgangen wer-
messa in scarico della portata della drive isolation system. den, um die Funktion der Umleitung des
pompa. • Overset the DR valve (1) to check the Fördermenge der Pumpe zum Ablauf zu
• Sovratarare la valvola DR - Rif. 1 per pressure of the HP valves. beseitigen.
controllare il valore reale di taratura dei Screw the adjuster in 1 turn. The HP • Das Ventil DR - Bez. 1 übereichen, um
limitatori HP. valves pressure should be 460 bar*. den tatsächlichen Eichwert der
Avvitare la vite - Rif. 1 di un giro. Begrenzer HP zu prüfen.
The HP limiting devices - Ref. 2 - shall Die Schraube - Bez. 1 um eine
La taratura dei limitatori HP - Rif. 2 be set to 460 bar. During this operation, Umdrehung anziehen.
dovrà essere 460 bar. a remarkable droop of the combustion
Durante questa operazione ci sarà una engine speed will take place, around Die Eichung der Begrenzer HP - Bez. 2
forte caduta del regime del motore termi- 500 ÷ 600 rpm. muss 460 bar ausmachen.
co all’incirca 500 ÷ 600 min-1. Während dieses Vorgangs kommt es zu
After checking the HP, set the DR valve einem starken Einbruch der Drehzahl
Dopo il controllo del HP, registrare la -Ref. 1- to a value 20 bar lower than HP des Verbrennungsmotors von circa 500 -
valvola DR - Rif. 1 a un valore inferiore Ref. 2. 600 min-1.
di 20 bar dal HP Rif. 2.
Nach der Prüfung von HP das Ventil DR
- Bez. 1 auf einen Wert einstellen, der
um 20 bar unter HP Bez. 2 liegt.
RIF. 2
REF. 2
BEZ. 2
MA
MB
RIF. 1 RIF. 2
REF. 1 REF. 2
BEZ. 1 BEZ. 2
25
75 MRT 1440-1640-1840 EASY
IT EN DE
REGISTRAZIONE DEI LIMITATORI HP: HP LIMITERS ADJUSTMENT: EINSTELLUNG DER BEGRENZER HP:
• Smontare la valvola completa dal corpo. • Dismantle the valve completely from the • Das Ventil ganz aus dem Gehäuse aus-
body. bauen.
• Svitare il grano Rif. 2, mantenendo fermo
con una chiave la vite Rif. 3. • Unscrew grub screw Ref. 2, holding • Die Madenschraube Bez. 2 losschrau-
screw Ref. 3 steady with a wrench. ben, wobei man die Schraube Bez. 3 mit
• Avvitando la vite Rif. 3 aumenta la pres- einem Schlüssel festhält.
sione (circa 44 bar 1 giro). • Tightening screw Ref. 3 will cause the
pressure to increase (approx. 44 bar /turn). • Beim Anziehen der Schraube Bez. 3
• Ribloccare il grano Rif. 2. nimmt der Druck zu (circa 44
• Relock grub screw Ref. 2. bar/Umdrehung).
• Die Madenschraube Bez. 2 wieder anzie-

hen.
BY PASS DEI LIMITATORI HP PER IL VEHICLE TOWING HP LIMITERS BY BY-PASS DER BEGRENZER HP ZUM
TRAINO DELLA MACCHINA : PASS: ABSCHLEPPEN DER MASCHINE:
• Rilevare la quota “X” • Measure “X” • Den Wert “X” messen.
• Sbloccare il controdado “4” • Unscrew lock nut “4” • Die Gegenmutter “4” freigeben.
• Avvitare la vite “1” fino alla pari del con- • Tighten screw “1” level with the lock nut • Die Mutter “1” bis zur Gegenmutter
trodado anziehen.
• Proceed in the reverse direction to restart
• Procedere in senso inverso per rimettere working of the HP limiters when the value • In der umgekehrten Richtung vorgehen,
in funzione i limitatori HP al raggiungi- “X” is reached. um die Begrenzer HP wieder in Betrieb
mento del valore della quota “X” zu setzen, wenn der Wert von “X”
erreicht ist.
Il traino dovrà essere effettuato a velocità The vehicle must be towed at very low Das Abschleppen ist bei minimaler
molto bassa e per breve distanza. speed and to a very short distance. Geschwindigkeit und nur über kurze
Strecken vorzunehmen.
3 2 4 1
26
MRT 1440-1640-1840 EASY 75
IT EN DE
TRASMISSIONE A 4 VG - A 6 VM TRANSMISSION A4VG-A6VM GETRIEBE A 4 VG - A 6 VM
CONTROLLI PRIMA DELLA MESSA IN CHECKS BEFORE PRESSURE TESTING PRÜFUNGEN VOR INBETRIEBNAHME
FUNZIONE DELLA TRASMISSIONE O DES GETRIEBES ODER NACH REPA-
DOPO UNA RIPARAZIONE RATUR
- Verificare il livello dell’olio nel serbatoio. - Check the transmission oil level. - Den Ölstand im Behälter prüfen.
- Verificare il perfetto serraggio di tutti i - Check there are no leaks at hoses or - Sicherstellen, dass alle Anschlüsse der
raccordi dei tubi flessibili. unions. Schläuche fest angezogen sind.
- Verificare le connessioni elettriche dell’e- - Die elektrischen Anschlüsse der

lettrovalvole. - Check the lectrical connections at the Magnetventile prüfen.
solenoid.
- Assicurarsi del buon riempimento del cir- - Sicherstellen, dass der Kreislauf gut
cuito, e nello stesso tempo riempire il fil- - Make sure the circuit is filled with oil. In gefüllt ist und gleichzeitig das Ölfilter vor
tro dell’olio prima del montaggio. der Montage füllen.
some cases the filter should be fitted
- Verificare il corretto montaggio dei tubi di with oil prior installation. - Prüfen, dass die Vorsteuerleitungen kor-
pilotaggio: rekt montiert worden sind:
* X1 pompa con X2 motore, - Confirm correct connection of pilot hoses: * X1 Pumpe mit X2 Motor,
* X2 pompa con X1 motore. * Port X1 on pump to X2 on motor, * X2 Pumpe mit X1 Motor.
* Port X2 on pump to X1 on motor.
- In tutti i casi, il pilotaggio è all’opposto dei - In allen Fällen befindet sich die
flessibili HP. (Esempio: se il flessibile HP Vorsteuerung den Schläuchen HP
della marcia avanti si trova a destra del - In all cases, the pilot hose be opposite gegenüber. (Beispiel: wenn der
motore, il flessibile del pilotaggio marcia the HP hose (e.g. If the HP for forward Schlauch HP zum Vorwärtsfahren sich
avanti sarà a sinistra, viceversa per la drive is on the right of the motor the for- rechts am Motor befindet, ist der
retromarcia). ward pilot hose must be on the left). Schlauch zum Vorsteuern der
Vorwärtsgänge links, umgekehrt für das
- Raccordare i manometri presa di pressio- Rückwärtsfahren).
ne sovralimentazione - pilotaggio - HP - - Install the pressure gauges for boost,
carcassa. pilot, HP and housing checks. - Die Manometer für die Druckanschlüsse
Aufladung - Vorsteuerung - HP -
MESSA IN FUNZIONE: PREPARATION: Gehäuse anschließen.
- Per motivi di sicurezza, mettere la mac- INBETRIEBNAHME:

- For safety purposes support the front
china su cavalletti.
wheels on blocks (disconnect 4 wd shaft - Die Maschine aus Sicherheitsgründen
- Far girare il motore termico senza farlo if applicable). aufbocken.
partire per fare un buon spurgo del cir-
cuito. (staccare il filo dell’elettrovalvola - Crank the engine a few times with the - Den Verbrennungsmotor laufen lassen,
stop sulla pompa d’iniezione). fuel shut off solenoid disconnected, to ohne dass er startet, um den Kreislauf
gut zu entlüften (Die Leitung des
ensure the circuit is charged with oil.
- Assicurarsi che la pressione di sovrali- Magnetventils Stop auf der
mentazione salga almeno 15 bar giran- Einspritzpumpe abtrennen).
do col motorino d’avviamento. - The boost pressure during cranking
"Assolutamente non mettere in funzione should be around 15 bar. “Never run the - Sicherstellen, dass der Aufladedruck um
la trasmissione con pressione transmission without boost pressure”. wenigstens 15 bar steigt, wenn man den
insufficiente di sovralimentazione, si Anlasser betätigt. "Das Getriebe absolut
rischia l’usura della trasmissione". nicht in Funktion setzen, wenn der
- Connect the fuel shut off solenoid. Aufladedruck unzureichend ist; es
- Ricollegare l’elettrovalvola stop sulla besteht Gefahr, dass das Getriebe ver-
pompa d’iniezione. - Start the engine and run for a few min- schleißt".
utes at idle. The boost pressure should
- Avviare il motore termico per qualche be between 35 and 40 bar. A flickering - Das Magnetventil Stopp wieder an der
minuto al minimo. Pressione di sovrali- Einspritzpumpe anschließen.
gauge indicates cavitation the in the sys-
mentazione 35 ÷ 40 bar.
tem. - Den Verbrennungsmotor ein paar
- Una instabilità dell’ago indica aspirazione With the drive selector in neutral the Minuten bei Mindestdrehzahl laufen las-
d’aria (olio emulsionato nel serbatoio, e pressure in the two HP circuits be the sen. Aufladedruck 35 - 40 bar.
rumore di cavitazione della trasmissione). same as the boost pressure.
- Das Ausschlagen der Nadel zeigt an,
- "Inversore in neutro" nelle due bocche dass Luft angesaugt wird (mit Luft ver-
- By pass the inching valve(s) using flexi-
circuito HP. La pressione è uguale alla mischtes Öl im Behälter und
pressione di sovralimentazione. ble hose. Kavitationsgeräusch des Getriebes).
- Fare scaldare l’olio del circuito acceleran- - When the oil temperature is 50° to 60° C - "Wendeschalter auf neutral" an den bei-
do progressivamente (mantenere bloc- check the engine speed : den Öffnungen des Kreislaufs HP. Der
cato il freno a mano per permettere la - Idle speed Druck ist so groß wie der Aufladedruck.
misurazione del HP in carico bloccato).
- Maximum speed - Das Öl im Kreislauf anwärmen, indem
- Quando l’olio è ad una temperatura di - Maximum speed under load man progressiv beschleunigt (die
50°÷ 60° verificare il regime del motore: (See specifications). Handbremse blockiert halten, um die
al minimo, al massimo a vuoto. (Vedere Messung des HP bei blockierter Last zu
specificche tecniche). gestatten).
- Wenn das Öl eine Temperatur von 50°-

60° C erreicht hat, die Motordrehzahl
prüfen: Mindestdrehzahl, oberer Leerlauf
(siehe technische Daten).
27
75 MRT 1440-1640-1840 EASY
IT EN DE
PUNTI DI CONTROLLO PRESSIONE PUMP A 4 VG 56 PRESUSRE MEA- DRUCKPRÜFSTELLEN AUF DER
SULLA POMPA A 4 VG 56 SURING POINTS PUMPE A 4 VG 56
Presa pressione pilotaggio

Pilot pressure
Druckanschluss Vorsteuerung
Presa pressione HP
High pressure HP R X1
X2
Druckanschluss HP
MA
Presa pressione HP G
High pressure HP Presa pressione carcassa
Druckanschluss HP Case pressure
Druckanschluss Gehäuse
MB
Presa pressione HP
High pressure HP
Druckanschluss HP
Necessario (avere nella valigia porta mano- Necessary (the portable tool box must Erforderlich: (im Koffer der Basismanometer
metri di base Rif. 549671 + Kit hydromatik always contain base manometers Ref. Bez. 549671 + Satz Hydromatik
Rif. 209572) 549671 + Hydromatik kit Ref. 209572) Bez. 209572 zu haben)
- Pressione Pilotaggio - Drive pressure - Vorsteuerdruck
• 2 Raccordi 165711 (Rif. 55) (M • 2 Connectors 165711 (Ref. 55) • 2 Anschlüsse 165711 (Bez. 55)
14 x 150) (M 14 x 150) (M 14 x 150)
• 2 Prese di manometro 58181 • 2 Manometer outlets 58181 (Ref.
• 2 Manometeranschlüsse 58181
(Rif. 49) (M 8 x 100) 49) (M 8 x 100)
(Bez. 49) (M 8 x 100)
• 2 Manometri (0÷40 bar) • 2 Manometers (0÷40 bar)
• 2 Tubi flessibili test 549887 • 2 Manometer (0-40 bar)
• 2 Flexible test hoses 549887
• 2 Prüfschläuche 549887
- Alta Pressione - High pressure
- Hochdruck
• 2 Prese di manometro 477484 • 2 Manometer outlets 477484
(Rif. 51) (M 12 x 1,5) (Ref. 51) (M 12 x 1,5) • 2 Manometeranschlüsse 477484
• 2 Manometri (0÷600 bar) • 2 Manometers (0÷600 bar) (Bez. 51) (M 12 x 1,5)
• 2 Tubi flessibili test 549887 • 2 Flexible test hoses 549887 • 2 Manometer (0-600 bar)
- Pressione di Sovralimentazione - Booster pressure
- Aufladedruck
• 1 Insieme raccordo + presa di • 1 Kit of connectors + manometer
manometro 199175 (Rif. 53.1) (M outlet 199175 (Ref. 53.1) (M 18 x 1,5)
18 x 1,5) • 1 Manometer (0÷40 bar) • 1 Gruppe Anschluss +
• 1 Manometro (0÷40 bar) • 1 Flexible test hoses 549887 Manometeranschluss 199175
• 1 Tubi flessibili test 549887 (Bez. 53.1) (M 18 x 1,5)
• 1 Manometer (0-40 bar)
- Pressione Carcassa - Body pressure • 1 Prüfschläuche 549887
• 1 Presa di manometro 477484 • 1 Manometer outlet 477484 (Ref. - Gehäusedruck

(Rif. 51) (M 12 x 1,5) 51) (M 12 x 1,5)
• 1 Manometro (0÷10 bar) • 1 Manometer (0÷10 bar)
• 1 Manometeranschluss 477484
• 1 Tubi flessibili test 549887 • 1 Flexible test hoses 549887
(Bez. 51) (M 12 x 1,5)
• 1 Manometer (0-10 bar)
28
MRT 1440-1640-1840 EASY 75
IT EN DE
PUNTI DI CONTROLLO PRESSIONE A 6 VM 80 PRESSURE MEASURING DRUCKPRÜFSTELLEN MOTOR
MOTORE A 6 VM 80 POINTS A 6 VM 80
Presa HP
HP Connect
Anschluss HP
Presa pressione della commutazione

Changeover pressure
Druckanschluss Umschaltung
NB: Il montaggio reale del motore diffe- N.B.: True installation of the motor dif- Anm.: Die tatsächliche Montage des
risce dalla figura in quanto ruotato di fers from what is shown in the figure in Motors unterscheidet sich von der in
180°. that it is rotated 180°. der Abbildung, weil er um 180° gedreht
ist.
Necessario (avere nella valigia porta mano- Necessary (the portable tool box must
metri di base Rif. 549671 + Kit hydromatik always contain base manometers Ref. Erforderlich (im Koffer der Basismanometer
Rif. 209572) 549671 + Hydromatik kit Ref. 209572) Bez. 549671 + Satz Hydromatik
Bez. 209572 zu haben)
- Alta Pressione - High pressure
- Hochdruck
• 1 Presa di manometro 58189 • 1 Manometer outlet 58189 (Ref.
(Rif. 52) (M 14 x 150) 52) (M 14 x 150) • 1 Manometeranschluss 58189
• 1 Manometro (0÷600 bar) • 1 Manometer (0÷600 bar) (Bez. 52) (M 14 x 150)
- Pressione della Commutazione - Switching pressure
- Umschaltdruck
• 1 Presa di manometro 477484 • 1 Manometer outlet 477484 (Ref.
(Rif. 51) (M 12 x 150) 51) (M 12 x 150) • 1 Manometeranschluss 477484
• 1 Manometro (0÷600 bar) • 1 Manometer (0÷600 bar) (Bez. 51) (M 12 x 150)
29
75 MRT 1440-1640-1840 EASY
IT EN DE
5 REGOLAZIONE MOTORE A 6 VM 5 ADJUSTINGMOTORDISPLACEMENT 5 EINSTELLUNG MOTOR A 6 VM
CHANGEOVER
A) CONTROLLO CILINDRATA MINIMA (MAX A) PRÜFUNG KLEINSTER HUBRAUM
VELOCITA’): A) CHECK MINIMUM DISPLACEMENT (MAX GESCHWINDIGKEIT):
(MAX.SPEED) :
• Il controllo si effettua: carrello su un terreno • Die Prüfung nimmt man wie folgt vor:
piano, regime motore al max, in marcia avanti. • The check is made driving the truck on Stapler eben abgestellt, Motor bei
• Collegare due manometri scala 600 bar come Höchstdrehzahl, auf Vorwärtsfahren.
level ground with the engine a full speed
indicato in figura. A velocità max della • Die beiden Manometer mit Skala 600 bar
in forward drive.
macchina, le due pressioni dovranno essere so anschließen, wie es in der Abbildung
uguali. Questo significa che, tenuto conto del • Connect two 600 bar pressure gauges as gezeigt ist. Bei Höchstgeschwindigkeit
rapporto della superficie del cilindro di coman- shown above.At maximum drive speed der Maschine müssen die beiden
do, il motore è commutato in cilindrata the two gauges should read the same. Drücke identisch sein. Das bedeutet,
minima. This signifies that the both sides of the dass unter Berücksichtigung der Fläche
• Per il controllo effettivo della velocità (verificare Servo piston are subject to the same des Steuerzylinders der Motor auf den
quanto riportato alle specifiche tecniche della pressure and the motor is at its mini- kleinsten Hubraum umgeschaltet ist.
macchina). mum displacement. • Für die tatsächliche Kontrolle der
Geschwindigkeit prüfen, was unter den
• To effectively check speed (check the
technischen Daten der Maschine steht.
machine technical specifications).
Questa registrazione -Rif. 1- si effettua al banco

The manufacturer performs this regulation -Ref. Diese Einstellung - Bez. 1- nimmt der
da parte del costruttore, non può Hersteller auf der Prüfbank vor; ohne vor-
assolutamente essere ritoccato tranne previa 1- at the bench. It cannot be modified in any
herige Genehmigung des Herstellers darf
autorizzazione dalla casa madre. way without prior authorization from the manu- sie absolut nicht geändert werden.
Rif. 1 VITE REGISTRO CILINDRATA MINIMA (avvitando la vite il piattellofacturer.
si spo-
sta verso il basso. In questo modo aumenta la cilindrata e diminuisce la velocità).
Ref. 1 MINIMUM DISPLACEMENT ADJUSTING SCREW
(On tightening the screw, the pad shifts downwards. In this way the displacement ALTA PRESSIONE
is increased and the speed is reduced).
Bez. 1 STELLSCHRAUBE KLEINSTER HUBRAUM (Beim Anziehen der HIGH PRESSURE
Schraube bewegt sich die Platte nach unten. Auf diese Weise nimmt der HOCHDRUCK
Hubraum zu und der Geschwindigkeit ab).
REGISTRO INIZIO REGOLAZIONE
DELLA COMMUTAZIONE
REGULATION PRESSURE
REGELBEGINN EINSTELLUNG DER
UMSCHALTUNG
PRESSIONE DELLA COMMUTAZIONE

CHANGEOVER PRESSURE
UMSCHALTDRUCK
B) CONTROLLO DELL’INIZIO DELLA B) CHECK START OF REGULATION : B) PRÜFUNG DES REGELBEGINNS

REGOLAZIONE
• Wenn die Maschine sich bei
• Quando la macchina sta in velocità max, • With the wheels raised from the ground Höchstgeschwindigkeit befindet, pro-
spingere progressivamente sui freni in maniera and the truck supported on blocks grad- gressiv die Bremsen betätigen, damit
da far salire la HP (la valvola inching dovrà ually apply the brake pedal to raise the der HP steigt (das Inching-Ventil muss
essere by passata). pressure in the HP circuits (inching valve umgangen werden).
• Osservare le due pressioni. Quando la HP arri by-pass). • Die beiden Drücke prüfen. Wenn der HP
verà ad un valore di 260 ÷ 280 bar, la • Watch the two gauges. When the HP einen Wert von 260-280 bar erreicht,
pressione di commutazione calerà e la HP gauge shows 260÷280 bar the fällt der Umschaltdruck ab und der HP
continuerà ad aumentare fino al valore di changeover pressure will drop then the steigt weiter an, bis er den Eichwert des
taratura della valvola DR. HP will continue to rise until it reaches Ventils DR erreicht.
• L’inizio regolazione della commutazione può the setting of the DR valve. • Der Beginn der Regelung der
essere tarato tramite la vite di regolazione sul • The changeover point can be adjusted by Umschaltung kann mit der Stellschraube
motore. the screw. auf dem Motor geeicht werden.
30
MRT 1440-1640-1840 EASY 75
IT EN DE
C) CILINDRATA MAX: (MAX FORZA C) MAXIMUM DISPLACEMENT : C) MAX. HUBRAUM (MAX. ZUGKRAFT)
DI TRAZIONE) (MAX. TRACTIVE FORCE)
• Um diese Einstellung vorzunehmen,
• Per effettuare questa regolazione, il • To make this adjustment, the machine muss der Stapler blockiert sein
carrello dovrà essere bloccato (freni should be chocked (brakes locked). (Bremsen blockiert).
bloccati). The check is made at maximum IC Die Prüfung wird bei der Höchstdrehzahl
Il controllo si effettua al regime max del engine speed in forward drive. des Verbrennungsmotors bei
motore termico in marcia avanti. • The switching pressure (large section Vorwärtsfahren vorgenommen.
• La pressione di commutazione (lato side of control cylinder) must be around • Der Umschaltdruck (Seite mit großem
sezione grande del cilindro di comando) zero bars. Querschnitt des Steuerzylinders) muss
dovrà essere vicino a zero bar. Adjust the control screw as required fast Null bar ausmachen.
Se necessario, registrare la vite di (tighten to increase the switching pres- Falls erforderlich, die Stellschraube ein-
regolazione (avvitare per aumentare la sure, loosen to reduce). stellen (anziehen, damit der
pressione di commutazione, svitare per • A check on the tractive force (using a Umschaltdruck steigt; losschrauben,
diminuire). hook) should then be carried out (refer damit er sinkt).
• Un controllo della forza di trazione (al to “Aide-Memoire Service” for values) . • Eine Prüfung der Zugkraft (am Haken)
gancio) deve essere eseguita (per i valo- muss vorgenommen werden (für die
ri, vedere sul manuale Uso Werte siehe die Betriebs- und
Manutenzione). Wartungsanleitung).
31
75 MRT 1440-1640-1840 EASY
IT
RICERCA GUASTI - POMPA/MOTORE
Pressione d’aspiraz. “S” pompa A4VG tubo d’aspirazione filtro serbatoio olio
tipo d’olio
punto di misura senso di rotazione temperatura d’olio
causa
scambiatore
Pressione d’alim. “G” pompa A4VG MOTORE A6VM
pompa ausiliaria
punto di misura
valvola di sovralimentazione usura
usura
pressione d’aliment.
temperatura olio scambiatore valvola di lavaggio
causa
valvola by pass
temperatura olio
numero giri
collegamento (giunto) pompa motore termico
Pressione di pilot. X1/X2 pompa A4VG MOTORE A6VM
strozzatori
punto di misura
valvola di regolazione DA/inching/valvola di parzializzazz. tubazione di pilotaggio
pressione d’aspiraz.
pressione d’aliment. taglio di pressione
elettrodistributore/magnete
causa
Alta pressione MA/MB pompa A4VG MOTORE A6VM
valvole HP - DR non bloccato

punto di misura
taglio di pressione giunto
spostamento piastra di distribuzione freno
pressione d’aspiraz. usura usura - olio di trafilamento
pressione d’aliment.
temperatura olio scambiatore temperatura d’olio
causa
scambiatore
motore termico
numero gi giri min/max

filtro diesel
filtro d’aria
potenza
32
MRT 1440-1640-1840 EASY 75
EN
TROUBLESHOOTING - PUMP/MOTOR
Intake pressure “S” pump A4VG intake pipe oil tank filter
type of oil
Measuring point rotation direction oil temperature
cause
heat exchanger
Feed pressure “G” pump A4VG MOTOR A6VM
auxiliary pump
Measuring point
booster valve wear
wear
Feed pressure
oil temperature heat exchanger wash valve
cause
bypass valve
oil temperature
r.p.m.
combustion engine pump connector (joint)
Drive pressure X1/X2 pump A4VG MOTOR A6VM
throttles
measuring point
DA adjusting valve/inching/partialization valve drive piping
intake pressure
pressure cut
feed pressure
electrodistributor/magnet
cause
High pressure MA/MB pump A4VG MOTOR A6VM
valve HP - DR not locked

measuring point
cut in pressure joint
shift in distributor plate brake
intake pressure wear wear - oil carryover
feed pressure
oil temperature heat exchanger oil temperature
cause
heat exchanger
combustion engine
r.p.m. min/max
diesel filter
air filter
power
33
75 MRT 1440-1640-1840 EASY
DE
FEHLERSUCHE - PUMPE/MOTOR
Saugdruck “S” Pumpe A4VG Saugleitung Öltankfilter

Ölsorte
Meßstelle Drehrichtung Öltemperatur
Ursache
Wärmeaustauscher
Versorgungsdruck “G” Pumpe A4VG MOTOR A6VM
Hilfspumpe
Meßstelle
Aufladeventil Verschleiß
Verschleiß
Versorgungsdruck
Öltemperatur Wärmeaustauscher Waschventil
Ursache
By-pass-Ventil
Öltemperatur
Drehzahl
Anschluss (Kupplung) Pumpe Verbr.motor
Vorsteuerdruck X1/X2 Pumpe A4VG MOTOR A6VM
Drosseln
Meßstelle
Regelventil DA/Inching/Teilstromventil Vorsteuerleitung
Saugdruck
Versorg.druck Druckschnitt
Elektro-Steuergerät/Magnet
Ursache
Hochdruck MA/MB Pumpe A4VG MOTOR A6VM
Ventile HP - DR nicht blockiert

Meßstelle
Druckschnitt Kupplung
Verschiebung Verteilungsplatte Bremse
Saugdruck Verschleiß Verschleiß-Öldurchsickern
Versorgungsdruck
Öltemperatur Wärmeaustauscher Öltemperatur
Ursache
Wärmeaustauscher
Verbrennungsmotor
Drehzahl min/max
Dieselfilter
Luftfilter
Leistung
34
MRT 1440-1640-1840 EASY 75
IT
RICERCA GUASTI - MACCHINA
Il motore diesel gira POMPA A4VG

Il veicolo non si arresta
elettrodistributore
inizio regolazione
causa
zero meccanico
Il veicolo si muove in ritardo POMPA A4VG
strozzatori
pressione d’aspirazione
causa
pressione di pilotaggio
inizio di regolazione
inching
Forte sovracc. del motore term. POMPA A4VG MOTORE A6VM
valvola DR inizio regolazione
usura angolo d’inclinazione
spostam. piastra di distribuzione

causa
motore termico
pompa d’iniezione
filtro carburante
Forza di trazione insuff. POMPA A4VG MACCHINA MOTORE A6VM
spostam. piastra di distrib. diametro ruota inizio regolazione
taglio pressione tubaz. di pilotaggio X1/X2
pressione di pilotaggio magnete
causa angolo d’inclinazione
motore termico
numero di giri
Velocità max
di trasferim.
non viene rag-
giunta POMPA A4VG MACCHINA MOTORE A6VM
pressione di pilotaggio trasmissione inizio regolazione
inching gomme magnete
angolo d’inclinazione
causa registrazione vite CC
motore termico
numero di giri
35
75 MRT 1440-1640-1840 EASY
EN
TROUBLESHOOTING - MACHINE
Diesel motor running PUMP A4VG

Vehicle not at a standstill
electrodistributor
start regulation
cause
zero mechanical set
Delay in vehicle movement PUMP A4VG
throttles
intake pressure
cause
drive pressure
start regulation
inching
Combustion engine strongly overloaded PUMP A4VG MOTOR A6VM
DR valve start regulation
wear slope angle
shift in distributor plate

causa
combustion engine
injection pump
fuel filter
Insufficient traction power PUMP A4VG MACHINE MOTOR A6VM
shift in distributor plate wheel diameter start regulation
cut in pressure drive piping X1/X2
driving pressure magnet
cause slope angle
combustion engine
r.p.m.
Max transfer
rate not
reached PUMP A4VG MACHINE MOTOR A6VM
drive pressure transmission start regulation
inching tires magnet
slope angle
cause
CC screw
adjustment
combustion engine
r.p.m.
36
MRT 1440-1640-1840 EASY 75
DE
FEHLERSUCHE - MASCHINE
Dieselmotor läuft PUMPE A4VG

Fahrzeug kommt nicht zum Stehen
Elektro-Steuergerät
Regelbeginn
Ursache
Mechanische Null
Das Fahrzeug bewegt sich mit Verspätung PUMPE A4VG
Drosseln
Saugdruck
Ursache
Vorsteuerdruck
Regelbeginn
Inching
Starke Überlastung des Verbr.motors PUMPE A4VG MOTOR A6VM
Ventil DR Regelbeginn
Verschleiß Neigewinkel
Verschiebung Verteilungsplatte
Ursache
Verbrennungsmotor
Einspritzpumpe
Kraftstofffilter
Zugkraft unzureichend PUMPE A4VG MASCHINE MOTOR A6VM
Verschieb. Verteilungsplatte Raddurchmesser Regelbeginn
Druckschnitt Vorsteuerleitung X1/X2
Vorsteuerdruck Magnet
Ursache Neigewinkel
Verbrennungsmotor
Drehzahl
Max. Fahr-
geschwindigkeit
wird nicht
erreicht PUMPE A4VG MASCHINE MOTOR A6VM
Vorsteuerdruck Getriebe Regelbeginn
Inching Reifen Magnet
Neigewinkel
Ursache Einstellung
Schraube CC
Verbrennungsmotor
Drehzahl
37
75
38
MANITOU - SCHEDA DI REGISTRAZIONE TRASMISSIONE IDROSTATICA - A4VG--DA / A6VM--DA
DATA DI CONTROLLO : TIPO DI MACCHINA : TIPO POMPA IDROSTATICA :
NOMINATIVO DEL CONCESSIONARIO: N° DI SERIE : N° SERIE POMPA :
NOMINATIVO DEL TECNICO : NUMERO DI ORE : TIPO MOTORE IDROSTATICO :
N° SERIE MOTORE :
REGIME MOTORE TERMICO min-1

1 minimo: ......... 2 max a vuoto: ...................... 3 max a carico idraulicamente:..................... 4 inizio regolazione: .................. 5 fine regolazione 400 bar: .......... 6 max a carico m. av: .............
POMPA IDROSTATICA MOTORE IDRAULICO

SITUAZIONE PRESSIONE DI ALTA PRESSIONE STATO CARRELLO
REGIME PRESSIONE DI PILOTAGGIO HP PRESSIONE DI DEPRESSIONE ALTA PRESSIONE
CARRELLO + POSIZIONE +
MOTORE SOVRALIMEN- LAVAGGIO ASPIRAZIONE PRESSIONE CILINDRO
controlli / registrazioni INVERSORE MARCIA RETRO- MARCIA RETRO POSIZIONE
TERMICO TAZIONE CARCASSA POMPA HP COMANDO
EFFETTUATE AVANTI MARCIA AVANTI MARCIA INVERSORE
REGISTRAZIONE MINIMO
A VUOTO
PRESSIONE NEUTRO
IN MOVIMENTO
SOVRALIMENTAZIONE MAX MARCIA AVANTI
REGIME MAX
INIZIO REGOLAZIONE
MARCIA
AVANTI
IT
A VUOTO MAX
REGISTRAZIONE MARCIA AVANTI IN
INIZIO REGOLAZIONE INIZIO REGOLAZIONE MOVIMENTO AL
RETRO-
MARCIA MOMENTO DELLA
MAX COMMUTAZIONE
REGIME MAX
A CARICO MARCIA
REGISTRAZIONE ALTA MAX
AVANTI
PRESSIONE HP
INALZANDO LA
VALVOLA DI TAGLIO RETRO- MARCIA AVANTI A
MAX
DR MARCIA CARICO
REGIME MAX
A CARICO MARCIA
AVANTI
MAX
REGISTRAZIONE
VALVOLA DI TAGLIO RETRO-
DR MARCIA
MAX
TIPO D’OLIO
MARCIA
FINE REGOLAZIONE
A CARICO AVANTI
CONTROLLO FINE TEMPERATURA D’OLIO.........................................°C
REGOLAZIONE RETRO-
FINE REGOLAZIONE
MARCIA
VELOCITA’ MAX A VUOTO:
A CARICO ...................................km/h
MARCIA
REGISTRAZIONE MAX
AVANTI
VALVOLA INCHING FORZA AL TRAINO.................................................kg
MRT 1440-1640-1840 EASY
MANITOU - HYDROSTATIC TRANSMISSION CHECK SHEET - A4VG--DA / A6VM--DA
DATE OF CHECK : TYPE OF MACHINE : PUMP TYPE :
NAME OF DEALR : SERIAL N° : SERIAL N° :
NAME OF ENGINEER : HOURS RUN : MOTOR TYPE :
SERIAL N° :
IC ENGINE SPEED IN RPM

1 idle: ............ 2 max speed: ...................... 3 max with hydraulics blocked :.................... 4 start of regulation: ................ 5 end of regulation 400 bar : ........ 6 max fwd drive blocked : ............
HYDROSTATIC PUMP HYDROSTATIC MOTOR

MRT 1440-1640-1840 EASY
PRESSURE MACHINE CONDITION

STATE OF HIGH PRESSURE CONTROL
DRIVE LEVER ENGINE BOOST PILOT CASE SUCTION + HIGH
MACHINE + PISTON
POSITION SPEED PRESSURE PRESSURE VACUUM DRIVE LEVER PRESSURE
CONTROLS FWD REV FWD REV PRESSURE
POSITION
IDLE
BOOT VALVE
NEUTRAL
ADJUSTMENT MAX FWD
MAX DRIVE SPEED
Start of regulation
FWD
EN
AT MAX SPEED
MAX
CONTROL
CARTRIDGE Start of regulation
ADJUSTMENT FWD DRIVE AT POINT
REV OF DISPLACEMENT
MAX CHANGE OVER
FWD MAX
BLOCKED
CHECK HP VALVE
(DR.VALVE OVERSET)
REV MAX FWD DRIVE BLOCKED
MAX SPEED
BLOCKED FWD MAX

DR VALVE
ADJUSTMENT REV MAX
OIL TYPE
BLOCKED FWD End of regulation

END OF OIL TEMPERATURE
REGULATION ...............................................°C
CHECK REV End of regulation
TRAVEL SPEED (MAX) :
BLOCKED ...................................km/h
INCHING VALVE FWD MAX
ADJUSTMENT DRAWBAR PULL .................................................kg
39
75
75
40
MANITOU - EINSTELLKARTE HYDROSTATISCHES GETRIEBE - A4VG--DA / A6VM--DA
PRÜFDATUM : MASCHINENTYP : TYP HYDROSTATISCHE PUMPE :
NAME VERTRAGSHÄNDLER : SERIEN-Nr. : SERIEN-Nr. PUMPE :
NAME DES TECHNIKERS : STUNDENZAHL : TYP HYDROSTATISCHER MOTOR:
SERIEN-Nr. MOTOR :
DREHZAHL VERBRENNUNGSMOTOR min-1

1 Mindestdr.......... 2 Oberer Leerlauf: ......................max
3 bei hydr. Last:..................... 4 Regelbeginn: .................. 5 Regelende 400 bar: .......... 6 max bei Last V.f.: .............
HYDROSTATISCHE PUMPE HYDROMOTOR

SITUATION VORSTEUER- HOCHDRUCK STAPLERZUSTAND
POSITION DREHZAHL DRUCK HP WASCH- UNTERDRUCK HOCH- DRUCK
STAPLER + AUS- AUFLADE- +
WENDE- VERBRENNUNGS- DRUCK SAUGLEITUNG DRUCK STEUER-
GEFÜHRTE Prüfungen/ DRUCK VOR- RÜCK- VOR- RÜCK- POSITION
SCHALTER MOTOR GEHÄUSE PUMPE HP ZYLINDER
Einstellungen WÄRTS WÄRTS WÄRTS WÄRTS WENDESCHALTER
MINDEST
EINSTELLUNG LEER
NEUTRAL
AUFLADEDRUCK BEI
MAX VORWÄRTSFAHREN
MAX. DREHZAHL
REGELBEGINN
VORWÄRTS
LEER MAX
DE
EINSTELLUNG
REGELBEGINN REGELBEGINN VORWÄRTFAHREN
RÜCKWÄRTS IM AUGENBLICK DER
MAX UMSCHALTUNG MAX.
DREHZAHL
BELASTET VORWÄRTS MAX
EINSTELLUNG
HOCHDRUCK HP
ERHÖHEN DES
RÜCKWÄRTS MAX VORWÄRTFAHREN
SCHNITTVENTILS DR
BEI LAST
MAX. DREHZAHL
BELASTET VORWÄRTS MAX
EINSTELLUNG
SCHNITTVENTIL DR RÜCKWÄRTS MAX
ÖLSORTE
VORWÄRTS REGELENDE
BELASTET
PRÜFUNG ÖLTEMPERATUR.........................................°C
REGELENDE
RÜCKWÄRTS REGELENDE
MAX. GESCHWINDIGKEIT, UNBELASTET:
BELASTET ...................................km/h
EINSTELLUNG VORWÄRTS MAX
INCHING-VENTIL ZUGKRAFT.................................................kg
MRT 1440-1640-1840 EASY
MO357A10
SPICER CLARK-HURTH
maintenance and repair

INSTRUCTION MANUAL
MANUALE D'ISTRUZIONE E RIPARAZIONE
WARTUNG UND REPARATURANLEITUNG
MANUAL DE MANUTENCION Y REPARACION
MANUAL ENTRETIEN ET REPARATION
DROP BOX TYPE 357

1
PRINTED IN ITALY
Copyright By DANA SPICER CLARK-HURTH
Vietata la riproduzione anche parziale di testo ed illustrazioni
Realizzazione a cura dell'Ufficio PubblicitaÁ e dell'Ufficio Post Vendita della DANA SPICER CLARK-HURTH
Impaginazione: TEMAS s.r.l. - Gallarate (Va)
Stampa: Gennaio 1998 (N.L. 7309)
Data subject to change without notice. We decline all responsability for the use of non-original components, or accessories which have
not been tested and submitted for approval.
Dati soggetti a modifiche senza impegno di preavviso. Si declina ogni responsabilitaÁ per l'utilizzo di componenti non originali o accessori
non collaudatied apporvati.
AÈnderungen ohne vorherige AnkuÈndingung vorbehalten. Es wird jede Verantwortung fuÈr die Verwendung von Nichtoriginalteilen oder
nicht abgenommenem und genehmigtem ZubehoÈr abgelehnt.
Los datos pueden ser modificados sin aviso previo. Se declina toda responsabilidad en el caso de uso de componentes no originales o
bien de accesorios no ensayados y aprobados.
Le constructeur se reÂserve le droit d'apporter des modifications aÁ sa production, sans pour cela eÃtre tenu d'en donner preÂavis. Nous
deÂclinons toute responsabiliteÂ pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.
2
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
GB
INTRODUCTION..................................................................................................................................................................................................... 4
MAINTENANCE AND LUBRICANT .......................................................................................................................................................................... 6
CONVERSION TABLES .......................................................................................................................................................................................... 7
TIGHTENING TORQUES ........................................................................................................................................................................................ 7
DIAGRAMS OF REDUCTION UNIT AND EXPLODED VIEWS ................................................................................................................................... 8
DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357........................................................................................................................ 10
REMOVAL OF HYDRAULIC GEAR CONTROL....................................................................................................................................................... 12
ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 ............................................................................................................................. 28
INSTALLATION OF HYDRAULIC GEAR CONTROL ............................................................................................................................................... 44
INTRODUZIONE .......................................................4 VORAUSSETZUNG .................................................. 4

ITA D
MANUTENZIONE E LUBRIFICANTI...........................6 WARTUNG UND SCHMIERSTOFFE ......................... 6
TABELLE DI CONVERSIONE....................................7 UMRECHNUNGSTABELLEN .................................... 7
COPPIE DI SERRAGGIO .............................................................7 ANZIEHDREHMOMENTE ............................................................ 7
SCHEMI RIDUTTORE ED ESPLOSI .............................................8 SCHEMAS FUÈR UNTERSETZUNGSGETRIEBE
SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO ........10 UND ZUSAMMENSTELLUNGSZEICHNUNGEN ........................... 8
RIMOZIONE COMANDO MARCIA IDRAULICO ...........................12 DIREKT GEFLANSCHTER REDUZIERER 357 ZERLEGEN ......... 10
ASSEMBLAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO.....28 HYDRAULISCHER GANGSCHALTUNG ENFERNEN.................. 12
INSTALLAZIONE COMANDO MARCIA IDRAULICO ....................44 DIREKT GEFLANSCHTER REDUZIERER 357 MONTIEREN ....... 28
HYDRAULISCHER GANGSCHALTUNG MONTIEREN ................ 44
PROLOGO ...............................................................4 INTRODUCTION....................................................... 4

ESP MANTENIMIENTO Y LUBRICANTES .........................6 F ENTRETIEN ET LUBRIFIANTS ................................. 6
TABLAS DE CONVERSION.......................................7 TABLEAUX DE CONVERSION.................................. 7
PARES DE TORSION ..................................................................7 COUPLES DE SERRAGE ............................................................ 7
DIAGRAMAS REDUCTOR Y VISTAS PORMENORIZADAS ...........8 TRACES REDUCTEUR ET EXPLOSIFS....................................... 8
DESMONTAJE GRUPO REDUCTOR 357 CON BRIDA ...............10 DEMONTAGE DU GROUPE REDUCTEUR BRIDE 357............... 10
REMOCION MANDO MARCHA HIDRAULICO.............................12 DEPLACEMENT DE LA COMMANDE DE VITESSES
MONTAJE GRUPO REDUCTOR 357 CON BRIDA ......................28 HYDRAULIQUE ........................................................................ 12
MONTAJE MANDO MARCHA HIDRAULICO...............................44 ASSEMBLAGE DU GROUPE REDUCTEUR BRIDE 357 ............. 28
INSTALLATION DE LA COMMANDE DE VITESSES
HYDRAULIQUE ........................................................................ 44
3
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, extractors and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la SPICER CLARK-HURTH.
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of SPICER mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
CLARK-HURTH. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Auszieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
4
der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos
Spiele, Vorspannungen und Drehmomente strengstens ein- de las herramientas especificas necesarias para la ejecucioÂn
gehalten werden. de las intervenciones de mantenimiento figuran al final del
manual; los recambios se pueden pedir al fabricante de la
GUÈ LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern maÂquina o directamente al Service Center o a Distribuidores
die Einheiten gehoÈren. Der Einfachheit halber sind die autorizados de SPICER CLARK-HURTH.
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer
= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂcessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
SPICER CLARK-HURTH bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
fournis par le constructeur du veÂhicule. En deÂcrivant les
El rendimiento y la duracioÂn de los oÂrganos
ESP opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mecaÂnicos depende, ademaÂs que del constante y
enleveÂ du veÂhicule.
correcto mantenimiento, tambieÂn de la interven-
cioÂn inmediata en caso de averõÂas o anomalõÂas. IMPORTANT: Pour faciliter le travail en sauvegardant en
Al proponer este manual, ha sido considerada la suposicioÂn de meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
una revisioÂn general del grupo, pero es el mecaÂnico quien tiene teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
que valorar la necesidad de montar cada uno de los telles que des eÂtais ou banc de support, maillets en plastique
componentes en caso de reparacioÂn. El manual es una guõÂa ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
raÂpida y segura que permite intervenciones precisas por medio Avant de proceÂder au deÂmontage des parties et vidanger
de fotografõÂas y de planos que muestran las distintas fases de l'huile, il vaut mieux nettoyer soigneusement le pont, en
las operaciones. A continuacioÂn figuran todas las informacio- enlevant incrustations et blocs de gras.
nes y advertencias necesarias para ejecutar un montaje
correcto, para las comprobaciones y el montaje de cada uno PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
de los componentes. Para remover el puente diferencial del doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
vehõÂculo hay que consultar los manuales de los fabricantes del approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
vehõÂculo. En la descripcioÂn de las operaciones siguientes se abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
supone que el puente ya ha sido sacado del vahõÂculo. particulier, de toutes les parties en mouvement (paliers,
engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
IMPORTANTE: Para facilitar el trabajo salvaguardando al bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
mismo tiempo las superficies mecanizadas y la seguridad de sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
los operadores, se aconseja que se usen equipos y herra- substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
mientas adecuados como caballetes y bancos de soporte, effectue une reÂvision ou une reÂparation des composants. Au
martillos de plaÂstico o de cobre, palancas adecuadas, moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
extractores y llaves especõÂficas. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
Antes de desmontar las partes y descargar el aceite, es conique, la substitution de l'un de ses engrenages comporte
conveniente que se haga una limpieza minuciosa del puente eÂgalement la substitution de l'autre. En phase de montage, il
sacando las incrustaciones y acumulaciones de grasa. faut respecter scrupuleusement les jeux, les preÂcharges et les
couples prescrits.
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados
tienen que ser limpiados minuciosamente con productos VALIDITE: Le manuel fournit la validiteÂ des groupes sous
adecuados y restaurados o sustituidos en el caso de que forme de matricule. Pour une meilleure interpreÂtation, les
presenten danÄos, desgaste, rajaduras, agarrotamientos, etc. validiteÂs sont indiqueÂes comme:
En particular, comprobar la integridad de todas las partes en
movimiento (cojinetes, engranajes, par coÂnico, ejes) y de = jusqu'aÁ l'immatriculation
estanqueidad (anillos OR, detenedor de aceite) sujetas a
mayores solicitaciones y desgaste. = aÁ partir de l'immatriculation et apreÁs
Se aconseja, de todas formas, que se sustituyan los oÂrganos
de estanqueidad cada vez que se ejecute la revisioÂn o Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
reparacioÂn de los componentes. deÂmontage et d'assemblage sont pareilles dans toutes les
Al volver a montar, los segmentos de compresioÂn tienen que versions.
estar lubricados en los bordes de estanqueidad. En el caso del
par coÂnico, la sustitucioÂn de uno de sus engranajes comporta INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
tambieÂn la sustitucioÂn del otro. Al montar hay que tener en Les dessins des installations speÂcifiques neÂcessaires pour
cuenta escrupulosamente los juegos, las precargas y los pares effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
descriptos. manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
constructeur de la machine ou directement aux Centres de
VALIDEZ: El manual suministra la validez de los grupos en Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ SPICER
forma de matrõÂcula. Para poder tener una interpretacioÂn CLARK-HURTH.
correcta, la validez estaÂ indicada:
= hasta la matrõÂcula
= desde la matrõÂcula en adelante
5
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS
D1240009
Oil fill and level plug Oil drain plug
1 2
Tappo carico e livello olio Tappo scarico olio
È leinfu
O È lstandschraube
Èll- und O È leinfu
O È lablaûschraube
Èll- und O
Tapo Â n de relleno y nivel aceite Tapo Â n de vaciado nivel aceite
Bouchon de remplissage et jauge d'huile Bouchon de vidage huile
1 2
3
MFG. BY CLARK-HURTH COMPONENTS S.P.A.
38062 Arco (Trento)
MADE IN ITALY
D1240011
Type and model unit Serial number Lubrificant
1 2 3
Tipo e modello gruppo Numero di serie Lubrificante
Type und modell Antriebes Seriennummer Schmieroel
Tipo y modelo unidad Â mero de serie
Nu Lubricante
Â le de ensemble
Type et mode Numero de serie Lubrificant
OPERATION FREQUENCY LUBRICANTS

OPERAZIONE Á
PERIODICITA LUBRIFICANTI
ARBEITSVORGANG ZEITABSTAND SCHMIERSTOFFE
OPERACION FRECUENCIA LUBRICANTES
OPERATION PERIODICITE LUBRIFIANTS
. Check levels: monthly
. Controllo livelli: mensile
. È lstandkontrolle:
O monatlich
. Control niveles: cada mes
. ControÃle niveaux: mensuel
SAE85W90 API GL3
. Oil change: every 1000 hours ]
. Cambio olio: ogni 1000 ore
. È lwechsel:
O alle 1000 Std.
. Cambio aceite: cada 1000 horas
. Vidange huile: toutes les 1000 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de
100 horas de trabajo - Initialement apreÁs 100 heures de travail
6
CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN
TABLAS DE CONVERSION - TABLEAUX DE CONVERSION
1 Atm%1 bar%105 PA%14.4 PSi

Pa
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1
TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE
TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS

SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS
TAMAN Ä O TORNILLO
8G/8,8 10k/10,9 12k/10,9
MESURE VIS Nm Nm Nm
M4 2,9 4,1 Ð
M6 10,0 14,0 Ð
M8 25,0 35,0 Ð
M10 49,0 69,0 Ð
M10x1,25 52,0 73,0 88,0
M12 86,0 120,0 Ð
M14 135,0 190,0 Ð
M14x1,5 150,0 210,0 250,0
M16 210,0 295,0 Ð
M18x1,5 325,0 460,0 550,0
A22 550
7
DIAGRAMS OF REDUCTION UNIT AND EXPLODED VIEWS - SCHEMI RIDUTTORE ED ESPLOSI - SCHEMAS FUÈR UNTERSETZUNGSGETRIEBE
UND ZUSAMMENSTELLUNGSZEICHNUNGEN - DIAGRAMAS REDUCTOR Y VISTAS PORMENORIZADAS - TRACES REDUCTEUR ET EXPLOSIFS
DIAGRAM
SCHEMA
SCHEMAS
DIAGRAMAS
TRACES
D1240001
TECHNICAL DATA - CARATTERISTICHE TECNICHE - TECHNISCHE DATEN - CARACTERI-

STICAS TECNICAS - CARACTERISTIQUES TECHNIQUES
A- Connector for hydraulic gear control - Pressure required 15±30 bar
Raccordi comando marce idraulico - Pressione di comando 15±30 bar
Anschluss fuÈr hydraulischer BetaÈtigung der Gangschaltung Schaltdruck 15±30 bar
ConexioÂn mando marcha hydraulico - PresioÂn de mando 15±30 bar
Raccord commande des vitesses hydraulique - Pression de commande 15±30 bar
REDUCTION GEAR
RIDUTTORE
UNTERSETZUNGSGETRIEBE
REDUCTOR
REDUCTEUR
D1240012
] OPTIONAL
8
Ist GEAR
Ië MARCIA
Ië GANG
Ië MARCHA
Ië VITESSE
D1240002
IInd GEAR
IIë MARCIA
IIë GANG
IIë MARCHA
IIë VITESSE
D1240003
9
SYMBOLS - SIMBOLI - SYMBOLS DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357- SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO - DIREKT GEFLANSCHTER
SIMBOLOS - SYMBOLES REDUZIERER 357 ZERLEGEN - DESMONTAJE GRUPO REDUCTOR 357 CON BRIDA - DEMONTAGE DU GROUPE REDUCTEUR BRIDE 357
Disassembly of assembly groups

Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts
Smontaggio di particolari ingombri
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention ! Important notice
Attenzione, indicazione importante F1240069 F1240070
Achtung, wichtiger Hinweis
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante GB a GB b
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc. Reduction gear directly flanged on the axle with mechanic gear Reduction gear directly flanged on the axle with hydraulic gear
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs. control. control.
Controlar y ajustar, por ej. pares, medidas, presiones, etc.
Controler, regler p.e. couples, mesures, pressions ecc.
T=Special tool P=page
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si neÂcessaire)
Renew at each reassembly
Sostituire con ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage F1240071
Unlock - lock e.g. split pin, locking plate, etc.

Togliere-mettere la sicura
Entsichern-Sichern GB c GB d
Quitar-colocar el seguro
Enlever-mettre la securite Reduction gear directly flanged on the axle with or without
Lock-adhere (liquid sealant) revolution indicator.
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung)
Colocar el seguro, pegar (mastique lõÂquido)
Mettre la securite, coller (mastic liquide)
Guard against material damage, damage to parts
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fuÈr den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje)
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈl-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈl, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
GB e GB f
Inserire pressione nel circuito idraulico
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique
To clean
Pulire
Reinigen
Limpiar
Nettoyer 10
Versione afflangiata al ponte con comando marcia Versione afflangiata al ponte con comando marcia
ITA meccanico. ITA idraulico.
Direkt an der Triebachse geflanscht mit mechanischer Direkt an der Triebachse geflanscht mit hydraulischer
D Gangschaltung. D Gangschaltung.
a b
VersioÂn con brida en el puente con mando mecaÂnico VersioÂn con brida en el puente con mando hidraÂulico
ESP de la marcha. ESP de la marcha.
ModeÁle brideÂ au pont aÁ commande de vitesses ModeÁle brideÂ au pont aÁ commande de vitesses
F meÂcanique. F hydraulique.
Versione afflangiata al ponte con o senza rilevatore di

ITA giri. ITA
Direkt an der Triebachse geflanscht mit oder ohne

D Drehzahlmesser. D
c d
VersioÂn con brida en el puente con o sin detector de
ESP revoluciones. ESP
ModeÁle brideÂ pont avec ou sans compteur de tours.

F F
ITA ITA
D D
e f
ESP ESP
F F
11
REMOVAL OF HYDRAULIC GEAR CONTROL - RIMOZIONE COMANDO IDRAULICO - HYDRAULISCHER GANGSCHALTUNG ENFERNEN -
REMOCION MANDO MARCHA HIDRAULICO - DEPLACEMENT DE LA COMMANDE DE VITESSES HYDRAULIQUE
F1240072 F1240073
GB a GB b
Remove the gear control rod. Pull out the control rod.
F1240074 F1240075
GB c GB d
Remove screws on the gear control cylinder. Remove the gear control cylinder.
F1240076 F1240077
GB e GB f
Pull out the gear control cylinder. Re-assembly arrangement of gear control cylinder parts.
Pay attention to the position of the O-rings. Remove the protection
plate.
12
Rimuovere l'asta di comando marce. Estrarre l'asta comando.
ITA ITA
Gangschalterhebel abnehmen. Hebel herausziehen.

D D
a b
Remover la varilla de mando de las marchas. Extraer la varilla de mando.
ESP ESP
Enlever la tringle de commande de vitesses. Extraire la tringle de commande.

F F
Rimuovere le viti del cilindro comando marce. Rimuovere il cilindro comando marce.
ITA ITA
Die Schrauben vom Zylinder des Gangschalters Zylinder des Gangschalters abnehmen.
D abnehmen. D
c d
Remover los tornillos del cilindro de mando de las Remover el cilindro de mando de las marchas.
ESP marchas. ESP
Enlever les vis du cylindre de commande de vitesses. Enlever le cylindre de commande de vitesses.
F F
Estrarre il cilindro comando marce. Ordine di rimontaggio dei particolari del cilindro di
ITA Prestare attenzione alla posizione degli anelli OR. ITA comando marce.
Rimuovere la lamiera di protezione.
Zylinder des Gangschalters herausziehen. Reihenfolge zur Montage der Einzelteile des Gangs-
D Auf die Position der O-Ringe achten. Schutzblech D chalterzylinders.
abnehmen.
e f
Extraer le cilindro de mando de las marchas. Orden para volver a montar las piezas del cilindro de
ESP Tener cuidado con la posicioÂn de los anillos OR. ESP mando de las marchas.
Remover la placa de proteccioÂn.
Extraire le cylindre de commande de vitesses Placer les pieÁces en ordre en vue du remontage du
F Faire attention au positionnement des bagues OR F cylindre de commande de vitesses.
Enlever la toÃle de protection.
13
DISASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357- SMONTAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO - DIREKT GEFLANSCHTER
REDUZIERER 357 ZERLEGEN - DESMONTAJE GRUPO REDUCTOR 357 CON BRIDA - DEMONTAGE DU GROUPE REDUCTEUR BRIDE 357
F1240078 F1240079
GB a GB b
Remove fastening screws from the reduction unit. Disjoin the entire reduction unit from the axle and place it on a
bench.
F1240080 F1240081
GB c GB d
Remove the sealing cover with the relative washer or the revolution Remove gear-in position switch, O-ring and washer.
indicator.
F1240082 F1240083
GB e GB f
Remove screw, spring, together with gear-and-neutral position Remove screw, spring and neutral position ball (hydraulic version).
spindle (mechanical version).
14
Rimuovere le viti di fissaggio del riduttore. Staccare il riduttore completo dal ponte e posizionarlo
ITA ITA su un banco.
Reduziererbefestigungsschrauben abschrauben. Den gesamten Reduzierer von der Triebachse neh-

D D men und einen Tisch legen.
a b
Remover los tornillos de fijacioÂn de reductor. Desprender el reductor completo del puente y posi-
ESP ESP cionarlo en un banco.
Enlever les vis de fixation du reÂducteur. DeÂtacher le reÂducteur tout entier du pont et le mettre
F F sur le banc.
Rimuovere il tappo di chiusura con rosetta oppure il Rimuovere l'interruttore di posizione marcia inserita
ITA rilevatore di giri. ITA con anello OR e rosetta.
Stopfen mit Unterlegscheibe oder Drehzahlmesser Schalter fuÈr die Position der Gangschaltung mit O-
D entfernen. D Ring und Unterlegscheibe entfernen.
c d
Remover el tapoÂn de cierre con la roseta o bien el Remover el interruptor de posicioÂn de marcha em-
ESP detector de revoluciones. ESP bragada con el anillo OR y la roseta.
Enlever le bouchon de verrouillage aÁ rondelle ou bien Enlever l'interrupteur de la position vitesses incorporeÂ
F le compteur de tours. F avec la bague OR et la rondelle.
Rimuovere la vite, la molla ed il puntalino di posizione Rimuovere la vite, la molla e la sfera di posizone folle
ITA marcia e folle (versione meccanica). ITA (versione idraulica).
Schraube, Feder und Stift fuÈr die Position der Gangs- Schraube, Feder und Kugel fuÈr die Position des
D chaltung und des Leerlaufs entfernen (mechanische D Leerlaufs entfernen (hydraulische AusfuÈhrung).
AusfuÈhrung).
e f
Remover el tornillo, el muelle y el pasador de posicioÂn Remover el tornillo, el muelle y la bola de posicioÂn de
ESP de marcha y punto neutro (versioÂn mecaÂnica). ESP punto neutro (versioÂn hidraÂulica).
Enlever la vis, le ressort et la buteÂe de position Enlever la vis, le ressort et la spheÁre de position point
F vitesses et point mort (modeÁle meÂcanique). F mort (modeÁle hydraulique).
15
F1240084 F1240085
GB a GB b
Remove screws from the motion input cover. Disjoin the motion entrance cover.
F1240086 F1240087
GB c GB d
Remove the nut from the flange. Remove the O-ring and pull out the flange.
F1240088
GB e GB f
Remove screws from the cover.
16
Rimuovere le viti del coperchio di entrata del moto. Staccare il coperchio di entrata del moto.
ITA ITA
Die Deckelschrauben am Anfang der Bewegung Deckel am Eingang des Bewegung abnehmen.
D abschrauben. D
a b
Remover los tornillos de la tapa de entrada del Desprender la tapa de entrada del movimiento.
ESP movimiento. ESP
Enlever les vis du couvercle d'entreÂe du mouvement. DeÂcrocher le couvercle d'entreÂe du mouvement.
F F
Rimuovere il dado della flangia. Asportare l'anello OR ed estrarre la flangia.

ITA ITA
Flanschmutter abschrauben. O-Ring abnehmen und Flansch herausziehen.

D D
c d
Remover la tuerca de la brida. Quitar el anillo OR y extraer la brida.
ESP ESP
Enlever l'eÂcrou de la flasque. Enlever la bague OR et extraire la flasque.

F F
Rimuovere le viti del coperchio.

ITA ITA
Deckelschrauben abschrauben.
D D
e f
Remover los tornillos de la tapa.
ESP ESP
Enlever les vis du couvercle.

F F
17
F1240089 F1240090
GB a GB b
Disjoin the cover. Remove the cover by fixing the distance washers onto the cover
itself.
Caution: the niche must be facing upwards.
F1240091 F1240092
GB c GB d
Remove screws. Remove the cover.
Take care not to damage planes.
F1240093
GB e GB f
Take away the cover.
Pay attention to the position of the pins.
18
Staccare il coperchio. Rimuovere il coperchio fissando gli spessori allo
ITA ITA stesso.
Attenzione: nicchia rivolta verso l'alto.
Deckel abnehmen. Deckel abnehmen und DistanzstuÈcke am Deckel

D D befestigen.
Achtung: die Nische ist nach oben gerichtet.
a b
Desprender la tapa. Remover la tapa fijando los espesores en la misma.
ESP ESP Cuidado: el hueco tiene que estar dirigido hacia
arriba.
DeÂcrocher le couvercle. Enlever le couvercle en fixant les cales aÁ ce dernier.

F F Attention: au logement tourneÂ vers le haut.
Rimuovere le viti. Rimuovere il coperchio.

ITA ITA Prestare attenzione per non danneggiare i piani.
Schrauben abschrauben. Deckel abnehmen.

D D Darauf achten, die FlaÈchen nicht zu beschaÈdigen.
c d
Remover los tornillos. Remover la tapa.
ESP ESP Poner mucho cuidado a fin de no danÄar las superfi-
cies.
Enlever les vis. Enlever le couvercle.

F F Faire attention aÁ ne pas endommager les surfaces.
Togliere il coperchio.
ITA Prestare attenzione alla posizione delle spine. ITA
Deckel abnehmen.
D Auf die Position der Stifte achten. D
e f
Sacar la tapa.
ESP Tener mucho cuidado con la posicioÂn de las clavijas. ESP
Enlever le couvercle.
F Faire attention aÁ la position des broches. F
19
F1240094 F1240095
GB a GB b
Pull out gear, needle bearings and distance piece form the box. Remove the bearing if it needs replacing.
F1240096 F1240097
GB c GB d
Re-introduce the bearing into the box. Remove the oil shield plate only if necessary.
Caution: the oil inlet must face upwards.
F1240098 F1240099
GB e GB f
Re-introduce the oil shield plate with oil inlet facing upwards. Fit the oil shield plate into position 5±5.5 mm from box plane.
Apply LOCTITE 510 on the outside.
20
Estrarre dalla scatola l'ingranaggio, i cuscinetti a Rimuovere il cuscinetto se eÁ da sostituire.
ITA rullini ed il distanziale. ITA
Aus der Schachtel das Zahnrad, die Kugellager und Lager herausnehmen, wenn es ausgewechselt wer-
D das DistanzstuÈck nehmen. D den soll.
a b
Extraer de la caja el engranaje, los cojinetes de agujas Remover el cojinete si hay que sustituirlo.
ESP y el separador. ESP
Extraire la boõÃte d'engrenage, les paliers aÁ rouleaux et Enlever le palier s'il est aÁ remplacer.
F l'entretoise. F
Reinserire il cuscinetto nella scatola. Rimuovere la lamiera paraolio solo se necessario.

ITA ITA Attenzione: l'entrata dell'olio deve essere rivolta verso
l'alto.
Lager in die Schachtel einsetzen. È labdichtung nur abnehmen, wenn es noÈtig sein
O
D D sollte.
È leingang muû nach oben gerichtet sein.
Achtung: der O
c d
Volver a colocar el cojinete en la caja. Remover el sello de aceite si fuera necesario.
ESP ESP Cuidado: la entrada del aceite tiene que estar dirigida
hacia arriba.
ReÂinseÂrer le palier dans la boõÃte. Enlever la toÃle pare-huile seulement si besoin.

F F Attention: l'orifice de huile doit eÃtre tourneÂe vers le
haut.
Reinserire lamiera paraolio con l'entrata dell'olio verso Posizionare la lamiera paraolio a 5v5,5 mm dal piano
ITA l'alto. ITA scatola.
Spalmare sull'esterno LOCTITE 510.
È labdichtung mit dem Eingang nach oben wieder

O È labdichtung in einem Abstand von 5v5,5 mm von
O
D einsetzen. D der SchachtelflaÈche einsetzen.
Auûen mit LOCTITE 510 schmieren.
e f
Volver a colocar el sello de aceite con la entrada del Posicionar el sello de aceite a 5v5,5 mm de la
ESP aceite hacia arriba. ESP superficie de la caja.
Engrasar por fuera con LOCTITE 510.
ReÂinseÂrer la toÃle pare-huile avec l'orifice de l'huile Placer la toÃle pare-huile aÁ 5v5,5 mm de la surface de
F tourneÂe vers le haut. F la boõÃte.
Enduire du LOCTITE 510 aÁ l'exteÂrieur.
21
F1240100 F1240101
GB a GB b
Remove the check screws from the flow regulator plate. Remove the plate and pull out coupling and fork at the same time.
F1240102 F1240103
GB c GB d
Check: sliding blocks, pin, and sliding coupling. Remove the lower shaft.
Replace if worn.
F1240104
GB e GB f
Remove the entire shaft and the flow regulator plate.
22
Rimuovere le viti di ritegno lamiera frangiflusso. Asportare la lamiera ed estrarre contemporaneamente
ITA ITA il manicotto e la forcella.
Befestigungsschrauben des Strahlreglers abschrau- Strahlregler abnehmen und gleichzeitig HuÈlse und
D ben. D Gabel herausziehen.
a b
Remover los tornillos de retencioÂn de la placa Sacar la placa y extraer contemporaÂneamente el
ESP deflectora. ESP manguito y la horquilla.
Enlever les vis de fixation de la toÃle brise-jet. Enlever la toÃle et extraire, en meÃme temps, le
F F manchon et la fourchette.
Verificare: pattini, spina e manicotto scorrevole. Rimuovere l'albero di uscita.

ITA Sostituirli se sono usurati. ITA
Zu kontrollieren: Gleitschuhe, Stift und GleithuÈlse. Ausgangswelle abnehmen.

D Wenn verschleiût, auswechseln. D
c d
Comprobar: patines, clavija y manguito corredizo. Remover el eje de salida.
ESP Sustituirlos si estaÂn gastados. ESP
VeÂrifier: pattes, broches et manchon coulissant. DeÂplacer l'arbre de sortie.

F Remplacer s'ils sont useÂs. F
Asportare l'albero completo e la lamiera frangiflusso.

ITA ITA
Die ganze Welle und den Strahlregler abnehmen.

D D
e f
Sacar el eje completo y la placa deflectora.
ESP ESP
Enlever l'arbre au complet ainsi que la toÃle brise-jet.

F F
23
F1240105 F1240106
GB a GB b
Disassembly of the entire lower shaft. Progressive arrangement of parts fitted onto the lower shaft.
F1240107 F1240108
GB c GB d
Assembly of lower shaft. Removal of upper shaft.
(In case of replacement, the shaft is supplied already assembled).
F1240109 F1240110
GB e GB f
Pull out the sealing ring. Re-insert a new sealing ring.
24
Smontaggio dell'albero di uscita completo. Disposizione progressiva dei particolari montati su
ITA ITA albero di uscita.
Ganze Ausgangswelle abmontieren. Reihenfolge der auf der Ausgangswelle montierten

D D Einzelteile.
a b
Desmontaje del eje de salida completo. DisposicioÂn progresiva de las piezas montadas en el
ESP ESP eje de salida.
DeÂmontage complet de l'arbre de sortie. Mise en place progressive des pieÁces monteÂes sur
F F l'arbre de sortie.
Assemblaggio dell'albero di uscita. Rimuovere l'albero di entrata.

ITA ITA (Nel caso di sostituzione, viene fornito premontato).
Zusammenbau der Ausgangswelle. Eingangswelle entfernen.

D D (Bei Ersatz, wird sie schon montiert geliefert).
c d
Montaje del eje de salida. Remover el eje de entrada.
ESP ESP (En el caso de sustitucioÂn, se entrega ya premontado).
Assemblage de l'arbre de sortie. DeÂplacer l'arbre d'entreÂe.

F F (En cas de substitution, il est fourni preÂmonteÂ).
Estrarre l'anello di tenuta. Reinserire il nuovo anello di tenuta.

ITA ITA
Dichtungsring herausziehen. Den neuen Dichtungsring einsetzen.

D D
e f
Extraer el segmento de compresioÂn. Volver a insertar el segmento de compresioÂn.
ESP ESP
Extraire la bague d'eÂtancheÂiteÂ. Introduire la bague d'eÂtancheÂiteÂ neuve.

F F
25
F1240111 F1240112
GB a GB b
Pull out the sealing ring of the cover. Re-insert a new sealing ring.
F1240113 F1240114
GB c GB d
Pull out the sealing ring from the motion input cover. Remove the bearing from the cover of the reduction unit.
GB e GB f
26
Estrarre l'anello di tenuta del coperchio. Reinserire il nuovo anello di tenuta.
ITA ITA
Dichtungsring des Deckels herausziehen. Den neuen Dichtungsring einsetzen.

D D
a b
Extraer el segmento de compresioÂn de la tapa. Insertar el nuevo segmento de compresioÂn.
ESP ESP
Extraire la bague d'eÂtancheÂiteÂ du couvercle. Introduire la bague d'eÂtancheÂiteÂ neuve.

F F
Estrarre l'anello di tenuta dal coperchio di ingresso del Rimuovere il cuscinetto dal coperchio riduttore.
ITA moto. ITA
Dichtungsring am Anfang der Bewegung herauszie- Lager des Reduziererdeckels entfernen.

D hen. D
c d
Extraer el segmento de compresioÂn de la tapa de Remover el cojinete de la tapa del reductor.
ESP entrada del movimiento. ESP
Extraire la bague d'eÂtancheÂiteÂ du couvercle d'entreÂe Enlever le palier du couvercle du reÂducteur.

F du mouvement. F
ITA ITA
D D
e f
ESP ESP
F F
27
ASSEMBLY OF DIRECTLY FLANGED REDUCTION GEAR 357 - ASSEMBLAGGIO GRUPPO RIDUTTORE 357 AFFLANGIATO - DIREKT GEFLANSCHTER
REDUZIERER 357 MONTIEREN - MONTAJE GRUPO REDUCTOR 357 CON BRIDA - ASSEMBLAGE DU GROUPE REDUCTEUR BRIDE 357
F1240115 F1240116
GB a GB b
Re-fit the bearing in the cover of the reduction unit using ordinary Re-insert the new sealing ring in the motion input cover.
tools.
F1240117 F1240118
GB c GB d
Re-assemble the cover, spreading LOCTITE 510 on planes and Tighten screws using a torque wrench setting of 49±51 Nm.
screws.
F1240119
GB e GB f
Lubricate the lip of the sealing ring with grease.
28
Rimontare il cuscinetto nel coperchio riduttore con i Reinserire il nuovo anello di tenuta coperchio di
ITA normali attrezzi. ITA ingresso del moto.
Lager in den Reduziererdeckel mit gewoÈhnlichen Den neuen Dichtungsring in den Deckel am Eingang
D Werkzeugen montieren. D der Bewegung montieren.
a b
Volver a montar el cojinete en la tapa del reductor con Volver a insertar el nuevo segmento de compresioÂn en
ESP las herramientas normales. ESP la tapa de entrada del movimiento.
Remonter le palier du couvercle reÂducteur aÁ l'aide Introduire la bague d'eÂtancheÂiteÂ neuve dans le
F d'outils habituels. F couvercle d'entreÂe du mouvement.
Rimontare il coperchio spalmando sui piani e sulle viti Serrare le viti con una coppia di serraggio di
ITA LOCTITE 510. ITA 49v51 Nm.
DeckelflaÈchen und -schrauben mit LOCTITE 510 Schrauben mit einem Anziehdrehmoment zu
D schmieren und montieren. D 49v51 Nm anziehen.
c d
Volver a montar la tapa engrasando las superficies y Apretar los tornillos a un par de torsioÂn de di
ESP los tornillos con LOCTITE 510. ESP 49v51 Nm.
Remonter le couvercle en eÂtalant du LOCTITE 510 sur Serrer les vis aÁ un couple de serrage de
F les surfaces et sur les vis. F 49v51 Nm.
Lubrificare con grasso il labbro dell'anello di tenuta.

ITA ITA
Dichtlippe mit Fett schmieren.

D D
e f
Lubricar con grasa el labio del segmento de compre-
ESP sioÂn. ESP
Lubrifier avec du gras la leÁvre de la bague d'eÂtan-

F cheÂiteÂ. F
29
F1240120 F1240104
GB a GB b
Re-assemble the motion upper shaft. Re-assemble the full lower shaft and the flow regulator plate.
F1240121 F1240122
GB c GB d
Position the shaft so that the bearing juts out approximately 5 mm Temporarily re-assemble the cover with screws.
from the cover of the reduction unit. (Be sure that the niche faces upwards).
F1240101 F1240100
GB e GB f
Simultaneously insert: fork and sliding blocks, coupling and flow Re-insert screws and tighten.
regulator plate.
30
Rimontare l'albero di entrata del moto. Rimontare l'albero uscita completo e la lamiera
ITA ITA frangiflusso.
Welle am Eingang der Bewegung montieren. Ganze Ausgangswelle und Strahlregler montieren.
D D
a b
Volver a montar el eje de entrada del movimiento. Volver a montar el eje de salida completo y la placa
ESP ESP deflectora.
Remonter l'arbre d'entreÂe du mouvement. Remonter l'arbre de sortie tout entier et la toÃle brise-
F F jet.
Posizionare l'albero in modo che il cuscinetto sporga Rimontare provvisoriamente il coperchio con le viti.
ITA dal coperchio riduttore circa 5 mm. ITA (Attenzione alla nicchia che deve essere rivolta verso
l'alto).
Die Welle so positionieren, daû das Lager vom VoruÈ bergehend den Deckel mit den Schrauben
D Reduziererdeckel ca. 5 mm herausragt. D montieren.
(Achtung, die Nische muû nach oben gerichtet sein).
c d
Posicionar el eje de manera que el cojinete sobresalga Volver a montar provisionalmente la tapa con los
ESP de la tapa del reductor en unos 5 mm aproximada- ESP tornillos. (Cuidado con el hueco que tiene que estar
mente. dirigido hacia arriba).
Positionner l'arbre de telle sorte que le palier saillisse Remonter provisoirement le couvercle avec les vis.
F du couvercle du reÂducteur d'environ 5 mm. F (Attention le logement doit eÃtre tourneÂ vers le haut).
Reinserire contemporaneamente: la forcella con patti- Reinserire le viti ed avvitarle.

ITA ni, il manicotto e la lamiera frangiflusso. ITA
Gleichzeitig Gabel mit Gleitschuh, HuÈlse und Strahl- Schrauben anbringen und festschrauben.
D regler montieren. D
e f
Volver a insertar contemporaÂneamente la horquilla Volver a introducir los tornillos y atornillarlos.
ESP con los patines, el manguito y la placa deflectora. ESP
ReÂinseÂrer en meÃme temps: la fourchette avec les Introduire les vis et visser.
F pattes, le manchon et la toÃle brise-jet. F
31
F1240123 F1240124
GB a GB b
Tighten screws using a torque wrench setting of 25±26 Nm. Re-assemble needle bearings, gear and distance piece.
F1240125 F1240126
GB c GB d
Check the insertion of pins. Spread LOCTITE 510 on the surface and assemble the cover.
F1240127
GB e GB f
Fasten the cover.
32
Serrare le viti con una coppia di serraggio di Rimontare i cuscinetti a rullini, l'ingranaggio ed il
ITA 25v26 Nm. ITA distanziale.
Schrauben mit einem Anziehdrehmoment zu Kugellager, Zahnrad und DistanzstuÈck montieren.

D 25v26 Nm anziehen. D
a b
Apretar los tornillos a un par de torsioÂn de Volver a montar los cojinetes de agujas, el engranaje y
ESP 25v26 Nm. ESP el separador.
Serrer les vis aÁ un couple de serrage de Remonter les paliers aÁ rouleaux, l'engrenage et
F 25v26 Nm. F l'entretoise.
Verificare l'inserimento delle spine. Spalmare la superficie con LOCTITE 510 e montare il
ITA ITA coperchio.
Einsatz der Stifte kontrollieren. FlaÈche mit LOCTITE 510 schmieren und Deckel
D D montieren.
c d
Comprobar la insercioÂn de las clavijas. Engrasar la superficie con LOCTITE 510 y montar la
ESP ESP tapa.
VeÂrifier l'introduction des broches. Enduire la surface avec du LOCTITE 510 et monter le
F F couvercle.
Mandare il coperchio in battuta.

ITA ITA
Den Deckel zum Anschlag bringen.

D D
e f
Llevar la tapa a tope.
ESP ESP
Lancer le couvercle buteÂe.

F F
33
F1240128 F1240082
GB a GB b
Tighten screws using a torque wrench setting of 49±51 Nm. Grease components and re-introduce spindle, spring and screw
Caution: tighten using the crossed method. (mechanical version).
Tighten using a max. torque wrench setting of 80±100 Nm.
F1240083 F1240081
GB c GB d
Grease components and re-introduce ball, spring and screw Fix the gear-in position switch with washer and O-ring.
(hydraulic version). Tighten with torque wrench setting of max. 54.2 Nm.
Tighten using a max. torque wrench setting of 80±100 Nm.
F1240080
GB e GB f
Assemble the sealing cover with washer and revolution indicator.
Tighten using a torque wrench setting of max. 25 Nm.
34
Serrare le viti con una coppia di serraggio di Ingrassare i componenti e reinserire il puntalino, la
ITA 49v51 Nm. ITA molla, la vite (versione meccanica). Serrare con una
Attenzione: serrare con il metodo incrociato. coppia di serraggio max. di 80v100 Nm.
Schrauben mit einem Anziehdrehmoment zu Einzelteile schmieren und Stift, Feder und Schraube
D 49v51 Nm anziehen. D einsetzen (mechanische AusfuÈhrung). Mit einem An-
Achtung: Schrauben abwechselnd im Kreuz anziehen. ziehdrehmoment zu max. 80v100 Nm anziehen.
a b
Apretar los tornillos a un par de torsioÂn de Engrasar los componentes y volver a insertar el
ESP 49v51 Nm. ESP pasador, el muelle, el tornillo (versioÂn mecaÂnica).
Cuidado: apretar con el meÂtodo cruzado. Apretar a un par de torsioÂn maÂx. dei 80v100 Nm.
Serrer les vis aÁ un couple de serrage de Graisser les composants et reÂinseÂrer la buteÂe, le
F 49v51 Nm. F ressort, la vis (modeÁle meÂcanique).
Attention: serrer avec la meÂthode croiseÂe. Serrer aÁ un couple de serrage max. de 80(100 Nm.
Ingrassare i componenti e reinserire la sfera, la molla e Montare l'interruttore di posizione marcia inserita con
ITA la vite (versione idraulica). ITA rosetta e anello OR.
Serrare con una coppia max. di 80v100 Nm. Serrare con una coppia di serraggio max. di 54,2 Nm.
Einzelteile schmieren und Kugel, Feder und Schraube Schalter fuÈr die Position der Gangschaltung mit
D einsetzen (hydraulische AusfuÈhrung). Mit einem An- D Unterlegscheibe und O-Ring montieren. Mit einem
ziehdrehmoment zu 80v100 Nm anziehen. Anziehdrehmoment zu max. 54,2 Nm anziehen.
c d
Engrasar los componentes y volver a colocar la bola, Montar el interruptor de posicioÂn marcha embragada
ESP el muelle y el tornillos (versioÂn hidraÂulica). ESP con roseta y anillo OR.
Apretar a un par maÂx. dei 80v100 Nm. Apretar a un par de torsioÂn maÂx. de 54,2 Nm.
Graisser les composants et reÂinseÂrer la spheÁre, le Monter l'interrupteur de position de vitesses incorporeÂ
F ressort et la vis (modeÁle hydraulique). F avec la rondelle et la bague OR.
Serrer aÁ un couple max. de 80v100 Nm. Serrer aÁ un couple de serrage max. de 54,2 Nm.
Montare tappo di chiusura con rosetta e rilevatore di

ITA giri. Serrare con una coppia max. di 25 Nm. ITA
Stopfen mit Unterlegscheibe und Drehzahlmesser

D montieren. Mit einem Anziehdrehmoment zu max. 25 D
Nm anziehen.
e f
Montar el tapoÂn de cierre con la roseta y el detector de
ESP revoluciones. Apretar a un par maÂx. de 25 Nm. ESP
Monter le bouchon de verrouilllage accompagneÂ de la

F rondelle et du compteur de tours. Serrer aÁ un couple F
max. de 25 Nm.
35
F1240129 F1240130
GB a GB b
Re-fit the reduction unit onto the axle by spreading LOCTITE 510 Fasten the support planes (turn flange to assist assembly).
on the planes.
F1240131 F1240132
GB c GB d
Insert screws by applying LOCTITE 510. Screw down by placing the reduction unit in a vertical position in
relation to the axis.
F1240133 F1240134
GB e GB f
Tighten screws using a torque wrench setting of 49±51 Nm. Extract screws and remove the temporarily assembled cover.
36
Rimontare il riduttore sul ponte spalmando i piani con Mandare in battuta i piani di appoggio (ruotare la
ITA LOCTITE 510. ITA flangia per facilitare il montaggio).
Reduzierer auf die Triebachse montieren; zuvor die AuflageflaÈchen bis zum Anschlag bringen (Flansch
D FlaÈchen mit LOCTITE 510 schmieren. D drehen um die Montage zu erleichtern).
a b
Volver a montar el reductor en el puente engrasando Llevar a tope las superficies de apoyo (girar la brida
ESP las superficies con LOCTITE 510. ESP para facilitar el montaje).
Remonter le reÂducteur au pont en eÂtalant sur les Lancer les surfaces d'appui en buteÂe (tourner la
F surfaces du LOCTITE 510. F flasque pour faciliter le montage).
Inserire le viti spalmandole con LOCTITE 510. Avvitare le viti posizionando il riduttore in modo
ITA ITA verticale rispetto l'asse.
Schrauben mit LOCTITE 510 schmieren und ein- Schrauben festschrauben; dabei den Reduzierer
D setzen. D senkrecht zur Achse halten.
c d
Insertar los tornillos engrasaÂndolos con LOCTITE 510. Atornillar los tornillos posicionando el reductor de
ESP ESP manera vertical con respecto al eje.
Introduire les vis en les enduisant d'abord de Visser les vis en placËant le reÂducteur verticalement par
F LOCTITE 510. F rapport aÁ l'axe.
Serrare le viti con una coppia di serraggio di Asportare le viti e rimuovere il coperchio montato
ITA 49v51 Nm. ITA provvisoriamente
Schrauben mit einem Anziehdrehmoment zu Schrauben abschrauben und voruÈbergehend montier-

D 49v51 Nm anziehen. D ter Deckel abnehmen.
e f
Apretar los tornillos a un par de torsioÂn de Sacar los tornillos y remover la tapa montada
ESP 49v51 Nm. ESP provisionalmente.
Serrer les vis aÁ un couple de serrage de Enlever les vis et enlever le couvercle provisoirement
F 49v51 Nm. F monteÂ.
37
F1240135 F1240136
GB a GB b
Fasten the bearing by using a standard tool. Measure dimension "A" between the bearing and the box plane
using an ordinary depth gauge (if parts are not replaced, use
disassembled distance washers).
S
F1240137 F1240138
GB c GB d
Measure dimension "B" on the cover, between the bearing plane Apply LOCTITE 510 on the surface, lubricate the sealing ring,
and bearing support. Calculate the dimension of the distance insert the distance washers and re-assemble the cover with niche
washers required: facing upwards.
S=Dimension B Ð Dimension A
Es: B=5.2±A=4.6 mm ± Backlash 0.2±0.3=Distance washer
required=0.4±0.3.
F1240139
GB e GB f
Fit screws after applying LOCTITE 510.
38
Mandare in battuta il cuscinetto utilizzando un Rilevare la quota "A" fra cuscinetto e piano scatola
ITA normale attrezzo. ITA usando un normale calibro di profonditaÁ.
(Se non vengono sostituiti pezzi, utilizzare gli spessori
smontati).
Das Lager bis zum Anschlag bringen; dazu ein Maû "A" zwischen Lager und SchachtelflaÈche mit
D gewoÈhnliches Werkzeug verwenden. D einem gewoÈhnlichen Kaliber messen (wenn keine
Teile ausgewechselt werden, die abmontierten Di-
stanzstuÈcke verwenden).
a b
Llevar a tope el cojinete utilizando una herramienta Registrar la cota "A" entre el cojinete y la superficie de
ESP normal. ESP la caja utilizando un normal calibre de profundidad.
(Si no se sustituyen las piezas, utilizar los espesores
desmontados).
Lancer en buteÂe le palier aÁ l'aide d'un outil normal. Relever la cote "A" entre palier et surface de la boõÃte aÁ
F F l'aide d'un calibre de profondeur normal (S'il n'y a pas
de pieÁces aÁ remplacer, utiliser les cales deÂmonteÂes).
Rilevare la quota "B" sul coperchio fra piano e Spalmare la superficie con LOCTITE 510, lubrificare
ITA appoggio cuscinetto. Calcolare gli spessori da inserire ITA l'anello di tenuta, inserire gli spessori e rimontare il
S=Quota B±Quota A coperchio con la nicchia rivolta verso l'alto.
Es: B=5,2±A=4,6 mm ± Gioco 0,2v0,3= Spessore da inseri-
re=0,4v0,3
Maû "B" am Deckel zwischen FlaÈche und Auflage- FlaÈche mit LOCTITE 510 schmieren; Dichtungsring
D flaÈche des Lagers messen. Die einzulegenden Di- D schmieren; DistanzstuÈcke einsetzen und Deckel mit
stanzstuÈcke ausrechnen. S=Maû B±Maû A Nische nach oben gerichtet, montieren.
Bsp: B=5,2±A=4,6 mm ± Spiel 0,2v0,3=einzusetzende Distanz-
c stuÈcke=0,4v0,3 d
Registrar la cota "B" en la tapa entre la superficie y el Engrasar la superficie con LOCTITE 510, lubricar el
ESP soporte del cojinete. Calcular los espesores que hay ESP segmento de compresioÂn, insertar los espesores y
que insertar S = Cota B±Cota A volver a montar la tapa con el hueco dirigido hacia
Es: B=5,2±A=4,6 mm ± Juego 0,2v0,3= Espesor a inser- arriba.
tar=0,4v0,3
Relever la cote "B" sur le couvercle entre surface et Enduire la surface de LOCTITE 510, lubrifier la bague
F support palier. Calculer le nombre de cales aÁ F d'eÂtancheÂiteÂ, introduire les cales et remonter ensuite
introduire S=Cote B±Cote A le couvercle avec le logement tourneÂ vers le haut.
Exp: B=5,2±A=4,6 mm ± Jeu 0,2v0,3=Cales aÁ introduire
=0,4v0,3
Inseire le viti dopo everle spalmate con

ITA LOCTITE 510. ITA
Schrauben einsetzen; zuvor mit LOCTITE 510

D schmieren. D
e f
Introducir los tornillos despueÂs de engrasarlos con
ESP LOCTITE 510. ESP
Introduire les vis apreÁs les avoir enduites de

F LOCTITE 510. F
39
F1240140 F1240141
GB a GB b
Tighten screws using a torque wrench setting of 49±51 Nm. Assemble flange, O-ring and nut using LOCTITE 242.
F1240142 F1240143
GB c GB d
Screw down the nut of the flange. Tighten the nut using a torque wrench setting of 260±280 Nm.
F1240144 F1240069
GB e GB f
Re-fix the protection plate after applying LOCTITE 510. Complete flanged reduction gear 357 with mechanical gear control.
40
Serrare le viti con una coppia di serraggio di Montare la flangia, l'anello OR e il dado con
ITA 49v51 Nm. ITA LOCTITE 242.
Schrauben mit einem Anziehdrehmoment zu Flansch, O-Ring und Mutter mit LOCTITE 242
D 49v51 Nm anziehen. D schmieren und montieren.
a b
Apretar los tornillos a un par de torsioÂn de Montar la brida, el anillo OR y la tuerca con
ESP 49v51 Nm. ESP LOCTITE 242.
Serrer les vis aÁ un couple de serrage de Monter la flasque, la bague OR et l'eÂcrou enduit de
F 49v51 Nm. F LOCTITE 242.
Avvitare il dado della flangia. Serrare il dado con una coppia di serraggio di
ITA ITA 260v280 Nm.
Flanschmutter festschrauben. Mutter mit einem Anziehdrehmoment zu

D D 260v280 Nm anziehen.
c d
Atornillar la tuerca de la brida. Apretar la tuerca a un par de torsioÂn de
ESP ESP 260v280 Nm.
Visser l'eÂcrou de la flasque. Serrer l'eÂcrou aÁ un couple de serrage de

F F 260v280 Nm.
Rimontare lamiera di protezione dopo everla spalmata Gruppo riduttore 357 afflangiato con comando marcia
ITA con LOCTITE 510. ITA meccanico completo.
Schutzblech mit LOCTITE 510 schmieren und mon- Ganzes direkt geflanschter Reduzierer 357 mit me-
D tieren. D chanischer Gangschaltung.
e f
Volver a montar la placa de proteccioÂn despueÂs de Grupo reductor 357 con brida con mando de marcha
ESP engrasarla con LOCTITE 510. ESP mecaÂnico completo.
Remonter la toÃle de protection apreÁs l'avoir enduite de Groupe reÂducteur brideÂ 357 aÁ commande de vitesses
F LOCTITE 510. F meÂcanique complet.
41
F1240145 F1240144
GB a GB b
Re-assemble all the parts of the gear control cylinder, according to Re-fix the protection plate after applying LOCTITE 510 on it.
their arrangement.
F1240146 F1240147
GB c GB d
Re-fit the gear control cylinder into place with its O-ring. Re-fit screws and screw down.
F1240148
GB e GB f
Re-introduce the gear control rod after applying LOCTITE 242 on it.
42
Rimontare tutti i particolari del cilindro comando Rimontare lamiera di protezione dopo averla spalmata
ITA marcia come disposti in ordine. ITA con LOCTITE 510.
Alle Einzelteile des Zylinders des Gangschalters der Schutzblech mit LOCTITE 510 schmieren und mon-
D Reihenfolge nach montieren. D tieren.
a b
Volver a montar todas las piezas del cilindro mando Volver a montar la placa de proteccioÂn despueÂs de
ESP marcha dispuestos en su orden. ESP engrasarla con LOCTITE 510.
Remonter toutes les pieÁces du cylindre de commande Remonter la toÃle de protection apreÁs l'avoir enduite de
F de vitesses placeÂ dans l'ordre. F LOCTITE 510.
Rimontare il cilindro comando marcia completo di Reinserire le viti ed avvitarle.

ITA anello OR. ITA
Zylinder des Gangschalters mit O-Ring montieren. Schrauben einsetzen und festschrauben.
D D
c d
Volver a montar el cilindro mando marcha completo de Volver a introducir los tornillos y atornillarlos.
ESP anillo OR. ESP
Remonter le cylindre de commande de vitesses Introduire les vis et visser.

F complet de bague OR. F
Reinserire asta di comando marcia dopo averla

ITA spalmata con LOCTITE 242. ITA
Gangschalterhebel mit LOCTITE 242 schmieren und

D montieren. D
e f
Volver a insertar la varilla de mando de la marcha
ESP despueÂs de engrasarla con LOCTITE 242. ESP
Introduire la tringle de commande de vitesses apreÁs

F l'avoir enduite de LOCTITE 242. F
43
INSTALLATION OF HYDRAULIC GEAR CONTROL - INSTALLAZIONE COMANDO MARCIA IDRAULICO - HYDRAULISCHER GANGSCHALTUNG
MONTIEREN - MONTAJE MANDO MARCHA HIDRAULICO - INSTALLATION DE LA COMMANDE DE VITESSES HYDRAULIQUE
F1240149 F1240150
GB a GB b
Tighten the gear control rod using a torque wrench setting of Tighten gear control cylinder screws using a torque wrench setting
25±26 Nm. of 49±51 Nm.
GB c GB d
GB e GB f
44
Serrare asta di comando marcia con una coppia di Serrare le viti cilindro comando marcia con una coppia
ITA serraggio di 25v26 Nm. ITA di serraggio di 49v51 Nm.
Den Gangschalterhebel mit einem Anziehdrehmoment Die Zylinderschrauben des Gangschalters mit einem
D zu 25v26 Nm anziehen. D Anziehdrehmoment zu 49v51 Nm anziehen.
a b
Apretar la varilla de mando a un par de torsioÂn de Apretar los tornillos de mando de la marcha a un par
ESP 25v26 Nm. ESP de torsioÂn de 49v51 Nm.
Serrer la tringle de commande de vitesses aÁ un couple Serrer les vis du cylindre de commande de vitesses aÁ
F de serrage de 25v26 Nm. F un couple de serrage de 49v51 Nm.
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
45
SMONTAGGIO DEL PONTE ANTERIORE-POSTERIORE E
DEL MOTORE IDROSTATICO
DISASSEMBLING FRONT-REAR AXLE AND HYDROSTATIC

MOTOR
AUSBAU DER VORDER-/HINTERACHSE UND

DES HYDROSTATISCHEN MOTORS
MRT 1440-1640-1840 EASY

IT-EN-DE
MRT 1440-1640-1840 EASY 30
INDICE - CONTENTS - INHALT
- SMONTAGGIO DEL PONTE ANTERIORE E DEL MOTORE IDROSTATICO

- DISASSEMBLING FRONT AXLE AND HYDROSTATIC MOTOR . . . . . . . . . . . . . . . .4
- AUSBAU DER VORDERACHSE UND DES HYDROSTATISCHEN MOTORS
- RIMONTAGGIO DEL PONTE ANTERIORE E DEL MOTORE IDROSTATICO

- ASSEMBLING THE FRONT AXLE AND HYDROSTATIC MOTOR . . . . . . . . . . . . . . .8
- WIEDEREINBAU VON VORDERACHSE UND HYDROSTATISCHEM MOTOR
- SMONTAGGIO DEL PONTE POSTERIORE

- DISASSEMBLING REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
- AUSBAU DER HINTERACHSE
- RIMONTAGGIO DEL PONTE POSTERIORE

- ASSEMBLING THE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
- WIEDEREINBAU DER HINTERACHSE
3
30 MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO DEL PONTE DISASSEMBLING FRONT AXLE AUSBAU DER VORDERACHSE UND
ANTERIORE E DEL MOTORE AND HYDROSTATIC MOTOR DES HYDROSTATISCHEN MOTORS
IDROSTATICO
Portare la macchina su un suolo piano. Bring the machine to level ground. Die Maschine auf einer ebenen Fläche
abstellen.
Sollevare la macchina tramite gli stabiliz- Lift the machine by means of the outrig-
zatori (portarla ad una altezza necessaria gers (raise it to the height necessary to Die Maschine mit den Stabilisatoren heben
per rimuovere le ruote, vedi Fig. 1) e spe- remove the wheels, see Fig. 1) and switch (sie auf die Höhe bringen, die erforderlich
gnere il motore termico. off the engine. ist, um die Räder zu entfernen, siehe Abb.
1) und den Verbrennungsmotor abstellen.
Rimuovere le ruote. Remove the wheels. Die Räder ausbauen.
Svitare le viti di fissaggio della flangia del- Unscrew the cardan shaft flange fixing Die Befestigungsschrauben des Flansches
l’albero cardanico (Fig. 2 - Rif. A) e scolle- screws (Fig. 2 - Ref. A) and disconnect the der Gelenkwelle (Abb. 2 - Bez. A) los-
gare l’albero. shaft. schrauben und die Welle abtrennen.
Scollegare il tubo (lato sinistro dell’assale) Disconnect the tube (left side of axle) rela- Die Leitung (linke Seite der Achse) für den
relativo al funzionamento dello sterzo (Fig. tive to steering operation (Fig. 2 - Ref. B). Lenkbetrieb abtrennen (Abb. 2 - Bez. B).
2 - Rif. B).
Scollegare il tubo (lato destro dell’assale) Disconnect the tube (right side of axle) rel- Die Leitung (rechte Seite der Achse) für
relativo al funzionamento dello sterzo (Fig. ative to steering operation (Fig. 3 - Ref. C). den Lenkbetrieb abtrennen (Abb. 3 - Bez.
3 - Rif. C). C).
Disconnect the two tubes (Fig. 3 - Ref. D).
Scollegare i due tubi (Fig. 3 - Rif. D). Die beiden Leitungen (Abb. 3 - Bez. D)
Disconnect the electric wiring (Fig. 3 - Ref. abtrennen.
E).
Staccare il collegamento elettrico (Fig. 3 - Die elektrische Verbindung abtrennen
Rif. E). (Abb. 3 - Bez. E).
Scollegare il tubo relativo al funzionamento Disconnect the tube relative to the working Die Leitung zum Betrieb der
del freno di servizio (Fig. 4 - Rif. F) e il of the foot brake (Fig. 4 - Ref. F) and park- Betriebsbremse (Abb. 4 - Bez. F) und der
freno di stazionamento (Fig. 5 - Rif. A). ing brake (Fig. 5 - Ref. A). Feststellbremse (Abb. 5 - Bez. A) abtren-
nen.
Staccare il collegamento elettrico del sen- Disconnect the electric wiring from the Die elektrische Verbindung des Sensors
sore allineamento ruote (Fig. 4 - Rif. G) e wheel alignment sensor (Fig. 4 - Ref. G) der Radausrichtung (Abb. 4 - Bez. G) und
del bulbo freno (Fig. 4 - Rif. H). and brake bulb (Fig. 4 - Ref. H). der Bremskugel (Abb. 4 - Bez. H) abtren-
nen.
Svitare le viti di collegamento delle flange Unscrew the flange connection screws Die Verbindungsschrauben der Flansche
(Fig. 6 - Rif. B e Fig. 8 - Rif. D) posizionate (Fig. 6 - Ref. B and Fig. 8 - Ref. D) on the losschrauben (Abb. 6 - Bez. B und Abb. 8 -
ai due lati del motore idrostatico e scolle- two sides of the hydrostatic motor and dis- Bez. D), die auf den beiden Seiten des
gare i tubi. connect the tubes. hydrostatischen Motors angeordnet sind,
und die Leitungen abtrennen
Scollegare i tubi idraulici (Fig. 7 - Rif. C e Disconnect the hydraulic pipes (Fig. 7 - Die hydraulischen Leitungen abtrennen
Fig. 8 - Rif. E). Ref. C and Fig. 8 - Ref. E). (Abb. 7 - Bez. C und Abb. 8 - Bez. E).
Scollegare i tubi (Fig. 8 - Rif. F) e staccare Disconnect the tubes (Fig. 8 - Ref. F) and Die Leitungen (Abb. 8 - Bez. F) abtrennen
il collegamento elettrico (Fig. 8 - Rif. G). the electric wiring (Fig. 8 - Ref. G). und die elektrische Verbindung (Abb. 8 -
Bez. G) abklemmen.
Assicurare il ponte anteriore e il motore Secure the front axle and hydrostatic Die Vorderachse und den hydrostatischen
idrostatico ad un carro ponte o elevatore motor to a bridge crane or elevator suit- Motor an einem Laufkran oder einem
adeguati al peso da sostenere. able for the weight to be supported. Gabelstapler absichern, die für das zu tra-
gende Gewicht geeignet sind.
4
MRT 1440-1640-1840 EASY 30
FIG. 1 FIG. 2
A
E G
C F
D
H
FIG. 3 FIG. 4
B
A
FIG. 5 FIG. 6
G
F
FIG. 7 FIG. 8
5
30 MRT 1440-1640-1840 EASY
IT EN DE
Svitare le viti di fissaggio dell’assale lato Unscrew the fixing screws on the left (Fig. Die Befestigungsschrauben der Achse auf
sinistro (Fig. 9 - Rif. A) e lato destro (Fig. 9 - Ref. A) and right (Fig. 10 - Ref. B) der linken Seite (Abb. 9 - Bez. A) und auf
10 - Rif. B). sides of the axle. der rechten Seite losschrauben (Abb. 10 -
Bez. B).
Smontare il ponte anteriore e il motore Dismantle the front axle and hydrostatic Die Vorderachse und den hydrostatischen
idrostatico. motor. Motor ausbauen.
Attenzione: evitare che le impurità Attention: prevent impurities Achtung: Unbedingt darauf achten, dass
contaminino il circuito idraulico. from contaminating the hydraulic circuit. kein Schmutz in den hydraulischen
Ricordarsi di tappare con nastro adesivo Remember to cover all the hydraulic open- Kreislauf gelangt.
tutti gli orifizi idraulici del motore idrostatico ings of the hydraulic motor and axle with Immer alle hydraulischen Öffnungen des
e del ponte prima dello smontaggio del adhesive tape before dismantling the axle hydrostatischen Motors und der Achse mit
ponte dalla macchina. from the machine. Klebeband verschließen, bevor man die
Achse aus der Maschine ausbaut.
6
MRT 1440-1640-1840 EASY 30
B
A
FIG. 9 FIG. 10
7
30 MRT 1440-1640-1840 EASY
IT EN DE
MONTAGGIO DEL PONTE ASSEMBLING THE FRONT AXLE EINBAU DER VORDERACHSE UND
ANTERIORE E DEL MOTORE AND HYDROSTATIC MOTOR DES HYDROSTATISCHEN MOTORS
IDROSTATICO
Con la macchina stabilizzata e motore With the machine stabilised and the engine Mit stabilisierter Maschine und abge-
termico spento, portare il ponte anteriore e switched off, bring the front axle and stelltem Verbrennungsmotor die Vorder-
il motore idrostatico in corrispondenza hydrostatic motor to their original position achse und den hydrostatischen Motor in
della loro posizione originaria e mantenerli and hold them in place. ihre ursprüngliche Position bringen und
fermi. dort festhalten.
Connect the axle to the chassis by means
Collegare l’assale al telaio tramite le viti of screws on the left (Fig. 1 - Ref. A) and Die Achse mit den Schrauben der linken
lato sinistro (Fig. 1 - Rif. A) e lato destro right (Fig. 2 - Ref. B) side. Seite (Abb. 1 - Bez. A) und der rechten
(Fig. 2 - Rif. B). Seite (Abb. 2 - Bez. B) am Fahrgestell
Connect the tubes dismantled earlier, fol- befestigen.
Eseguire il collegamento dei tubi prece- lowing the procedure for dismantling in
dentemente smontati, seguendo la proce- reverse order. Den Anschluss der zuvor abgetrennten
dura per lo smontaggio in senso contrario. Leitungen vornehmen. Dazu die
Reconnect the cardan shaft in its prede- Ausbauprozedur in der umgekehrten
Ricollegare l’albero cardanico nella sua fined position (Fig. 3 - Ref. C) using Loctite Reihenfolge ausführen.
posizione predefinita (Fig. 3 - Rif. C) 270 for fixing the bolts.
utilizzando loctite 270 per il fissaggio delle Die Gelenkwelle in ihrer vorgegebenen
viti. Restore the electric wiring connections. Position (Abb. 3 - Bez. C) wieder ansch-
ließen und zur Befestigung der Schrauben
Ripristinare i collegamenti elettrici. Refit the wheels. Loctite 270 benutzen.
Rimontare le ruote. Die elektrischen Anschlüsse wieder-

herstellen.
Die Räder wieder montieren.
Prima di rimettere in servizio la macchina Before restarting the machine, check the Bevor man die Maschine wieder in Betrieb
ricordarsi di controllare l’efficienza dell’im- working of the braking system, and bleed nimmt, nicht vergessen, die Bremsanlage
pianto frenante e se necessario spurgare il the circuit, if necessary. auf Funktionstüchtigkeit zu prüfen und das
circuito. System bei Bedarf zu entlüften.
8
MRT 1440-1640-1840 EASY 30
A B
FIG. 1 FIG. 2
FIG. 3
C
9
30 MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO DEL PONTE DISASSEMBLING REAR AXLE AUSBAU DER HINTERACHSE

POSTERIORE
Position the machine on level ground. Die Maschine auf einer ebenen Fläche
Posizionare la macchina su una superficie abstellen.
piana. Raise the machine by means of the outrig-
gers (raising it to the height necessary to Die Maschine mit den Stabilisatoren heben
Sollevare la macchina tramite gli stabiliz- remove the wheels) and switch off the (sie auf die Höhe bringen, die zum
zatori (portarla ad un’altezza necessaria engine. Ausbauen der Räder erforderlich ist) und
per rimuovere le ruote) e spegnere il moto- den Verbrennungsmotor abstellen.
re termico. Remove the wheels.
Rimuovere le ruote. Die Räder entfernen.

Unscrew the cardan shaft flange fixing
Svitare le viti di fissaggio della flangia del- screws (Fig. 1 - Ref. A) and disconnect the Die Befestigungsschrauben des Flansches
l’albero cardanico (Fig. 1 - Rif. A) e scolle- shaft. des Gelenkwelle (Abb. 1 - Bez. A) los-
gare l’albero. schrauben und die Welle abtrennen.
Disconnect the tube (left of axle) relative to
Scollegare il tubo (lato sinistro dell’assale) functioning of the steering (Fig. 1 - Ref. B). Die Leitung (linke Seite der Achse) zum
relativo al funzionamento dello sterzo (Fig. Lenkbetrieb (Abb. 1 - Bez. B) abtrennen.
1 - Rif. B).
Scollegare il tubo (lato destro dell’assale) Disconnect the tube (right of axle) relative Die Leitung (rechte Seite der Achse) zum
relativo al funzionamento dello sterzo (Fig. to functioning of the steering (Fig. 2 - Ref. Lenkbetrieb (Abb. 2 - Bez. C) abtrennen.
2 - Rif. C). C).
Die elektrische Verbindung des Sensors

Staccare il collegamento elettrico del sen- Disconnect the electric wiring of the wheel der Radausrichtung (Abb. 3 - Bez. A)
sore di allineamento ruote (Fig. 3 - Rif. A). alignment sensor (Fig. 3 - Ref. A). abtrennen.
Die Hinterachse und den hydrostatischen

Assicurare il ponte anteriore e il motore Secure the front axle and hydrostatic Motor mit einem Laufkran oder einem
idrostatico ad un carro ponte o elevatore motor to a bridge crane or elevator suit- Gabelstapler absichern, die zum zu heben-
adeguati al peso da sostenere. able for the weight to be supported. den Gewicht passen.
Svitare le viti di fissaggio assale al telaio Unscrew the axle fixing screws of the front Die Befestigungsschrauben der Achse am
lato anteriore (Fig. 4 - Rif. B) e lato poste- (Fig. 4 - Ref. B) and rear (Fig. 5 - Ref. C). Fahrgestell auf der Vorderseite (Abb. 4 -
riore (Fig. 5 - Rif. C). Bez. B) und der Hinterseite (Abb. 5 - Bez.
Dismantle the rear axle. C) losschrauben.
Smontare il ponte posteriore.
Die Hinterachse ausbauen.
10
MRT 1440-1640-1840 EASY 30
B
A
FIG. 1 FIG. 2

A

FIG. 3 B
FIG. 4

C FIG. 5
11
30 MRT 1440-1640-1840 EASY
IT EN DE
MONTAGGIO DEL PONTE ASSEMBLING THE REAR AXLE EINBAU DER HINTERACHSE
POSTERIORE
Con la macchina stabilizzata e motore ter- With the machine stabilised and the engine Mit stabilisierter Maschine und abge-
mico spento, portare l’assale posteriore in switched off, bring the rear axle to corre- stelltem Verbrennungsmotor die Hinter-
corrispondenza della sua posizione origi- spond with its original position and hold it achse auf die Höhe ihrer ursprünglichen
naria e mantenerlo fermo. in place. Position bringen und dort festhalten.
Collegare l’assale al telaio tramite le viti Connect the axle to the chassis by means Die Achse mit den Schrauben auf der
lato anteriore (Fig. 1 - Rif. A) e lato poste- of the screws on the front (Fig. 1 - Ref. A) Vorderseite (Abb. 1 - Bez. A) und der
riore (Fig. 2 - Rif. B). and rear side (Fig. 2 - Ref. B). Hinterseite (Abb. 2 - Bez. B) mit dem
Fahrgestell verbinden.
Prima del collegamento assicurarsi che il Before making the connection, make sure Vor der Verbindung sicherstellen, dass der
riferimento punzonato sul telaio (Fig. 3 - the reference punched on the chassis (Fig. auf dem Fahrgestell eingeschlagene
Rif. C) corrisponda col riferimento della 3 - Ref. C) corresponds to the reference Bezugspunkt (Abb. 3 - Bez. C) mit dem
staffa (Fig. 3 - Rif. D). on the bracket (Fig. 3 - Ref. D). Bezug auf dem Bügel (Abb. 3 - Bez. D)
übereinstimmt.
Eseguire il collegamento dei tubi prece- Connect the tubes dismantled earlier. Die zuvor ausgebauten Leitungen wieder
dentemente smontati. anschließen.
Ricollegare l’albero cardanico nella sua Re-connect the cardan shaft in its prede- Die Gelenkwelle wieder in ihrer vorge-
posizione predefinita (Fig. 4 - Rif. E) utiliz- fined position (Fig. 4 - Ref. E) using Loctite gebenen Position (Abb. 4 - Bez. E) ansch-
zando loctite 270 per il fissaggio delle viti. 270 to secure the screws. ließen und zur Befestigung der Schrauben
Loctite 270 benutzen.
Ripristinare i collegamenti elettrici. Restore the electric wiring connections.
Die elektrischen Verbindungen wieder-
Rimontare le ruote. Refit the wheels. herstellen.
Die Räder wieder montieren.
12
MRT 1440-1640-1840 EASY 30

A
FIG. 1 B FIG. 2
FIG. 3 FIG. 4
13
-AINTENANCE AND 2EPAIR -ANUAL

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6IETATA LA RIPRODUZIONE ANCHE PARZIALE DI TESTO ED ILLUSTRAZIONI
2EALIZZAZIONE A CURA DELL5FlCIO 0UBBLICITÜ E DELL5FlCIO 0OST 6ENDITA DELLA $!.! )4!,)! 3P!
)MPAGINAZIONE &/4/ 3(/0 02/&%33)/.!, 2IVA DEL 'ARDA
$ATA SUBJECT TO CHANGE WITHOUT NOTICE 7E DECLINE ALL RESPONSABILITY FOR THE USE OF NON ORIGINAL COMPONENTS OR ACCESSORIES WHICH HAVE
NOT BEEN TESTED AND SUBMITTED FOR APPROVAL
$ATI SOGGETTI A MODIlCHE SENZA IMPEGNO DI PREAVVISO 3I DECLINA OGNI RESPONSABILITÜ á PER LUTILIZZO DI COMPONENTI NON ORIGINALI O
ACCESSORI NON COLLAUDATI ED APPROVATI
ÇNDERUNGEN OHNE VORHERIGE !NKÓNDINGUNG VORBEHALTEN %S WIRD JEDE 6ERANTWORTUNG FÓR DIE 6ERWENDUNG VON .ICHTORIGINALTEILEN ODER
NICHT ABGENOMMENEM UND GENEHMIGTEM :UBEHR ABGELEHNT
,OS DATOS PUEDEN SER MODIlCADOS SIN AVISO PREVIO 3E DECLINA TODA RESPONSABILIDAD EN EL CASO DE USO DE COMPONENTES NO ORIGINALES O
BIEN DE ACCESORIOS NO ENSAYADOS Y APROBADOS
,E CONSTRUCTEUR SE R£SERVE LE DROIT DAPPORTER DES MODIlCATIONS Ü SA PRODUCTION SANS POUR CELA ETRE TENU DEN DONNER PR£AVIS
.OUS D£CLINONS TOUTE RESPONSABILIT£ POUR LUTILISATION DE PI£CES NON ORIGINALES OU DACCESSOIRES NON TEST£S ET HOMOLOGU£S
INTRODUCTION ..........................................................5 PLANETARY REDUCTION

GB MAINTENANCE AND LUBRICANT . Disassembly.........................................................................40
. Definition of viewpoints............................................7 . Assembly .............................................................................48
. Data plate ..............................................................................7 STEERING CYLINDER
. Maintenance points ................................................................7 . Removal ..............................................................................56
. Maintenance intervals.............................................................8 . Installation ...........................................................................60
. Adjustment and checks ..........................................................8 . Disassembly.........................................................................66
. Conversion tables...................................................................9 . Assembly .............................................................................70
. Tightening torques .................................................................9 DIFFERENTIAL UNIT
. Screw-locking, sealing and lubricating materials ....................10 . Removal and disassembly ....................................................74
NOTES ON SAFETY PRECAUTIONS ........................................13 . Assembly, adjusting and installation......................................82
CHECKING WEAR AND REPLACING THE BRAKING DISKS BEVEL PINION
. Disassembly the braking units ..............................................14 . Removal ..............................................................................92
. Assembly the braking units ...................................................18 . Adjusting and installation ......................................................98
STEERING CASE SPECIAL TOOLS .................................................................... 110
. Removal and disassembly ....................................................22 TROUBLESHOOTING.............................................................. 117
. Assembly and installation .....................................................26 OPTIONALS ........................................................................... 127
U-JOINT
. Removal and disassembly ....................................................30
. Assembly and installation .....................................................36
INTRODUZIONE .......................................................5 RIDUTTORE EPICICLOIDALE

ITA MANUTENZIONE E LUBRIFICANTI . Smontaggio..........................................................................40
. Definizione viste ..................................................7 . Assemblaggio ......................................................................48
. Targa matricola ......................................................................7 CILINDRO DI STERZATURA
. Punti di manutenzione ............................................................7 . Rimozione............................................................................56
. Intervalli di manutenzione .......................................................8 . Installazione.........................................................................60
. Registrazione e controlli .........................................................8 . Smontaggio..........................................................................66
. Tabelle di conversione............................................................9 . Assemblaggio ......................................................................70
. Coppie di serraggio ................................................................9 GRUPPO DIFFERENZIALE
. Materiali per bloccaggio viti, tenuta e lubrificazione................10 . Rimozione e smontaggio.......................................................74
NOTE RIGUARDANTI LA SICUREZZA ......................................13 . Assemblaggio, registrazione ed installazione .........................82
CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO PIGNONE CONICO
. Smontaggio gruppi di frenatura .............................................14 . Rimozione............................................................................92
. Assemblaggio dei gruppi di frenatura ....................................18 . Registrazione ed installazione...............................................98
SCATOLA SNODO ATTREZZI SPECIALI............................................................... 110
. Rimozione e smontaggio ......................................................22 RICERCA GUASTI................................................................... 117
. Assemblaggio ed installazione ..............................................26 OPZIONALI............................................................................. 127
DOPPIO GIUNTO CARDANICO
. Rimozione e smontaggio ......................................................30
. Assemblaggio ed installazione ..............................................36
VORAUSSETZUNG .................................................5 PLANETENGETRIEB

D WARTUNG UND SCHMIERSTOFFE . Abmontieren ........................................................................40
. Definition der Ansichten......................................7 . Montieren.............................................................................48
. Kennummernschild.................................................................7 LENKZYLINDER
. Wartungsstellen .....................................................................7 . Abmontieren ........................................................................56
. Wartungsintervalle..................................................................8 . Installieren ...........................................................................60
. Einstellungen und Kontrollen ..................................................8 . Abmontieren ........................................................................66
. Umrechnungstabellen.............................................................9 . Montieren.............................................................................70
. Anziehdrehmomente...............................................................9 DIFFERENTIAL
. Material zur Blockierung von Schrauben und . Abmontieren und zerlegen ....................................................74
fuÈr Dichtungen und Schmiermittel .........................................10 . Montieren und installieren.....................................................82
BEMERKUNGEN ZUR SICHERHEIT...........................................13 KEGELRAD
VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN . Abmontieren ........................................................................92
AUSWECHSELN . Installieren und einstellen .....................................................98
. Bremsaggregate abmontieren ...............................................14 SONDERWERZZEUGE ............................................................ 110
. Bremsaggregate montieren ...................................................18 FEHLERSUCHE....................................................................... 117
GELENKGEHAÈUSE OPTIONS................................................................................ 127
. Abmontieren ........................................................................22
. Montieren ............................................................................26
DOPPELGELENKWELLE
. Abmontieren ........................................................................30
. Montieren ............................................................................36
PROLOGO................................................................ 5 REDUCTOR EPICICLOIDAL

ESP MANTENIMIENTO Y LUBRICANTES . Desmontaje ......................................................................... 40
. Definicion vistas................................................... 7 . Montaje ............................................................................... 48
. Matricula ............................................................................... 7 CILINDRO DE DIRECCIOÂN
. Puntos de manutencion.......................................................... 7 . Remocion ............................................................................ 56
. Intervalos de manutencioÁn...................................................... 8 . Instalacion ........................................................................... 60
. Ajuste y controles .................................................................. 8 . Desmontaje ......................................................................... 66
. Tablas de conversion ............................................................. 9 . Montaje ............................................................................... 70
. Pares de torsion .................................................................... 9 GRUPO DIFERENCIAL
. Materiales para el bloqueo, estanqueidad y lubricacion ......... 10 . Remocion y desmontaje ....................................................... 74
NORMAS CONCERNIENTES A LA SEGURIDAD ....................... 13 . Montaje e instalacion ........................................................... 82
CONTROL DEL DESGASTE Y SUSTITUCION DE LOS PINÄON CONICO
DISCOS DEL FRENO . Remocion ............................................................................ 92
. Montaje de los grupos de frenado......................................... 14 . Instalacion y ajuste .............................................................. 98
. Desmontaje de los grupos de frenado................................... 18 HERRAMIENTAS ESPECIALES............................................... 110
CARTER DE ROTULA COMPLETO BUSQUEDA DE AVERIAS....................................................... 117
. Remocion ............................................................................ 22 OPCIONALES......................................................................... 127
. Montaje ............................................................................... 26
SEMIEJES
. Remocion ............................................................................ 30
. Instalacion ........................................................................... 36
INTRODUCTION ....................................................... 5 REDUCTEUR EPICYCLOIDAL

F ENTRETIEN ET LUBRIFIANTS . Desassemblage ................................................................... 40
. DeÂfinition vues ..................................................... 7 . Assemblage......................................................................... 48
. Plaque d'immatriculation ........................................................ 7 CYLINDRE DE BRAQUAGE
. Points d'entretien................................................................... 7 . Depose................................................................................ 56
. Intervalle de service ............................................................... 8 . Installation ........................................................................... 60
. Reglages et controles............................................................. 8 . Demontage .......................................................................... 66
. Tableaux de conversion ......................................................... 9 . Assemblage......................................................................... 70
. Couples de serrage................................................................ 9 GROUPE DIFFERENTIEL
. MateÂriaux pour le blocage vis, eÂtancheÂiteÂ et lubrification........ 10 . Depose et demontage .......................................................... 74
NOTES EN MATIERE DE SECURITE......................................... 13 . Assemblage et installation .................................................... 82
CONTROLE D'USURE ET SUBSTITUTION DES PIGNON CONIQUE
DISQUES DE FREINAGE . Depose................................................................................ 92
. Desassemblage des groupes de freinage .............................. 14 . Installation et reglage ........................................................... 98
. Assemblage des groupes de freinage ................................... 18 OUTILS SPECIAL ................................................................... 110
BOITIER ARTICULATION COMPLET RECHERCHE DES PANNES.................................................... 117
. Depose................................................................................ 22 OPTIONNELS ......................................................................... 127
. Assemblage......................................................................... 26
JOINT DE CARDAN DOUBLE
. Depose................................................................................ 30
. Installation ........................................................................... 36
The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, pullers and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la SPICER CLARK-HURTH.
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of SPICER mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
CLARK-HURTH. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Abzieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
5
der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos
Spiele, Vorspannungen und Drehmomente strengstens ein- de las herramientas especificas necesarias para la ejecucioÂn
gehalten werden. de las intervenciones de mantenimiento figuran al final del
manual; los recambios se pueden pedir al fabricante de la
GUÈ LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern maÂquina o directamente al Service Center o a Distribuidores
die Einheiten gehoÈren. Der Einfachheit halber sind die autorizados de SPICER CLARK-HURTH.
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer
= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂcessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
SPICER CLARK-HURTH bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
fournis par le constructeur du veÂhicule. En deÂcrivant les
El rendimiento y la duracioÂn de los oÂrganos
ESP opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mecaÂnicos depende, ademaÂs que del constante y
enleveÂ du veÂhicule.
correcto mantenimiento, tambieÂn de la interven-
cioÂn inmediata en caso de averõÂas o anomalõÂas. IMPORTANT: Pour faciliter le travail en sauvegardant en
Al proponer este manual, ha sido considerada la suposicioÂn de meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
una revisioÂn general del grupo, pero es el mecaÂnico quien tiene teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
que valorar la necesidad de montar cada uno de los telles que des eÂtais ou banc de support, maillets en plastique
componentes en caso de reparacioÂn. El manual es una guõÂa ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
raÂpida y segura que permite intervenciones precisas por medio Avant de proceÂder au deÂmontage des parties et vidanger
de fotografõÂas y de planos que muestran las distintas fases de l'huile, il vaut mieux nettoyer soigneusement le pont, en
las operaciones. A continuacioÂn figuran todas las informacio- enlevant incrustations et blocs de gras.
nes y advertencias necesarias para ejecutar un montaje
correcto, para las comprobaciones y el montaje de cada uno PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
de los componentes. Para remover el puente diferencial del doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
vehõÂculo hay que consultar los manuales de los fabricantes del approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
vehõÂculo. En la descripcioÂn de las operaciones siguientes se abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
supone que el puente ya ha sido sacado del vahõÂculo. particulier, de toutes les parties en mouvement (paliers,
engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
IMPORTANTE: Para facilitar el trabajo salvaguardando al bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
mismo tiempo las superficies mecanizadas y la seguridad de sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
los operadores, se aconseja que se usen equipos y herra- substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
mientas adecuados como caballetes y bancos de soporte, effectue une reÂvision ou une reÂparation des composants. Au
martillos de plaÂstico o de cobre, palancas adecuadas, moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
extractores y llaves especõÂficas. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
Antes de desmontar las partes y descargar el aceite, es conique, la substitution de l'un de ses engrenages comporte
conveniente que se haga una limpieza minuciosa del puente eÂgalement la substitution de l'autre. En phase de montage, il
sacando las incrustaciones y acumulaciones de grasa. faut respecter scrupuleusement les jeux, les preÂcharges et les
couples prescrits.
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados
tienen que ser limpiados minuciosamente con productos VALIDITE: Le manuel fournit la validiteÂ des groupes sous
adecuados y restaurados o sustituidos en el caso de que forme de matricule. Pour une meilleure interpreÂtation, les
presenten danÄos, desgaste, rajaduras, agarrotamientos, etc. validiteÂs sont indiqueÂes comme:
En particular, comprobar la integridad de todas las partes en
movimiento (cojinetes, engranajes, par coÂnico, ejes) y de = jusqu'aÁ l'immatriculation
estanqueidad (anillos OR, detenedor de aceite) sujetas a
mayores solicitaciones y desgaste. = aÁ partir de l'immatriculation et apreÁs
Se aconseja, de todas formas, que se sustituyan los oÂrganos
de estanqueidad cada vez que se ejecute la revisioÂn o Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
reparacioÂn de los componentes. deÂmontage et d'assemblage sont pareilles dans toutes les
Al volver a montar, los segmentos de compresioÂn tienen que versions.
estar lubricados en los bordes de estanqueidad. En el caso del
par coÂnico, la sustitucioÂn de uno de sus engranajes comporta INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
tambieÂn la sustitucioÂn del otro. Al montar hay que tener en Les dessins des installations speÂcifiques neÂcessaires pour
cuenta escrupulosamente los juegos, las precargas y los pares effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
descriptos. manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
constructeur de la machine ou directement aux Centres de
VALIDEZ: El manual suministra la validez de los grupos en Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ SPICER
forma de matrõÂcula. Para poder tener una interpretacioÂn CLARK-HURTH.
correcta, la validez estaÂ indicada:
= hasta la matrõÂcula
= desde la matrõÂcula en adelante
6
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS
DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DEÂFINITION VUES
LEFT SIDE RIGHT SIDE

LATO SINISTRO LATO DESTRO
LINKE SEITE RECHTE SEITE
LADO IZQUIERDO LADO DERECHO
COTE GAUCHE COTE DROITE
D1240027
DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION
Type and model unit - modification index
1
Tipo e modello gruppo - indice di modifica
Typ und Modelleles Antriebes - AÈ nderungsverzeichnis
Tipo y modelo grupo - indice de modificacion
Type et modeÂle de ensemble - tableau des modifications
1 2 Serial number
2
Numero di serie
Seriennummer
3 NuÂmero de serie
Numero de serie
MFG. BY CLARK-HURTH COMPONENTS S.P.A. Lubricant
3
38062 Arco (Trento) Lubrificante
Schmieroel
MADE IN ITALY Lubricante
Lubrificant
D1240011
MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN
3 1 2 4
3
4
2
4
1
Oil filling plug - Tappo di carico
EinfuÈllstopfen - Tapon de carga
Bouchon de ravitaillement
2
Oil draining plug - Tappo di scarico
Ablasstopfen - Tapon de descarga
Bouchon de vidange
3
Check level plug - Tappo controllo livello
È lpegelkontrolle -
Stopfen zur O
1 3 Tapon de contrl de nivel - Jauge de niveau
2
4
Grease nipples - Ingrassatori
Schmierer - Engrasadores
Graisseurs
D1240028
7
MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIOÁN - INTERVALLE DE SERVICE
OPERATION - OPERAZIONE - FREQUENCY - PERIODICITAÁ

LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE -
ARBEITSVORGANG - - ZEITABSTAND -
LUBRICANTES - LUBRIFIANTS
OPERACION - OPERATION FRECUENCIA - PERIODICITE
Differential monthly
Differenziale mensile
Im differential monatlich . SAE85W90 (API GL4 - MIL L-2105)
. Check levels: Diferencial cada mes With additives for oil-bath brakes
. Controllo livelli: Differentiel mensuel Con additivi per freni a bagno d'olio
. È lstandkontrolle:
O Mit Zusatzmittel fuÈr Bremsen in OÈ lbad
. Control niveles: Planetary reduction every 200 hours
Con aditivos para frenos de banÄo de aceite
. ControÃle niveaux: Riduzione epicicloidale ogni 200 ore
Avec adjuvants pour freins en bain d'huile
Planetengetrieb alle 200 Std.
ReduccioÂn epicicloidal cada 200 horas . SAE85W90 (API GL5 - MIL 2105-B)
Reduction epicycloidale toutes les 200 heures With additives for oil-bath brakes, for units pre-
Differential every 800 hours ] senting hypoid crown wheel and pinion and /or
Differenziale ogni 800 ore self-locking differential gear
Im differential alle 800 Std. Per esecuzioni con coppia conica ipoide e/o con
Diferencial cada 800 horas differenziale autobloccante, con additivi per freni
Differentiel toutes les 800 heures a bagno d'olio
Bei AusfuÈhrungen mit Kegel- und Telleradpaar
. Oil change: Planetary reduction every 1000 hours ]
und/oder Selbstsperrdifferential, mit Zusatzmit-
. Cambio olio: Riduzione epicicloidale ogni 1000 ore È lbad
È lwechsel: teln fuÈr Bremsen in O
. O Planetengetrieb alle 1000 Std.
Para ejecuciones con par coÂnico hipoide y/o con
. Cambio aceite: ReduccioÂn epicicloidal cada 1000 horas
diferencial autobloqueante con aditivos para fre-
. Vidange huile: Reduction epicycloidale toutes les 1000 heures
nos de banÄo de aceite.
Self-locking differential gear every 700 hours ] r Pour exeÂcutions avec couple conique hypoõÈde et/
Differenziale autobloccante ogni 700 ore ou diffeÂrentiel autobloquant, avec adjuvants pour
Selbstsperrdifferential alle 700 Std. freins en bain d'huile
Diferencial autobloqueante cada 700 horas
Differentiel autobloquant toutes les 700 heures
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100 horas
de trabajo - Initialement apreÁs 100 heures de travail
r When it starts sounding noisy - Anche ai primi cenni di rumorositaÁ - Auch falls ungewoÈhnliche GeraÈusche zu bemerken sind - TambieÂn al primer
indicio de ruido - MeÃme aux premiers signaux de bruit
OPERATION - OPERAZIONE - MEMBER - ORGANO - CONDITIONS - CONDIZIONI - FREQUENCY - PERIODICITAÁ - LUBRICANTS - LUBRIFICANTI -
ARBEITSVORGANG - ELEMENT - BEDINGUNG - ZEITABSTAND - SCHMIERSTOFFE -
OPERACION - OPERATION ORGANO - ORGANE CONDICIONES - CONDITIONS FRECUENCIA - PERIODICITE LUBRICANTES - LUBRIFIANTS
Normal work monthly
Lavori normali mensile
Normale Arbeit monatlich
Greasing Articulations Trabajos normales cada mes
Ingrassaggio Snodi TaÃches ordinaires mensuel
Schmieren Gelenk MOLIKOTE
Engrase RoÂtula Awkward work Weekly
Graissage Articulations Lavori gravosi Settimanale
Schwere Arbeit WoÈchentlich
Trabajos pesados Semanal
TaÃches extraordinaires Hebdomadaire
ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES
UNIT - GRUPPO - OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ - SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI -
AGGREGAT - ARBEITSVORGANG - ZEITABSTAND - BREMSKREISLAUF - CIRCUITO MANDOS FRENOS -
GRUPO - GROUPE OPERACION - OPERATION FRECUENCIA - PERIODICITE CIRCUIT DE COMMANDE DES FREINS
Negative brake Adjustment every 1000 hours ]
Freno negativo Registrazione ogni 1000 ore Only for mineral oil use e.g. ATF Dexron II. Make sure
Federspeicherbremse Einstellen alle 1000 Std. that master cylinder seals are suitable for mineral oil.
Freno negativo Ajuste cada 1000 horas Usare esclusivamente olio minerale ATF Dexron II. Ac-
Frein neÂgatif ReÂglage toutes les 1000 hours certarsi che le guarnizioni del cilindro master siano
adatte a questo olio.
Service brake Adjustment every 500 hours È l verwenden, z.B.: ATF Dexron II.
Nur mineralisches O
Freni di servizio Registrazione ogni 500 ore
Achtung: Dichtringe des Hauptbremszylinders muÈs-
Hilfsbremse Einstellen alle 500 Std. È l geeignet sein.
sen fuÈr dieses O
Frenos de ejercicio Ajuste cada 500 horas
Usar exclusivamente aceite mineral ATF Dexron II.
Freins de service ReÂglage toutes les 500 hours
Asegurarse de que las juntas del cilindro principal
Wheel nuts Tightening every 200 hours son adecuadas para este aceite.
Dadi ruota Serraggio - ogni 200 ore Utiliser exclusivement huile mineÂrale ATF Dexron II.
Radmuttern Festziehen alle 200 Std. VeÂrifier que les joints du maõÃtre-cylindre, soien compa-
Tuercas rueda Apriete cada 200 horas tibles avec cette huile.
Ecrous de roue Serrage toutes les 200 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100
horas de trabajo - Initialement apreÁs 100 heures de travail
8
CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN
TABLAS DE CONVERSION - TABLEAUX DE CONVERSION
Units of pressure - UnitaÁ di pressione - Druckeinheiten

Unidad de presioÂn - UniteÂs de pression: 1 Atm%1 bar%105 PA%14.4 PSi
Units of weight - UnitaÁ di peso - Gewichtseinheiten Units of torque - UnitaÁ di coppia - Drehmomenteinheiten
Unidad de peso - UniteÂs de poids Unidad de par - UniteÂs de couple
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1
TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE
Unit - UnitaÁ di misura - Meûeinheiten - Unidad de medida - UniteÂs de mesure: Nm

TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS
SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS 8.8 10.9 12.9
TAMAN Ä O TORNILLO
MESURE VIS Normali Normali Normali
+ Loctite 242 Loctite 270 + Loctite 242 Loctite 270 + Loctite 242 Loctite 270
M6 x 1 9,5-10,5 10,5-11,5 14,3-15,7 15,2-16,8 16,2-17,8 18,1-20,0
COARSE PITCH - PASSO GROSSO - GROûER
SCHRITT - PASO GRUESO - GROS PAS
M8 x 1,25 23,8-26,2 25,6-28,4 34,2-37,8 36,7-40,5 39,0-43,0 43,7-48,3

M10 x 1,5 48-53 52-58 68-75 73-81 80-88 88-97
M12 x 1,75 82-91 90-100 116-128 126-139 139-153 152-168
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263
M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2,5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2,5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2,5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3,5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
M8 x 1 25,7-28,3 27,5-30,5 36,2-39,8 40,0-44,0 42,8-47,2 47,5-52,5

FINE PITCH - PASSO FINE - KLEINER SCHRITT
M10 x 1,25 49,4-54,6 55,2-61,0 71,5-78,5 78,0-86,0 86,0-94,0 93,0-103,0

M12 x 1,25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1,5 86-95 94-104 120-132 133-147 143-158 159-175
PASO FINO - PAS FIN
M14 x 1,5 143-158 157-173 200-222 219-242 238-263 261-289

M16 x 1,5 214-236 233-257 302-334 333-368 361-399 394-436
M18 x 1,5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1,5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1,5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082
9
SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR
BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION -
MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION
1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
I materiali per il bloccaggio, tenuta e lubrificazione specifica indicati nel manuale, sono quelli usati in fabbrica.
Die Materialien zur Blockierung von Schrauben, fuÈr Dichtungen und Schmiermittel, die im Handbuch aufgefuÈhrt sind, sind
dieselben die auch vom Hersteller verwendet werden.
Los materiales para el bloqueo, estanqueidad y lubricacioÂn especõÂfica indicados en el manual, son los que se usan en la faÂbrica
Les mateÂriaux de blocage, d'eÂtancheÂiteÂ et de lubrification speÂcifieÂs indiqueÂs dans ce manuel sont ceux employeÂs aÁ l'usine.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar
products marketed by different brand names with different trade marks.
Di questi materiali, vengono riportate le applicazioni tipiche che li distinguono, in modo da poterli sostituire con prodotti similari
commercializzati da altre marche e quindi con altre sigle.
Von diesen Materialien werden die typischen Anwendungen genannt, um sie mit aÈhnlichen Materialien zu ersetzen, die unter
anderen Namen und Kennzeichnungen im Handel erhaÈltlich sind.
De estos materiales damos las aplicaciones tõÂpicas que los distinguen, de manera que se puedan sustituir con productos similares
comercializados por otras marcas y por tanto con otras siglas.
De ces mateÂriaux ne sont reporteÂes que les applications typiques qui les distinguent de telle sorte qu'ils puissent eÃtre substitueÂs
par des produits semblables se trouvant dans le commerce sous d'autres marques et par conseÂquent sous d'autres sigles.
DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength loc-
king. Before using it, completely remove any lubricant by using the specific activator.
. Prodotto anaerobico adatto a prevenire l'allentamento di viti, dadi e tappi. Usato per la frenatura a media re-
sistenza. Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
. Anaerobes Produkt, um das Lockern von Schrauben, Muttern und Stopfen zu verhindern. FuÈr mittlere Wi-
derstandskraÈfte geeignet. Darf erst aufgetragen werden, wenn die FlaÈchen von Schmiermittel richtig sauber
Loctite 242
sind. Dazu das entsprechende Produkt verwenden.
. Producto anaeroÂbico apto para prevenir el aflojamiento de tornillos, tuerca y tapones. Usado para el frenado
de media resistencia. Tiene que ser usado soÂlo despueÂs de haber quitado todo residuo de lubricante con el
activador especõÂfico.
. Produit anareÂobic servant aÁ preÂvenir le relaÃchement des vis, eÂcrous et bouchons. UtiliseÂ pour le freinage
demi reÂsistant. Il doit eÃtre utiliseÂ apreÁs avoir enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
. Prodotto alternativo al 242 che, essendo oleocompatibile, non richiede l'attivazione di superfici lubrificate.
. Alternatives Produkt zu Loctite 242. Da es oÈlkompatibel ist muÈssen die geschmierten FlaÈchen nicht aktiviert
Loctite 243 werden.
. Producto alternativo al 242 que, siendo oleocompatible, no requiere la activacioÂn de superficies lubricadas.
. Produit en alternance avec le 242 lequel eÂtant oleÂocompatible ne requiert aucune activation des surfaces
lubrifieÂes.
. Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any
lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80ëC approx.
. Prodotto anaerobico adatto per la frenatura ad altissima resistenza di viti e dadi. Deve essere usato dopo aver
asportato ogni traccia di lubrificante con l'attivatore specifico.
La rimozione delle parti, puoÁ richiedere un riscaldamento a circa 80ëC.
. Anaerobes Produkt fuÈr hohe WiderstandskraÈfte fuÈr Schrauben und Muttern geeignet. Zuerst die FlaÈche sorg-
Loctite 270
faÈltig aktivieren. Um die FlaÈchen zu saÈubern, diese auf ca. 80ëC erwaÈrmen.
. Producto anaeroÂbico apto para el frenado de alta resistencia de tornillos y tuercas. tiene que ser usado de-
spueÂs de haber quitado todo residuo de lubricante con el activador especõÂfico.
La remocioÂn de las partes, puede requerir un calentamiento a unos 80ëC.
. Produit anareÂobic apte au freinage aÁ treÁs haute reÂsistance des vis et des eÂcrous. Il doit eÃtre utiliseÂ apreÁs avoir
enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts,
for pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a max.
diametrical clearance of 0.25 mm.
. Prodotto anaerobico adatto per la frenatura e sigillatura ad alta resistenza di parti filettate, bulloni e prigionieri
di grandi dimensioni, protezione antimanomissione e sigillatura di tubazioni; puoÁ sigillare accoppiamenti con
gioco diametrale massimo di 0,25 mm.
. Anaerobes Produkt zum Bremsen und Siegeln von groûen Gewinden, Muttern und Stiftschrauben , sehr
Loctite 275 widerstandsfaÈhig, verschleierungsbestaÈndig, und zum Siegeln von Rohrleitungen geeignet; kann Kupplun-
gen mit einer maximalen Lagerluft von 0,25 mm siegeln.
. Producto anaerobico apto para el frenado y selladura a alta resistencia de tornillos, tuercas y prisioneros de
grandes dimensiones, protecion anti manomision y selladura de tubaciones ; puede sellar encolcados con
juego diametral.
. Produit anaeÂrobie adapteÂ au freinage et au scellage aÁ haute reÂsistance des parties fileteÂes, boulons et pri-
sonniers de grandes dimensions, protection anti-alteÂration et scellage de tuyauteries; il peut sceller des ac-
couplements ayant un jeu diameÂtral maximal de 0,25 mm.
10
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can
seal clearances between flanges up to 0.2 mm.
. Prodotto anaerobico adatto alla tenuta ermetica di fluidi tra assiemi flangiati e di viti a foro comunicante con i
fluidi. PuoÁ sigillare giochi tra le flange fino a 0,2 mm.
. Anaerobes Produkt zur Abdichtung von FluÈssigkeiten an Flanschen und Schrauben mit LoÈcher, die mit FluÈs-
Loctite 510
sigkeiten in Kontakt stehen. Kann ein Spiel zwischen Flanschen bis 0,2 mm abdichten.
. Producto anaeroÂbico apto para le estanqueidad de fluidos entre grupos bridados y de tornillos de orificio co-
municante con los fluidos. Puede sellar juegos entre las bridas hasta 0,2 mm.
. Produit anareÂobic apte aÁ la tenue eÂtanche des fluides entre les pieÁces aÁ brides et des vis aÁ trou en contact
avec les fluides. Il peut sceller un jeu parmi les flasques jusqu'aÁ 0,2 mm.
. Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using
it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather dif-
ficult, so heating may be necessary for larger diameters.
. Prodotto anaerobico sigillante rapido per la tenuta di filettature di raccordi conici o cilindrici fino a M80.
Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
Dopo la polimerizzazione presenta una moderata difficoltaÁ di smontaggio per cui puoÁ richiedere, per i diametri
maggiori, un riscaldamento.
. Anaerobes Produkt zum schnellen Siegeln und Abdichten von Kegel- oder Zylinderkupplungen bis M80.
Darf erst aufgetragen werden, nachdem mit einem spezifischen Wirkstoff jede Spur von Schmiermittel ab-
getragen worden ist.
Loctite 577
Nach der Polymerisation koÈnnte das Abmontieren etwas schwierig sein weshalb groÈûere Durchmesser
zuerst erhitzt werden muÈssen.
. Producto anaerobico sellante rapido para el estanqueido de tornillos de empalme conico o cilindrico hasta
M80. Debe de ser utilisado despues de haber quitado cada mancha de lubrificante con activador especifico.
Despues de la polimeracion presenta una moderada dificultaÁde desmontaje por lo tanto puede necesitar, para
los diametros majores, un calientamiento.
. Produit anaeÂrobie collage rapide assurant l'eÂtancheÂiteÂ des filetages des raccords coniques ou cylindriques
jusqu'aÁ M80. Il doit eÃtre utiliseÂ apreÁs qu'on ait enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
Une certaine difficulteÂ de deÂmontage se preÂsente apreÁs la polymeÂrisation, on peut donc avoir la neÂcessiteÂ de
devoir chauffer preÂalablement pour de plus amples diameÁtres.
. Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue to-
gether parts with clearance ranging between 0.1 and 0.25 mm.
. Adesivo anaerobico per l'incollaggio rapido ad alta resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco tra 0,1 e 0, 25 mm.
. Anaerober Klebstoff fuÈr groûe WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 638
ben). Kann Einzelteil mit einem Radialspiel zwischen 0,1 mm und 0,25 mm zusammenkleben.
. Adhesivo anaeroÂbico para el encolado raÂpido de alta resistencia de juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego entre 0,1 mm y 0,25 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide et hautement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre). Il peut servir aÁ coller des pieÁces avec un jeu allant de 0,1 aÁ 0,25 mm.
. Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue
together parts with radial clearance below 0.1 mm.
. Adesivo anaerobico per l'incollaggio rapido a media resistenza di giunti cilindrici in metallo (mozzo su albero).
PuoÁ incollare particolari con gioco radiale inferiore a 0,1 mm.
. Anaerober Klebstoff fuÈr mittlere WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 648 ben). Kann Einzelteil mit einem Radialspiel von weniger als 0,1 mm zusammenkleben.
. Adhesivo anaeroÂbico para encolado raÂpido de media resistencia juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego radial inferior a 0,1 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide moyennement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre).
Il peut servir aÁ coller des pieÁces avec un jeu radial infeÂrieur aÁ 0,1 mm.
. Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer
diameter of sealing rings for rotating shafts with outer metal reinforcement.
(AREXONS) . Mastice sigillante per guarnizioni elastiche a base di solvente, essicante per evaporazione.
Repositionable jointing
compound for seals Viene utilizzato per la tenuta sul diamentro esterno di anelli di tenuta per alberi rotanti con armatura metallica
Mastice per guarnizioni esterna.
riposizionabile . Klebstoff fuÈr Gummidichtung auf LoÈsemittelbasis, trocknet durch Verdampfung.
Klebstoff fuÈr verstellbare Wird am aÈuûeren Durchmesser von Dichtungsringe bei rotierenden Wellen mit Metallmantel verwendet.
Dichtungen . Pasta para juntas de sellado para juntas elaÂsticas a base de disolvente, deshidratante por evaporacioÂn.
Pasta para juntas Se utiliza para la estanqueidad en el diaÂmetro externo de segmentos de compresioÂn, para ejes giratorios con
reposicionable
armadura metaÂlica exterior.
Mastic pour garnitures aÁ
remettre en place . Mastic adheÂsif aÁ base de solvants pour garnitures eÂlastiques, seÂchant par eÂvaporation.
Il sert garder eÂtanche le diameÁtre exteÂrieur des bagues d'eÂtancheÂiteÂ des arbres rotatifs ayant une arma-
ture meÂtallique externe.
11
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and
physical elements. Polymerises with non-corrosive dampness.
Silicone . Materiale adesivo semifluido usato per sigillatura, riempimenti e per la protezione di componenti dagli elementi
Silicone ambientali e fisici. Polimerizza con umiditaÁ non corrosiva.
. HalbfluÈssiger Klebstoff zum Befestigen, FuÈllen und zum Schutz von Bestandteilen vor aÈuûeren Einwirkun-
Silikon
gen. Polymerisiert durch nicht korrosive Feuchtigkeit
Silicona . Material adhesivo semifluido usado para el sellado, llenado y para la proteccioÂn de componentes de elemen-
Silicone tos ambientales y fõÂsicos. Polimeriza con humedad no corrosiva.
. Produit adheÂsif semi-fluide utiliseÂ pour le scellage, remplissage et protection des eÂleÂments ambiants et phy-
siques. PolymeÂrise aÁ une humiditeÂ non corrosive.
. Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
. Grasso sintetico con elevato grado di adesivitaÁ, additivato con composti siliconici.
(TECNO LUPE/101) Applicato su viti di registrazione a foro comunicante con fluidi di tipo oleoso.
Silicone-based grease Usato quando si richiedono frequenti interventi di registrazione.
Grasso al silicone . Synthetisches Fett mit hoher Haftfestigkeit, mit silikonhaltigen Stoffen legiert.
Wird auf Stellschrauben mit Loch, die mit oÈlhaltigen FluÈssigkeiten in Kontakt stehen, angebracht.
Silikonfett Wird verwendet, wenn die Schraub oÈfters eingestellt werden muû.
Grasa a la silicona . Grasa sinteÂtica con elevado grado de adhesioÂn, aditivada con componentes silicoÂnicos.
Graisse au silicone Aplicada en tornillos de ajuste de orificio comunicante con fluidos de tipo oleoso.
Se usa cuando se requieren frecuentes intervenciones de ajuste.
. Graisse syntheÂtique ayant un degreÂ d'adheÂsiviteÂ eÂleveÂ, adjuveÂ de composeÂs au silicone.
AppliqueÂ sur les vis de reÂglage aÁ trou communiquant avec des fluides du type huileux.
UtiliseÂ quand il y a besoin de reÂglages freÂquents.
. Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent
sticking and oxidation of parts that are not lubricated on a regular basis.
. Composto lubrificante contenente bisolfuro di molibdeno, usato per la lubrificazione di perni snodo e per pre-
venire incollamenti ed ossidazioni di particolari non lubrificati in modo continuo.
Molikote . Schmierstoff mit MolybidaÈndisulfid; wird zum Schmieren von Gelenkstiften und gegen Ankleben und Oxy-
(DOW CORNING) dation von nicht dauergeschmierten Einzelteilen verwendet.
. Compuesto lubricante que contiene bisulfuro de molibdeno, usado para la lubricacioÂn de roÂtulas y para pre-
venir encoladuras y oxidaciones de piezas no lubricadas de manera continua.
. ComposeÂ lubrifiant contenant du bisulfure de molybdeÁne, utiliseÂ pour lubrifier les axes d'articulation et preÂ-
venir collages et oxydations des pieÁces qui ne sont pas continuellement lubrifieÂes.
. Applied to bearings, sliding parts and used to lubricate seals or parts during assembly
(Lithium-based) Grease . Applicato a cuscinetti, parti scorrevoli e per lubrificare guarnizioni o pezzi in fase di montaggio.
Grasso (al Litio) . Wird auf Lager, Gleitteilen aufgetragen und zum Schmieren von Dichtungen oder von Teilen bei der Mon-
(Lithium) Fett tage verwendet.
Grasa (al Litio) . Aplicada a cojinetes, partes deslizables o para lubricar juntas o piezas en fase de montaje.
Graisse (au Lithium) . AppliqueÂ sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pieÁces pendant la phase de
montage.
12
NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR
SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
1 - During all operations described in this manual, the LoÈsemittel muÈssen als SondermuÈll und auf jeden Fall laut den
GB axle should be fastened onto a trestle, while the oÈrtlich geltenden Vorschriften entsorgt werden.
other parts mentioned should rest on supporting 9- Zur Reinigung ausschlieûlich schwache LoÈsemittel wie Petroleum,
benches. Terpentin oder wasserhaltige LoÈsemittel verwenden. Auf keinen
2- When removing one of the arms, an anti-tilting safety trestle Fall TrichloraÈthylen, tuolol- oder xylolhlatige LoÈsemittel usw.
should be placed under the other arm. verwenden.
3- When working on an arm that is fitted on the machine, make sure 10 - Um die ArbeitsvorgaÈnge verstaÈndlich abzubilden, werden in
that the supporting trestles are correctly positioned and that the einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst
machine is locked lengthways. bei der Arbeit nicht abmontiert werden muÈssen.
4- Do not admit any other person inside the work area; mark off the Nur die beschriebenen Teile abmontieren.
area, hang warning signs and remove the ignition key from the 11 - Unter RECHTS und LINKS versteht man in diesem Handbuch die
machine. Seite einer Person, die zur Achse schaut und zwar dem Antrieb
5- Use only clean, quality tools; discard all worn, damaged, low- entgegengesetzt.
quality or improvised wrenches and tools. Ensure that all 12 - Nach beendeten Arbeiten und um Rostbildungen zu vermeiden,
dynamometric wrenches have been checked and calibrated. die Teile an denen der Lack ggf. beschaÈdigt worden ist,
6- Always wear gloves and non-slip rubber shoes when performing anstreichen.
repair work. 1 - Las operaciones descritas se refieren al eje blo-
7- Should you stain a surface with oil, remove marks straight away. ESP queado en un caballete y a algunas partes apoyadas
8- Dispose of all lubricants, seals, rags and solvents once work has en el banco de trabajo.
been completed. Treat them as special waste and dispose of them 2- Cuando se saca un brazo del eje, colocar debajo del otro un
according to the relative law provisions obtaining in the country caballete de seguridad antivuelco.
where the axles are being overhauled. 3- Si se trabaja con un eje montado en la maÂquina, asegurarse de
9- Make sure that only weak solvents are used for cleaning haber colocado caballetes soporte y de haber inmovilizado
purposes; avoid using turpentine, dilutants and toluol-, xylol- longitudinalmente la maÂquina.
based or similar solvents; use light solvents such as Kerosene, 4- No permitir que personas extranÄas entren en la zona de trabajo;
mineral spirits or water-based, environment friendly solvents. delimitar esta zona, colgar carteles de aviso de hombres
10 - For the sake of clarity, the parts that do not normally need to be trabajando y sacar las llaves de arranque de la maÂquina.
removed have not been reproduced in some of the diagrams. 5- Usar soÂlo y exclusivamente herramientas limpias y de buena
11 - The terms RIGHT and LEFT in this manual refer to the position of cualidad; descartar llaves o herramientas gastadas o danÄadas, de
the operator facing the axle from the side opposite the drive. calidad mediocre o improvisadas. Asegurarse de que las llaves
12 - After repair work has been completed, accurately touch up any dinamomeÂtricas han sido controladas y calibradas.
coated part that may have been damaged. 6- Durante las operaciones de reparacioÂn, llevar siempre guantes y
calzado antideslizamiento.
1 - Le operazioni descritte sono riferite all'assale bloc- 7- Limpiar inmediatamente las zonas que pudieran estar sucias de
ITA cato su cavalletto ed alcuni particolari appoggiati su aceite.
un banco di lavoro.
8- Los lubricantes, las juntas, los trapos para la limpieza y los
2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro disolventes usados hay que eliminarlos como desechos especia-
braccio un cavalletto di sicurezza antiribaltamento. les y, de todas formas, de acuerdo con las normativas vigentes en
3 - Se si opera su un'assale montato sulla macchina, assicurarsi di el paõÂs en el que se revisan los ejes.
aver sistemato dei cavalletti di sostentamento e di aver immobi- 9- Para limpiar, utilizar soÂlo disolventes deÂbiles excluyendo en
lizzato longitudinalmente la macchina. absoluto tricloroetileno, diluyentes y disolventes a base de toluol,
4 - Non permettere che persone estranee entrino nella zona di lavoro; silol, etc.; usar soÂlo disolventes ligeros como queroseno, aguarraÂs
delimitare questa zona, appendere dei cartelli di avviso di lavori in minerales o disolventes ecoloÂgicos a base de agua.
corso ed asportare le chiavi di avviamento della macchina. 10 - Para que resulte clara la exposicioÂn y la ilustracioÂn, en las figuras
5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualitaÁ; de algunos grupos faltan algunas piezas que por lo general se
scartare chiavi od attrezzi usurati o danneggiati, di bassa qualitaÁ pueden dejar montadas. Sacar soÂlo las partes descritas.
od improvvisati. Assicurarsi che le chiavi dinamometriche siano 11 - Las palabras DERECHA E IZQUIERDA usadas en el manual se
state controllate e tarate. refieren a la persona que mira el eje del lado opuesto a la toma de
6 - Durante le operazioni di riparazione, indossare sempre guanti e movimiento.
scarpe antiscivolo. 12 - Al final de las reparaciones, para evitar oxidaciones, retocar
7 - Pulire immediatamente le zone eventualmente imbrattate d'olio. cuidadosamente las partes pintadas que estuvieran danÄadas.
8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i
solventi usati devono essere smaltiti come rifiuti speciali e 1 - Les opeÂrations deÂcrites se rapportent aÁ l'essieu
comunque secondo le normative vigenti nel Paese ove vengono F bloqueÂ sur chevalet et de quelques pieÁces poseÂes
revisionati gli assali. sur un eÂtabli de travail.
9 - Per la pulizia, usare solo solventi deboli escludendo categorica- 2- Quand on enleÁve un essieu monteÂ sur la machine, ajuster sous
mente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.; l'autre bras un chevalet de seÂcuriteÂ contre tout basculement.
usare solo solventi leggeri quali cherosene, ragie minerali o 3- Si on oeuvre sur un essieu monteÂ sur la machine, s'assurer
solventi ecologici a base d'acqua. d'avoir ameÂnageÂ des chevalets de soutien et d'avoir bloqueÂ la
10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni machine en longueur.
gruppi mancano dei particolari che, normalmente, possono essere 4- Ne jamais permettre aÁ des eÂtrangers de peÂneÂtrer dans la zone de
lasciati montati. Rimuovere solo i particolari descritti. travail; deÂlimiter cette zone, mettre des pancartes de signalisation
11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla de travaux en cours et enlever les cleÂs de contact de la machine.
persona che guarda l'assale dal lato opposto alla presa di moto. 5- N'utiliser que des outils propres et de bonne qualiteÂ; eÂliminer cleÂ
12 - Al termine delle riparazioni, per evitare dannose ossidazioni, ou autres outils useÂs, abõÃmeÂs, de mauvaise qualiteÂ ou improviseÂs.
ritoccare con cura le parti verniciate eventualmente danneggiate. Veiller aÁ ce que les cleÂs dynamomeÂtriques aient eÂteÂ controÃleÂes et
calibreÂes.
1 - Die beschriebenen VorgaÈnge werden an der Achse 6- Pendant les opeÂrations de reÂparation, endosser toujours gants et
D vorgenommen, wenn diese auf einem Bock blockiert chaussures antideÂrapantes.
ist. Zur Bearbeitung der Einzelteile, werden diese 7- Nettoyer tout de suite les eÂventuelles zones souilleÂes d'huile.
auf die Werkbank gelegt. 8- Les lubrifiants, les garnitures, les eÂventuels chiffons servant au
2- Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter nettoyage et les solvants utiliseÂs devront eÃtre reÂcolteÂs et traiteÂs
den zweiten Arm legen. comme rebut speÂcial conformeÂment aux lois en vigueur dans le
3- Werden Arbeiten an der Achse vorgenommen, wenn diese noch pays ouÁ les essieux sont en reÂvision.
an der Maschine montiert ist, BoÈcke zur Halterung unter die 9- Pour le nettoyage, n'utiliser que des solvants aÁ base de toluol,
Achse stellen und die Maschine der LaÈnge nach blockieren. xylol, etc.; n'utiliser que des solvants leÂgers tels que keÂroseÁne,
4- Es duÈrfen sich keine fremde Personen in der NaÈhe der Maschine essences mineÂrales, ou solvants eÂcologiques aÁ base d'eau.
waÈhrend der Arbeiten aufhalten; diesen Bereich absperren und 10 - En ce qui concerne la clarteÂ en matieÁre d'illustration et exposition,
mit Schilder kennzeichnen, die auf die laufenden Arbeiten sur les figures de certains groupes, il y a des pieÁces manquantes
hinweisen. ZuÈndschluÈssel von der Maschine abnehmen. qui normalement peuvent rester monteÂes.
5- Nur saubere Werkzeuge guter QualitaÈt verwenden; alte, beschaÈ- Enlever uniquement les pieÁces deÂcrites.
digte oder improvisierte Hilfsmittel nicht verwenden. Sicher- 11 - Les termes DROITE et GAUCHE utiliseÂs dans ce manuel se
stellen, daû die Dynamometer gepruÈft und geeicht worden sind. rapportent aÁ la personne regardant l'essieu du coÃteÂ opposeÂ aÁ celui
6- Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen. de la prise de mouvement.
7- Mit OÈ l beschmutzte Stellen, sofort reinigen. 12 - A la fin des opeÂrations, afin d'eÂviter un risque d'oxydation
8- Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und nuisible, retoucher soigneusement les parties vernies eÂventuelle-
ment abõÃmeÂes.
13
SYMBOLS - SIMBOLI - SYMBOLS CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS
SIMBOLOS - SYMBOLES KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROLE D'USURE ET SUBSTITUTION DES DISQUES DE FREINAGE
Disassembly of assembly groups

Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts 1
Smontaggio di particolari ingombri T1
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention ! Important notice
Attenzione, indicazione importante S
Achtung, wichtiger Hinweis F1240382 F1240383
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc.
GB a bar GB b
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs.
Controlar y ajustar, por ej. pares, medidas, presiones, etc. CAUTION! Perform all operations on both arms. Apply the brakes and, keeping them under pressure, check the
Controler, regler p.e. couples, mesures, pressions ecc. Remove the oil-level plug (1). linings "S" between the disks using tool T1.
T=Special tool P=page Minimum "S": 4.5 mm.
T=Attrezzature speciali P=Pagina CAUTION! Replace the braking disks and the intermediate disks
T=Spezialwerkzeug P=Seite on both sides if necessary.
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual 2 3
Controler, examiner, controle visuel 17
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si neÂcessaire)
Renew at each reassembly A
Sostituire ad ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage
Unlock - lock e.g. split pin, locking plate, etc.
Togliere-mettere la sicura F1240384 F1240385
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
GB c GB d
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung) Remove the swinging support (2) on the side opposite the drive. Disconnect the pins of the steering bars from the steering case
Colocar el seguro, pegar (mastique lõÂquido) NOTE. If the bushing (17) is worn and needs replacing, note down (See «HOW TO REMOVE THE STEERING CYLINDER»).
Mettre la securite, coller (mastic liquide) Sling the arm (3) to be removed and put the rod under slight
the assembly side of the connection notch "A".
Guard against material damage, damage to parts tension.
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fuÈr den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje)
Marquer avant le demontage (pour le montage) 4 5 6
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
EinfuÈllen - AuffuÈllen - NachfuÈllen (O
Cargar - llenar (aceite lubricante)
È l-Schmiermittel) 7
Charger - remplir (huile - lubrifiant)
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈ l, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
3
Apply pressure into hydraulic circuit 3
Inserire pressione nel circuito idraulico F1240386 F1240387
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique GB e GB f
To clean
Pulire Unloose and remove the screws (4) and the washers (5) that fix the Remove the arm (3) together with the pack of the braking disks (7).
Reinigen
Limpiar arm (3) to the central body (6). Place the arm on a bench.
Nettoyer
Lubricate - grease
Lubrificare - ingrassare
Schmieren - einfetten
Lubrificar - Engrasar
Lubrifier - Graisser
14
ATTENZIONE! Eseguire tutte le operazioni per i due Eseguire una frenata e, mantenendo la pressione,
ITA bracci. ITA controllare con l'attrezzo T1 lo spessore "S" tra i
Asportare il tappo (1) di livello olio. dischi.
"S" minimo: 4,5 mm
ATTENZIONE! Se necessario, sostituire i dischi freno ed intermedi
di ambedue i lati.
ACHTUNG! Alle VorgaÈnge fuÈr beide Arme durch- Die Bremse einmal betaÈtigen und bei betaÈtigter
D fuÈhren. D Bremse mit dem T1 Werkzeug das DistanzstuÈck "S"
OÈ lpegelstopfen (1) abnehmen. zwischen den Scheiben kontrollieren.
"S" mindestens: 4,5 mm
a b ACHTUNG! Wenn noÈtig, die Bremsscheiben und die mittleren
Scheiben auf beiden Seiten auswechseln.
CUIDADO! Ejecutar todas las operaciones para los Ejecutar un frenado y, manteniendo la presioÂn,
ESP dos brazos. ESP controlar con la herramienta T1, el espesor "S" entre
Sacar el tapoÂn (1) de carga de nivel aceite. los discos.
"S" mõÂnimo: 4,5 mm
CUIDADO! Si fuera necesario, sustituir los discos del freno y los
intermedios a ambos lados.
ATTENTION! Effectuer toutes les opeÂrations sur les 2 Effectuer un freinage, puis en tenant sous pression,
F bras. F controÃler aÁ l'aide de l'outil T1 la cale "S" entre les
Enlever le bouchon de la jauge d'huile (1). disques.
"S" minimum: 4,5 mm.
ATTENTION! Si besoin, substituer les disques de freinage et les
intermeÂdiaires des deux coÃteÂs.
Rimuovere il supporto oscillante (2) del lato opposto Scollegare dalle scatole snodo i perni delle barre di
ITA alla presa di moto. ITA sterzatura (Vedere «RIMOZIONE DEL CILINDRO DI
NOTA. Se si deve sostituire la bronzina (17) percheÁ STERZATURA»).
usurata, annotare il senso di montaggio del taglio di giunzione "A". Imbragare il braccio (3) da asportare e mettere in leggera tensione
la fune.
Schwenkbare Halterung (2) an der der Zapfwelle Von den GelenkgehaÈusen die Stifte der Lenkstangen
D entgegensetzten Seite abnehmen. D abtrennen (Siehe «LENKZYLINDER ABMONTIEREN»).
BEMERKUNG. Soll das Bronzelager (17) wegen Arm (3) anschlagen und das Seil spannen.
Verschleiû ausgewechselt werden, Montagerichtung des Verbin-
c dungsschnitts "A" beachten. d
Remover el soporte oscilante (2) del lado opuesto a la Desconectar de los caÂrters de las roÂtulas los pernos de
ESP toma de movimiento. ESP las barras de direccioÂn (VeÂase «REMOCION DEL
NOTA. Si hay que sustituir la chumacera (17) porque CILINDRO DE DIRECCION»).
estaÂ gastada, anotar el sentido de montaje del corte de unioÂn "A". Eslingar el brazo (3) que hay que sacar y poner en tensioÂn ligera el
cable.
Enlever le support oscillant (2) du coÃteÂ opposeÂ aÁ celui DeÂbrancher des boõÃtiers articulation les tourillons des
F de la prise de mouvement. F barres de braquage (Voir «DEPOSE DU CYLINDRE
NOTE. Si on doit remplacer le coussinet (17) parce DE BRAQUAGE»).
qu'il est useÂ, prendre note du sens de montage de l'entaille de Elinguer le bras (3) aÁ extraire et mettre leÂgeÁrement en tension la
jonction "A". corde.
Allentare ed asportare le viti (4) e le rondelle (5) che Rimuovere il braccio (3) e con esso il pacco dei dischi
ITA fissano il braccio (3) al corpo centrale (6). ITA di frenatura (7).
Posizionare il braccio su un banco di lavoro.
Schrauben (4) mit den Unterlegscheiben (5) lockern Arm (3) samt Bremsscheiben (7) abnehmen.
D und abschrauben, die den Arm (3) am zentralen D Arm auf die Werkbank legen.
KoÈrper (6) befestigen.
e f
Aflojar y extraer los tornillos (4) y las arandelas (5) que Remover el brazo (3) y con el mismo el paquete de
ESP fijan el brazo (3) al cuerpo central (6). ESP discos de frenado (7).
Posicionar el brazo en un banco de trabajo.
Desserrer et enlever les vis (4), les rondelles (5) qui DeÂposer le bras (3) et avec ce dernier le paquet de
F fixent le bras (3) au corps central (6). F disques de freinage (7).
Placer le bras sur l'eÂtabli d'usinage.
15
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROLE D'USURE ET SUBSTITUTION DES DISQUES DE FREINAGE
8
9
18
7 8
F1240388 F1240389
GB a GB b
Remove the braking disks (7) and note down their order of Remove the reversal springs (8) from the piston (9).
assembly. NOTE. If the springs (8) are weak or deformed they must be
NOTE. 1 - If the disks do not need replacing, avoid switching their replaced.
position.
2 - Extract the u-joint (18).
10 9
F1240390 F1240391
GB c bar GB d
Remove the pin screws (10) guiding the piston (9). Slowly introduce compressed air through the connection of the
CAUTION! If the screws are to be replaced, note down the different braking circuit in order to extract the entire piston.
colours for the different brake gap. CAUTION! Hold on to the piston as it may be suddenly ejected and
(See «HOW TO ASSEMBLE THE BRAKING UNITS») damaged.
10
15
17
9
17 8
11
14 MAX 10°
16
2
1
3
13
12
6 18
GB e GB f
7
5
4
D1240037
16
Rimuovere i dischi di frenatura (7) annotando l'ordine Rimuovere le molle (8) di rientro del pistone (9).
ITA di montaggio. ITA
NOTA. Se le molle (8) risultano snervate o deformate,
NOTA. 1 - Se i dischi non vanno sostituiti, evitare lo devono essere sostituite.
scambio di posizione.
2 - Estrarre il doppio giunto cardanico (18).
Bremsscheiben (7) abnehmen und auf die Reihenfolge RuÈckzugsfedern (8) des Kolbens (9) abnehmen.
D der Montage achten. D
BEMERKUNG. Wenn die Federn (8) nachgesetzt oder
BEMERKUNG. 1 - Sollen die Scheiben nicht ausge- verformt sind, diese auswechseln.
wechselt werden, diese in der richtigen Reihenfolge zur Seite
a legen. b
2 - Doppelgelenkwelle (18) abnehmen.
Remover los discos de frenado (7) anotando el orden Remover los muelles (8) de vuelta del pistoÂn (9).
ESP de montaje. ESP
NOTA. Si los muelles (8) estaÂn desnervados o
NOTA. 1 - Si los discos no tienen que ser sustituidos, deformados, hay que sustituirlos.
evitar el intercambio de posicioÂn.
2 - Extraer el semieje (18).
Enlever les disques de freinage (7) en prenant note de Enlever les ressorts (8) de rentreÂe du piston (9).
F l'ordre de montage. F
NOTE. Si les ressorts (8) sont eÂnerveÂs ou deÂformeÂs, il
NOTE. 1 - Si les disques ne sont pas aÁ remplacer, faut les remplacer.
eÂviter le changement de position.
2 - Extraire le joint de cardan double (18).
Rimuovere le viti a perno (10) di guida del pistone (9). Immettere lentamente aria compressa attraverso
ITA ITA l'attacco del circuito frenante per estrarre il pistone
ATTENZIONE! Se le viti devono essere sostituite,
annotare la colorazione distintiva per i giochi freno completo.
(Vedere «ASSEMBLAGGIO GRUPPI DI FRENATURA»). ATTENZIONE! Trattenere il pistone che puoÁ essere espulso
velocemente ed essere danneggiato.
Die Stiftschraube (10) zur KolbenfuÈhrung (9) entfer- Langsam Druckluft in den Bremskreislauf blasen, um
D nen. D den kompletten Kolben herauszuziehen.
ACHTUNG! Sollen die Schrauben ausgewechselt ACHTUNG! Den Kolben mit der Hand halten, um zu
werden, auf die farbige Kennzeichnung fuÈr das Bremsenspiel vermeiden daû er zu schnell herausgestoûen und beschaÈdigt wird.
c achten (Siehe «ZUSAMMENBAU DER BREMSAGGREGATE»). d
Remover los pernos roscados (10) de guõÂa del pistoÂn Introducir lentamente aire comprimido a traveÂs de la
ESP (9). ESP unioÂn del circuito frenante para extraer el pistoÂn
CUIDADO! Si hay que sustituir los pernos, anotar el completo.
color distintivo para los juegos del freno (VeÂase «MONTAJE DE CUIDADO! Retener el pistoÂn porque puede ser expulsado
LOS GRUPOS DE FRENADO»). raÂpidamente y quedar danÄado.
Enlever les vis goujon (10) de guidage du piston (9). Injecter tout doucement de l'air comprimeÂ aÁ travers le
F F raccord du circuit freinant pour extraire le piston
ATTENTION! Si les vis doivent eÃtre remplaceÂes,
prendre note de la couleur de distinction des jeux de complet.
frein (Voir «ASSEMBLAGE DU GROUPE DE FREINAGE»). ATTENTION! Retenir le piston qui pourrait eÃtre eÂjecteÂ fortement et
s'abõÃmer.
ITA ITA
D D
e f
ESP ESP
F F
17
HOW TO ASSEMBLE THE BRAKING UNITS - ASSEMBLAGGIO DEI GRUPPI DI FRENATURA - BREMSAGGREGATE MONTIEREN -
MONTAJE DE LOS GRUPOS DE FRENADO - ASSEMBLAGE DES GROUPES DE FREINAGE
14
12
11
13
15
3
15 9
9
F1240392 F1240393
GB a GB b
Accurately clean the piston (9) and the seats of slide and seal. Insert the stroke automatic regulation springs (15); place them in
Replace the O-rings (11) and (12) and the anti-extrusion rings (13) line with the piston (9).
and (14); make sure that the assembly side is correct.
CAUTION! Accurately check the positioning of the anti-extrusion
rings (13) and (14).
9
9
F1240394 F1240395
GB c GB d
Lubricate the seals (11) and (12) and fit the piston (9) into the arm Assist the insertion of the piston (9) by lightly hammering around
(3). the edge with a plastic hammer.
CAUTION! Make sure that the piston seat fits into the stop pin (A)
inside the arm.
8
10 9
8
F1240390 F1240389
GB e GB f
Fit the pin screws (10) making sure that they are all of the same Fit the reversal springs (8) on the piston (9).
colour. White: 1 mm gap CAUTION! Pay due attention not to deform the connections of the
Yellow: 0.75 mm gap springs.
Blue: 0.5 mm gap
Apply Loctite 270 to the thread.
Torque wrench setting: 5±7 Nm.
18
Pulire accuratamente il pistone (9) e le sedi di Inserire a filo del pistone (9) le molle (15) per
ITA scorrimento e tenuta. ITA l'autoregolazione della corsa.
Sostituire le guarnizioni OR (11) e (12) e gli anelli
antiestrusione (13) e (14), rispettando il senso di montaggio.
ATTENZIONE! Controllare attentamente il posizionamento degli
anelli antiestrusione (13) e (14).
Kolben (9) sowie Gleit- und Dichtungssitze sorgfaÈltig Den Kolben (9) und die Federn (15) zur Selbstregelung
D reinigen. D des Hubs genau einsetzen.
O-Ringe (11) und (12) sowie die Halteringe (13) und
(14) auswechseln; dabei auf die Reihenfolge der Montage achten.
a ACHTUNG! Position der Halteringe (13) und (14) sorgfaÈltig b
kontrollieren.
Limpiar minuciosamente el pistoÂn (9) y los alojamien- Introducir a ras del pistoÂn (9) los muelles (15) para la
ESP tos de deslizamiento y estanqueidad. ESP autorregulacioÂn de la carrera.
Sustituir las juntas OR (11) y (12) y los anillos
antiextrusioÂn (13) y (14) teniendo en cuenta el sentido de montaje.
CUIDADO! Controlar atentamente el posicionamiento de los anillos
antiextrusioÂn (13) y (14).
Nettoyer soigneusement le piston (9), les logements Introduire, au fil du bord du piston (9) les ressorts (15)
F de coulissement et d'eÂtancheÂiteÂ. F pour l'autoreÂgulation de la course.
Remplacer les garnitures OR (11) et (12), les anneaux
anti-extrusion (13) et (14) en respectant le sens du montage.
ATTENTION! ControÃler soigneusement la position des anneaux
anti-extrusion (13) et (14).
Lubrificare le guarnizioni (11) e (12) e montare nel Aiutare l'inserimento del pistone (9) con leggeri colpi
ITA braccio (3) il pistone (9). ITA di mazzuolo in materiale plastico distribuiti lungo la
ATTENZIONE!: Controllare che la sede del pistone circonferenza.
imbocchi la spina di arresto (A) interna al braccio.
Dichtungen (11) und (12) schmieren und Arm (3) und Den Kolben (9) einsetzen; diesen dazu leicht mit
D Kolben (9) montieren. D einem Gummihammer entlang seiner Kreislinie schla-
ACHTUNG! Der Kolben muû den Anhaltestift (A) im gen.
Inneren des Arms aufnehmen.
c d
Lubricar las juntas (11) y (12) y montar en el brazo (3) Facilitar la insercioÂn del pistoÂn (9) con ligeros golpes
ESP el pistoÂn (9). ESP de martillo de material plaÂstico distribuidos en toda la
CUIDADO! Controlar que el alojamiento del pistoÂn circunferencia.
encaje en la clavija de tope (A) dentro del brazo.
Lubrifier les garnitures (11) et (12), puis monter dans le Accompagner l'introduction du piston (9) par de leÂgers
F bras (3) le piston (9). F coups de maillet en matieÁre plastique distribueÂs tout le
ATTENTION! ControÃler que le logement du piston long de la circonfeÂrence.
s'emboõÃte bien avec la broche d'arreÃt (A) aÁ l'inteÂrieur du bras.
Montare le viti a perno (10) controllando che siano Montare le molle (8) di ritorno del pistone (9).
ITA tutte dello stesso colore. Bianco: gioco 1 mm ITA
ATTENZIONE! Usare molta cautela per non deforma-
Giallo: gioco 0,75 mm re gli attacchi delle molle.
Azzurro: gioco 0,5 mm.
Spalmare la filettatura con Loctite 270.
Coppia di serraggio: 5v7 Nm
Die Stiftschrauben (10) einsetzen. Diese muÈssen alle Die RuÈckzugsfedern (8) des Kolbens (9) montieren.
D gleichfarbig sein. Weiû: Spiel 1 mm D
ACHTUNG! Sehr vorsichtig vorgehen, um die Federn
Gelb: Spiel 0,75 mm am Anschluû nicht zu verformen.
Hellblau: Spiel 0,5 mm.
e Das Gewinde mit Loctite 270 schmieren.
Anzugsmoment: 5v7 Nm.
f
Montar los pernos roscados (10) controlando que sean Montar los muelles (8) de retorno del pistoÂn (9).
ESP todos del mismo color. Blanco: juego 1 mm ESP
CUIDADO! Tener mucho cuidado a fin de no deformar
Amarillo: juego 0,75 mm las uniones de los muelles.
Azul: juego 0,5 mm.
Pasar en la rosca Loctite 270.
Par de torsioÂn: 5v7 Nm.
Monter les vis aÁ tourillon (10) en controÃlant si elles sont Monter les ressorts (8) de retour du piston (9).
F toutes de ma meÃme couleur. Blanc: jeu 1 mm F
ATTENTION! Faire treÁs attention aÁ ne pas deÂformer
Jaune: jeu 0,75 mm les raccords des ressorts.
Bleu ciel: jeu 0,5 mm.
Enduire le filetage de Loctite 270.
Couple de serrage: 5v7 Nm.
19
HOW TO ASSEMBLE THE BRAKING UNITS - ASSEMBLAGGIO DEI GRUPPI DI FRENATURA - BREMSAGGREGATE MONTIEREN -
MONTAJE DE LOS GRUPOS DE FRENADO - ASSEMBLAGE DES GROUPES DE FREINAGE
7
16
F1240398 F1240387
GB a GB b
Slightly lubricate the braking disks (7) and fit them in the arm Check that the positioning of the sealing ring (16) on the arm is
following the correct sequence; orient them so that the oil intact; install the complete arm. Lock it into position using two
circulation holes and the marks "B" are perfectly lined up. facing screws (4) and washers (5).
NOTE. When installing the steel discs, the slot corresponding to
the oil level cap should always be kept free.
T2
F1240400
GB c GB d
Check the flatness of the arms using tool T2 and finally lock the
arms with the screws (4) and the washer (5) using the cross-
tightening method.
Torque wrench setting: 298 Nm
GB e GB f
20
Lubrificare leggermente i dischi di frenatura (7) e Verificare l'integritaÁ ed il posizionamento dell'anello di
ITA montarli nel braccio con la giusta sequenza, orientati ITA tenuta (16) del braccio; installare il braccio completo.
in modo che i fori di circolazione dell'olio ed i Fissarlo in posizione con due viti (4) e rondelle (5)
contrassegni "B" siano perfettamente allineati. contrapposte.
NOTA. I dischi in acciaio devono essere montati lasciando libera la
cava corrispondente al tappo livello olio.
Die Bremsscheiben (7) leicht schmieren und in der Kontrollieren ob der Kolbenring (16) unbeschaÈdigt und
D richtigen Reihenfolge auf den Arm montieren. Dabei D auf den Arm richtig montiert ist; den kompletten Arm
È lleitungsloÈcher
muÈssen sie so orientiert sein, daû O montieren.
genau mit den Kennzeichnungen "B" uÈbereinstimmen. In seiner Position mit zwei Schrauben (4) und den entgegen-
a BEMERKUNG. Bei der Montage der Stahlscheiben die dem
È lfuÈllstopfen entspricht, freilassen.
b gesetzten Unterlegscheiben (5) befestigen.
O
Lubricar ligeramente los discos de frenado (7) y Comprobar la integridad y el posicionamiento del
ESP montarlos en el brazo con la secuencia exacta, ESP segmento de compresioÂn (16) del brazo; instalar el
orientados de manera que los orificios de circulacioÂn brazo completo.
del aceite y las marcas "B" esteÂn perfectamente alineados. Fijarlo en su posicioÂn con dos tornillos (4) y arandelas (5)
NOTA. Los discos en acero deben de ser asemblados dejando contrapuestas.
libre el nicho correspondiente a la tapa de nivel aceite.
Lubrifier leÂgeÁrement les disques de freinage (7), puis VeÂrifier le bon eÂtat et la position de la bague
F monter ceux-ci dans le bras aÁ la juste seÂquence, F d'eÂtancheÂiteÂ (16) du bras, installer le bras complet.
orienteÂs de telle sorte aÁ ce que les trous de circulation Fixer celui-ci aÁ sa place aÁ l'aide des deux vis (4) et des
de l'huile et ceux marqueÂs "B" soient parfaitement aligneÂs. rondelles (5) superposeÂes.
NOTE. Les disques en acier doivent eÃtre monteÂs sans deÂranger la
rainure du bouchon du niveau de l'huile.
Controllare la planaritaÁ dei bracci con l'attrezzo T2 e

ITA fissarli definitivamente con le viti (4) e le rondelle (5) ITA
con il metodo del serraggio incrociato.
Coppia di serraggio: 298 Nm
Die Ebenheit der Arme mit dem Werkzeug T2 kontroll-

D ieren und die Arme endguÈltig mit den Schrauben (4) D
und Unterlegscheiben (5) abwechselnd und gegen-
seitig festschrauben.
c Anzugsmoments: 298 Nm d
Controlar la planaridad de los brazos utilizando la
ESP herramienta T2 y fijarlos definitivamente con los ESP
tornillos (4) y las arandelas (5) con el meÂtodo de
torsioÂn cruzado.
Par de torsioÂn: 298 Nm
ControÃler l'uniformiteÂ des bras aÁ l'aide de l'outil T2

F puis fixer deÂfinitivement ces derniers avec les vis (4) et F
les rondelles (5) par le biais du mode de serrage
croiseÂ.
Couple de serrage: 298 Nm
ITA ITA
D D
e f
ESP ESP
F F
21
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22
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24
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'" C '" D
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26
,UBRIlCARE IL TERMINALE DEL DOPPIO GIUNTO CARDANICO 0REPARARE UNA SERIE DI SPESSORI DA MM DA
)4! E MONTARE IL GRUPPO SCATOLA SNODO )4! MONTARE SOTTO IL PERNO SUPERIORE
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27
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28
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29
HOW TO REMOVE THE U-JOINT - RIMOZIONE DOPPIO GIUNTO CARDANICO - DOPPELGELENKWELLE ABMONTIEREN -
REMOCION SEMIEJES - DEPOSE DE JOINT DE CARDAN DOUBLE
3
2 3
F1240365 F1240366
GB a GB b
Unloose and remove the top and bottom check nuts (2) from the Remove top and bottom check dowels (3) from the flange (5) or
dowels (3). bush (13).
30
NOTES - NOTE - BEMERKUNG - NOTAS - NOTE
GB The u-joint can only be removed after extraction of the 3 - Achse mit mechanisch gesteuerten Bremsen: in diesem Fall
steering case has been performed (See: «REMOVING muÈssen die aÈuûeren Steuerhebel untereinander unter Span-
THE STEERING CASE»). Different procedures need to nung gesetzt werden.
be followed depending on the kind of repair operation needed and
the type of axle: 4 - Zum Abmontieren, Arm auf die Werkbank legen.
1 - Axle without parking brakes: compressed air (7 bar approx.) Die ErlaÈuterungen beziehen sich auf das Abmontieren an der
should be introduced in the braking circuit in order to hold the Werkbank, wobei die VorgaÈnge fuÈr alle anderen LoÈsungen oder
braking disks in position. AusfuÈhrungen gleich sind.
2 - Axle with negative brake: does not require any preparation as
the disks are mechanically locked in position. La remocioÂn de los semiejes se puede ejecutar
ESP solamente despueÂs de la remocioÂn del caÂrter de la
3 - Axle with mechanical brake: requires that the external control roÂtula (VeÂase «REMOCION CAJA DE ROTULA») y de
levers are put under tension in relation to each other. manera diversificada en funcioÂn del tipo de reparacioÂn que hay que
4 - Disassembly to be carried out with the arm resting on the bench. ejecutar y del tipo de eje:
The explanations reported herewith refer to removal operations 1 - Eje sin frenos de estacionamiento: es necesario hacer entrar
carried out on the bench; the different stages of u-joint removal also aire comprimido (aproximadamente 7 bares) en el circuito de
apply to all other solutions or versions. frenado para mantener en posicioÂn los discos de los frenos.
2 - Eje con freno negativo: no requiere ninguna preparacioÂn puesto
que los discos quedan bloqueados mecaÂnicamente.
La rimozione del doppio giunto cardanico puoÁ essere
ITA eseguita solo dopo la rimozione della scatola snodo 3 - Eje con freno de mando mecaÂnico: requiere la puesta en tensioÂn
(Vedere «RIMOZIONE SCATOLA SNODO») ed in modo entre sõÂ de las palancas exteriores de mando.
diversificato, in funzione del tipo di riparazione da eseguire e del 4 - Desmontaje ejecutado con el brazo apoyado en el banco.
tipo di assale:
Las explicaciones que aquõÂ figuran se refieren a la remocioÂn
1 - Assale senza freni di stazionamento: eÁ necessario immettere ejecutada en el banco y las fases son comunes para otras
aria compressa (circa 7 bar) nel circuito di frenatura per tenere in soluciones o versiones.
posizione i dischi freni.
2 - Assale con freno negativo: non richiede alcuna preparazione in
quanto i dischi restano bloccati meccanicamente. La deÂpose de joint de cardan double ne peut eÃtre
F effectueÂe qu'apreÁs la deÂpose du boõÃtier articulation
3 - Assale con freno a comando meccanico: richiede di mettere in (Voir, DEPOSE DU BOITIER ARTICULATION), d'une
tensione tra loro le leve esterne di comando. facËon diversifieÂe, en fonction du type de reÂparation aÁ effectuer et du
4 - Smontaggio eseguito con il braccio appoggiato sul banco. type d'essieu:
Le spiegazioni riportate si riferiscono alla rimozione eseguita al 1 - Essieu sans freins de stationnement: il faut introduire de l'air
banco e le fasi sono comuni alle altre soluzioni o versioni. comprimeÂ (environ 7 bar) dans le circuit de freinage pour
maintenir les disques de freinage en place.
2 - Essieu aÁ frein neÂgatif: ne requiert aucune preÂparation parce que
les disques meÂcaniquement restent bloqueÂs.
Die Doppelgelenkwelle koÈnnen erst abmontiert werden,
D wenn das GelenkgehaÈuse schon abgenommen worden 3 - Essieu aÁ frein de commande meÂcanique: requiert de mettre sous
ist (Siehe, «GELENKGEHAÈUSE ABMONTIEREN»). Der tension des leviers externes de commande entre-eux.
Vorgang ist je nach benoÈtigter Reparatur und je nach Achsentyp 4 - DeÂmontage effectueÂ et bras deÂposeÂ sur l'eÂtabli.
unterschiedlich:
1 - Achse ohne Feststellbremse: die Bremsanlage mit ca. 7 bar Les explications reporteÂes se reÂfeÁrent aÁ la deÂpose effectueÂe sur
unter Druck setzen, um die Bremsscheiben in ihrer Position l'eÂtabli, les phases sont les meÃmes que pour les autres solutions ou
festzuhalten. versions.
2 - Achse mit negativer Bremse: benoÈtigt keinerlei Vorbereitung, da
die Scheiben mechanisch blockiert bleiben.
Allentare ed asportare i dadi superiori ed inferiori (2) di Asportare i grani superiore ed inferiore (3) di ritegno
ITA bloccaggio dei grani (3). ITA flangia (5) o della bussola (13).
Obere und untere Muttern (2) die die Stifte (3) blok- Obere und untere Stifte (3), die den Flansch (5) oder
D kieren, abschrauben. D die Buchse (13) halten, abnehmen.
a b
Aflojar y sacar las tuercas superiores e inferiores (2) Sacar la espigas superior y la inferior (3) de retencioÂn
ESP que bloquean las espigas (3). ESP de la brida (5) o del manguito (13).
Desserrer puis enlever les eÂcrous supeÂrieurs et Enlever les grains supeÂrieurs et infeÂrieurs (3) de
F infeÂrieurs (2) de blocage des grains (3). F fixation de la flasque (5) ou de la douille (13).
31
FLANGED VERSION - VERSIONE A FLANGIA - AUSFUÈHRUNG MIT FLANSCH - VERSION A BRIDA - VERSION A FLASQUE
9
F1240576 F1240368
GB a GB b
Remove the u-joint (4). Remove the snap ring (9) from the bearing as well as the packing
NOTE. To remove the u-joint use, if necessary, a plastic hammer or ring (5).
a lever.
5
7
5
F1240369 F1240370
GB c GB d
Position the entire u-joint (4) under a press and remove the bearing Extract the sealing ring of the shaft from the flange (5).
(8) and the ring (5) simultaneously. NOTE. Note down the assembly side of the ring.
COUPLING VERSION - VERSIONE A MANICOTTO - AUSFUÈHRUNG MIT MUFFE - VERSION A MANGUITO - VERSION A MANCHON
13
4 9
F1240367 F1240371
GB e GB f
Remove the entire u-joint (4). Remove the snap ring (9) from the bushing unit (13).
NOTE. To remove the u-joint use, if necessary, a plastic hammer or
a lever.
32
Estrarre il doppio giunto cardanico (4) completo. Asportare l'anello di ritegno (9) del cuscinetto e
ITA ITA dell'anello porta guarnizioni (5).
NOTA. Se necessario, per l'estrazione del doppio
giunto cardanico usare un mazzuolo in materiale
plastico od una leva.
Komplette Doppelgelenkwelle (4) heraus ziehen. Den Haltering (9) des Lagers und des Dichtungsrings
D D (5) abnehmen.
BEMERKUNG. Wenn noÈtig, einen Gummihammer
oder einen Hebel verwenden, um die Doppelgelen-
kwelle heraus zu ziehen.
a b
Extraer el semieje (4) completo. Sacar el anillo de retencioÂn (9) del cojinete y del anillo
ESP ESP porta juntas (5).
NOTA. Si fuera necesario, para extraer el semieje,
utilizar un martillo de material plaÂstico o una palanca.
Extraire le joint de cardan double (4) complet. Enlever la bague de retenue (9) du palier, puis la
F F bague porte-garniture (5).
NOTE. Si besoin, pour l'extraction du joint de cardan
double, utiliser un maillet en matieÁre plastique ou un
levier.
Sistemare il doppio giunto cardanico completo (4) Estrarre dalla flangia (5) l'anello di tenuta dell'albero.
ITA sotto una pressa e rimuovere il cuscinetto (8) e ITA
NOTA. Annotare il senso di montaggio dell'anello.
contemporaneamente l'anello (5).
Die komplette Doppelgelenkwelle (4) unter eine Vom Flansch (5) den Wellenkolbenring abnehmen.
D Presse setzen und gleichzeitig das Lager (8) und D
BEMERKUNG. Auf die Montagerichtung des Ringes
den Ring (5) abnehmen. achten.
c d
Colocar el semieje completo (4) debajo de una prensa Extraer de la brida (5) el segmento de compresioÂn del
ESP y remover el cojinete (8) y al mismo tiempo el anillo (5). ESP eje.
NOTA. Anotar el sentido de montaje del anillo.
Ajuster le joint de cardan double complet (4) sous une Extraire de la flasque (5) la bague d'eÂtancheÂiteÂ de
F presse puis enlever le palier (8) et la bague (5) en F l'arbre.
meÃme temps. NOTE. Prendre note du sens de montage de la bague.
Estrarre il doppio giunto cardanico (4) completo. Asportare l'anello elastico di ritegno (9) del gruppo
ITA ITA bussola (13).
NOTA. Se necessario, per l'estrazione del doppio
giunto cardanico usare un mazzuolo in materiale
plastico od una leva.
Komplette Doppelgelenkwelle (4) heraus ziehen. Haltering (9) von der Buchse (13) abnehmen.
D D
BEMERKUNG. Wenn noÈtig, einen Gummihammer
oder einen Hebel verwenden, um die Doppelgelen-
kwelle heraus zu ziehen.
e f
Extraer el semieje (4) completo. Sacar el anillo elaÂstico de retencioÂn (9) del grupo del
ESP ESP manguito (13).
NOTA. Si fuera necesario, para extraer el semieje,
utilizar un martillo de material plaÂstico o una palanca.
Extraire le joint de cardan double (4) complet. Enlever l'anneau eÂlastique de retenue (9) du groupe
F F de douille (13).
NOTE. Si besoin, pour l'extraction du joint de cardan
double, utiliser un maillet en matieÁre plastique ou un
levier.
33
13 10
11 11 12
F1240375 F1240372
GB a GB b
Position the entire u-joint (4) under a press and remove the Remove the snap ring (10) from the bearing (11). Use a puller to
complete bush (13). remove the bearing (11), the sealing ring (12) and the O-ring (14).
NOTE. Note down the assembly side of the ring (12).
1 3
FLANGED VERSION
VERSIONE A FLANGIA
AUSFUÈHRUNG MIT FLANSCH
VERSION A BRIDA
9 VERSION A FLASQUE
8
7
6
5
GB c GB d
4
2
3 9
10
11
12
13
COUPLING VERSION
VERSIONE A MANICOTTO 14
AUSFUÈHRUNG MIT MUFFE
VERSION A MANGUITO D1240039
VERSION A MANCHON
GB e GB f
34
Sistemare il doppio giunto cardanico completo (4) Asportare l'anello elastico di ritegno (10) del cuscinet-
ITA sotto una pressa e rimuovere la bussola (13) completa. ITA to (11).
Con un estrattore, rimuovere il cuscinetto (11) e
l'anello di tenuta (12) e la guarnizione OR (14).
NOTA. Annotare il senso di montaggio dell'anello (12).
Die komplette Doppelgelenkwelle (4) unter eine Haltering (10) des Lagers (11) abnehmen.
D Presse setzen und die komplette Buchse (13) ab- D Mit dem Abzieher, das Lager (11) und den Dichtring
nehmen. (12) sowie den O-Ring (14) abnehmen.
BEMERKUNG. Auf die Montagerichtung des Ringes (12) achten.
a b
Colocar el semieje completo (4) debajo de una prensa Sacar el anillo de retencioÂn (10) del cojinete (11).
ESP y remover el manguito (13) completo. ESP Utilizando un extractor, remover el cojinete (11) y el
segmento de compresioÂn (12) y la junta OR (14).
NOTA. Anotar el sentido de montaje del anillo (12).
Ajuster le joint de cardan double complet (4) sous une Enlever l'anneau de retenue (10) du palier (11).
F presse, puis enlever la douille (13) compleÁte. F A l'aide d'un extracteur, enlever le palier (11) et la
bague d'eÂtancheÂiteÂ (12) puis la garniture OR (14).
NOTE. Prendre note du sens de montage de la bague (12).
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
35
INSTALLATION OF U-JOINT - INSTALLAZIONE DOPPIO GIUNTO CARDANICO - DOPPELGELENKWELLE INSTALLIEREN -
INSTALACION SEMIEJES - INSTALLATION DE JOINT DE CARDAN DOUBLE
FLANGED VERSION - VERSIONE A FLANGIA - AUSFUÈHRUNG MIT FLANSCH - VERSION A BRIDA - VERSION A FLASQUE
6 5
7
5
T5 8
F1240373 F1240374
GB a GB b
Insert the sealing ring (7) of the shaft in the flange (5), using tool T5. Fit the flange (5) onto the u-joint (4).
NOTE. Carefully check the assembly side. Also replace the outer Heat the bearing (8) at an approx. temperature of 100ë C, fit it on
O-ring (6). the u-joint and fasten.
9
F1240368
GB c GB d
Fit the snap ring (9) on the bearing (8).
COUPLING VERSION - VERSIONE A MANICOTTO - AUSFUÈHRUNG MIT MUFFE - VERSION A MANGUITO - VERSION A MANCHON
T5 T6
10
11
12 11
13 13
F1240376 F1240377
GB e GB f
Using tools T5 and T6, insert the sealing ring (12) and the bearing Fit the snap ring (10) on the bearing (11).
(11) in the bush (13).
NOTE. Carefully check the assembly side of the seal (12).
36
Utilizzando l'attrezzo T5 inserire nella flangia (5) Infilare la flangia (5) sul doppio giunto cardanico (4).
ITA l'anello di tenuta (7) dell'albero. ITA Scaldare il cuscinetto (8) a circa 100ëC, infilarlo sul
NOTA. Controllare attentamente il senso di montaggio. doppio giunto cardanico e mandarlo in battuta.
Sostituire anche l'anello OR esterno (6).
Mit dem Werkzeug T5, den Kolbenring (7) in den Flansch (5) in die Doppelgelenkwelle (4) einsetzen.
D Flansch (5) montieren. D Lager (8) auf ca. 100ëC erhitzen und auf die
BEMERKUNG. Montagerichtung sorgfaÈltig kontrollie- Doppelgelenkwelle setzen; bis zum Anschlag schie-
ren. Den aÈuûeren O-Ring (6) auswechseln. ben.
a b
Utilizando la herramienta T5 introducir en la brida (5) Introducir la brida (5) en el semieje (4).
ESP el segmento de compresioÂn (7) del eje. ESP Calentar el cojinete (8) a unos 100ëC, introducirlo en
NOTA. Controlar atentamente el sentido de montaje. el semieje hasta el tope.
Sustituir tambieÂn el anillo OR exterior (6).
A l'aide d'un outil T5 introduire dans la flasque (5) la Enfiler la flasque (5) sur le joint de cardan double (4).
F bague d'eÂtancheÂiteÂ (7) de l'arbre. F Chauffer le palier (8) aÁ environ 100ëC, enfiler celui-ci
NOTE. ControÃler soigneusement le sens de montage. sur le joint de cardan double et l'envoyer en buteÂe.
Remplacer eÂgalement la garniture OR (6).
Montare l'anello elastico (9) di ritegno del cuscinetto (8).

ITA ITA
Haltering (9) auf das Lager (8) montieren.

D D
c d
Montar el anillo elaÂstico (9) de retencioÂn del cojinete (8).
ESP ESP
Monter l'anneau eÂlastique (9) de retenue du palier (8).

F F
Utilizzando gli attrezzi T5 e T6 inserire nella bussola Montare l'anello elastico (10) di ritegno del cuscinetto (11).
ITA (13) l'anello di tenuta (12) ed il cuscinetto (11). ITA
NOTA. Controllare attentamente il senso di montaggio
della guarnizione (12).
Mit den Werkzeugen T5 und T6 den Haltering (12) und Haltering (10) des Lagers (11) montieren.
D das Lager (11) in die Buchse (13) setzen. D
BEMERKUNG. Montagerichtung der Dichtung (12)
aufmerksam kontrollieren.
e f
Utilizando las herramientas T5 y T6, introducir en el Montar el anillo elaÂstico (10) de retencioÂn del cojinete (11).
ESP manguito (13) el segmento de compresioÂn (12) y el ESP
cojinete (11).
NOTA. Controlar atentamente el sentido de montaje de la junta
(12).
A l'aide des outils T5 et T6 introduire dans la douille Monter l'anneau eÂlastique (10) de retenue du palier (11).
F (13) la bague d'eÂtancheÂiteÂ (12) et le palier (11). F
NOTE. ControÃler soigneusement le sens de montage
de la garniture (12).
37
INSTALLATION OF U-JOINT - INSTALLAZIONE DOPPIO GIUNTO CARDANICO - DOPPELGELENKWELLE INSTALLIEREN -
INSTALACION SEMIEJES - INSTALLATION DE JOINT DE CARDAN DOUBLE
14
13
13
4
9
F1240378 F1240371
GB a GB b
Heat the bearing in oil at an approx. temperature of 100ëC and fit Fit the check ring (9) on the bushing unit (13); also put the O-ring
the entire bush (13) on the u-joint (4). (14) into position.
2
2
F1240379 F1240380
GB c GB d
Insert the u-joint and tighten the top and bottom dowels (2). Apply Loctite 242 to the jutting parts of the dowels (2).
Torque wrench setting: Max. 15 Nm.
NOTE. For u-joint coming with a bush, centre the point of the check
dowels in the slot.
3 2 3 2
3
D1240082
F1240381
GB e GB f
Screw the check nuts (3) of the dowels (2) and lock them using a
dynamometric wrench.
Torque wrench setting: 122 Nm
38
Scaldare in olio il cuscinetto a circa 100ëC ed infilare Montare l'anello di ritegno (9) del gruppo bussola (13);
ITA sul doppio giunto cardanico (4) la bussola completa ITA posizionare anche la guarnizione OR (14).
(13).
Lager in OÈ l auf ca. 100ëC erhitzen und auf die Haltering (9) des Buchsenaggregats (13) montieren;
D Doppelgelenkwelle (4) die komplette Buchse (13) D O-Ring (14) ebenfalls montieren.
schieben.
a b
Calentar en aceite el cojinete a unos 100ëC e Montar el anillo de retencioÂn (9) del grupo del
ESP introducir en el semieje (4) el manguito completo (13). ESP manguito (13); posicionar tambieÂn la junta OR (14).
Chauffer dans l'huile aÁ environ 100ëC le palier puis Monter l'anneau de retenue (9) du groupe douille (13):
F enfiler sur le joint de cardan double (4) la douille F placer eÂgalement la garniture OR (14).
compleÁte (13).
Infilare il doppio giunto cardanico e serrare i grani Spalmare con Loctite 242 le porzioni sporgenti dei
ITA superiore ed inferiore (2). ITA grani (2).
Coppia di serraggio: Max. 15 Nm.
NOTA. Per il doppio giunto cardanico con bussola, centrare la
punta dei grani di ritegno nella cava.
Doppelgelenkwelle einsetzen und obere und untere Mit Loctite 242 die herausragenden Stifte (2) schmie-
D Stifte (2) festschrauben. D ren.
Anzugsmoment: Max. 15 Nm
BEMERKUNG. Bei der Doppelgelenkwelle mit Buchse, Stiftspitze
c genau zentrieren. d
Introducir el semieje y apretar la espiga superior y la Pasar Loctite 242 en las partes salientes de las
ESP inferior (2). ESP espigas (2).
Par de torsioÂn: MaÂx. 15 Nm.
NOTA. Para el semieje con manguito, centrar la punta de las
espigas de retencioÂn en la ranura.
Enfiler le joint de cardan double et serrer les grains Enduire de Loctite 242 les parties saillantes des grains (2).
F supeÂrieurs et infeÂrieurs (2). F
Couple de serrage: Max. 15 Nm.
NOTE. Pour le joint de cardan double aÁ douille, centrer la pointe
des grains de fixation dans le creux.
Avvitare i dadi (3) di bloccaggio dei grani (2) e bloccarli

ITA con chiave dinamometrica. ITA
Coppia di serraggio: 122 Nm
Muttern (3) zur Befestigung der Stifte (2) zuschrauben

D und mit einem MomentenschluÈssel blockieren. D
Anzugsmoment: 122 Nm
e f
Atornillar las tuercas (3) de bloqueo de las espigas (2)
ESP y bloquearlas con llave dinamomeÂtrica. ESP
Par de torsioÂn: 122 Nm
Visser les eÂcrous (3) de blocage des grains (2), puis

F bloquer aÁ l'aide d'une cleÂ dynamomeÂtrique. F
Couple de serrage: 122 Nm
39
HOW TO DISASSEMBLE THE PLANETARY REDUCTION - SMONTAGGIO RIDUTTORE EPICICLOIDALE - PLANETENGETRIEB ABMONTIEREN -
DESMONTAJE REDUCTOR EPICICLOIDAL - DESASSEMBLAGE DU REDUCTEUR EPICYCLOIDAL
1
3
2
1
F1240437 F1240438
GB a GB b
Disconnect the steering bars from the steering case (3). Disjoint the planetary carrier cover (2) from the steering case (3) by
For details, see «HOW TO REMOVE THE COMPLETE STEERING alternatively forcing a screwdriver into the appropriate slots.
CASE».
Remove the securing screws (1) from the planetary carrier cover
(2).
2
5
4
F1240439 F1240440
GB c GB d
Remove the complete planetary carrier cover (2). Unloose and remove the tightening nuts (4) from the crown flange
(5).
5
6
F1240441 F1240442
GB e GB f
Remove the safety flange (6). Using a puller, remove the complete crown flange (5) by acting on
the stud bolts.
40
Scollegare dalla scatola snodo (3) le barre di sterza- Utilizzando un cacciavite inserito alternativamente
ITA tura. ITA nelle cave predisposte, staccare il coperchio portasa-
Per i dettagli, vedere «RIMOZIONE SCATOLA SNO- telliti (2) dalla scatola snodo (3).
DO COMPLETA».
Asportare le viti (1) di fissaggio del coperchio portasatelliti (2).
GelenkgehaÈuse (3) von den Lenkstangen trennen. Mit einem Schraubenzieher den Planetenradhalter-
D Siehe «KOMPLETTES GELENKGEHAÈUSE ABMON- D deckel (2) vom GelenkgehaÈuse (3) trennen. Dazu den
TIEREN». Schraubenzieher abwechselnd in die vorgesehenen
Befestigungsschrauben (1) vom Planetenradhalterdeckel (2) ab- Nuten stecken und anheben.
a schrauben. b
Separar de la caja de roÂtula (3) las barras de direccioÂn. Utilizando un destornillador introducido alternativa-
ESP Para los detalles, veÂase «REMOCION CAJA DE ESP mente en las ranuras predispuestas, desprender la
ROTULA COMPLETA». tapa portasateÂlites (2) de la caja de la roÂtula (3).
Sacar los tornillos (1) de fijacioÂn de la tapa portasateÂlites (2).
DeÂbrancher, du boõÃtier articulation (3), les barres de A l'aide d'un tournevis introduit au fur et aÁ mesure
F braquage. F dans les creux preÂdisposeÂs, deÂcrocher le couvercle
Pour de plus amples deÂtails, voir «DEPOSE DU porte-satellites (2) du boõÃtier articulation (3).
BOITIER D'ARTICULATION COMPLET».
Enlever les vis de fixation (1) du couvercle porte-satellites (2).
Asportare il coperchio portasatelliti (2) completo. Allentare ed asportare i dadi (4) che fissano la flangia
ITA ITA portacorona (5).
Kompletter Planetenradhalterdeckel (2) abnehmen. Befestigungsmuttern (4) des Kranzhalterflansches (5)

D D lockern.
c d
Sacar la tapa portasateÂlites (2) completa. Aflojar y quitar las tuercas (4) que fijan la brida
ESP ESP portacorona (5).
Enlever le couvercle porte-satellites (2) complet. Desserrer et enlever les eÂcrous (4) de fixation de la
F F flasque porte-couronne (5).
Rimuovere la flangia di sicurezza (6). Utilizzando un estrattore e, facendo reazione sui

ITA ITA prigionieri, rimuovere la flangia portacorona (5) com-
pleta.
Sicherheitsflansch (6) abnehmen. Durch einen Abzieher uÈber die Stiftschrauben, den
D D kompletten Kranzhalterflansch (5) abnehmen.
e f
Remover la brida de seguridad (6). Utilizando un extractor y apalancando los prisioneros,
ESP ESP remover la brida portacorona (5) completa.
Enlever la flasque de seÂcuriteÂ (6). En utilisant l'extracteur et en faisant reÂagir les

F F prisonniers, enlever la flasque porte-couronne (5)
compleÁte.
41
8
7
F1240443 F1240444
GB a GB b
Partially extract the hub (7) using a plastic hammer. Remove the external bearing (8).
NOTE. Alternately hammer on several equidistant points.
7
3
F1240445 F1240446
GB c GB d
By hand remove the complete hub (7). Remove the pins and remove the steering case (3).
For details, see «HOW TO REMOVE THE COMPLETE STEERING
CASE»
10
9
F1240447 F1240448
GB e GB f
Remove the snap rings (9). With the help of a puller, remove the planet wheel gears (10).
NOTE. Note down the assembly side of planet wheels.
42
Utilizzando un mazzuolo in materiale plastico, sfilare Asportare il cuscinetto esterno (8).
ITA parzialmente il mozzo portaruota (7). ITA
NOTA. Battere alternativamente in piuÁ punti equidi-
stanti.
Mit einem Gummihammer, die Radhalternabe (7) AÈuûeres (8) Lager abnehmen.
D etwas heraus schieben. D
BEMERKUNG. Abwechselnd an verschiedenen,
gleich entfernten Stellen schlagen.
a b
Utilizando un martillo de material plaÂstico, extraer Sacar el cojinete exterior (8).
ESP parcialmente el cubo portarruedas (7). ESP
NOTA. Golpear alternativamente en varios puntos
equidistantes.
A l'aide d'un maillet en matieÁre plastique, extraire Enlever le palier externe (8).
F partiellement le moyeu porte-roue (7). F
NOTE. Frapper sur plusieurs points aÁ la meÃme
distance.
Sfilare il mozzo portaruota (7). Asportare i perni e rimuovere la scatola snodo (3).
ITA ITA Per i dettagli di rimozione dei perni, vedere «RIMO-
ZIONE SCATOLA SNODO COMPLETA».
Radhalternabe (7) herausziehen. Stifte und GelenkgehaÈuse (3) entfernen.

D D Siehe «KOMPLETTES GELENKGEHAÈUSE ABMON-
TIEREN».
c d
Extraer el cubo portarruedas (7). Sacar los pernos y remover la caja de la roÂtula (3).
ESP ESP Para los detalles de remocioÂn de los pernos, veÂase
«REMOCION CAJA DE ROTULA COMPLETA».
Extraire le moyeu porte-roue (7). Enlever les tourillons, enlever le boõÃtier articulation (3).
F F Pour de plus amples deÂtails, voir «DEPOSE DU
BOITIER ARTICULATION COMPLET».
Asportare gli anelli elastici (9). Utilizzando un estrattore, asportare gli ingranaggi
ITA ITA satelliti (10).
NOTA. Annotare il senso di montaggio dei satelliti.
Die Kolbenringe (9) entfernen. Mit einem Abzieher, die PlanetenraÈder (10) heraus
D D nehmen.
BEMERKUNG. Montagerichtung der PlanetenraÈder
beachten.
e f
Sacar los anillos elaÂsticos (9). Utilizando un extractor, sacar los engranajes sateÂlites
ESP ESP (10).
NOTA. Anotar el sentido de montaje de los sateÂlites.
Enlever les anneaux eÂlastiques (9). A l'aide d'un extracteur, extraire les engrenages
F F satellites (10).
NOTE. Prendre note du sens de montage des
satellites.
43
12 5
13
F1240450 F1240451
GB a GB b
Remove the snap ring (12) from the crown (13). Remove the crown flange (5).
14 15
F1240452 F1240453
GB c GB d
Remove the sealing ring from the hub (14). Remove the internal bearing (15).
16
17
16 17 18
7 18
F1240454 F1240455
GB e GB f
Remove the external thrust blocks from the bearings (8) and (15) Use a puller to remove the centring ring (16), the sealing ring (17)
forcing a pin-driver into the appropriate slots on the hub (7). and the bearing (18) from the steering case (3).
NOTE. Hammer in an alternate way so as to avoid crawling or NOTE. Note down the orientation of both centring ring (16) and
deformation of the thrust blocks. sealing ring (17).
44
Asportare l'anello elastico (12) di ritegno della corona Rimuovere la flangia portacorona (5).
ITA (13). ITA
Den Kolbenring (12) vom Kranz (13) abnehmen. Kranzhalterflansch (5) abnehmen.
D D
a b
Sacar el anillo elaÂstico (12) de retencioÂn de la corona Remover la brida portacorona (5).
ESP (13). ESP
Enlever l'anneau eÂlastique (12) de retenue de la DeÂposer la flasque porte-couronne (5).

F couronne (13). F
Rimuovere dal mozzo portaruota (14) l'anello di Rimuovere il cuscinetto interno (15).
ITA tenuta. ITA
Von der Radhalternabe (14) den Kolbenring abneh- Inneres Lager (15) abnehmen.
D men. D
c d
Remover del cubo portarruedas (14) el segmento de Remover el cojinete interior (15).
ESP compresioÂn. ESP
Enlever, du moyeu porte-roue (14), la bague d'eÂtan- Enlever le palier interne (15).
F cheÂiteÂ. F
Rimuovere le ralle esterne dei cuscinetti (8) e (15) Utilizzando un estrattore, asportare dalla scatola
ITA utilizzando un cacciaspine inserito nelle cave predi- ITA snodo (3), l'anello centratore (16), l'anello di tenuta
sposte sul mozzo (7). (17) e la bronzina (18).
NOTA. Battere in modo alternato per evitare impuntamenti e NOTA. Annotare gli orientamenti dell'anello centratore (16) e
deformazione delle ralle. dell'anello di tenuta (17).
Die aÈuûeren Scheiben der Lager (8) und (15) mit einem Mit einem Abzieher das GelenkgehaÈuse (3), den
D DuÈbel durch die NabenloÈcher (7) herausschlagen. D Zentrierring (16), den Kolbenring (17) und das Bron-
BEMERKUNG. Abwechselnd herausschlagen, um zelager (18) abnehmen.
Verformungen zu vermeiden. BEMERKUNG. Auf die Montagerichtung des Zentrierringes (16)
e f und des Kolbenringes (17) achten.
Remover las ranguas exteriores (8) y (15) de los Utilizando un extractor, sacar de la caja de la roÂtula (3)
ESP cojinetes utilizando un extractor para clavijas inser- ESP el anillo de centraje (16), el segmento de compresioÂn
tado en las ranuras predispuestas en el cubo (7). (17) y la chumacera (18).
NOTA. Golpear de manera alternada para evitar danÄos y NOTA. Anotar las orientaciones del anillo de centraje (16) y del
deformaciones de las ranguas. segmento de compresioÂn (17).
Enlever les crapaudines externes des paliers (8) et (15) A l'aide d'un extracteur, extraire le boõÃtier articulation
F aÁ l'aide d'une chasse-goupilles placeÂ dans les creux F (3), l'anneau de centrage (16), la bague d'eÂtancheÂiteÂ
speÂcialement concËus aÁ cet effet sur le moyeu (7). (17) et le coussinet (18).
NOTE. Taper d'une manieÁre alterneÂe afin d'eÂviter talonnage et NOTE. Prendre note du sens de l'anneau de centrage (16) et de la
deÂformation des crapaudines. bague d'eÂtancheÂiteÂ (17).
45
19
16
18
3
17
GB a GB b
7
14 12
15 5
9
10
8
20
13 11
6
4
9
10
1
2 D1240040
GB c GB d
GB e GB f
46
ITA ITA
D D
a b
ESP ESP
F F
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
47
ASSEMBLING THE PLANETARY REDUCTION - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE - PLANETENGETRIEB MONTIEREN -
MONTAJE REDUCTOR EPICICLOIDAL - ASSEMBLAGE DU REDUCTEUR EPICYCLOIDAL
3 T7
16 17 T8
18
F1240456 F1240457
GB a GB b
Lubricate the bushing (18) and the seat of the steering case (3). Lubricate the outer surface of the sealing ring (17) and centring ring
Install the bushing (18), using tool T7. (16); fit them into their seat using tool T8.
8 15
T9A T9A
F1240458 F1240459
GB c GB d
Position the lower part of tool T9A and the thrust block of the Lubricate the seats of the bearings and position the hub (7) on tool
external bearing (8) under the press. T9A; position the thrust block of the internal bearing (15).
NOTE. Check that the thrust block is correctly oriented.
15
T9B
F1240460 F1240461
GB e GB f
Position the upper part of tool T9B and press the thrust blocks into Fit the bearing (15) into the internal thrust block.
the hub (7) all the way down.
48
Lubrificare la bronzina (18) e la sede della scatola Lubrificare la superficie esterna dell'anello di tenuta
ITA snodo (3). ITA (17) e dell'anello centratore (16); montarli in sede
Utilizzando l'attrezzo T7 montare la bronzina (18). utilizzando l'attrezzo T8.
Das Bronzelager (18) und das GelenkgehaÈuse (3) Die aÈuûere FlaÈche des Kolbenringes (17) und des
D schmieren. D Zentrierringes (16) schmieren; die beiden Ringe mit
Mit einem Werkzeug T7 das Bronzelager (18) montie- einem Werkzeug T8 montieren.
ren.
a b
Lubricar la chumacera (18) y el alojamiento de la caja Lubricar la superficie exterior del segmento de
ESP de la roÂtula (3). ESP compresioÂn (17) y del anillo de centraje (16); montarlos
Montar la chumacera (18) utilizando la herramienta en un alojamiento utilizando la herramienta T8.
T7.
Lubrifier le coussinet (18) et le logement du boõÃtier Lubrifier la surface externe de la bague d'eÂtancheÂiteÂ
F articulation (3). F (17), et de l'anneau de centrage (16), puis monter
A l'aide de l'outil T7 monter le coussinet (18). ceux-ci dans leur logement aÁ l'aide de l'outil T8.
Posizionare sotto la pressa la parte inferiore dell'at- Lubrificare le sedi dei cuscinetti e posizionare sull'at-
ITA trezzo T9A e la ralla del cuscinetto esterno (8). ITA trezzo T9A il mozzo portaruota (7); posizionare la ralla
del cuscinetto interno (15).
NOTA. Controllare l'orientamento della ralla.
Unter einer Presse den unteren Teil des Werkzeugs Die Lagersitze schmieren und am Werkzeug T9A die
D T9A und die Scheibe des aÈuûeren Lagers (8) D Radhalternabe (7) positionieren; die Scheibe des
positionieren. inneren Lagers (15) positionieren.
BEMERKUNG. Die Position der Scheibe beachten.
c d
Posicionar debajo de la prensa la parte inferior de la Lubricar los alojamientos de los cojinetes y posicionar
ESP herramienta T9A y la rangua del cojinete exterior (8). ESP en la herramienta T9A el cubo portarruedas (7);
posicionar la rangua del cojinete interior (15).
NOTA. Controlar la orientacioÂn de la rangua.
Placer sous la presse la partie infeÂrieure de l'outil T9A Lubrifier le logement des paliers et placer sur l'outil
F et la crapaudine du palier externe (8). F T9A le moyeu porte-roue (7); placer la crapaudine du
palier interne (15).
NOTE. ControÃler les sens de la crapaudine.
Posizionare la parte superiore dell'attrezzo T9B e Montare il cuscinetto (15) nella ralla interna.
ITA pressare a fondo le ralle nel mozzo portaruota (7). ITA
Das obere Teil des Werkzeugs T9B positionieren und Lager (15) in die innere Scheibe montieren.
D die Scheiben in die Radhalternabe (7) fest eindruÈcken. D
e f
Posicionar la parte superior de la herramienta T9B y Montar el cojinete (15) en la rangua interior.
ESP presionar a fondo las ranguas en el cubo portarruedas (7). ESP
Placer la partie supeÂrieure de l'outil T9B, puis presser aÁ Monter le palier (15) dans la crapaudine interne.
F fond les crapaudines du moyeu porte-roue (7). F
49
T10
14
7 14
F1240462 F1240463
GB a GB b
Apply a repositionable jointing compound for seals to the outer Position tool T10 and press the sealing ring (14) into its seat.
surface of the sealing ring (14). Position the sealing ring (14) in the
hub (7).
NOTE. Check that the ring (14) is correctly oriented.
12
13
5
13
F1240451 F1240465
GB c GB d
Insert the flange (5) in the crown (13). Insert the snap ring (12) in order to fix the flange (5) in the crown
(13).
NOTE. Carefully check that ring (12) is properly inserted in the slot
of the crown (13)
T11
9
10 10
F1240467 F1240447
GB e GB f
With the help of tool T11, insert the planet wheel gears (10) into the Lock the gears (10) into position by fitting the snap rings (9).
cover (2).
Accurately check the orientation.
50
Spalmare la superficie esterna dell'anello di tenuta Posizionare l'attrezzo T10 e pressare in sede l'anello
ITA (14) con mastice per guarnizioni riposizionabile. ITA di tenuta (14).
Posizionare l'anello di tenuta (14) nel mozzo (7).
NOTA. Controllare l'orientamento dell'anello (14).
Die aÈuûere FlaÈche des Kolbenringes (14) mit Klebstoff Das Werkzeug T10 positionieren und den Kolbenring
D fuÈr verstellbare Dichtungen schmieren. D (14) in seinen Sitz pressen.
Den Kolbenring (14) in die Nabe (7) montieren.
BEMERKUNG. Richtung des Ringes (14) beachten.
a b
Pasar sobre la superficie exterior del anillo de Posicionar la herramienta T10 y presionar en su
ESP compresioÂn (14) un pasta para juntas reposicionable. ESP alojamiento el segmento de compresioÂn (14).
Posicionar el segmento de compresioÂn (14) en el
cubo (7).
NOTA. Controlar la orientacioÂn del anillo (14).
Enduire la surface externe de la bague d'eÂtancheÂiteÂ Placer l'outil T10 et presser dans son logement la
F (14) avec mastic pour garnitures aÁ remettre en place. F bague d'eÂtancheÂiteÂ (14).
Placer la bague d'eÂtancheÂiteÂ (14) dans le moyeu (7).
NOTE. ControÃler le sens de la bague (14).
Inserire la flangia (5) nella corona (13). Inserire l'anello elastico (12) per fissare la posizione
ITA ITA della flangia (5) nella corona (13).
NOTA. Controllare attentamente l'inserimento dell'a-
nello (12) nella cava della corona (13).
Flansch (5) in den Kranz (13) montieren. Den Kolbenring (12) einsetzen, um die Position des
D D Flansches (5) im Kranz (13) zu sichern.
BEMERKUNG. SorgfaÈltig kontrollieren, ob der Ring
(12) in der Nut des Kranzes (13) richtig eingesetzt ist.
c d
Introducir la brida (5) en la corona (13). Introducir el anillo elaÂstico (12) para fijar la posicioÂn de
ESP ESP la brida (5) en la corona (13).
NOTA. Controlar atentamente la insercioÂn del anillo
(12) en la ranura de la corona (13).
Introduire la flasque (5) dans la couronne (13). Introduire l'anneau eÂlastique (12) pour fixer la position
F F de la flasque (5) dans la couronne (13).
NOTE. ControÃler soigneusement l'introduction de la
bague (12) dans le creux de la couronne (13).
Utilizzando l'attrezzo T11 inserire nel coperchio (2) gli Bloccare la posizione degli ingranaggi (10) montando
ITA ingranaggi satelliti (10). ITA gli anelli elastici di ritegno (9).
Controllare attentamente l'orientamento.
Mit dem Werkzeug T11 in den Deckel (2) die Die Position der RaÈder (10) mit den Halteringen (9)
D PlanetenraÈder (10) einsetzen. D blockieren.
Die Position sorgfaÈltig kontrollieren.
e f
Utilizando la herramienta T11 introducir en la tapa (2) Bloquear la posicioÂn de los engranajes (10) montando
ESP los engranajes sateÂlites (10). ESP los anillos elaÂsticos de retencioÂn (9).
Controlar atentamente la orientacioÂn.
A l'aide de l'outil T11 introduire dans le couvercle (2) Bloquer la position des engrenages (10) en montant
F les engrenages satellites (10). F les anneaux eÂlastiques de retenue (9).
ControÃler attentivement le sens.
51
19
F1240446 F1240425
GB a GB b
Fit the steering case (3) onto the U-joint (19) and install the Connect the steering bars.
articulation pins. For pin assembly details, see «HOW TO For details, see «HOW TO INSTALL THE COMPLETE STEERING
ASSEMBLE THE COMPLETE STEERING CASE». CASE».
7 8
F1240445 F1240444
GB c GB d
Install the hub (7). Install the external bearing (8).
NOTE. Using a plastic hammer, drive the bearing to the limit stop
by lightly hammering around the edge.
5
6
5
F1240470 F1240441
GB e GB f
Fit the complete crown flange (5). Apply Tecnolube Seal 101 grease to the surface of the safety
NOTE. In order to fasten the flange (5), use a plastic hammer and flange (6) which touches the crown flange (5).
alternately hammer on several equidistant points. Fit the safety flange (6).
52
Infilare la scatola snodo (3) sul doppio giunto (19) e Collegare le barre di sterzatura.
ITA montare i perni snodo. ITA Per i dettagli, vedere «INSTALLAZIONE SCATOLA
Per i dettagli di montaggio dei perni snodo, vedere SNODO COMPLETA».
«ASSEMBLAGGIO SCATOLA SNODO COMPLETA».
GelenkgehaÈuse (3) auf die Doppelkupplung (19) Lenkstangen anschlieûen.

D setzen und die Gelenkstifte montieren. D Siehe «KOMPLETTES GELENKGEHAÈUSE INSTAL-
Siehe zur Montage der Gelenkstifte «KOMPLETTES LIEREN».
GELENKGEHAÈUSE ZUSAMMENBAUEN».
a b
Introducir la caja de la roÂtula (3) en la junta doble (19) y Conectar las barras de direccioÂn.
ESP montar las roÂtulas. ESP Para los detalles, veÂase «INSTALACION CAJA DE
Para los detalles de montaje de las roÂtulas, veÂase ROTULA COMPLETA».
«MONTAJE DE LA CAJA DE ROTULA COMPLETA».
Introduire le boõÃtier articulation (3) sur le double joint Relier les barres de braquage.
F (19), puis monter les tourillons d'articulation. F Pour de plus amples deÂtails voir «INSTALLATION DU
Pour de plus amples deÂtails sur le montage des BOITIER ARTICULATION COMPLET».
tourillons d'articulation, voir «ASSEMBLAGE DU BOITIER ARTI-
CULATION COMPLET».
Montare il mozzo portaruota (7). Montare il cuscinetto esterno (8).

ITA ITA
NOTA. Mandare a fondo corsa il cuscinetto con
leggeri colpi di mazzuolo distribuiti su tutta la
circonferenza.
Radhalternabe (7) montieren. AÈuûeres Lager (8) montieren.

D D
BEMERKUNG. Das Lager bis zum Anschlag ein-
setzen; dazu einen Gummihammer verwenden und
entlang der Kreislinie einschlagen.
c d
Montar el cubo portarruedas (7). Montar el cojinete exterior (8).
ESP ESP
NOTA. Llevar al fondo de carrera el cojinete con
ligeros golpes de martillo distribuidos en toda la
circunferencia.
Monter le moyeu porte-roue (7). Monter le palier externe (8).

F F
NOTE. Envoyer le palier en fin de course avec des
petits coups de maillet distribueÂs sur toute la circonfeÂ-
rence.
Montare la flangia portacorona (5) completa. Lubrificare con grasso Tecnolube Seal 101 la superfi-
ITA ITA cie della flangia di sicurezza (6) a contatto con la
NOTA. Per mandare in battuta la flangia (5), usare un
mazzuolo in materiale plastico battuto alternativamen- flangia portacorona (5).
te in piuÁ punti equidistanti. Montare la flangia di sicurezza (6).
Kompletter Kranzhlaterflansch (5) montieren. Mit Fett Typ Tecnolube Seal 101 die OberflaÈche des
D D Sicherheitsflansch (6) schmieren, der am Kranzhalter-
BEMERKUNG. Um den Flansch (5) bis zum Anschlag
einzusetzen, einen Gummihammer verwenden und flansch (5) anliegt.
abwechselnd an gleich entfernten Stellen einschlagen. Sicherheitsflansch (6) montieren.
e f
Montar la brida portacorona (5). Lubricar con grasa Tecnolube Seal 101 la superficie
ESP ESP de la brida de seguridad (6) en contacto con la brida
NOTA. Para llevar a tope la brida (5) usar un martillo
de material plaÂstico golpeaÂndolo alternativamente en portacorona (5).
varios puntos equidistantes. Montar la brida de seguridad (6).
Monter la flasque porte-couronne (5) compleÁte. Lubrifier avec du gras Tecnolube Seal 101 la surface
F F de la flasque de seÂcuriteÂ (6) en contact avec la flasque
NOTE. Pour envoyer la flasque (5) en buteÂe, utiliser un
maillet en matieÁre plastique en battant sur plusieurs porte-couronne (5).
points eÂquidistants. Monter la flasque de seÂcuriteÂ (6).
53
F1240472 F1240473
GB a GB b
Apply Loctite 242 to the studs and fit in the nuts (4). Cross tighten the nuts (4) in two stages.
Initial torque wrench setting: 120 Nm
Final torque wrench setting: 255±285 Nm
20
3
1
2
2
F1240439 F1240475
GB c GB d
Fit the planetary carrier cover (2) onto the hub (3). Lock the planetary carrier cover (2) by tightening the screws (1).
CAUTION! Check that the O-ring (20) is in good condition and in Torque wrench setting for screws: 40±50 Nm
position.
GB e GB f
54
Spalmare i prigionieri con Loctite 242 e montare i dadi Serrare i dadi (4) in due tempi e con il metodo del
ITA (4). ITA serraggio incrociato.
Coppia di serraggio iniziale: 120 Nm
Coppia di serraggio finale 255v285 Nm
Die Stiftschrauben mit Loctite 242 schmieren und die Die Mutter (4) abwechseln und entgegengesetzt fest-
D Muttern (4) montieren. D schrauben.
AnfaÈnglicher Anzugsmoment: 120 Nm
EndguÈltiger Anzugsmoment: 255v285 Nm
a b
Pasar en los prisioneros Loctite 242 y montar las Apretar las tuercas (4) en dos tiempos y siempre con el
ESP tuercas (4). ESP meÂtodo de torsioÂn cruzada.
Par de torsioÂn inicial: 120 Nm
Par de torsioÂn final 255v285 Nm
Enduire les prisonniers avec du Loctite 242 puis Serrer les eÂcrous (4) en deux temps par le biais du
F monter les eÂcrous (4). F mode de serrage croiseÂ.
Couple de serrage initial: 120 Nm
Couple de serrage final: 255v285 Nm
Montare il coperchio portasatelliti (2) sul mozzo Bloccare il coperchio portasatelliti (2) con le viti (1).
ITA portaruota (3). ITA Coppia di serraggio viti: 40v50 Nm
ATTENZIONE! Controllare lo stato e la posizione della
guarnizione OR (20).
Planetenradhalterdeckel (2) auf die Radhalternabe (3) Planetenhalterdeckel (2) mit den Schraube (1) fest-
D montieren. D schrauben.
ACHTUNG! Den Zustand und die Position des O- Anzugsmoment der Schrauben: 40v50 Nm
Ringes (20) kontrollieren.
c d
Montar la tapa portasateÂlites (2) en el cubo portarrue- Bloquear la tapa portasateÂlites (2) con los tornillos (1).
ESP das (3). ESP Par de torsioÂn tornillos: 40v50 Nm
CUIDADO! Controlar el estado y la posicioÂn de la junta
OR (20).
Monter le couvercle porte-satellites (2) sur le moyeu Bloquer le couvercle porte-satellites (2) avec les vis
F porte-roue (3). F (1).
ATTENTION! ControÃler l'eÂtat et la position de la Couple de serrage vis: 40v50 Nm
garniture OR (20).
ITA ITA
D D
e f
ESP ESP
F F
55
HOW TO REMOVE THE STEERING CYLINDER - RIMOZIONE CILINDRO DI STERZATURA - LENKZYLINDER ABMONTIEREN -
REMOCION CILINDRO DE DIRECCIOÂN - DEPOSE DU CYLINDRE DE BRAQUAGE
1
2
6
3
F1240401 F1240402
GB a GB b
Remove the centring sensor (1) of the steering piston (2), if Remove the safety cotter pins (3) from the articulation pins (4) of
supplied. the steering bars (5).
CAUTION! Dispose of used cotter pins.
4 5
7
F1240403 F1240404
GB c GB d
Remove the castellated nuts (6) that lock the articulation pins (4). Disconnect the tapered pins of the articulation (4) from the steering
case (7) by means of a puller.
13 2
F1240405 F1240406
GB e GB f
If the connection of the steering bars includes a safety collar (13), Disconnect left and right steering bars (5) from the piston (2).
raise the border.
56
Se eÁ previsto rimuovere il sensore (1) di centraggio Asportare le copiglie (3) di sicurezza perni snodo (4)
ITA della corsa del pistone di sterzatura (2). ITA delle barre di sterzatura (5).
ATTENZIONE! Scartare le copiglie usate.
Wenn vorgesehen, Sensor (1) zur Zentrierung des Splint (3) der Gelenkstifte (4) der Lenkstangen (5)
D Hubs des Lenkkolbens (2) abnehmen. D abnehmen.
ACHTUNG! Verbrauchte Splinte nicht verwenden.
a b
Si ha sido previsto, remover el sensor (1) de centraje Sacar las clavijas (3) de seguridad de la roÂtulas (4) de
ESP de la carrera del pistoÂn de direccioÂn (2). ESP las barras de direccioÂn (5).
CUIDADO! Tirar las clavijas usadas.
Si preÂvu, enlever le capteur (1) de centrage de la Enlever la goupille (3) de suÃreteÂ des tourillons
F course du piston de braquage (2). F d'articulation (4) des barres de braquage (5).
ATTENTION! Eliminer les goupilles useÂes.
Rimuovere i dadi ad intaglio (6) di ritegno perni snodo Utilizzando un estrattore, scollegare i perni conici
ITA (4). ITA dello snodo sterzo (4) dalla scatola snodo (7).
Kronenmutter (6) von den Gelenkstiften (4) abnehmen. Mit einem Abzieher, die Kegelstifte des Gelenks (4)
D D von dem GelenkgehaÈuse (7) abnehmen.
c d
Remover las tuercas ranuradas (6) de retencioÂn de las Utilizando un extractor, desconectar los pernos
ESP roÂtulas (4). ESP coÂnicos de la roÂtula de direccioÂn (4) del caÂrter de la
roÂtula (7).
Enlever les eÂcrous canneleÂs (6) de fixation des A l'aide d'un extracteur, deÂbrancher les pivots
F tourillons d'articulation (4). F coniques d'articulation de braquage (4) du boõÃtier
articulation (7).
Se il collegamento delle barre di sterzatura prevede il Scollegare dal pistone (2) le barre di sterzatura destra
ITA collare di sicurezza (13) rialzare la bordatura. ITA e sinistra (5).
Falls die Lenkstangen mit einem Sicherheitsbund (13) Vom Kolben (2) die rechte und linke Lenkstange (5)
D versehen sind, den Rand anheben. D abnehmen.
e f
Si la conexioÂn de las barras de direccioÂn preveÂ el Desconectar del pistoÂn (2) las barras de direccioÂn
ESP collarõÂn de seguridad (13) elevar los rebordes. ESP derecha e izquierda (5).
Si le raccordement des barres de braquage est eÂquipeÂ DeÂsassembler du piston (2) les barres de braquage
F de collet de seÂcuriteÂ (13) rehausser la bordure. F droite et gauche (5).
57
HOW TO REMOVE THE STEERING CYLINDER - RIMOZIONE CILINDRO DI STERZATURA - LENKZYLINDER ABMONTIEREN -
REMOCION CILINDRO DE DIRECCIOÂN - DEPOSE DU CYLINDRE DE BRAQUAGE
F1240407 F1240408
GB a GB b
Remove the securing screws (8) from the steering cylinder (9). Extract the cylinder (9) using a plastic hammer.
NOTE. For cylinder disassembly, refer to «HOW TO DISASSEM-
BLE THE STEERING CYLINDER».
7 15
5 9
11
1 10 2
15
4
6 GB c 8GB d
3
14 7
12
4
12
14
6 13
3
13
6
3
6
3 D1240041
GB e GB f
58
Asportare le viti (8) di fissaggio del cilindro di Estrarre il cilindro (9) utilizzando un mazzuolo in
ITA sterzatura (9). ITA materiale plastico.
NOTA. Per lo smontaggio del cilindro, vedere
«SMONTAGGIO CILINDRO DI STERZATURA».
Die Befestigungsschrauben (8) des Lenkzylinders (9) Den Zylinder (9) mit einem Gummihammer heraus-
D abnehmen. D schlagen.
BEMERKUNG. Um den Zylinder abzumontieren, siehe
«LENKZYLINDER ABMONTIEREN».
a b
Sacar los tornillos (8) que fijan el cilindro de direccioÂn Extraer el cilindro (9) utilizando un martillo de material
ESP (9). ESP plaÂstico.
NOTA. Para desmontar el cilindro, veÂase «DESMON-
TAJE CILINDRO DE DIRECCIO Â N».
Enlever les vis (8) de fixation du cylindre de braquage Extraire le cylindre (9) aÁ l'aide d'un maillet en matieÁre
F (9). F plastique.
NOTE. Pour deÂmonter le cylindre, voir «DEMONTAGE
DU CYLINDRE DE BRAQUAGE».
59
HOW TO INSTALL THE STEERING CYLINDER - INSTALLAZIONE CILINDRO DI STERZATURA - LENKZYLINDER INSTALLIEREN -
INSTALACION CILINDRO DE DIRECCIOÂN - INSTALLATION DU CYLINDRE DE BRAQUAGE
9 8
9
F1240409 F1240410
GB a GB b
Check that the O-rings (15) of the axle unit are in good condition; Lock the cylinder by cross- tightening the screws (8).
lubricate the seats of the seals (15) and fit the steering cylinder (9) Torque wrench setting: 116±128 Nm
into its seat.
13
F1240411 F1240412
GB c GB d
Apply Loctite 242 to the thread and connect the steering bars by Insert the pins (4) in the steering case (7) and lock into position
screwing the terminals onto the piston stem. using a torque wrench setting of 260±290 Nm.
Torque wrench setting: 240±270 Nm Find the position of the notching in relation to the hole of the cotter
NOTE. Versions with coupling require that the rim of the pins and tighten the nut (6) further.
articulation (13) is riveted onto the surfaces of the piston stem. CAUTION! Check that rubber guards (A) are intact.
10
6 3
F1240413 F1240401
GB e GB f
Insert the cotter pins (3) and bend the safety stems. Install the proximity (1) for checking piston centring - if applicable -
CAUTION! Use new cotter pins. and tighten the screws (10).
Torque wrench setting: 5±6 Nm
60
Controllare lo stato delle guarnizioni OR (15) del corpo Bloccare il cilindro con le viti (8) serrate con il metodo
ITA assale; lubrificare le sedi di tenuta delle guarnizioni ITA incrociato.
(15) e montare in sede il cilindro di sterzatura (9). Coppia di serraggio: 116v128 Nm
O-Ringe (15) des AchsenkoÈrpers kontrollieren; die Zylinder mit den Schrauben (8) blockieren; dabei die
D Sitze der Dichtungen (15) schmieren und den Lenk- D Schrauben entgegengesetzt und abwechselnd fest-
zylinder (9) in seinen Sitz montieren. schrauben.
Anzugsmoment 116v128 Nm
a b
Controlar el estado de las juntas OR (15) del cuerpo Bloquear el cilindro con los tornillos (8) apretados con
ESP del eje; lubricar los alojamientos de estanqueidad de ESP el meÂtodo cruzado.
las juntas (15) y montar en el alojamiento el cilindro de Par de torsioÂn: 116v128 Nm
direccioÂn (9).
ControÃler le bon eÂtat des garnitures OR (15) du corps Bloquer le cylindre aÁ l'aide des vis (8) serreÂes par le
F d'essieu, lubrifier les logements d'eÂtancheÂiteÂ des F biais du mode croiseÂ.
garnitures (15), puis monter le logement du cylindre Couple de serrage: 116v128 Nm
de braquage (9).
Spalmare la filettatura con Loctite 242 e collegare le Inserire nella scatola snodo (7) i perni (4) e bloccare la
ITA barre di sterzatura avvitando nello stelo del pistone i ITA posizione serrandoli con una coppia di 260v290 Nm.
terminali. Ricercare la posizione dell'intaglio rispetto al foro delle
Coppia di serraggio: 240v270 Nm copiglie serrando ulteriormente il dado (6).
NOTA. Per la versione a manicotto, ribadire il bordo dello snodo ATTENZIONE! Controllare l'integritaÁ delle protezioni in gomma (A).
(13) sui piani dello stelo del pistone.
Das Gewinde mit Loctite 242 schmieren und die In das GelenkgehaÈuse (7) die Stifte (4) einsetzen und
D Lenkstangen verbinden; dabei die EndstuÈcke auf D mit einem Anzugsmoment von 260v290 Nm fest-
den Kolbenschaft festschrauben. schrauben. Die Position des Schnitts zum Loch der
Anzugsmoment: 240v270 Nm Splinte suchen, und die Mutter (6) nochmals festziehen.
c BEMERKUNG. Bei der AusfuÈhrung mit Muffe, den Gelenkrand (13) d ACHTUNG! Kontrollieren ob die Gummiringe (A) in Ordnung sind.
an den KolbenschaftflaÈchen boÈrdeln.
Pasar por la rosca Loctite 242 y conectar las barras de Introducir en el caÂrter de la roÂtula (7) los pernos (4) y
ESP direccioÂn atornillando en el vaÂstago del pistoÂn los ESP bloquear la posicioÂn apretaÂndolos con un par de
terminales. 260v290 Nm.
Par de torsioÂn: 240v270 Nm Buscar la posicioÂn de la ranura con respecto al orificio de las
NOTA. Para la versioÂn de manguito, rebordear el borde de la roÂtula clavijas apretando auÂn la tuerca (6).
(13) en las superficies maÂs importantes del vaÂstago del pistoÂn. CUIDADO! Controlar la integridad de las protecciones de goma (A).
Enduire le filetage avec du Loctite 242 et brancher la Introduire dans le boõÃtier articulation (7) les tourillons
F barre de braquage en vissant les embouts dans la tige F (4), puis bloquer dans la position en serrant ceux-ci aÁ
du piston. un couple de 260v290 Nm.
Couple de serrage: 240v270 Nm Chercher la position de l'entaille par rapport au trou de la goupille
NOTE. Dans la version aÁ manchon, river le bord de l'articulation en serrant encore l'eÂcrou (6).
(13) sur les plans cleÂ de la tige du piston. ATTENTION! ControÃler le bon eÂtat des protections en caoutchouc (A).
Inserire le copiglie (3) e piegare i gambi di sicurezza. Se eÁ previsto, installare il sensore di prossimitaÁ (1) per
ITA ITA il controllo della centratura del pistone e serrare le viti
ATTENZIONE! Usare copiglie nuove.
(10).
Coppia di serraggio: 5v6 Nm
Die Splinte (3) einsetzen und die beiden Sicherheits- Wenn vorgesehen, den NaÈherungsschalter (1) zur
D stifte knicken. D Kontrolle der Kolbenzentrierung installieren und mit
ACHTUNG! Neue Splinte verwenden. den Schrauben (10) festschrauben.
Anzugsmoment: 5v6 Nm
e f
Introducir las clavijas (3) y doblar las patas de Si ha sido previsto, instalar el sensor de proximidad (1)
ESP seguridad. ESP para el control del centraje del pistoÂn y apretar los
CUIDADO! Usar clavijas nuevas. tornillos (10).
Par de torsioÂn: 5v6 Nm
Introduire les goupilles (3) et plier les tiges de seÂcuriteÂ. Si preÂvu, installer le capteur de proximiteÂ (1) de
F F controÃle de centrage piston et serrer les vis (10).
ATTENTION! Utiliser des goupilles neuves.
Couple de serrage: 5v6 Nm
61
1
T12
T12
F1240415 F1240416
bar GB a GB b
CAUTION. Eliminate the action of the negative brake, if fitted. Connect the sensor (1) to the inspection device according to either
Apply tools T12 to the hubs and lock them. diagram.
Using a level "B", check that tools are perfectly flat and parallel to
each other.
I max=0,80 A I max=0,80 A
NERO NERO
BLACK BLACK
CONNETTORE CONNETTORE
CONNECTOR CONNECTOR BATTERIA
2 BATTERY
2 BLU
1 3
BLU
-- 1 3
BLUE
--
4 BLUE 4
BATTERIA
BATTERY
MARRONE MARRONE
BROWN
+ BROWN
+
2A 2A
D1240029 D1240030
GB c GB d
Sensor connection card, STANDARD version. Sensor connection card, OPTIONAL version.
= =
C
F1240550 F1240418
GB e GB f
Centre the piston by slowly moving it first in one direction then in Inspect jut "C" on one side of the piston and note down the size for
the other and position it half way on the stroke, which is determined checking later adjustments.
by the switching on and off of the signal lamp of the inspection NOTE. If cylinders come without a sensor, the centring of the
device in the reversal stage. piston must be carried out on the basis of the maximum stroke.
62
ATTENZIONE! Se previsto, eliminare l'azione del Collegare il sensore (1) al dispositivo di controllo
ITA freno negativo. ITA secondo uno dei due schemi.
Applicare sui mozzi portaruota gli attrezzi T12 e
bloccarli.
Controllare con una livella "B" che gli attrezzi siano perfettamente
in piano e paralleli tra loro.
ACHTUNG! Wenn vorgesehen, Wirkung der Negativ- Sensor (1) mit der Kontrollvorrichtung nach einem der
D bremse beseitigen. D beiden PlaÈne verbinden.
An den Radhalternaben die T12 Werkzeuge anbrin-
gen und blockieren.
a Mit einer Libelle "B" kontrollieren, ob die Werkzeuge livelliert und
parallel liegen.
b
CUIDADO! Si ha sido previsto, eliminar la accioÂn el Conectar el sensor (1) al dispositivo de control seguÂn
ESP freno negativo ESP uno de los dos esquemas.
Aplicar en los cubos portarruedas las herramientas
T12 y bloquearlas.
Controlar utilizando un nivel "B" que las herramientas esteÂn
perfectamente niveladas y paralelas entre sõÂ.
ATTENTION! Si preÂvu, eÂliminer l'action du frein Connecter le capteur (1) au dispositif de controÃle aÁ
F neÂgatif. F l'aide de l'un des deux scheÂmas.
Appliquer sur les moyeux des roues les outils T12 puis
bloquer.
ControÃler aÁ l'aide d'un niveau "B" que les outils soient parfaitement
aÁ plat et paralleÁles entre-eux.
Scheda collegamento sensore versione STANDARD. Scheda collegamento sensore versione OPZIONALE.
ITA ITA
Verbindungskarte fuÈr Sensor STANDARD AusfuÈh- Verbindungskarte fuÈr Sensor OPTION AusfuÈhrung.
D rung. D
c d
Tarjeta de conexioÂn sensor versioÂn ESTAÂNDAR. Tarjeta de conexioÂn sensor versioÂn OPCIONAL.
ESP ESP
Carte de connexion du capteur version STANDARD. Carte de connexion du capteur version OPTIONNEL.
F F
Eseguire la centratura spostando lentamente il pistone Controllare la sporgenza "C" del pistone su un lato ed
ITA prima in un senso e poi nell'altro, posizionandolo a ITA annotare la misura per il controllo delle regolazioni
metaÁ della corsa determinata dalle accensioni e dallo successive.
spegnimento in fase di ritorno, della lampada di segnalazione del NOTA. Per i cilindri senza sensore, la centratura del pistone deve
dispositivo di controllo. essere eseguita in base alla corsa massima.
Die Zentrierung vornehmen, dabei den Kolben zuerst Den Vorsprung "C" des Kolbens an einer Seite
D leicht in die eine, dann in die andere Richtung drehen D kontrollieren und das Maû zur Kontrolle der nachfol-
und auf halbem Hubweg positionieren. Dieser halber genden Einstellungen notieren.
Weg liegt zwischen dem Ein- und Ausschalten der Kontrolleuchte BEMERKUNG. FuÈr Zylinder ohne Sensor, erfolgt die Kolbenzen-
e der Kontrollvorrichtung. f trierung aufgrund des maximalen Hubs.
Ejecutar el centraje desplazando lentamente el pistoÂn Controlar la parte saliente de "C" del pistoÂn en un lado
ESP primero en un sentido y despueÂ s en el otro, ESP y anotar la medida para el control de las regulaciones
posicionaÂndolo a mitad de la carrera determinada sucesivas.
por el encendido y el apagado en fase de retorno, de la laÂmpara de NOTA. Para los cilindros sin sensor, el centraje del pistoÂn tiene que
senÄalizacioÂn del dispositivo de control. ser ejecutado de acuerdo con la carrera maÂxima.
Effectuer le centrage en deÂplacËant lentement le piston ControÃler la saillie "C" d'un coÃteÂ du piston et prendre
F d'abord dans un sens, puis dans l'autre, en le placËant F note de la mesure pour controÃler les reÂgulations
aÁ mi-course qui est deÂtermineÂe par la lampe-teÂmoin suivantes.
qui s'allume et qui s'eÂteint pendant la phase de retour et qui se NOTE. Pour les cylindres sans capteur, le centrage du piston doit
trouve sur le dispositif de controÃle. eÃtre effectueÂ en se basant sur la course maximale.
63
5 14
T12
T12
F1240419 F1240420
GB a GB b
Without moving the piston, check front and rear size at the edge of If necessary, adjust convergency without moving the centring of
tools T12. the piston and adjust the length of the steering bars (5) or (14).
Max. difference: 0.6±0.7 mm NOTE. With a half turn of screw, the front size is reduced by about
NOTE. In order to check the rear size, rotate the bevel pinion and 3 mm, whereas the rear one is increased by about 3 mm.
check that tools T12 are flat.
12 16
F1240421 F1240422
GB c GB d
CONVERGENCY ADJUSTMENT ON UNITS WITH COLLAR Rotate the ball-and-socket joints (16) until convergency has been
Unloose the nuts on the collars (12). obtained.
Check that articulations move easily and lock the collars (12).
Torque wrench setting for nuts: 42±52 Nm
15
15 11
11
F1240423 F1240424
GB e GB f
CONVERGENCY ADJUSTMENT ON ALTERNATIVE VERSIONS Hold the articulations still and rotate the ball-and-socket joints (15).
Unloose the nuts (11) and screw them onto the ball-and-socket Once the convergency has been adjusted, lock the nuts (11).
joints (15). Torque wrench setting for nuts: 298±328 Nm
64
Senza spostare il pistone controllare la misura Se necessario, regolare la convergenza senza spo-
ITA anteriore e posteriore all'estremitaÁ degli attrezzi T12. ITA stare la centratura del pistone, regolando la lunghezza
Differenza max: 0,6v0,7 mm delle barre di sterzatura (5) o (14).
NOTA. Per controllare la misura posteriore, far ruotare il pignone NOTA. Mezzo giro di avvitamento restringe la misura anteriore di
conico e controllare planaritaÁ e parallelismo degli attrezzi T12. circa 3 mm ed allarga la posteriore di circa 3 mm.
Ohne den Kolben zu verstellen, das vordere und hintere Wenn noÈtig, die Konvergenz einstellen, ohne die
D Maû am EndstuÈck der Werkzeuge T12 kontrollieren. D Kolbenzentrierung zu verstellen; dazu die LaÈnge der
Max. Unterschied: 0,6v0,7 mm Lenkstangen (5) oder (14) einstellen.
BEMERKUNG. Um das hintere Maû zu kontrollieren, das Kegelrad BEMERKUNG. Eine halbe Umdrehung verringert das Vordermaû
a drehen und kontrollieren ob die Werkzeuge T12 eben und parallel b um ca. 3 mm und erweitert das hintere Maû um ca. 3 mm.
liegen.
Sin desplazar el pistoÂn, controlar la medida anterior y Si fuera necesario, regular la convergencia sin
ESP posterior en los extremos de las herramientas T12. ESP desplazar el centraje del pistoÂn, regulando la longitud
Diferencia maÂx.: 0,6v0,7 mm de las barras de direccioÂn (5) o (14).
NOTA. Para controlar la medida posterior, hacer girar el pinÄoÂn NOTA. Media vuelta de atornillado restringe la medida anterior en
coÂnico y controlar la planaridad y el paralelismo de las herramien- aproximadamente 3 mm y ensancha la posterior en aproximada-
tas T12. mente 3 mm.
Sans deÂplacer le piston, controÃler les mesures avant Si besoin, reÂgler la convergence sans deÂplacer le
F et arrieÁre de l'extreÂmiteÂ des outils T12. F centrage du piston, en reÂglant la longueur des barres
DiffeÂrence max.: 0,6v0,7 mm de braquage (5) ou (14).
NOTE. Pour controÃler la mesure arrieÁre, faire tourner le pignon NOTE. Un demi-tour de vis diminue la mesure avant d'environ 3
conique et controÃler l'uniformiteÂ et le paralleÂlisme des outils T12. mm et eÂlargit celle de derrieÁre d'environ 3 mm.
REGOLAZIONE CONVERGENZA PER VERSIONI Ruotare i perni sferici (16) fino ad ottenere la
ITA CON COLLARE ITA convergenza.
Allentare i dadi dei collari (12). Controllare la libertaÁ di movimento degli snodi e
bloccare i collari (12).
Coppia di serraggio dadi: 42v52 Nm
KONVERGENZ BEI DEN AUSFU È HRUNGEN MIT Die kugeligen Stifte (16) drehen, bis die Konvergenz
D BUND EINSTELLEN D erreicht worden ist.
Die Bundmuttern (12) lockern. Die freie Bewegung der Gelenke uÈberpruÈfen und mit
den Bunden (12) blockieren.
c d Anzugsmoment der Muttern: 42v52 Nm
REGULACIO Â N CONVERGENCIA PARA VERSIONES Girar los pernos esfeÂricos (16) hasta obtener la
ESP CON COLLARIÂN ESP convergencia.
Aflojar las tuercas de los collarines (12). Controlar la libertad de movimiento de las roÂtulas y
bloquear los collarines (12).
Par de torsioÂn de las tuercas: 42v52 Nm
REGLAGE DE CONVERGENCE DES VERSION A Tourner les tourillons spheÂriques (16) jusqu'aÁ obtenir
F COLLIER DE SERRAGE F la convergence.
Desserrer les eÂcrous des colliers de serrage (12). ControÃler le libre mouvement des articulations et
bloquer les colliers de serrage (12).
Couple de serrage des eÂcrous: 42v52 Nm
REGOLAZIONE CONVERGENZA PER VERSIONE Mantenendo fermi gli snodi, ruotare i perni sferici (15).
ITA ALTERNATIVA ITA A convergenza regolata, bloccare i dadi (11).
Allentare i dadi (11) ed avvitarli sui perni sferici (15). Coppia di serraggio dadi: 298v328 Nm
KONVERGENZ BEI DEN ALTERNATIVEN AUSFU È H- Die Gelenke festhalten und die kugeligen Stifte (15)
D RUNGEN EINSTELLEN D drehen.
Die Muttern (11) lockern und auf die kugeligen Stifte Wenn die Konvergenz eingestellt ist, die Muttern (11)
(15) festschrauben. blockieren.
e f Anzugsmoment der Muttern: 298v328 Nm
REGULACIO Â N CONVERGENCIA PARA VERSIO ÂN Manteniendo firmes las roÂtulas, girar los pernos
ESP ALTERNATIVA ESP esfeÂricos (15).
Aflojar las tuercas (11) y atornillarlas en los pernos Una vez regulada la convergencia, bloquear las
esfeÂricos (15). tuercas (11).
Par de torsioÂn de las tuercas: 298v328 Nm
REGLAGE DE LA CONVERGENCE EN VERSION Tout en maintenant fermement les articulations,

F ALTERNATIVE F tourner les tourillons spheÂriques (15).
Desserrer les eÂcrous (11) puis visser les tourillons Lorsque la convergence est reÂgleÂe, bloquer les eÂcrous
spheÂriques (15). (11).
Couple de serrage des eÂcrous: 298v328 Nm
65
Pos. 2 Pos. 4
Pos. 3 Pos. 1
34%%2).' #9,).$%2
STEERING CYLINDER
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CILINDRO STERZ O
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'" A '" B
!$*534).' 4(% 34%%2).' !.',% 0ERFORM ONE FULL STEERING OPERATION UNTIL THE ADJUSTED SCREW LEANS
./4% 0ERFORM THE SAME OPERATIONS ON BOTH SIDES SEE DIA AGAINST THE ARM STOP
GRAM
,OOSEN THE NUT OF ONE OF THE ADJUSTING SREWS ON CYLINDER SIDE
'" C '" D
0ERFORM ONE FULL STEERING OPERATION UNTIL THE ADJUSTED SCREW LEANS !S YOU HOLD THE ADJUSTED SCREW IN POSITION AGAINST THE ARM STOP
AGAINST THE ARM STOP ADJUST THE SCREW OPPOSITE ON NON CYLINDER SIDE UNTIL IT LEANS
AGAINST THE ARM STOP
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STOPS ALL AT THE SAME TIME
66
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67
HOW TO DISASSEMBLE THE STEERING CYLINDER - SMONTAGGIO CILINDRO DI STERZATURA - LENKZYLINDER ABMONTIEREN -
DESMONTAJE CILINDRO DE DIRECCION - DEMONTAGE DU CYLINDRE DE BRAQUAGE
2
3
F1240354 F1240355
GB a GB b
Remove the snap ring (1) from the cylinder head (2). With the help of a plastic hammer, push the head (2) inside the
cylinder (3).
NOTE. The head should line up with the edge of the cylinder.
5
3
2
F1240356 F1240357
GB c GB d
With the help of a drift, apply pressure to the stop ring (4) that is Hammer the piston (5) on the rear of the head (2) using a plastic
placed inside the cylinder (3) and extract the ring using a hammer.
screwdriver. Continue hammering until the head (2) is ejected from the cylinder
(3).
A F1240358
GB e GB f
Disassemble the cylinder unit (3) by extracting first the head (2), Remove all seals, anti-extrusion rings and scraper rings from head
then the piston (5). (2), cylinder (3) and piston (5).
CAUTION! Note down the assembly side of the piston (5). The NOTE. 1 - All seals must be replaced every time the unit is
bevelled part "A" of the piston is oriented towards the head (2). disassembled. 2 - Particular attention must be paid not to damage
the seats of both seals and piston slide.
68
Rimuovere l'anello elastico (1) di ritegno della testata (2). Con leggeri colpi di un mazzuolo in materiale plastico,
ITA ITA spingere la testata (2) verso l'interno del cilindro (3).
NOTA. Inserire la testata fino a filo del cilindro.
Kolbenring (1) vom Kopf (2) abnehmen. Mit einem Gummihammer den Kopf (2) leicht zum
D D Zylinder (3) hin schlagen.
BEMERKUNG. Den Kopf bis an den Zylinderrand
hinein schlagen.
a b
Remover el anillo elaÂstico (1) de retencioÂn de la culata (2). Con ligeros golpes de martillo de material plaÂstico,
ESP ESP empujar la culata (2) dentro del cilindro (3).
NOTA. Introducir la culata hasta que quede a ras del
cilindro.
Enlever l'anneau eÂlastique (1) de retenue de la Avec de leÂgers coups de maillet en matieÁre plastique,
F culasse (2). F pousser la culasse (2) aÁ l'inteÂrieur du cylindre (3).
NOTE. Introduire la culasse jusqu'au bord du cylindre.
Utilizzando un punteruolo, forzare l'anello di arresto Con un mazzuolo in materiale plastico, mandare in
ITA (4) interno al cilindro (3) ed estrarlo utilizzando un ITA battuta il pistone (5) a ridosso della testata (2).
cacciavite. Proseguire fino all'espulsione della testata (2) dal
cilindro (3).
Mit einem DuÈbel den Sprengring (4) in den Zylinder (3) Mit einem Gummihammer den Kolben (5) bis zum
D ausdruÈcken und mit einem Schraubenzieher heraus- D Anschlag des Kopfes (2) bringen.
nehmen. Weiter schlagen, bis der Kopf (2) aus dem Zylinder (3)
geschlagen worden ist.
c d
Utilizando un punzoÂn, forzar el anillo de tope (4) Con un martillo de material plaÂstico, mandar a tope el
ESP dentro del cilindro (3) y extraerlo utilizando un ESP pistoÂn (5) detraÂs de la culata (2).
destornillador. Continuar hasta la expulsioÂn de la culata (2) del
cilindro (3).
A l'aide d'un pointeau forcer l'anneau de buteÂe (4) aÁ A l'aide d'un maillet en matieÁre plastique, envoyer en
F l'inteÂrieur du cylindre (3), extraire ce dernier aÁ l'aide F buteÂe le piston (5) aÁ l'abri de la culasse (2).
d'un tournevis. Continuer jusqu'aÁ l'eÂjection de la culasse (2) hors du
cylindre (3).
Scomporre il gruppo cilindro (3) estraendo nell'ordine Rimuovere dalla testata (2), dal cilindro (3) e dal
ITA la testata (2) ed il pistone (5). ITA pistone (5) tutte le guarnizioni, gli anelli antiestrusione
ATTENZIONE! Annotare il senso di montaggio del e gli anelli raschiatori.
pistone che ha la parte smussata "A" orientata verso la testata (2). NOTA. 1 - Tutte le tenute devono essere sostituite ad ogni
smontaggio. 2 - Prestare molta attenzione per non rovinare le sedi
delle guarnizioni e dello scorrimento del pistone.
Das Zylinderaggregat (3) zerlegen; dazu der Reihen- Vom Kopf (2), vom Zylinder (3) und vom Kolben (5) alle
D folge nach den Kopf (2) und den Kolben (5) abnehmen. D Dichtungen, Halteringe und Abschaber wegnehmen.
ACHTUNG! Montagerichtung des Kolbens beachten: BEMERKUNG. 1 - Alle Dichtungen muÈssen jedesmal
das abgerundete Teil "A" muû zum Kopf (2) gerichtet sein. gewechselt werden, wenn der Zylinder zerlegt wird. 2 - Sehr
e f vorsichtig vorgehen, um die Dichtungs- und Kolbensitze nicht zu
beschaÈdigen.
Descomponer el grupo cilindro (3) extrayendo en su Remover de la culata (2) del cilindro (3) y del pistoÂn (5)
ESP orden la culata (2) y el pistoÂn 5. ESP todas las juntas, los anillos antiextrusioÂn y los anillos
ATENCION! Anotar el sentido de montaje del piston raspadores.
que tiena la parte descantillada "A" orientada hacia culata (2). NOTA. 1 - Todas las estanqueidades tienen que ser sustituidas a
cada desmontaje. 2 - Tener mucho cuidado a fin de no danÄar los
alojamientos de las juntas y del deslizamiento del pistoÂn.
DeÂcomposer le groupe cylindre (3) en extrayant dans Enlever de la culasse (2), du cylindre (3) et du piston
F l'ordre d'abord la culasse (2), puis le piston (5). F (5), toutes les garnitures, anneaux anti-extrusion et les
ATTENTION! Prendre note du sens de montage du anneaux racleurs.
piston, la partie arrondie "A" tourneÂe vers la culasse (2). NOTE. 1 - Toutes les eÂtancheÂiteÂs doivent eÃtre remplaceÂes aÁ
chaque deÂmontage. 2 - Faire treÁs attention aÁ ne pas abõÃmer les
logements des garnitures et de coulissement du piston.
69
HOW TO ASSEMBLE THE STEERING CYLINDER - ASSEMBLAGGIO CILINDRO DI STERZATURA - LENKZYLINDER MONTIEREN - MONTAJE
CILINDRO DE DIRECCION - ASSEMBLAGE DU CYLINDRE DE BRAQUAGE
6 7 8 8 7 6
D1240031 D1240032
GB a GB b
After applying grease, install the sealing ring (6) of the shaft, the After applying grease, install the sealing ring (6) of the shaft, the
anti-extrusion ring (7) and the scraper ring (8) inside the cylinder anti-extrusion ring (7) and the scraper ring (8) in the head (2).
(3). CAUTION! Thoroughly check that positioning of the anti-extrusion
CAUTION! Thoroughly check that positioning of the anti-extrusion (7) ring is correct.
ring (7) is correct.
9 11
13 10
12 5
D1240033 D1240034
GB c GB d
Fit the seal (9) onto the outside of the head (2). Prepare the piston (5) by fitting it with the guide ring (10), the
CAUTION! magnetic ring (11), the O-ring (12) and the seal (13).
1 - In order to facilitate assembly, apply grease to the outer surface CAUTION!
of the piston. 1 - In order to facilitate assembly, apply grease.
2 - Do not roll the seal (9) up. 2 - If a centring sensor is not fitted, then the magnetic ring (11)
should be replaced by another guide ring (10).
T18
5
5
3
F1240359 F1240360
GB e GB f
Apply tool T18 to the shaft on the opposite side of the head (2) and Push the piston (5) into the cylinder for 100 mm using a plastic
centre it on the cylinder (3) so that it fits into the piston (5). hammer.
NOTE. Apply a little grease to seals and cylinder.
70
Lubrificare con grasso ed installare nel cilindro (3) Lubrificare con grasso ed installare nella testata (2)
ITA l'anello di tenuta (6) dello stelo, l'anello antiestrusione ITA l'anello di tenuta (6) dello stelo, l'anello antiestrusione
(7) e l'anello raschiatore (8). (7) e l'anello raschiatore (8).
ATTENZIONE! Controllare attentamente il posizionamento dell'a- ATTENZIONE! Controllare attentamente il posizionamento dell'a-
nello antiestrusione (7). nello antiestrusione (7).
Mit Fett die Dichtung (6) des Schaftes, den Haltering Mit Fett die Dichtung (6) des Schaftes, den Haltering
D (7) und den Abschaber (8) schmieren und in den D (7) und den Abschaber (8) schmieren und in den Kopf
Zylinder (3) montieren. (2) montieren.
ACHTUNG! SorgfaÈltig die Position des Halterings (7) kontrollieren. ACHTUNG! SorgfaÈltig die Position des Halterings (7) kontrollieren.
a b
Lubricar con grasa e instalar en el cilindro (3) el Lubricar con grasa e instalar en la culata (2) el
ESP segmento de compresioÂn (6) del vaÂstago, el anillo ESP segmento de compresioÂn (6), el anillo antiextrusioÂn (7)
antiextrusioÂn (7) y el anillo raspador (8). y el anillo raspador (8).
CUIDADO! Controlar atentamente el posicionamiento del anillo CUIDADO! Controlar atentamente el posicionamiento del anillo
antiextrusioÂn (7). antiextrusioÂn (7).
Lubrifier avec du gras et installer dans le cylindre (3) la Lubrifier avec du gras et installer dans le cylindre (2) la
F bague d'eÂtancheÂiteÂ (6) de la tige, l'anneau anti- F bague d'eÂtancheÂiteÂ (6) de la tige, l'anneau anti-
extrusion (7) et l'anneau racleur (8). extrusion (7) et l'anneau racleur (8).
ATTENTION! ControÃler attentivement le positionnement de l'an- ATTENTION! ControÃler attentivement le positionnement de l'an-
neau anti-extrusion (7). neau anti-extrusion (7).
Montare all'esterno della testata (2) la guarnizione (9). Preparare il pistone (5) montando l'anello di guida (10),
ITA ITA l'anello magnetico (11), l'OR (12) e la guarnizione (13).
ATTENZIONE!
1 - Per facilitare il montaggio, lubrificare con grasso la ATTENZIONE! 1 - Per facilitare il montaggio, lubrificare con grasso.
superficie esterna del pistone. 2 - Se non eÁ previsto il sensore di centratura, l'anello magnetico
2 - Non arrotolare la guarnizione (9). (11) eÁ sostituito con un secondo anello di guida (10).
Auûen am Kopf (2) die Dichtung (9) montieren. Den Kolben (5) mit dem FuÈhrungsring (10), dem
D D magnetischen Ring (11), den O-Ring (12) und der
ACHTUNG!
1 - Um die Montage zu erleichtern, die aÈuûere Dichtung (13) vorbereiten.
KolbenflaÈche mit Fett schmieren. ACHTUNG! 1 - Um die Montage zu erleichtern, mit Fett schmieren.
c 2 - Die Dichtung (9) nicht wickeln. d 2 - Wenn kein Zentrierungssensor vorgesehen ist, ist der magne-
tische Ring (11) mit einem zweiten FuÈhrungsring (10) ersetzt.
Montar fuera de la culata (2) la junta (9). Preparar el pistoÂn (5) montando el anillo de guõÂa (10),
ESP ESP el anillo de imaÂn (11), el OR (12) y la junta (13).
CUIDADO!
1 - Para facilitar el montaje, lubricar con grasa la CUIDADO!1 - Para facilitar el montaje, lubricar con
superficie exterior del pistoÂn. grasa.
2 - No enrollar la junta (9). 2 - Si no ha sido previsto el sensor de centraje, el anillo de imaÂn
(11) es sustituido por un segundo anillo de guõÂa (10).
Monter aÁ l'exteÂrieur de la culasse (2) la garniture (9). PreÂparer le piston (5) en montant l'anneau de guidage
F F (10), l'anneau magneÂtique (11), la OR (12) et la
ATTENTION!
1 - Pour rendre plus aiseÂ le montage, lubrifier avec du garniture (13).
gras la surface externe du piston. ATTENTION! 1 - Pour rendre plus aiseÂ le montage, lubrifier avec du
2 - Ne pas enrouler les garnitures (9). gras. 2 - Si le capteur de centrage n'est pas preÂvu, l'anneau
magneÂtique (11) est remplaceÂ par un second anneau de guidage (10).
Applicare l'attrezzo T18 sullo stelo lato opposto Con un mazzuolo in materiale plastico, inserire il
ITA testata (2) e centrarlo nel cilindro (3) fino ad imboccare ITA pistone (5) nel cilindro per circa 100 mm.
il pistone (5).
NOTA. Lubrificare leggermente con grasso le guarnizioni ed il
cilindro.
Das Werkzeug T18 auf den Schaft an der dem Kopf (2) Mit einem Gummihammer, den Kolben (5) in den
D entgegengesetzten Seite anbringen und auf den D Zylinder 100 mm lang schlagen.
Zylinder (3) zentrieren, bis es auf dem Kolben (5) sitzt.
BEMERKUNG. Die Dichtungen und den Zylinder leicht mit Fett
e schmieren. f
Aplicar la herramienta T18 sobre el vastago lado Con un martillo de material plaÂstico, introducir el
ESP opuesto culata (2) y centrarlo en el cilindro (3) hasta ESP pistoÂn (5) en el cilindro unos 100 mm.
entrar en el piston. (5).
NOTA. Lubrificar ligermente con grasa las juntas y el cilindro.
Appliquer l'outil T18 sur la tige du coÃteÂ opposeÂ aÁ la A l'aide d'un maillet en matieÁre plastique, introduire le
F culasse (2) et centrer celui-ci dans le cylindre (3) F piston (5) d'environ 100 mm dans le cylindre.
jusqu'aÁ engager le piston (5).
NOTE. Lubrifier leÂgeÁrement les garnitures et le cylindre avec du
gras.
71
HOW TO ASSEMBLE THE STEERING CYLINDER - ASSEMBLAGGIO CILINDRO DI STERZATURA - LENKZYLINDER MONTIEREN -
MONTAJE CILINDRO DE DIRECCION - ASSEMBLAGE DU CYLINDRE DE BRAQUAGE
T18 2
T18
5
2 5
F1240361 F1240362
GB a GB b
Remove tool T18 and apply it to the opposite side of the piston (5). Apply grease to head (2) seals, fit the head onto the piston and
push it into the cylinder (3) using a plastic hammer.
NOTE. Insert the head as to line it up with the edge of the cylinder.
2
3
F1240363 F1240364
GB c GB d
Insert the stop ring (4) ensuring that it fits into the seat of the Apply pressure to the head using two screwdrivers or levers until
cylinder (3). the head is fastened onto the stop ring (4).
F1240354
GB e
Fit the snap ring (1) on the head (2).
CAUTION! Make sure that the snap ring (1) is securely fastened in
its seat.
If necessary, force it into its seat using a drift and a hammer.
72
Rimuovere l'attrezzo T18 ed applicarlo sul lato Lubrificare con grasso le guarnizioni della testata (2),
ITA opposto del pistone (5). ITA infilarla sul pistone e, con un mazzuolo in materiale
plastico, inserirla nel cilindro (3).
NOTA. Inserire la testata fino a filo del cilindro.
Werkzeug T18 abnehmen und an der anderen Die Dichtungen des Kopfes (2) mit Fett schmieren.
D Kolbenseite (5) anbringen. D Den Kopf auf den Kolben schieben und mit einem
Gummihammer in den Zylinder (3) schlagen.
BEMERKUNG. Den Kopf bis zum Zylinderrand hinein schlagen.
a b
Remover la herramienta T18 y aplicarla en el lado Lubricar con grasa las juntas de la culata (2),
ESP opuesto del pistoÂn (5). ESP introducirla en el pistoÂn y, utilizando un martillo de
material plaÂstico, introducirla en el cilindro (3).
NOTA. Introducir la culata hasta nivel del cilindro.
Enlever l'outil T18 et appliquer ce dernier sur le coÃteÂ Lubrifier avec du gras les garnitures de la culasse (2).
F opposeÂ du piston (5). F Enfiler celle-ci sur le piston, et aÁ l'aide d'un maillet en
matieÁre plastique, introduire dans le cylindre (3).
NOTE. Introduire la culasse jusqu'au bord du cylindre.
Inserire l'anello di arresto (4) assicurandosi che si Utilizzando due cacciaviti o leve, forzare la testata fino
ITA assesti nella sede del cilindro (3). ITA alla battuta sull'anello di arresto (4).
Den Haltering (4) einsetzen und kontrollieren, ob er Mit zwei Schraubenzieher oder Hebeln, den Kopf bis
D richtig im Sitz des Zylinders (3) sitzt. D zum Anschlag des Sprengrings (4) schieben.
c d
Introducir el anillo de tope (4) aseguraÂndose de que se Utilizando dos destornilladores o palancas, forzar la
ESP ajuste en el alojamiento del cilindro (3). ESP culata hasta el tope en el anillo de tope (4).
Introduire l'anneau de buteÂe (4) en s'assurant qu'il A l'aide de deux tournevis ou leviers, envoyer en buteÂe
F s'ajuste bien dans le logement du cylindre (3). F la teÃte sur l'anneau de buteÂe (4).
Montare l'anello elastico (1) di ritegno della testata (2).

ITA
ATTENZIONE! Assicurarsi che l'anello elastico (1) sia
impegnato a fondo nella sede.
Se necessario, forzarlo in sede con un punteruolo ed
un martello.
Den Kolbenring (1) des Kopfes (2) montieren.

D
ACHTUNG! Kontrollieren ob der Kolbenring (1) in
seinem Sitz richtig sitzt.
Wenn noÈtig, in seinen Sitz mit einem DuÈbel und einen
e Hammer schlagen.
Montar el anillo elaÂstico (1) de retencioÂn de la culata

ESP (2).
CUIDADO! Asegurarse de que el anillo elaÂstico (1)
estaÂ colocado a fondo en la sede.
Si fuera necesario, forzarlo en el alojamiento utilizan-
do un punzoÂn y un martillo.
Monter l'anneau eÂlastique (1) de retenue de la culasse

F (2).
ATTENTION! S'assurer que l'anneau eÂlastique (1) soit
engageÂ aÁ fond dans le logement.
Si besoin, forcer dans le logement aÁ l'aide d'un poincËon et d'un
marteau.
73
HOW TO REMOVE AND DISASSEMBLE THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - DIFFERENTIAL
ABMONTIEREN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL - DEPOSE ET DEMONTAGE DU GROUPE DIFFERENTIEL
REMOVING - RIMOZIONE - ABMONTIEREN - REMOCION - DEPOSE
1
F1240385 F1240478
GB a GB b
Remove the complete arms. Mark the position of the ring nuts (1). Remove the fittin screws (3)
For details, see «CHECKING WEAR AND REPLACING THE from the ring nuts (1).
BRAKING DISKS».
1 T13
F1240479 F1240480
GB c GB d
Uniformly heat the ring nuts (1) up to a temperature of 80ë C. Apply tool T13 and remove the ring nuts.
NOTE. Accurately clean the threaded portions on ring nuts of body
and cover.
4 5 6
5
4
F1240481 F1240482
GB e GB f
Remove the fittin screws (4) from the middle cover (5). Insert a screw-driver in the opposing slots then force and remove
the middle cover (5) and the complete differential unit (6).
NOTE. Support the pieces using a rod.
74
Rimuovere i bracci completi. Contrassegnare la posizione delle ghiere (1).
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA Rimuovere le viti (3) di ritegno delle ghiere (1).
SOSTITUZIONE DISCHI FRENO».
Die kompletten Arme abmontieren. Position der Nutmutter (1) markieren. Schrauben (3)
D Siehe «VERSCHLEISS KONTROLLIEREN UND D der Nutmutter (1) abschrauben.
BREMSSCHEIBEN AUSWECHSELN».
a b
Remover los brazos completos. Marcar la posicioÂn de las virolas (1).
ESP Para los detalles, veÂase «CONTROL DEL DESGASTE ESP Remover los tornillos (3) de retencioÂn de las virolas (1).
Y SUSTITUCION DE LOS DISCOS DEL FRENO».
DeÂposer les bras complets. Marquer la position des colliers de serrage (1). Enlever
F Pour de plus amples deÂ tails voir «CONTROLE F les vis (3) de fixation des colliers de serrage (1).
D'USURE ET SUBSTITUTION DES DISQUES DE
FREINAGE».
Scaldare le ghiere (1) in modo uniforme fino ad una Applicare l'attrezzo T13 ed asportare le ghiere.
ITA temperatura di circa 80ëC. ITA
NOTA. Pulire accuratamente le filettature delle ghiere
del corpo e del coperchio.
Nutmutter (1) gleichmaÈûig auf ca. 80ëC erhitzen. Werkzeug T13 anbringen und Nutmutter entfernen.
D D
BEMERKUNG. SorgfaÈltig das Gewinde der Nutmutter,
des KoÈrpers und des Deckels reinigen.
c d
Calentar las virolas (1) de manera uniforme hasta un Aplicar la herramienta T13 y sacar las virolas.
ESP temperatura de unos 80ëC. ESP
NOTA. limpiar con cuidado las roscas de las virolas
del cuerpo y de la tapa.
Chauffer les colliers de serrage (1) de facËon uniforme Appliquer l'outil T13 et enlever les anneaux de
F jusqu'aÁ une tempeÂrature d'environ 80ëC. F fixation.
NOTE. Nettoyer soigneusement le filetage des an-
neaux de fixation, du corps et du couvercle.
Asportare le viti (4) di ritegno del coperchio intermedio Forzare con un cacciavite introdotto nei vani contrap-
ITA (5). ITA posti e rimuovere il coperchio intermedio (5) ed il
gruppo differenziale completo (6).
NOTA. Sostenere i pezzi con un'asta.
Schrauben (4) des mittleren Deckels (5) abschrauben. Einen Schraubenzieher in die HohlraÈume stecken und
D D anheben, um den mittleren Deckel (5) und das
komplette Differentialaggregat (6) zu entfernen.
BEMERKUNG. Die Teile mit einem Stab halten.
e f
Sacar los tornillos (4) de retencioÂn de la tapa Forzar utilizando un destornillador introducido en los
ESP intermedia (5). ESP compartimentos contrapuestos y remover la tapa
intermedia (5) y el grupo diferencial completo (6).
NOTA. Sostener las piezas utilizando una varilla.
Enlever les vis (4) de fixation du couvercle intermeÂ- Forcer aÁ l'aide d'un tournevis, introduit dans les creux
F diaire (5). F interposeÂs, enlever le couvercle intermeÂdiaire (5) et le
groupe diffeÂrentiel complet (6).
NOTE. Soutenir les pieÁces avec une tige.
75
2 8 10
7
5 9
F1240483 F1240484
GB a GB b
If the bearings need replacing, extract the external thrust blocks of Remove the top plug (10).
the bearings (7) and (8) from middle cover (5) and central body (2).
NOTE. Accurately check the O-ring (9).
DISASSEMBLING - SMONTAGGIO - ZERLEGEN - DESMONTAJE - DESASSEMBLAGE
11
12 12
F1240485 F1240486
GB c GB d
Remove the fittin screws (11) from the crown (12). If the bearing need replacing, extract the bearing (7) and remove
the crown (12).
13
14
8
15
F1240487 F1240488
GB e GB f
Remove the shim washer (13) and the planetary gear (14). If the bearing need replacing, extract the bearing (8) from the
differential carrier (15).
76
Se si devono sostituire i cuscinetti, estrarre dal Rimuovere il tappo superiore (10).
ITA coperchio intermedio (5) e dal corpo centrale (2) le ITA
NOTA. Il tappo deve essere sostituito ad ogni
ralle esterne dei cuscinetti (7) e (8). rimozione.
NOTA. Controllare attentamente l'anello OR (9).
Wenn Lager ausgewechselt werden muÈssen, vom Oberer Stopfen (10) entfernen.
D mittleren Deckel (5) und vom zentralen KoÈrper (2) die D
aÈuûeren Scheiben der Lager (7) und (8) entfernen.
BEMERKUNG. O-Ring (9) sorgfaÈltig kontrollieren.
a b
Si hay que sustituir los cojinetes, extraer de la tapa Remover el tapoÂn superior (10).
ESP intermedia (5) y del cuerpo central (2) las ranguas ESP
exteriores (7) y (8) de los cojinetes.
NOTA. Controlar atentamente el anillo OR (9).
Si on doit remplacer les paliers, extraire du couvercle Enlever le bouchon supeÂrieur (10).
F intermeÂdiaire (5) et du corps central (2), les crapau- F
dines externes des paliers (7) et (8).
NOTE. ControÃler attentivement la garniture OR (9).
Rimuovere le viti (11) di ritegno della corona (12). Se si deve sostituire, estrarre il cuscinetto (7) e
ITA ITA rimuovere la corona (12).
Die Schrauben (11) des Kranzes (12) abschrauben. Falls das Lager ausgewechselt werden muû, Lager (7)
D D heraus nehmen und Kranz (12) entfernen.
c d
Remover los tornillos (11) de retencioÂn de la corona Si hay que sustituirlo, extraer el cojinete (7) y remover
ESP (12). ESP la corona (12).
Enlever les vis (11) de fixation de la couronne (12). Extraire le palier (7) et deÂposer la couronne (12) en cas
F F que le premier doit eÃtre remplaceÂ.
Rimuovere la rondella di rasamento (13) e l'ingranag- Se si deve sostituire, estrarre il cuscinetto (8) dalla
ITA gio planetario (14). ITA scatola differenziale (15).
Zwischenlegscheibe (13) und Planetenrad (14) entfer- Wenn das Lager ausgewechselt werden muû, Lager
D nen. D (8) aus dem DifferentialgehaÈuse (15) nehmen.
e f
Remover la arandela de espesor (13) y el engranaje Si hay que sustituirlo, extraer el cojinete (8) de la caja
ESP planetario (14). ESP del diferencial (15).
Enlever la rondelle de rasage (13) et l'engrenage Extraire le palier (8) du boõÃtier diffeÂrentiel (15) en cas
F planeÂtaire (14). F que le premier doit eÃtre remplaceÂ.
77
T14
18 18
16 17
F1240489 F1240490
GB a GB b
Remove the snap rings (16) from the two pins (17) of the planet Insert tool T14 between the planet wheel gears (18).
wheel gears (18).
T16B
T15
T16B
17
15 15
17
F1240491 F1240492
GB c GB d
Force tool T14 in-between the planet wheel gears (18) using two Place the differential carrier (15) under a press, position bush T15
pin-drivers. and insert gudgeon T16A. Press T16A pin to limit position.
CAUTION! Make sure that tool T14 is perfectly lined up with the
pins (17) when locked.
T16A
T15
15
F1240493 F1240491
GB e GB f
Remove gudgeon T16A and bush T15. Remove tool T14 together with the pin (17) of the planet wheel.
NOTE. In this condition the tool T14 contains pin (17).
78
Rimuovere gli anelli elastici (16) dai perni (17) degli Inserire tra gli ingranaggi satelliti (18) l'attrezzo T14.
ITA ingranaggi satelliti (18). ITA
Kolbenringe (16) von den Stiften (17) der PlantenraÈder Zwischen den PlanetenraÈdern (18) das Werkzeug T14
D (18) entfernen. D einsetzen.
a b
Remover los anillos elaÂsticos (16) de los dos pernos Introducir entre los engranajes sateÂlites (18) la
ESP (17) de los engranajes sateÂlites (18). ESP herramienta T14.
Enlever les anneaux eÂlastiques (16) des tourillons (17) Introduire entre les engrenages satellites (18) l'outil
F des engrenages satellites (18). F T14.
Operando con due cacciaspine, forzare l'attrezzo T14 Sistemare il corpo differenziale (15) sotto una pressa,
ITA tra gli ingranaggi satelliti (18). ITA posizionare la boccola T15 ed inserire lo spinotto
ATTENZIONE! Controllare attentamente che l'attrez- T16A. Pressare lo spinotto T16A fino a fondo corsa.
zo T14 rimanga allineato ai perni (17) quando eÁ bloccato.
Mit zwei DuÈbeln, das Werkzeug T14 zwischen den Das DifferentialgehaÈuse (15) unter eine Presse legen
D PlanetenraÈdern (18) fest einsetzen. D und die Buchse T15 positionieren; Bolzen T16A
ACHTUNG: SorgfaÈltig darauf achten, daû das blok- einsetzen. DruÈcken, bis der Bolzen T16A.
kierte Werkzeug T14 mit den Stiften (17) fluchtgerecht ist.
c d
Trabajando con dos extractores de clavijas, forzar la Colocar la caja del diferencial (15) debajo de una
ESP herramienta T14 entre los engranajes sateÂlite (18). ESP prensa; posicionar el casquillo T15 e introducir la
CUIDADO! Controlar atentamente que la herramienta cruceta T16A. Presionar la cruceta T16A.
T14 quede alineada con los pernos (17) cuando estaÂ bloqueada.
En oeuvrant avec deux chasse-goupilles, forcer l'outil Ajuster le boõÃtier diffeÂrentiel (15) sous la presse, placer
F T14 entre les engrenages satellites (18). F la bague T15 et introduire le goujon T16A.
ATTENTION! ControÃler attentivement si l'outil T14 Presser le goujon T16A.
reste aligneÂ aux tourillons (17) quand il est bloqueÂ.
Asportare lo spinotto T16A e la bussola T15. Rimuovere l'attrezzo T14 e con esso il perno (17) del
ITA ITA satellite.
NOTA. In questa condizione, il perno (17) eÁ contenuto
nell'attrezzo T14.
Bolzen T16A und die Buchse T15 abnehmen. Das Werkzeug T14 und damit den Stift (17) des
D D Planetenrades abnehmen.
BEMERKUNG. In diesem Zustand, ist der Stift (17) im
Werkzeug T14 enthalten.
e f
Sacar la cruceta T16A y el manguito T15. Remover la herramienta T14 y con ella el perno (17)
ESP ESP del sateÂlite.
NOTA. En esta condicioÂn el perno (17) se encuentra
en la herramienta T14.
Enlever le goujon T16A et la douille T15. Enlever l'outil T14 et, avec ce dernier, le tourillon (17)
F F du satellite.
NOTE. Dans cette condition le tourillon (17) se trouve
dans l'outil T14.
79
T14 18 14
13
15
18
F1240490 F1240494
GB a GB b
Leave the released planetary gear in position and again lock tool Remove tool T14 and remove the last two planet wheel gears (18),
T14. the 2nd differential unit gear (14) and the relative shim washer (13)
Repeat the operations for the extraction of the pin of the 2nd planet from the differential carrier.
wheel (17).
Repeat the operations for all other pins.
4
3 5 16
1
20
9 11
17
19
20
17 16
19
18
13
GB c GB d
14
7 13
15 10
12 18 8
2
19
17
20 19
16
17
20
6
16
3
1
GB e GB f
D1240036
80
Lasciando in posizione l'ingranaggio satellite che si eÁ Rimuovere l'attrezzo T14 ed asportare dal corpo
ITA liberato, bloccare nuovamente l'attrezzo T14. ITA differenziale gli ultimi due ingranaggi satelliti (18), il
Ripetere le operazioni di estrazione del perno del 2ë ingranaggio planetario (14) e la relativa rondella di
secondo perno satellite (17). rasamento (13).
Ripetere le operazioni per gli altri perni.
Das nun freie Planetenrad in seiner Position lassen Werkzeug T14 entfernen und vom DifferentialgehaÈuse
D und das Werkzeug T14 wieder blockieren. D die letzten beiden PlanetenraÈder (18), das 2. Differen-
Die VorgaÈnge fuÈr das Herausnehmen des Stiftes des tialrad (14) und die Zwischenlegscheibe (13) abneh-
2. Planetenrades (17) wiederholen. men.
a Die VorgaÈnge auch fuÈr die anderen Stifte wiederholen. b
Dejando en posicioÂn el engranaje sateÂlite que ha Remover la herramienta T14 y sacar de la caja del
ESP quedado libre, bloquear otra vez la herramienta T14. ESP diferencial los uÂltimos dos engranajes sateÂlite (18), el
Repetir las operaciones de extraccioÂn del perno del 2ë engranaje diferencial (14) y la arandela de espesor
segundo perno sateÂlite (17). correspondiente (13).
Repetir las operaciones con los demaÂs pernos.
En maintenant la position de l'engrenage satellite Enlever l'outil T14 et extraire du boõÃtier diffeÂrentiel les
F deÂgageÂ, bloquer de nouveau l'outil T14. F deux derniers engrenages satellites (18), le 2ë
ReÂpeÂter les opeÂrations d'extraction du tourillon du 2ë engrenage du diffeÂrentiel (14) et la relative rondelle
satellite (17). de rasage (13).
ReÂpeÂter les opeÂrations pour les autres tourillons.
81
HOW TO ASSEMBLE AND INSTALL THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE -
DIFFERENTIALAGGREGAT MONTIEREN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL
ASSEMBLING - ASSEMBLAGGIO - MONTIEREN - MONTAJE - MONTAGE
18
14
19
13
15 T16C
F1240494 F1240495
GB a GB b
Insert the shim washer (13) and the planetary gear (14) in the Position the shim washer (19) and the first planet wheel gear (18).
differential carrier (15). Hold them in position using bar T16C.
18 T14
T16A
19 15
T16C
T16C
F1240496 F1240497
GB c GB d
With the help of gudgeon T16A, position the second planet wheel Insert tool T14 between the two planetary gears (18). Line up the
gear (18) and the relative shim washer (19). entire unit by pushing bar T16C all the way down until gudgeon
T16A is ejected.
T14 20 17
18 18
F1240490 F1240498
GB e GB f
Lock tool T14 behind the planet wheel gears (18). Fit the snap rings (20) onto the pins (17).
After locking, remove bar T16C.
82
Inserire nel corpo differenziale (15), la rondella di Posizionare la rondella di rasamento (19), il primo
ITA rasamento (13) e l'ingranaggio planetario (14). ITA ingranaggio satellite (18).
Tenerli in posizione con la barra T16C.
Das DifferentialgehaÈuse (15), die Zwischenlegscheibe Die Zwischenlegscheibe (19) und das erste Planeten-
D (13) und das Planetenrad (14) einsetzen. D rad (18) positionieren.
Mit dem Stab T16C diese in ihrer Position halten.
a b
Introducir en la caja del diferencial (15) la arandela de Posicionar la arandela de espesor (19), el primer
ESP espesor (13) y el engranaje planetario (14). ESP engranaje sateÂlite (18).
Mantenerlos en posicioÂn por medio de la barra T16C.
Introduire, dans le boõÃtier du diffeÂrentiel (15), la Placer la rondelle de rasage (19) et le premier
F rondelle de rasage (13) et l'engrenage planeÂtaire (14). F engrenage satellite (18).
Maintenir ceux-ci en place aÁ l'aide de la barre T16C.
Utilizzando lo spinotto T16A, posizionare il secondo Inserire tra i due ingranaggi satelliti (18) l'attrezzo T14.
ITA ingranaggio satellite (18) e la relativa rondella di ITA Allineare tutto il gruppo inserendo a fondo la barra
rasamento (19). T16C fino ad espellere lo spinotto T16A.
Mit dem Bolzen T16A das zweite Planetenrad (18) und Zwischen den beiden PlanetenraÈder (18) das Werk-
D die entsprechende Zwischenlegscheibe (19) positio- D zeug T14 einsetzen.
nieren. Das gesamte Aggregat fluchten; dazu den Stab T16C
ganz einschieben bis die Bolzen T16A herausgestoûen worden
c d sind.
Utilizando la cruceta T16A, posicionar el segundo Introducir entre los dos engranajes sateÂlite (18) la
ESP engranaje sateÂlite (18) y la arandela de espesor ESP herramienta T14.
correspondiente (19). Alinear todo el grupo introduciendo a fondo la barra
T16C hasta expulsar la cruceta T16A.
A l'aide du goujon T16A placer le second engrenage Introduire entre les deux engrenages satellites (18)
F satellite (18) et sa relative rondelle de rasage (19). F l'outil T14.
Aligner tout le groupe en inseÂrant aÁ fond la barre T16C
jusqu'aÁ eÂjecter le goujon T16A.
Bloccare l'attrezzo T14 a ridosso degli ingranaggi Montare sui perni (17) gli anelli elastici (20).
ITA satelliti (18). ITA
Dopo il bloccaggio, rimuovere la barra T16C.
Werkzeug T14 an den PlanetenraÈdern (18) anliegend, Auf die Stifte (17) die Kolbenringe (20) montieren.
D blockieren. D
Danach Stab T16C entfernen.
e f
Bloquear la herramienta T14 detraÂs de los engranajes Montar en los pernos (17) los anillos elaÂsticos (20).
ESP sateÂlite (18). ESP
DespueÂs de bloquearlos, remover la barra T16C.
Bloquer l'outil T14 aÁ l'abri des engrenages satellites Monter sur les tourillons (17) les anneaux eÂlastiques
F (18). F (20).
ApreÁs avoir bloqueÂ, enlever la barre T16C.
83
T16B 17
17
T15
T15
T16B
17
F1240499 F1240500
GB a GB b
Place the differential carrier (15) under the press, position bush Put gudgeon T16B on top of the planet wheel pin (17).
T15 and insert the planet wheel pin (17).
T16B
T15
T16B
16
17
17
15
F1240492 F1240502
GB c GB d
Press T16B pin all the way down. Remove gudgeon T16B, bush T15 and fit the snap ring (16) on the
pin (17).
CAUTION! Make sure that the snap ring centres the seat and that it
rests on the surface of the differential carrier.
Repeat the operations on the other planet wheel pin or planet
wheel axle.
13
14
12
15
F1240487 F1240504
GB e GB f
Position the second planetary gear (14) in the differential carrier Position the shim washer (13) on the crown (12).
(15). NOTE. In order to hold the shim washer (13) in position, apply
grease to it.
84
Posizionare sotto la pressa il corpo differenziale (15), Sovrapporre al perno satellite (17) lo spinotto T16B.
ITA sistemare la boccola T15 ed inserire il perno satellite ITA
(17).
Unter der Presse das DifferentialgehaÈuse (15) positio- È ber den Planetenradstift (17) den Bolzen T16B
U
D nieren, die Buchse T15 anbringen und den Planeten- D anbringen.
radstift (17) einsetzen.
a b
Posicionar debajo de la prensa la caja del diferencial Superponer al perno sateÂlite (17) la cruceta T16B.
ESP (15), colocar el casquillo T15 e introducir el engranaje ESP
sateÂlite (17).
Placer sous la presse le boõÃtier diffeÂrentiel (15), ajuster Juxtaposer sur le tourillon satellite (17) le goujon
F la bague T15 et introduire le tourillon satellite (17). F T16B.
Pressare lo spinotto T16B a fondo. Rimuovere lo spinotto T16B, la boccola T15 e montare
ITA ITA sul perno (17) l'anello elastico (16).
ATTENZIONE! Assicurarsi che l'anello elastico centri
la sede e che appoggi sul piano del corpo differenziale.
Ripetere le operazioni per l'altro perno satellite e per l'altro asse
satelliti.
Den Stift T16B fest hinein druÈcken. Bolzen T16B, Buchse T15 entfernen und auf den Stift
D D (17) den Kolbenring (16) montieren.
ACHTUNG! Der Kolbenring muû im Sitz zentriert sein
und an der FlaÈche des DifferentialgehaÈuses anliegen.
c d Dieselben VorgaÈnge fuÈr den anderen Planetenradstift und die
andere Planetenradachse wiederholen.
Apretar la cruceta T16B a hondo. Remover la cruceta T16B, el casquillo T15 y montar
ESP ESP en el perno (17) el anillo elaÂstico (16).
CUIDADO! Asegurarse de que el anillo elaÂstico esteÂ
centrado en el alojamiento y que esteÂ apoyado en la superficie de
la caja del diferencial. Repetir las operaciones en el otro perno
sateÂlite y en el otro eje sateÂlite.
Presser aÁ fond sur l'axe T16B. Enlever le goujon T16B de la douille T15 puis monter
F F sur le tourillon (17) l'anneau eÂlastique (16).
ATTENTION! S'assurer que l'anneau eÂlastique est
bien centreÂ dans son logement et qu'il repose sur le plan du boõÃtier
diffeÂrentiel. ReÂpeÂter ces meÃmes opeÂrations pour l'autre tourillon
satellite et pour l'autre axe satellites.
Posizionare il secondo ingranaggio planetario (14) nel Posizionare la rondella di rasamento (13) sulla corona
ITA corpo differenziale (15). ITA (12).
NOTA. Per mantenere la posizione, spalmare la
rondella di rasamento (13) con grasso.
Das zweite Planetenrad (14) im DifferentialkoÈrper (15) Zwischenlegscheibe (13) auf den Kranz (12) positio-
D positionieren. D nieren.
BEMERKUNG. Um die Position zu sichern, die
Zwischenlegscheibe (13) mit Fett einschmieren.
e f
Posicionar el segundo engranaje planetario (14) en el Posicionar la arandela de espesor (13) en la corona
ESP cuerpo del diferencial (15). ESP (12).
NOTA. Para mantener la posicioÂn, pasar grasa en la
arandela de espesor (13).
Placer le second engrenage planeÂtaire (14) dans le Placer la rondelle de rasage (13) sur la couronne (12).
F corps diffeÂrentiel (15). F
NOTE. Pour maintenir cette position, enduire la
rondelle de rasage (13) avec du gras.
85
11 12 T17 8
T17 7
15
F1240505 F1240506
GB a GB b
Position the crown (12) on the differential carrier (15) and lock it Install the bearings (7) and (8) using tool T17.
with screws (11) applied with Loctite 242.
Torque wrench setting for screws: 128±142 Nm
NOTE. Secure the screws using the cross-tightening method.
F1240507
GB c
If the bearings are replaced, insert the external thrust blocks in the
middle cover (5) and in the central body (2).
INSTALLING - INSTALLAZIONE - INSTALLIEREN - INSTALACION - INSTALLATION
1 2 9 4
5 5
4
4
F1240482 F1240852
GB e GB f
Position the differential unit (6) in the central body (2) with the help Lock the middle cover (5) with screws (4).
of a bar and fit the middle cover (5). Torque wrench setting for screw: 23.8±26.2 Nm
NOTE. Thoroughly check the state of the O-ring (9) and make sure
that the cover is fitted with the oil discharge in the lower position.
86
Posizionare la corona (12) sul corpo differenziale (15) Utilizzando l'attrezzo T17, montare i cuscinetti (7) e
ITA e bloccarla con le viti (11) spalmate con Loctite 242. ITA (8).
Coppia di serraggio viti: 128v142 Nm
NOTA. Serrare le viti con il metodo del serraggio incrociato.
Den Kranz (12) auf den DifferentialkoÈrper (15) positio- Mit dem Werkzeug T17 die Lager (7) und (8)
D nieren und mit den Schrauben (11) blockieren. D montieren.
Anzugsmoment der Schrauben: 128v142 Nm
BEMERKUNG. Die Schrauben abwechselnd und entgegengesetzt
a festschrauben. b
Posicionar la corona (12) en el cuerpo del diferencial Utilizando la herramienta T17, montar los cojinetes (7)
ESP (15) y bloquearla con los tornillos (11) pasarles Loctite ESP y (8).
242.
Par de torsioÂn: 128v142 Nm
NOTA. Apretar los tornillos con el meÂtodo de torsioÂn cruzado.
Placer la couronne (12) sur le corps du diffeÂrentiel (15) A l'aide de l'outil T17 monter les paliers (7) et (8).
F puis bloquer avec les vis (11) enduites avec Loctite F
242.
Couple de serrage des vis: 128v142 Nm.
NOTE. Serrer les vis par le biais du mode de serrage croiseÂ.
Se vengono sostituiti i cuscinetti, inserire nel coper-

ITA chio intermedio (5) e nel corpo centrale (2) le ralle
esterne.
Falls die Lager ausgewechselt werden sollen, in den

D mittleren Deckel (5) und in den zentralen KoÈrper (2) die
aÈuûeren Scheiben einsetzen.
c
Si se sustituyen los cojinetes, introducir en la tapa
ESP intermedia (5) y en el cuerpo central (2) las ranguas
exteriores.
Si les paliers doivent eÃtre remplaceÂs, introduire dans

F le couvercle intermeÂdiaire (5) et, dans le corps central
(2), les crapaudines externes.
Utilizzando una barra, posizionare il gruppo differen- Bloccare il coperchio intermedio (5) con le viti (4).
ITA ziale (6) nel corpo centrale (2) e montare il coperchio ITA Coppia di serraggio viti: 23,8v26,2 Nm
intermedio (5).
NOTA. Controllare attentamente la condizione dell'anello OR (9) e
che il coperchio venga montato con lo scarico olio nella posizione
inferiore.
Mit einem Stab das Differentialaggregat (6) in den Mit den Schrauben (4) blockieren den mittleren Deckel
D zentralen KoÈrper (2) positionieren und den mittleren D (5).
Deckel (5) montieren. Anzugsmoment der Schrauben: 23,8v26,2 Nm
BEMERKUNG. SorgfaÈltig den Zustand des O-Ringes (9) kontroll-
e ieren und sicherstellen, daû der Deckel mit dem O È lablaûstopfen f
nach unten gerichtet montiert wird.
Utilizando una barra, posicionar el grupo diferencial Bloqueare la tapa intermedia (5) con los tornillos (4).
ESP (6) en el cuerpo central (2) y montar la tapa intermedia ESP Par de torsioÂn tornillos: 23,8v26,2 Nm
(5).
NOTA. Controlar atentamente las condicioÁnes del segmento OR (9)
y que la tapa venga montada con el descarge aceite en la posicioÁn
inferior.
A l'aide d'une barre, placer le groupe diffeÂrentiel (6) Bloquer le couvercle intermeÂdiaire (5) dernier avec les
F dans le corps central (2) et monter le couvercle F vis (4).
intermeÂdiaire (5). Couple de serrage des vis: 23,8v26,2 Nm
NOTE. ControÃler attentivement les conditions de l'anneau torique
(9) te que le couvercle soit monteÂ avec le bouchon de vidange pour
l'huile dans la position infeÂrieure.
87
T13 T19
F1240509 F1240510
GB a GB b
NOTE. If the ring nuts (1) are removed, spread them with Loctite Pre-set the bearings by means of the ring nut situated on the
242. opposite side of the crown, so as to increase pinion torque up to
Tighten ring nuts on the crown side until clearance between pinion 140v210 Ncm.
and crown is zero, then lock the crown; go back 1/4v1/2 turn. CAUTION! If bearings are not new, check the static torque; if
bearings are new, check the continuous torque.
12 A A
F1240511 F1240512
GB c GB d
Introduce a comparator with rotary key "A" through the top plug Manually move the crown (12) in both directions in order to check
hole (10). Position the comparator on the centre of one of the teeth the existing backlash between the pinion and the crown.
of the crown (12), pre-set it to 1mm and reset it.
RATIO - RAPPORTO CLEARANCE - GIOCO - SPIEL

VERHAÈ LTNIS JUEGO - JEU
RAPORTE - RAPPORT MIN. MAX.
9v34 0,18 0,23
T13 9v35 0,13 0,18
11v31 0,20 0,28
11v35 0,13 0,18
12v35 0,13 0,18
12v41 0,15 0,20
14v32 0,18 0,23
14v36 0,15 0,20
14v41 0,15 0,20
15v32 0,18 0,23
F1240509
15v47 0,13 0,18
Difference between MIN and MAX clearance for whole circumference should
GB e not exceed 0.09 mm. GB f
La differenza tra gioco MIN e MAX rilevata sull'intera circonferenza non deve
superare il valore di 0,09 mm.
Adjust the backlash between the pinion and the crown by Der Unterschied zwischen dem MIN e MAX Spiel der gesamten Kreislinie darf
unloosing one of the ring nuts (1) and tightening the opposite to den Wert von 0,09 mm nicht uÈberschreiten.
compensate. La diferencia entre el juego Min y Max determinada sobre la entera
Normal backlash: see table. circonferencia no debe de superar el valor de 0,09 mm.
La diffeÂrence de jeu entre MIN et MAX releveÂe sur toute la circonfeÂrence ne
doit pas aller au-delaÁ de la valeur de 0,09 mm.
88
NOTA. Se le ghiere (1) vengono rimosse, spalmarle Precaricare i cuscinetti tramite la ghiera lato opposto
ITA con Loctite 242. ITA corona per incrementare la coppia di rotazione
Serrare le ghiere dal lato corona fino ad azzerare i pignone fino a 140v210 Ncm.
giochi tra pignone e corona e bloccarla; ritornare indietro di circa ATTENZIONE! Con cuscinetti usati, controllare la coppia di spunto;
1/4v1/2 giro. con cuscinetti nuovi, controllare la coppia di rotazione continua.
BEMERKUNG. Wenn die Nutmuttern (1) ausgewech- Lager durch die Nutmutter an der dem Kranz ent-
D selt werden, diese mit Loctite 242 schmieren. D gegengesetzten Seite vorladen, um das Gegenmo-
Nutmuttern an der Kranzseite fest ziehen bis kein ment des Rades auf 140v210 Ncm zu bringen.
Spiel mehr zwischen Rad und Kranz uÈbrig bleibt ; danach um 1/ ACHTUNG! Bei verbrauchten Lagern, das Anlaufdrehmoment kontroll-
a 4v1/2 Umdrehung wieder aufschrauben. b ieren; bei neuen Lagern, das kontinuierliche Drehmoment kontrollieren.
NOTA. Si se remueven las virolas (1) pasarles Loctite Precargar los cojinetes atraves la virola lado opuesto
ESP 242. ESP corona para incrementar el par de rotacion pinon
Apretar las virolas del lado corona hasta acerar los hasta 140v210 Ncm.
juegos entre el pinon y la corona y bloquearla, volver atras de 1/ CUIDADO! Con cojinetes usados, controlar el par de inicio, con
4v1/2 giro approx. cojinetes nuevos, controlar el par de rotacioÂn continua.
NOTE. Si les anneaux (1) sont enleveÂs, les enduire PreÂcharger les paliers au moyen d'anneaux de fixation
F avec du Loctite 242. F du coÃteÂ opposeÂ de la couronne pour augmenter le
Serrer les anneaux de fixation du coÃteÂ couronne couple de rotation pignon jusqu'aÁ 140v210 Ncm.
jusqu'aÁ mettre aÁ zeÂro les jeux entre pignon et couronne et bloquer: ATTENTION! Avec les paliers useÂs, controÃler le couple de pointe;
revenir en arrieÁre d'environ 1/4v1/2 tour. avec les paliers neufs, controÃler le couple de rotation continu.
Posizionare, attraverso il foro per il tappo superiore Muovere manualmente nei due sensi la corona (12)
ITA (10), un comparatore a tasto orientabile "A". ITA per controllare il gioco esistente tra pignone e corona.
Posizionarlo sul centro di un dente della corona (12),
precaricarlo di circa 1 mm ed azzerarlo.
Durch das Loch des oberen Stopfens (10) eine Den Kranz (12) von Hand in beide Richtungen
D schwenkbare Meûuhr "A" in der Mitte eine Kranzzah- D bewegen und das Spiel zwischen Rad und Kranz
nes (12) anbringen. Die Meûuhr auf 1 mm vorladen pruÈfen.
und auf Null stellen.
c d
Posicionar, a traveÂs del orificio para el tapoÂn superior Mover manualmente en los dos sentidos la corona (12)
ESP (10), un comparador de tecla orientable "A". ESP para controlar el juego que hay entre el pinÄoÂn y la
Posicionarlo en el centro de un diente de la corona corona.
(12), precargarlo de aproximadamente 1 mm y ponerlo a cero.
Placer, par le trou du bouchon supeÂrieur (10), un DeÂplacer la couronne (12) manuellement dans les
F comparateur aÁ touche orientable "A". F deux sens pour controÃler le jeu existant entre pignon
Placer ce dernier au centre d'une dent de la couronne et couronne.
(12), preÂcharger d'environ 1 mm, puis le mettre aÁ zeÂro.
Regolare il gioco tra pignone e corona allentando una

ITA ghiera (1) e serrando la ghiera opposta in egual
misura.
Gioco normale: vedere tabella.
Das Spiel zwischen Rad und Kranz einstellen; dazu

D eine Nutmutter (1) lockern und die entgegengesetzte
Nutmutter auf dieselbe Weise zuschrauben.
Normales Spiel: siehe Tabelle.
e
Regular el juego entre el pinÄoÂn y la corona aflojando
ESP una virola (1) y apretando la virola opuesta en la
misma medida.
Juego normal: veÂase la tabla.
ReÂgler le jeu entre pignon et couronne en desserrant

F un collier de serrage (1) puis en serrant le collier de
serrage opposeÂ avec la meÃme mesure de jeu.
Jeu normal: voir tableau.
89
10
3 3
F1240513 F1240385
GB a GB b
Apply Loctite 242 to the screws (3), fit them into one of the two Re-install the complete arms.
holes and tighten. For details, see «CHECKING WEAR AND REPLACING THE
Torque wrench setting: 23.8±26.2 Nm BRAKING DISKS».
Fit the top plug (10) after applying repositionable jointing
compound for seals to the rims.
90
Spalmare le viti (3) con Loctite 242 ed avvitarle in uno Rimontare i bracci completi.
ITA dei due fori predisposti. ITA Per i dettagli, vedere «CONTROLLO USURA E
Coppia di serraggio: 23,8v26,2 Nm SOSTITUZIONE DISCHI FRENO».
Montare il tappo superiore (10) dopo aver spalmato i bordi con
mastice per guarnizioni riposizionabile.
Die Schrauben (3) mit Loctite 242 schmieren und in Die beiden kompletten Arme montieren.
D eines der beiden vorgesehenen LoÈcher schrauben. D Siehe «VERSCHLEISS KONTROLLIEREN UND
Anzugsmoment: 23,8v26,2 Nm BREMSSCHEIBEN AUSWECHSELN».
Die RaÈnder des oberen Stopfens (10) mit Klebstoff fuÈr verstellbare
a Dichtungen schmieren und den Stopfen montieren. b
Pasar Loctite 242 en los tornillos (3) y atornillarlos en Volver a montar los brazos completos.
ESP uno de los dos orificios predispuestos. ESP Para los detalles, veÂase «CONTROL DEL DESGASTE
Par de torsioÂn: 23,8v26,2 Nm Y SUSTITUCION DE LOS DISCOS DEL FRENO».
Montar el tapoÂn superior (10) despueÂs de repasar los bordes con
pasta para juntas reposicionable.
Enduire les vis (3) avec du Loctite 242, puis visser Remonter les bras complets.
F celles-ci dans l'un des deux trous preÂdisposeÂs. F Pour de plus amples deÂtails, voir «CONTROLE
Couple de serrage: 23,8v26,2 Nm USURE ET SUBSTITUTION DES DISQUES DE
Monter le bouchon supeÂrieur (10) apreÁs avoir enduit les bords avec FREINAGE».
mastic pour garnitures aÁ remettre en place.
91
HOW TO REMOVE THE BEVEL PINION - RIMOZIONE PIGNONE CONICO - KEGELRAD ABMONTIEREN -
REMOCION PINÄON CONICO - DEPOSE DU PIGNON CONIQUE
F1240385 F1240514
GB a GB b
Remove the complete arms and the differential unit. If disassembly is awkward, heat the check nut (1) of the flange (2) at
For details, see «CHECKING WEAR AND REPLACING THE 80ëC.
BRAKING DISKS» and «REMOVING THE DIFFERENTIAL UNIT». NOTE. Heating is meant to unloose the setting of Loctite on the nut
(1).
T20A
(T20B)
3 2
F1240515 F1240516
GB c GB d
Position tool T20A (or T20B), so as to avoid pinion rotation. Remove the flange (2) complete with guard (4) by means of a
Unloose and remove the nut (1); also remove the O-ring (3). puller.
F1240517 F1240518
GB e GB f
Remove the swinging support (5). Remove the sealing ring (6).
92
Rimuovere i bracci completi ed il differenziale. Se lo smontaggio risulta faticoso, scaldare a circa
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA 80ëC il dado (1) di ritegno della flangia (2).
SOSTITUZIONE DISCHI FRENO» e «RIMOZIONE NOTA. Il riscaldamento ha lo scopo di allentare la
GRUPPO DIFFERENZIALE». presa del Loctite di bloccaggio del dado (1).
Komplette Arme und Differential abnehmen. Wenn das Abmontieren schwierig ist, die Mutter (1)
D Siehe «VERSCHLEISS KONTROLLIEREN UND D zur Halterung des Flansches (2) auf ca. 80ëC erwaÈr-
BREMSSCHEIBEN AUSWECHSELN» und «DIFFE- men.
RENTIALAGGREGAT ABMONTIEREN». BEMERKUNG. Durch das Erhitzen wird das Fett aufgeweicht, das
a b die Mutter (1) blockiert.
Remover los brazos completos y el diferencial. Si el desmontaje resulta difõÂcil, calentar a unos 80ëC la
ESP Para los detalles veÂase «CONTROL DESGASTE Y ESP tuerca (1) de retencioÂn de la brida (2).
SUSTITUCION DE LOS DISCOS DEL FRENO» y NOTA. El calentamiento tiene la finalidad de aflojar la
«REMOCION GRUPO DIFERENCIAL». adhesioÂn del Loctite de bloqueo de la tuerca (1).
Enlever compleÁtement les bras complets et le diffeÂ- Si deÂmonter est difficile, chauffer l'eÂcrou (1) de fixation
F rentiel. F de la flasque (2) aÁ environ 80ëC.
Pour de plus amples deÂtails, voir «CONTROLE NOTE. Le chauffage aÁ pour objet de ralentir la prise du
USURE ET SUBSTITUTION DES DISQUES DE FREINAGE» et Loctite de blocage de l'eÂcrou (1).
«DEPOSE DU GROUPE DIFFERENTIEL».
Applicare l'attrezzo T20A (oppure T20B) ed impe- Utilizzando un estrattore, rimuovere la flangia (2)
ITA gnarlo in modo da evitare la rotazione del pignone. ITA completa della protezione (4).
Allentare ed asportare il dado (1); asportare anche
l'anello OR (3).
Werkzeug T20A (T20B) so anbringen, daû das Rad Mit einem Abzieher, Flansch (2) samt Schutzteil (4)
D nicht mehr drehen kann. D abnehmen.
Mutter (1) lockern und abschrauben; O-Ring (3)
ebenfalls abnehmen.
c d
Aplicar la herramienta T20A (T20B) y bloquearla a fin Utilizando un extractor, remover la brida (2) completa
ESP de evitar la rotacioÂn del pinÄoÂn. ESP con la proteccioÂn (4).
Aflojar y sacar la tuerca (1); sacar tambieÂn el anillo OR
(3).
Appliquer l'outil T20A (ou T20B) engager ce dernier A l'aide d'un extracteur, enlever la flasque (2)
F de manieÁre aÁ eÂviter la rotation du pignon. F compleÁte de la protection (4).
RelaÃcher et enlever l'eÂcrou (1) enlever eÂgalement la
garniture OR (3).
Rimuovere il supporto oscillante (5). Rimuovere l'anello di tenuta (6).

ITA ITA
Schwenkbare Halterung (5) entfernen. Kolbenring (6) entfernen.

D D
e f
Remover el soporte oscilante (5). Remover el segmento de compresioÂn (6).
ESP ESP
Enlever le support oscillant (5). Enlever la bague d'eÂtancheÂiteÂ (6).

F F
93
12
T23
7
8
T21
T22
F1240519 F1240520
GB a GB b
Position wrench T22 onto the ring nut (7) and apply bar hold T21 to Apply blocks T23 and, with the help of a puller, extract the pinion
the pinion (8). (8) complete with the internal bearing (9), the distance piece (10)
Stop wrench T22 and rotate the pinion so as to release and remove and shims (11).
the ring nut (7). NOTE. The thrust blocks of the bearings remain in the central body
NOTE. If disassembly proves awkward, weld the ring nut at approx. (12).
80ëC.
10
8
8
9
11
F1240543 F1240578
GB c GB d
Remove the pinion (8), shims (11) and distance piece (10). Using a puller and a press, remove the inner bearing (9) from the
pinion (8).
13
14
9
F1240521 F1240522
GB e GB f
Remove the thrust block of the external bearing (13). Insert a drift in the appropriate holes and remove the thrust block of
the internal bearing (9) as well as the shim washers (14).
94
Impegnare la chiave speciale T22 sulla ghiera (7) ed Applicare i blocchi T23 e con un estrattore, estrarre il
ITA applicare sul pignone (8) il codolo T21. ITA pignone (8) completo del cuscinetto interno (9), del
Fermare la chiave T22 e ruotare il pignone per distanziale (10) e degli spessori (11).
allentare ed asportare la ghiera (7). NOTA. Le ralle dei cuscinetti rimangono nel corpo centrale (12).
NOTA. Se lo smontaggio risulta faticoso, scaldare la ghiera a circa
80 ëC.
Den speziellen SchluÈssel T22 in die Nutmutter (7) Die BloÈcke T23 anbringen und mit einem Abzieher das
D setzen und am Rad (8) den Schaft T21 anbringen. D Rad (8) samt dem inneren Lager (9), DistanzstuÈck (10)
SchluÈssel T22 festhalten und das Rad drehen, um die und der Scheiben (11) herausziehen.
Nutmutter (7) zu lockern und abzunehmen. BEMERKUNG. Die Lagerscheiben bleiben im zentralen KoÈrper (12)
a BEMERKUNG. Falls die Nutmutter zu fest sitzt, diese auf ca. 80ëC b sitzen.
erhitzen.
Bloquear la llave especial T22 en la virola (7) y aplicar Aplicar los bloqueos T23 y con un extractor, extraer el
ESP en el pinÄoÂn (8) el mango T21. ESP pinÄoÂn (8) con su cojinete interior (9) del separador (10)
Bloquear la llave T22 y girar el pinÄoÂn para aflojar y y de los posibles espesores (11).
extraer la virola (7). NOTA. Las ranguas de los cojinetes quedan en el cuerpo central
NOTA. Si el desmontaje resulta difõÂcil, calentar la virola a unos (12).
80ëC.
Engager la cleÂ speÂciale T22 sur le collier de serrage Appliquer les blocs T23 et aÁ l'aide d'un extracteur,
F (7) et appliquer sur le pignon (8) le coÃne T21. F extraire le pignon (8) complet du palier interne (9), du
Bloquer la cleÂ T22, tourner le pignon pour relaÃcher et diffeÂrentiel (10) et des eÂventuelles cales (11).
enlever le collier de serrage (7). NOTE. Les crapaudines des paliers demeurent dans le corps
NOTE. Si le deÂsassemblage est rendu difficile, chauffer la bague aÁ central (12).
une chaleur de 80ëC.
Asportare il pignone (8), gli spessori (11) ed il Utilizzando un estrattore ed una pressa, rimuovere dal
ITA distanziale (10). ITA pignone (8) il cuscinetto interno (9).
Rad (8), Unterlegscheibe (11) und DistanzstuÈck (10) Mit einem Abzieher und einer Presse, vom Rad (8) das
D abnehmen. D innere Lager (9) abnehmen.
c d
Sacar el pinÄoÂn (8), los espesores (11) y el separador Utilizando un extractor y una prensa, remover del
ESP (10). ESP pinÄoÂn (8) el cojinete interior (9).
Enlever le pignon (8), les cales (11) et l'entretoise (10). A l'aide de l'extracteur et d'une presse, oÃter du pignon
F F (8) le palier interne (9).
Rimuovere la ralla del cuscinetto esterno (13). Con un punzone inserito nelle cave predisposte,
ITA ITA rimuovere la ralla del cuscinetto interno (9) e gli
spessori di rasamento (14).
Scheibe vom aÈuûeren Lager (13) abnehmen. Einen DuÈbel in die vorgesehenen Nuten stecken und
D D die Scheibe des inneren Lagers (9) und die Zwischen-
legscheiben (14) entfernen.
e f
Remover la rangua del cojinete exterior (13). Utilizando un punzoÂn introducido en las ranuras
ESP ESP predispuestas, remover la rangua del cojinete interior
(9) y los espesores (14).
Enlever la crapaudine du palier externe (13). A l'aide d'un poussoir introduit dans le creux
F F preÂdisposeÂ, enlever la crapaudine du palier interne
(9) et les cales de rasage (14).
95
14
GB a GB b
12
10
13
6
5
11
7
3
1 4
2 D1240042
GB c GB d
GB e GB f
96
97
HOW TO INSTALL AND ADJUST THE BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - KEGELRAD INSTALLIEREN
UND EINSTELLEN - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE
DG DG
T24
9
F1240523 F1240524
GB a GB b
Using a surface plate, reset a centesimal comparator "DG" and Bring the internal bearing (9), complete with its thrust block, under
place it on the measurement ring T24 (with a thickness of 30.2 the comparator "DG".
mm). Determine overall thickness "D" of the bearing checking the
Preset the comparator to approx. 2 mm. discrepancy between this size and the size of the measurement
ring.
CAUTION! Press the thrust block in the centre and take several
measurements while rotating the thrust block.
T25B T24 T25C T25A
13
T25C
T25A 13
F1240525 F1240526
GB c GB d
Partially insert the thrust block of the external bearing (13). Install tension rod T25C, measurement ring T24 and front guide
tool T25A on the thrust block of the external bearing (13).
T26C T24 T26B

13
F1240527 F1240528
GB e GB f
Connect the tension rod to the press and move the thrust block of Insert tool T26B complete with external bearing (13), measurement
the external bearing (13) into its seat. ring T24 and gauged ring nut T26C.
Disconnect the press and remove the tension rod. Manually tighten.
NOTE. Before starting the next stage, make sure that the thrust
block has been completely inserted into its seat.
98
Utilizzando un piano di riscontro, azzerare sull'anello Portare sotto il comparatore "DG" il cuscinetto interno
ITA di misura T24 (di spessore conosciuto pari a 30,2 mm) ITA (9) completo di ralla.
un comparatore centesimale "DG". Determinare lo spessore totale "D" del cuscinetto
Precaricare il comparatore di circa 2 mm. controllando lo scostamento rispetto la misura dell'anello di misura.
ATTENZIONE! Premere la ralla in modo centrato ed eseguire piuÁ
volte la misurazione ruotando la ralla.
Mit Hilfe eines Anschlags am Meûring T24 (bekannte Unter die Meûuhr "DG" das innere Lager (9) samt
D StaÈrke 30,2 mm) eine hundertteilige Meûuhr "DG" auf D Scheibe legen.
Null stellen. Gesamte StaÈrke "D" des Lagers messen und die
Meûuhr auf 2 mm vorladen. Abweichung im VerhaÈltnis zum Meûring kontrollieren.
a b ACHTUNG! Die Scheibe muû zentriert sein und den Meûvorgang
mehrmals bei gedrehter Scheibe wiederholen.
Utilizando una superficie para la comparacioÂn, poner Poner debajo del comparador "DG" el cojinete interior
ESP a cero en el anillo de medida T24 (del que se conoce ESP (9) con la rangua.
el espesor igual a 30,2 mm) un comparador centesi- Determinar el espesor total "D" del cojinete controlan-
mal "DG". do la diferencia con respecto al tamanÄo del anillo de medida.
Precargar el comparador en 2 mm aproximadamente. CUIDADO! Presionar la rangua de manera centrada y ejecutar
varias veces la medida girando la rangua.
A l'aide d'un plan de comparaison, mettre aÁ zeÂro sur Amener sous le comparateur "DG" le palier interne (9)
F l'anneau de mesurage T24 (d'une eÂpaisseur connue F eÂquipeÂ de crapaudine.
eÂgale aÁ 30,2 mm), un comparateur centeÂsimal "DG". DeÂfinir l'eÂpaisseur totale "D" du palier en controÃlant
PreÂcharger le comparateur d'environ 2 mm. l'eÂcart par rapport aÁ celle mesureÂe par l'anneau de mesurage.
ATTENTION! Presser la crapaudine vers le centre, puis en
effectuer plusieurs fois le mesurage en tournant la crapaudine.
Inserire parzialmente nel corpo centrale (12) la ralla Montare il tirante T25C, l'anello di misura T24, ed
ITA del cuscinetto esterno (13). ITA infine l'attrezzo anteriore T25A di guida della ralla (13)
del cuscinetto esterno.
Auf den zentralen KoÈrper (12) die Scheibe des Die Spannstange T25C, den Meûring T24, und zuletzt
D aÈuûeren Lagers (13). D das vordere Werkzeug T25A zur FuÈhrung der Scheibe
(13) des aÈuûeren Lagers montieren.
c d
Introducir parcialmente en el cuerpo central (12) la Montar el tirante T25C, el anillo de medida T24, y por
ESP rangua el cojinete exterior (13). ESP uÂltimo la herramienta anterior T25A guõÂa de la rangua
(13) del cojinete exterior.
Introduire, partiellement dans le corps central (12), la Monter la tringle T25C, l'anneau de mesurage T24, et
F crapaudine du palier externe (13). F enfin l'outil anteÂrieur T25A de guidage de la crapau-
dine (13) du palier externe.
Collegare il tirante alla pressa e mandare in sede la Inserire l'attrezzo T26B completo di cuscinetto ester-
ITA ralla del cuscinetto esterno (13). ITA no (13) anello di misura T24 e ghiera di altezza
Scollegare la pressa e rimuovere il tirante. calibrata T26C.
NOTA. Prima di proseguire, assicurarsi dell'inserimento totale Serrare a fondo manualmente.
della ralla.
Spannstange mit der Presse verbinden und die Werkzeug T26B mit dem aÈuûeren Lager (13), Meûring
D Scheibe in ihren Sitz im aÈuûeren Lager (13) einsetzen. D T24 und in der HoÈhe kalibrierte Nutmutter T26C
Von der Presse abnehmen und Spannstange ab- einsetzen.
nehmen. Von Hand festschrauben.
e BEMERKUNG. SorgfaÈltig kontrollieren, ob die Scheibe richtig f
eingesetzt worden ist.
Conectar el tirante a la prensa y colocar en el Introducir la herramienta T26B con el cojinete exterior
ESP alojamiento la rangua del cojinete exterior (13). ESP (13), el anillo de medida T24 y la virola de altura
Sacar la prensa y remover el tirante. calibrada T26C.
NOTA. Antes de continuar, asegurarse de que la rangua estaÂ Apretar a fondo manualmente.
completamente insertada.
Brancher la tringle aÁ la presse, puis envoyer dans son Introduire l'outil T26C eÂquipeÂ du palier externe (13),
F logement la crapaudine du palier externe (13). F l'anneau de mesurage T24 et le collier de serrage de
DeÂbrancher la presse et enlever la tringle. hauteur taraudeÂ T26C.
NOTE. Avant de continuer, s'assurer que la crapaudine est Serrer aÁ fond manuellement.
compleÁtement inseÂreÂe.
99
DG1
T26A T26C
GB
GB T26A
A
F1240529 F1240530
GB a GB b
Fit a centesimal comparator "DG1" with long stem into bar T26A; Lay bar T26A on gauged nut T26C and take the size "A" at about
when the bar rests on two size- blocks "GB" of 57 mm, reset the 57 mm corresponding to the maximum diameter of arms centring.
comparator.
Preset the comparator to approx. 2 mm and reset.
T24
T26C 8
X
R115
T26B
A Y
30.2 61
(61-A)+115+30.2=B B D1240070
F1240531
GB c GB d
Calculate size "B" which will be the first useful value for calculating Check the nominal size (X) marked on the pinion and add or
the size of the shims (14) that are to be inserted under the thrust subtract the indicated variation (Y) so as to obtain size "Z".
block of the internal bearing (9). e.g.: Z= 118 + 0.1 = 118.1
Z= 118 ± 0.2 = 117.8
B-C=S
14
(14) S
D Z
C=Z+D C
D1240069
F1240541
GB e GB f
Calculate size "C" which represents the second value for Calculate the difference between sizes "B" and "C" so as to obtain
calculating the size of the shims "S" that are to be placed under the size "S" of the shim (14) that will go under the thrust block of the
the thrust block of the internal bearing (9). internal bearing (9).
100
Montare un comparatore centesimale "DG1" con stelo Appoggiare la barra T26A sulla ghiera calibrata T26C
ITA prolungato, nella barra T26A; azzerare il comparatore ITA e rilevare la misura "A" circa 57mm in corrispondenza
quando la barra appoggia su due blocchetti "GB" del diametro massimo della centratura dei bracci.
calibrati da 57 mm.
Precaricare il comparatore di circa 2 mm ed azzerarlo.
Die hundertteilige Meûuhr "DG1" mit dem VerlaÈng- Stab T26A auf die kalibrierte Nutmutter T26C legen
D erungsstift in den Stab T26A montieren; die Meûuhr D und das Maû "A" bei ca. 57 mm am maximalen
auf Null stellen, nachdem der Stab auf zwei kalibrierte Durchmesser der Armzentrierung messen.
BloÈcke "GB" zu 57 mm gelegt worden ist.
a Meûuhr auf 2 mm vorladen und auf Null stellen. b
Montar un comparador centesimal "DG1" con vaÂstago Apoyar la barra T26A en la virola calibrada T26C y
ESP prolongado en la barra T26A; poner a cero el ESP registrar la medida "A" unos 57 mm en correspon-
comparador cuando la barra estaÂ apoyada en dos dencia del diaÂmetro maÂximo del centraje de los
bloques "GB" calibrados de 57 mm. brazos.
Precargar el comparador en 2 mm aproximadamente y ponerlo a
cero.
Monter un comparateur centeÂsimal "DG1" muni de Poser la barre T26A sur le collier de serrage taraudeÂ
F tige de prolongation dans la barre T26A; mettre le F T26C, relever la mesure "A" aÁ environ 57 mm en
comparateur aÁ zeÂro lorsque la barre poseÂe sur les correspondance du diameÁtre de centrage maximal des
deux blocs calibreÂs "GB" est aÁ 57 mm. bras.
PreÂcharger le comparateur aÁ environ 2 mm et remettre aÁ zeÂro.
Eseguire il calcolo per ottenere la prima misura utile Controllare la misura nominale (X) segnata sul
ITA "B", per il calcolo degli spessori (14) da inserire sotto ITA pignone e sommare o sottrarre ad essa la variazione
la ralla del cuscinetto interno (9). indicata: (Y) per ottenere la misurazione "Z".
Es: Z=118+0,1=118,1
Z=118 ± 0,2=117,8
Das Maû "B" ausrechnen, das zur Ermittlung der Das Nennmaû (X), das am Rad markiert ist, kontroll-
D DistanzstuÈcke (14) dient, die unterhalb der Scheibe D ieren und die Abweichung addieren oder abziehen. (Y)
des inneren Lagers (9) eingesetzt werden sollen. fuÈr das Maû "Z".
Beisp.: Z= 118 + 0,1 = 118,1
c d Z= 118 ± 0,2 = 117,8
Ejecutar el caÂlculo para obtener la primera medida uÂtil Controlar la medida nominal (X) marcada en el pinÄoÂn y
ESP "B" para el caÂlculo de los espesores (14) que hay que ESP sumarle o restarle la variacioÂn indicada (Y) para
insertar debajo de la rangua del cojinete interior (9). obtener la medida "Z".
Ej.: Z= 118 + 0,1 = 118,1
Z= 118 ± 0,2 = 117,8
Faire le calcul pour obtenir la premieÁre mesure utile ControÃler la mesure nominale (X) marqueÂe sur le
F "B" pour calculer les cales (14) aÁ introduire au- F pignon et additionner ou soustraire aÁ celle-ci la
dessous de la crapaudine du palier interne (9). variation indiqueÂe (Y) pour obtenir le mesurage "Z".
Exp. Z= 118 + 0,1 = 118,1
Z= 118 ± 0,2 = 117,8
Calcolare la seconda misura utile "C" per il calcolo Eseguire la differenza tra le misure "B" e "C" per
ITA dello spessore "S" da inserire sotto la ralla del ITA stabilire la misura "S" dello spessore (14) da inserire
cuscinetto interno (9). sotto la ralla del cuscinetto interno (9).
Das zweite Maû "C" fuÈ r das DistanzstuÈ ck "S" Den Unterschied zwischen Maû "B" und "C" ausrech-
D ausrechnen, das unter die Scheibe des inneren D nen, um das DistanzstuÈck "S" (14) auszurechnen, das
Lagers (9) eingesetzt werden soll. unter die Scheibe des inneren Lagers (9) eingesetzt
werden soll.
e f
Calcular la segunda medida uÂtil "C" para el caÂlculo del Sacar la diferencia entre las medidas "B" y "C" para
ESP espesor "S" a insertar debajo de la rangua del cojinete ESP establecer la medida "S" del espesor (14) a insertar
interior (9). debajo de la rangua del cojinete interior (9).
Calculer la seconde mesure utile "C" pour calculer la Effectuer la diffeÂrence entre les mesures "B" et "C"
F cale "S" aÁ introduire au-dessous de la crapaudine du F pour eÂtablir la mesure "S" de la cale (14) aÁ introduire
palier interne (9). au-dessous de la crapaudine du palier interne (9).
101
14
T25C T25A
9
F1240533 F1240534
GB a GB b
Insert shim "S" (14) and the thrust block of the internal bearing (9) Position tool T25A and tension rod T25C.
in the central body. Connect the tension rod to the press, fasten the thrust block and
NOTE. To hold shim "S" (14) in position, apply grease. then remove the tools.
NOTE. Before going on to the next stage, make sure that the thrust
block has been completely inserted.
DDG
T26C 9 13
T26B
F1240535 F1240536
GB c GB d
Position tools T26C and T26B complete with tapered bearings (9) Insert the stem of a depth comparator "DDG" in either side hole of
and (13); manually tighten until a rolling torque has been obtained. tool T26C; reset the comparator with a presetting of approx. 3 mm.
H
DDG
T26C 9
10 13
T26B
9 T26C
13
T26B
F1240574 F1240537
GB e GB f
Remove the comparator and release tools and bearings from the Insert depth comparator "DDG" into tool T26B-T26C and measure
central body. variation "H" in relation to the zero setting performed back at point
Re-install all and insert the distance piece (10) between bearings d.
(9) and (13); manually tighten the whole pack.
102
Inserire nel corpo centrale lo spessore "S" (14) e la Montare l'attrezzo T25A ed il tirante T25C.
ITA ralla del cuscinetto interno (9). ITA Collegare il tirante alla pressa, mandare in battuta la
NOTA. Per tenere in posizione lo spessore "S" (14), ralla e quindi smontare gli attrezzi.
spalmarlo leggermente con grasso. NOTA. Prima di proseguire, assicurarsi dell'inserimento totale
della ralla.
In den zentralen KoÈrper das DistanzstuÈck "S" (14) und Werkzeug T25A und Spannstange T25C montieren.
D die Scheibe des inneren Lagers (9) einsetzen. D Spannstange mit der Presse verbinden und die
BEMERKUNG. Um das DistanzstuÈck "S" (14) in seiner Scheibe bis zum Anschlag einsetzen. Danach die
Position festzuhalten, dieses leicht mit Fett schmieren. Werkzeuge abmontieren.
a b BEMERKUNG. SorgfaÈltig kontrollieren ob die Scheibe richtig
eingesetzt worden ist.
Introducir en el cuerpo central el espesor "S" (14) y la Montar la herramienta T25A y el tirante T25C.
ESP rangua del cojinete interior (9). ESP Conectar el tirante a la prensa, llevar a tope la rangua
NOTA. Para mantener en su posicioÂn el espesor "S" y luego desmontar las herramientas.
(14), pasarle ligeramente un poco de grasa. NOTA. Antes de continuar, asegurarse de que la rangua ha sido
totalmente introducida.
Introduire dans le corps central la cale "S" (14) et la Monter l'outil T25A et la tringle T25C.
F cale du palier interne (9). F Relier la tringle aÁ la presse, envoyer en buteÂe la
NOTE. Enduire leÂgeÁrement celle-ci de gras pour la crapaudine, puis deÂmonter les outils.
maintenir dans sa position. NOTE. Avant de continuer, s'assurer que la crapaudine est
entieÁrement inseÂreÂe.
Inserire gli attrezzi T26C e T26B completi dei Inserire in uno dei due fori laterali dell'attrezzo T26C lo
ITA cuscinetti conici (9) e (13); serrare manualmente fino ITA stelo di un comparatore di profonditaÁ "DDG"; azzerare
ad avere sicuramente una coppia di rotolamento. il comparatore con un precarico di circa 3 mm.
Die Werkzeuge T26C und T26B samt Kegellager (9) In eines der beiden seitlichen LoÈcher des Werkzeugs
D und (13) einsetzen; von Hand zudrehen bis ein D T26C den Stift der Meûuhr "DDG" stecken; die Meûuhr
Drehmoment erreicht worden ist. auf 3 mm vorladen und auf Null stellen.
c d
Introducir las herramientas T26C y T26B con sus Introducir en uno de los dos orificios laterales de la
ESP cojinetes coÂnicos (9) y (13); apretar manualmente ESP herramienta T26C el vaÂstago de un comparador de
hasta obtener con seguridad un par de rodamiento. profundidad "DDG"; poner a cero el comparador con
una precarga de aproximadamente 3 mm.
Introduire les outils T26C et T26B eÂquipeÂs des paliers Introduire dans l'un des deux trous lateÂraux de l'outil
F coniques (9) et (13); serrer manuellement jusqu'aÁ eÃtre F T26C, la tige d'un comparateur de profondeur "DDG",
suÃr d'avoir un couple de roulement. mettre le comparateur aÁ zeÂro avec une preÂcharge
d'environ 3 mm.
Rimuovere il comparatore e smontare dal corpo Inserire nell'attrezzo T26B-T26C il comparatore di

ITA centrale il gruppo attrezzi e cuscinetti. ITA profonditaÁ "DDG" e rilevare lo scostamento "H"
Rimontare il tutto inserendo tra i cuscinetti (9) e (13) il rispetto l'azzeramento eseguito al punto d.
distanziale (10); serrare manualmente l'intero pacco.
Die Meûuhr abnehmen und vom zentralen KoÈrper die In das Werkzeug T26B-T26C die Meûuhr "DDG" fuÈr
D Werkzeuge und Lager abmontieren. D die Tiefe einsetzen und die Abweichung "H" im
Das ganze wieder montieren und dabei zwischen den VerhaÈltnis zur unter Punkt d vorgenommenen Null-
Lagern (9) und (13) das DistanzstuÈck (10) einsetzen; von Hand das stellung messen.
e Ganze festschrauben. f
Remover el comparador y desmontar del cuerpo Introducir en la herramienta T26B-T26C el compara-
ESP central el grupo de las herramientas y cojinetes. ESP dor de profundidad "DDG" y relevar el alejamiento "H"
Volver a montar todo introduciendo entre los cojinetes respecto al aceramiento efectuado al punto d.
(9) y (13) el separador (10); apretar manualmente todo el paquete.
Enlever le comparateur et deÂmonter du corps central Introduire l'outil T26B-T26C le comparateur de pro-
F le groupe outils et paliers. F fondeur "DDG" et relever l'eÂcart "H" par rapport aÁ la
Remonter le tout en inseÂrant entre les paliers (9) et mise aÁ zeÂro effectueÂ au point d.
(13), l'entretoise (10); serrer tout le paquet aÁ la main.
103
H+0,12÷ 0,13=S1
11 S1
F1240541 F1240542
GB a GB b
The variation is to be added to a set value of 0.12±0.13 mm., so as Position the internal bearing (9) and the pinion (8) under a press;
to obtain the size of shim "S1" (11) which will be inserted between force the bearing onto the pinion.
the external bearing (13) and the distance piece (10) and
subsequently, to determine the preload for the bearings.
12
10
8 9 11 10
13
11
F1240543 F1240538
GB c GB d
Fit the pinion (8), shim "S1" (11) and distance piece (10) in the main Insert the external bearing (13) in the central body in order to
body (12). complete the pack arranged as in the figure.
NOTE. The finer shims must be placed in- between the thicker
ones
8
8
7
F1240575 F1240539
GB e GB f
Connect the pinion (8) to the tie rod T28A and T28B; connect the Apply Loctite 242 to the thread of the ring nut (7) and screw the nut
tie rod T28C (see special tools) to the press and block. onto the pinion (8).
104
Lo scostamento rilevato eÁ da sommare ad una misura Posizionare il cuscinetto interno (9) e pignone (8) sotto
ITA fissa di 0,12v0,13 mm, per ottenere lo spessore "S1" ITA una pressa; forzare sul pignone il cuscinetto.
(11) da inserire tra cuscinetto esterno (13) e distanziale
(10) e quindi, determinare il precarico stabilito per i cuscinetti.
Die ermittelte Abweichung wird dem festen Maû von Das innere Lager (9) und das Rad (8) unter eine
D 0,12v0,13 mm hinzu gerechnet, um das DistanzstuÈck D Presse setzen; auf das Rad das Lager druÈcken.
"S1" (11) zu ermitteln, das zwischen dem aÈuûeren
Lager (13) und das DistanzstuÈck (10) eingesetzt werden soll und
a folglich die benoÈtigte Vorbelastung der Lager festzulegen. b
La separacioÂn registrada hay que sumarla a una Posicionar el cojinete interior (9) y el pinÄoÂn (8) debajo
ESP medida fija de 0,12v0,13 mm para obtener el espesor ESP de una prensa; forzar en el pinÄoÂn el cojinete.
"S1" (11) que hay que introducir entre el cojinete
exterior (13) y el separador (10) y luego, determinar la precarga
establecida para los cojinetes.
L'eÂcart releveÂ est aÁ additionner aÁ une mesure fixe de Placer le palier interne (9) et le pignon (8) sous presse;
F 0,12v0,13 mm pour obtenir la cale "S1" (11) aÁ F forcer sur pignon et palier.
introduire entre le palier externe (13) et entretoise
(10) et par conseÂquent deÂterminer la preÂcharge preÂconiseÂe pour les
paliers.
Montare nel corpo centrale (12), il pignone (8), gli Inserire nel corpo centrale il cuscinetto esterno (13) in
ITA spessori "S1" (11) e il distanziale (10). ITA modo da completare il pacco come composto in figura.
NOTA. Gli spessori piuÁ fini devono essere contenuti
tra quelli piuÁ spessi.
Zentralen KoÈrper (12), Rad (8), Unterlegscheibe "S1" In den zentralen KoÈrper das aÈuûere Lager (13)
D (11) und DistanzstuÈck (10) montieren. D einsetzen wie in der Abbildung gezeigt.
BEMERKUNG. Die duÈnneren Unterlegscheiben muÈs-
sen zwischen den staÈrkeren gelegt werden.
c d
Montar en el cuerpo central (12) el pinÄoÂn (8) los Introducir en el cuerpo central el cojinete exterior (13)
ESP espesores "S1" (11) y el separador (10). ESP de manera que el paquete quede completo como ha
NOTA. Los espesores maÂs delgados tienen que sido formado en la figura.
colocarse entre los maÂs gruesos.
Monter le corps central (12), le pignon (8), les cales Introduire dans le corps central, le palier externe (13),
F "S1" (11) et l'entretoise (10). F de manieÁre aÁ compleÂter le paquet comme composeÂ
NOTE. Les cales plus minces doivent eÃtre intercaleÂes sur la figure.
parmi les plus eÂpaisses.
Collegare il pignone (8) al tirante T28A e T28B; Spalmare la filettatura della ghiera (7) con Loctite 242
ITA collegare il tirante T28C (Vedere attrezzature speciali) ITA ed avvitarla sul pignone (8).
alla pressa e mandare in blocco.
Ritzel (8) mit der Zugstange T28A und T28B ver- Das Gewinde der Nutmutter (7) mit Loctite 242
D binden; Zugstange T28C (siehe SpezialausruÈstung) D schmieren und auf das Rad (8) schrauben.
mit der Presse verbinden und blockieren.
e f
Conectar el pignon (8) al tirante T28A y T28B; Pasar sobre la rosca de la virola (7) Loctite 242 y
ESP conectar el tirante T28C (Vease herramientas espe- ESP atornillarla en el pinÄoÂn (8).
ciales) a la prensa y bloquear.
Brancher le pignon (8) aÁ la tringle T28A et T28B; relier Enduire le filetage du collier de serrage (7) avec du
F la tringle T28C (voir installations speÂciales) aÁ la presse F Loctite 242, puis visser celui-ci sur le pignon (8).
puis envoyer en buteÂe.
105
T21 T19
T22
F1240540 F1240510
GB a GB b
Apply special wrench T22 to the ring nut (7) and bar-hold T21 to the Apply onto the pinion (8) the bar-hold and with the help of a torque
pinion (8). metre, check the torque of the pinion (8).
Lock the wrench T22 and rotate the pinion using a dynamometric Torque: 120±170 Ncm
wrench, up to a minimum required torque setting of 500 Nm. CAUTION! If torque exceeds the maximum value, then the size of
shim "S1" (11) between the bearing (13) and the distance piece (10)
needs to be increased.
If torque does not reach the set value, increase the torque setting
of the ring nut (7) in different stages to obtain a maximum value of
570 Nm.
CAUTION! If torque does not reach the minimum value, then the
size of shim "S1" (11) needs to be reduced.
CAUTION! When calculating the increase or decrease in size of
shim "S1", bear in mind that a variation of shim (11) of 0.01 mm
corresponds to a variation of 60 Ncm in the torque of the pinion (8).
106
Impegnare la chiave speciale T22 sulla ghiera (7) ed Applicare sul pignone (8) il codolo T19 e con un
ITA applicare il codolo T21 sul pignone (8). ITA torsiometro, controllare la coppia di rotazione del
Fermare la chiave T22 e ruotare il pignone con una pignone.
chiave dinamometrica fino alla coppia minima richiesta di 500 Nm. Coppia di rotazione: 120v170 Ncm
ATTENZIONE! Se la coppia supera il valore massimo bisogna
aumentare lo spessore "S1" (11) tra cuscinetto (13) e distanziale
(10).
Den speziellen SchluÈssel T22 auf die Nutmutter (7) Se la coppia di rotazione non raggiunge il valore stabilito,
D setzen und den Schaft T21 auf das Rad (8) montieren. aumentare la coppia di serraggio della ghiera (7) in piuÁ tempi fino
Den SchluÈssel T22 festhalten und das Rad mit einem a raggiungere il valore massimo ammesso di 570 Nm.
MomentenschluÈssel drehen bis das mindeste Anzugsmoment von
a 500 Nm erreicht worden ist. ATTENZIONE! Se la coppia di rotazione non raggiunge il valore
minimo, eÁ necessario diminuire lo spessore "S1" (11).
ATTENZIONE! Al fine di poter calcolare gli incrementi o la
Colocar la llave especial T22 en la virola (7) y aplicar el diminuzione dello spessore "S1", eÁ necessario considerare che la
ESP mango T21 en el pinÄoÂn (8). variazione dello spessore (11) di 0,01 mm, fa variare la coppia di
Parar la llave T22 y girar el pinÄoÂn con una llave rotazione del pignone (8) di 60 Ncm.
dinamomeÂtrica hasta el par mõÂnimo requerido de 500 Nm.
Engager la cleÂ speÂciale T22 sur le collier (7) et

F appliquer la queue T21 sur le pignon (8).
Bloquer la cleÂ T22, tourner le pignon avec une cleÂ
dynamomeÂtrique jusqu'au couple minimum requis de 500 Nm.
Den Shaft T19 montieren auf das Rad (8) und mit
D einem Drehungsmesser das Drehmoment des Rads
kontrollieren.
Drehmoment: 120v170 Ncm
ACHTUNG! Falls das Drehmoment groÈûer als der maximale Wert
sein sollte, muû ein groÈûeres DistanzstuÈck "S1" (11) zwischen
Lager (13) und DistanzstuÈck (10) eingesetzt werden.
Falls das Drehmoment den benoÈtigten Wert nicht erreicht, muû das
Drehmoment der Nutmutter (7) stufenweise erhoÈht werden, bis der
maximal zugelassene Wert von 570 Nm erreicht worden ist.
ACHTUNG! Falls das Drehmoment den minimalen Wert nicht
erreicht, muû das DistanzstuÈck "S1" (11) kleiner gewaÈhlt werden.
ACHTUNG! Um die ErhoÈhungen oder Verringerungen des Distanz-
stuÈcks "S1" ausrechnen zu koÈnnen, muû beachtet werden, daû ein
Unterschied von 0,01 mm des DistanzstuÈcks (11), das Drehmoment
des Rads (8) um 60 Ncm veraÈndert.
Aplicar el mango T19 en el pinÄoÂn (8) y con un

ESP torsioÂmetro, controlar el par de rotacioÂn del pinÄoÂn.
Par de rotacioÂn: 120v170 Ncm
CUIDADO! Si el par supera el valor maÂximo, hay que aumentar el
espesor "S1" (11) entre el cojinete (13) y el separador (10).
Si el par de rotacioÂn no alcanza el valor establecido, aumentar el
par de torsioÂn de la virola (7) varias veces hasta alcanzar el valor
maÂximo admitido de 570 Nm.
CUIDADO! Si el par de rotacioÂn no alcanza el valor mõÂnimo, hay
que disminuir el espesor "S1" (11).
CUIDADO! A fin de poder calcular los incrementos o la disminucioÂn
del espesor "S1", hay que considerar que el espesor (11) de 0,01
mm hace variar el par de rotacioÂn del pinÄoÂn (8) en 60 Ncm.
Appliquer la queue T19 sur le pignon (8) et l'aide d'un

F torsiomeÁtre, controÃler le couple de rotation du pignon.
Couple de rotation: 120v170 Ncm
ATTENTION! Si le couple deÂpasse la valeur maximale, il faut
augmenter la cale "S1" (11) entre palier (13) et entretoise (10).
Si le couple de rotation n'atteint pas la valeur eÂtablie, augmenter le
couple de serrage du collier de serrage (7) en plusieurs fois jusqu'aÁ
atteindre la valeur maximale preÂconiseÂe de 570 Nm.
ATTENTION! Si le couple de rotation n'atteint pas la valeur
minimale, il faut diminuer la cale "S1" (11).
ATTENTION! Pour pouvoir calculer l'increÂmentation ou la diminu-
tion de la cale "S1", il faut tenir compte que la variation de la cale
(11) de 0,01 mm, modifie le couple de rotation du pignon (8) de 60
Ncm.
107
5
6
T27 12
F1240545 F1240517
GB a GB b
Lubricate the outer surface of the new sealing ring (6) and fit it onto Install the swinging support (5).
the central body (12) using tool T27. NOTE. Check that it is properly oriented.
T20A
(T20B)
2 4
F1240546 F1240547
GB c GB d
Fit the flange (2) complete with the guard (4) and fasten it. Apply Loctite 242 to the threaded part of the pinion (8).
For keying the flange (2), use a plastic hammer if necessary. Position tool T20A (or T20B) and fasten it in order to avoid rotation.
NOTE. Make sure that the guard (4) is securely fastened onto the Insert O-ring (3) the nut (1) and tighten it using a dynamometric
flange and that it is not deformed. wrench.
Torque wrench setting: 280±310 Nm
T23
F1240579
GB e
Remove blocks T23 (used for extracting the pinion) and re-install
the arms.
For details, see «CHECKING WEAR AND REPLACING THE
BRAKING DISKS».
108
Lubrificare la superficie esterna del nuovo anello di Montare il supporto oscillante (5).
ITA tenuta (6) e montarlo nel corpo centrale (12) utilizzan- ITA
NOTA: Controllare attentamente l'orientamento.
do l'attrezzo T27.
Die aÈuûere FlaÈche des neuen Ringes (6) schmieren Die schwenkbare Halterung (5) montieren.
D und den zentralen KoÈrper (12) mit Hilfe des Werk- D
BEMERKUNG. Richtung sorgfaÈltig kontrollieren.
zeugs T27 montieren.
a b
Lubricar la superficie exterior del nuevo segmento de Montar el soporte oscilante (5).
ESP compresioÂn (6) y montarlo en el cuerpo central (12) ESP
NOTA. Controlar atentamente la orientacioÂn.
utilizando la herramienta T27.
Lubrifier la surface externe de la bague d'eÂtancheÂiteÂ Monter le support oscillant (5).

F neuve (6), puis monter celle-ci dans le corps central F
NOTE. ControÃler attentivement le sens.
(12) aÁ l'aide de l'outil T27.
Montare la flangia (2) completa della protezione (4) e Spalmare la porzione filettata del pignone (8) con
ITA mandarla in battuta. ITA Loctite 242.
Se necessario, per il calettamento della flangia (2), Montare l'attrezzo T20A (oppure T20B) ed impegnarlo
usare un mazzuolo in materiale plastico. per evitare la rotazione. Montare l'anello OR (3) ed il dado (1);
NOTA. Controllare che la protezione (4) sia ben forzata sulla serrare con chiave dinamometrica.
flangia e che non sia deformata. Coppia di serraggio: 280v310 Nm
Flansch (2) samt Schutzteil (4) montieren und bis zum Das Gewinde des Rads (8) mit Loctite 242 schmieren.
D Anschlag bringen. D Das Werkzeug T20A (T20B) montieren und blok-
Wenn noÈtig, den Flansch (2) mit einem Gummi- kieren, damit es nicht drehen kann.
hammer einschieben. O-Ring (3) und Mutter (1) montieren und mit einem Momenten-
c BEMERKUNG. Kontrollieren ob das Schutzteil (4) richtig auf dem
Flansch sitzt und nicht verformt ist.
d schluÈssel festschrauben.
Anzugsmoment: 280v310 Nm
Montar la brida (2) con su proteccioÂn (4) y llevarla Pasar en la parte roscada del pinÄoÂn (8) Loctite 242.
ESP hasta el tope. ESP Montar la herramienta T20A (o T20B) y bloquearla
Si fuera necesario, para ensamblar de la brida (2) usar para evitar la rotacioÂn.
un martillo de material plaÂstico. Montar el anillo OR (3) y la tuerca (1) y apretarlos con llave
NOTA. Controlar que la proteccioÂn (4) estaÂ bien forzada en la brida dinamomeÂtrica.
y que no estaÂ deformada. Par de torsioÂn: 280v310 Nm
Monter la flasque (2) eÂquipeÂe de protection (4), puis Enduire la partie fileteÂe du pignon (8) avec du Loctite
F envoyer celle-ci en buteÂe. F 242. Monter et fixer l'outil T20A (ou T20B) pour eÂviter
Si besoin, pour caler la flasque (2) utiliser un maillet en la rotation.
matieÁre plastique. Monter le OR (3) et l'eÂcrou (1), puis serrer aÁ l'aide de la cleÂ
NOTE. Veiller aÁ ce que la protection (4) est bien forceÂe sur la dynamomeÂtrique.
flasque et qu'elle n'est pas deÂformeÂe. Couple de serrage: 280v310 Nm
Asportare i blocchi T23 montati per l'estrazione del

ITA pignone e rimontare i bracci.
Per i dettagli, vedere «CONTROLLO USURA E
SOSTITUZIONE DISCHI FRENO».
BloÈcke T23 abnehmen, die zum Herausnehmen des

D Rads montiert wurden und Arme wieder montieren.
Siehe «VERSCHLEISS KONTROLLIEREN UND
BREMSSCHEIBEN AUSWECHSELN».
e
Sacar los bloques T23 montados para la extraccioÂn
ESP del pinÄoÂn y volver a montar los brazos.
Para los detalles, veÂase «CONTROL DEL DESGASTE
Y SUSTITUCION DE LOS DISCOS DEL FRENO».
Enlever les blocs T23 monteÂs pour l'extraction des

F pignons, puis remonter les bras.
Pour de plus amples deÂtails, voir «CONTROLE DE
L'USURE ET SUBSTITUTION DES FREINS».
109
SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
4.3 T1 T2
45°
20
25
1
32
32
=
200
=
90
= =
50
160
110
120± 0.1
120± 0.1
32
32
25
1
840
45 °
10 4.5 930
D1240043
D1240046
2313 2305
Ø25 T3 T4 Ø54,5 -- 00.1 T5

Ø30 Ø30
3 x45°
R35
50
2 x45°
0.8
46
50
70
Proteggere da
cementazione
14 10
150
Proteggere da
cementazione
0.8
0.8
2,5 -- 00.2
150
180
169
0.8
3 x15°
7
0.8
Ø54 + 00.1
Ø79
1.5x45°
Ø90 -- 0.15
.5
R5
R7
D1240047
1.5
3342
0.4 10
20 10
19 +-- 0.15
0.8 0.8
R2
9
Ø64 T7
0.8
3x15°
Ø35 ---- 0.08

0.12 Ø67
D1240045 Ø25
Ø50 D1240044
3364 2302
3x15°
50
Ø30 T6
Proteggere da
cementazione
3x45°
30
150
cementazione
Proteggere da
213
2 x45°
130
R1
155
3-- 00.2
0
13
1.5 x45°
0.8
.
0.8
R1
0
R1
52
50
10
R1 0.8
5x15°
Ø35
0.8
49.5
Ø50 ---- 0.1
0.2
89 D1240049
2301 D1240048 2303
110
Ø75 T8 Ø158.5
] Ø158.5
T9
Ø25
Ø50 H7 20° Ø35
Ø30
3x45°
0.8
50
16
0.8
R3
113
-- 0.3
-- 0.5
129
117
R3
148
102
Proteggere da
cementazione
Ø132
R5 20°
100
150
25
R3
8x15°
Ø40
Ø140
233
Ø50---- 0.12
0.08
Ø150
]
0
R1
Ø200 ±0.03
3-- 00.2
13
Ø95
0.8
0.8
] é148 For Timken thrust block
Per ralla TIMKEN
75
FuÈr TIMKEN scheibe

70
Para rangua TIMKEN

Pour ralla TIMKEN
é150 For Koyo thrust block
Per ralla KOYO
Ø35
5x15°
FuÈr KOYO scheibe

0.8
Ø50 ---- 0.1

0.2 Para rangua KOYO
Pour ralla KOYO
Ø56
D1240058
Ø64 D1240050
3363 3354
Ø40
T10 Ø35 T11
2 x45°
2x45°
120
1x45°
175
0.8
1---- 0.2
0.3
41
26
19
0.8 0.8
5.5
5x15°
0.8
0
Ø139.5 -- 0.1
R3
Ø153
10 15
Ø168
0.8
25
Ø180 D1260052
2x15°
Ø39 0.8
Ø50
3502 2304
D1260051
T12
R110
100
50
R1
5 5x45°
27.5 ±0.2
55 500
555
17±0.1
Ø23
125
D1260053
1867 125
111
Ø125 T13 T14
10x15°
Ø35.5 ---- 0.1
0.2 Ø41
0.8
Ø25
Ø20 + 00.2
1x45°
Ø15H7-n6
Ø5.5
R1
0.8
100
Ø14
2 x15°
5
8
0.8
36
31
26
24
20
17
20
238
0
R1 Ø25
0.8
Ø10
Ø35 M26X1.5
123
125
33
36
Ø5.5
18
22.5
0.8
33
Ø37H7-n6
6 9
10.5
Ø47
1 x45°
6
0.8
Ø106 ± 0.1
Ø20 + 00.2
R30
25
Ø25
Ø41 D1240055
D1240054
3333 3708
T15 T16A T16B

T16
3x30° 2x30°
24.5 ⫾ 0.0.1
Ø28.5 ± 0.2
-- 0.1
Ø19.9 +-- 0.1

+0
0
Ø19.9
Ø30
8.5
0.8
Ø6
5
10 46.45 ± 0.1 ± 0.5
15° 10 19.6
56.6 29.6 0.5x45°
Ø20 ++ 0.08
0.12
Ø27 ---- 0.1
0.2
T16C
Ø23
Ø30
0.8
Ø19.9 +-- 0.1
0
D1240056
1x30°
175
3424 2306 D1240057
T17 Ø45 ---- 0.05

0.10 T18
0.8
M8x1.25
1.5x45°
R2 5°
.5
0.8
15
30
3
1
44
68
0.8
14
75
6
7
38
1
1x45
30°
0.8
-- 0.1
Ø38.5 -- 0.2
Ø55 Ø6.5
Ø63 Ø20.4-- 00.05
Ø65 D1240059
Ø43.6 + 00.05
3332 2724 D1240072
112
T19 T20
T20A Ø185 ± 0.2
] 38x1.25x29 DIN 5480
Ø105 ± 0.2
120
80
Ø75
Ø55 ---- 0.08

0.12
]
Ø105 ± 0.2
25
5x15
Tornito Ø 125
0.8
32,25
10
15
125
25
35
Ø10
60
15
14
Ø34.5--+ 00.2
Ø50 2307
48
59
T20B 135 ±0.5

R5
30
97
73
M6
5
61.5
Ø20
61.5
Ø40H7-n6 1/4”
85
Ø44
126 12
Ø32 150
10
15
100
D1240060
3317/4 2308 Ø45 D1240061
T21 Ø85
T22
] 38x1.25x29 DIN 5480
Ø66
Ø55H7
Ø75
0.8
Ø55 –– 0.08
0.12
0.8
]
22
5 x15
Tornito Ø
0.8
75
32,25
7
10
35
6
60
15
14
34
60
6
3/4"
Ø15H7-n6
20
40
20
15°
60
100
275
D1240064
3317/3 D1240063
3317/A
113
99.5 T23 Ø30.2 ± 0.001 T24
Ø17
5X45°
25
Ø88.8 ± 0.005
131
Ø42
20
2309 2310
D1240066
D1240065
T25
T25A
Ø19.55H7
21°
0.8
R5
R2
T25B
23
Ø83
Ø40
Ø88
3x15°
R2
0.8
0.8
T25C
Ø20 +-- 00.1
0.8 T25C T25B

T25B T25A
T25A
21°
Ø89 ---- 0.12

0.08
Ø55
Ø83
0.8
23 40 R2
3329/2 73
0.8
R2
10 56
66 2311
T25C
Ø19.5 ---- 0.12
0.08
Ø16.5---- 0.2
0.1
M18x1.5
M18x1.5
473.5
433.5
0.8 0.8 0.8
Ø35
Ø40
15°
5 5x15°
11 30
45
3329/3 D1240067
T26 T27
4 x45°
Ø50
T26A
5x45°
15
14
63
40 300
87
T26B
74
Ø20 Ø110
R5
2 -- 0.2
Ø65
0
M14 x1
M14 x1
12
20
25 25
0.8
12
50
61-- 0.02
-- 0.01
3x15°
R5
41
0.8
30
Ø37.75 ++ 0.08
0.8
Ø41.2 +-- 0.03

0
Ø20 0.12
195
Ø9
T26C
95
Ø55 ---- 0.2

0.3
Ø89
Ø11
35
Ø99
Ø80
10
50
D1240073
Ø6.5
2312 D1240075
3327
114
T28
ENERPAC Mod. RCH-123 T28C T28B T28A
23
3x15°
R2
0.8
64 0.8
0.8
R3
21°
Ø89 ---- 0.08

0.12
Ø55
Ø83
Ø40
Ø40H8
Ø70
Ø54
0.8 R2
R2
10 56
66
312
M18X1.5
M18X1.5
267
50 5x15° 0.8
0.8
15°
Ø40H8
R3
-- 0.2
-- 0
Ø19
17min.
30
D1240074
3329
Ø28 ---- 0.08

0.12
T29 T31 T32
3x15°
-- 0.08
Ø24
0.8
-- 0.12
5x45°
10
5x45°
0.8
15
65 Ø30
Proteggere da
cementazione
30
50
30
Proteggere da
cementazione
110
140.5
130
120
5°
3x45°
152
Ø26
R5
0.5
Ø33 D1240093
3543
2x45°
15
R5
0.8
3
0.8
3x15°
T30
15
12 10
Ø50
0.8
M12x1.25
Ø64 + 0.2
0
1
0.8
Ø84.5
15
0.8
18
2x15°
Ø94.5 Ø55 ---- 0.2

0.3
Ø110 Ø60
35
D1240097
Ø72 ---- 0.2
0.3
17
D1240099
Ø16.2 -- 00.1
Ø17 ++ 0.2
0.1 D1240096
2316 3739 2317
115
116
TROUBLESHOOTING - RICERCA GUASTI - FEHLERSUCHE - BUSQUEDA DE AVERIAS -
RECHERCHE DES PANNES
PROBLEM - PROBLEMA - PROBLEM - CAUSE - CAUSE - URSACHE - CORRECTION - RIMEDI - ABHILFE -

PROBLEMA - PROBLEME CAUSAS - CAUSE REMEDIOS - REMEDE
Insufficient braking 1. Incorrect adjustment Inspect disc thickness and if discs are usable read-
just brakes to the specifications in the vehicle's man-
Frenatura insufficiente ual.
UngeneÈgende Bremswirkung 1. Incorretta registrazione Controllare lo spessore dei dischi freno e, se i dischi
Frenado insuficiente freno possono essere riutilizzati, registrarli come da
istruzioni del manuale del veicolo.
Freinage insuffisant
1. Fehlerhafte Einstellung BremsscheibenstaÈrke uÈberpruÈfen, koennen die
Bremscheiben noch verwendet werden, Spiel neu
einstellen gemaÈû Anweisungen im Handbuch des
Fahrzeuges.
1. Ajuste incorrecto Controlar el espesor de los discos del freno y, si los
discos del freno pueden volver a utilizarse, ajustarlos
de acuerdo con las instrucciones del manual del ve-
hõÂculo.
1. Mauvais reglage Inspecter l'eÂpaisseur des disques frein et, si les dis-
ques frein sont en bon etat, regler selon les instruc-
tions du manuel du vehicule.
2. Brake discs worn out Inspect disc thickness and replace if necessary.
2. Dischi freno usurati Controllare lo spessore dei dischi freno e, se neces-
sario, sostituirli.
2. Bremsscheiben verschlissen BremsscheibenstaÈrke uÈberpruÈfen und falls erforder-
lich ersetzen.
2. Discos del freno gastados Controlar el espesor de los discos del freno y, si fuera
necesario, sustituirlos.
2. Disques frein useÂs Inspecter l'eÂpaisseur des disques frein et si neÂces-
saire remplacer les disques.
Replace all seals in axle and master cylinder that

3. Incorrect brake fluid have made contact with the incorrect fluid and all
brake hoses.
If incorrect fluid leaked into axle oil, seals and o-rings
in axle must be replaced.
3. Fluido non idoneo nel circuito Sostituire tutti gli anelli di tenuta del ponte e del cilin-
dro master che sono venuti a contatto con il fluido
non idoneo noncheÂ i tubi flessibili.
Se il fluido non idoneo eÁ entrato nel ponte e si eÁ me-
scolato con il lubrificante devono essere sostituiti tutti
gli anelli di tenuta ed gli O-rings.
3. Ungeeignete Fluessigkeit in der Alle Dichtringe und GummischlaÈuche die mit der fal-
Bremsanlage schen FluÈssigkeit in Kontakt gekommen sind, in der
Achse und im Hauptbremszylinder ersetzen.
Sollte diese FluÈssigkeit auch in die Achse gelaugt
sein, sind auch saÈmtliche O-Ringe und Dichtringe
der Achse zu ersetzen.
3. Fluido no adecuado para el circuito Sustituir todos los segmentos de compresioÂn del
puente y del cilindro principal que han estado en con-
tacto con el fluido no adecuado como asõÂ tambieÂn los
tubos flexibles.
Si el fluido no adecuado ha entrado en el puente y se
ha mezclado con el lubricante, hay que sustituir to-
dos los segmentos de compresioÂn y los O-Rings.
3. Fluide inadeÂquat dans le circuit Substituer tous les joints d'eÂtencheiteÂ du pont et du
maõÃtre-cylindre qui ont eÂteÂ en contact avec ce fluide
mais aussi les tubes flexibles.
Si le fluide incorrect est entreÂ dans le pont et s'est
melange avec le lubrifiant tous les joints d'eÂtancheÂiteÂ
et o-ring doivent eÃtre changeÂs.
117
TROUBLESHOOTING - RICERCA GUASTI - FEHLERSUCHE - BUSQUEDA DE AVERIAS - RECHERCHE DES PANNES

Insufficient braking 4. Loss of brake fluid Inspect for and repair any leaks in outside circuit or
master cylinder.
Frenatura insufficiente If caused by incorrect brake fluid see correction N. 3.
UngeneÈgende Bremswirkung If leak is to the outside replace the o-rings between
the center and intermediate housings.
Frenado insuficiente If leak is to the inside replace above o-rings and brake
Freinage insuffisant piston o-rings.
4. Perdita del fluido dal circuito freno Controllare e riparare tutte le perdite del circuito ester-
no o del circuito master.
Se la causa eÁ dovuta al fluido non idoneo vedere rime-
dio n. 3.
Se la perdita eÁ verso l'esterno del ponte sostituire gli
O-ring tra la scatola centrale ed il coperchio interme-
dio.
Se la perdita eÁ verso l'interno del ponte, sostituire gli
O-ring sopra menzionati e quelli del pistone freno.
4. Verlust von BremsfluÈssigkeit AÈussere Bremsanlage und Hauptbremszylinder auf
OÈ lverluste pruÈfen.
Sollte der Verlust auf ungeeignete Bremsfluessigkeit
zuruÈckzufuÈhren sein, siehe Abhilfe N.3.
Sollte der Verlust nach aussen sein, die O-Ringe zwi-
schen dem AchsmittengehaÈuse und den Zwischen-
gehaÈuse ersetzen.
Sollte der Verlust nach innen sein, oben genannte O-
Ringe und jene der Bremskolben ersetzen.
4. PeÂrdida del fluido del circuito Controlar y reparar todas las peÂrdidas del circuito ex-
del freno terior o del cilindro principal.
Si la causa se debe al fluido no idoÂneo, veÂase el reme-
dio në3.
Si la peÂrdida es hacia fuera del puente, sustituir los O-
Ring entre la caja central y la tapa intermedia.
Si la peÂrdida es hacia el interior del puente, sustituir
los O-Ring mencionados maÂs arriba y los del pistoÂn
del freno.
4. FluideÂ dans le circuit de freinage Inspecter et reÂparer toutes les fuites du circuit ex-
terne ou du maõÃtre-cylindre.
Si la cause est duÃe aÁ l'utilisation d'un fluide non in-
dique voir remeÁde N. 3.
Si la fruite est vers l'exterieur du pont, substituer les
o-rings entre le carter central et les carters interme-
diaires.
Si la fruite est vers l'interieur du pont substituer les o-
rings mentionneÂs ci-dessus et ceux des pistons frein.
5. Overheated axle causing brake See «overheating» problem.

fluid to vaporize.
(Brake return when axle cools)
5. Surriscaldamento del ponte con va- Vedere problema: Surriscaldamento.
porizzazione del fluido.
(I freni ritornano quando il ponte si
raffredda)
5. Verdunstung der Bremsflussigkeit È berhitzung.
Siehe Problem: U
wegen UÈ berhitzung.
(Im abgekuÈhlten Zustand ist die
Bremswirkung wieder hergestellt)
5. Sobrecalentamiento del puente con VeÂase el problema: Sobrecalentamiento.
vaporizacioÂn del fluido.
(Los frenos vuelven a funcionar
cuando se enfrõÂa el puente)
5. Surchauffe du pont avec vaporisa- Voir probleme: Surchauffe.
tion du fluide.
(Les freins fonctionnent aÁ nouveau
quand le fluide se refroidit).
118
Soft brake pedal 6. Air in brake circuit Bleed brakes as described in the vehicle's service
manual.
Pedale del freno non risponde
6. Aria nel circuito frenante Spurgare il circuito frenante come da istruzioni di spur-
Leichtes Bremspedal go del manuale del veicolo.
El pedal del freno no funciona 6. Luft in der Bremsanlage Bremsen entluÈften gemaÈû Anweisungen im Hand-
Pedale du frein ne repond pas buch des Failrzeuges.
6. Aire en el circuito frenante Purgar el circuito frenante se acuerdo con las instruc-
ciones de purga del manual del vehõÂculo.
6. Air dans le circuit Purger le circuit de frein selon «instructions de purge»
du manuel du veÂhicule.
Ineffective safety brake 7. Incorrect adjustment See correction N. 1.

Freno negativo inefficiente 7. Registrazione incorretta Vedere rimedio N. 1.
Federspeicherbremse ohne 7. Fehlerhafte Einstellung des Siehe Abhilfe N. 1.
Funktion. Bremsscheibenspieles
Freno negativo ineficiente 7. Ajuste incorrecto VeÂase remedio N.1.
Inefficacite du frein negatif 7. Mauvais reglage Voir remeÁde N. 1.
8. Brake disc worn out See correction N. 2.

8. Dischi freno usurati Vedere rimedio N. 2.
8. Bremslamellen verschlissen Siehe Abhilfe N. 2.
8. Discos del freno gastados VeÂase remedio N. 2.
8. Usure disques frein Voir remeÁde N. 2.
Overheating 9. Oil level wrong Drain, flush and refill oil to proper level.
Surriscaldamento 9. Livello olio non corretto Scaricare, eseguire un lavaggio e riempire d'olio fino a
È berhitzung livello.
U
È lspiegel-Falscher
9. Niedriger O OÈ l ablassen, reinigen und richtigen O
È lstand wieder
Sobrecalentamiento È lstand
O herstellen.
Surchauffe 9. Nivel de aceite no correcto Descargar, ejecutar un lavado y llenar con aceite has-
ta el nivel.
9. Niveau d'huile pas incorrect Vidanger, rincer et refaire le niveau d'huile.
10. Too small of a brake gap Readjust brakes to the specifications in the vehicle's
service manual.
10. Poco gioco tra i dischi freno Registrare il freno come istruzioni da manuale del vei-
colo.
10. Zu wenig Spiel zwischen den Spiel gemaÈû Anweisungen im Handbuch des Fahr-
Bremslamellen zeuges herstellen.
10. Poco juego entre los discos del Ajustar el freno de acuerdo con las instrucciones del
freno manual del vehõÂculo
10. Peu de jeu entre les disques frein Regler le frein selon les instructions du manuel du veÂ-
hicule.
11. Park brake dragging Unlock the brake and adjust the correct gap.
11. Freno di parcheggio in trazione Sbloccare il freno ripristinando il gioco corretto.
11. Feststellbremse zieht Bremsen loÈsen und richtiges Lamellenspiel einstel-
len.
11. Freno de estacionamiento en Desbloquear el freno restableciendo el juego correcto.
traccioÂn
11. Frein de parc mal reÂgleÂ DeÂbloquer le frein et reÂgler le jeu.
119

Overheating 12. Incorrect brake fluid in system See correction N. 3.

Surriscaldamento 12. Fluido non idoneo nel circuito Vedere rimedio N. 3.
È berhitzung
U 12. Ungeeignete FluÈssigkeit in der Siehe Abhilfe N. 3.
Bremsanlage
Sobrecalentamiento
12. Fluido no adecuado en el circuito VeÂase remedio N. 3
Surchauffe
12. Fluide incorrect dans le circuit Voir remeÁde N. 3.
13. No free-pedal at master cylinder Readjust brake pedal as described in the vehicle's
service manual.
13. Non c'eÁ corsa a vuoto sul cilindro Registrare il pedale del freno come istruzioni da ma-
master nuale del veicolo.
13. Kein Leerweg am Bremspedal Bremspedal gemaÈû Anweisungen im Handbuch des
Fahrzeuges einstellen.
13. No hay carrera en vacõÂo en el Ajustar el pedal del freno de acuerdo con las instruc-
cilindro principal ciones del manual del vehõÂculo.
13. Pas de garde sur la pedale du ReÂgler la pedale du frein selon les instructions du ma-
maõÃtre-cylindre nuel du veÂhicule.
14. Restriction in brake lines Inspect for and replace damage lines.
14. Restringimento sul circuito del Controllare e riparare i condotti ammaccati o piegati.
freno
14. Verengung in der Bremsanlage Anlage uÈberpruÈfen und verbeulte oder geknickte Lei-
tungen ersetzen.
14. Circuito del freno restringido Controlar y reparar los conductos golpeados o plega-
dos.
14. Reglage sur circuit du frein Inspecter et reÂparer les conduites endommageÂes.
15. Restriction in return line of brake Inspect for and replace damaged return line.
Servo system Inspect for and remove any filter, tee'd in line or any
other source of back pressure from the return line.
15. Restringimento sul condotto di Controllare e riparare il condotto ammaccato o piegato.
ritorno del sistema servo Controllare e sostituire tutti i filtri e raccordi sul circuito o
qualsiasi altro ostacolo nel condotto di ritorno.
15. Verengung in der RuÈckflussleitung Anlage uÈberpruÈfen und verbeulte oder geknickte Lei-
des Servobremssystems tungen ersetzen.
Alle Filter und Abzweigungen in der Anlage uÈberpruÈ-
fen, saÈmtliche Hindernisse fuÈr den freien Durchfluû
entfernen.
15. Conducto de retorno del sistema Controlar y reparar el conducto golpeado o plegado.
servo restringido Controlar y sustituir todos los filtros y empalmes en el
circuito o cualquier otro obstaÂculo en el conducto de
retorno.
15. Etranglement sur la conduite de Inspecter et reÂparer la conduite endommageÂe.
retour du servo-frein Inspecter et changer tous les filtres, raccords en «T»
ou autre obstacle sur le circuit de retour.
16. Incorrect lubricant Change the retaining rings of the brake circuit and
brake pump.
16. Lubrificante non idoneo Sostituire gli anelli di tenuta del circuito freno e della
pompa freno.
16. Ungeeignetes Schmieroel Die Abdichtungsringe des Bremskreislaufs der Brem-
spumpe ersetzen.
16. Lubricante no adecuado Sustituir los segmentos de compresioÂn del circuito del
freno y de la bomba del freno.
16. Lubrifiant incorrect Replacer les anneaux d'eÂtancheÂiteÂ du circuit et de la
pompe de frein.
120
Diff-lock inoperative 17. If manual control, loose or misadju- Inspect and correct linkage and readjust as indicated
sted linkage in vehicle's service manual.
Il blocco differenziale non
funziona 17. Se il comando eÁ manuale: comando Controllare, riparare e registrare il comando indicato
scollegato o registrato male nel manuale del veicolo.
Differentialsperre ohne
Wirkung 17. Bei mechanisch betaÈtigter Sperre, Hebel uÈberpruÈfen und gemaÈû Anweisungen im Hand-
loser oder schlecht eingestellter buch des Fahrzeuges einstellen.
El bloque del diferencial Hebel
no funciona
17. Si el mando es manual: mando des- Controlar, reparar y ajustar el mando indicado en el
Mauvais fonctionnement du conectado o mal ajustado manual del vehõÂculo.
blocage du diffeÂrentiel
17. Si la commande est manuel: com- Inspecter, reÂparer er reÂgler la commande selon le ma-
mande deÂconnecteÂe ou mal reÂgleÂe nuel du veÂhicule.
18. If hydraulic control, problems in the Refer to the service manual for the vehicle.
hydraulic or electrical circuits of the
vehicle
18. Se il comando eÁ idraulico: problemi Fare riferimento alle istruzioni nel manuale del veicolo.
nel circuito elettrico del veicolo
18. Bei hydraulisch betaÈtigter Sperre, Siehe Anweisungen im Handbuch des Fahrzeuges.
Probleme in der hydraulischen oder
elektrischen Anlage des Fahrzeuges
18. Si el mando es hidraÂulico: problemas Consultar las instrucciones del manual del vehõÂculo.
en el circuito eleÂctrico del vehõÂculo
18. Si la commande est hydraulique: Voir instructions dans manuel du veÂhicule.
probleÁme dans le circuit eÂlectrique
dans le veÂhicule
19. If hydraulic control: problems in ac- Rebuilt cylinder.

tuating cylinder (noteable through
loss of hydraulic oil or increase of
the oillevel in axle)
19. Se il comando eÁ idraulico: problemi Controllare e riparare il cilindro.
nell'attuatore (caratterizzati da per-
dite del fluido idraulico o da aumen-
to del livello d'olio nel ponte)
19. Bei hydraulisch betaÈtigter Sperre, È berpruÈfen und Zylinder reparieren.
U
OÈ lverlust im BetaÈtigungszylinder
(erkentlich durch Verlust von hy-
draulisch Fluessigkeit oder Anstieg
des Oelniveaus in der Achse)
19. Si el mando es hidraÂulico: proble- Controlar y reparar el cilindro.
mas en el actuador (caracterizados
por peÂrdidas del fluido hidraÂulico o
por un aumento del nivel del aceite
en el puente)
19. Si la commande est hydraulique: Inspecter et reparer le cylindre.
probleÁmes dans le veÂrin (caracteri-
seÂs par des fuites de fluide hydrau-
lique ou augmentation du niveau
d'huile dans le pont)
20. If with lim. slip differential, worn Replace discs.

discs
20. Se il differenziale eÁ del tipo Sostituire i dischi.
autobloccante, dischi usurati
20. Wenn mit Selbstsperrdifferential, Scheiben ersetzen.
Scheiben verschlissen
20. Si el diferencial es del tipo autoblo- Sustituir los discos.
queante: discos gastados
20. Si avec diffeÂrentiel aÁ glissement Remplacer les disques.
limiteÂ, usure sur les disques
121

Oil coming out of breather 21. Leak in internal brake system See correction N. 2 and 3.
Olio fuoriesce dallo sfiato 21. Perdita di fluido idraulico dal siste- Vedere rimedio N. 2 e 3.
È laustritt aus dem EntluÈfter ma frenante
O
21. Verlust von hydraulisch FluÈssigkeit Siehe Abhilfe N. 2 und 3.
El aceite sale del purgador der Bremsanlage
Huile sort du reniflard 21. PeÂrdida de fluido hidraÂulico del sis- VeÂanse remedios N. 2 y 3.
tema frenante
21. Fuite de fluide hydraulique du sys- Voir remeÁde N. 2 et 3.
teme de freinage
22. Leak in diff-lock actuating cylinder See correction N. 19.

22. Perdita d'olio idraulico dal circuito Vedere rimedio N. 19.
del blocco differenziale
22. Verlust von Hydraulisch FluÈssigkeit Siehe Abhilfe N. 19.
der hydraulisch Anlage der Diffe-
rentialsperre
22. PeÂrdida de aceite hidraÂulico del cir- VeÂase remedio N. 19.
cuito del bloque del diferencial
22. Fuite d'huile hydraulique du circuit Voir remeÁde N. 19.
de blocage du diffeÂrentiel
NoSpin indexing noise when 23. Unequal tire pressure left anal right Inflate tires to the recommended pressure in the ser-
driving straight vice manual, or until the rolling radius is equal.
CAUTION! With NoSpin, fatigue
damage can occur on the side 23. Pressione disuguale nei pneumatici Gonfiare i pneumatici alla pressione raccomandata nel
with the larger tire. sui due lati manuale o comunque fino ad ottenere un raggio stati-
co uguale.
Il NoSpin eÁ rumoroso viaggian-
do sul rettilineo 23. UngleichmaÈssiger Reifendruck Reifen vorschriftsgemaÈû auf pumpen bis ein gleich-
ATTENZIONE! Con il NoSpin links und rechts groûer statischer Halbmesser erreicht wird.
possono verificarsi avarie da fa- 23. PresioÂn desigual en los neumaÂticos Hinchar los neumaÂticos a la presioÂn recomendada en
tica sul lato con il pneumatico a ambos lados el manual o, de todas formas, hasta obtener un rayo
piuÁ grande.
estaÂtico igual.
NoSpin macht GeraÈusche bei
Geracheausfahrt 23. Pressions diffeÂrentes dans les Gonfler les pneumatiques selon la pression recom-
ACHTUNG! Mit NoSpin koÈnnen
pneumatiques sur les deux cotes mandeÂe dans le manuel os jusq'aÁ obtenir le meÃme
auf der Seite mit dem groÈsseren du veÂhicule rayon sous charge.
Reifenradius ErmuÈdungsschaÈ-
den auftreten.
24. Different style, size or brand of tires Change tires to make the rolling radius equal.
El NoSpin hace ruido andando between left and right hand side Vary the tire pressure within the specifications until
en un rectilõÂneo the rolling radius is equal.
CUIDADO! con el No Spin se
pueden producir averõÂas por fa- 24. Pneumatico di disegno, marca o co- Cambiare pneumatici o rendere i raggi statici dei pneu-
tiga en un lado en el neumaÂtico struttore diversi sui due lati matici eguali.
maÂs grande. Variare la pressione dei pneumatici nei campi di tolle-
ranza prescritti dai costruttori dei pneumatici stessi, fi-
Le No-Spin fait du bruit en rou- no ad ottenere un raggio statico uguale.
lant en ligne droite
ATTENTION! Avec le NoSpin, 24. Unterschiedliche Reifen, -groÈûen - Reifen ersetzen sodaû ein gleich-groûer Statischer
des ruptures de fatigue peu- marken, links und rechts Halbmesser erreicht wird.
vent se produire du coÃteÂ des Reifendruck im Bereich der Vorschriften aÈndern bis
pneumatiques les plus grands. ein gleichgroûer Halbmesser erreicht wird.
24. NeumaÂticos de disenÄo, marca o fa- Cambiar los neumaÂticos o hacer que los rayos estaÂti-
bricante distintos a los dos lados cos de los neumaÂticos sean iguales.
Variar la presioÂn de los neumaÂticos en los campos de
tolerancia prescritos por los fabricantes de dichos
neumaÂticos, hasta obtener un radio estaÂtico igual.uÁ
24. Pneumatiques de sculptures ou de Changer les pneumatiques ou rendre les rayons sans
constructeurs differents sur les charge des pneumatiques eÂgaux.
deux coÃtes du vehicule Modifier la pression des pneumatiques dans les toleÂ-
rances prescrites par les constructeurs de ces me-
mes pneumatiques, jusq'aÁ obtenir un rayon sous
charge identique.
122
Noise during coast and under

power the same
25. Wheel bearings damaged Replace and adjust.
RumorositaÁ uguale sia in tiro
che in rilascio 25. Cuscinetti dei mozzi danneggiati Sostituire i particolari in avaria.
GeraÈusch im Zug und im 25. Lager der Radnaben beschaÈdigt BeschaÈdigte Teile gemaÈû Anweisungen.
Schub gleich stark 25. Cojinetes de los cubos danÄados Sustituir las piezas averiadas.
Ruido igual tanto en traccioÂn 25. Roulements des moyeux endom- Remplacer les pieÁces endommageÂes.
como en inercia mageÂs
Bruit en traction ou en retenue
Noise under power greater 26. Low oil level Refill oil to proper level.
than during coast
26. Livello olio basso Ripristinare il livello olio.
RumorositaÁ piuÁ elevata in tiro È lstand È lstand wieder
26. Niedriger O SchmieroÈl nachfuÈllen bis richtiger O
piuttosto che in rilascio
hergestellt ist.
GeraÈeusch staÈerker im Zug als
26. Nivel de aceite bajo Restablecer el nivel del aceite.
im Schub
26. Niveau d'huile insuffisant Refaire le niveau d'huile.
Ruido maÂs elevado en traccioÂn
que en inercia
Bruit pus eÂleve en traction 27. Incorrect lubricant See correction N. 16.
qu'en retenue. 27. Olio non idoneo Vedere rimedio N. 16.
27. Ungeeignetes SchmieroÈl Siehe Abhilfe N. 16.
27. Aceite no adecuado VeÂase remedio N. 16.
27. Huile incorrect Voir remeÁde N. 16.
28. Ring and pinion worn Inspect through top cover. Replace and adjust.
28. Coppia conica usurata Controllare attraverso il coperchio superiore.
Sostituire la coppia conica.
28. Kegel- und Tellerrad verschlissen Durch die obere Bohrung uÈberpruÈfen. Kegel- und Tel-
lerrad ersetzen.
28. Par coÂnico gastado Controlar a traveÂs de la tapa superior.
Sustituir el par coÂnico.
28. Usure du couple conique Inspectioner au travers du couvercle superieur.
Remplacer le couple conique.
29. Worn ring and pinion bearings Replace and adjust.

29. Cuscinetti della coppia conica Sostituire i particolari in avaria.
usurati
29. Kegelrollenlager des Kegel- und BeschaÈdigte Teile ersetzen.
Tellerradpaares verschlissen
29. Cojinetes del par coÂnico gastados Sustituir las piezas averiadas.
29. Usure des roulements du couple Remplacer les pieÁces endommageÂes.
conique
30. Worn planetary gears or bearings Replace.

30. Planetari o cuscinetti dell'epicicloi- Sostituire i particolari in avaria.
dale usurati
30. PlanetenraÈder oder Lager der Pla- BeschaÈdigte Teile ersetzen.
netenabtriebe verschlissen
30. Planetarios y cojinetes del epicicloi- Sustituir las piezas averiadas.
dal gastados
30. Usure des planeÂtaires ou roule- Remplacer les pieÁces endommageÂes.
ment de l'eÂpicycloõÈdale
123

Noise during coast greater 31. Loose pinion nut Inspect ring, pinion and pinion bearings. If unda-
than under power maged, retighten nut.
RumorositaÁ piuÁ elevata in rilas- 31. Ghiera pignone allentata Controllare la coppia conica ed i rispettivi cuscinetti,
cio piuttosto che in tiro se non fossero danneggiati serrare la ghiera.
GeraÈeusch staÈerker im Schub 31. Wellenmutter des Kegelritzels lose Kegel- und Tellerrad und Lager uÈberpruÈfen. Sollten
als im Zug diese nicht beschaÈdigt sein, Wellenmutter anziehen.
Ruido maÂs elevado en inercia 31. Virola del pinÄoÂn floja Controlar el par coÂnico y los cojinetes correspondientes.
que en traccioÂn
31. Ecrou du pinion deÂvisseÂ Inspecter le couple conique et les roulements et si
Bruit plus eÂleve en retenue rien n'est endommageÂ, resserrer l'ecrou.
qu'en traction
See correction N. 29.
32. Only pinion bearing damaged
32. Solo un cuscinetto del pignone eÁ
Vedere rimedio N. 29.
danneggiato
32. Nur eines der Lager des Kegelrit-
Siehe Abhilfe N. 29.
zels ist beschaÈdigt
32. SoÂlo un cojinete del pinÄoÂn estaÂ da-
VeÂase remedio N. 29.
nÄado
32. Seulement un roulement du pignon
Voir remeÁde N. 29.
est endommageÂ
Noise during turn

(without NoSpin) 33. Worn spider and/or side gears Replace.
Rumore sotto sterzo 33. Satelliti e/o planetari del differenzia- Sostituire i particolari danneggiati.
(senza NoSpin) le danneggiati
GeraÈusch waÈhrend der 33. Ausgleich kegelraÈder und/oder BeschaÈdigte Teile ersetzen.
Kurvenfahrt (ohne NoSpin) welleraÈder verschlissen
Ruido en la direccioÂn 33. SateÂlites y/o planetarios del diferen- Sustituir las piezas danÄadas.
(sin NoSpin) cial danÄados
Bruit en braquage 33. Satellites et/ou planeÂtaires du diffeÂ- Remplacer les pieÁces endommageÂes.
(sans NoSpin) rentiel endommageÂes
A «Stick slip» noise when 34. Worn or damaged cardanshaft Inspect and replace as described in vehicle's service
going from forward to reverse manual.
Un rumore tipo «Stick slip» si 34. Giunto cardanico danneggiato Controllare e sostituire il giunto come indicato nel ma-
manifesta durante l'inversione nuale del veicolo.
di marcia È berpruÈfen und Kardanwelle gemaÈû. Anweisungen
34. Kardanwelle beschaÈdigt U
«Stick slip» -GeraÈusch bei AÈn- im Handbuch des Fahrzeuges ersetzen.
derung der Fahrtrichtung
34. Junta cardaÂnica danÄada Controlar y sustituir la junta como se indica en el ma-
Un ruido tipo «Stick slip» se nual del vehõÂculo.
manifiesta al invertir la marcha
34. Joint cardan endommageÂ Inspecter et remplacer le joint cardan selon les indi-
Un bruit type «Stick slip» se cations du manuel du veÂhicule.
manifeste pendant l'inversion
35. Loose wheel Inspect for wheel and wheel stud damage. Replace if
needed and retorque lugnuts.
35. Ruota allentata Ispezionare eventuali danni al disco ed alle colonnette
del mozzo ruota, se necessario sostituire i particolari
danneggiati e serrare i dadi alla coppia prescritta.
35. Rad lose Eventuelle SchaÈden an der Felge und an den Radbol-
zen uÈberpruÈfen. Falls erforderlich beschaÈdigte Teile
ersetzen und Radmuttern gemaÈû vorgeschriebenem
Drehmoment anziehen.
35. Rueda floja Inspeccionar los posibles danÄos al disco y a las colum-
nas del cubo de la rueda; si fuera necesario, sustituir las
piezas danÄadas y apretar las tuercas al par prescrito.
35. Roue deÂvisseÂe Inspecter les eÂventuels dommages au disque et aux
goujons du moyeu de rue. Si neÂcessaire remplace les
pieces endommageÂes et serrer les eÂcrous au couple
prescrit.
124
A «Stick slip» noise when 36. Articulation box joint and achsel Inspect and replace.
going from forward to reverse shaft damaged
Un rumore tipo «Stick slip» si 36. Giunti della scatola snodo, semiassi Ispezionare e sostituire i particolari danneggiati.
manifesta durante l'inversione o snodi di sterzatura danneggiati
di marcia È berpruÈfen und beschaÈdigte Teile ersetzen.
36. Kupplung des GelenkgehaÈuseg, U
«Stick slip» -GeraÈusch bei AÈn- Halbachse beschaÈdigt
derung der Fahrtrichtung
36. Juntas de la caja de la roÂtula, semie- Inspeccionar y sustituir las piezas danÄadas.
Un ruido tipo «Stick slip» se je o perno de direccioÂn danÄados
manifiesta al invertir la marcha
36. Joint boõÃtier d'articulation, demi-es- Inspecter et remplacer les pieÁces endommageÂes.
Un bruit type «Stick slip» se sieu endommageÂ
manifeste pendant l'inversion
37. Spider pins loose in diff-carrier Inspect through top cover. Replace.
37. Satelliti liberi nella scatola differen- Controllare attraverso il coperchio superiore, sostituire
ziale i particolari danneggiati.
37. Ausgleich kegelraÈder im Differen- Durch die obere Bohrung uÈberpruÈfen. BeschaÈdigte
tial lose Teile ersetzen.
37. SateÂlites libres en la caja del dife- Inspectioner au travers du couvercle superieur.
rencial
37. Satellites libres dans le carter cen- Remplacer les pieÁces endommageÂes.
tral
38. Damaged or missing spider and/or See correction N. 33.

side gear washers
38. Rondelle di rasamento del differen- Vedere rimedio N. 33.
ziale usurate
38. Anlaufscheiben im Differential ver- Siehe Abhilfe N. 33.
schlissen
38. Arandelas de espesor del diferen- VeÂase remedio N. 33.
cial gastadas
38. Usure des rondelles du diffeÂrentiel Voir remeÁde N. 33.
125
OPTIONAL DEVICES
GB MECHANICAL PARKING BRAKE 4" INCOMING BRAKE (2 AND 3 FUNCTION VERSIONS)
. Removal and disassembly ................................... 128 . Disassembly....................................................................... 164
. Assembly and installation ................................................... 132 . Assembly ........................................................................... 174
EXTERNAL HYDRAULIC NEGATIVE BRAKE LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%)
. Removal and disassembly .................................................. 136 . Disassembly....................................................................... 184
EXTERNAL HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE HYDRAULIC DIFFERENTIAL LOCK
INCOMING DRUM BRAKE INCORPORATED REDUCTION GEAR AND PINION (602)
DISPOSITIVI OPTIONALI
ITA FRENO DI STAZIONAMENTO A COMANDO MECCANICO FRENO IN ENTRATA DA 4" (A 2 E 3 FUNZIONI)
. Rimozione e smontaggio.................................... 128 . Smontaggio........................................................................ 164
. Assemblaggio ed installazione ............................................ 132 . Assemblaggio .................................................................... 174
FRENO NEGATIVO IDRAULICO ESTERNO DIFFERENZIALE A SLITTAMENTO LIMITATO (25% E 45%)
. Rimozione e smontaggio .................................................... 136 . Smontaggio........................................................................ 184
FRENO NEGATIVO IDRAULICO ESTERNO CON SBLOCCAGGIO RAPIDO BLOCCAGGIO DIFFERENZIALE A COMANDO IDRAULICO
FRENO A TAMBURO IN ENTRATA RIDUTTORE INTEGRATO (602)
OPTIONEN
D FESTSTELLBREMSE MIT MECHANISCHER STEUERUNG BREMSE AM EINGANG ZU 4" (MIT 2 UND 3 FUNKTIONEN)
. Entfernen und abmontieren............................... 128 . Abmontieren ...................................................................... 164
. Zusammenbau und Installation ........................................... 132 . Zusammenbau ................................................................... 174
AÈUûERE HYDRAULISCHE NEGATIVBREMSE È GEN (25% UND 45%)
DIFFERENTIAL MIT BEGRENZTEM GLEITVERMO
. Entfernen und abmontieren................................................. 136 . Abmontieren ...................................................................... 184
AÈUûERE HYDRAULISCHE NEGATIVBREMSE MIT SCHNELLENTSICHERUNG DIFFERENTIALBLOCKIERUNG MIT HYDRAULISCHER STEUERUNG
TROMMELBREMSE AM EINGANG INTEGRIERTER REDUZIERER (602)
DISPOSITIVI OPTIONALI
ESP GRUPO FRENO ESTACIONAMIENTO MECANICO FRENO EN ENTRADA DE 4" (A 2 Y 3 FUNCIOONES)
. Remocion y desmontaje.................................... 128 . Desmontaje........................................................................ 164
. Asemblaje y instalacion ...................................................... 132 . Instalacion ......................................................................... 174
FRENO NEGATIVO HYDRAULICO EXTERIOR DIFERENCIAL A DESLIZAMIENTO LIMITADO (25% Y 45%)
. Remocion y desmontaje ..................................................... 136 . Desmontaje........................................................................ 184
FRENO NEGATIVO HYDRAULICO ESTERNO CON SBLOQUEO RAPIDO BLOQUEO DIFERENCIAL A MANDO HYDRAULICO
FRENO DE TAMBOR EN ENTRADA REDUCTOR ENCORPORADO Y PINON (602)
DISPOSITIFS OPTIONNELS
F FREIN DE STATIONNEMENT MECANIQUE FREIN EN ENTREE 4" (A 2 ET 3 FONCTIONS)
. Enlever et deÂmonter ......................................... 128 . DeÂmonter........................................................................... 164
. Assemblage et installation .................................................. 132 . Assembler.......................................................................... 174
FREIN NEGATIF HYDRAULIQUE EXTERNE DIFFERENTIEL A GLISSEMENT REDUIT (25% ET 45%)
. Enlever et deÂmonter ........................................................... 136 . DeÂmonter........................................................................... 184
FREIN NEGATIF HYDRAULIQUE EXTERNE AVEC DEBLOCAGE RAPIDE BLOCAGE DIFFERENTIEL A COMMANDE HYDRAULIQUE
FREIN A TAMBOUR EN ENTREE REDUCTEUR INTEGRE (602)
126
(9$2!5,)# .%'!4)6% "2!+% &2%./ .%'!4)6/ )$2!5,)#/
'" 2EMOVAL AND DISASSEMBLY )4! 2IMOZIONE E SMONTAGGIO
!SSEMBLY AND INSTALLATION !SSEMBLAGGIO ED INSTALLAZIONE
(9$2!5,)3#(% .%'!4)6"2%-3% &2%./ .%'!4)6/ (9$2!5,)#/

$ %NTFERNEN UND ABMONTIEREN %30 2EMOCION Y DESMONTAJE
:USAMMENBAU UND )NSTALLATION !SEMBLAJE Y INSTALACION
&2%). .%'!4)& (9$2!5,)15%

& %NLEVER ET D£MONTER
!SSEMBLAGE ET INSTALLATION
127
HOW TO DISASSEMBLE THE MECHANIC PARKING BRAKE UNIT - SMONTAGGIO GRUPPO FRENO DI STAZIONAMENTO A COMANDO
MECCANICO - MECHANISQUE HANDBREMSE ABMONTIEREN - DESMONTAJE GRUPO FRENO ESTACIONAMIENTO MECANICO -
DEMONTAGE DU FREIN DE STATIONNEMENT MECANIQUE
2
3
F1240657 F1240658
GB a GB b
NOTE. The same disassembly procedure applies to both arms and Draw out the screw (1) locking the washer (2) that stops the lever
may only be carried out when levers (3) are released. (3).
Disconnect the tension bar from the steering case. For details, see
«HOW TO REMOVE THE STEERING CYLINDER».
6
2
4 3 7
12 13
F1240659
5 F1240660
GB c GB d
Remove washer (2), lever (3) and O-rings (4). Draw out the screws (5) and remove bush (6) along with O-ring (7).
Mark the positions of levers (3) in relation to the thrust levers (12)
and (13).
10
8 F1240641
9 F1240661
GB e GB f
Connect the whole arm (8) to the hoist and put the rod under light Remove the braking disks (9) and the whole piston (10).
tension. For details, see «CHECKING AND REPLACING THE BRAKING
Remove the whole arm; for details, see «CHECKING AND DISKS».
REPLACING THE BRAKING DISKS».
128
NOTA. Lo smontaggio eÁ uguale per i due bracci e puoÁ Asportare la vite (1) di bloccaggio della rondella (2) di
ITA essere eseguito solo a leve (3) libere. ITA ritegno della leva (3).
Scollegare dalla scatola snodo il tirante di sterzatura.
Per i dettagli, vedere «RIMOZIONE CILINDRO DI STERZATURA».
BEMERKUNG. Beide Arme werden auf dieselbe Die Schraube (1) zur Befestigung der Unterlegscheibe
D Weise abmontiert; dies kann jedoch nur erfolgen, D (2) des Hebels (3) abschrauben.
wenn die Hebel (3) frei sind.
Spannstange vom GelenkgehaÈuse abtrennen.
a Weitere Einzelheiten im Paragraph «LENKZYLINDER ABMONTIE-
REN».
b
NOTA El desmontaje es ugual por los dos brazos y Sacar el tornillo (1) de bloqueo de la arandela (2) de
ESP puede ser efectuado solo a palancas (3) libres. ESP retencion palanca (3).
Desconectar del carter de las rotulas el tirante de
direccion.
Para los detalles, vease «REMOCION CILINDRO DE DIRECCION».
NOTE. Le deÂmontage est pareil pour les deux bras et Enlever la vis (1) de blocage de la rondelle (2) de
F ne peut eÃtre effectueÂ que lorsque les leviers (3) sont F fixation du levier (3).
libres.
DeÂbrancher de la boõÃte articulation la tringle de braquage.
Pour tout deÂtail, voir «DEPOSE CYLINDRE DE BRAQUAGE».
Rimuovere la rondella (2), la leva (3) e le guarnizioni Asportare le viti (5) e rimuovere la boccola (6) completa
ITA OR (4). ITA di guarnizione OR (7).
Contrassegnare le posizioni delle leve (3) rispetto le
leve di spinta (12) e (13).
Unterlegscheibe (2), Hebel (3) und O-Ringe (4) ab- Schrauben (5) abschrauben und Buchse (6) samt O-
D nehmen. D Ring (7) abnehmen.
Die Positionen der Hebel (3) im VerhaÈltnis zu den
Druckhebeln (12) und (13) kennzeichnen.
c d
Remover la arandela (2), la palanca (3) y las Sacar los tornillos (5) y remover el casquillo (6)
ESP guarniciones OR (4). ESP completo de guarniciones OR (7).
Senalar las posicioÁnes de las palancas (3) respecto a
las palancas de empuje (12)
Enlever la rondelle (2), le levier (3) et les garnitures OR Enlever les vis (5) et extraire la douille (6) eÂquipeÂe de
F (4). F garnitures OR (7).
Marquer les positions des leviers (3) par rapport aux
leviers (12) et (13).
Agganciare il braccio completo (8) ad un mezzo di Rimuovere i dischi freni (9) ed il pistone completo (10).
ITA sollevamento e mettere il leggera tensione la fune. ITA Per i dettagli, vedere «CONTROLLO E SOSTITUZIO-
Rimuovere il braccio completo; per i dettagli, vedere NE DISCHI FRENI».
«CONTROLLO E SOSTITUZIONE DISCHI FRENI».
VollstaÈndigen Arm (8) mit einem Hebekarren anheben Bremsscheiben (9) und den ganzen Kolben (10)
D bis das Seil gespannt ist. D abnehmen. Weitere Einzelheiten im Paragraph
VollstaÈndigen Arm abtrennen; weitere Einzelheiten im «BREMSSCHEIBEN KONTROLLIEREN UND AUS-
Paragraph «BREMSSCHEIBEN KONTROLLIEREN UND AUS- WECHSELN».
e WECHSELN». f
Enganchar el brazo completo (8) y un medio de Remover los discos frenos (9) y el piston completo
ESP levantamiento y poner en ligera tension el cable. ESP (10).
Remover el brazo completo; por los detalles, vease Por los detalles, vease «CONTROL Y SUSTITUCION
«CONTROL Y SUSTITUCION DISCOS FRENOS». DISCOS FRENOS».
Accrocher le bras complet (8) aÁ un moyen de relevage Enlever les disques freins (9) et le piston complet (10).
F et mettre la corde leÂgeÁrement en tension. F Pour tout deÂtail, voir «CONTROLE ET SUBSTITUTION
Enlever le bras complet: pour tout deÂ tail, voir DES DISQUES FREINS».
«CONTROLE ET SUBSTITUTION DES DISQUES FREINS».
129
HOW TO DISASSEMBLE THE MECHANIC PARKING BRAKE UNIT - SMONTAGGIO GRUPPO FRENO DI STAZIONAMENTO A COMANDO
MECCANICO - MECHANISQUE HANDBREMSE ABMONTIEREN - DESMONTAJE GRUPO FRENO ESTACIONAMIENTO MECANICO -
DEMONTAGE DU FREIN DE STATIONNEMENT MECANIQUE
10
8
11
14 12 13
F1240662 F1240663
GB a GB b
If pins (11) need replacing, block the piston (10) into a vice whose If thrust levers (12) and (13) need replacing, remove the U-joint (14)
jaws are covered in smooth material and remove the pins. before removing the arms (8).
For details, see «HOW TO REMOVE THE U-JOINT».
1
16 2
15 4
3
4
5 6
GB c 12 GB d
13
11
10
8 14
9
11
F1240079
GB e GB f
130
Se si devono sostituire i puntali (11), bloccare il Se si devono sostituire le leve di spinta (12) e (13),
ITA pistone (10) in una morsa con ganasce in materiale ITA prima di rimuovere i bracci (8) rimuovere il giunto
tenero e rimuovere i puntali. cardanico (14).
Per i dettagli, vedere «RIMOZIONE DEL DOPPIO GIUNTO
CARDANICO».
Falls die Schafte (11) ausgewechselt werden sollen, Falls die Druckhebel (12) und (13) ausgewechselt
D Kolben (10) in einem Spannbackenpaar aus weichem D werden sollen, zuerst die Doppelgelenkwelle (14) und
Material blockieren und Schafte abnehmen. dann die Arme (8) abnehmen. Weitere Einzelheiten im
Paragraph «DOPPELGELENKWELLE INSTALLIEREN».
a b
Si se deben cambiar las puntas (11), bloquear el Si se deben cambiar las palancas de empuje (12) y
ESP piston (10) en un corchete con mordazas en material ESP (13), antes de remover los brazos (8) remover los
tierno y remover las puntas. semiejes (14).
Por los detalles, vease «REMOCION DE LOS SEMIEJES».
Si l'on doit substituer les tiges (11), bloquer le piston Si l'on doit substituer les leviers de pousseÂe (12) et
F (10) dans un eÂtau aÁ maÃchoire en mateÂriel tendre, puis F (13), avant d'enlever les bras (8) enlever le joint de
enlever les tiges. cardan double (14).
Pour tout deÂtail, voir «DEPOSE DE JOINT DE CARDAN DOUBLE».
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
131
HOW TO ASSEMBLE THE MECHANIC PARKING BRAKE UNIT - ASSEMBLAGGIO GRUPPO FRENO DI STAZIONAMENTO A COMANDO
MECCANICO - MECHANISQUE HANDBREMSE MONTIEREN - ASEMBLAJE GRUPO FRENO ESTACIONAMIENTO MECANICO -
ASSEMBLAGE DU FREIN DE STATIONNEMENT MECANIQUE
10
11
14 12 13
F1240663 F1240664
GB a GB b
Install thrust levers (12) and (13), then install the U-joint (14). For Apply Loctite 270 to the threaded portion of the pins (11) and fit
details, see «HOW TO INSTALL THE U-JOINT». them onto the piston (10).
Block them: torque wrench setting 30 ± 35 Nm.
10
9 F1240661
8 F1240641
GB c GB d
Re-install the piston (10) and the braking disks (9). For details, see Install the arms (8) into the main body; check flatness and block
«HOW TO ASSEMBLE THE BRAKING UNITS». arms following the appropriate procedures illustrated in section
«HOW TO ASSEMBLE THE BRAKING UNITS».
6
1
3
5
F1240665 F1240666
GB e GB f
Install the bush (6) complete with O-ring (7) and block it with screws Install in sequence the lower O-ring (4), the lever (3) and the washer
(5). Tighten screws with a torque wrench setting of 23.8 ± 26.2 Nm. (2) with the relative O-ring (4). Block with screw (1) and tighten
using a torque wrench setting of 23.8 ± 26.2 Nm.
CAUTION! Refer and keep to the positions marked during
disassembly.
132
Montare le leve di spinta (12) e (13) e successivamente Spalmare la filettatura dei puntali (11) con Loctite 270
ITA il doppio giunto cardanico (14). ITA e montarli sul pistone (10).
Per i dettagli di montaggio del doppio giunto cardani- Bloccarli con una coppia di serraggio di 30v35 Nm.
co, vedere «INSTALLAZIONE DEL DOPPIO GIUNTO CARDANI-
CO».
Druckhebel (12) und (13) montieren; danach Doppel- Schafte (11) mit Loctite 270 schmieren und auf den
D gelenkwelle (14) montieren. D Kolben (10) montieren.
Weitere Einzelheiten im Paragraph «DOPPELGELEN- Anzugsmoment: 30v35 Nm.
KWELLE INSTALLIEREN».
a b
Montar la palancas de empuje (12) y (13) y al final los Pasar la rosca de las puntales (11) con Loctite 270 y
ESP semiejes (14). ESP montarlas sobre los pistones (10).
Por los detalles de montaje de los semiejes, vease Bloquearlos con un par de torsion de 30v35 Nm.
«INSTALACION DE LOS SEMIEJES».
Monter les leviers de pousseÂe (12) et (13) et ensuite le Enduire le filetage des tiges (11) avec du Loctite 270
F joint de cardan double (14). F puis les monter sur le piston (10).
Pour tout deÂtail, voir «DEPOSE DE JOINT DE Bloquer aÁ un couple de serrage de 30v35 Nm.
CARDAN DOUBLE».
Rimontare il pistone (10) ed i dischi freno (9). Montare i bracci (8) sul corpo centrale; controllare il
ITA Per i dettagli, vedere «ASSEMBLAGGIO DEI GRUPPI ITA livellamento e quindi bloccarli con le modalitaÁ descritte
DI FRENATURA». per l'«ASSEMBLAGGIO DEI GRUPPI DI FRENATU-
RA».
Kolben (10) und Bremsscheiben (9) wieder montieren. Die Arme (8) auf den zentralen KoÈrper montieren;
D Weitere Einzelheiten im Paragraph «ZUSAMMENBAU D danach abrichten und laut Anweisungen des Para-
DER BREMSAGGREGATE». graphs «ZUSAMMENBAU DER BREMSAGGREGAT»
blockieren.
c d
Remontar los pistones (10) y los discos frenos (9). Montar los brazos (8) sobre el cuerpo central, controlar
ESP Por los detalles, vease «ASEMBLAJE DE LOS ESP el nivelamiento y entonces bloquearlos con las
GRUPOS DE FRENADURA». modalidades descritas por «ASEMBLAJE DE LOS
GRUPOS DE FRENADURA».
Remonter le piston (10) et les disques freins (9). Monter les bras (8) sur le corps central; controÃler le
F Pour tout deÂtail, voir «ASSEMBLAGE DES GROUPES F niveau, puis bloquer en suivant le mode deÂcrit dans
DE FREINAGE». l'«ASSEMBLAGE DES GROUPES DE FREINAGE».
Montare la boccola (6) completa di guarnizione OR (7) Montare nell'ordine la guarnizione OR inferiore (4), la
ITA e bloccarla con le viti (5). ITA leva (3) e la rondella (2) completa della relativa
Serrare le viti con una coppia di 23,8v26,2 Nm. guarnizione OR (4).
Bloccarla con la vite (1) serrata ad una coppia di 23,8v26,2 Nm.
ATTENZIONE! Rispettare le posizioni contrassegnate in fase di
smontaggio.
Buchse (6) samt O-Ring (7) montieren und mit den Der Reihenfolge nach den unteren O-Ring (4), Hebel
D Schrauben (5) festschrauben. D (3) und Unterlegscheibe (2) samt O-Ring (4) montieren.
Anzugsmoment der Schrauben: 23,8v26,2 Nm. Mit der Schraube (1) festschrauben. Anzugsmoment
der Schraube: 23,8v26,2 Nm.
e f ACHTUNG! Die beim Abmontieren markierten Positionen einhal-
ten.
Montar el casquillo (6) completa de guarnicion OR (7) y Montar en el orden la guarnicion OR inferior (4), la
ESP bloquearla con tornillos (5). ESP palanca (3) y la arandela (2) completa de la relativa
Apretar los tornillos con un par de 23,8v26,2 Nm. guarnicion OR (4).
Bloquearla con el tornillo (1) apretada a un par de 23,8v26,2 Nm.
ATENCION! Respectar las posicioÁnes senaladas en fase de
montaje.
Monter la douille (6) eÂquipeÂe de garniture OR (7) et Monter dans l'ordre la garniture OR infeÂrieure (4), le
F bloquer cette dernieÁre avec les vis (5). F levier (3) et la rondelle (2) eÂquipeÂe de sa relative
Serrer les vis aÁ un couple de serrage de 23,8v26,2 garniture OR (4).
Nm. Bloquer celle-ci avec la vis (1) serrer aÁ un couple de 23,8v26,2 Nm.
ATTENTION! Respecter les positions noteÂes en phase de
deÂmontage.
133
HOW TO ASSEMBLE THE MECHANIC PARKING BRAKE UNIT - ASSEMBLAGGIO GRUPPO FRENO DI STAZIONAMENTO A COMANDO
MECCANICO - MECHANISQUE HANDBREMSE MONTIEREN - ASEMBLAJE GRUPO FRENO ESTACIONAMIENTO MECANICO -
ASSEMBLAGE DU FREIN DE STATIONNEMENT MECANIQUE
16 6
3
16
15
8÷10 N
3 (0,8÷1 kg)
F1240936 F1240938
GB a GB b
Connect the braking circuit and apply maximum working pressure Apply a force of 8 ± 10 N (0.8 ± 1 kg) to lever (3). Direct the force
to set the disks. towards the braking direction in order to eliminate the idle stroke.
Release the pressure, loosen nut (15) and unscrew dowel (16) by a While the force is being applied, tighten dowel (16) until it is caused
few turns. to rest onto bush (6).
16
15
F1240936
GB c GB d
Lock dowel (16) in this position with nut (15). CAUTION! After connecting the control cable, check that when
Torque wrench setting: 20 ± 25 Nm. brakes are released both dowels (16) do lean against bush (6).
CAUTION! The idle stroke should be eliminated without preloading
thrust levers (12) and (13).
GB e GB f
134
Collegare il circuito frenante ed inserire la massima Applicare alla leva (3) una forza di 8v10 N (0,8v1 kg),
ITA pressione di lavoro per assestare i dischi. ITA diretta nel senso di frenatura per eliminare la corsa a
Rilasciare la pressione, allentare il dado (15) e svitare vuoto.
di qualche giro il grano (16). Mantenendo la forza, avvitare il grano (16) fino all'appoggio sulla
boccola (6).
Den Bremskreislauf anschlieûen und den maximale Auf den Hebel (3) eine Kraft von 8v0 N (0,8v1 kg) in
D Arbeitsdruck einlassen, um die Scheiben zu setzen. D die Bremsrichtung anbringen, um den leeren Lauf
Den Druck ablassen, die Mutter (15) lockern und den auszuschlieûen.
Stift (16), um einige Umdrehungen aufschrauben. Bei angebrachter Kraft, Stift (16) aufschrauben, bis er an der
a b Buchse (6) anliegt.
Conectar el circuito frenante y introducir la maxima Aplicar a la palanca (3) una fuerza de 8v10 N (0,8v1
ESP presioÁn de trabajo para ajustar los discos. ESP kg), directa en el sentido de frenadura para eliminar la
Soltar la presion, aflojar las tuercas (15) y destornillar carrera a vacio.
de algun giro la espiga (16). Manteniendo la fuerza, atornillar la espiga (16) hasta el apoyo
sobre el casquillo (6).
Brancher le circuit freinant et inseÂrer le maximum de Appliquer au levier (3) une contrainte de 8v10 N
F pression d'usinage pour ajuster les disques. F (0,8v1 kg), orienteÂe dans le sens du freinage pour
RelaÃcher la pression, desserrer l'eÂcrou (15) et deÂvisser eÂliminer la course aÁ vide.
le grain (16) de quelques tours. En maintenant la contrainte, visser le grain (16) jusqu'aÁ ce qu'il se
pose sur le fourreau (6).
Bloccare il grano (16) in questa posizione con il dado (15). ATTENZIONE! Dopo il collegamento del cavo di coman-
ITA Coppia di serraggio: 20v25 Nm. ITA do, controllare che in fase di rilascio dei freni, ambedue i
ATTENZIONE! La corsa a vuoto va eliminata senza grani (16) vadano in appoggio sulla boccola (6).
precaricare le leve di spinta (12) e (13).
Stift (16) in dieser Position mit der Mutter (15) blok- ACHTUNG! Nach dem Anschluû des Steuerkabels,
D kieren. D kontrollieren, ob beim Loslassen der Bremsen, beide
Anzugsmoment: 20v25 Nm. Stifte (16) an der Buchse anliegen (6).
ACHTUNG! Der leere Lauf muû beseitigt werden ohne die
c Druckhebel (12) und (13) vorzuladen. d
Bloquear la espiga (16) en esta colocacion con la ATENCION! Despues de la conexion del cable de
ESP tuerca (15). ESP mando, controlar que en fase de suelte de los frenos,
Par de torsion: 20v25 Nm. las dos espigas (16) vayan en apoyo sobre el
ATENCION! La carrera a vacio debe de ser eliminada sin precargar casquillo (6).
las palancas de impulso (12) y (13).
Bloquer le grain (16) dans cette position aÁ l'aide de ATTENTION! ApreÁs avoir brancheÂ le caÃ ble de
F l'eÂcrou (15). F commande, controÃler que pendant la phase de
Couple de serrage: 20v25 Nm. relaÃchement des freins, les deux grains (16) aillent
ATTENTION! La course aÁ vide doit eÃtre eÂlimineÂe sans preÂcharger se poser sur l'embout (6).
les leviers d'appui (12) et (13).
ITA ITA
D D
e f
ESP ESP
F F
135
HOW TO REMOVE AND DISASSEMBLE THE EXTERNAL HYDRAULIC NEGATIVE BRAKE - RIMOZIONE E SMONTAGGIO FRENO NEGATIVO
IDRAULICO ESTERNO - AÈUûERE HYDRAULISCHE NEGATIVBREMSE ABMONTIEREN - REMOCION Y DESMONTAJE FRENO NEGATIVO
HYDRAULICO EXTERIOR - ENLEVER ET DEMONTER DU FREIN NEGATIF HYDRAULIQUE EXTERNE
F1240947 F1240951
bar GB a GB b
Insert pressure into cylinder (4) in order to release the brakes. Loosen and remove the external nut (7).
NOTE. If the machine hydraulic system cannot be used, use an
external manual pump.
3
8
4
2
F1240948 F1240949
GB c GB d
Release the pressure in the cylinder and disconnect the pressure Remove the snap ring (1) that checks the support (8) and remove
delivery tube. the distance piece (2).
Remove the fulcrum pin (3) from the cylinder (4).
4 D
6 5
9
4 13
12
8 10
F1240950 F1240747
GB e GB f
Remove the cylinder assembly (4) complete with rod (5), internal Place cylinder (4) into a vice with the spring seat side (10) engaged
nut (6) and support (8). in it and, using a bar "D", loosen and remove the cylinder unit (9)
complete with piston (13) and spring (12).
136
Immettere pressione nel cilindro (4) per sbloccare i Allentare ed asportare il dado esterno (7).
ITA freni. ITA
NOTA. Se non eÁ possibile utilizzare l'impianto
idraulico macchina, utilizzare una pompa manuale esterna.
Den Druck in den Zylinder (4) lassen, um die Bremsen Die aÈuûere Mutter (7) abschrauben.
D frei zu machen. D
BEMERKUNG: Falls die hydraulische Anlage der
Maschine nicht verwendet werden kann, eine manuelle getrennte
a Pumpe verwenden. b
Meter presioÁn en el cilindro (4) para bloquear los Aflojar y sacar la tuerca esterna (7).
ESP frenos. ESP
NOTA. Si no es posible utilisar el equipo hydralico
maquina, utilisar una pompa manual exterior.
Envoyer de la pression dans le cylindre (4) pour Desserrer et enlever l'eÂcrou externe (7).
F deÂbloquer les freins. F
NOTE. Si utiliser l'installation hydraulique de la
machine n'est pas possible, utiliser une pompe manuelle externe.
Rilasciare la pressione del cilindro e scollegare il tubo Rimuovere l'anello elastico (1) di ritegno supporto (8)
ITA di mandata della pressione. ITA ed asportare il distanziale (2).
Rimuovere il perno di fulcro (3) del cilindro (4).
Den Druck vom Zylinder ablassen und die Druck- Den Kolbenring (1) der Halterung (8) abnehmen und
D leitung abtrennen. D das DistanzstuÈck (2) abnehmen.
Den Zentrierstift (3) des Zylinders (4) abnehmen.
c d
Solter la presioÁn del cilindro y desconectar el tubo de Remover el anillo elastico (1) de retencion suporte (8) y
ESP ida de la presioÁn. ESP sacar el distancial (2).
Remover la rotula (3) del cilindro (4).
RelaÃcher la pression du cylindre et deÂbrancher le tube Enlever l'anneau aÁ ressort (1) de retenue au support
F de refoulement de pression. Enlever l'axe du point F (8), puis enlever l'entretoise (2).
d'appui (3) du cylindre (4).
Rimuovere il gruppo cilindro (4), completo di asta (5), Fissare il cilindro (4) in una morsa dal lato sede molla
ITA dado interno (6) e supporto (8). ITA (10) e, utilizzando una barra "D", allentare ed
asportare il corpo cilindro (9) completo di pistone (13)
e la molla (12).
Das Zylinderaggregat (4) samt Stab (5), innere Mutter Den Zylinder (4) in einem Spannstock an der Feder-
D (6) und Halterung (8) abnehmen. D seite (10) einklemmen und mit dem Stab "D" den
ZylinderkoÈrper (9) lockern und samt Kolben (13) und
Feder (12) abnehmen.
e f
Remover el grupo cilindro (4), completo de varilla (5), Fijar el cilindro (4) en un corchete del lado muelle (10)
ESP tuerca interna (6) y suporte (8). ESP y, utilizando un varilla "D", aflojar y sacar el cuerpo
cilindro (9) completo de piston (13) y el muelle (12).
Enlever le groupe cylindre (4), complet de tige (5), Fixer le cylindre (4) dans un eÂtau du coÃteÂ du sieÁge
F eÂcrou interne (6) et support (8). F ressort (10), puis aÁ l'aide dune barre "D", desserrer et
enlever le corps cylindre (9) complet du piston (13) et
du ressort (12).
137
HOW TO REMOVE AND DISASSEMBLE THE EXTERNAL HYDRAULIC NEGATIVE BRAKE - RIMOZIONE E SMONTAGGIO FRENO NEGATIVO
IDRAULICO ESTERNO - AÈUûERE HYDRAULISCHE NEGATIVBREMSE ABMONTIEREN - REMOCION Y DESMONTAJE FRENO NEGATIVO
HYDRAULICO EXTERIOR - ENLEVER ET DEMONTER DU FREIN NEGATIF HYDRAULIQUE EXTERNE
14 15 14
15 14
14
13 9
13
F1240748 F1240749
bar GB a GB b
Gently introduce the union piece of the cylinder unit (9) so as to Remove seals (14) and guide ring (15) from the piston (13).
eject the piston (13). NOTE. Note down seals direction of assembly.
CAUTION! Hold the piston as it may be forced out rapidly and be
damaged.
10
11
F1240750
GB c GB d
ONLY IF NECESSARY
Remove the guide ring (11) from the spring seat (10).
CAUTION! If the guide ring (11) is removed, it must be replaced.
11 10
6 12
7
8 16
15
5 13
14
17 9
18 3
4
19
GB e GB f
2
1 4
D1240101
138
Immettere lentamente il raccordo del corpo cilindro (9) Rimuovere dal pistone (13) le guarnizioni (14) e
ITA per espellere il pistone (13). ITA l'anello di guida (15).
ATTENZIONE! Trattenere il pistone che puoÁ essere NOTA. Annotare il senso di montaggio delle guarni-
espulso velocemente ed essere danneggiato. zioni.
Langsam das AnschluûstuÈck des ZylinderkoÈrpers (9) Den Kolben (13), die Dichtungen (14) und den
D einsetzen, um den Kolben (13) auszustoûen. D FuÈhrungsring (15) abnehmen.
ACHTUNG! Den Kolben halten, denn er koÈnnte BEMERKUNG. Montagerichtung der Dichtungen be-
ploÈtzlich herausspringen und beschaÈdigt werden. merken.
a b
Meter lentamente el empalme del cuerpo cilindro (9) Remover del piston (13) las guarniciones (14) y el
ESP para la expulsion del piston (13). ESP anillo de guõÁa (15).
ATENCION! Tener el piston que puede ser expulso NOTA. Anotar el sentido de desmontaje de las
rapidamente y danarse. guarniciones.
Introduire lentement le raccord du corps cylindre (9) et Enlever du piston (13) les garnitures (14) et la bague
F expulser le piston (13). F de guidage (15).
ATTENTION! Retenir le piston qui expulseÂ rapide- NOTE. Prendre note du sens de montage des
ment peut par conseÂquent s'endommager. garnitures.
SOLO SE NECESSARIO
ITA Rimuovere dalla sede molla (10) l'anello di guida (11). ITA
ATTENZIONE! Se l'anello di guida (11) viene smonta-
to, deve essere sostituito.
NUR WENN NOTWENDIG

D Aus dem Federsitz (10) den FuÈhrungsring (11) D
nehmen.
ACHTUNG! Falls der FuÈhrungsring (11) abmontiert wird, muû er
c ausgewechselt werden. d
SOLO SI NECESARIO
ESP Remover de la sede muelle (10) el anillo de guõÁa (11). ESP
ATENCION! Si el anillo de guõÁa (11) viene desmon-
tado, debe de ser sobstituido.
SEUL SI BESOIN
F Enlever du sieÁge ressort (10), la bague de guidage F
(11).
ATTENTION! Si la bague de guidage (11) est deÂmonteÂe, il faut la
substituer.
ITA ITA
D D
e f
ESP ESP
F F
139
HOW TO ASSEMBLE AND INSTALL THE EXTERNAL HYDRAULIC NEGATIVE BRAKE - ASSEMBLAGGIO ED INSTALLAZIONE FRENO NEGATIVO
IDRAULICO ESTERNO - AÈUûERE HYDRAULISCHE NEGATIVBREMSE MONTIEREN - ASEMBLAJE Y INSTALACION FRENO NEGATIVO
HYDRAULICO EXTERIOR - ASSEMBLAGE ET INSTALLATION DU FREIN NEGATIF HYDRAULIQUE EXTERNE
14 15 14
13 9
15 14
14
13
F1240749 F1240751
GB a GB b
Install guide ring (15) and seals (14) onto the piston (13). Lubricate the seals (14) and the inside of the cylinder (9); introduce
CAUTION! Carefully check seals assembly direction. the whole piston and move it to end of stroke.
10
12 9
11
10
F1240750 F1240752
GB c GB d
If guide ring has been removed, insert a new one (11) into the seat Position the spring seat (10) in a vice and insert spring (12).
of the spring. Lubricate the thread. Assemble the whole cylinder (9).
Lubricate the guide ring.
5
4
10
F1240753 F1240958
GB e GB f
Screw the cylinder (9) into the spring seat (10) and lock it using a Apply Loctite 270 to the rod (5) and screw it in the piston (13) as far
bar "D". as it will go.
140
Montare sul pistone (13) l'anello di guida (15) e le Lubrificare le guarnizioni (14) e l'interno del cilindro
ITA guarnizioni (14). ITA (9); inserire il pistone completo e mandarlo a fine
ATTENZIONE! Controllare attentamente il senso di corsa.
montaggio delle guarnizioni.
Auf den Kolben (13) den FuÈhrungsring (15) und die Dichtungen (14) und das Zylinderinnere (9) schmieren;
D Dichtungen (14) montieren. D den vollstaÈndigen Kolben einsetzen und bis zum
ACHTUNG! Auf die Montagerichtung der Dichtungen Anschlag einschieben.
sorgfaÈltig achten.
a b
Montar sobre el piston (13) el anillo de guõÁa (15) y las Lubrificar las guarniciones (14) y el interno del cilindro
ESP guarniciones (14). ESP (9); introducir el piston completo y mandarlo a final de
ATENCION! Controlar atentamente el sentido de carrera.
montaje de las guarniciones.
Monter sur le piston (13) la bague de guidage (15) et Lubrifier les garnitures (14) aÁ l'inteÂrieur du cylindre (9);
F les garnitures (14). F y introduire le piston complet et l'envoyer en fin de
ATTENTION! ControÃler attentivement le sens du course.
montage des garnitures.
Se eÁ stato smontato, inserire il nuovo anello di guida Posizionare la sede molla (10) in una morsa ed inserire
ITA (11) nella sede molla (10). ITA la molla (12).
Lubrificare l'anello di guida. Lubrificare la filettatura. Montare il cilindro completo (9).
Falls der FuÈhrungsring (11) abmontiert worden ist, Federsitz (10) in einen Spannbock einklemmen und
D diesen in den Federsitz (10) einsetzen. D die Feder (12) einsetzen.
Den FuÈhrungsring schmieren. Gewinde schmieren. Den vollstaÈndigen Zylinder (9)
montieren.
c d
Si ha sido desmontado, introducir el nuevo anillo de Colocar la sede muelle (10) en un corchete y introducir
ESP guõÁa (11) en la sede muelle (10). ESP un muelle (12).
Lubrificar el anillo de guõÁa. Lubrificar la rosca. Montar el cilindro completo (9).
Si elle a eÂteÂ deÂmonteÂe, introduire la bague de guidage Placer le sieÁge ressort (10) dans un eÂtau et y introduire
F neuve (11) dans le sieÁge ressort (10). F le ressort (12).
Lubrifier la bague de guidage. Lubrifier le filetage. Monter le cylindre complet (9).
Avvitare il cilindro (9) nella sede molla (10) e bloccarlo Spalmare l'asta (5) con Loctite 270 ed avvitarla a
ITA utilizzando una barra "D". ITA fondo nel pistone (13).
Den Zylinder (9) in den Sitze der Feder (10) schrauben Den Stab (5) mit Loctite 270 schmieren und in den
D und mit Hilfe des Stabs "D" blockieren. D Kolben (13) festschrauben.
e f
Atornillar el cilindro (9) en la sede muelle (10) y Pasar la varilla (5) con Loctite 270 y aternillarla a fondo
ESP bloquearlo utilizando una varilla "D". ESP en el piston (13).
Visser le cylindre (9) dans le sieÁge ressort (10), puis Enduire la tige (5) avec du Loctite 270 et visser celle-ci
F bloquer celui-ci aÁ l'aide d'une barre "D". F aÁ fond dans le piston (13).
141
HOW TO ASSEMBLE AND INSTALL THE EXTERNAL HYDRAULIC NEGATIVE BRAKE - ASSEMBLAGGIO ED INSTALLAZIONE FRENO NEGATIVO
IDRAULICO ESTERNO - AÈUûERE HYDRAULISCHE NEGATIVBREMSE MONTIEREN - ASEMBLAJE Y INSTALACION FRENO NEGATIVO
HYDRAULICO EXTERIOR - ASSEMBLAGE ET INSTALLATION DU FREIN NEGATIF HYDRAULIQUE EXTERNE
19 2
8÷10 N
(0,8÷1 kg)
1
17 18
F1240756 F1240949
GB a GB b
Loosen nuts (17) and set braking levers (19) clearances to zero by Install distance piece (2) and insert the pin of support (10) into the
turning dowels (18); lock nuts (17) with a torque wrench setting of right-hand braking lever. Fit the second distance piece (2) and snap
20 ± 25 Nm. ring (1).
CAUTION! Clearances should be set to zero without causing any
preloading.
4 3
5
5
6
F1240947 F1240757
bar
GB c GB d
Install cylinder (4) complete with rod (5) and internal nut (6). Centre the hole of fulcrum pin (3).
Apply Loctite 242 to the pin thread, screw and tighten pin with a
dynamometric wrench set at 25 ± 30 Nm.
18 7 18
6 4 ÷ 5 mm 4
A
5
8 19
19 13
F1240951 D1240100
GB e GB f
Introduce pressure into the cylinder (4) and whilst holding both Check that, when the brakes are released (pressure inserted),
levers (19) back against the adjusting screws (18), move nuts (6) levers (19) do lean against the screws (18) without prestressing
and (7) so that they are made to rest against support (8); lock the them and make sure that a clearance "A" is left between cylinder
nuts with a torque wrench setting of 50 ± 60 Nm. (4) and lever (19).
Also check that when pressure is released, piston (13) projects out
by 4 ± 5 mm.
142
Allentare i dadi (17) ed azzerare i giochi delle leve di Montare il distanziale (2) ed infilare il perno del
ITA frenatura (19) con i grani (18); bloccare i dadi (17) ad ITA supporto (10) nella leva di frenatura destra. Montare
una coppia di 20v25 Nm. il secondo distanziale (2) e l'anello elastico (1).
ATTENZIONE! I giochi devono risultare azzerati senza provocare
precarico.
Muttern (17) lockern und die Spiele der Bremshebel Das DistanzstuÈck (2) montieren und den Halterungs-
D (19) mit den Stiften (18) zuruÈckstellen; die Mutter (17) D stift (10) in den rechten Bremshebel einsetzen. Das
bei einem Anzugsmoment von 20v25 Nm bockieren. zweite DistanzstuÈck (2) in den Kolbenring (1) montie-
ACHTUNG! Die Spiele muÈssen zuruÈckgestellt werden, ohne das ren.
a Teil vorzuladen. b
Aflojar las tuercas (17) y poner a zero los juegos de las Montar el distancial (2) y insertar el perno del suporte
ESP palancas de frenadura (19) con las espigas (18); ESP (10) en la palanca de frenadura derecha. Montar el
bloquear las tuercas (17) a un par de 20v25 Nm. segundo distancial (2) y el anillo elastico.
ATENCION! Los guegos deben de resultar a zero sin provocar
precarga.
Desserrer les eÂcrous (17) et mettre aÁ zeÂro les jeux des Monter l'entretoise (2), puis introduire l'axe du support
F leviers de freinage (19) avec les grains (18); bloquer F (10) dans le levier de freinage droit. Monter la
les eÂcrous (17) aÁ un couple de 20v25 Nm. deuxieÁme entretoise (2) et l'anneau aÁ ressort (1).
ATTENTION! Les jeux doivent eÃtre mis aÁ zeÂro sans provoquer de
preÂcharge.
Montare il cilindro (4) completo di asta (5) e del dado Centrare il foro del perno di fulcro (3).
ITA interno (6). ITA Spalmare la filettatura del perno (3) con Loctite 242,
avvitarlo e serrarlo con chiave dinamometrica tarata a
25v30 Nm.
Den Zylinder (4) samt Stab (5) und innere Mutter (6) Das Loch des Zentrierstiftes (3) zentrieren.
D montieren. D Das Stiftgewinde (3) mit Loctite 242 schmieren und mit
einem MomentenschluÈssel bei 25v30 Nm fest ziehen.
c d
Montar el cilindro (4) completo de varilla (5) y de la Centrar el agujero de la rotula del fulcro (3).
ESP tuerca interna (6). ESP Pasar la rosca de la rotula (3) con Loctite 242,
atornillarlo y apretarlo con llave dinamometrica tarada
a 25v30 Nm.
Monter le cylindre (4) eÂquipeÂ de la tige (5) et de l'eÂcrou Centrer le trou de l'axe du fourreau (3).
F interne (6). F Enduire le filetage de l'axe (3) avec du Loctite 242,
visser et serrer celui-ci aÁ l'aide d'une cleÂ dynamomeÂ-
trique calibreÂe aÁ 25v30 Nm.
Immettere pressione nel cilindro (4) e, mantenendo Controllare che a freni sbloccati (pressione inserita), le
ITA entrambe le leve (19) appoggiate alle viti di registro ITA leve (19) vadano in appoggio sulle viti (18) senza
(18), mandare in appoggio i dadi (6) e (7) sul supporto precaricarle e che tra cilindro (4) e leva (19) rimanga
(8); bloccare i dadi con una coppia di 50v60 Nm. un gioco "A".
Controllare anche che a pressione rilasciata, il pistone (13) abbia
una sporgenza di 4v5 mm.
Den Druck in den Zylinder (4) einlassen. Beide Hebel Kontrollieren, ob bei freien Bremsen (eingelassener
D (19) an den Stellschrauben (18) anliegen lassen und D Druck), die Hebel (19) an den Schrauben (18) an-
die Muttern (6) und (7) bis zum Anschlag der Halterung liegen, ohne sie vorzuladen und ob zwischen Zylinder
(8) bringen; die Muttern mit einem Anzugsmoment von 50v60 Nm (4) und Hebel (19) ein Spiel "A" besteht.
e fest ziehen. f Kontrollieren, ob bei abgelassenem Druck, der Kolben (13) um 4v5
mm herausragt.
Meter presioÁn en el cilindro 4)y, manteniendo las dos Controlar que a frenos bloqueados (presioÁn insertada),
ESP palancas (19) en apoyo a las tuercas de registro (18), ESP las palancas (19) vayan en apoyo sobre los tornillos
mandasr en apoyo las tuercas (6) y (7) sobre el suporte (18) sin precargarlas y que entre el cilindro (4) y la
(8); bloquear las tuercas con un par de 50v60 Nm. palanca (19) haya un juego "A".
Controlar tambien que a presioÁn soltada el piston (13) tenga una
resalte de 4v5 m/m.
Emettre de la pression dans le cylindre (4), puis en ControÃler que lorsque les freins sont deÂbloqueÂs
F maintenant les deux leviers (19) poseÂs sur les vis de F (pression introduite), les leviers (19) aillent se poser
reÂglage (18), envoyer les eÂcrous (6) et (7) en appui sur sur les vis (18) sans preÂcharger ces dernieÁres, et
le support (8); bloquer les eÂcrous aÁ un couple de 50v60 Nm. qu'entre cylindre (4) et levier (19) il y ait un jeu "A".
ControÃler eÂgalement que lorsque la pression est relaÃcheÂe, le piston
(13) ait une saillie de 4v5 mm.
143
HOW TO DISASSEMBLE THE EXTERNAL HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE - SMONTAGGIO FRENO NEGATIVO IDRAULICO ESTERNO CON
SBLOCCAGGIO RAPIDO - AÈUûERE HYDRAULISCHE NEGATIVBREMSE MIT SCHNELLENTSICHERUNG ABMONTIEREN - DESMONTAJE FRENO NEGATIVO
HYDRAULICO ESTERNO CON SBLOQUEO RAPIDO - ENLEVER ET DEMONTER DU FREIN NEGATIF HYDRAULIQUE EXTERNE AVEC DEBLOCAGE RAPIDE
F1240761 F1240738
GB a GB b
CAUTION! Before starting any operation on the assembly, disable Remove snap ring (1) and extract distance piece (2).
the cylinder by giving a light hammer blow to the external ring of
the check unit.
3 4
4
F1240739 F1240740
GB c GB d
Remove the fulcrum pin (3) from the cylinder (4). Remove the complete cylinder set (4).
9
10 7
5 6
8
7
9
F1240741 F1240742
GB e GB f
Remove snap ring (5) from stem (6) and extract the check unit (7). Remove snap ring (8) and washer (9) and separate support (10) and
second washer (9) from the check unit (7).
144
ATTENZIONE! Prima di intervenire nel gruppo, Rimuovere l'anello elastico (1) ed asportare il distan-
ITA disattivare l'azione del cilindro con un leggero colpo ITA ziale (2).
di mazzuolo sull'anello esterno del gruppo di ritegno.
ACHTUNG! Bevor am Aggregat gearbeitet wird, die Den Kolbenring (1) entfernen und das DistanzstuÈck (2)
D Zylinderwirkung mit einem leichten Hammerschlag auf D abnehmen.
den aÈuûeren Ring des Halteaggregats loÈschen.
a b
ATENCION! Antes de intervenir en el grupo, desco- Remover el anillo elastico (1) y sacar el distancial (2).
ESP nectar la accioÁn del cilindro con un lijero golpe de ESP
martillo sobre el anillo esterior del grupo de retencioÁn.
ATTENTION! Avant d'intervenir dans le groupe, Enlever l'anneau aÁ ressort (1), puis enlever l'entretoise
F deÂsactiver l'action du cylindre par un leÂger coup de F (2).
maillet sur l'anneau externe du groupe de fixation.
Rimuovere il perno di fulcro (3) del cilindro (4). Asportare il gruppo cilindro completo (4).
ITA ITA
Den Zentrierstift (3) des Zylinders (4) abnehmen. Gesamtes Zylinderaggregat (4) abnehmen.
D D
c d
Remover la rotula de fulcro (3) del cilindro (4). Sacar el grupo cilindro completo (4).
ESP ESP
Enlever l'axe du fourreau (3) du cylindre (4). Enlever le groupe cylindre complet (4).
F F
Rimuovere l'anello elastico (5) dallo stelo (6) e sfilare il Asportare l'anello elastico (8), la rondella (9) e
ITA gruppo di ritegno (7). ITA separare dal gruppo di ritegno (7) il supporto (10) e
la seconda rondella (9).
Den Kolbenring (5) vom Schaft (6) abnehmen und das Den Kolbenring (8), die Unterlegscheibe (9) abnehmen
D Halteaggregat (7) abziehen. D und das Halteaggregat (7) von der Halterung (10) und
der Unterlegscheibe (9) trennen.
e f
Remover el anillo elastico (5) del vastago (6) y deshilar Sacar el anillo elastico (8), la arandela (9) y separar del
ESP el grupo de retencioÁn (7). ESP grupo de retencioÁn (7) el suporte (10) y la segunda
arandela (9).
Enlever l'anneau aÁ ressort (5) de la tige (6) et extraire Enlever l'anneau aÁ ressort (8), la rondelle (9) et
F le groupe de retenue (7). F seÂparer du groupe de retenue (7) le support (10) et
la deuxieÁme rondelle (9).
145
C
A 11 B
7 12
F1240743 F1240744
GB a GB b
Introduce an M14x100 screw "A" into the hole of the check unit (7) Rotate snap ring (12) until ring ends match slot "C".
and screw a nut "B" until the spring seat (11) is moved to the end of Remove snap ring (12).
stroke.
NOTE. Use a T.C.E.I. screw.
14 18
15 16 17
11
13 6
14
11 B
F1240745 F1240746
GB c GB d
Slowly release nut "B" and disassemble the check unit. Loosen nut (17) and remove stem (6) from the cylinder (18).
19
23 19
19 23
22
20
F1240747 F1240748
GB e bar
GB f
Place the cylinder in a vice with the spring seat (20) side engaged Slowly introduce air through the union piece of the cylinder unit (19)
in it and, using a bar "D", loosen and remove the cylinder unit (19) to expel the piston (23).
complete with piston (23) and spring (22). CAUTION! Hold the piston as it may be rapidly ejected and
damaged.
146
Inserire nel foro del gruppo di ritegno (7) una vite "A" Far ruotare l'anello elastico (12) fino a portare le
ITA da M14x100 ed avvitare un dado "B" fino a mandare a ITA estremitaÁ in corrispondenza della nicchia "C".
fondo corsa la sede molla (11). Rimuovere l'anello elastico (12).
NOTA. Usare una vite T.C.E.I.
In das Loch des Halteaggregats (7) eine Schraube "A" Den Kolbenring (12) drehen, bis die Enden die Nische
D M14x100 einsetzen und eine Mutter "B" bis zum D "C" erreichen.
Federsitz (11) einschrauben. Kolbenring (12) abnehmen.
BEMERKUNG. Eine T.C.E.I. Schraube verwenden.
a b
Insertar en el agujero del grupo de retencioÁn (7) un Hacer girar el anillo elastico (12) hasta llevar las
ESP tornillo "A" de M14x100 y atornillar una tuerca "B" ESP extremidades en corrispondencia del nicho "C".
hasta mandar a fondo carrera el alojamiento muelle Remover el anillo elastico (12).
(11).
NOTA. Usar un tornillo T.C.E.I.
Introduire dans le trou du groupe de fixation (7) une vis Faire tourner l'anneau aÁ ressort (12) jusqu'aÁ en
F "A" de M 14 x 100 et visser un eÂcrou "B" jusqu'aÁ F amener l'extreÂmiteÂ face aÁ la niche "C".
envoyer en fin de course le sieÁge ressort (11). Enlever l'anneau aÁ ressort (12).
NOTE. Utiliser une vis T.C.E.I.
Rilasciare lentamente il dado "B" e scomporre il Allentare il dado (17) e rimuovere dal cilindro (18) lo
ITA gruppo di ritegno. ITA stelo (6).
Langsam die Mutter "B" abschrauben und das Mutter (17) lockern und den Schaft (6) vom Zylinder
D Halteaggregat auseinander nehmen. D (18) abnehmen.
c d
Dejar lentamente la turca "B" y descomponer el grupo Aflojar la tuerca (17) y remover del cilindro (18) el
ESP de retencioÁn. ESP vastago (6).
Desserrer lentement l'eÂcrou "B" et deÂsassembler le Desserrer l'eÂcrou (17), puis enlever le cylindre (18) la
F groupe de retenue. F tige (6).
Fissare il cilindro (18) in una morsa dal lato sede molla Immettere lentamente aria attraverso il raccordo del
ITA (20) e, utilizzando una barra "D", allentare ed ITA corpo cilindro (19) per espellere il pistone (23).
asportare il corpo cilindro (19) completo di pistone ATTENZIONE! Trattenere il pistone che puoÁ essere
(23) e la molla (22). espulso velocemente ed essere danneggiato.
Den Zylinder (18) in einem Spannbock an der Langsam Luft durch das AnschluûstuÈck des Zylinder-
D Federseite (20) einklemmen und mit Hilfe des Stabs D koÈrpers (19) einlassen, um den Kolben (23) auszu-
"D" den ZylinderkoÈrper (19) lockern und samt Kolben stoûen.
(23) und Feder (22) abnehmen. ACHTUNG! Den Kolben halten, denn er koÈnnte ploÈtzlich heraus-
e f springen und beschaÈdigt werden.
Fijar el cilindro (18) en un corchete del lado de Meter lentamente aire atraves del empalme del cuerpo
ESP alojamiento de varilla "D", aflojar y sacar el cuerpo ESP cilindro (19) para expulsar el pistoÁn (23).
cilindro (19) completo de piston (23) y el muelle (22). ATENCION! Tener el pistoÁn que puede ser expulso
rapidamente y ser danado.
Fixer le cylindre (18) dans un eÂtau du coÃteÂ du sieÁge Emettre lentement de l'air aÁ travers le raccord du
F ressort (20), puis, aÁ l'aide d'une barre "D", desserrer et F corps cylindre (19) et expulser le piston (23).
enlever le corps cylindre (19) complet de piston (23), ATTENTION! Retenir le piston qui expulseÂ rapide-
puis le ressort (22). ment peut par conseÂquent s'endommager.
147
25 24
20
25 24
24
21
23
F1240749 F1240750
GB a GB b
Remove seals (24) and guide ring (25) from the piston (23). ONLY IF NECESSARY
NOTE. Note down seals installation direction. Remove guide ring (21) from spring seat (20).
CAUTION! If guide ring (21) is taken out, it must be replaced.
21
20
22
25 18
23
5 24
7
12
11 GB c GB d
19
13
14 4
16
9
10
14 6
15
9
8
17 3
26
27
28
2
4
GB 1 e GB f
D1240091
148
Rimuovere dal pistone (23) le guarnizioni (24) e SOLO SE NECESSARIO
ITA l'anello di guida (25). ITA Rimuovere dalla sede molla (20) l'anello di guida (21).
NOTA. Annotare il senso di montaggio delle guarni- ATTENZIONE! Se l'anello di guida (21) viene smonta-
zioni. to, deve essere sostituito.
Den Kolben (23) und die Dichtungen (24) sowie den NUR WENN NO È TIG
D FuÈhrungsring (25) abnehmen. D Vom Federsitz (20) den FuÈhrungsring (21) abnehmen.
BEMERKUNG. Montagerichtung der Dichtungen be- ACHTUNG! Wird der FuÈhrungsring (21) abmontiert,
merken. muû er ausgewechselt werden.
a b
Remover del pistoÁn (23) las guarniciones (24) y el SOLO SI FUERA NECESARIO
ESP anillo de guõÁa (25). ESP Remover del alojamiento muelle (20) el anillo de guõÁa
NOTA. Anotar el sentido de desmontaje de las (21).
guarniciones. ATENCION! Si el anillo de guõÁa (21) viene desmontado, debe de
ser sobstituido.
Enlever le piston (23), les garnitures (24) et la bague SEULEMENT SI BESOIN

F de guidage (25). F Enlever du sieÁge ressort (20) la bague de guidage (21).
NOTE. Noter le sens du montage des garnitures ATTENTION! Une fois la bague de guidage (21)
deÂmonteÂe, elle doit eÃtre substitueÂe.
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
149
HOW TO ASSEMBLE THE EXTERNAL HYDRAULIC NEGATIVE BRAKE WITH QUICK RELEASE - ASSEMBLAGGIO FRENO NEGATIVO IDRAULICO ESTERNO CON
SBLOCCAGGIO RAPIDO - AÈUûERE HYDRAULISCHE NEGATIVBREMSE MIT SCHNELLENTSICHERUNG MONTIEREN - ASEMBLAJE FRENO NEGATIVO
HYDRAULICO ESTERNO CON SBLOQUEO RAPIDO - ASSEMBLAGE ET INSTALLATION DU FREIN NEGATIF HYDRAULIQUE EXTERNE AVEC DEBLOCAGE RAPIDE
25 24
23 19
25 24
24
23
F1240749 F1240751
GB a GB b
Fit guide ring (25) and seals (24) onto the piston (23). Lubricate seals (24) and the inside part of the cylinder (19);
CAUTION! Carefully check seals installation direction. introduce the whole piston and move it to end of stroke.
20
22 18
21
20
F1240750 F1240752
GB c GB d
It the guide ring has been taken out, fit a new one (21) into the Position the spring seat (20) in a vice and insert spring (22).
spring seat (20). Lubricate the thread. Install the whole cylinder (18).
Lubricate the guide ring.
D
17
18 6
20
F1240753 F1240754
GB e GB f
Screw the cylinder (18) into the spring seat (20) and lock it using a Screw stem (6) into the piston without locking the nut (17).
bar "D".
150
Montare sul pistone (23) l'anello di guida (25) e le Lubrificare le guarnizioni (24) e l'interno del cilindro
ITA guarnizioni (24). ITA (19); inserire il pistone completo e mandarlo a fine
ATTENZIONE! Controllare attentamente il senso di corsa.
montaggio delle guarnizioni.
Auf den Kolben (23) den FuÈhrungsring (25) und die Dichtungen (24) und das Zylinderinnere (19) schmie-
D Dichtungen (24) montieren. D ren; den vollstaÈndigen Kolben einsetzen und bis zum
ACHTUNG! Montagerichtung der Dichtungen sorgfaÈl- Anschlag einschieben.
tig kontrollieren.
a b
Montar sobre el piston (23) el anillo de guõÁa (25) y las Lubrificar las guarniciones (24) y el interno del cilindro
ESP guarniciones (24). ESP (19); introducir el piston completo y mandarlo a final de
ATENCION! Controlar atentamente el sentido de carrera.
montaje de las guarniciones.
Monter sur le piston (23) la bague de guidage (25) et Lubrifier les garnitures (24) et l'inteÂrieur du cylindre
F les garnitures (24). F (19); introduire le piston complet et envoyer celui-ci en
ATTENTION! ControÃler attentivement le sens de fin de course.
montage des garnitures.
Se eÁ stato smontato, inserire il nuovo anello di guida Posizionare la sede molla (20) in una morsa ed inserire
ITA (21) nella sede molla (20). ITA la molla (22).
Lubrificare l'anello di guida. Lubrificare la filettatura. Montare il cilindro completo
(18).
Falls der FuÈhrungsring (21) abmontiert worden ist, Federsitz (20) in einen Spannbock einklemmen und
D diesen in den Federsitz (20) einsetzen. D die Feder (22) einsetzen.
Den FuÈhrungsring schmieren. Gewinde schmieren. Den vollstaÈndigen Zylinder (18)
montieren.
c d
Si ha sido desmontado, introducir un nuevo anillo de Colocar el alojamiento muelle (20) en un corchete y
ESP guõÁa (21) en el alojamiento muelle (20). ESP introducir la muelle (22).
Lubrificar el anillo de guõÁa. Lubrificar la rosca. Montar el cilindro completo (18).
Si elle a eÂteÂ deÂmonteÂe, introduire la bague de guidage Placer le sieÁge ressort (20) dans un eÂtau et y introduire
F neuve (21) dans le sieÁge ressort (20). F le ressort (22).
Lubrifier la bague de guidage. Lubrifier le filetage. Monter le cylindre (18) complet.
Avvitare il cilindro (18) nella sede molla (20) e bloccarlo Avvitare lo stelo (6) nel pistone senza bloccare il dado
ITA utilizzando una barra "D". ITA (17).
Den Zylinder (18) in den Federsitz (20) montieren und Den Schaft (6) in den Kolben schrauben, ohne die
D mit Hilfe eines Stabs "D" blockieren. D Mutter (17) zu blockieren.
e f
Atornillar el cilindro (18) en el alojamiento muelle (20) y Atornillar el vastago (6) en el piston sin bloquear la
ESP bloquearlo utilizando una varilla "D". ESP tuerca (17).
Visser le cylindre (18) dans le sieÁge ressort (20) puis Visser la tige (6) dans le piston sans bloquer l'eÂcrou
F bloquer celui-ci aÁ l'aide d'une barre "D". F (17).
151
14
15 16
6
11 7
13
14
11 B
F1240745 F1240755
GB a GB b
Assemble the check unit (7) by inverting the steps followed in the Using a plastic hammer, install the check unit (7) onto the stem (6).
disassembly procedure.
5 6
7
F1240741
GB c GB d
Fit the safety snap ring (5) onto the stem (6). CAUTION! In case the braking disks have been replaced or if brake
pistons have been removed: before adjusting the negative braking
unit, apply the brakes several times at maximum pressure in order
to set clearances.
10
28
8÷10 N
2
(0,8÷1 kg)
1
26 27
F1240756 F1240738
GB e GB f
Loosen nuts (26) and apply a force of 8 ± 10 N (0.8 ± 1 kg) to levers Fit the distance piece (2) and insert the pin of support (10) in the
(28). Direct the force towards the braking direction to eliminate the right-hand braking lever. Fit the snap ring (1).
clearances by using dowels (27); lock nuts (26) to a torque wrench
setting of 20 ± 25 Nm.
CAUTION! The idle stroke should be eliminated without causing
any preloading.
152
Assemblare il gruppo di ritegno (7) seguendo la Utilizzando un mazzuolo in materiale plastico, monta-
ITA procedura di smontaggio in senso inverso. ITA re il gruppo di ritegno (7) sullo stelo (6).
Halteaggregat (7) in umgekehrter Reihenfolge als Mit einem Gummihammer das Halteaggregat (7) auf
D beim Abmontieren, wieder zusammenbauen. D den Schaft (6) montieren.
a b
Asemblar el grupo de retencioÁn (7) siguiendo la Utilizando un martillo de plastica, montar el grupo de
ESP procedura de desmontaje en sentido invertido. ESP retencioÁn (7) sobre el vastago (6).
Assembler le groupe de retenue (7) en suivant la A l'aide d'un maillet en matieÁre plastique, monter le
F proceÂdure du deÂmontage mais dans le sens contraire. F groupe de retenue (7) sur la tige (6).
Montare sullo stelo (6) l'anello elastico di sicurezza (5). ATTENZIONE! Se sono stati sostituiti i dischi di
ITA ITA frenatura o sono stati smontati i pistoni dei freni,
prima di registrare il gruppo freno negativo eseguire
piuÁ frenate alla massima pressione per assestare i giochi.
Auf den Schaft (6) den Sicherheitskolbenring (5) ACHTUNG! Falls die Bremsscheiben ausgewechselt
D montieren. D oder die Bremskolben abmontiert worden sind, mehr-
mals bei maximalen Druck bremsen, um das Spiel zu
setzen, bevor das Bremsaggregat eingestellt wird.
c d
Montar sobre vastago (6) el anillo elastico de seguri- ATENCION! Si han sido sobstituidos los discos de
ESP dad (5). ESP frenadura o han sido desmontados los pistones de los
frenos, antes de registrar el grupo freno negativo
ejecutar mas frenadas a la maxima presioÁn para asestar los juegos.
Monter sur la tige (6) l'anneau aÁ ressort de seÂcuriteÂ (5). ATTENTION! Si les disques de freinage ont eÂteÂ
F F remplaceÂs ouÁ que les pistons des freins ont eÂteÂ
deÂmonteÂs, avant de reÂgler le groupe frein neÂgatif,
effectuer quelques freinages au max. de la pression pour ajuster
les jeux.
Allentare i dadi (26) ed applicare alle leve (28) una Montare il distanziale (2) ed infilare il perno del
ITA forza di 8v10 N (0,8v1 kg) diretta nel senso di ITA supporto (10) nella leva di frenatura destra. Montare
frenatura per eliminare i giochi utilizzando i grani (27); l'anello elastico (1).
bloccare i dadi (26) ad una coppia di 20v25 Nm.
ATTENZIONE! La corsa a vuoto deve essere eliminata senza
provocare precarico.
Muttern (26) lockern und an den Hebeln (28) eine Kraft Das DistanzstuÈck (2) montieren und den Stift der
D von 8v10 N (0,8v1 kg) in die Bremsrichtung an- D Halterung (10) in den rechten Bremshebel montieren.
bringen, um die Spiele der Stifte (27) zu beseitigen; die Den Kolbenring (1) montieren.
Muttern (26) bei einem Anzugsmoment von 20v25 Nm blockieren.
e ACHTUNG! Der leere Lauf muû beseitigt werden, ohne das Teil f
vorzuladen.
Aflojar las tuercas (26) y aplicar a las palancas (28) Montar el distancial (2) y introducir la rotula del
ESP una fuerza de 8v10 N (0,8v1 kg) directa en el sentido ESP suporte (10) en la palanca de frenadura derecha.
de frenadura para eliminar los juegos utilizando las Montar el anillo elastico (1).
espigas (27); bloquear las tuercas (26) a un par de 20v25 Nm.
ATENCION! La carrera a vacio debe de ser eliminada sin provocar
precarga.
Desserrer les eÂcrous (26), puis appliquer aux leviers Monter l'entretoise (2) et introduire l'axe du support
F (28) une contrainte de 8v10 N (0,8v1 kg) orienteÂe F (10) dans le levier de freinage droit. Monter l'anneau aÁ
dans le sens du freinage pour eÂliminer les jeux aÁ l'aide ressort (1).
des grains (27); bloquer les eÂcrous (26) aÁ un couple de 20v25 Nm.
ATTENTION! La course aÁ vide doit eÃtre eÂlimineÂe sans provoquer
de preÂcharge.
153
27
18
3
A
28
6
D1240094
F1240757
GB a GB b
Rotate stem (6) to centre the hole of the fulcrum pin (3). Check that a clearance "A" is left between the lever (28) on the
Apply Loctite 242 to the thread of the fulcrum pin (3), screw and cylinder side (resting against the adjustment dowel) and cylinder
tighten pin with a dynamometric wrench set to 25 ± 30 Nm. (18).
If necessary, remove the lever, turn it by one tooth in relation to the
spline and repeat idle stroke elimination procedure.
4
23
6
7
27
17
28
F1240940 F1240941
bar
GB c GB d
Introduce pressure into the cylinder (4) and, with the levers (28) Lock nut (17) in position against the stem of the piston (23).
resting against the adjustment dowels (27), screw rod (6) to engage Torque wrench setting for the nut: max. 40 Nm.
the quick release (7) in the slot.
4÷5 mm 18
7
4
23
23
F1240760 F1240761
GB e bar
GB f
Release the pressure and check that piston (23) returns and stops Release the check unit (7) by giving a hammer blow to the external
in a position where it projects out from the cylinder head (4) by 4 ± 5 ring.
mm. Introduce pressure again and check that at the end of piston
stroke, the check unit (7) is actually engaged onto the rod (6).
154
Ruotare lo stelo (6) fino a centrare il foro del perno di Controllare che tra la leva (28) lato cilindro (in
ITA fulcro (3). ITA appoggio sul grano di registrazione) ed il cilindro (18)
Spalmare la filettatura del perno di fulcro (3) con rimanga un gioco "A".
Loctite 242, avvitarlo e serrarlo con chiave dinamometrica tarata a Se necessario, rimuovere la leva, ruotarla di un dente rispetto al
25v30 Nm. profilo scanalato e ripetere l'eliminazione della corsa a vuoto.
Den Schaft (6) drehen bis das Loch des Zentrierstifts Kontrollieren, ob zwischen dem Hebel (28) an der
D (3) zentriert ist. D Zylinderseite (am Stellstift anliegend) und dem Zylin-
Das Gewinde des Zentrierstiftes (3) mit Loctite 242 der (18) ein Spiel "A" uÈbrig bleibt.
schmieren und mit einem MomentenschluÈssel bei 25v30 Nm fest Wenn noÈtig, den Hebel abnehmen, um einen Zahn drehen und den
a ziehen. b Vorgang wiederholen.
Girar el vastago (6) hasta centrar el agujero de la Controlar que entre la palanca (28) lado cilindro (en
ESP rotula de fulcro (3). ESP apoyo sobre la espiga de registracioÁn) y el cilindro (18)
Pasar la rosca de la rotula del fulcro (3) con Loctite quede un juego "A".
242, atornillarla y apretarla con llave dinamometrica tarata a 25v30 Si necesario, remover la palanca, girar de un diente respecto al
Nm. perfil rayado y repetir la eliminacioÁn de la carrera a vacio.
Tourner la tige (6) jusqu'aÁ centrer le trou de l'axe du ControÃler qu'entre le levier (28) du coÃteÂ cylindre (poseÂ
F fourreau (3). F sur le grain de reÂglage) et le cylindre (18) il y ait un jeu
Enduire le filetage de l'axe du fourreau (3) avec du "A".
Loctite 242, visser celui-ci aÁ l'aide de la cleÂ dynamomeÂtrique Si besoin, enlever le levier, tourner celui-ci d'une dent par rapport
calibreÂe aÁ 25v30 Nm. au profil canneleÂ et eÂliminer de nouveau la course aÁ vide.
Inserire pressione nel cilindro (4) e, mantenendo le Bloccare il dado (17) contro lo stelo del pistone (23).
ITA leve (28) appoggiate ai grani di registro (27), avvitare ITA Coppia di serraggio dado: max. 40 Nm.
l'asta (6) fino ad agganciare lo sblocco rapido (7) nella
cava.
Druck in den Zylinder (4) einlassen. Die Hebel (28) am Mutter (17) gegen den Kolbenschaft (23) blockieren.
D Stellstift (27) anliegen lassen und den Stab (6) D Anzugsmoment fuÈr die Mutter: max. 40 Nm.
festschrauben, bis er im der Schnellentsicherung (7)
der Nut einrastet.
c d
Introducir presioÁn en el cilindro (4) y, manteniendo las Bloquear la tuerca (17) contra el vastago del piston
ESP palancas (28) en apoyo a las espigas del registro (27), ESP (23).
atornillar la varilla (6) hasta enganciar el bloqueo Par de torsion tuerca: max. 40 Nm.
rapido (7) en el nicho.
Introduire de la pression dans le cylindre (4), puis en Bloquer l'eÂcrou (17) contre la tige du piston (23).
F maintenant le levier (28) poseÂ sur les grains de reÂglage F Couple de serrage eÂcrou: max. 40 Nm.
(27), visser la tige (6) jusqu'aÁ accrocher le deÂblocage
rapide (7) dans le creux.
Rilasciare la pressione e controllare che il pistone (23) Sbloccare il gruppo di ritegno (7) con un colpo di
ITA rientri fino ad avere una sporgenza di 4v5 mm rispetto ITA mazzuolo sull'anello esterno.
la testata del cilindro (4). Inserire nuovamente pressione e controllare che a fine
corsa del pistone avvenga l'aggancio del gruppo di ritegno (7)
sull'asta (6).
Den Druck ablassen und kontrollieren, ob der Kolben Das Halteaggregat (7) mit einem Hammerschlag am
D (23) zuruÈck faÈhrt bis er um 4v5 mm im VerhaÈltnis zum D aÈuûeren Ring entsichern.
Zylinderkopf (4) herausragt. Nochmals Druck einlassen und kontrollieren, ob am
Hubende des Kolbens das Halteaggregat (7) im Stab (6) einrastet.
e f
Dejar la presioÁn y controlar que el piston (23) vuelva Sbloquear el grupo de retencioÁn (7) con un golpe de
ESP hasta tener un resalte de 4v5 mm respecto la culata ESP martillo sobre el anillo elatico.
del cilindro (4). Introducir de nuevo presioÁn y controlar que a final
carrera del piston suceda el enganche del grupo de retencioÁn (7)
sobre la varilla (6).
RelaÃcher la pression et controÃler que le piston (23) DeÂbloquer le groupe de retenue (7) par un coup de
F rentre jusqu'aÁ ce qu'il y ait une saillie de 4v5 mm par F maillet sur l'anneau externe.
rapport aÁ la culasse du cylindre (4). Introduire de nouveau de la pression et controÃler qu'aÁ
la fin de course du groupe piston, il y ait un accrochage du groupe
de retenue (7) sur la tige (6).
155
DISASSEMBLING THE INCOMING DRUM BRAKE - SMONTAGGIO FRENO A TAMBURO IN ENTRATA - TROMMELBREMSE AM EINGANG
ABMONTIEREN - DESMONTAJE FRENO DE TAMBOR EN ENTRADA- DEMONTAGE DU FREIN D'ENTREE A TAMBOUR
1 2
F1240551 F1240552
GB a GB b
Pull out the drum (1) and remove dust from friction surfaces. Hold the upper shoe into position (2) and release the spring (3)
CAUTION! Use only brush-type vacuum cleaners.
5 8
7
4 6
F1240553 F1240554
GB c GB d
Remove the shoe assembly (4). Remove the snap ring (7) from its seat around the screws (8).
If necessary, remove the snap ring (5) and pull out the lever (6) Remove the screws (8).
T20A
9 (T20B) 10
11
9
F1240555 F1240556
GB e GB f
Fit tool T20A (T20B), engage the stop rod and loosen the check nut Remove parts in the following sequence: nut (9), O-ring (11), flange
(9) of the flange (10). (10) and stop ring (7).
156
Rimuovere il tamburo (1) ed asportare la polvere delle Tenendo in posizione la ganascia superiore (2),
ITA guarnizioni di attrito. ITA sganciare la molla (3).
ATTENZIONE! Usare solo aspirapolvere e pennello.
Trommel (1) abnehmen und die Reibungsdichtungen Die obere Backe (2) festhalten und Feder (3) ab-
D vom Staub reinigen. D nehmen.
ACHTUNG! Nur mit einem Staubsauger und einem
Pinsel.
a b
Remover el tambor (1) y sacar el polvo de las juntas de Manteniendo en posicioÂn la mordaza superior (2),
ESP roce. ESP desenganchar el muelle (3).
CUIDADO! Usar soÂlo aspirador y pincel.
DeÂplacer le tambour (1) et enlever la poussieÁre des En tenant bien en place la maÃchoire supeÂrieure (2)
F garnitures de frottement. F deÂcrocher le ressort (3).
ATTENTION! Utiliser seulement un aspirateur et un
pinceau.
Rimuovere il gruppo ganasce (4). Rimuovere dalla sede l'anello elastico (7) di ritegno in
ITA Se necessario, rimuovere l'anello elastico (5) e sfilare ITA posizione delle viti (8).
la leva (6). Asportare le viti (8).
Backeneinheit (4) abnehmen. Wenn noÈtig Federring Federring (7) von den Schrauben (8) abnehmen.
D (5) abnehmen und Hebel (6) heraus ziehen. D Schrauben (8) abschrauben.
c d
Remover el grupo mordazas (4). Remover de su alojamiento el anillo elaÂstico (7) de
ESP Si fuera necesario, remover el anillo elaÂstico (5) y ESP retencioÂn en posicioÂn de los tornillos (8).
sacar la palanca (6) Sacar los tornillos (8).
Enlever le groupe maÃchoire (4). Extraire de son logement l'anneau aÁ ressort (7) fixeÂ sur
F Si besoin, enlever l'anneau ressort (5) et extraire le F les vis (8).
levier (6). Enlever les vis (8).
Montare l'attrezzo T20A (oppure T20B), impegnare Asportare nell'ordine, il dado (9), la guarnizione OR
ITA l'asta di arresto ed allentare il dado (9) di ritegno della ITA (11), la flangia (10) e l'anello di arresto (7).
flangia (10).
Werkzeug T20A (T20B) montieren und Sperrstab Der Reihe nach Mutter (9), O-Ring (11), Flansch (10)
D einsetzen; Mutter (9) zur Befestigung des Flansches D und Sperring (7) abnehmen.
(19) lockern.
e f
Montar la herramienta T20A (T20B), bloquear la Sacar en su orden, la tuerca (9), la junta OR (11), la
ESP varilla de tope y aflojar la tuerca (9) de retencioÂn de ESP brida (10) y el anillo de tope (7).
la brida (10).
Monter l'outil T20A (T20B) engager la tige de buteÂe et Enlever dans l'ordre, l'eÂcrou (9), la garniture OR (11),
F desserrer l'eÂcrou (9) de fixation de la flasque (10). F la flasque (10) et la bague de buteÂe (7).
157
DISASSEMBLING THE INCOMING DRUM BRAKE - SMONTAGGIO FRENO A TAMBURO IN ENTRATA - TROMMELBREMSE AM EINGANG
ABMONTIEREN - DESMONTAJE FRENO DE TAMBOR EN ENTRADA- DEMONTAGE DU FREIN D'ENTREE A TAMBOUR
12
12 14
13
F1240557 F1240558
GB a GB b
Remove the seal (12) and discard it. Remove the securing screws (13) from brake support (14).
NOTE. Note down assembly direction.
14
16
15
F1240559 F1240560
GB c GB d
Remove brake support (14). Remove the distance piece (15).
NOTE. If operations are to be carried out the bevel pinion, see the
specific axle section.
17 16
14
4
8 13
1 11 15
GB e GB f
5
12 3 6
7
10
9
D1240077
158
Rimuovere l'anello di tenuta (12) e scartarlo. Rimuovere le viti (13) di fissaggio del supporto freno
ITA ITA (14).
NOTA. Annotare il senso di montaggio.
Dichtung (12) abnehmen und nicht mehr verwenden. Schrauben (13) zur Befestigung der Bremsenhalte-
D D rung (14) abschrauben.
BEMERKUNG. Montagerichtung bemerken.
a b
Remover la junta (12) y descartarla. Remover los tornillos (13) de fijacioÂn del soporte del
ESP ESP freno (14).
NOTA. Anotar el sentido de montaje.
Enlever la garniture (12) puis l'eÂliminer. Enlever les vis (13) de fixation du support du frein (14).
F F
NOTE. Prendre note du sens du montage.
Rimuovere il supporto freno (14). Rimuovere il distanziale (15).

ITA ITA
NOTA. Se si deve intervenire sul gruppo pignone
conico, vedere il paragrafo specifico dell'assale.
Bremsenhalterung (14) abnehmen. DistanzstuÈck (15) abnehmen.

D D
BEMERKUNG. Falls Eingriffe am Kegelrad noÈtig sind,
siehe entsprechender Abschnitt betreffend Achsen.
c d
Remover el soporte del freno (14). Remover el separador (15).
ESP ESP
NOTA. Si hay que intervenir en el grupo pinÄoÂn coÂnico,
veÂase el apartado especõÂfico del eje.
Enlever le support du frein (14). Enlever l'entretoise (15).

F F
NOTE. Si on doit intervenir sur le groupe pignon
conique, voir le paragraphe concernant speÂcifique-
ment l'essieu.
ITA ITA
D D
e f
ESP ESP
F F
159
ASSEMBLING THE INCOMING DRUM BRAKE - ASSEMBLAGGIO FRENO A TAMBURO IN ENTRATA - TROMMELBREMSE AM EINGANG
MONTIEREN - MONTAJE DEL FRENO DE TAMBOR EN ENTRADA - ASSEMBLAGE DU FREIN D'ENTREE A TAMBOUR
14
16
15
F1240560 F1240559
GB a GB b
Fit the distance piece (15) onto the pinion (16). Lubricate the coupling surfaces and position brake support (14).
Check that the O-ring (17) is intact.
12
14
13
T27
F1240561 F1240562
GB c GB d
Apply Loctite 242 to the screws (13) and tighten using the criss- Lubricate the outer part of the seal (12) and insert it into the brake
cross method. Torque wrench setting: 34.2 ± 37.8 Nm support (14) using tool T27.
NOTE. Carefully check assembly direction.
10 T20A
11 (T20B)
9
9
F1240556 F1240563
GB e GB f
Install parts in the following sequence: flange (10), O-ring (11) and Fit tools T20A (or T20B), engage the stop rod and tighten the nut
nut (9). Spread Loctite 242 on the threaded portion of the pinion (9). Torque wrench setting: 280 ± 310 Nm
(16)
160
Montare sul pignone (16) il distanziale (15). Lubrificare le superfici di accoppiamento e posizionare
ITA ITA il supporto freno (14).
Controllare l'integritaÁ della guarnizione OR (17).
DistanzstuÈck (15) auf das Rad (16) montieren KupplungsflaÈchen schmieren und Bremsenhalterung
D D (14) positionieren.
Zustand des O-Rings (17) kontrollieren.
a b
Montar en el pinÄoÂn (16), el separador. Lubricar las superficies de acoplamiento y posicionar
ESP ESP el soporte del freno (14).
Controlar la integridad de la junta OR (17).
Monter sur le pignon (16) l'entretoise (15). Lubrifier les surfaces d'accouplement et mettre en
F F place le support du frein (14).
ControÃler le bon eÂtat de la garniture OR (17).
Spalmare le viti (13) con Loctite 242 ed avvitarle Lubrificare l'esterno dell'anello di tenuta (12) ed
ITA serrandole con il metodo incrociato. ITA inserirla nel supporto freno (14) con l'attrezzo T27.
Coppia di serraggio: 34,2v37,8 Nm NOTA. Controllare attentamente il senso di montaggio.
Schrauben (13) mit Loctite 242 schmieren und im Dichtung (12) auûen schmieren und in die Bremsen-
D Kreuz anziehen. D halterung (14) mit dem Werkzeug T27 einsetzen.
Anzugsmoment: 34,2v37,8 Nm BEMERKUNG. Montagerichtung pruÈfen.
c d
Pasar sobre los tornillos (13) Loctite 242 y atornillarlos Lubricar la parte externa de la junta (12) e introducirla
ESP apretaÂndolos con el meÂtodo cruzado. ESP en el soporte del freno (14) con la herramienta T27.
Par de torsioÂn: 34,2v37,8 Nm. NOTA. Controlar atentamente el sentido de montaje.
Enduire les vis (13) avec du Loctite 242, et les visser Lubrifier la partie externe de la garniture (12) puis
F en les serrant avec la meÂthode croiseÂe. F l'inseÂrer dans le support du frein (14) aÁ l'aide de l'outil
Couple de serrage: 34,2v37,8 Nm T27.
NOTE. ControÃler soigneusement le sens du montage.
Montare nell'ordine la flangia (10), la guarnizione OR Montare gli attrezzi T20A (oppure T20B), impegnare
ITA (11) ed il dado (9). ITA l'asta di arresto e serrare il dado (9).
Spalmare il filetto del pignone (16) con Loctite 242. Coppia di serraggio: 280v310 Nm
Der Reihe nach Flansch (10), O-Ring (11) und Mutter Werkzeug T20A (oder T20B) montieren, Sperrstab
D (9) montieren. D einsetzen und Mutter (9) anziehen.
Radgewinde (16) mit Loctite 242 schmieren. Anzugsmoment: 280v310 Nm
e f
Montar en su orden la brida (10), la junta OR (11) y la Montar la herramienta T20A (o T20B), bloquear la
ESP tuerca (9). ESP varilla de tope y apretar la tuerca (9).
Pasar en la rosca del pinÄoÂn (16) Loctite 242. Par de torsioÂn: 280v310 Nm.
Monter dans l'ordre la flasque (10), la garniture OR Monter l'outil T20A (ou T20B), engager la tige de
F (11) et l'eÂcrou (9). F buteÂe et serrer l'eÂcrou (9).
Enduire le filet du pignon (16) avec du Loctite 242. Couple de serrage: 280v310 Nm
161
ASSEMBLING THE INCOMING DRUM BRAKE - ASSEMBLAGGIO FRENO A TAMBURO IN ENTRATA - TROMMELBREMSE AM EINGANG
MONTIEREN - MONTAJE DEL FRENO DE TAMBOR EN ENTRADA - ASSEMBLAGE DU FREIN D'ENTREE A TAMBOUR
8 5
7
4 6
F1240554 F1240553
GB a GB b
Insert the screws (8) and hold them in position with the snap ring If the lever (6) has been removed, install it and hold it in position
(7). with the snap ring (5). Fit the shoes assembly (4).
NOTE. Make sure that the ring is properly set in its seat.
F1240552 F1240564
GB c GB d
Make sure that the shoes (4) centre the slot of the fulcrum pin and Fit the drum (1).
rest on the surface of the lever (6). NOTE. Make sure that the friction surface of the drum carries no
trace of grease and is perfectly clean.
GB e GB f
162
Inserire le viti (8) e mantenerle in posizione con Se eÁ stata rimossa, montare la leva (6) e mantenerla in
ITA l'anello elastico (7). ITA posizione con l'anello elastico (5).
NOTA. Assicurarsi che l'anello elastico sia perfetta- Montare il gruppo ganasce (4).
mente in sede.
Schraube (8) einsetzen und mit dem Federring (7) Falls der Hebel (6) abmontiert worden ist, diesen
D positionieren. D wieder montieren und mit dem Federring (5) positio-
BEMERKUNG. Sicherstellen, daû der Federring richtig nieren.
sitzt. Backeneinheit (4) montieren.
a b
Introducir los tornillos (8) y mantenerlos en posicioÂn Si ha sido quitada, montar la palanca (6) y mantenerla
ESP por medio del anillo elaÂstico(7). ESP en posicioÂn con el anillo elaÂstico (5).
NOTA. Asegurarse de que el anillo elaÂstico se Montar el grupo mordazas (4).
encuentra perfectamente en sede.
InseÂrer les vis (8) et les tenir en place avec l'anneau Si enleveÂ, remonter le levier (6) et le tenir en place aÁ
F ressort (7). F l'aide de l'anneau ressort (5).
NOTE. S'assurer que l'anneau soit parfaitement dans Monter le groupe maÃchoires (4).
son logement.
Assicurarsi che le ganasce (4) centrino la cava del Montare il tamburo (1).
ITA perno di fulcro ed appoggino sui piani della leva (6). ITA
NOTA. Assicurarsi che la superficie di attrito del
Aiutandosi con un cacciavite, impegnare la molla (3). tamburo sia perfettamente sgrassata e pulita.
Kontrollieren ob die Backen (4) in der Nut des Trommel (1) montieren.
D Zentrierstiftes zentriert sind und auf die FlaÈchen des D
BEMERKUNG. Kontrollieren ob die ReibungsflaÈche
Hebels (6) anliegen. der Trommel richtig entfettet und sauber ist.
Mit Hilfe eines Schraubenziehers, Feder (3) einhaken.
c d
Asegurarse de que las mordazas (4) centren la ranura Montar el tambor (1).
ESP del perno de fulcro y apoyen sobre las superficies de ESP
NOTA. Asegurarse de que la superficie de roce del
la palanca (6). tambor estaÂ perfectamente desengrasada y limpia.
AyudaÂndose con un destornillador, bloquear el muelle (3).
S'assurer que les maÃchoires (4) sont au centre du Monter le tambour (1).
F creux de l'axe du point d'appui et qu'elles reposent F
NOTE. S'assurer que la surface de frottement du
sur les surfaces du levier (6). tambour est bien deÂgraisseÂe et propre.
A l'aide d'un tournevis, engager le ressort (3).
ITA ITA
D D
e f
ESP ESP
F F
163
HOW TO DISASSEMBLE THE 4" INCOMING BRAKE (2 AND 3 FUNCTION VERSIONS) - SMONTAGGIO FRENO IN ENTRATA DA 4" (A 2 E 3
FUNZIONI) - BREMSE AM EINGANG ZU 4" (MIT 2 UND 3 FUNKTIONEN) ABMONTIEREN - DESMONTAJE FRENO EN ENTRADA DE 4" (A 2 Y 3
FUNCIOONES) - DESMONTAJE FREIN EN ENTREE 4" (A 2 ET 3 FONCTIONS)
1
2
F1240763 F1240764
GB a GB b
Remove movement sensor (1), if fitted. Loosen the two nuts and remove lubrication tube (2).
3 7 6
F1240765 F1240766
GB c GB d
Remove nut (3), O-ring (4) and flange (5). Loosen screws (6) in an alternate and criss-cross manner until the
NOTE. If disassembly is awkward, heat nut (3) at about 80ÊC. action of Belleville washers (11) becomes null.
Remove screws (6) and spring washers of cover (8).
8 11
12
9 10
F1240767 F1240768
GB e bar
GB f
Pull out cover (8), shims (9) separating ring (10) and Belleville Slowly introduce compressed air through the negative brake
washers (11). connection point in order to extract the piston (12).
NOTE. Take note of the assembly direction of: shims (9) and CAUTION! Hold piston (12) as it may be rapidly ejected and
Belleville washers (11). damaged.
164
Se eÁ montato, rimuovere il sensore di movimento (1). Allentare i due dadi e rimuovere il tubo (2) della
ITA ITA lubrificazione.
Wenn montiert, den Bewegungsgeber (1) abnehmen. Die beiden Muttern lockern und die Schmierleitung (2)
D D abnehmen.
a b
Si ha sido montado, remover el sensor de movimiento Aflojar las dos tuercas y remover el tubo (2) de la
ESP (1). ESP lubrificacioÁn.
S'il est monteÂ, enlever le capteur de deÂplacement (1). DeÂvisser le deux eÂcrous et enlever le tuyau (2) pour la
F F lubrification.
Rimuovere il dado (3), la guarnizione OR (4) e la Allentare in modo alternato ed incrociato le viti (6) fino
ITA flangia (5). ITA ad annullare l'azione delle molle a tazza (11).
NOTA. Se lo smontaggio risulta difficoltoso, scaldare il Rimuovere le viti (6) e le rondelle elastiche di ritegno
dado (3) a circa 80ëC. coperchio (8).
Die Mutter (3), den O-Ring (4) und den Flansch (5) Abwechselnd und im Kreuz die Schrauben (6) lockern,
D abnehmen. D bis die Wirkung der Tellerfeder (11) gleich Null ist.
BEMERKUNG. Falls das Abmontieren schwer sein Schrauben (6) und Federscheiben des Deckels (8)
sollte, die Mutter (3) bis auf ca. 80ëC erwaÈrmen. abnehmen.
c d
Remover la tuerca (3), la guarnicion OR (4) y la brida Aflojar de manera alterna y cruzada los tornillos (6)
ESP (5). ESP hasta anular la acioÁn de los muelles a taza (11).
NOTA. Si el desmontaje resulta dificil, calentar la Remover los tornillos (6) y las arandelas elasticas de
tuerca (3) a 80ëC approx. retencioÁn tapa (8).
Enlever l'eÂcrou (3), la garniture OR (4) et la flasque (5). DeÂvisser alternativement et de facËon croiseÂe les vis (6)
F NOTE. Si le deÂmontage est difficile, chauffer l'eÂcrou F jusqu'aÁ annuler l'action des ressorts belleville (11).
(3) aÁ environ 80ëC. Enlever les vis (6) et les rondelles aÁ segment de
fixation du couvercle (8).
Asportare il coperchio (8), i rasamenti (9), l'anello di Immettere lentamente aria compressa attraverso
ITA battuta (10) e le molle a tazza (11). ITA l'attacco per il freno negativo per estrarre il pistone
NOTA. Annotare il senso di montaggio dei rasamenti (12).
(9) e delle molle (11). ATTENZIONE! Trattenere il pistone (12) che puoÁ essere espulso
Deckel (8), Scheiben (9), Anschlagring (10) und Langsam Druckluft durch den Anschluû fuÈr die
D Tellerfedern (11) abnehmen. D Negativbremse einlassen, um den Kolben (12) auszu-
BEMERKUNG. Montagerichtung der Scheiben (9) und stoûen.
der Federn (11) bemerken. ACHTUNG! Den Kolben (12) halten, denn er koÈnnte ploÈtzlich
e f herausspringen und beschaÈdigt werden.
Quitar la tapa (8), las raspaduras (9), el anillo de tope Introducir lentamente aire comprimida atraves el
ESP (10) y los muelles a taza (11). ESP ataque para el freno negativo para extraer el piston
NOTA. Anotar el sentido de las raspaduras (9) y de los (12).
muelles (11). ATENCION! Tener el piston (12) que puede ser expulso rapida-
mente y ser danado.
Enlever le couvercle (8), les rasages (9), l'anneau de Emettre lentement de l'air comprimeÂ aÁ travers le point
F buteÂe (10) et les ressorts belleville (11). F d'enclenchement du frein neÂgatif pour en extraire le
NOTE. Noter le sens de montage des rasages (9) et piston (12).
des ressorts (11). ATTENTION! Retenir le piston (12) qui eÃtre expulseÂ rapidement
peut par conseÂquent s'endommager.
165
18
17
17 19
18
F1240769 F1240770
GB a GB b
Remove check screws (17) from cylinder (18). Remove cylinder (18) complete with guide pin (19) of piston (12).
NOTE. Take note of direction of assembly.
23 25 26
24
27
F1240771 F1240772
GB c GB d
With the help of a lever, prize off the distance piece (23) complete Remove friction discs (25), (26) and hub (27).
with O-ring (24).
NOTE. Thoroughly clean the face of bevel pinion support where
the hub rests, check the O-ring (24) and replace it if necessary.
28 29
31
28 29
30
F1240773 F1240774
GB e GB f
3-FUNCTION VERSION ONLY 3-FUNCTION VERSION ONLY
Loosen nuts (28) (no. 3) and unscrew dowels (29) (no. 3) to retract Loosen and remove the pin-type screws (31).
the adjustment points (30). NOTE. Loosen screws (31) in an alternate and criss-cross manner.
NOTE. Loosen dowels (29) in an alternate manner until the piston
comes to end of backstroke.
ONLY IF NECESSARY. Remove points (30).
166
Rimuovere le viti (17) di ritegno del cilindro (18). Rimuovere il cilindro (18) completo della spina (19) di
ITA ITA guida del pistone (12).
Die Schrauben (17) zur Halterung des Zylinders (18) Den Zylinder (18) samt Stift (19) zur FuÈhrung des
D abnehmen. D Kolbens (12) abnehmen.
BEMERKUNG. Montagerichtung bemerken.
a b
Sacar los tornillos (17) di retencioÁn del cilindro (18). Sacar el cilindro (18) completo de espina (19) de guõÁa
ESP ESP del piston (12).
NOTA. Anotar el sentido de montaje.
Enlever les vis (17) de fixation du cylindre (18). Enlever le cylindre (18) complet de broche (19) de
F F guidage du piston (12).
NOTE. Prendre note du sens de montage.
Forzando con una leva, rimuovere il distanziale (23) Asportare i dischi di frizione (25), (26) ed il mozzo (27).
ITA completo di OR (24). ITA
NOTA. Pulire accuratamente la superficie di appoggio
al mozzo di supporto pignone conico, controllare l'OR (24) e, se
necessario, sostituirlo.
Mit Hilfe eines Hebels, das DistanzstuÈck (23) samt O- Kupplungsscheiben (25), (26) und Nabe (27) abneh-
D Ring (24) entfernen. D men.
BEMERKUNG. SorgfaÈltig die AuflageflaÈche an der
Nabe des kegeligen Kolbenhalters reinigen und O-Ring (24)
c kontrollieren. Wenn noÈtig, auswechseln. d
Haciendo fuerza con una palanca, sacar el distancial Sacar los discos de fricioÁn (25), (26) y el cubo (27).
ESP (23) completo de OR (24). ESP
NOTA. Limpiar con atencioÁn la superficie de apoyo al
cubo de suporte pinon conico, controlar el OR (24) y, si necesario,
sobstituirlo.
En forcËant sur le levier, enlever l'entretoise (23) Enlever les disques de friction (25), (26) et le moyeu
F complet de OR (24). F (27).
NOTE. Nettoyer soigneusement la surface d'appui du
moyeu de support du pignon conique, controÃler la OR (24) et si
besoin, la remplacer.
SOLO PER VERSIONE A 3 FUNZIONI SOLO PER VERSIONE A 3 FUNZIONI

ITA Allentare i dadi (28) (në 3) e svitare i grani (29) (në 3) ITA Allentare ed asportare le viti a perno (31).
per far rientrare i puntali di registro (30). NOTA. Allentare le viti (31) in modo alternato ed
NOTA. Allentare i grani (29) in modo alternato fino a fine corsa di incrociato.
ritorno del pistone.
SOLO SE NECESSARIO. Asportare i puntali (30).
NUR FU È R AUSFU È HRUNG MIT 3 FUNKTIONEN NUR FU È R AUSFUÈ HRUNG MIT 3 FUNKTIONEN
D Muttern (28) (3 St.) lockern und Stifte (29) (3 St.) D Stiftschrauben (31) abschrauben.
abschrauben. StellschaÈfte (30) zuruÈck zu fahren. BEMERKUNG. Schrauben (31) abwechselnd und im
BEMERKUNG. Stifte (29) abwechselnd bis zum RuÈcklaufende des Kreuz abschrauben.
e Kolbens lockern.
È TIG. SchaÈfte (30) abnehmen.
f
NUR WENN NO
SOLO POR VERSION A 3 FUNCIONES SOLO POR VERSION A 3 FUNCIONES

ESP Aflojar los dados (28) (në3) y destornillar las espigas (29) ESP Aflojar y sacar los tornillos a rotula (31).
(në3) para hacer entrar los puntales de registro (30). NOTA. Aflojar los tornillos (31) de manera alternada y
NOTA. Aflojar las espigas (29) de manera alternada hasta final cruzada.
carrera de vuelta del piston.
SOLO SI NECESARIO. Sacar los puntales (30).
SEULEMENT DANS LES VERSIONS A 3 FONCTIONS. SEULEMENT DANS LES VERSIONS A 3 FONCTIONS.
F Desserrer les eÂcrous (28) (në3) et deÂvisser les grains F Desserrer et enlever les vis aÁ cheville (31).
(29) (në3) pour faire rentrer les tringles de reÂglage (30). NOTE. Desserrer les vis (31) de facËon alterneÂe et
NOTE. Desserrer les grains (29) de facËon alterneÂe jusqu'au retour croiseÂe.
de fin de course du piston.
SEULEMENT SI BESOIN. Enlever les tringles (30).
167
32 33
33
F1240775 F1240776
GB a GB b
Remove springs (32) of piston (33) backward movement. Slowly introduce compressed air through the connection point of
the service brake to extract the piston (33).
CAUTION! Hold piston (33) as it may be rapidly ejected and
damaged.
39
38
F1240777 F1240778
GB c GB d
2-FUNCTION VERSION ONLY Remove sealing ring (38) from cover (8).
Remove the distance piece (39). NOTE. Take note of direction of assembly of ring (38) and replace
ring every time the unit is disassembled.
14 13 35 34
36 37
13 14
15 16
33
34 35 36 37
15 16 12
F1240942 F1240943
GB e GB f
Remove sealing rings (13) and (15) and anti-extrusion rings (14) 3-FUNCTION VERSION ONLY
and (16) from the piston (12). Remove sealing rings (34) and (36) and anti-extrusion rings (35)
NOTE. Sealing rings (13) and (15) and anti-extrusion rings (14) and and (37) from piston (33).
(16) must be replaced each time the unit is disassembled. NOTE. Sealing rings (34), (36) and anti-extrusion rings (35), (37)
must be replaced each time the unit is disassembled.
168
ITA Rimuovere le molle (32) di ritorno del pistone (33). ITA Immettere lentamente aria compressa attraverso l'at-
tacco del freno di servizio per estrarre il pistone (33).
ATTENZIONE! Trattenere il pistone (33) che puoÁ essere espulso
NUR FU È R AUSFU È HRUNG MIT 3 FUNKTIONEN NUR FUÈ R AUSFU È HRUNG MIT 3 FUNKTIONEN
D RuÈckzugsfeder (32) des Kolbens (33) abnehmen. D Langsam Druckluft durch den Anschluû der Hilfs-
bremse einlassen, um den Kolben (33) auszustoûen.
ACHTUNG! Den Kolben (33) halten, denn er koÈnnte ploÈtzlich
a b herausgestoûen und beschaÈdigt werden.

ESP Sacar los muelles (32) de vuelta del piston (33). ESP Introducir lentamente aire comprimida atraves el
ataque del freno de servicio para sacar el piston (33).
ATENCION. Tener el piston (33) que puede ser expulso rapida-
mente y ser danado.
F Enlever les ressorts (32) de retour du piston (33). F Emettre lentement de l'air comprimeÂ aÁ travers le point
de montage du frein de service pour en extraire le
piston (33).
ATTENTION! Retenir le piston (33) qui expulseÂ rapidement peut
eÃtre par conseÂquent endommageÂ.
SOLO PER VERSIONE A 2 FUNZIONI Rimuovere dal coperchio (8) l'anello di tenuta (38).
ITA Asportare il distanziale (39). ITA
NOTA. Annotare il senso di montaggio dell'anello (38)
e sostituirlo ad ogni smontaggio.
NUR FU È R AUSFU È HRUNG MIT 2 FUNKTIONEN Vom Deckel (8) den Dichtring (38) abnehmen.
D DistanzstuÈck (39) abnehmen. D
BEMERKUNG. Montagerichtung des Ringes (38)
bemerken und beim Abmontieren jedesmal auswech-
seln.
c d
SOLO POR VERSION A 3 FUNCIONES Remover de la tapa (8) el segmento de compresioÁn
ESP Sacar el distancial (39). ESP (38).
NOTA. Anotar el sentido de montaje del segmento
(38) y sobstituirlo cada desmontaje.
SEULEMENT DANS LES VERSIONS A 2 FONCTIONS. Enlever du couvercle (8) la bague d'eÂtancheÂiteÂ (38).
F Enlever l'entretoise (39). F
NOTE. Prendre note du sens de montage de la bague
(38), la remplacer aÁ chaque deÂmontage.
Rimuovere dal pistone (12) gli anelli di tenuta (13) e SOLO PER VERSIONE A 3 FUNZIONI
ITA (15) e gli anelli antiestrusione (14) e (16). ITA Rimuovere dal pistone (33) gli anelli di tenuta (34) e
NOTA. Gli anelli di tenuta (13), (15) ed antiestrusione (36) e gli anelli antiestrusione (35) e (37).
(14), (16) devono essere sostituiti ad ogni smontaggio. NOTA. Gli anelli di tenuta (34), (36) ed antiestrusione (35), (37)
devono essere sostituiti ad ogni smontaggio.
Vom Kolben (12) Dichtringe (13) und (15) sowie die NUR FU È R AUSFU È HRUNG MIT 3 FUNKTIONEN
D Halteringe (14) und (16) abnehmen. D Vom Kolben (33) die Dichtringe (34) und (36) sowie die
BEMERKUNG. Die Dichtringe (13), (15) und Halterin- Halteringe (35) und (37) abnehmen.
ge (14). (16) muÈssen bei jedem Abmontieren ausgewechselt BEMERKUNG. Die Dichtringe (34), (36) und Halteringe (35), (37)
e werden. f jedesmal auswechseln, wenn sie abmontiert werden.
Sacar el piston (12) los segmentos de compresion (13) SOLO POR VERSION DE 3 FUNCIONES
ESP y (15) y los segmentos anti-extrusioÁn (14) y (16). ESP Remover del piston (33) los segmentos de compresioÁn
NOTA. Los segmentos de compresioÁn (13) y (15) y (34) y (36) y los segmentos anti-extrusioÁn (35) y (37).
anti-axtrusioÁn (14), (16) deben de ser cambiados cada desmontaje. NOTA. Los segmentos de compresion (34), (36) y anti-extrusioÁn
(35), (37) deben de ser sobstituidos a cada desmontaje.
Enlever le piston (12) les bagues d'eÂtancheÂiteÂ (13) et SEULEMENT DANS LES VERSIONS A 3 FONCTIONS.
F (15) et les anneaux anti-extrusion (14), et (16). F Enlever du piston (33) les bagues d'eÂtancheÂiteÂ (34) et
NOTE. Les bagues d'eÂtancheÂiteÂ (13), (15) et anti- (36) et les anneaux anti-extrusion (35) et (37).
extrusion (14), (16) doivent eÃtre remplaceÂes aÁ chaque deÂmontage. NOTE. Les bagues d'eÂtancheÂiteÂ (34), (36) et anti-extrusion (35),
(37) doivent eÃtre remplaceÂes aÁ chaque deÂmontage.
169
26 A 25
A minimo =1,36 mm
D1240083 D1240095
GB a GB b
CAUTION! Always check the thickness of braking discs (26), even BRAKING DISCS PACK CONTENTS
if the braking unit is being disassembled for other reasons than The braking discs pack is comprised of: 11 braking discs and 12
this. steel counterdiscs.
If thickness "A" of one of the discs (26) is close to the minimum
admissible size of 1.36 mm, replace the whole pack.
9 10 11
42
41
D1240084 D1240085
GB c GB d
CAUTION! If the braking discs unit is replaced, shims (9) - which ONLY WHEN REPLACEMENT IS NECESSARY
determine the preloading of Belleville washers (11) - must to be Remove the union pieces (41) and (42) connecting the lubrication
restored. tube (2).
NOTE. During the assembly stage, union pieces (41) and (42) must
be coated with Loctite 577 and tightened to a torque wrench setting
of 35 ± 50 Nm.
GB e GB f
170
ATTENZIONE! Anche se il gruppo freno viene COMPOSIZIONE PACCO DISCHI DI FRENATURA
ITA smontato solo per motivi diversi, controllare lo spes- ITA Il pacco dei dischi di frenatura comprende: në 11
sore dei dischi di frenatura (26). dischi di frenatura e në 12 controdischi in acciaio.
Se lo spessore "A" di un solo disco (26) si avvicina alla misura
minima ammessa di 1,36 mm, sostituire l'intero pacco.
ACHTUNG! Jedesmal wenn das Bremsaggregat aus DER SATZ DER BREMSSCHEIBEN BESTEHT AUS
D irgend einem Grund abmontiert wird, die StaÈrke der D 11 Bremsscheiben und 12 Gegenscheiben aus Stahl.
Bremsscheiben (26) kontrollieren.
Falls die StaÈrke "A" auch nur einer Scheibe (26) dem Mindestmaû
a nah liegt, den ganzen Satz auswechseln. b
ATENCION! Tambien si el grupo freno viene desmon- COMPOSICION PAQUETE DISCOS DE FRENADU-
ESP tado solo por motivos diferentes, controlar el espesor ESP RA
de los discos de frenadura (26). El paquete de los discos de frenadura se compone de:
Si el espesor "A" de un solo disco (26) se acerca a la medida në11 discos de frenadura y në12 contra-discos en acero.
minima admetida de 1,36 mm, sobstituir el intero paquete.
ATTENTION! MeÃme si le groupe frein est deÂmonteÂ COMPOSITION DU PAQUET DE DISQUES DE FREI-
F pour des raisons diverses, controÃler les cales des F NAGE
disques de freinage (26). Le paquet de disques de freinage comprend: në 11
Si la cale "A" d'un seul disque (26) se rapproche de la mesure disques de freinage et në 12 contre-disques en acier.
minimum consentie de 1,36 mm, substituer tout le paquet.
ATTENZIONE! Nel caso venga sostituito il gruppo dei SOLO SE EÁ NECESSARIA LA SOSTITUZIONE
ITA dischi di frenatura, eÁ necessario ripristinare gli ITA Rimuovere i raccordi (41), (42) di attacco del tubo di
spessori (9) determinanti il precarico delle molle a lubrificazione (2).
tazza (11). NOTA. In fase di montaggio, i raccordi (41), (42) devono essere
spalmati con Loctite 577 e serrati con una coppia di 35v50 Nm.
ACHTUNG! Falls das Bremscheibenaggregat ausge- NUR WENN DAS AUSWECHSELN NO È TIG IST
D wechselt wird, die DistanzstuÈck wieder (9) wieder D AnschluÈsse (41), (42) der Schmierleitung (2) abneh-
einsetzen, die die Tellerfedern (11) vorladen. men.
BEMERKUNG. Bei der Montage, die AnschluÈsse (41), (42) mit
c d Loctite 577 schmieren und mit einem Anzugsmoment von 35v50
Nm fest zeihen.
ATENCION! En el caso venga sobstituido el grupo de SOLO SI NECESARIA LA SOBSTITUCION

ESP los discos de frenadura, es necesario restablecer los ESP Remover los empalmes (41), (42) de ataque del tubo
espesores (9) determinados la precarga de los muelles de lubrificacioÁn (2).
a taza (11). NOTA. En fase de montaje, los empalmes (41), (42) deben de ser
pasados con Loctite 577 y cerrados con un par de 35v50 Nm.
ATTENTION! Dans le cas ouÁ le groupe des disques SEULEMENT QUAND LA SUBSTITUTION EST NE-
F de freinage est substitueÂ, remettre les cales (9) qui F CESSAIRE
deÂterminent la preÂcharge des ressorts belleville (11). Enlever les raccords (41), (42) de branchement du
tube de lubrification (2).
NOTE. En phase de montage, les raccords (41), (42) doivent eÃtre
enduits avec du Loctite 577 et serreÂs aÁ un couple de 35v50 Nm.
ITA ITA
D D
e f
ESP ESP
F F
171
VARIANT FOR 2-FUNTION VERSION

VARIANTE PER 2 FUNZIONI
È R 2 FUNKTIONEN
VARIANTE FU
VARIANTE POR 2 FUNCIONES
VARIANTE POUR 2 FONCTIONS
18 39
17
19
14 20 21
13 22
12
GB 11 a GB b
10
9
40 16
8 38 15 28 1
29
5
30
3 4
] 32
] 31 ] 35 ] 34
7 ] 33
6
24
26 ] 37
] 36
26
26
GB c 41
GB 42 d
25 23
27 2
25
RKZA0040
] 3-FUNTION VERSION ONLY

D1240088
25 SOLO PER VERSIONE A 3 FUNZIONI
È R AUSFU
NUR FU È HRUNG MIT 3 FUNKTIONEN
SOLO POR VERSION A 3 FUNCIONES
SEULEMENT POUR VERSIONS A 3 FONCTIONS
GB e GB f
172
ITA ITA
D D
a b
ESP ESP
F F
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
173
HOW TO ASSEMBLE THE 4" INCOMING BRAKE (2 AND 3 FUNCTION VERSIONS) - ASSEMBLAGGIO FRENO IN ENTRATA DA 4" (A 2 E 3
FUNZIONI) - BREMSE AM EINGANG ZU 4" (MIT 2 UND 3 FUNKTIONEN) MONTIEREN - ASEMBLAJE FRENO EN ENTRADA DE 4" (A 2 Y 3
FUNCIONES) - MONTAJE DEL FREIN EN ENTREE 4" (A 2 ET 3 FONCTIONS)
35 34 14 13
36 37
13 14
15 16
33
34 35 36 37
15 16 12
F1240943 F1240942
GB a GB b
3-FUNCTION VERSION ONLY Fit the sealing rings (13), (15) and the anti-extrusion rings (14), (16)
Fit the sealing rings (34), (36) and the anti-extrusion rings (35), (37) onto the piston (12) of the negative brake.
onto the piston (33) of the service brake. NOTE. Carefully check the assembly position of the anti-extrusion
NOTE. Carefully check the assembly position of anti-extrusion rings.
rings.
T31 A1
38
8
12
F1240781 F1240782
GB c GB d
Lubricate sealing ring (38) and, using tool T31, fit it into the cover 3-FUNCTION VERSION ONLY
(8). Measure size "A1" of piston (12) and note it down.
NOTE. Carefully check the direction of ring (38).
10
10 9
B1
S
8
D1240086
F1240783
GB e GB f
Fit the separating ring (10) of Belleville washers onto the cover (8), Using the measurements just taken, calculate thickness "S" of
measure size "B1" and note it down. shims (9) as follows: S=(A1+1.5)±(B1+18.4) where:
S=Shim thickness - 1.5 mm=fixed measure of braking discs
clearance - 18.4 mm=fixed measure of Belleville washers.
174
SOLO PER VERSIONE A 3 FUNZIONI Montare sul pistone (12) del freno negativo gli anelli di
ITA Montare sul pistone (33) del freno di servizio gli anelli ITA tenuta (13), (15) e gli anelli antiestrusione (14), (16).
di tenuta (34), (36) e gli anelli antiestrusione (35), (37). NOTA. Controllare attentamente la posizione di
NOTA. Controllare attentamente la posizione di montaggio degli montaggio degli anelli antiestrusione.
anelli antiestrusione.
NUR FU È R AUSFU È HRUNG MIT 3 FUNKTIONEN Auf den Kolben (12) der Negativbremse die Dichtringe
D Auf den Kolben (33) der Hilfsbremse die Dichtringe D (13), (15) und die Halteringe (14), (16) montieren.
(34), (36) und die Halteringe (35), (37) montieren. BEMERKUNG. SorgfaÈltig die Montagerichtung der
BEMERKUNG. SorgfaÈltig die Montagerichtung der Halteringe Halteringe pruÈfen.
a pruÈfen. b
SOLO POR VERSION A 3 FUNCIONES Monter sobre el piston (12) del freno negativo los
ESP Montar sobre el piston (33) del freno de servicio los ESP segmentos de compresioÁn (13), (15) y los segmentos
segmentos de compresion (34), (36) y los segmentos anti-extrusion (14), (16).
de anti-extrusion (35), (37). NOTA. Controlar con cuidado la colocacioÁn ce montaje de los
NOTA. Controlar con cuidado la colocacioÁn de montaje de los segmentos anti-extrusion.
segmentos anti-extrusioÁn.
SEULEMENT DANS LES VERSIONS A 3 FONCTIONS. Monter sur le piston (12) du frein neÂgatif les bagues
F Monter sur le piston (33) du frein de service les bagues F d'eÂtancheÂiteÂ (13), (15) et les anneaux anti-extrusion
d'eÂtancheÂiteÂ (34), (36) et les anneaux anti-extrusion (14), (16).
(35), (37). NOTE. ControÃler attentivement la position du montage des
NOTE. ControÃler attentivement la position du montage des anneaux anti-extrusion.
anneaux anti-extrusion.
Lubrificare l'anello di tenuta (38) e, utilizzando SOLO PER VERSIONE A 3 FUNZIONI

ITA l'attrezzo T31, montarlo nel coperchio (8). ITA Rilevare la misura "A1" del pistone (12) e trascriverla.
NOTA. Controllare attentamente l'orientamento del-
l'anello (38).
Dichtring (38) schmieren und mit Hilfe des Werkzeugs NUR FUÈ R AUSFUÈ HRUNG MIT 3 FUNKTIONEN
D T31 den Deckel (8) montieren. D Maû "A1" des Kolbens (12) messen und anmerken.
BEMERKUNG. SorgfaÈltig die Montagerichtung des
Ringes (38) pruÈfen.
c d
Lubrificar el segmento de compresioÁn (38) y utilizando SOLO POR VERSION A 3 FUNCIONES
ESP la herramienta T31, montarlo sobre la tapa (8). ESP Relevar la medida "A1" del piston (12) y registrarla.
NOTA. Controlar con cuidado la direccioÁn del seg-
mento (38).
Lubrifier la bague d'eÂtancheÂiteÂ (38), puis aÁ l'aide de SEULEMENT DANS LES VERSIONS A 3 FONCTIONS.
F l'outil T31, monter celle-ci dans le couvercle (8). F Relever la mesure "A1" du piston (12) et enregistrer
NOTE. ControÃler attentivement l'orientation de la cette dernieÁre.
bague (38).

ITA Montare sul coperchio (8) l'anello di battuta (10) delle ITA Utilizzando le misure rilevate, determinare lo spessore
molle a tazza, rilevare la misura "B1" e trascriverla. "S" dei rasamenti (9) con il seguente calcolo:
S=(A1+1,5)±(B1+18,4) ove:
S=Spessori rasamenti - 1,5 mm=misura fissa del gioco dischi
freno - 18,4 mm=misura fissa delle molle a tazza.
NUR FUÈ R AUSFU È HRUNG MIT 3 FUNKTIONEN NUR FUÈ R AUSFU È HRUNG MIT 3 FUNKTIONEN
D Auf den Deckel (8) den Anschlagring (10) der Tellerfe- D Anhand der ermittelten Maûe die StaÈrke "S" der
dern montieren. Das Maû "B1" messen und anmerken. Scheiben (9) folgendermaûen ausrechnen:
S=(A1+1,5)±(B1+18,4) wo:
e f S=ScheibenstaÈrke - 1,5 mm=feste Maû fuÈr das Spiel der Brems-
scheiben - 18,4 mm=feste Maû fuÈr Tellerfedern.

ESP Montar sobre la tapa (8) el segmento a tope (10) de los ESP Utilisando las medidas relevadas, determinar el espe-
muelles a taza, relevar la medida "B1" y registrarla. sor "S" de las raspaduras (9) con el siguiente calcolo:
S=(A1+1,5)±(B1+18,4) donde:
S=espesor raspaduras - 1,5 mm=medida fija del juego discos
freno - 18,4 mm=medida fija de los muelles a taza.
F Monter sur le couvercle (8) l'anneau de buteÂe (10) des F A l'aide de la mesure releveÂe, deÂfinir la cale "S" des
ressorts Belleville, relever la mesure "B1" et enregis- rasages (9) par le calcul suivant:
trer cette dernieÁre. S=(A1+1,5)±(B1+18,4) ou:
S=Cales rasages - 1,5 mm=mesure fixe du jeu des disques
frein - 18,4 mm=mesure fixe des ressorts Belleville.
175
33 32 33
30
F1240784 F1240775
GB a GB b
Lubricate the O-rings and install the whole piston (33). Orient the Insert springs (32) for piston (33) backward movement.
piston with the help of a lever and push it to end of stroke with a
plastic hammer.
CAUTION! Check that the adjusting stakes (30) are thoroughly
inserted and make sure they perform a sliding motion in relation to
each other.
31
31
31
F1240774 F1240785
GB c GB d
Apply Loctite 242 to the thread of screws (31) and tighten. Lock screws (31) in a criss-cross manner by using a dynamometric
NOTE. Tighten the screws with a normal wrench in an alternate wrench set to a max. torque of 10 Nm.
and criss-cross manner. CAUTION! Do not exceed the specified torque setting.
12 23
18
25 26
27
F1240786 F1240787
GB e GB f
Lubricate seals (13), (15) and fit the piston (12) into the cylinder Lightly lubricate the braking discs (25), (26) and fit them onto the
(18). Engage piston on the pin (19). For the assembly, use a plastic hub (27).
hammer and push the piston (12) to end of stroke. Align discs (25) and fit the distance piece (23).
NOTE. The braking discs pack starts and ends with steel discs
(25).
176
ITA Lubrificare le guarnizioni OR e montare il pistone (33) ITA Inserire le molle (32) di ritorno del pistone (33).
completo. Orientare il pistone con una leva e mandarlo
a fondo corsa con un mazzuolo in materiale plastico.
ATTENZIONE! Controllare che i pioli di registro (30) siano inseriti a
fondo e che scorrano tra loro.
NUR FU È R AUSFUÈ HRUNG MIT 3 FUNKTIONEN NUR FU È R AUSFUÈ HRUNG MIT 3 FUNKTIONEN
D O-Ringe schmieren und den vollstaÈndigen Kolben (33) D RuÈckzugsfedern (32) in den Kolben (33) einsetzen.
montieren. Den Kolben mit einem Hebel orientieren
und bis zum Hubende mit einem Gummihammer schlagen.
a ACHTUNG! Kontrollieren, ob die Regelungspole (30) bis zum b
Anschlag eingesetzt sind und verschiebt werden koÈnnen.

ESP Lubrificar las guarniciones OR y montar el piston (33) ESP Introducir los muelles (32) de vuelta del piston (33).
completo. Orientar el piston con una palanca y
mandarlo a final carrera con un martillo en material plastico.
ATENCION! Controlar que las extremidades de registro (30) sean
introducidas a fondo y que deslizen entre ellas.
F Lubrifier les garnitures OR et monter le piston (33) F Introduire les ressorts (32) de retour du piston (33).
complet. Orienter le piston aÁ l'aide d'un levier puis
l'envoyer en fin de course aÁ l'aide d'un maillet en matieÁre plastique.
ATTENTION! ControÃler, que les poÃles de reÂgistration (30) soient
inseÂreÂs aÁ fond et qu'ils puissent glisser.

ITA Spalmare il filetto delle viti (31) con Loctite 242 ed ITA Bloccare le viti (31) in modo incrociato utilizzando una
avvitarle. chiave dinamometrica tarata ad una coppia massima
NOTA. Mandare in battuta le viti con una chiave normale con il di 10 Nm.
metodo alternato ed incrociato. ATTENZIONE! Non superare la coppia di serraggio indicata.
NUR FUÈ R AUSFU È HRUNG MIT 3 FUNKTIONEN NUR FU È R AUSFUÈ HRUNG MIT 3 FUNKTIONEN
D Schraubengewinde (31) mit Loctite 242 schmieren und D Die Schrauben (31) im Kreuz mit einem Momenten-
Schrauben fest schrauben. schluÈssel und einem Anzugsmoment von 10 Nm fest
schrauben.
c d ACHTUNG! Das angegebene Moment nicht uÈberschreiten.

ESP Pasar la rosca de los tornillos (31) con Loctite 242 y ESP Bloquear los tornillos (31) de manera cruzada utilizan-
atornillarlas. do una llave dinamometrica tarada a un par maximo
NOTA. Mandar a tope los tornillos con una llave normal de manera de 10 Nm.
alternada y cruzada. ATENCION! No superar el par de torsion indicado.
F Enduire le filet des vis (31) avec du Loctite 242, puis F Bloquer les vis (31) de manieÁre croiseÂe aÁ l'aide d'une cleÂ
visser. dynamomeÂtrique calibreÂe aÁ un couple max. de 10 Nm.
NOTE. Envoyer en buteÂe les vis aÁ l'aide d'une cleÂ normale avec la ATTENTION! Ne jamais deÂpasser le couple de serrage indiqueÂ.
meÂthode alterneÂe, croiseÂe.
Lubrificare le guarnizioni (13), (15) e montare nel Lubrificare leggermente i dischi di frenatura (25), (26)
ITA cilindro (18) il pistone (12) orientandolo sulla spina (19). ITA e montarli sul mozzo (27).
Per il montaggio, utilizzare un mazzuolo in materiale Allineare i dischi (25) e montare il distanziale (23).
plastico e mandare il pistone (12) a fondo corsa. NOTA. La composizione del pacco dei dischi di frenatura inizia e
termina con i dischi di acciaio (25).
Dichtungen (13), (15) schmieren und in en Zylinder Bremsscheiben (25), (26) leicht schmieren und auf die
D (18) den Kolben (12) montieren und auf den Stift (19) D Nabe (27) montieren.
orientieren. Zur Montage einen Gummihammer ver- Scheiben (25) ausrichten und DistanzstuÈck (23)
wenden, um den Kolben (12) bis zum Hubende zu schlagen. montieren.
e f BEMERKUNG. Der Satz der Bremsscheiben beginnt und endet mit
den Stahlscheiben (25).
Lubrificar las guarnicioÁnes (13), (15) y montar en el Lubrificar ligermente los discos de frenadura (25), (26)
ESP cilindro (18) el piston (12) dirijiendolo sobre la espina ESP y montarlos sobre el cubo (27).
(19). Alinear los discos (25) y montar el distancial (23).
Para el montaje, utilizar un martillo en material plastico y mandar el NOTA. La composicioÁn del paquete de los discos de frenadura
piston (12) a final carrera. empieza y termina con los discos en acero (25).
Lubrifier les garnitures (13), (15) puis monter dans Lubrifier leÂgeÁrement les disques de freinage (25), (26)
F cylindre (18) le piston (12) en l'orientant sur la broche F et monter ceux-ci sur le moyeu (27).
(19). Aligner les disques (25) et monter l'entretoise (23).
Pour le montage, utiliser un maillet en matieÁre plastique et envoyer NOTE. La composition du paquet des disques de freinage
le piston (12) en fin de course. commence et s'acheÁve par des disques en acier (25).
177
18
23
12 24
F1240788 F1240789
GB a GB b
Apply Loctite 510 on the face of the distance piece (23). Lubricate the O-ring (24) and fit cylinder (18) complete with piston
Fit the discs-hub-distance piece assembly prepared in the previous (12).
stages onto the pinion and engage it.
17
12
17
F1240790 F1240791
GB c GB d
Introduce screws (17) and tighten in a criss-cross manner: use a 3-FUNCTION VERSION ONLY
torque wrench setting of 9.5 ± 10.5 Nm. Using a plastic hammer, push the piston (12) to the end of stroke.
NOTE. Before giving the final tightening, align the external
surfaces of the components.
10
10
A B
9
F1241069 F1240793
GB e GB f
2-FUNCTION VERSION ONLY Lightly lubricate the shims (9) required according to calculations
Fit the separating ring (10) of Belleville washers onto the cover (8), and the separating ring (10) of the Belleville washers.
measure size "B" and note it down. Fit shims and ring on the cover (8).
Measure size "A" which you will need for calculating the shims (9) NOTE. Position the larger shim so that it leans against the cover.
according to the following:
S=A±(B+18.4) where: S=Shim thickness - 18.4 mm=fixed mea-
sure of Belleville washers.
178
Spalmare il piano di appoggio del distanziale (23) con Lubrificare la guarnizione OR (24) e montare il cilindro
ITA Loctite 510. ITA (18) completo di pistone (12).
Montare sul pignone il gruppo dischi-mozzo-distanzia-
le preparato nelle fasi precedenti e mandarlo in battuta.
Die AuflageflaÈche des DistanzstuÈckes (23) mit Loctite O-Ring (24) schmieren und den Zylinder (18) samt
D 510 schmieren. D Kolben (12) montieren.
Auf den Kolben das Aggregat Scheiben-Nabe-Distanz-
stuÈck montieren, das zuvor vorbereitet wurden und bis zum
a Anschlag einsetzen. b
Pasar la superficie de apoyo del distancial (23) con Lubrificar la guarnicion OR (24) y montar el cilindro
ESP Loctite 510. ESP (18) completo de piston (12).
Montar sobre el pinoÁn el grupo discos-cubo-distancial
preparado en la fase precedente y mandarlo a tope.
Enduire le plan d'appui de l'entretoise (23) avec du Lubrifier la garniture OR (24) et monter le cylindre (18)
F Loctite 510. F eÂquipeÂ du piston (12).
Monter sur le pignon le groupe disques-moyeu-
entretoise preÂpareÂ lors des phases preÂceÂdentes et l'envoyer en
buteÂe.
Inserire le viti (17) ed avvitarle a fondo in modo SOLO PER VERSIONE A 2 FUNZIONI
ITA incrociato; serrarle con una coppia di 9,5v10,5 Nm. ITA Utilizzando un mazzuolo in materiale plastico, manda-
NOTA. Prima del serraggio finale, allineare le superfici re a fondo corsa il pistone (12).
esterne dei componenti.
Schrauben (17) einsetzen und bis zum Anschlag im NUR FU È R AUSFU

È HRUNG MIT 2 FUNKTIONEN
D Kreuz mit einem Anzugsmoment von 9,5v10,5 Nm D Mit einem Gummihammer den Kolben (12) bis zum
fest schrauben. Anschlag schlagen.
BEMERKUNG. Bevor die Teile endguÈltig festgezogen werden, die
c aÈuûeren FlaÈchen ausrichten. d
Introducir los tornillos (17) y atornillarlos a tope de SOLO POR VERSION A 2 FUNCIONES
ESP manera cruzada; apretarlos con un par de 9,5v10,5 Nm. ESP Utilizando un martillo en material plastico, mandar a
NOTA. Antes de apretarlos definitivamente, alinear final carrera el piston (12).
las superficies exteriores de los componentes.
Introduire les vis (17) et visser aÁ fond de facËon croiseÂe; SEULEMENT DANS LES VERSIONS A 2 FONCTIONS.
F serrer celles-ci aÁ un couple de 9,5v10,5 Nm. F A l'aide du maillet en matieÁre plastique, envoyer le
NOTE. Avant le serrage final, aligner les surfaces piston (12) en fin de course.
externes des composants.
SOLO PER VERSIONE A 2 FUNZIONI Lubrificare leggermente gli spessori (9) calcolati e
ITA Montare sul coperchio (8) l'anello di battuta (10) delle ITA l'anello (10) di battuta delle molle a tazza.
molle a tazza, rilevare la misura "B" e trascriverla. Montare spessori ed anello sul coperchio (8).
Rilevare la misura "A" necessaria al calcolo dei rasamenti (9) con la NOTA. Posizionare lo spessore maggiore a ridosso del coperchio.
formula: S=A±(B+18,4) ove: S=Spessori rasamenti - 18,4
mm=misura fissa delle molle a tazza.
NUR FU È R AUSFU È HRUNG MIT 2 FUNKTIONEN Die Scheiben (9) und den Anschlagring (10) der
D Auf den Deckel (8) den Anschlagring (10) der Tellerfe- D Tellerfedern leicht schmieren.
dern montieren. Das Maû "B" messen und anmerken. Scheiben und Ring auf den Deckel (8) montieren.
Das Maû "A" messen, das zur Rechnung der Scheiben (9) mit BEMERKUNG. Die groÈûere Scheibe sollte am Deckel anliegen.
e nachstehender Formel noÈtig ist: S=A±(B+18,4) wo:
S=ScheibenstaÈrke - 18,4 mm=feste Maû fuÈr Tellerfedern.
f
SOLO POR VERSION A 2 FUNCIONES Lubrificar ligermente los espesores (9) calculados y el
ESP Montar sobre la tapa (8) el segmento a tope (10) de los ESP segmento (10) a tope de los muelles a taza.
muelles a taza, relevar la medida "B" y registrarla. Montar el espesor major detras de la tapa.
Relevar la medida "A" necesaria al calculo de las raspaduras (9) NOTA. Colocar el espesor major detras de la tapa.
con la formula: S=A±(B+18,4) donde: S=espesor raspaduras -
18,4 mm=medida fija de los muelles a taza.
SEULEMENT DANS LES VERSIONS A 2 FONCTIONS. Lubrifier leÂgeÁrement les cales (9) calculeÂes et l'anneau
F Monter sur le couvercle (8) l'anneau de buteÂe (10) des F (10) de buteÂe des ressorts belleville.
ressorts Belleville, relever la mesure "B" et enregistrer Monter cales et anneau sur le couvercle (8).
cette dernieÁre. Relever la mesure "A" neÂcessaire pour calculer les NOTE. Placer la cale la plus grande au-dessus du couvercle.
rasages (9) avec la formule: S=A±(B+18,4) ou: S=Cales
rasages - 18,4 mm=mesure fixe des ressorts Belleville.
179
11
38
10 11
8 9
8
40
5
F1240794 F1240795
GB a GB b
Check the state of the O-ring (40). Fit the Belleville washers (11) onto the cover (8), thoroughly
Lubricate sealing ring (38) and fit flange (5) into the cover (8). checking washers orientation.
40 8
6 7
F1240796 F1240797
GB c GB d
Lubricate the O-ring (40) and install the cover assembly (8). Fit screws (6) and washers (7); lock the cover with a torque wrench
setting of 116 ± 128 Nm.
NOTE. Tighten in an alternate and criss-cross manner.
F1240798 F1240764
GB e GB f
Apply Loctite 242 to the threaded portion of the pinion, fit O-ring (4) Install the lubrication tube (2).
and nut (3); tighten the nut with a dynamometric wrench set to
280 ± 310 Nm.
NOTE. Use tools T21-T22.
180
Controllare lo stato dell'anello OR (40). Montare sul coperchio (8) le molle a tazza (11)
ITA Lubrificare l'anello di tenuta (38) e montare la flangia ITA controllandone attentamente l'orientamento.
(5) nel coperchio (8).
Zustand des O-Rings (40) kontrollieren. Auf den Deckel (8) die Tellerfeder (11) montieren und
D Dichtring (38) schmieren und Flansch (5) in den Dek- D sorgfaÈltig auf die Montagerichtung achten.
kel (8) montieren.
a b
Controlar el estado del anillo OR (40). Montar sobre la tapa (8) los muelles a taza (11)
ESP Lubrificar el anillo de compresioÁn (38) y montar la ESP controlando con cuidado la direccioÁn.
brida (5) sobre la tapa (8).
ControÃler l'eÂtat de la garniture OR (40). Monter sur le couvercle (8) les ressorts belleville (11)
F Lubrifier la bague d'eÂtancheÂiteÂ (38) et monter la F en controÃlant attentivement leur orientation.
flasque (5) dans le couvercle (8).
Lubrificare l'anello OR (40) ed installare il gruppo Montare le viti (6) e le rondelle (7); bloccare il
ITA coperchio (8). ITA coperchio con una coppia di 116v128 Nm.
NOTA. Eseguire il serraggio in modo alternato ed
incrociato.
O-Ring (40) schmieren und Deckelaggregat (8) instal- Schrauben (6) und Unterlegscheiben (7) montieren; den
D lieren. D Deckel mit einem Anzugsmoment von 116v128 Nm
blockieren.
BEMERKUNG. Schrauben abwechselnd und im Kreuz fest
c d schrauben.
Lubrificar el anillo OR (40) y montar el grupo tapa (8). Montar los tornillos (6) y las arandelas (7); bloquear la
ESP ESP tapa con un par de 116v128 Nm.
NOTA. Apretar de manera alternada y cruzada.
Lubrifier la garniture OR (40) et installer le groupe Monter les vis (6) et les rondelles (7); bloquer le
F couvercle (8). F couvercle aÁ un couple de 116v128 Nm.
NOTE. Effectuer le serrage de facËon alterneÂe et
croiseÂe.
Spalmare la porzione filettata del pignone con Loctite Montare il tubo (2) della lubrificazione.
ITA 242, montare l'anello OR (4) ed il dado (3); serrare il ITA
dado con chiave dinamometrica tarata a 280v310 Nm.
NOTA. Utilizzare gli attrezzi T21-T22.
Das Gewinde des Kolbens mit Loctite 242 schmieren Schmierleitung (2) montieren.
D und den O-Ring (4) und die Mutter (3) montieren; die D
Mutter mit einem Anzugsmoment von 280v310 Nm
fest schrauben.
e BEMERKUNG. Werkzeuge T21-T22 verwenden. f
Pasar la parte roscada del pinoÁn con Loctite 242, Montar el tubo (2) de la lubrificacioÁn
ESP montar el segmento OR (4) y la tuerca (3); apretar la ESP
tuerca con llave dinamometrica tarada a 280v310 Nm.
NOTA. Utilizar las herramientas T21-T22.
Enduire la partie fileteÂe du pignon avec du Loctite 242, Monter le tube (2) de lubrification.
F monter la garniture OR (4) et l'eÂcrou (3); serrer l'eÂcrou F
aÁ l'aide d'une cleÂ dynamomeÂ trique calibreÂ e aÁ
280v310 Nm.
NOTE. Utiliser les outils T21-T22.
181
28 29
33 30
29 30
F1240944 F1240945
bar GB a bar
GB b
Connet the service and negative brakes to an external pump; Screw dowels (29) until pins (30) position themselves against the
introduce pressure up to a value of 20 ± 25 Nm. piston (33), then unscrew dowels by one turn to obtain a 1.5 mm
NOTE. Check that pressure is kept stable for at least 5 minutes and stroke.
make sure there are no leaks. Lock dowels (29) into position with the nuts (28) tightened at 15
Nm.
Release pressure.
0,8÷1,2mm
1
F1240801 F1240763
bar
GB c GB d
Check negative brake release by introducing a pressure of 16v35 Fit the movement sensor (1) and screw it up to the limit stop.
bar and by manually rotating the flange (5). Unscrew sensor by 3/4 turn and lock into position with nut. Locking
Release pressure. torque: MAX 30 Nm.
CAUTION! Do not exceed the specified torque setting.
17 mm
21 22
D1240098
F1240802
GB e GB f
CAUTION! To release the negative brake during an emergency, When the emergency is over, loosen the dowels in an alternate
(lack of pressure due to vehicle breakdown), loosen nuts (22) and manner until a 17 mm projection is obtained; lock into position with
screw dowels (21) in an alternate and gradual manner until you the nuts (22) tightened to15 Nm.
notice some preloading; continue by giving another 1.5 turns.
182
ITA Collegare i freni di servizio e negativo ad una pompa ITA Avvitare i grani (29) fino all'appoggio dei pioli (30) sul
esterna; immettere pressione fino ad un valore di pistone (33) e quindi svitarli di 1 giro per creare una
20v25 Nm. corsa del pistone di 1,5 mm.
NOTA. Controllare che la pressione rimanga stabile per almeno 5 Bloccare la posizione dei grani (29) con i dadi (28) serrati a 15 Nm.
minuti e quindi non vi siano perdite. Rilasciare la pressione.
NUR FU È R AUSFUÈ HRUNG MIT 3 FUNKTIONEN NUR FU È R AUSFU È HRUNG MIT 3 FUNKTIONEN
D Die Hilfsbremse und Negativbremse an eine getrennte D Stifte (29) bis zum Anschlag der Sprossen (30) am
Pumpe schlieûen; Druck bis zu einem Wert von 20v25 Kolben (33) schrauben und dann um 1 Umdrehung
Nm einlassen. aufdrehen, um einen Hub von 1,5 mm herzustellen.
a BEMERKUNG. Kontrollieren, ob der Druck mindestens 5 Minuten b Die Position der Stifte (29) mit den Muttern (28) bei einem
Anzugsmoment von 15 Nm blockieren. Druck ablassen.
lang stabil bleibt und nirgends austritt.

ESP Conectar los frenos de servicio y negativo a una pompa ESP Atornillar las espigas (29) hasta el apoyo de las
externa; introducir hasta un valor de 20v25 Nm. extremidades (30) sobre el piston (33) y ahora destorni-
NOTA. Controlar que la presion quede estabil por lo menos por 5 llarlos de 1 giro para averiguar una carrera del pistoÁn de 1,5 mm.
minutos y que no hayan perdidas. Bloquear la posicioÁn de las espigas (29) con las tuercas (28)
apretadas a 15 Nm. Dejar la presioÁn.
F Brancher les freins de service et neÂgatif aÁ une pompe F Visser les grains (29) jusqu'aÁ la deÂpose des chevilles
externe; eÂmettre de la pression jusqu'aÁ une valeur de (30) sur le piston (33), puis deÂvisser ceux-ci d'un tour
20v25 Nm. pour creÂer une course du piston de 1,5 mm.
NOTE. ControÃler que la pression soit stable pendant 5 minutes au Bloquer la position des grains (29) avec les eÂcrous (28) serreÂs aÁ
moins et qu'il n'y ait pas de fuites. 15 Nm. RelaÃcher la pression.
Controllare lo sblocco del freno negativo immettendo Montare il sensore di movimento (1) ed avvitarlo
ITA una pressione di 16v35 bar e ruotando manualmente ITA manualmente a fondo corsa. Svitarlo di 3/4 di giro e
la flangia (5). bloccare la posizione con il dado. Coppia di bloccag-
Rilasciare la pressione. gio: MAX 30 Nm.
ATTENZIONE! Non superare la coppia indicata.
Kontrollieren ob, beim einlassen von einem Druck von Den Bewegungsgeber (1) montieren und von Hand bis
D 16v35 bar die Negativbremse entsichert und von D zum Anschlag montieren. Dann um 3/4 Umdrehung
Hand den Flansch (5) drehen. aufdrehen und die Position mit der Mutter blockieren.
Druck ablassen. Anzugsmoment: max. 30 Nm.
c d ACHTUNG! Das Anzugsmoment nicht uÈberschreiten.
Controlar el bloqueo del frenonegativo indroduciendo Montar el sensor de movimiento (1) y atornillarlo
ESP una presioÁn de 16v35 bar y ruotando manualmente la ESP manualmente a final carrera. Destornillarlo de 3/4 de
brida (5). vuelta y bloquear la posicioÁn con la tuerca.
Dejar la presioÁn. Par de bloqueo: Max 30 Nm.
ATENCION! No superar la mesura indicada.
ControÃler le deÂbrayage du frein neÂgatif en eÂmettant de Monter le capteur de deÂplacement (1) et visser celui-ci
F la pression aÁ 16v35 bar et en tournant la flasque (5) F aÁ la main en fin de course. DeÂvisser encore celui-di de
manuellement. 3/4 de tour et bloquer sa position avec l'eÂcrou. Couple
RelaÃcher la pression. de blocage: MAX. 30 Nm.
ATTENTION! Ne jamais deÂpasser le couple indiqueÂ.
ATTEZIONE! Per sbloccare il freno negativo in fase di Dopo l'emergenza svitare i grani in modo alternato
ITA emergenza (mancanza di pressione per avaria del ITA fino ad ottenere una sporgenza di 17 mm; bloccare la
veicolo), allentare i dadi (22) ed avvitare in modo posizione con i dadi (22) serrati a 15 Nm.
progressivo alternato, i grani (21) fino ad avvertire un precarico;
proseguire ulteriormente per 1,5 giri.
ACHTUNG! Um die Negativbremse im Notfall zu Nach dem Notfall, die Stifte abwechselnd aufschrau-
D entsichern (Druck bleibt wegen einer StoÈrung am D ben, bis ein Vorsprung von 17 mm erreicht wird; die
Fahrzeug aus), die Muttern (22) lockern und ab- Position mit den Muttern (22) bei einem Anzugsmo-
wechseln die Stifte (21) fest schrauben bis sie vorgeladen sind; ment von 15 Nm blockieren.
e um weitere 1,5 Umdrehungen fest drehen. f
ATENCION! Para sbloquear el freno negativo en fase Despues de una emergencia destornillar las espigas
ESP de emergencia (falta de presioÁn por gaste del veiculo), ESP de manera alternada hasta obtener una parte saliente
aflojar las tuercas (22) y atornillar de manera progre- de 17 mm, bloquear la posicioÁn con las tuercas (22)
siva alternada, las espigas (21) hasta averiguar una precarga, apretadas a 15 Nm.
seguir ulteriormente por 1,5 giros.
ATTENTION! Pour deÂgager le frein neÂgatif en cas ApreÁs l'eÂmergence deÂvisser les grains de facËon
F d'eÂmergence (manque de pression en cas de panne F alterneÂe jusqu'aÁ obtenir une saillie de 17 mm; bloquer
du veÂhicule) desserrer les eÂcrous (22) et visser de la position aÁ l'aide des eÂcrous (22) serreÂs aÁ 15 Nm.
facËon progressive alterneÂe, les grains (21) jusqu'aÁ avertir une
preÂcharge; faire encore 1,5 tour.
183
HOW TO DISASSEMBLE THE LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) - SMONTAGGIO DIFFERENZIALE A SLITTAMENTO LIMITATO
(25% E 45%) - DIFFERENTIAL MIT BEGRENZTEM GLEITVERMOÈGEN (25% UND 45%) ABMONTIEREN - DESMONTAJE DIFERENCIAL A
DESLIZAMIENTO LIMITADO (25% Y 45%) - DESMONTAJE DIFFERENTIEL A GLISSEMENT REDUIT (25% ET 45%)
F1240804 F1240485
GB a GB b
Remove the whole differential unit (2) from the central axle unit (1). Remove the check screws (3) of the crown (4).
For details, see «REMOVING THE DIFFERENTIAL UNIT». NOTE. Note down the position of the niches of the central hole in
relation to the protrusions of the friction unit steel discs.
7
5
6
4
F1240806 F1240803
GB c GB d
If bearing (5) needs replacing, remove it; remove crown (4). Remove the planetary gear (6) and the whole friction unit (7).
8
10 11
9
F1240807 F1240489
GB e GB f
If bearing (8) needs replacing, extract it from the differential unit (9). Remove the snap rings (10) from the pins (11) of the planet gears
(12).
184
Asportare dal corpo centrale assale (1) il gruppo Rimuovere le viti (3) di ritegno della corona (4).
ITA differenziale (2) completo. ITA
NOTA. Annotare la posizione delle nicchie del foro
Per i dettagli, vedere «RIMOZIONE GRUPPO DIFFE- centrale rispetto alle sporgenze dei dischi d'acciaio
RENZIALE». dei gruppi di frizione.
Vom zentralen AchsenkoÈrper (1) das vollstaÈndige Die Schrauben (3) zur Halterung des Kranzes (4)
D Differentialaggregat (2) abnehmen. D abnehmen.
Weitere Einzelheiten, siehe «DIFFERENTIALAGGRE- BEMERKUNG. Die Position der Nischen des zentralen
GAT ABNEHMEN». Lochs im VerhaÈltnis zu den Stahlscheiben der Kupplungsaggre-
a b gate anmerken.
Sacar del cuerpo central axial (1) el grupo diferencial Remover los tornillos (3) de retencioÁn de la corona (4).
ESP (2) completo. ESP
NOTA. Anotar la colocacioÁn de los nichos del agujero
Por los detalles, vease «REMOCION GRUPO DIFE- central respecto a las partes salientes de los discos de
RENCIAL». acero de los grupos de fricioÁn.
Enlever le corps central essieu (1) le groupe diffeÂren- Enlever les vis (3) de fixation de la couronne (4).
F tiel (2) complet. F
NOTE. Prendre note de la position des logements du
Pour tout deÂtail, voir «DEPOSE DU GROUPE DIFFE- trou central par rapport aÁ la saillie des disques d'acier
RENTIEL». des groupes de friction.
Se si deve sostituire, estrarre il cuscinetto (5); Rimuovere l'ingranaggio planetario (6) ed il gruppo
ITA rimuovere la corona (4). ITA frizione (7) completo.
Wenn es ausgewechselt werden muû, das Lager (5) Das Planetengetriebe (6) und das vollstaÈndige Kup-
D heraus nehmen; Kranz (4) abnehmen. D plungsaggregat (7) abnehmen.
c d
Si se debe de sobstituir, extraer el cojinete (5); Remover el engranaje planetario (6) y el grupo fricioÁn
ESP remover la corona (4). ESP (7) completo.
Si on doit substituer, extraire le palier (5); enlever la Enlever l'engrenage planeÂtaire (6) et le groupe de
F couronne (4). F friction (7) complet.
Se si deve sostituire, estrarre il cuscinetto (8) dal corpo Rimuovere gli anelli elastici (10) dai perni (11) degli
ITA differenziale (9). ITA ingranaggi satelliti (12).
Wenn es ausgewechselt werden muû, das Lager (8) Die Kolbenringen (10) von den Stiften (11) der
D vom DifferentialkoÈrper (9) heraus nehmen. D Planetengetriebe (12) abnehmen.
e f
Si se debe de sobstituir, extraer el cojinete (8) del Remover los segmentos elasticos (10) de los pernos
ESP cuerpo diferencial (9). ESP (11) de los engranajes satelites (12).
Si on doit substituer, extraire le palier (8) du corps Enlever les anneaux aÁ ressort (10) des axes (11) des
F diffeÂrentiel (9). F engrenages satellites (12).
185
T14
12 12
11
F1240809 F1240491
GB a GB b
Introduce tool T14 in-between the planet gears (12). Using two pin-drivers, engage tool T14 in between the planet gears
(12).
CAUTION! Carefully check that tool T14 keeps in an aligned
position with the pins (11) when locked.
T16A T16A
T15 T15
T16A
11
F1240492 F1240493
bar
GB c GB d
Place the differential unit (9) under a press, position bush T15 and Remove gudgeon T16A and bush T15.
insert gudgeon T16A. Press gudgeon T16A to end of stroke. NOTE. In this state, the pin (11) is contained within tool T14.
T14
12
12
9
F1240491 F1240809
GB e GB f
Remove tool T14 and planet pin (11) with it. Leaving the released planet in its position, lock again tool T14.
Repeat pin extraction operation on the second planet pin (11).
Repeat the same operations on the remaining pins.
186
Inserire tra gli ingranaggi satelliti (12) l'attrezzo T14. Operando con due cacciaspine, forzare l'attrezzo T14
ITA ITA tra gli ingranaggi satelliti (12).
ATTENZIONE! Controllare attentamente che l'attrez-
zo T14 rimanga allineato ai perni (11) quando eÁ bloccato.
Zwischen den Planetengetriebe (12) das Werkzeug Mit zwei DuÈbeln das Werkzeug T14 zwischen den
D T14 stecken. D ZahnraÈdern des Planetengetriebes (12) forcieren.
ACHTUNG! SorgfaÈltig kontrollieren, ob das Werkzeug
T14 mit den Stiften (11) ausgerichtet ist, nachdem es blockiert
a b worden ist.
Introducir entre los engranajes satelites (12) la Obrando con dos extractores de clivijas, hacer fuerza
ESP herramienta T14. ESP sobre la herramienta T14 entre los engranajes
satelites (12).
ATENCION! Controlar con cuidado que la herramienta T14 quede
en linea a los pernos (11) cuando esta bloqueado.
Introduire entre les engrenages satellites (12) l'outil En oeuvrant avec deux dispositifs arrache-broches,
F T14. F forcer l'outil T14 entre les engrenages satellites (12).
ATTENTION! ControÃler attentivement que l'outil T14
demeure aligneÂ aux axes (11) quand il est bloqueÂ.
Sistemare il corpo differenziale (9) sotto una pressa, Asportare lo spinotto T16A e la bussola T15.
ITA posizionare la boccola T15 ed inserire lo spinotto ITA
NOTA. In questa condizione, il perno (11) eÁ contenuto
T16A. Pressare lo spinotto T16A fino a fondo corsa. nell'attrezzo T14.
Den DifferentialkoÈrper (9) unter eine Presse legen, die Den Bolzen T16A und die Buchse T15 abnehmen.
D Buchse T15 positionieren und den Bolzen T16A D
BEMERKUNG. In diesem Zustand befindet sich der
einsetzen. Den Bolzen T16A bis zum Anschlag Stift (11) im Werkzeug T14.
einpressen.
c d
Sistemar el cuerpo diferencial (9) bajo una presa, Sacar la cruceta T16A y el manguito T15.
ESP colocar el carquillo T15 y introducir la cruceta T16A. ESP
NOTA. En esta condicion, el perno (11) esta contenido
Empujar la cruceta T16A a tope. en la herramineta T14.
Ajuster le corps diffeÂrentiel (9) sous une presse, placer Enlever la cheville T16A et la bague T15.
F l'embout T15 et introduire la cheville T16A. Presser la F
NOTE. Dans ces conditions, l'axe (11) est contenu
cheville T16A jusqu'en fin de course. dans l'outil T14.
Rimuovere l'attrezzo T14 e con esso il perno (11) del Lasciando in posizione l'ingranaggio satellite che si eÁ
ITA satellite. ITA liberato, bloccare nuovamente l'attrezzo T14.
Ripetere le operazioni di estrazione del perno del
secondo perno satellite (11).
Ripetere le operazioni per gli altri perni.
Das Werkzeug T14 und damit auch den Stift (11) des Das Planetengetriebe, das sich freigesetzt hat, in
D Planetengetriebes abnehmen. D seiner Position lassen, und Werkzeug T14 wieder
blockieren.
Die VorgaÈnge zum Abnehmen des zweiten Stiftes des Planeten-
e f getriebes (11) wiederholen.
Die VorgaÈnge fuÈr alle anderen Stifte wiederholen.
Remover la herramienta T14 y con esta el perno (11) Dejando en posicioÁn el engranaje satelite que se ha
ESP del satelite. ESP librado, bloquear de nuevo la herramienta T14.
Repetir las operaciones de extracioÁn del perno de
segundo perno satelite (11).
Repetir las operacioÁnes para los otros pernos.
Enlever l'outil T14 et avec celui-ci l'axe (11) du En laissant dans sa position l'engrenage satellite qui
F satellite. F s'est deÂgageÂ, bloquer de nouveau l'outil T14.
ReÂpeÂter les opeÂrations pour extraire l'axe du deu-
xieÁme axe satellite (11).
ReÂpeÂter les opeÂrations pour les autres axes.
187
F1240814
GB a GB b
Remove tool T14 and extract from the differential unit (9) the two
final planet gears (12), the 2nd planet gear (6) and the whole friction
assembly concerned (7).
45% VERSION
15 VERSIONE 45%
AUSFUÈ HRUNG 45%
3 13 VERSION 45%
VERSION 45%
5 10
4
19
16 13
11
14
17 18 15
16 7
14
12 18 11 6
6
14
GB c 19 10 GB d
15 7 16
14
13 16
7 17
12 9
13 8
18 1
11 15
19 7
10
18
11
19
10
2
e f
D1240090
GB GB
188
Rimuovere l'attrezzo T14 ed asportare dal corpo
ITA differenziale (9) gli ultimi due ingranaggi satelliti (12), ITA
il 2ë ingranaggio planetario (6) ed il relativo gruppo di
frizione (7) completo.
Das Werkzeug T14 abnehmen und vom Differential-

D koÈrper (9) die letzten beiden ZahnraÈder des Planeten- D
getriebes (12), das 2. Planetengetriebe und das
entsprechende Kupplungsaggregat (7) abnehmen.
a b
Remover la herramienta T14 y sacar del cuerpo
ESP diferencial (9) los ultimos dos engranajes satelites ESP
(12), el 2ë engranaje planetario (6) y el relativo grupo
de fricioÁn (7) completo.
Enlever l'outil T14 puis extraire du corps diffeÂrentiel

F (9) les deux derniers engrenages satellites (12), le 2ë F
engrenage planeÂtaire (6) et le groupe de friction relatif
(7) complet.
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
189
HOW TO ASSEMBLE THE LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) - ASSEMBLAGGIO DIFFERENZIALE A SLITTAMENTO LIMITATO
(25% E 45%) - DIFFERENTIAL MIT BEGRENZTEM GLEITVERMOÈGEN (25% UND 45%) MONTIEREN - ASEMBLAJE DIFERENCIAL A
DESLIZAMIENTO LIMITADO (25% Y 45%) - MONTAJE DIFFERENTIEL A GLISSEMENT REDUIT (25% ET 45%)
18,2 ± 0,1
6
6 13
14
7
6 17
9
15
16
F1240814
25% F1240815
GB a GB b
Place a friction unit (7) - suitable for the specific type of slipping - 25% FRICTION UNIT COMPOSITION
and planetary gear (6) into the differential unit (9). Friction ring with increased shim (13), steel rings (14) and friction
The composition of the unit is illustrated in the points below. rings (15) alternated, end ring (16) and distance piece (17).
CAUTION! As to rings (13) and (16), the side without notches must
face outwards.
18,2 ± 0,1
6 12
6
13 14 18
T16C
15
16
45% F1240816 F1240495
GB c GB d
45% FRICTION UNIT COMPOSITION Position shim washer (18) and the first planet gear (12).
Friction ring with increased shim (13), steel rings (14) and friction Hold them in position with bar T16C.
rings (15) alternated, end ring (16) and distance piece (17).
CAUTION! As to rings (13) and (16), the side without notches must
face outwards.
12 T14
T16A
18 9
T16C
T16C
F1240496 F1240497
GB e GB f
Using gudgeon T16A, position the second planet gear (12) and Insert tool T14 in-between the two planet gears (12). Align the
relative shim washer (18). whole unit, pushing bar T16C in as far as it will go, until gudgeon
T16A is expelled.
190
Inserire nel corpo differenziale (9), il gruppo di frizione COMPOSIZIONE GRUPPO DI FRIZIONE 25%
ITA (7) specifico per il tipo di slittamento e l'ingranaggio ITA Anello di frizione con spessore maggiorato (13), anelli
planetario (6). d'acciaio (14) ed anelli di frizione (15) alternati, anello
La composizione del gruppo di frizione eÁ indicata in seguito. terminale (16), anello distanziatore (17).
ATTENZIONE! Gli anelli (13) e (16) devono avere la parte senza
intagli rivolta verso l'esterno.
In den DifferentialkoÈrper (9) das fuÈr die Gleitungsart ZUSAMMENBAU DES KUPPLUNGSAGGREGATS 25%
D und das Planetengetriebe (6) geeignete Kupplungsag- D Kupplungsringe mit groÈûerer StaÈrke (13), Stahlringe
gregat (7) einsetzen. (14) und Kupplungsringe (15), Abschluûring (16),
Die Zusammensetzung des Kupplungsaggregats ist nachstehend Distanzscheibe (17).
a beschrieben. b ACHTUNG! Die Ringe (13) und (16) muÈssen die glatte Seite nach
auûen gerichtet haben.
Introducir en el cuerpo diferencial (9), el grupo de COMPOSICION GRUPO DE FRICION 25%

ESP fricioÁn (7) especifico por el tipo de deslizamiento y el ESP Segmento de fricioÁn con espesor major (13), segmen-
engranaje planetario (6). to de acero (14) y segmento de fricioÁn (15) alternados,
La composicioÁn del grupo de fricioÁn es indicada a seguir. segmento terminal(16), segmento distancial (17).
ATENCION! Los segmentos (13) y (16) deben de tener la parte sin
ranaduras hacia el esterno.
Introduire dans le corps diffeÂrentiel (9), le groupe de COMPOSITION DU GROUPE DE FRICTION 25%
F friction (7) speÂcifique pour le type de patinage et F Garniture de friction avec cale majoreÂe (13), anneaux
l'engrenage planeÂtaire (6). d'acier (14) et garniture de friction (15) alterneÂs,
La composition du groupe de friction est indiqueÂe ci-dessous. anneau terminal (16), bague entretoise (17).
ATTENTION! Les garnitures (13) et (16) doivent avoir la partie sans
entailles tourneÂe vers l'exteÂrieur.
COMPOSIZIONE GRUPPO DI FRIZIONE 45% Posizionare la rondella di rasamento (18), il primo

ITA Anello di frizione con spessore maggiorato (13), anelli ITA ingranaggio satellite (12).
d'acciaio (14) ed anelli di frizione (15) alternati, anello Tenerli in posizione con la barra T16C.
terminale (16).
ATTENZIONE! Gli anelli (13) e (16) devono avere la parte senza
intagli rivolta verso l'esterno.
ZUSAMMENBAU DES KUPPLUNGSAGGREGATS 45% Die Zwischenlegscheibe (18) und das erste Planeten-
D Kupplungsringe mit groÈûerer StaÈrke (13), Stahlringe D getriebe (12) positionieren.
(14) und Kupplungsringe (15), Abschluûring (16). In dieser Position mit dem Stab T16C halten.
ACHTUNG! Die Ringe (13) und (16) muÈssen die glatte Seite nach
c auûen gerichtet haben. d
COMPOSICION GRUPO DE FRICION 45% Colocar la arandela de raspadura (18), el primer
ESP Segmento de fricioÁn con espesor major (13), segmen- ESP engranaje satelite (12).
to de acero (14) y anillo de fricioÁn (15) alternados, Tenerlos en posicioÁn con la barra T16C.
segmento terminal (16).
ATENCION! Los segmentos (13) y (16) deben tener la parte sin
ranaduras hacia el esterno.
COMPOSITION DU GROUPE DE FRICTION 45% Mettre la rondelle de rasage (18) en place, puis le
F Garniture de la friction avec cale majoreÂe (13), F premier engrenage satellite (12).
anneaux d'acier (14) et garniture de friction (15) Maintenir ceux-ci en place avec la barre T16C.
alterneÂs, anneau terminal (16).
ATTENTION! Les garnitures (13) et (16) doivent avoir la partie sans
entailles tourneÂe vers l'exteÂrieur.
Utilizzando lo spinotto T16A, posizionare il secondo Inserire tra i due ingranaggi satelliti (12) l'attrezzo T14.
ITA ingranaggio satellite (12) e la relativa rondella di ITA Allineare tutto il gruppo inserendo a fondo la barra
rasamento (18). T16C fino ad espellere lo spinotto T16A.
Mit einem Bolzen T16A das zweite Planetengetriebe Die beiden Planetengetriebe (12) mit dem Werkzeug
D (12) und die Zwischenlegscheibe (18) positionieren. D T14 einsetzen. Das ganze Aggregat ausrichten indem
der Stab T16C eingesetzt wird, bis der Bolzen T16A
ausgestoûen wird.
e f
Utilizando la cruceta T16A, colocar el segundo Introducir entre los dos engranajes satelites (12) la
ESP engranaje satelite (12) y la relativa arandela de ESP herramienta T14.
raspadura (18). Alinear todo el grupo introduciendo a tope la barra
T16C hasta sacar la cruceta T16A.
A l'aide de la cheville T16C, mettre en place le Introduire entre les deux engrenages satellites (12)
F deuxieÁme engrenage satellite (12) et sa rondelle de F l'outil T14.
rasage (18). Aligner tout le groupe en introduisant la barre T16C aÁ
fond jusqu'aÁ expulser la cheville T16A.
191
T14 19 11
6 6
F1240809 F1240498
GB a GB b
Lock tool T14 behind the planet gears (12). Fit snap rings (19) onto the pins (11).
After locking the tool, remove bar T16C.
T16B 11
11
T15
T15
T16B
11
9
F1240499 F1240500
bar
GB c GB d
Position the differential unit (9) under the press, position bush T15 Place gudgeon T16B on top of the planet pin (11).
and insert the planet pin (11).
T16A
T15
T16A
10
11
11
9
F1240492 F1240502
bar
GB e GB f
Press gudgeon T16B as far down as it will go. Remove gudgeon T16B, bush T15, and fit the snap ring (10) onto
the pin (11).
CAUTION! Make sure that the snap ring centers the seat and
positions itself on the differential unit face.
Repeat the operations on the other planet pin and on the other
planet unit.
192
Bloccare l'attrezzo T14 a ridosso degli ingranaggi Montare sui perni (11) gli anelli elastici (19).
ITA satelliti (12). ITA
Dopo il bloccaggio, rimuovere la barra T16C.
Das Werkzeug T14 am Anschlag der Planetengetriebe Auf die Stifte (11) die Kolbenringe (19) montieren.
D (12) blockieren. D
Danach Stab T16C abnehmen.
a b
Bloquear la herramienta T14 detras de los engranajes Montar sobre los pernos (11) los segmentos elasticos
ESP satelites (12). ESP (19).
Despues del bloqueo, remover la barra T16C.
Bloquer l'outil T14 au-dessus des engrenages satel- Monter sur les axes (11) les anneaux aÁ ressort (19).
F lites (12). F
ApreÁs le blocage, enlever la barre T16C.
Posizionare sotto la pressa il corpo differenziale (9), Sovrapporre al perno satellite (11) lo spinotto T16B.
ITA sistemare la boccola T15 ed inserire il perno satellite ITA
(11).
Unter einer Presse den DifferentialkoÈrper (9) positio- Auf den Planetenstift (11) den Bolzen T16B legen.
D nieren, die Buchse T15 einlegen und den Planetenstift D
(11) einsetzen.
c d
Colocar bajo la prensa el cuerpo diferencial (9), Sobreponer al perno satelite (11) la cruceta T16B.
ESP colocar el casquillo T15 y introducir el perno satelite ESP
(11).
Placer le corps diffeÂrentiel (9) sous la presse, ajuster Poser sur l'axe satellite (11) la cheville T16B.
F l'embout T15 et inseÂrer l'axe satellite (11). F
Pressare lo spinotto T16B a fondo. Rimuovere lo spinotto T16B, la boccola T15 e montare
ITA ITA sul perno (11) l'anello elastico (10).
ATTENZIONE! Assicurarsi che l'anello elastico centri
la sede e che appoggi sul piano del corpo differenziale.
Ripetere le operazioni per l'altro perno satellite e per l'altro asse
satelliti.
Den Bolzen T16B fest einpressen. Den Bolzen T16B, die Buchse T15 abnehmen und auf
D D den Stift (11) den Kolbenring (10) montieren.
ACHTUNG! Kontrollieren, ob der Kolbenring im Sitz zentriert ist
und auf der FlaÈche der FlaÈche des DifferentialkoÈrpers liegt.
e f Die VorgaÈnge fuÈr den anderen Planetenstift und die andere
Planetenachse wiederholen.
Apretar la cruceta T16B a tope. Remover la cruceta T16B, el casquillo T15 y montar
ESP ESP sobre el perno (11) el segmento elastico (10).
ATENCION! Averiguar que el segmento elastico sea centrado en su
alojamiento y que apoye sobre la superficie del cuerpo diferencial.
Repetir las operacioÁnes para el otro perno satelite y para el otro eje
satelite.
Presser la cheville T16B aÁ fond. Enlever la cheville T16B, l'embout T15 et monter sur
F F l'axe (11) l'anneau aÁ ressort (10).
ATTENTION! S'assurer que l'anneau aÁ ressort soit
bien centreÂ sur le sieÁge et poseÂ sur la surface du corps diffeÂrentiel.
ReÂpeÂter les opeÂrations pour l'autre axe satellite et l'autre essieu
satellite.
193
3
4
6
9
9
F1240803 F1240946
GB a GB b
Check that planets have a light clearance in relation to the first Line the lubrication holes up with the slots in the differential carrier.
planet gear. Orient the holes of the crown (4) towards the protrusions of the
Position the second planetary gear (6) and the second friction unit braking unit.
(7) into the differential unit (9). Position the crown (4) on the differential unit (9) and lock it with the
screws (3) previously coated with Loctite 242.
Torque wrench setting for screws: 128 ± 142 Nm.
NOTE. Tighten screws using the criss-cross method.
T17 8
T17 5
F1240506 F1240804
GB c GB d
If bearings (5) and (8) have been removed, install them using tool Install the whole differential assembly (2) into the central body (1).
T17. For details, see «INSTALLING THE DIFFERENTIAL UNIT».
GB e GB f
194
Controllare che i satelliti abbiano un leggero gioco Allineare i fori di lubrificazione della corona (4) con le
ITA rispetto il primo ingranaggio planetario. ITA cave della scatola differenziale sulle sporgenze del
Posizionare il secondo ingranaggio planetario (6) ed il gruppo di frenatura. Posizionare la corona (4) sul corpo
secondo gruppo di frizione (7) nel corpo differenziale (9). differenziale (9) e bloccarla con le viti (3) spalmate con Loctite 242.
Coppia di serraggio viti: 128v142 Nm
NOTA. Serrare le viti con il metodo del serraggio incrociato.
Kontrollieren, ob die Planetengetriebe etwas Spiel im Die SchmierloÈcher des Kranzes (4) der Differential-
D VerhaÈltnis zum ersten Planetengetriebe haben. D schachtel mit den VorspruÈngen des Bremsaggregats
Das zweite Planetengetriebe (6) und das zweite ausrichten. Den Kranz (4) auf den DifferentialkoÈrper (9) positionieren
Kupplungsaggregat (7) in den DifferentialkoÈrper (9) einsetzen. und mit den Schrauben (3), die zuvor mit Loctite 242 geschmiert
a b wurden, blockieren. Anzugsmoment der Schrauben: 128v142 Nm.
BEMERKUNG. Sie Schrauben im Kreuz fest schrauben.
Controlar que los satelites tengan un ligero juego Alinear los agujeros de lubrificar de la corona con los
ESP respecto al primero engranaje planetario. ESP nichos de la caja diferencial (4) sobre las partes
Colocar el segundo engranaje planetario (6) y el salientes del grupo de frenadura.
segundo grupo de fricioÁn (7) en el cuerpo diferencial (9). Colocar la corona (4) sobre el cuerpo diferencial (9) y bloquearla
con los tornilloss: 128v142 Nm.
NOTA. Apretar los tornillos de manera cruzada.
ControÃler que les satellites aient un peu de jeu par Aligner les trous de lubrification de la couronne (4) avec
F rapport au premier engrenage planeÂtaire. F les creux du carter diffeÂrentiel sur les saillies du groupe
Mettre le deuxieÁme engrenage planeÂtaire (6) en place de freinage. Placer la couronne (4) sur le corps diffeÂrentiel
ainsi que le second groupe de friction (7) du corps diffeÂrentiel (9). (9) et bloquer celle-ci avec les vis (3) enduites de Loctite 242.
Couple de serrage des vis: 128v142 Nm.
NOTE. Serrer les vis avec la meÂthode de serrage croiseÂe.
Se sono stati rimossi, montare i cuscinetti (5) e (8) Installare nel corpo centrale (1) il gruppo differenziale
ITA utilizzando l'attrezzo T17. ITA (2) completo.
Per i dettagli, vedere «INSTALLAZIONE GRUPPO
DIFFERENZIALE».
Falls sie abmontiert wurden, die Lager (5) und (8) mit In den zentralen KoÈrper (1) das vollstaÈndige Differen-
D dem Werkzeug T17 montieren. D tialaggregat (2) installieren.
FuÈr weitere Einzelheiten, siehe «INSTALLATION DES
DIFFERENTIALAGGREGATS».
c d
Si han sido removidos, montar los cojinetes (5) y (8) Introducir en el cuerpo central (1) el grupo diferencial
ESP utilizando la herramienta T17. ESP (2) completo.
Para los detalles, vease «INSTALACION GRUPO
DIFERENCIAL»
S'ils ont eÂteÂ enleveÂs, remonter les paliers (5) et (8) aÁ Installer dans le corps central (1) le groupe diffeÂrentiel
F l'aide de l'outil T17. F (2) complet.
Pour tout deÂtail, voir «INSTALLATION DU GROUPE
DIFFERENTIEL».
ITA ITA
D D
e f
ESP ESP
F F
195
HOW TO DISASSEMBLE THE HYDRAULIC DIFFERENTIAL LOCK - SMONTAGGIO BLOCCAGGIO DIFFERENZIALE A COMANDO IDRAULICO -
DIFFERENTIALBLOCKIERUNG MIT HYDRAULISCHER STEUERUNG ABMONTIEREN - DESMONTAJE BLOQUEO DIFERENCIAL A MANDO
HYDRAULICO - DESMONTAJE BLOCAGE DIFFERENTIEL A COMMANDE HYDRAULIQUE
F1240385 F1240827
GB a GB b
Remove the arms. Remove the top cap (1).
For details, see «CHECKING WEAR AND REPLACING THE NOTE. The cap must be replaced each time the unit is
BRAKING DISCS». disassembled.
5 4
2
F1240828 F1240829
GB c GB d
Remove the microswitch (2), signalling differential lock operation. Loosen the lock nut (4) of fork (5) by about 2 turns.
NOTE. Check the state of the O-ring (3).
5
6 6
F1240830 F1240831
GB e GB f
Using a metal punch and a hammer, disengage fork (5) from piston Using two wrenches, lock piston (6) and remove nut (4).
cone (6).
196
Asportare i bracci. Rimuovere il tappo superiore (1).
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA
NOTA. Il tappo deve essere sostituito ad ogni
SOSTITUZIONE DISCHI FRENO». smontaggio.
Die Arme abnehmen. Unterer Stopfen (1) abnehmen.

D FuÈr weitere Einzelheiten, siehe «VERSCHLEISS D
BEMERKUNG. Der Stopfen muû jedesmal ausge-
KONTROLLIEREN UND BREMSSCHEIBEN AUS- wechselt werden, wenn er abmontiert wird.
WECHSELN».
a b
Sacar los brazos. Remover la tapa superior (1).
ESP Para los detalles, vease «CONTROL DESGASTE Y ESP
NOTA. La tapa debe de ser sobstituida a cada
SOBSTITUCION DISCOS FRENOS». desmontaje.
Enlever les bras. Enlever le bouchon supeÂrieur (1).

F Pour tout deÂtail, voir «CONTROLE DE L'USURE ET F
NOTE. Le bouchon doit eÃtre remplaceÂ aÁ chaque
SUBSTITUTION DES DISQUES FREIN». deÂmontage.
Rimuovere il microinterruttore (2) di segnalazione Allentare il dado (4) di bloccaggio della forcella (5) di
ITA inserimento bloccaggio differenziale. ITA circa 2 giri.
NOTA. Controllare lo stato della guarnizione OR (3).
Den Mikroschalter (2) abnehmen, der den Einsatz der Mutter (4) zur Blockierung der Gabel (5) um ca. 2
D Differentialblockierung meldet. D Umdrehungen lockern.
BEMERKUNG. Zustand des O-Rings (3) kontrollieren.
c d
Remover el microinterruptor (2) de senalacioÁn intro- Aflojar la tuerca (4) de bloqueo de la horquilla (5) de 2
ESP ducioÁn bloqueo diferencial. ESP giros approx.
NOTA. Controlar el estado de la guarnicioÁn OR (3).
Enlever le microinterrupteur (2) qui signale l'insertion Desserrer l'eÂcrou (4) de blocage de la fourchette (5)
F du blocage diffeÂrentiel. F d'environ 2 tours.
NOTE. ControÃler l'eÂtat des garnitures OR (3).
Utilizzando un punzone metallico ed un mazzuolo, Utilizzando due chiavi, bloccare il pistone (6) ed
ITA sbloccare la forcella (5) dal cono del pistone (6). ITA asportare il dado (4).
Mit einem Metallstift und einem Hammer die Gabel (5) Mit Hilfe von zwei SchluÈsseln, den Kolben (6) blok-
D von dem Kolbentrichter (6) freisetzen. D kieren und die Mutter (4) abnehmen.
e f
Utilizando un punzon metalico y un martillo, bloquear Utilizando dos llaves, bloquear el pistoÁn (6) y sacar la
ESP l'horquilla (5) del cono del pistoÁn (6). ESP tuerca (4).
A l'aide d'un poussoir meÂtallique et d'un maillet, A l'aide de deux cleÂs, bloquer le piston (6) et enlever
F deÂbloquer la fourchette (5) du coÃne du piston (6). F l'eÂcrou (4).
197
14 13 5
15
F1240832 F1240833
GB a GB b
Remove screws (14) and remove the intermediate cover (13). Disconnect fork (5) from piston (6). While holding the fork up,
NOTE. Support the differential unit with a lever. remove the differential unit (15).
5 6
12
F1240834 F1240835
GB c GB d
Extract fork (5). Remove snap ring (12) and whole piston (6).
6
11
9
10
7
8
9
F1240836 F1240837
GB e GB f
Remove guide ring (11) and O-ring (10). Remove snap ring (9) and take piston unit (6) apart. Remove all
NOTE. The guide ring (11) and O-ring (10) must be replaced each component parts.
time the unit is disassembled.
198
Rimuovere le viti (14) e rimuovere il coperchio Scollegare dal pistone (6) la forcella (5) e, tenendola
ITA intermedio (13). ITA sollevata, rimuovere il gruppo differenziale (15).
NOTA. Sostenere il gruppo differenziale con una leva.
Die Schrauben (14) abnehmen und den mittleren Dek- Vom Kolben (6) die Gabel (5) abtrennen. Die anheben
D kel (13) entfernen. D und des Differentialaggregat (15) entfernen.
BEMERKUNG. Das Differentialaggregat mit einem
Hebel stuÈtzen.
a b
Remover los tornillos (14) y remover la tapa intermedia Desconectar del pistoÁn (6) la horquilla y, teniendola
ESP (13). ESP levantada, remover el grupo diferencial (15).
NOTA. Sostener el grupo diferencial con una palanca.
Enlever les vis (14) puis enlever le couvercle inter- DeÂbrancher du piston (6) la fourchette (5) et en tenant
F meÂdiaire (13). F cette dernieÁre souleveÂe, enlever le groupe diffeÂrentiel
NOTE. Soutenir le groupe diffeÂrentiel aÁ l'aide d'un (15).
levier.
Estrarre la forcella (5). Rimuovere l'anello elastico (12) ed il pistone completo

ITA ITA (6).
Die Gabel (5) heraus nehmen. Den Kolbenring (12) und den vollstaÈndigen Kolben (6)
D D abnehmen.
c d
Extraer la harquilla (5). Remover el segmento elastico (12) y el pistoÁn
ESP ESP completo (6).
Extraire la fourchette (5). Enlever l'anneau aÁ ressort (12) et le piston complet (6).
F F
Asportare l'anello di guida (11) e la guarnizione OR Rimuovere l'anello elastico (9) e scomporre il gruppo
ITA (10). ITA pistone (6) in tutti i suoi componenti (7), (8).
NOTA. L'anello di guida (11) e la guarnizione (10)
devono essere sostituiti ad ogni smontaggio.
Den FuÈhrungsring (11) und den O-Ring (10) ab- Den Kolbenring (9) abnehmen und das Kolbenaggre-
D nehmen. D gat (6) auseinander nehmen, um die Teile (7) und (8)
BEMERKUNG. Der FuÈhrungsring (11) und die Dich- frei zu setzen.
tung (10) muÈssen jedesmal ausgewechselt werden, wenn sie
e abmontiert werden. f
Sacar el segmento de guõÁa (11) y la guarnicioÁn OR Remover el segmento elastico (9) y descomponer el
ESP (10). ESP grupo pistoÁn (6) en todos sus componentes (7) y (8).
NOTA. El segmento de guõÁa (11) y la guarnicioÁn (10)
deben de ser sobstituidos a cada desmontaje.
Enlever la bague de guidage (11) et la garniture OR Enlever l'anneau aÁ ressort (9) et deÂsassembler le
F (10). F groupe piston (6) de tous ses composants (7), (8).
NOTE. La bague de guidage (11) et la garniture (10)
doivent eÃtre substitueÂes aÁ chaque deÂmontage.
199
21
19
18 15
16
17 20
F1240838 F1240839
GB a GB b
Remove bearing (16) from the differential carrier (17) as well as the ONLY IF NECESSARY
stop ring (18), the coupling (19) and the spheres (20). Remove the coupling guide key (21) and disassemble the
NOTE. Note down the direction of assembly of the stop ring (18). differential unit (15).
(For details, see «HOW TO DISASSEMBLE THE DIFFERENTIAL
UNIT».
14
2
13
3
23 4
5
15 20 12
8
7
6
10
11
9
21 1
GB c GB d
22
17
19
18
16
D1240092
GB e GB f
200
Rimuovere il cuscinetto (16) dalla scatola differenziale SOLO SE NECESSARIO
ITA (17), l'anello di arresto (18), il manicotto (19) e le sfere ITA Rimuovere la chiavetta (21) di guida del manicotto e
(20). smontare il gruppo differenziale (15).
NOTA. Annotare il senso di montaggio dell'anello di arresto (18). (Per i dettagli, vedere «SMONTAGGIO GRUPPO DIFFERENZIA-
LE»).
Lager (16) von der Differentialschachtel (17), den NUR FALLS NOTWENDIG
D Sperring (18), die HuÈlse (19) und die Kugeln (20) D Den Keil (21) zur FuÈhrung der HuÈlse entfernen und
entfernen. das Differentialaggregat (15) abmontieren.
BEMERKUNG. Montagerichtung des Sperrings (18) bemerken. (FuÈr weitere Einzelheiten, siehe «DIFFERENTIALAGGREGAT AB-
a b MONTIEREN»).
Remover los cojinetes (16) de la caja diferencial (17), SOLO SI NECESARIO

ESP el segmento de paro (18) el manguito (19) y las ESP Remover la Laave (21) de guõÁa del manguito y
espheras (20). desmontar el grupo diferencial (15).
NOTA. Anotar el sentido de montaje del segmento de paro (18). Para los detalles, vease «DESMONTAJE GRUPO DIFERENCIAL».
Enlever le palier (16) du carter diffeÂrentiel (17), la SEULEMENT SI BESOIN

F bague de buteÂe (18), le manchon (19) et les spheÁres F Enlever la clavette (21) de guidage du manchon et
(20). deÂmonter le groupe diffeÂrentiel (15).
NOTE. Prendre note du sens de montage de la bague de buteÂe (Pour tout deÂtail, voir «DEMONTAAGE DU GROUPE DIFFEREN-
(18). TIEL».
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
201
HOW TO ASSEMBLE THE HYDRAULIC DIFFERENTIAL LOCK - ASSEMBLAGGIO BLOCCAGGIO DIFFERENZIALE A COMANDO IDRAULICO -
DIFFERENTIALBLOCKIERUNG MIT HYDRAULISCHER STEUERUNG MONTIEREN - ASEMBLAJE BLOQUEO DIFERENCIAL A MANDO
HYDRAULICO - MONTAJE BLOCAGE DIFFERENTIEL A COMMANDE HYDRAULIQUE
21 18
19
15
20
F1240839 F1240840
GB a GB b
ONLY IF PREVIOUSLY DISASSEMBLED Install spheres (20), coupling (19) and stop ring (18).
Assemble the differential unit (15). NOTE. Pay great attention to ring orientation (18).
(For details, see «HOW TO ASSEMBLE THE DIFFERENTIAL
UNIT»).
Position the guide key (21) of coupling (19).
11 10
6
16
17
T29
F1240841 F1240842
GB c GB d
Fit bearing (16) onto the differential carrier (17). Fit O-ring (10) and guide ring (11) onto the piston (6). Lubricate
NOTE. Make sure that the bearing is well set in the differential seals and insert the assembly into tool T29.
carrier.
7 T30
T29 22
8 6
F1240843 D1240089
GB e GB f
Insert tool T29 in the central unit (22) and push the piston (6) into Fit spring (7) and washer (8) on the piston (6) and install tool T30.
the seat.
Remove tool T29.
202
SOLO SE EÁ STATO SMONTATO Montare le sfere (20), il manicotto (19) e l'anello di
ITA Assemblare il gruppo differenziale (15). ITA arresto (18).
(Per i dettagli, vedere «ASSEMBLAGGIO GRUPPO NOTA. Controllare attentamente l'orientamento del-
DIFFERENZIALE»). l'anello (18).
Posizionare la chiavetta (21) di guida del manicotto (19).
NUR WENN ES ABMONTIERT WURDE Die Kugeln (20), die HuÈlse (19) und den Sperring (18)
D Differentialaggregat (15) zusammenbauen. D montieren.
(FuÈr weitere Einzelheiten, siehe «DIFFERENTIALAG-
GREGAT ZUSAMMENBAUEN»).
a Den Keil (21) auf die FuÈhrung der HuÈlse (19) positionieren. b
SOLO SI ESTA DESMONTADO Montar las espheras (20), el manguito (19) y el
ESP Asemblar el grupo diferencial (15). ESP segmento de paro (18).
(Para los detalles, vease «ASEMBLAJE GRUPO NOTA. Controlar atentamente la direccioÁn del seg-
DIFERENCIAL»). mento (18).
Colocar la llave (21) de guõÁa del manguito (19).
SEULEMENT SI DEMONTE Monter les spheÁres (20), le manchon (19) et l'anneau

F Assembler le groupe diffeÂrentiel (15). F de buteÂe (18).
(Pour tout deÂtail, voir «ASSEMBLAGE DU GROUPE NOTE. ControÃler attentivement l'orientation de l'an-
DIFFERENTIEL»). neau (18).
Mettre la clavette (21) de guidage du manchon (19) en place.
Montare sulla scatola differenziale (17) il cuscinetto Montare sul pistone (6) l'anello OR (10) e l'anello di
ITA (16). ITA guida (11). Lubrificare le guarnizioni ed inserire il
NOTA. Assicurarsi che il cuscinetto vada in sicura gruppo nell'attrezzo T29.
battuta sulla scatola differenziale.
Auf die Diffenrentialschachtel (17) das Lager (16) Auf den Kolben (6) den O-Ring (10) und den
D montieren. D FuÈhrungsring (11) montieren. Die Dichtungen Schmie-
BEMERKUNG. Sicherstellen, daû das Lager richtig in ren und das Aggregat in das Werkzeug T29 setzen.
der Differentialschachtel anschlaÈgt.
c d
Montar sobre la caja diferencial (17) el cojinete (16). Montar sobre el piston (6) el segmento OR (10) y el
ESP ESP segmento de guõÁa (11). Lubrificar las guarnicioÁnes y
NOTA. Asegurarse que el cojinete vaya seguramente
a tope sobre la caja diferencial. insertar el grupo en la herramienta T29.
Monter sur le carter du diffeÂrentiel (17) le palier (16). Monter sur le piston (6) la garniture OR (10) et la
F F bague de guidage (11). Lubrifier les garnitures et
NOTE. S'assurer que le palier aille en buteÂe sur le
carter du diffeÂrentiel. introduire le groupe dans l'outil T29.
Inserire l'attrezzo T29 nel corpo centrale (22) e Montare sul pistone (6) la molla (7) e la rondella (8) e
ITA spingere il pistone (6) nella sede. ITA montare l'attrezzo T30.
Rimuovere l'attrezzo T29.
Das Werkzeug T19 in den zentralen KoÈrper (22) Auf den Kolben (6) die Feder (7) und die Scheibe (8)
D setzen und den Kolben (6) in den Sitz druÈcken. D montieren und das Werkzeug T30 montieren.
Das Werkzeug T29 entfernen.
e f
Introducir la herramienta T29 en el cuerpo central (22) Montar sobre el pistoÁn (6) el muelle (7) y la arandela (8)
ESP y empujar el pistoÁn (6) en su alojamiento. ESP y montar la herramienta T30.
Remover la herramienta T29.
Introduire l'outil T29 dans le corps central (22) et Monter sur le piston (6) le ressort (7) et la rondelle (8)
F pousser le piston (6) dans son sieÁge. F puis monter l'outil T30.
Enlever l'outil T29.
203
HOW TO ASSEMBLE THE HYDRAULIC DIFFERENTIAL LOCK - ASSEMBLAGGIO BLOCCAGGIO DIFFERENZIALE A COMANDO IDRAULICO -
DIFFERENTIALBLOCKIERUNG MIT HYDRAULISCHER STEUERUNG MONTIEREN - ASEMBLAJE BLOQUEO DIFERENCIAL A MANDO
HYDRAULICO - MONTAJE BLOCAGE DIFFERENTIEL A COMMANDE HYDRAULIQUE
6
12
T30
F1240844 F1240845
GB a GB b
Screw tool T30 on the thread of the piston (6) to compress spring Fit the snap ring (12) of the unit.
(7) and vacate the seat for introducing the snap ring (12). Remove tool T30 and fit the snap ring (9) of spring (7).
5 14 13 23
22
15
F1240833 F1240850
GB c GB d
Insert the fork (5) and the differential unit (15) into the central unit Fit the intermediate cover (13) and lock it with screws (14). Tighten
(22). screws using a torque wrench setting of 23.8 ± 26.2 Nm.
Engage the fork (5) in the coupling (19) and on the piston (6). NOTE. Carefully check the state of the O-ring (23).
4 1
F1240846 F1240847
GB e GB f
Fit the lock nut (4) of the fork (5) and lock it with a dynamometric Fit the microswitch (2) complete with O-ring; torque wrench setting:
wrench set to a torque of 70 ± 75 Nm. max. 30 Nm.
If necessary, adjust differential unit clearances. (see «DIFFEREN-
TIAL UNIT ASSEMBLY»).
Fit the top cap (1) and the arms. (For details, see «CHECKING
WEAR AND REPLACING THE BRAKING DISKS»).
204
Avvitare l'attrezzo T30 sul filetto del pistone (6) per Montare l'anello elastico (12) di ritegno del gruppo.
ITA comprimere la molla (7) e liberare la sede per l'anello ITA Rimuovere l'attrezzo T30 e montare l'anello elastico
elastico (12). (9) di ritegno molla (7).
Das Werkzeug T30 auf das Kolbengewinde (6) Den Kolbenring (12) zur Halterung des Aggregats
D schrauben, um die Feder (7) zu komprimieren und D montieren.
den Sitz fuÈr den Kolbenring (12) freizusetzen. Das Werkzeug T30 abnehmen und den Kolbenring (9)
zur Halterung der Feder (7) montieren.
a b
Atornillar la herramienta T30 sobre la rosca del pistoÁn IMontar el segmento elastico (12) de compresioÁn del
ESP (6) para comprimir el muelle (7) y dejar libre el ESP grupo.
alojamiento para el anillo elastico(12). Removerla herramienta T30 y montar el segmento
elastico (9) de compresion muelle (7).
Visser l'outil T30 sur le filet du piston (6) pour Monter l'anneau aÁ ressort (12) de retenue du groupe.
F comprimer le ressort (7) et deÂgager le sieÁge pour F Enlever l'outil T30 et monter l'anneau aÁ ressort (9) de
l'anneau aÁ ressort (12). retenue ressort (7).
Inserire nel corpo centrale (22) la forcella (5) ed il Montare il coperchio intermedio (13) e bloccarlo con le
ITA gruppo differenziale (15). ITA viti (14) serrate con una coppia di 23,8v26,2 Nm.
Impegnare la forcella (5) nel manicotto (19) e sul NOTA. Controllare attentamente la condizione dell'a-
pistone (6). nello OR (23).
In den zentralen KoÈrper (22) die Gabel (5) und das Den mittleren Deckel (13) montieren und mit den
D Differentialaggregat (15) einsetzen. D Schrauben (14) mit einem Anzugsmoment von
Die Gabel (5) in der HuÈllse (19) und auf den Kolben (6) 23,8v26,2 Nm blockieren.
einsetzen. BEMERKUNG. Zustand des O-Ringes (23) sorgfaÈltig kontrollieren.
c d
ntroducir en el cuerpo (22) la horquilla (5) y el grupo Montar la tapa intermedia (13) y bloquearla con
ESP diferencial (15). ESP tornillos (14) apretadas con un par de 23,8v26,2 Nm.
Insertar la horquilla (5) en el manguito (19) y sobre el NOTA. Controlar con cuidado la condicioÁn del
pistyoÁn (6). segmento OR (23).
Introduire dans le corps central (22) la fourchette (5) et Monter le couvercle intermeÂdiaire (13) et bloquer celui-
F le groupe diffeÂrentiel (15). F ci avec les vis (14) serreÂes aÁ un couple de 23,8v26,2
Engager la fourchette (5) dans le manchon (19) puis Nm.
sur le piston (6). NOTE. ControÃler attentivement l'eÂtat de la garniture OR (23).
Montare il dado (4) di ritegno forcella (5) e bloccarlo Montare il microinterruttore (2) completo di guarnizione OR;
ITA con una chiave dinamometrica tarata ad una coppia di ITA coppia di serraggio: max. 30 Nm.
70v75 Nm. Se necessario, registrare i giochi differenziale. (Vede-
re «ASSEMBLAGGIO DIFFERENZIALE»).
Montare il tappo superiore (1) ed i bracci. (Per i dettagli, vedere
«CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO»).
Die Mutter (4) zur Halterung der Gabel (5) montieren Die Mikroschalter (2) samt O-Ring montieren. Anzu-
D und mit einem MomentenschluÈssel und einem Anzu- D gsmoment: max. 30 Nm.
gsmoment von 70v75 Nm blockieren. Wenn noÈtig, die Differentialspiele einstellen (Siehe «DIFFEREN-
TIAL ZUSAMMENBAUEN»). Den unteren Stopfen (1) und die Arme
e f montieren. (FuÈr weitere Einzelheiten, sieh «VERSCHLEISS KON-
TROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN»).
Montar la tuerca (4) de compresioÁn horquilla (5) y Montar el microinterruptor (2) completo de guarnicioÁn
ESP bloquearla con un llave dinamometrica tarada a un par ESP OR; par de torsion: max. 30 Nm.
de 70v75 Nm. Si necesario, registrar los juegos diferenciales.
(Vease «ASEMBLAJE DIFERENCIAL»):
Montar la tapa superior (1) y los ejes. (Para los detalles, vease
«CONTROL DESGASTE Y SOBSTITUCION DISCOS FRENOS»).
Monter l'eÂcrou (4) de fixation fourchette (5) et bloquer Monter le microinterrupteur (2) eÂquipeÂ de garniture
F celui-ci aÁ l'aide d'une cleÂ dynamomeÂtrique calibreÂe aÁ F OR; couple de serrage: max. 30 Nm.
un couple de 70v75 Nm. Si besoin, reÂgler les jeux du diffeÂrentiel (Voir «ASSEM-
BLAGE DU DIFFERENTIEL»). Monter le bouchon supeÂrieur (1) et
les bras. (Pour tout deÂtail, voir «CONTROLE DE L'USURE ET
SUBSTITUTION DES DISQUES FREIN»).
205
HOW TO DISASSEMBLE INCORPORATED REDUCTION GEAR AND PINION - SMONTAGGIO RIDUTTORE INTEGRATO (602) - INTEGRIERTER
REDUZIERER ABMONTIEREN (602) - DESMONTAJE REDUCTOR ENCORPORADO Y PINON (602) - DESMONTAJE REDUCTEUR INTEGRE (602)
2
2
F1240625 F1240626
GB a GB b
The figure shows the axle with incorporated reduction gear with Unloose the check nuts on upper (1) and lower (2) flange.
Mechanic flanges; disassembly and assembly procedures also
apply to DIN flanges.
5
1
4
3
F1240627 F1240628
GB c GB d
Draw out nuts (3) and O-rings (4). Remove the upper flange (2) together with dust ring (5).
2
F1240629 F1240630
GB e GB f
Remove the snap ring (6) and discard it. Remove the lower flange (2)
206
La figura illustra l'assale con riduttore incorporato, con Allentare i dadi di ritegno delle flange superiore (1) ed
ITA flange Mecchanic; lo smontaggio e l'assemblaggio ITA inferiore (2).
sono uguali anche per le flange DIN.
Die Abbildung zeigt die Achse mit eingebautem Befestigungsmuttern der oberen Flanschen (1) und
D Reduzierer und Mecchanic Flanschen; das Abmontie- D der unteren Flanschen (2) lockern.
ren und Zusammenbauen erfolgt wie fuÈr die Flan-
schen DIN.
a b
La figura ilustra el eje con reductor encorporado, con Aflojar las tuercas de retencion de las bridas superior
ESP bridas Mechanic; el desmontaje y el asemblaje son ESP (1) y inferior (2).
uguales tambien por las bridas DIN.
La figure illustre l'essieu aÁ reÂducteur incorporeÂ, avec Desserrer les eÂcrous de fixation des flasques supeÂri-
F Flasque Mecchanic; le deÂmontage et l'assemblage F eures (1) et infeÂrieures (2).
sont pareils meÃme pour les flasques DIN.
Asportare i dadi (3) e le guarnizioni OR (4). Rimuovere la flangia superiore (1) completa di anello
ITA ITA parapolvere (5).
Muttern (3) abschrauben und O-Ringe (4) abnehmen. Den oberen Flansch (1) samt Staubdichtungsring (5)
D D abnehmen.
c d
Sacar las tuercas (3) y las guarniciones OR (4). Remover la brida superior (1) completa de segmento
ESP ESP parapolvos (5).
Enlever les eÂcrous (3) et les garnitures OR (4). Enlever la flasque supeÂrieure (1) eÂquipeÂe d'anneau
F F anti-poussieÁre (5).
Rimuovere l'anello di tenuta (6) e scartarlo. Rimuovere la flangia inferiore (2).

ITA ITA
Kolbenring (6) abnehmen und entsorgen. Unteren Flansch abnehmen (2).

D D
e f
Remover el segmento de compresion (6) y descartarlo. Remover la brida inferior (2).
ESP ESP
Enlever la bague d'eÂtancheÂiteÂ (6) et la jeter. Enlever la flasque infeÂrieure (2).

F F
207
REDUZIERER ABMONTIEREN (602) - DESMONTAJE REDUCTOR ENCORPORADO Y PINON - DESMONTAJE REDUCTEUR INTEGRE (602)
9 10
8
11
7
F1240631 F1240632
GB a GB b
Remove check screws (7), (8) and relative washers (10) from cover In turn, insert a punch in the slots provided and, tapping lightly with
(9). a hammer, separate the cover (9) from the body of the reduction
gear (11).
9
11 9
F1240633 F1240634
GB c GB d
Insert two levers in the provided slots and move the cover (9) away Lightly tap with a hammer to disengage cover (9) from upper gear
from the body of the reduction gear (11). (12).
9 12
13
F1240635 F1240636
GB e GB f
Draw out cover (9) and remove any sealant left. Remove lower gear (13).
208
Rimuovere le viti (7), (8) di ritegno del coperchio (9) e le Inserire alternativamente nelle cave predisposte uno
ITA relative rondelle (10). ITA spintore e, con leggeri colpi di martello, separare il
coperchio (9) dal corpo riduttore (11).
Befestigungsschrauben (7) und (8) des Deckels (9) mit Abwechselnd, in die Nuten einen StoÈûel stecken und
D den Unterlegscheiben (10) abschrauben. D diesen mit einem Hammer leicht schlagen, bis sich der
Deckel (9) vom ReduziererkoÈrper (11) loÈst.
a b
Remover los tornillos (7), (8) de retencion de la tapa (9) Introducir alternativamente en los orificios propuestas
ESP y las relativas arandelas (10). ESP un empuje y, con ligeros golpes de martillo, separar la
tapa (9) del cuerpo reductor (11).
Enlever les vis (7), (8) de fixation du couvercle (9) et Introduire alternativement dans les creux preÂdisposeÂs
F ses relatives rondelles (10). F un poussoir et, aÁ l'aide de leÂgers coups de maillet,
seÂparer le couvercle (9) du corps reÂducteur (11).
Inserire due leve nelle cave predisposte ed allontanare Battere leggeri colpi con un mazzuolo per disimpe-
ITA il coperchio (9) dal corpo riduttore (11). ITA gnare il coperchio (9) dall'ingranaggio superiore (12).
Zwei Hebel in die Nuten stecken und den Deckel (9) Mit leichten HammerschlaÈgen, den Deckel (9) vom
D vom ReduziererkoÈrper (11) abheben. D oberen Zahnrad (12) trennen.
c d
Introducir dos palancas en los orificios propuestas un Golpear con ligeros golpes con un martillo para
ESP empuje y alejar la tapa (9) del cuerpo reductor (11). ESP desconectar la tapa (9) del engranaje superior (12).
introduire deux leviers dans les creux preÂdisposeÂs et Donner de leÂgers coups de maillet pour deÂgager le
F eÂloigner le couvercle (9) du corps reÂducteur (11). F couvercle (9) de l'engrenage supeÂrieur (12).
Asportare il coperchio (9) e rimuovere ogni traccia di Asportare l'ingranaggio inferiore (13).
ITA sigillante. ITA
Deckel (9) abnehmen und Dichtungsmaûe vollstaÈndig Das untere Zahnrad (13) entfernen.
D entfernen. D
e f
Introducir la tapa (9) y remover cada mancha de cola. Sacar el engranaje inferior (13).
ESP ESP
Enlever le couvercle (9) et nettoyer toute trace de Enlever l'engrenage infeÂrieur (13).
F colle. F
209
14
12
15 9
F1240637 F1240638
GB a GB b
Remove upper gear assembly (12) complete with bearings (14). Using a puller, remove snap ring (15) from cover (9) and discard it.
NOTE. Note down direction of installation.
14
14
16
12
12
14
14
12
F1240639 F1240640
GB c GB d
Remove inner bearing (14) from gear assembly (12). Remove outer bearing (14) and distance piece (16).
17
18
F1240641 F1240642
GB e GB f
Disjoin from the steering case the steering bar located by the side Remove the intermediate cover (17) and the whole differential unit
of the intermediate cover (17). (18).
Remove the complete arm. For details, see «HOW TO REMOVE THE DIFFERENTIAL UNIT».
For details, see «CHECKING WEAR AND REPLACING THE
BRAKING DISCS».
210
Rimuovere il gruppo ingranaggio superiore (12) Utilizzando un estrattore, rimuovere dal coperchio (9)
ITA completo di cuscinetti (14). ITA l'anello di tenuta (15) e scartarlo.
Das obere Zahnradaggregat (12) samt Lager (14) Mit einem Abzieher, vom Deckel (9) den Kolbenring
D entfernen. D (15) abnehmen und entsorgen.
BEMERKUNG. Auf die Montagerichtung achten.
a b
Remover el grupo engranaje superior (12) completo de Utilizando un estractor, remover la tapa (9) el
ESP cojinetes (14). ESP segmento de compresion (15) y descartarlo.
NOTA Anotar el sentido de montaje.
Enlever le groupe engrenage supeÂrieur (12) eÂquipeÂ A l'aide de l'extracteur, enlever le couvercle (9) la
F des paliers (14). F bague d'eÂtancheÂiteÂ (15) et l'eÂliminer.
NOTE. Prendre note du sens de montage.
Rimuovere dal gruppo ingranaggio (12) il cuscinetto Rimuovere il cuscinetto esterno (14) ed il distanziale
ITA interno (14). ITA (16).
Vom Zahnradaggregat (12) das innere Lager (14) Das aÈuûere Lager (14) und das DistanzstuÈck (16)
D abnehmen. D entfernen.
c d
Remover del grupo engranaje (12) el cojinete interior Remover el cojinete esterior (14) y el distancial (16).
ESP (14). ESP
Enlever le groupe engrenage (12) le palier interne (14). Enlever le palier (14) et l'entretoise (16).
F F
Scollegare dalla scatola snodo la barra di sterzatura Rimuovere il coperchio intermedio (17) ed il differen-
ITA del lato del coperchio intermedio (17). ITA ziale completo (18).
Rimuovere il braccio completo. Per i dettagli, vedere «RIMOZIONE GRUPPO DIFFE-
Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE RENZIALE».
DISCHI FRENO».
Vom GelenkgehaÈuse die Lenkstange an der Seite des Den mittleren Deckel (17) und das ganze Differential
D mittleren Deckels (17) abmontieren. D (18) abnehmen.
Den ganzen Arm abnehmen. Weitere Einzelheiten im Paragraph «DIFFERENTIA-
Weitere Einzelheiten im Paragraph «VERSCHLEISS KONTROLL- LAGGREGAT ABNEHMEN».
e IEREN UND BREMSSCHEIBEN AUSWECHSELN». f
Desconectar del carter de las rotulas la barra de Remover la tapa intermedia (17) y el diferencial
ESP direccion del lado de la tapa intermedia (17). ESP completo (18).
Remover el brazo completo. Por los detalles, vease «REMOVER GRUPO DIFE-
Para los detalles, vease «CONTROL DESGASTE Y SUBSTITU- RENCIAL».
CION DISCOS FRENO».
DeÂbrancher la boõÃte d'articulation de la barre de Enlever le couvercle intermeÂdiaire (17) et le diffeÂrentiel

F braquage du coÃteÂ couvercle intermeÂdiaire (17). F complet (18).
Enlever le bras complet. Pour les deÂtails, voir «DEPOSE DU GROUPE DIFFE-
Pour les deÂtails, voir «CONTROLE USURE ET SUBSTITUTION RENTIEL».
DES DISQUES FREINS».
211
T29
T30
19
F1240643 F1240644
GB a GB b
Heat the ring nut (19) at approx. 80ëC. Engage special wrench T30 on the ring nut (19) and apply bar-hold
T29 on the pinion (20).
11
20
19
F1240645 F1240646
GB c GB d
Remove ring nut (19) Using a puller, extract pinion (20) complete with inner bearing (21),
distance piece (22) and distance washers.
NOTE. The thrust blocks of the bearings remain in the central body
(11).
25
20
F1240647 F1240648
GB e GB f
Remove the complete pinion (20). Using a punch and a hammer, extract the snap ring (25).
NOTE. Carefully check and note direction of installation of NOTE. Note direction of installation of snap ring (24).
distance piece.
212
Scaldare a circa 80ëC la ghiera (19). Impegnare la chiave speciale T30 sulla ghiera (19) ed
ITA ITA applicare sul pignone (20) il codolo T29.
Fermare la chiave T30 e ruotare il pignone (20) per
allentare la ghiera (19).
Nutmutter (19) bis auf ca. 80ëC erwaÈrmen. SpezialschluÈssel T30 in die Nutmutter (19) stecken
D D und auf das Rad (20) den Schaft T29 anbringen.
Den SchluÈssel T30 festhalten und das Rad (20)
drehen, um die Nutmutter (19) zu lockern.
a b
Calentar hasta aproximadamente 80ëC la virola (19). Empenar la llave especial T30 sobre la virola (19) y
ESP ESP aplicar sobre el pinon (20) el mango T29.
Parar la llave T30 y girar el pinon (20) para aflojar la
virola (19).
Chauffer l'anneau (19) aÁ environ 80ëC. Engager la cleÂ speÂciale T30 sur l'anneau de fixation
F F (19) et appliquer sur le pignon (20) l'embout T29.
ArreÃter la cleÂ T30 et tourner le pignon (20) pour
desserrer l'anneau de fixation (19).
Asportare la ghiera (19). Utilizzando un estrattore, estrarre il pignone (20)

ITA ITA completo del cuscinetto interno (21), del distanziale
(22) e degli spessori (23) e (24).
NOTA. Le ralle dei cuscinetti rimangono nel corpo centrale (11).
Nutmutter (19) entfernen. Mit einem Abzieher, Rad (20) samt inneres Lager (21),
D D DistanzstuÈck (22) und Unterlegscheiben (23) und (24)
herausnehmen.
BEMERKUNG. die Scheiben der Lager bleiben im ZentralkoÈrper
c d (11) sitzen.
Sacar la virola (19). Utilizando un estractor, estraer el pinon (20) completo

ESP ESP de cojinete interno (21), del distancial (22) y de los
espesores (23) y (24).
NOTA. Las ranguas de los cojinetes quedan en el cuerpo central
(11).
Enlever l'anneau (19). A l'aide d'un extracteur extraire le pignon (20) eÂquipeÂ
F F de palier interne (21), de l'entretoise (22) et des cales
(23) et (24).
NOTE. Les crapaudines des paliers demeurent dans le corps
central (11).
Rimuovere il pignone completo (20). Utilizzando uno spintore ed un mazzuolo, estrarre

ITA ITA l'anello di tenuta (25).
NOTA. Controllare attentamente ed annotare il senso
di montaggio del distanziale (22). NOTA. Annotare il senso di montaggio dell'anello di
tenuta (24).
Das gesamte Rad (20) abnehmen. Mit einem StoÈûel und einem Hammer, den Kolbenring
D D (25) herausnehmen.
BEMERKUNG. SorgfaÈltig die Montagerichtung des
DistanzstuÈckes (22) kontrollieren. BEMERKUNG. Montagerichtung des Kolbenrings (24)
beachten.
e f
Remover el pinon completo (20). Utilizando un empuje y un martillo, estaer el segmento
ESP ESP de compresion (25).
NOTA. Controlar con cuidado y anotar el sentido de
montaje del distancial (22). NOTA. Anotar el sentido de montaje del segmento de
compresion (24).
Enlever le pignon complet (20). A l'aide d'un poussoir et d'un maillet, extraire la bague
F F d'eÂtancheÂiteÂ (25).
NOTE. ControÃler attentivement et prendre note du
sens de montage de l'entretoise (22). NOTE. Prendre note du sens du montage de la bague
d'eÂtancheÂiteÂ (24).
213
20
14 21
24
12 23
16
GB
14 a GB b
10
8 9
6 11
5 22
1 25
21
4 19
3 18
13
15 17
10
4 2 7
3 F1240078
GB c GB d
GB e GB f
214
GB CAUTION! 1 - If disassembly has been carried out ESP CUIDADO! 1 - Si el desmontaje ha sido efectuado
only as a means to replace the snap ring (24), solo por la sustitucion del segmento de compresion
position the new ring and reassemble the unit by keeping to the (24), remontar el grupo respectando los pares de torsion
torque wrench settings indicated in the following section and indicadas en el capitulo siguiente y utilizando los productos de
using the prescribed locking products. bloque descritos.
2 - If disassembly is carried out in order to replace crown wheel 2 - Si el desmontaje viene efectuado para la sustitucion del par
and pinion, bearings, or planetary gear, break up distance conico, de los cojinetes o de los engranajes satelites, proceder
washers and calculate clearances as indicated in the sections a la descomposicion y a la busqueda de los espesores y de los
regarding removal, disassembly, assembly and installation of juegos como indicados en los capitulos concernientes la
differential unit and bevel pinion. remocioÁn, el desmontaje, el asemblaje y la instalacion del
diferencial y del pinoÁn conico.
ITA ATTENZIONE! 1 - Se lo smontaggio eÁ stato ese-

guito solo per la sostituzione dell'anello di tenuta ATTENTION! 1 - Si le deÂmontage n'a eu lieu que
(24), procedere al posizionamento del nuovo anello e rimontare F
pour la substitution de la bague d'eÂtancheÂiteÂ (24),
il gruppo rispettando le coppie di serraggio indicate nel positionner la bague d'eÂtancheÂiteÂ et remonter le groupe en
paragrafo seguente ed utilizzando i prodotti di bloccaggio respectant les couples de serrage indiqueÂs dans le paragraphe
prescritti. suivant et en utilisant les produits de blocage preÂconiseÂs.
2 - Se lo smontaggio viene eseguito per la sostituzione della 2 - Si le deÂmontage a lieu pour substituer le couple conique, les
coppia conica, dei cuscinetti o degli ingranaggi satelliti, paliers ou les engrenages satellites, deÂsassembler et recher-
procedere alla scomposizione ed alla ricerca degli spessori e cher les cales et les jeux comme indiqueÂ dans les paragraphes
dei giochi come indicato nei paragrafi riguardanti la rimozione, ayant trait aÁ la deÂpose, au deÂmontage, aÁ l'assemblage et aÁ
lo smontaggio, l'assemblaggio e l'installazione del differenziale l'installation du diffeÂrentiel et du pignon conique.
e del pignone conico.
D ACHTUNG! 1 - Falls die Teile nur abmontiert wor-

den sind, um den Kolbenring (24) auszuwechseln,
den neuen Kolbenring einsetzen und das Aggregat wieder
zusammenbauen; dabei die im nachfolgenden Paragraph
angegebene Anzugsmomente beachten und die vorgeschrie-
benen Befestigungsprodukte verwenden.
2 - Falls die Teile abmontiert worden sind, um den Kegelrad-
trieb, die Lager oder die Planetengetriebe auszuwechseln, die
Unterlegscheiben auseinander nehmen und die Spiele beach-
ten, die in den Paragraphen zum Entfernen, Abmontieren,
Zusammenbau und zur Installation des Differentials und des
Kegelrads angegeben sind.
215
HOW TO ASSEMBLE INCORPORATED REDUCTION GEAR AND PINION - ASSEMBLAGGIO RIDUTTORE INTEGRATO (602) - INTEGRIERTER
REDUZIERER MONTIEREN (602) - ASEMBLAJE REDUCTOR INCORPORADO Y PINON - MONTAJE REDUCTEUR INTEGRE (602)
11
22
T7
F1240649 F1240650
GB a GB b
Find the value of the distance washers (23) and (24) and insert Assemble the pinion assembly as shown in the picture,
the thrust blocks of the conical bearing of the pinion into the checking that distance piece (22) is correctly oriented.
body of the reduction gear (11) (See «HOW TO INSTALL AND NOTE. Apply grease to the outer surface of the distance piece
ADJUST THE BEVEL PINION»). (22).
Using tool T7 insert the snap ring (25) previously lubricated
with grease.
T29
T30
20
F1240651 F1240652
GB c GB d
With tools T28C, T28D and T28B connected to a press, insert Apply Loctite 242 to the thread of the pinion and screw the ring
the complete pinion assembly (20). nut (19). Engage special wrench T30 on the ring nut and apply
bar-hold T29 to the pinion (20). Tighten the ring nut (19)
following the appropriate procedure (See «HOW TO INSTALL
AND ADJUST THE BEVEL PINION») and check that torque is
170 ± 220Ncm.
T32 T32
14 6
12 15
F1240653
9 9 F1240654
GB e GB f
Using a press, fit the bearings (14) and the distance piece (16) Grease snap rings (15) and (6); position the snap rings in the
on the upper gear (12). cover (9) using tool T32.
CAUTION! The distance piece (16) must be positioned
between the outer bearing and the gear.
216
Ricercare il valore degli spessori (23) e (24) ed inserire Comporre il gruppo pignone come in figura, control-
ITA nel corpo riduttore (11) le ralle dei cuscinetti conici del ITA lando che il distanziale (22) sia orientato correttamen-
pignone (Vedere «INSTALLAZIONE E REGISTRAZIO- te.
NE PIGNONE CONICO»). NOTA. Lubrificare con grasso la superficie esterna del distanziale
Utilizzando l'attrezzo T7 inserire l'anello di tenuta (25) dopo averlo (22).
lubrificato con grasso.
Die GroÈûen der Unterlegscheiben (23) und (24) Das Radaggregat wie in der Abbildung gezeigt
D kontrollieren und in den ReduziererkoÈrper (11) die D zusammenbauen; dabei uÈberpruÈfen ob das Distanz-
Lagerscheiben des Rades einsetzen (Siehe «INSTAL- stuÈck (22) auch richtig orientiert ist.
LATION UND EINSTELLUNG DES KEGELRADES»). BEMERKUNG. Die aÈuûere FlaÈche des DistanzstuÈckes (22) mit Fett
a Mit Hilfe des Werkzeugs T7 den zuvor eingefetteten Kolbenring
(25) einsetzen.
b schmieren.
Buscar el valor de los espesores (23) y (24) y Componer el grupo pinon como en figura, controlando
ESP introducir en el cuerpo reductor (11) las ranguas de ESP que el distancial (22) sea orientado correctamente.
los cojinetes conicos del pinon (Vease «INSTALACION NOTA. Lubrificar con grasa la superficie exterior del
Y REGISTRACION PINON CONICO»). distancial (22).
Utilizando la herramienta T7 introducir el segmento de compresion
(25) despues de haberlo lubrificado con grasa.
Chercher la valeur des cales (23) et (24), puis Composer le groupe pignon comme sur la figure,
F introduire dans le corps reÂducteur (11) les crapaudines F controÃler si l'entretoise (22) est orienteÂe correctement.
des paliers coniques du pignon (voir «INSTALLATION NOTE. Lubrifier avec du gras la surface externe de
ET REGLAGE DU PIGNON CONIQUE»). l'entretoise (22).
A l'aide de l'outil T7 introduire la bague d'eÂtancheÂiteÂ (25) apreÁs
l'avoir lubrifieÂe avec du gras.
Utilizzando gli attrezzi T28C, T28D e T28B collegati Spalmare la filettatura del pignone con Loctite 242 ed
ITA ad una pressa, inserire il gruppo pignone (20) ITA avvitare la ghiera (19). Impegnare la chiave speciale
completo. T30 sulla ghiera ed applicare il codolo T29 sul
pignone (20). Serrare la ghiera (19) con le modalitaÁ prescritte
(Vedere «INSTALLAZIONE E REGISTRAZIONE PIGNONE CONI-
CO») e controllare che la coppia di rotazione sia di 170v220 Ncm.
Mit Hilfe der an einer Presse angeschlossenen Werk- Radgewinde mit Loctite 242 schmieren und die Nut-
D zeuge T28C, T28D und T28B, das ganze Radaggre- D mutter (19) zuschrauben. Den SpezialschluÈssel T30 in
gat (20) einsetzen. die Nutmutter setzen und den Schaft T29 auf das Rad
(20) setzen. Nutmutter (19) laut Anweisungen fest ziehen (Siehe
c d «INSTALLATION UND EINSTELLUNG DES KEGELRADES») und
das Gegenmoment kontrollieren, das 170v220 Ncm betragen muû.
Utilizando las herramientas T28C, T28D y T28B Pasar sobre la rosca del pinon Loctite 242 y entornillar
ESP conectar a un prensa, insertar el grupo pinon (20) ESP la virola (19). Empenar la llave especial T30 sobre la
completo. virola y aplicar el mango T29 sobre el pinon (20).
Apretar la virola (19) con las modalidades prescritas (Vease
«INSTALACION Y REGISTRACION PINON CONICO») y controlar
que el par de rotacion sea de 170v220 Ncm.
A l'aide des outils T28C, T28D et T28B relieÂs aÁ une Enduire le filetage du pignon avec du Loctite 242 et
F presse, introduire le groupe pignon (20) complet. F visser l'anneau (19). Engager la cleÂ speÂciale T30 sur
l'anneau et appliquer l'embout T29 sur le pignon (20).
Serrer l'anneau (19) de la facËon preÂconiseÂe (voir «INSTALLATION
ET REGLAGE DU PIGNON CONIQUE») et controÃler que le couple
de rotation est de 170v220 Ncm.
Utilizzando una pressa, montare sull'ingranaggio Lubrificare con grasso gli anelli di tenuta (15) e (6);
ITA superiore (12) i cuscinetti (14) ed il distanziale (16). ITA posizionarli nel coperchio (9) utilizzando l'attrezzo
ATTENZIONE! Il distanziale (16) va posizionato tra il T32.
cuscinetto esterno e l'ingranaggio.
Mit Hilfe einer Presse, die Lager (14) und das Die Kolbenringe (15) und (6) mit Fett schmieren; diese
D DistanzstuÈck (16) auf das obere Zahnrad (12) montie- D mit dem Werkzeug T32 auf den Deckel (9) positionie-
ren. ren.
ACHTUNG! Das DistanzstuÈck (16) muû zwischen dem aÈuûeren
e Lager und das Zahnrad liegen. f
Utilizando una prensa, montar sobre el engranaje Lubrificar con grasa los segmento de compresion (15)
ESP superior (12) los cojinetes (14) y el distancial (16). ESP y (16); colocarlos en la tapa (9) utilizando la herra-
CUIDADO. El distancial (16) viene colocado entre el mienta T32.
cojinete exterior y el engranaje.
A l'aide d'une presse, monter sur l'engrenage Lubrifier avec du gras les bagues d'eÂtancheÂiteÂ (15) et
F supeÂrieur (12) les paliers (14) et l'entretoise (16). F (16): placer ces dernieÁres dans le couvercle (9) aÁ l'aide
ATTENTION! L'entretoise doit eÃtre placeÂe entre le de l'outil T32.
palier et l'engrenage.
217
17
18
F1240642 F1240641
GB a GB b
Re-install the differential unit (18) and the intermediate cover Re-install the complete arm checking flatness and blocking the
(17). arm by keeping to the appropriate procedures illustrated in
CAUTION! If the crown has been replaced, reinstate clear- section «HOW TO ASSEMBLE THE BRAKING UNITS».
ances. Also connect the steering bar.
For details, see «HOW TO ASSEMBLE AND ADJUST THE
DIFFERENTIAL UNIT».
12
11
20
13
F1240636 F1240637
GB c GB d
Fit the lower gear (13) onto the pinion (20). Insert the upper gear unit (12) into the body of the reduction
gear (11).
9 12 9
8
10
F1240635 F1240655
GB e GB f
Apply Loctite 510 to the locking surface of the body of the Block cover (9) with screws (7) and (8) and relative washers
reduction gear (11). (10). Tighten using the criss-cross method.
Lubricate snap rings (6) and (15); fit cover (9) and set cover (if Torque wrench setting: 82 ± 91 Nm
necessary) by lightly tapping with a plastic hammer.
218
Rimontare il gruppo differenziale (18) ed il coperchio Rimontare il braccio completo, controllando la plana-
ITA intermedio (17). ITA ritaÁ e bloccandolo con le modalitaÁ indicate nel
ATTENZIONE! Se eÁ stata sostituita la corona, ristabi- paragrafo «ASSEMBLAGGIO DEI GRUPPI DI FRE-
lire i giochi. NATURA».
Per i dettagli, vedere «ASSEMBLAGGIO ED INSTALLAZIONE Collegare anche la barra di sterzatura.
GRUPPO DIFFERENZIALE».
Das Differentialaggregat (18) und den mittleren Deckel Den gesamten Arm wieder montieren und Ebenheit
D (17) wieder montieren. D laut Anweisungen des Paragraphs «ZUSAMMENBAU
ACHTUNG! Falls der Kranz ausgewechselt worden ist, DER BREMSAGGREGATE» kontrollieren.
Spiele wieder herstellen. Lenkstange ebenfalls anschlieûen.
a Weitere Einzelheiten im Paragraph «ZUSAMMENBAU UND IN- b
STALLATION DES DIFFERENTIALAGGREGATS».
Remontar el grupo diferencial (18) y la tapa intermedia Remontar el brazo completo, controlando la planari-
ESP (17). ESP dad y bloqueando con las modalidades indicadas en
CUIDADO! Si ha sido cambiada la corona, restabilizar al capitulo «ASEMBLAJE DE LOS GRUPOS DE
los juegos. FRENADURA».
Para los detalles, vease «ASEMBLAJE Y INSTALACION GRUPO Conectar tambien la barra de direccion.
DIFERENCIAL».
Remonter le groupe diffeÂrentiel (18) et le couvercle Remonter le bras complet, en controÃler l'uniformiteÂ et
F intermeÂdiaire (17). F le bloquer suivant le mode indiqueÂ au paragraphe
ATTENTION! Si la couronne a eÂteÂ substitueÂe, reÂtablir «ASSEMBLAGE DES GROUPES DE FREINAGE».
les jeux. Brancher eÂgalement la barre de braquage.
Pour tout deÂtail, voir «ASSEMBLAGE ET INSTALLATION GROUPE
DIFFERENTIEL».
Montare sul pignone (20) l'ingranaggio inferiore (13). Inserire nel corpo riduttore (11) il gruppo ingranaggio
ITA ITA superiore (12).
Das untere Zahnrad (13) auf das Rad (20) montieren. Das obere Zahnradaggregat (12) in den Reduzierer-
D D koÈrper (11) einsetzen.
c d
Montar sobre el pinon (20) el engranaje inferior (13). Introducir en el cuerpo reductor (11) el grupo
ESP ESP engranaje superior (12).
Monter sur le pignon (20) l'engrenage infeÂrieur (13). Introduire dans le corps reÂducteur (11) le groupe
F F engrenage supeÂrieur (12).
Spalmare la superficie di chiusura del corpo riduttore Bloccare il coperchio (9) con le viti (7) e (8) e le relative
ITA (11) con Loctite 510. ITA rondelle (10) serrando con il metodo di serraggio
Lubrificare gli anelli di tenuta (6) e (15); montare il incrociato.
coperchio (9) assestandolo (se necessario) con leggeri colpi di un Coppia di serraggio: 82v91 Nm
mazzuolo in materiale plastico.
Die SchlieûflaÈche des ReduziererkoÈrpers (11) mit Deckel (9) mit den Schrauben (7) und (8) und den
D Loctite 510 schmieren. D Unterlegscheiben (10) festschrauben; die Schrauben
Kolbenringe (6) und (15) schmieren; Deckel (9) im Kreuz abwechselnd fest ziehen.
montieren und wenn noÈtig, mit einem Gummihammer leicht Anzugsmoment: 82v91 Nm.
e schlagen. f
Pasar la superficie de cierre del cuerpo reductor (11) Bloquear la tapa (9) con los tornillos (7) y (8) y las
ESP con Loctite 510. ESP relativas arandelas (10) apretando con el metodo de
Lubrificar los segmentos de compresion (6) y (15); torsion cruzado.
montar la tapa (9) arreglando (si necesario) con ligeros golpes de Par de torsion : 82v91 Nm.
martillo en material plastico.
Enduire la surface de fermeture du corps reÂducteur Bloquer le couvercle (9) avec les vis (7) et (8) et leurs
F (11) avec du Loctite 510. F relatives rondelles (10) en serrant aÁ l'aide du systeÁme
de serrage croiseÂ.
Couple de serrage: 82v91 Nm.
219
1
20 1
3 4
T20A
(T20B)
2
2 F1240627
3 F1240656
GB a GB b
Fit the upper (1) and lower (2) flanges. Apply tool T20A (or T20B) to flanges (1) and (2) and tighten
Apply Loctite 242 to the threaded portion of pinion (20) and nuts (3) using a dynamometric wrench.
upper gear (12). Fit O-rings (4) and nuts (3). Torque wrench setting: 280 ± 310 Nm
GB c GB d
GB e GB f
220
Montare le flange superiore (1) ed inferiore (2). Applicare alle flange (1) e (2) l'attrezzo T20A (oppure
ITA Spalmare le filettature del pignone (20) e dell'ingra- ITA T20B) e serrare i dadi (3) con una chiave dinamome-
naggio superiore (12) con Loctite 242. trica.
Montare gli anelli OR (4) ed i dadi (3). Coppia di serraggio: 280v310 Nm
Obere (1) und untere Flanschen (2) montieren. An den Flanschen (1) und (2) das Werkzeug T20A
D Radgewinde (20) und oberes Zahnrad (12) mit Loctite D (oder T20B) anbringen und Muttern (3) mit einem
242 schmieren. MomentenschluÈssel fest ziehen.
O-Ringe (4) und Muttern (3) montieren. Anzugsmoment: 280v310 Nm.
a b
Montar las bridas superior (1) y inferior (2). Aplicar a las bridas (1) y (2) la herramienta T20A (o
ESP Pasar las roscas del pinon (20) y del engranaje ESP T20B) y apretar las tuercas (3) con una llave
superior (12) Loctite 242. dinamometrica.
Montar los segmentos OR (4) y las tuercas (3). Par de torsin : 280v310 Nm.
Monter les flasques supeÂrieures (1) et infeÂrieures (2). Appliquer aux flasques (1) et (2) l'outil T20A (ou T20B)
F Enduire les filetages du pignon (20) et de l'engrenage F et serrer les eÂcrous (3) au moyen d'une cleÂ dynamo-
supeÂrieur (12) avec du Loctite 242. meÂtrique.
Monter les bagues OR (4) et les eÂcrous (3). Couple de serrage: 280v310 Nm.
ITA ITA
D D
c d
ESP ESP
F F
ITA ITA
D D
e f
ESP ESP
F F
221
2 23
22
4
25
28
5 19
26
10
18
27
1 3 14
223
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224
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225
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'" C '" D
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226
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228
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229
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230
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231
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./4% ,IGHTLY HAMMER ALL AROUND THE EDGE IN AN ALTERNATE
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0OSITION THE "ELLEVILLE WASHERS AND ENGAGE THE CYLINDER 0OSITION THE "ELLEVILLE WASHERS AND ENGAGE THE CYLINDER
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CENTRING CENTRING
232
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233
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234
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235
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236
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237
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4AKE THE MEASURE FROM THE SURFACE OF THE INTERMEDIATE DISK TO 0UT THE BRAKE DISC PACK INCLUDING THE SHIM UNDER A PRESS LOAD
THE COVER SEALING SURFACE WITH BAR OF PRESSURE INTRODUCED WITH KG AND TAKE THE MEASURE h6v
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238
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239
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3LIGHTLY LUBRICATE THE BRAKING DISKS AND lT THEM IN THE ARM
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240
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241
SMONTAGGIO E RIMONTAGGIO DALLA MACCHINA
DEL BRACCIO TELESCOPICO
DISASSEMBLING AND REASSEMBLING THE TELESCOPIC BOOM

FROM THE MACHINE
AUSBAU UND WIEDEREINBAU DES TELESKOPFAUSLEGERS

AUS DER MASCHINE
MRT 1840 EASY
IT-EN-DE
50 MRT 1840 EASY
IT EN DE
SMONTAGGIO DEL BRACCIO DISASSEMBLING THE TELESCO- AUSBAU DES TELESKOPAUS-

TELESCOPICO DALLA MACCHINA PIC BOOM FROM THE MACHINE LEGERS AUS DER MASCHINE
Posizionare la macchina su una superficie Position the vehicle on level ground, rest Die Maschine auf einer ebenen Fläche
piana, appogiare gli stabilizzatori per the outriggers to ensure maximum stability abstellen, die Stabilisatoren aufstellen, um
garantire la massima stabilità e sicurezza and safety (do not switch off the internal ein Höchstmaß an Standsicherheit und
(non spegnere il motore termico). combustion engine). Sicherheit zu gewährleisten (den
Verbrennungsmotor nicht abstellen).
Smontare la lamiera di chiusura posteriore Dismantle the turret rear cover plate by
della torretta svitando le 4 viti di fissaggio unscrewing the four fixing screws (Fig. 1 - Das hintere Abschlussblech des Turms
(Fig. 1 - Rif. A). Ref. A). abnehmen, nachdem man die 4
Befestigungsschrauben (Abb. 1 - Bez. A)
Svitare la ghiera di fermo (Fig. 2 - Rif. B) e Unscrew lock nut (Fig. 2 - Ref. B) and abgeschraubt hat.
sfilare il perno di incernieramento martinet- extract the rod side tilting cylinder pivot pin
to di brandeggio lato stelo al TS (Fig. 2 - at the TS (Fig. 2 - Ref. C). Die Feststellmutter (Abb. 2 - Bez. B) los-
Rif. C). schrauben und den Kippbolzen des
Schwenkzylinders auf der Schaftseite zum
Teleskop (Abb. 2 - Bez. C) herausziehen.
Assicurare il TS ad un carro ponte o ad Secure the TS to a bridge crane or an ele-
un elevatore (Fig. 3 - Rif. D), svitare la vite vator (Fig. 3 - Ref. D), unscrew stop screw Den Teleskopausleger mit einerm Laufkran
di fermo (Fig. 3 - Rif. E) e sfilare il perno di (Fig. 3 - Ref. E) and extract the TS pivot oder einem Gabelstapler absichern (Abb. 3 -
incernieramento TS alla testa del braccio pin on the boom head (Fig. 3 - Ref. F). Bez. D), die Anschlagschraube (Abb. 3 -
(Fig. 3 - Rif. F). Bez. E) losschrauben und den
Teleskopkippbolzen auf der Kopfseite des
Togliere dalla sua sede il TS. Remove the TS from its housing. Auslegers herausziehen (Abb. 3 - Bez. F).
Den Teleskopausleger aus seiner Aufnahme

Azionare il comando di sollevamento brac- Activate the boom lift control, raising the herausnehmen.
cio e portare questo al di sopra della sago- boom above the cab profile (Fig. 4 - Ref.
ma della cabina (Fig. 4 - Rif. G), così da G), to allow easy access to the cylinder
permettere un facile accesso al perno di pivot pin of the stem-boom side from both Das Bedienelement zum Heben des
incernieramento del martinetto di solleva- sides. Auslegers betätigen und diesen über die
mento lato stelo-braccio da entrambe i lati Kontur der Kabine hinausbringen (Abb. 4 -
Bez. G), damit der Zugang zum Kippbolzen
des Hubzylinders Seite Schaft-Ausleger auf
beiden Seiten vereinfacht wird.
Assicurare il braccio ad un carro ponte o Secure the boom to a bridge crane or an
ad un elevatore attraverso gli appositi elevator by means of the eyelets provided
occhielli (Fig. 5 - Rif. A) che si trovano (Fig. 5 - Ref. A) in the upper part of the Den Ausleger an einem Laufkran oder
nella parte superiore del braccio stesso. boom. einem Gabelstapler mit den vorgesehenen
Kranösen absichern (Abb. 5 - Bez. A), die
Assicurare il martinetto di sollevamento ad Secure the lift cylinder to a bracket. sich im oberen Teil des Auslegers befinden.
un sostegno.
Den Hubzylinder durch eine Halterung absi-
chern.
Svitare la vite di fermo (Fig. 6 - Rif. B) e Unscrew stop screws (Fig. 6 - Ref. B) and
sfilare il perno di incernieramento martinet- extract the stem-boom lift cylinder pivot pin Die Feststellschraube (Abb. 6 - Bez. B) los-
to di sollevamento lato stelo-braccio (Fig. 6 (Fig. 6 - Ref. C). schrauben und den Kippbolzen des
- Rif. C). Hubzylinders auf der Seite Schaft-Ausleger
herausziehen (Abb. 6 - Bez. C).
Adagiare il martinetto di sollevamento sulla Rest the lift cylinder on the turret on a Den Hubzylinder auf den Turm legen, nach-
torretta sottoponendovi un trave in legno e wooden beam and use the control inside dem man einen Holzbalken darunter gelegt
fare rientrare lo stelo tramite il comando in the cab to retract the stem (Fig. 7 - Ref. hat, und den Schaft durch das
cabina (Fig. 7 - Rif. D). D). Bedienelement in der Kabine wieder einfah-
ren lassen (Abb. 7 - Bez. D).
Abbassare il braccio telescopico in posizio- Lower the telescopic boom to a more or
ne pressochè orizzontale agendo sul carro less horizontal position by acting on the Den Teleskopausleger in eine fast horizonta-
ponte o l’elevatore impiegato. bridge crane or elevator used. le Lage fahren, und zwar mittels des ver-
wendeten Gabelstaplers oder Laufkrans.
Arrestare il motore termico. Stop the internal combustion engine.
Den Verbrennungsmotor abstellen.
Riattivare la chiave di accensione in posi- Turn the ignition key to the “I” position Den Zündschlüssel in die Position “I” brin-
zione “I” (contatto chiave-accensione cru- (key-dashboard ignition contact) and carry gen (Schlüsselkontakt-Zündung
scotto) ed eseguire tutti i movimenti possi- out all possible movements using the com- Armaturenbrett) und mit den
bili con i comandi (Fig. 8) per annullare le mands (Fig. 8) to annul the residual pres- Bedienelementen (Abb. 8) alle möglichen
pressioni residue all’interno del circuito sures inside the hydraulic circuit. Bewegungsabläufe ausführen, um die
idraulico.. Restdrücke innerhalb des hydraulischen
Kreislaufs zu beseitigen.
2
MRT 1840 EASY 50
A A
B
A A C
1 2
E G
3 4
B
A A
5 6
D
7 8
3
50 MRT 1840 EASY
IT EN DE
Disattivare la chiave di accensione e stac- Turn off the ignition key and disconnect the Die Zündung ausschalten und die
care i morsetti dalla batteria. terminals from the battery. Batterieklemmen abtrennen.
Eliminare tutte le fascette dei tubi idraulici Remove all the clamps from the hydraulic Alle Binder der hydraulischen Leitungen
e dei cavi elettrici posti nella parte poste- pipes and electric wiring in the top rear und der elektrischen Kabel entfernen, die
riore superiore del braccio (Fig. 9 - Rif. A) part of the boom (Fig. 9 - Ref. A) (Fig. 10 - sich hinten im oberen Teil des Auslegers
(Fig. 10 - Rif. B), assicurandosi che al ter- Ref. B), making sure they are all comple- befinden (Abb. 9 - Bez. A) (Abb. 10 - Bez.
mine dell’operazione siano tutti completa- tely free of one another at the end of the B), wobei sicherzustellen ist, dass am
mente svincolati l’uno dall’altro. operation. Ende des Vorgangs jedes Element vom
anderen getrennt ist.
Scollegare il connettore per il cavo dei Disconnect the connector for the cable of Den Steckverbinder für das Kabel der
microinterruttori sicurezza catene (Fig. 9 - the chain safety microswitches (Fig. 9 - Endschalter Kettensicherheit abtrennen
Rif. C). Ref. C). (Abb. 9 - Bez. C).
Unter Benutzung der entsprechenden

Agendo sull’apposita ghiera disconnettere Using the ring nut provided, disconnect the Ringmutter die elektrische Steckver-
la spina-cablaggio elettrico posta nella plug-wiring in the top rear part of the bindung im hinteren Teil des Auslegers,
parte posteriore del braccio, se presente boom, if present (Fig. 10 - Ref. D). falls vorhanden, entfernen (Abb. 10 - Bez.
(Fig. 10 - Rif. D). D).
Scollegare e tappare con i tappi a tenuta i Disconnect and fit seal plugs on the boom Alle hydraulischen Leitungen zur
tubi idraulici di alimentazione del braccio hydraulic feed pipes (Fig. 11 - Ref. E) Versorgung des Auslegers abtrennen und
(Fig. 11 - Rif. E) avendo cura di contrasse- taking care to mark the connections to mit gut dichtenden Stopfen versehen (Abb.
gnare le corrispondenze di collegamento ensure correct reassembly. 11 - Bez. E), wobei die Verbindungsenden
per un corretto rimontaggio. zu markieren sind, um sie anschließend
wieder korrekt verbinden zu können.
Per evitare perdite di olio dal circuito idrau- To prevent oil leakage from the hydraulic
lico, tappare con tappi a tenuta tutti i rac- circuit, fit all pipe unions on the boom with Um Ölaustritt aus dem hydraulischen
cordi passa parete posizionati sul braccio seal plugs (Fig. 12 - Ref. F). Kreislauf zu vermeiden, alle auf dem
Ausleger vorhandenen Anschlüsse mit
dicht schließenden Stopfen versehen (Abb.
12 - Bez. F)
Eliminare la fascettatura dei cavi elettrici Remove the clamps from the electric wires
posti nella parte interna della torretta (Fig. inside the turret (Fig. 13 - Ref. A), (Fig. 14
13 - Rif. A), (Fig. 14 - Rif. B), (Fig. 15 - Rif. - Ref. B), (Fig. 15 - Ref. C), making sure
C), assicurandosi che al termine dell’ope- that at the end of the operation, all the Alle Binder der elektrischen Kabel entfer-
razione siano tutti completamente svinco- wires are free of one another. nen, die sich im inneren Teil des Turms
lati l’uno dall’altro. befinden (Abb. 13 - Bez. A) (Abb. 14 - Bez.
B), (Abb. 15 - Bez. C), wobei sicherzustel-
len ist, dass am Ende des Vorgangs jedes
Element vollkommen vom anderen
getrennt ist.
Smontare il proximity per la segnalazione Dismantle the proximity switch that indica-
3m di altezza della testa braccio e per la tes the 3m height of the boom head with
segnalazione 60° di inclinazione con relati- relative bracket (Fig. 16 - Ref. D), without,
vo supporto (Fig. 16 - Rif. D), senza però however, disconnecting the electric wiring. Den Näherungsschalter für die Meldung
scollegarne la connessione elettrica.(Fig. der Höhe von 3 m des Auslegerkopfs und
12 - Rif. F). für die Meldung 60° Neigung mit entspre-
chendem Träger ausbauen (Abb. 16 - Bez.
D), ohne jedoch den elektrischen
Anschluss abzuklemmen.
4
MRT 1840 EASY 50
9 10
E
11 12
A
B B
13 14
C C
D
C
15 16
5
50 MRT 1840 EASY
IT EN DE
Smontare il proximity per la segnalazione Dismantle the proximity switch that indica- Den Näherungsschalter für die Meldung
braccio completamente rientrato con relati- tes boom completely retracted with relative Ausleger ganz eingefahren mit entspre-
vo supporto (Fig. 17 - Rif. A), senza però bracket (Fig. 17 - Ref. A), without, howe- chendem Träger ausbauen (Abb. 17 - Bez.
scollegarne la connessione elettrica. ver, disconnecting the electric wiring. A), ohne jedoch den elektrischen
Anschluss abzuklemmen.
Smontare il microinterruttore di fine corsa Dismantle the proximity switch that indica- Den Endschalter für das Hochfahren des
per la salita del braccio con il relativo sup- tes 60° boom tilt with relative bracket (Fig. Auslegers mit dem entsprechenden Träger
porto (Fig. 18 - Rif. B) posto all’estremità 18 - Ref. B) at the top end of the turret, ausbauen (Abb. 18 - Bez. B), der sich am
superiore della torretta, senza però scolle- without, however, disconnecting the elec- oberen Turmende befindet, ohne jedoch
garne la connessione elettrica. tric wiring. den elektrischen Anschluss abzuklemmen.
Smontare il coperchio dell’arrotolatore del Remove the “M.S.S.” anti-tilting system Den Deckel des Aufwicklers des
sistema antiribaltamento “M.S.S.” (Fig. 19 - cable cover (Fig. 19 - Ref. C). Sicherheitssystems “M.S.S.” gegen
Rif. C). Umkippen (Abb. 19 - Bez. C) entfernen.
Scollegare il cavo elettrico schermato Disconnect the shielded electric cable Das abgeschirmte elektrische Kabel
agendo sulle viti della morsettiera (Fig. 20 using the screws on the terminal (Fig. 20 - abklemmen, wozu man die Schrauben der
- Rif. D) e sfilarlo interamente dal tubo di Ref. D) and extract these from the metal Klemmenleiste benutzt (Abb. 20 - Bez. D),
protezione metallico posto nella parte sleeve in the top rear part of the boom und es ganz aus dem schützenden
superiore del braccio (Fig. 21 - Rif. A). (Fig. 21 - Ref. A). Metallrohr im oberen Teil des Auslegers
herausziehen (Abb. 21 - Bez. A).
Rimontare il coperchio dell’arrotolatore del Refit the “M.S.S.” anti-tilting system winder
sistema antiribaltamento “M.S.S.”. cable cover.
Den Deckel des Aufwicklers des
Sicherheitssystems “M.S.S.” gegen
Agendo sul carro ponte o l’elevatore, solle- By means of the bridge crane or elevator, Umkippen wieder aufsetzen.
vare o abbassare molto lentamente (di gently raise or lower the boom (by a few
qualche grado) il braccio, alla ricerca di un degrees) to find the point of balance
punto di equilibrio tra forza di ancoraggio between the anchoring force of the boom
del braccio al carro ponte e reazione del to the bridge crane and the reaction of the Den Ausleger mit dem Laufkran bzw. dem
martinetto di compensazione, in modo che compensation cylinder, in such a way that Gabelstapler sehr langsam (um ein paar
il peso del braccio non gravi interamente the weight of the arms does not lie entirely Grade) heben oder senken, um die
sul perno di incernieramento del braccio on the pivot pin on the turret (Fig. 22). Gleichgewichtsposition zwischen der
alla torretta (Fig. 22). Verankerungskraft des Auslegers am
Laufkran und der Reaktion des
Ausgleichszylinders zu suchen, damit das
Svitare la vite di fermo (Fig. 22 - Rif. B) e Unscrew stop screws (Fig. 22 - Ref. B) Gewicht des Auslegers nicht ganz auf dem
sfilare il perno di incernieramento braccio and extract the boom pivot pin on the tur- Kippbolzen am Turm lastet (Abb. 22).
alla torretta (Fig. 22 - Rif. C). ret (Fig. 22 - Ref. C).
Die Feststellschrauben (Abb. 22 - Bez. B)

losschrauben und den Auslegerkippbolzen
am Turm herausziehen (Abb. 22 - Bez. C).
6
MRT 1840 EASY 50
17 18
19 20
21 22
7
50 MRT 1840 EASY
IT EN DE
Con l’aiuto del carro ponte o l’elevatore, Using the bridge crane or elevator, extract Mit der Hilfe des Laufkrans oder des
trarre il braccio molto lentamente e con the boom very slowly and with great care Gabelstaplers den Ausleger sehr langsam
molta cautela verso il lato anteriore della towards the front of the machine by about und mit größter Vorsicht ein paar
macchina di qualche centimetro in modo a few centimetres so that the compensa- Zentimeter zur Vorderseite der Maschine
che il perno di incernieramento del cilindro tion cylinder pivot pin projects from the tur- ziehen, damit der Kippbolzen des
di compensazione esca dalla sagoma della ret outline (Fig. 23). During this operation, Ausgleichszylinders aus der Konturlinie
torretta (Fig. 23). Durante questa operazio- take care to keep the boom more or less des Turms heraustritt (Abb. 23). Während
ne avere cura di mantenere il braccio pres- horizontal, avoid sudden movements and dieses Vorgangs sollte der Ausleger fast
sochè orizzontale, prestare la massima avoid knocking the other machine compo- horizontal gehalten werden. Besonders
attenzione per non compiere movimenti nents against the boom (only partially darauf achten, dass es nicht zu plötzlichen
bruschi ed evitare di urtare col braccio released). Bewegungen kommt und dass man mit
(solo parzialmente svincolato) agli altri dem Ausleger (der nur teilweise freigege-
componenti della macchina. ben ist) nicht gegen die anderen
Bestandteile der Maschine stößt.
Smontare la vite di fermo (Fig. 23 - Rif. A) Remove the stop screw (Fig. 23 - Ref. A)
e sfilare il perno di incernieramento del and extract the compensation cylinder Die Feststellschraube (Abb. 23 - Bez. A)
cilindro di compensazione con l’ausilio di pivot pin using a suitable extractor (Fig. 24 entfernen und den Kippbolzen des
un eventuale estrattore (Fig. 24 - Rif. B). - Ref. B). Ausgleichszylinders mit der Hilfe eines
etwaigen Abziehers (Abb. 24 - Bez. B) her-
ausziehen.
Con l’ausilio del carro ponte o dell’elevato- Using the bridge crane or elevator, remove Den Ausleger mit der Hilfe des Laufkrans
re togliere il braccio dalla sede della torret- the boom from the turret seating (Fig. 25). oder des Gabelstaplers aus seiner
ta (Fig. 25). Aufnahme im Turm entfernen (Abb. 25).
8
MRT 1840 EASY 50
23 24
25
9
50 MRT 1840 EASY
IT EN DE
RIMONTAGGIO DEL BRACCIO REASSEMBLING THE TELESCO- WIEDEREINBAU DES TELE-

TELESCOPICO SULLA MACCHINA PING BOOM ON THE MACHINE SKOPAUSLEGERS AUF DER
MASCHINE
Predisporre la torretta della macchina con Preset the machine turret with the lift cylin- Den Turm der Maschine so vorbereiten,
il cilindro di sollevamento (Rif. A) e quello der (Ref. A) and compensation cylinder dass der Hubzylinder (Bez. A) und der
di compensazione (Rif. B) nelle posizioni (Ref. B) in the positions indicated (Fig. 1). Ausgleichszylinder (Bez. B) sich in den
indicate (Fig. 1). gezeigten Positionen befinden (Abb. 1).
Con l’ausilio di un carro ponte o un eleva- Using a bridge crane or elevator, hook the Mit der Hilfe eines Laufkrans oder eines
tore, agganciare il braccio negli appositi boom in the eyelets and position it on the Gabelstaplers den Ausleger in den
occhielli e posizionarlo sulla macchina nel- machine in the niches provided on the tur- Kranösen anschlagen und auf der
l’apposita nicchia della torretta (Fig. 2). ret (Fig. 2). Maschine in der dafür vorgesehenen
Nische im Turm anordnen (Abb. 2).
Eseguire il centraggio tra occhiello stelo Align the compensation cylinder rod eyelet Die Zentrierung zwischen der Öse auf dem
martinetto compensazione e boccola corri- with the corresponding bushing on the Schaft des Ausgleichszylinders und der
spondente sul braccio (Fig. 3 - Rif. C). boom (Fig. 3 - Ref. C). entsprechende Buchse auf dem Ausleger
vornehmen (Abb. 3 - Bez. C).
Infilare il perno di incernieramento del mar- Den Kippbolzen des Ausgleichszylinders in

Insert the compensation cylinder pivot in
tinetto di compensazione nel braccio (Fig. den Ausleger stecken (Abb. 4 - Bez. D)
the boom (Fig. 4 - Ref. D) and fit the stop
4 - Rif. D) e avvitare la vite di fermo (Fig. 4 und die Feststellschraube (Abb. 4 - Bez.
screws (Fig. 4 - Ref. E).
- Rif. E). E) anziehen.
Agendo sul carro ponte o sull’elevatore, Using the bridge crane or elevator, align Mittels des Laufkrans oder des
eseguire il centraggio delle boccole della the bushing on the turret with that on the Gabelstaplers die Zentrierung der
torretta con quella del braccio per il mon- boom for assembling the boom pivot pin to Turmbuchsen auf die Buchsen des
taggio del perno di incernieramento del the turret. Auslegers vornehmen, um den Kippbolzen
braccio alla torretta. des Auslegers im Turm montieren zu kön-
nen.
Infilare il perno di incernieramento del Insert the boom pivot pin on the turret (Fig. Den Kippbolzen des Auslegers im Turm
braccio sulla torretta (Fig. 5 - Rif. A) dopo 5 - Ref. A) after smearing grease on it, and einstecken (Abb. 5 - Bez. A), nachdem
averlo cosparso di grasso, e avvitare la fit the stop screw (Fig. 5 - Ref. B). man ihn mit Fett eingestrichen hat, und
vite di fermo (Fig. 5 - Rif. B). dann die Feststellschraube anziehen (Abb.
5 - Bez. B).
Agendo sul carro ponte o sull’elevatore, By means of the bridge crane or elevator, Mittels des Laufkrans oder des
abbassare il braccio telescopico per ese- lower the telescopic boom to align the lift Gabelstaplers den Teleskopausleger sen-
guire il centraggio dell’occhiello del marti- cylinder eyelet with the bushings located in ken, um die Zentrierung der Öse des
netto di sollevamento con le apposite boc- the lower part of the boom (Fig. 6 - Ref. Hubzylinders auf die entsprechenden
cole poste nella parte inferiore del braccio C). Buchsen im unteren Teil des Auslegers
(Fig. 6 - Rif. C). vorzunehmen (Abb. 6 - Bez. C).
Infilare il perno di incernieramento marti- Insert the boom lifting cylinder pivot pin Den Kippbolzen des Hubzylinders des
netto di sollevamento braccio (Fig. 7 - Rif. (Fig. 7 - Ref. D) and fit the stop screw (Fig. Auslegers (Abb. 7 - Bez. D) einstecken
D) e montare la vite di fermo perno (Fig. 7 7 - Ref. E). und die Feststellschraube montieren (Abb.
- Rif. E). 7 - Bez. E).
Rimontare il proximity per la segnalazione Refit the proximity switch that indicates the Den Näherungsschalter für die Meldung
3m di altezza della testa braccio e per la 3m height of the boom head and that for der Höhe des Auslegerkopfs von 3 m und
segnalazione 60° di inclinazione del brac- the 60° boom tilt together with the relative für die Meldung 60° Neigung des
cio con relativo supporto (Fig. 8 - Rif. F). bracket (Fig. 8 - Ref. F). Auslegers mit seinem Träger wieder mon-
tieren (Abb. 8 - Bez. F).
10
MRT 1840 EASY 50
1 2
D
C
E
C
3 4
⇪
⇪
B C
5 6
7 8
11
50 MRT 1840 EASY
IT EN DE
montare il proximity per la segnalazione Refit the proximity switch that indicates the Den Näherungsschalter für die Meldung
“braccio rientrato completamente” con rela- “boom retracted completely” together with “Ausleger ganz eingefahren” mit seinem
tivo supporto (Fig. 9 - Rif. A). its relative bracket (Fig. 9 - Ref. A). Träger wieder montieren (Abb. 9 - Bez. A).
Rimontare il microinterruttore di finecorsa Refit the boom lift travel end microswitch Den Endschalter für das Hochfahren des
per la salita del braccio con il relativo sup- together with its relative bracket (Fig. 10 - Auslegers mit seinem Träger (Abb. 10 -
porto (Fig. 10 - Rif. B) posti all’estremità Ref. B) located at the top end of the turret. Bez. B), der sich am oberen Ende des
superiore della torretta. Turms befindet, wieder montieren.
Ripristinare la fascettatura dei cavi elettrici Fit the clamps back around the electric Die Kabelbinder an den elektrischen
posti nella parte interna della torretta (Fig. wiring inside the turret (Fig. 11 - Ref. C), Kabeln im inneren Teil des Turms wieder
11 - Rif. C), (Fig. 12 - Rif. D), (Fig. 13 - Rif. (Fig. 12 - Ref. D), (Fig. 13 - Ref. A). anbringen (Abb. 11 - Bez. C), (Abb. 12 -
A). Bez. D), (Abb. 13 - Bez. A).
Ricollegare i tubi idraulici di alimentazione Reconnect the boom feed hydraulic pipes Die hydraulischen Leitungen zur
del braccio (Fig. 14 - Rif. B) avendo cura (Fig. 14 - Ref. B) ensuring the correct con- Versorgung des Auslegers wieder ansch-
di rispettare le corrispondenze di collega- nections. ließen (Abb. 14 - Bez. B), wobei die ent-
mento. sprechenden Markierungen für den korrek-
ten Anschluss zu beachten sind.
Agendo sull’apposita ghiera connettere la Using the special ring nut provided, con- Mit der entsprechenden Ringmutter die
spina-cablaggio elettrico posta nella parte nect the plug-electric wiring in the rear part Steckverbindung auf der Rückseite des
posteriore del braccio, se presente (Fig. 15 of the boom, if present (Fig. 15 - Ref. C). Auslegers anschließen, falls vorhanden
- Rif. C) . (Abb. 15 - Bez. C).
Collegare il connettore per il cavo dei Connect the connector for the cable of the Den Steckverbinder für das Kabel der
microinterruttori sicurezza catene (Fig. 16 - chain safety microswitches (Fig. 16 - Ref. Kettensicherheits-Endschalter ansch-
Rif. D). D). ließen (Abb. 16 - Bez. D).
Ripristinare la fascettatura dei tubi idraulici Refit the clamps on the hydraulic pipes Die hydraulischen Leitungen und die elek-
e dei cavi elettrici posti nella parte poste- and electric wiring in the top rear part of trischen Kabel auf der Rückseite oben im
riore superiore del braccio (Fig. 15 - Rif. E) the boom (Fig. 15 - Ref. E) and (Fig. 16 - Ausleger wieder mit den Kabelbindern ver-
(Fig. 16 - Rif. F). Ref. F). binden (Abb. 15 - Bez. E) und (Abb. 16 -
Bez. F).
12
MRT 1840 EASY 50
9 10
C
D D
11 12
A A
A
B
13 14
E F
15 16
13
50 MRT 1840 EASY
IT EN DE
Rimontare la lamiera di chiusura posteriore Refit the rear cover plate on the turret, by Das hintere Abschlussblech des Turms
della torretta avvitando le 4 viti di fissaggio means of the four fixing screws (Fig. 17 - wieder aufsetzen und mit den 4 Befesti-
(Fig. 17 - Rif. A). Ref. A). gungsschrauben blockieren (Abb. 17 -
Bez. A).
Smontare il coperchio dell’arrotolatore del Dismantle the “M.S.S.” anti-tilting system Den Deckel des Aufwicklers des
sistema antiribaltamento “M.S.S.”. winder cable cover. Sicherheitssystems “M.S.S.” abnehmen.
Das abgeschirmte elektrische Kabel des

Sicherheitssystems “M.S.S.” nehmen und
Prendere il cavo elettrico schermato del Insert the electric wire of the “M.S.S.” anti- in das schützende Metallrohr stecken, das
sistema antiribaltamento “M.S.S.”e infilarlo tilting system completely into the metal sich im oberen Teil des Auslegers befindet
interamente nel tubo di protezione metalli- sleeve in the top part of the boom (Fig. 18 (Abb. 18 - Bez. B), um dann die
co posto nella parte superiore del braccio - Ref. B) and refit the clamps (Fig. 18 - Kabelbinder wieder anzubringen (Abb. 18 -
(Fig. 18 - Rif. B) ripristinando la fascettatu- Ref. C). Bez. C).
ra (Fig. 18 - Rif. C).
Ricollegare il cavo elettrico schermato Reconnect the shielded wire in its terminal Das abgeschirmte elektrische Kabel wie-
nella apposita morsettiera (Fig. 19 - Rif. board (Fig. 19 - Ref. D). der an der Klemmenleiste anschließen
D). (Abb. 19 - Bez. D).
Rimontare il coperchio dell’arrotolatore del Refit the “M.S.S.” anti-tilting system cover Den Deckel des Aufwicklers des
sistema antiribaltamento “M.S.S.” (Fig. 20 - (Fig. 20 - Ref. E). Sicherheitssystems “M.S.S.” wieder
Rif. E). anbringen (Abb. 20 - Bez. E).
Reconnect the terminals to the battery.
Ricollegare i morsetti alla batteria. Die Batterieklemmen wieder anschließen.
Sollevare appropriatamente il TS con Lift the TS by means of a bridge crane or Den Teleskopausleger mit Hilfe des
l’ausilio del carro ponte o un elevatore e elevator and reposition it in its seat on the Laufkrans bzw. des Gabelstaplers ange-
riposizionarlo nell’apposita sede sulla testa boom head (Fig. 21). messen heben und ihn wieder in seine
del braccio (Fig. 21). Aufnahme auf dem Auslegerkopf bringen
(Abb. 21).
Infilare il perno di incernieramento TS alla Insert the TS pivot pin in the boom head Den Kippbolzen des Teleskops am Kopf
testa del braccio (Fig. 22 - Rif. A) e riavvi- (Fig. 22 - Ref. A) and fit the stop screws des Auslegers einstecken (Abb. 22 - Bez.
tare la vite di fermo (Fig. 22 - Rif. B). (Fig. 22 - Ref. B). A) und die Feststellschrauben wieder
anziehen (Abb. 22 - Bez. B).
Infilare il perno di incernieramento marti- Insert the rod side tilting cylinder pivot pin Den Kippbolzen des Schwenkzylinders
netto di brandeggio lato stelo al TS (Fig. in the TS (Fig. 23 - Ref. C) and fit the stop auf der Schaftseite am Teleskop ein-
23 - Rif. C) e riavvitare la ghiera di fermo screws (Fig. 23 - Ref. D). stecken (Abb. 23 - Bez. C) und die
(Fig. 23 - Rif. D). Feststellmutter wieder anschrauben (Abb.
23 - Bez. D).
14
MRT 1840 EASY 50
A A B
A A
17 18
19 20
21 22
23
15
50 MRT 1840 EASY
IT EN DE
Verificare il corretto funzionamento dei Check the correct working of the proximity Die folgenden Näherungsschalter und
proximity e microinterruttori sottoelencati : switches and microswitches listed below : Endschalter auf korrekte Funktion prüfen:
- microinterruttore finecorsa salita braccio - boom lift stroke end microswitch (Fig. 24 - Endschalter Aufwärtsbewegen Ausleger
(Fig. 24 - Rif. A) - Ref. A) (Abb. 24 - Bez. A)
- proximity inclinazione braccio 60° (Fig. - 60° boom tilt proximity switch (Fig. 25 - - Näherungsschalter Ausleger 60° Neigung
25 - Rif. B) Ref. B) (Abb. 25 - Bez. B)
- proximity 3 m di altezza della testa brac- - proximity switch indicating 3 m height of - Näherungsschalter 3 m Höhe des
cio (Fig. 25 - Rif. B) boom head (Fig. 25 - Ref. B) Auslegerkopfs (Abb. 25 - Bez. B)
- proximity braccio completamente rientra- - boom completely retracted proximity swit- - Näherungsschalter Ausleger ganz einge-
to (Fig. 26 - Rif. C) ch (Fig. 26 - Ref. C) fahren (Abb. 26 - Bez. C)
Prima di utilizzare la macchina, ingrassare Before using the machine, grease the tele- Vor der Benutzung der Maschine die
i pattini del braccio telescopico come scopic boom pads as follows: Gleitschuhe des Teleskopauslegers wie
segue: - extend the telescopic boom completely. folgt schmieren:
- fare uscire completamente il braccio tele- - using a brush, apply a layer of grease - Den Teleskopausleger ganz ausfahren.
scopico. ("LUBRICANTS AND FUELS" chart in - Mit einem Pinsel eine Schicht Fett (siehe
- usando un pennello, applicare uno strato the Use and Maintenance manual) on Betriebs- und Wartungsanleitung in der
di grasso (vedere nel manuale Uso e the four sides of the telescopic boom “FÜLLMENGEN-TABELLE”) auf den 4
Manutenzione nella “TABELLA RIEMPI- (Fig. 27). Seiten des Teleskopauslegers auftragen
MENTI”) sui 4 lati del braccio telescopico - operate the telescopic boom a number of (Abb. 27).
(Fig. 27). times to distribute the grease uniformly. - Den Teleskopausleger mehrfach betäti-
- azionare il braccio telescopico più volte - remove excess grease. fen, um das Fett gleichmäßig zu vertei-
per distribuire il grasso in modo unifor- len.
me. - Das überschüssige Fett entfernen.
- togliere l’eccesso di grasso.
16
MRT 1840 EASY 50
24 25
26
27
17
SMONTAGGIO E RIMONTAGGIO DALLA MACCHINA
DEL BRACCIO TELESCOPICO
DISASSEMBLING AND REASSEMBLING THE TELESCOPIC BOOM

FROM THE MACHINE
AUSBAU UND WIEDEREINBAU DES TELESKOPFAUSLEGERS

AUS DER MASCHINE
MRT 1440-1640 EASY
IT-EN-DE
50 MRT 1440-1640 EASY
IT EN DE
SMONTAGGIO DEL BRACCIO DISASSEMBLING THE TELESCO- AUSBAU DES TELESKOPAUS-

TELESCOPICO DALLA MACCHINA PIC BOOM FROM THE MACHINE LEGERS AUS DER MASCHINE
Posizionare la macchina su una superficie Position the vehicle on level ground, rest Die Maschine auf einer ebenen Fläche
abstellen, die Stabilisatoren aufstellen, um
piana, appogiare gli stabilizzatori per the outriggers to ensure maximum stability
ein Höchstmaß an Standsicherheit und
garantire la massima stabilità e sicurezza and safety (do not switch off the internal
Sicherheit zu gewährleisten (den
(non spegnere il motore termico). combustion engine). Verbrennungsmotor nicht abstellen).
Smontare la lamiera di chiusura posteriore Dismantle the turret rear cover plate by Das hintere Abschlussblech des Turms
della torretta svitando le 4 viti di fissaggio unscrewing the four fixing screws (Fig. 1 - abnehmen, nachdem man die 4
(Fig. 1 - Rif. A). Ref. A). Befestigungsschrauben (Abb. 1 - Bez. A)
abgeschraubt hat.
Svitare la ghiera di fermo (Fig. 2 - Rif. B) e Unscrew lock nut (Fig. 2 - Ref. B) and
sfilare il perno di incernieramento martinet- extract the rod side tilting cylinder pivot pin Die Feststellmutter (Abb. 2 - Bez. B) los-
to di brandeggio lato stelo al TS (Fig. 2 - at the TS (Fig. 2 - Ref. C). schrauben und den Kippbolzen des
Rif. C). Schwenkzylinders auf der Schaftseite zum
Teleskop (Abb. 2 - Bez. C) herausziehen.
Assicurare il TS ad un carro ponte o ad Secure the TS to a bridge crane or an ele- Den Teleskopausleger mit einem Laufkran
un elevatore (Fig. 3 - Rif. D), svitare la vite vator (Fig. 3 - Ref. D), unscrew stop screw oder einem Gabelstapler absichern (Abb. 3
di fermo (Fig. 3 - Rif. E) e sfilare il perno di (Fig. 3 - Ref. E) and extract the TS pivot - Bez. D), die Anschlagschraube (Abb. 3 -
incernieramento TS alla testa del braccio pin on the boom head (Fig. 3 - Ref. F). Bez. E) losschrauben und den
(Fig. 3 - Rif. F). Teleskopkippbolzen auf der Kopfseite des
Auslegers herausziehen (Abb. 3 - Bez. F).
Togliere dalla sua sede il TS. Remove the TS from its housing.
Den Teleskopausleger aus seiner
Aufnahme herausnehmen.
Azionare il comando di sollevamento brac- Activate the boom lift control, raising the
cio e portare questo al di sopra della sago- boom above the cab profile (Fig. 4 - Ref. Das Bedienelement zum Heben des
ma della cabina (Fig. 4 - Rif. G), così da G), to allow easy access to the cylinder Auslegers betätigen und diesen über die
permettere un facile accesso al perno di pivot pin of the stem-boom side from both Kontur der Kabine hinausbringen (Abb. 4 -
incernieramento del martinetto di solleva- sides. Bez. G), damit der Zugang zum
mento lato stelo-braccio da entrambe i lati. Kippbolzen des Hubzylinders Seite Schaft-
Ausleger auf beiden Seiten vereinfacht
wird.
Assicurare il braccio ad un carro ponte o Secure the boom to a bridge crane or an

ad un elevatore attraverso gli appositi elevator by means of the eyelets provided Den Ausleger an einem Laufkran oder
occhielli (Fig. 5 - Rif. A) che si trovano (Fig. 5 - Ref. A) in the upper part of the einem Gabelstapler mit den vorgesehenen
nella parte superiore del braccio stesso. boom. Kranösen absichern (Abb. 5 - Bez. A), die
sich im oberen Teil des Auslegers befin-
den.
Assicurare il martinetto di sollevamento ad Secure the lift cylinder to a bracket.
un sostegno.
Den Hubzylinder durch eine Halterung
absichern.
Svitare la vite di fermo (Fig. 6 - Rif. B) e Unscrew stop screws (Fig. 6 - Ref. B) and Die Feststellschraube (Abb. 6 - Bez. B)
sfilare il perno di incernieramento martinet- extract the stem-boom lift cylinder pivot pin losschrauben und den Kippbolzen des
to di sollevamento lato stelo-braccio (Fig. 6 (Fig. 6 - Ref. C). Hubzylinders auf der Seite Schaft-Ausleger
- Rif. C). herausziehen (Abb. 6 - Bez. C).
Adagiare il martinetto di sollevamento sulla Rest the lift cylinder on the turret on a Den Hubzylinder auf den Turm legen,
torretta sottoponendovi un trave in legno e wooden beam and use the control inside nachdem man einen Holzbalken darunter
fare rientrare lo stelo tramite il comando in the cab to retract the stem (Fig. 7 - Ref. D). gelegt hat, und den Schaft durch das
cabina (Fig. 7 - Rif. D). Bedienelement in der Kabine wieder ein-
fahren lassen (Abb. 7 - Bez. D).
Abbassare il braccio telescopico in posizio- Lower the telescopic boom to a more or Den Teleskopausleger in eine fast horizon-
ne pressochè orizzontale agendo sul carro less horizontal position by acting on the tale Lage fahren, und zwar mittels des ver-
ponte o l’elevatore impiegato. bridge crane or elevator used. wendeten Gabelstaplers oder Laufkrans.
Arrestare il motore termico. Stop the internal combustion engine. Den Verbrennungsmotor abstellen.
Riattivare la chiave di accensione in posi- Turn the ignition key to the “I” position Den Zündschlüssel in die Position “I” brin-
zione “I” (contatto chiave-accensione cru- (key-dashboard ignition contact) and carry gen (Schlüsselkontakt-Zündung
scotto) ed eseguire tutti i movimenti possi- out all possible movements using the com- Armaturenbrett) und mit den
bili con i comandi (Fig. 8) per annullare le mands (Fig. 8) to annul the residual pres- Bedienelementen (Abb. 8) alle möglichen
pressioni residue all’interno del circuito sures inside the hydraulic circuit. Bewegungsabläufe ausführen, um die
idraulico. Restdrücke innerhalb des hydraulischen
Kreislaufs zu beseitigen.
2
MRT 1440-1640 EASY 50
A A
B
A A C
1 2
G
3 4
C
A A
5 6

OK OK
7 8
3
50 MRT 1440-1640 EASY
IT EN DE
Disattivare la chiave di accensione e stac- Turn off the ignition key and disconnect the Die Zündung ausschalten und die
care i morsetti dalla batteria. terminals from the battery. Batterieklemmen abtrennen.
Eliminare tutte le fascette dei tubi idraulici Remove all the clamps from the hydraulic Alle Binder der hydraulischen Leitungen und
e dei cavi elettrici posti nella parte poste- pipes and electric wiring in the top rear der elektrischen Kabel entfernen, die sich
riore superiore del braccio (Fig. 9 - Rif. A), part of the boom (Fig. 9 - Ref. A), making hinten im oberen Teil des Auslegers befin-
assicurandosi che al termine dell’operazio- sure they are all completely free of one den (Abb. 9 - Bez. A), wobei sicherzustellen
ne siano tutti completamente svincolati another at the end of the operation. ist, dass am Ende des Vorgangs jedes
l’uno dall’altro. Element vom anderen getrennt ist.
Agendo sull’apposita ghiera disconnettere Using the ring nut provided, disconnect the Unter Benutzung der entsprechenden
la spina-cablaggio elettrico posta nella plug-wiring in the top rear part of the Ringmutter die elektrische Steckverbindung
parte posteriore del braccio, se presente boom, if present (Fig. 10 - Ref. B). im hinteren Teil des Auslegers, falls vorhan-
(Fig. 10 - Rif. B). den, entfernen (Abb. 10 - Bez. B).
Scollegare il tubo di canalizzazione per il Disconnect the drainage pipe at the top of Die Leitung für den Ablauf des Öls am Kopf
drenaggio in testa al braccio (Fig. 11 - Rif. the boom (Fig. 11 - Ref. C), if present. des Auslegers (Abb. 11 - Bez. C) abtrennen,
C), se presente. falls sie vorhanden ist.
Scollegare e tappare con tappi a tenuta i Disconnect and fit seal plugs on the boom Alle hydraulischen Leitungen zur
tubi idraulici di alimentazione del braccio hydraulic feed pipes (Fig. 11 - Ref. D) Versorgung des Auslegers abtrennen und
(Fig. 11 - Rif. D) avendo cura di contrasse- taking care to mark the connections to mit gut dichtenden Stopfen versehen (Abb.
gnare le corrispondenze di collegamento ensure correct reassembly. 11 - Bez. D), wobei die Verbindungsenden
per un corretto rimontaggio. zu markieren sind, um sie anschließend wie-
der korrekt verbinden zu können.
Per evitare perdite di olio dal circuito idrauli- To avoid oil leakage from the hydraulic cir-
co, tappare con tappi a tenuta tutti i raccordi cuit, fit the all pipe unions on the boom Um Ölaustritt aus dem hydraulischen
posizionati sul braccio (Fig. 12 - Rif. E). with seal plugs (Fig. 12 - Ref. E). Kreislauf zu vermeiden, alle auf dem
Ausleger vorhandenen Anschlüsse mit dicht
schließenden Stopfen versehen (Abb. 12 -
Smontare il proximity per la segnalazione Dismantle the proximity switch that indica- Bez. E).
3m di altezza della testa braccio con relati- tes the 3m height of the boom head with
vo supporto (Fig. 13 - Rif. A), senza però relative bracket (Fig. 13 - Ref. A) without,
scollegarne la connessione elettrica. however, disconnecting the electric wiring. Den Näherungsschalter für die Meldung der
Höhe von 3 m des Auslegerkopfs mit ent-
sprechendem Träger ausbauen (Abb. 13 -
Smontare il proximity per la segnalazione Dismantle the proximity switch that indica- Bez. A), ohne jedoch den elektrischen
braccio completamente rientrato con relati- tes boom completely retracted with relative Anschluss abzuklemmen.
vo supporto (Fig. 13 - Rif. B), senza però bracket (Fig. 13 - Ref. B), without, howe-
scollegarne la connessione elettrica. ver, disconnecting the electric wiring. Den Näherungsschalter für die Meldung
Ausleger ganz eingefahren mit entsprechen-
dem Träger ausbauen (Abb. 13 - Bez. B),
Smontare il proximity per la segnalazione Dismantle the proximity switch that indica- ohne jedoch den elektrischen Anschluss
60° di inclinazione del braccio con relativo tes 60° boom tilt with relative bracket (Fig. abzuklemmen.
supporto (Fig. 14 - Rif. C), senza però 14 - Ref. C), without, however, disconnec-
scollegarne la connessione elettrica. ting the electric wiring. Den Näherungsschalter für die Meldung 60°
Neigung des Auslegers mit entsprechendem
Träger ausbauen (Abb. 14 - Bez. C), ohne
jedoch den elektrischen Anschluss abzu-
Smontare il microinterruttore di fine corsa Dismantle the boom lift travel end micro- klemmen.
per la salita del braccio con il relativo sup- switch with its relative bracket (Fig. 15 -
porto (Fig. 15 - Rif. D) posto all’estremità Ref. D) located at the top end of the turret
superiore della torretta, senza però scolle- without, however, disconnecting the elec- Den Endschalter für das Hochfahren des
garne la connessione elettrica. tric wiring. Auslegers mit dem entsprechenden Träger
ausbauen (Abb. 15 - Bez. D), der sich am
oberen Turmende befindet, ohne jedoch den
elektrischen Anschluss abzuklemmen.
Smontare il coperchio dell’arrotolatore del Remove the “M.S.S.” anti-tilting system Den Deckel des Aufwicklers des
sistema antiribaltamento “M.S.S.” (Fig. 16 - cable cover (Fig. 16 - Ref. E). Sicherheitssystems “M.S.S.” gegen
Rif. E). Umkippen (Abb. 16 - Bez. E) entfernen.
4
MRT 1440-1640 EASY 50
9 10
D
E
C
D
11 12
13 14
D E
15 16
5
50 MRT 1440-1640 EASY
IT EN DE
Scollegare il cavo elettrico schermato Disconnect the shielded electric cable Das abgeschirmte elektrische Kabel
agendo sulle viti della morsettiera (Fig. 17 using the screws on the terminal (Fig. 17 - abklemmen, wozu man die Schrauben der
- Rif. A) e sfilarlo interamente dal tubo di Ref. A) and extract these from the metal Klemmenleiste benutzt (Abb. 17 - Bez. A),
protezione metallico posto nella parte sleeve in the top rear part of the boom und es ganz aus dem schützenden
superiore del braccio (Fig. 18 - Rif. B). (Fig. 18 - Ref. B). Metallrohr im oberen Teil des Auslegers
herausziehen (Abb. 18 - Bez. B).
Rimontare il coperchio dell’arrotolatore del Refit the “M.S.S.” anti-tilting system winder Den Deckel des Aufwicklers des
sistema antiribaltamento “M.S.S.”. cable cover. Sicherheitssystems “M.S.S.” wieder
aufsetzen.
Agendo sul carro ponte o l’elevatore, solle- By means of the bridge crane or elevator, Den Ausleger mit dem Laufkran bzw. dem
vare o abbassare molto lentamente (di gently raise or lower the boom (by a few Gabelstapler sehr langsam (um ein paar
qualche grado) il braccio, alla ricerca di un degrees) to find the point of balance Grade) heben oder senken, um die
punto di equilibrio tra forza di ancoraggio between the anchoring force of the boom Gleichgewichtsposition zwischen der
del braccio al carro ponte e reazione del to the bridge crane and the reaction of the Verankerungskraft des Auslegers am
martinetto di compensazione, in modo che compensation cylinder, in such a way that Laufkran und der Reaktion des
il peso del braccio non gravi interamente the weight of the arms does not lie entirely Ausgleichszylinders zu suchen, damit das
sul perno di incernieramento alla torretta on the pivot pin on the turret (Fig. 19). Gewicht des Auslegers nicht ganz auf dem
(Fig. 19). Kippbolzen am Turm lastet (Abb. 19).
Svitare la vite di fermo (Fig. 19 - Rif. C) e Unscrew stop screws (Fig. 19 - Ref. C) Die Feststellschrauben (Abb. 19 - Bez. C)
sfilare il perno di incernieramento braccio and extract the boom pivot pin on the tur- losschrauben und den Auslegerkippbolzen
alla torretta (Fig. 19 - Rif. D). ret (Fig. 19 - Ref. D). am Turm herausziehen (Abb. 19 - Bez. D).
Con l’aiuto del carro ponte o l’elevatore, Using the bridge crane or elevator, extract Mit der Hilfe des Laufkrans oder des
trarre il braccio molto lentamente e con the boom very slowly and with great care Gabelstaplers den Ausleger sehr langsam
molta cautela verso il lato anteriore della towards the front of the machine by about und mit größter Vorsicht ein paar
macchina di qualche centimetro in modo a few centimetres so that the compensa- Zentimeter zur Vorderseite der Maschine
che il perno di incernieramento del cilindro tion cylinder pivot pin projects from the tur- ziehen, damit der Kippbolzen des
di compensazione esca dalla sagoma della ret outline (Fig. 20). During this operation, Ausgleichszylinders aus der Konturlinie
torretta (Fig. 20). Durante questa operazio- take care to keep the boom more or less des Turms heraustritt (Abb. 20). Während
ne avere cura di mantenere il braccio pres- horizontal, avoid sudden movements and dieses Vorgangs sollte der Ausleger fast
sochè orizzontale, prestare la massima avoid knocking the other machine compo- horizontal gehalten werden. Besonders
attenzione per non compiere movimenti nents against the boom (only partially darauf achten, dass es nicht zu plötzlichen
bruschi ed evitare di urtare col braccio released). Bewegungen kommt und dass man mit
(solo parzialmente svincolato) gli altri com- dem Ausleger (der nur teilweise freigege-
ponenti della macchina. ben ist) nicht gegen die anderen
Bestandteile der Maschine stößt.
Smontare la vite di fermo (Fig. 20 - Rif. A) Remove the stop screw (Fig. 20 - Ref. A) Die Feststellschraube (Abb. 20 - Bez. A)
e sfilare il perno di incernieramento del and extract the compensation cylinder entfernen und den Kippbolzen des
cilindro di compensazione con l’ausilio di pivot pin using a suitable extractor (Fig. 21 Ausgleichszylinders mit der Hilfe eines
un eventuale estrattore (Fig. 21 - Rif. B). - Ref. B). etwaigen Abziehers (Abb. 21 - Bez. B) her-
ausziehen.
Con l’ausilio del carro ponte o dell’elevato- Using the bridge crane or elevator, remove Den Ausleger mit der Hilfe des Laufkrans
re togliere il braccio dalla sede della torret- the boom from the turret seating (Fig. 22). oder des Gabelstaplers aus seiner
ta (Fig. 22). Aufnahme im Turm entfernen (Abb. 22).
6
MRT 1440-1640 EASY 50
B
A
17 18
⇪
D
19 20
21 22
7
50 MRT 1440-1640 EASY
IT EN DE
RIMONTAGGIO DEL BRACCIO REASSEMBLING THE TELESCO- WIEDEREINBAU DES TELE-

TELESCOPICO SULLA MACCHINA PING BOOM ON THE MACHINE SKOPAUSLEGERS AUF DER
MASCHINE
Predisporre la torretta della macchina con Preset the machine turret with the lift cylin-
Den Turm der Maschine so vorbereiten,
il cilindro di sollevamento (Rif. A) e quello der (Ref. A) and compensation cylinder (Ref. dass der Hubzylinder (Bez. A) und der
di compensazione (Rif. B) nelle posizioni B) in the positions indicated (Fig. 1). Ausgleichszylinder (Bez. B) sich in den
indicate (Fig. 1). gezeigten Positionen befinden (Abb. 1).
Con l’ausilio di un carro ponte o un eleva- Using a bridge crane or elevator, hook the Mit der Hilfe eines Laufkrans oder eines
tore, agganciare il braccio negli appositi boom in the eyelets and position it on the Gabelstaplers den Ausleger in den
occhielli e posizionarlo sulla macchina nel- machine in the niches provided on the tur- Kranösen anschlagen und auf der
Maschine in der dafür vorgesehenen
l’apposita nicchia della torretta (Fig. 2). ret (Fig. 2).
Nische im Turm anordnen (Abb. 2).
Eseguire il centraggio tra occhiello stelo Align the compensation cylinder rod eyelet Die Zentrierung zwischen der Öse auf dem
martinetto compensazione e boccola corri- with the corresponding bushing on the Schaft des Ausgleichszylinders und der
entsprechende Buchse auf dem Ausleger
spondente sul braccio (Fig. 3 - Rif. C). boom (Fig. 3 - Ref. C).
vornehmen (Abb. 3 - Bez. C).
Infilare il perno di incernieramento del mar- Insert the compensation cylinder pivot in Den Kippbolzen des Ausgleichszylinders in
tinetto di compensazione nel braccio (Fig. the boom (Fig. 4 - Ref. D) and fit the stop den Ausleger stecken (Abb. 4 - Bez. D)
und die Feststellschraube anziehen.
4 - Rif. D) e avvitare la vite di fermo. screws.
Agendo sul carro ponte o sull’elevatore, Mittels des Laufkrans oder des
Using the bridge crane or elevator, align
eseguire il centraggio delle boccole della Gabelstaplers die Zentrierung der
the bushing on the turret with that on the
torretta con quella del braccio per il mon- Turmbuchsen auf die Buchsen des
boom for assembling the boom pivot pin to
taggio del perno di incernieramento del Auslegers vornehmen, um den Kippbolzen
the turret.
braccio alla torretta. des Auslegers im Turm montieren zu können.
Infilare il perno di incernieramento del Insert the boom pivot pin on the turret (Fig. Den Kippbolzen des Auslegers im Turm
braccio sulla torretta (Fig. 5 - Rif. A) dopo 5 - Ref. A) after smearing grease on it, and einstecken (Abb. 5 - Bez. A), nachdem
averlo cosparso di grasso, e avvitare la fit the stop screw (Fig. 5 - Ref. B). man ihn mit Fett eingestrichen hat, und
vite di fermo (Fig. 5 - Rif. B). dann die Feststellschraube anziehen (Abb.
5 - Bez. B).
Agendo sul carro ponte o sull’elevatore, By means of the bridge crane or elevator,
abbassare il braccio telescopico per ese- lower the telescopic boom to align the lift Mittels des Laufkrans oder des
guire il centraggio dell’occhiello del marti- cylinder eyelet with the bushings located in Gabelstaplers den Teleskopausleger sen-
netto di sollevamento con le apposite boc- the lower part of the boom (Fig. 6 - Ref. C). ken, um die Zentrierung der Öse des
cole poste nella parte inferiore del braccio Hubzylinders auf die entsprechenden
(Fig. 6 - Rif. C). Buchsen im unteren Teil des Auslegers
vorzunehmen (Abb. 6 - Bez. C).
Infilare il perno di incernieramento martinetto Insert the boom lifting cylinder pivot pin Den Kippbolzen des Hubzylinders des
di sollevamento braccio (Fig. 7 - Rif. D) e (Fig. 7 - Ref. D) and fit the stop screw (Fig. Auslegers (Abb. 7 - Bez. D) einstecken
montare la vite di fermo (Fig. 7 - Rif. E). 7 - Ref. E). und die Feststellschraube montieren (Abb.
7 - Bez. E).
3m di altezza della testa braccio con relati- 3m height of the boom head together with der Höhe des Auslegerkopfs von 3 m mit
vo supporto (Fig. 8 - Rif. F). its relative bracket (Fig. 8 - Ref. F). dem entsprechenden Träger wieder mon-
tieren (Abb. 8 - Bez. F).
“braccio rientrato completamente” con rela- “boom retracted completely” together with “Ausleger ganz eingefahren” mit seinem
tivo supporto (Fig. 8 - Rif. G). its relative bracket (Fig. 8 - Ref. G). Träger wieder montieren (Abb. 8 - Bez. G).
8
MRT 1440-1640 EASY 50
1 2
C
D
3 4
⇪
⇪
C
B
5 6
E F
7 8
9
50 MRT 1440-1640 EASY
IT EN DE
60° di inclinazione del braccio con relativo 60° boom tilt together with its relative der Auslegerneigung von 60° mit seinem
supporto (Fig. 9 - Rif. A). bracket (Fig. 9 - Ref. A). Träger wieder montieren (Abb. 9 - Bez. A).
Rimontare il microinterruttore di finecorsa Refit the boom lift travel end microswitch Den Endschalter für das Hochfahren des
per la salita del braccio con il relativo sup- together with its relative bracket (Fig. 10 - Auslegers mit seinem Träger (Abb. 10 -
porto (Fig. 10 - Rif. B) posti all’estremità Ref. B) located at the top end of the turret. Bez. B), der sich am oberen Ende des
superiore della torretta. Turms befindet, wieder montieren.
Ricollegare i tubi idraulici di alimentazione Reconnect the boom feed hydraulic pipes Die hydraulischen Leitungen zur
del braccio (Fig. 11 - Rif. C) avendo cura (Fig. 11 - Ref. C) ensuring the correct con- Versorgung des Auslegers wieder ansch-
di rispettare le corrispondenze di collega- nections. ließen (Abb. 11 - Bez. C), wobei die ent-
mento. sprechenden Markierungen für den korrek-
ten Anschluss zu beachten sind.
Ricollegare il tubo di canalizzazione per il Reconnect the drainage pipe at the top of Die Leitung für das rücklaufende Öl vom
drenaggio in testa al braccio (Fig. 11 - Rif. the boom (Fig. 11 - Ref. D), if present. Kopf des Auslegers wieder anschließen
D), se presente. (Abb. 11 - Bez. D), falls sie vorhanden ist.
Agendo sull’apposita ghiera connettere la Using the special ring nut provided, con- Mit der entsprechenden Ringmutter die
spina-cablaggio elettrico posta nella parte nect the plug-electric wiring in the rear part Steckverbindung auf der Rückseite des
posteriore del braccio, se presente (Fig. 12 of the boom, if present (Fig. 12 - Ref. E). Auslegers anschließen, falls vorhanden
- Rif. E). (Abb. 12 - Bez. E).
Ripristinare la fascettatura dei tubi idraulici Refit the clamps on the hydraulic pipes Die hydraulischen Leitungen und die elek-
e dei cavi elettrici posti nella parte poste- and electric wiring in the top rear part of trischen Kabel auf der Rückseite oben im
riore superiore del braccio (Fig. 13 - Rif. A) the boom (Fig. 13 - Ref. A) and (Fig. 14 - Ausleger wieder mit den Kabelbindern ver-
e (Fig. 14 - Rif. B). Ref. B). binden (Abb. 13 - Bez. A) und (Abb. 14 -
Bez. B).
Rimontare la lamiera di chiusura posteriore Refit the rear cover plate on the turret, by Das hintere Abschlussblech des Turms
della torretta avvitando le 4 viti di fissaggio means of the four fixing screws (Fig. 15 - wieder aufsetzen und mit den 4 Befesti-
(Fig. 15 - Rif. C). Ref. C). gungsschrauben blockieren (Abb. 15 -
Bez. C).
Smontare il coperchio dell’arrotolatore del Dismantle the “M.S.S.” anti-tilting system Den Deckel des Aufwicklers des
sistema antiribaltamento “M.S.S.”. winder cable cover. Sicherheitssystems “M.S.S.” abnehmen.
Prendere il cavo elettrico schermato del Insert the electric wire of the “M.S.S.” anti- Das abgeschirmte elektrische Kabel des
sistema antiribaltamento “M.S.S.”e infilarlo tilting system completely into the metal Sicherheitssystems “M.S.S.” nehmen und
interamente nel tubo di protezione metalli- sleeve in the top part of the boom (Fig. 16 in das schützende Metallrohr stecken, das
co posto nella parte superiore del braccio - Ref. D) and refit the clamps (Fig. 16 - Ref. E). sich im oberen Teil des Auslegers befindet
(Fig. 16 - Rif. D) ripristinando la fascettatu- (Abb. 16 - Bez. D), um dann die
ra (Fig. 16 - Rif. E). Kabelbinder wieder anzubringen (Abb. 16 -
Bez. E).
10
MRT 1440-1640 EASY 50
9 10
D
C
E
11 12
B
B
A
A
13 14
C C
C C
15 16
11
50 MRT 1440-1640 EASY
IT EN DE
Ricollegare il cavo elettrico schermato nel- Reconnect the shielded wire in its terminal Das abgeschirmte elektrische Kabel wie-
l’apposita morsettiera (Fig. 17 - Rif. A). board (Fig. 17- Ref. A). der an der Klemmenleiste anschließen
(Abb. 17 - Bez. A).
Rimontare il coperchio dell’arrotolatore del Refit the “M.S.S.” anti-tilting system cover Den Deckel des Aufwicklers des
sistema antiribaltamento “M.S.S.” (Fig. 18 - (Fig. 18 - Ref. B). Sicherheitssystems “M.S.S.” wieder
Rif. B). anbringen (Abb. 18 - Bez. B).
Ricollegare i morsetti alla batteria. Reconnect the terminals to the battery. Die Batterieklemmen wieder anschließen.
Sollevare appropriatamente il TS con Lift the TS by means of a bridge crane or Den Teleskopausleger mit Hilfe des
l’ausilio del carro ponte o dell’elevatore e elevator and reposition it in its seat on the Laufkrans bzw. des Gabelstaplers ange-
riposizionarlo nell’apposita sede sulla testa boom head (Fig. 19). messen heben und ihn wieder in seine
del braccio (Fig. 19). Aufnahme auf dem Auslegerkopf bringen
(Abb. 19).
Infilare il perno di incernieramento TS alla Insert the TS pivot pin in the boom head Den Kippbolzen des Teleskops am Kopf
testa del braccio (Fig. 20 - Rif. C) e riavvi- (Fig. 20 - Ref. C) and fit the stop screws des Auslegers einstecken (Abb. 20 - Bez.
tare la vite di fermo (Fig. 20 - Rif. D). (Fig. 20 - Ref. D). C) und die Feststellschrauben wieder
anziehen (Abb. 20 - Bez. D).
Infilare il perno di incernieramento marti- Insert the rod side tilting cylinder pivot pin Den Kippbolzen des Schwenkzylinders
netto di brandeggio lato stelo al TS (Fig. in the TS (Fig. 21 - Ref. A) and fit the stop auf der Schaftseite am Teleskop ein-
21 - Rif. A) e riavvitare la ghiera di fermo screws (Fig. 21 - Ref. B). stecken (Abb. 21 - Bez. A) und die
(Fig. 21 - Rif. B). Feststellmutter wieder anschrauben (Abb.
21 - Bez. B).
Verificare il corretto funzionamento dei Check the correct working of the proximity Die folgenden Näherungsschalter und
proximity e microinterruttori sottoelencati : switches and microswitches listed below : Endschalter auf korrekte Funktion prüfen:
- microinterruttore finecorsa salita braccio - boom lift stroke end microswitch (Fig. 22 - Endschalter Aufwärtsbewegen Ausleger
(Fig. 22 - Rif. C) - Ref. C) (Abb. 22 - Bez. C)
- proximity inclinazione braccio 60° (Fig. - 60° boom tilt proximity switch (Fig. 23 - - Näherungsschalter Ausleger 60° (Abb. 23
23 - Rif. D) Ref. D) - Bez. D)
- proximity braccio completamente rientra- - boom completely retracted proximity swit- - Näherungsschalter Ausleger ganz einge-
to (Fig. 24 - Rif. E) ch (Fig. 24 - Ref. E) fahren (Abb. 24 - Bez. E)
- proximity 3 m di altezza della testa brac- - proximity switch indicating 3 m height of - Näherungsschalter 3 m Höhe des
cio (Fig. 24 - Rif. F) boom head (Fig. 24 - Ref. F) Auslegerkopfs (Abb. 24 - Bez. F)
12
MRT 1440-1640 EASY 50
17 18
19 20
21 22
23 24
13
50 MRT 1440-1640 EASY
IT EN DE
Prima di utilizzare la macchina, Before using the machine, grease the Vor der Benutzung der Maschine die
ingrassare i pattini del braccio tele- telescopic boom pads as follows: Gleitschuhe des Teleskopauslegers
scopico come segue: - extend the telescopic boom com- wie folgt schmieren:
- fare uscire completamente il braccio pletely. - Den Teleskopausleger ganz
telescopico. - using a brush, apply a layer of ausfahren.
- usando un pennello, applicare uno grease ("LUBRICANTS AND - Mit einem Pinsel eine Schicht Fett
strato di grasso (vedere nel manua- FUELS" chart in the Use and (siehe Betriebs- und
le Uso e Manutenzione nella Maintenance manual) on the four Wartungsanleitung in der
“TABELLA RIEMPIMENTI”) sui 4 lati sides of the telescopic boom (Fig. 25). “FÜLLMENGEN-TABELLE”) auf den
del braccio telescopico (Fig. 25). - operate the telescopic boom a num- 4 Seiten des Teleskopauslegers auf-
- azionare il braccio telescopico più ber of times to distribute the grease tragen (Abb. 25).
volte per distribuire il grasso in uniformly. - Den Teleskopausleger mehrfach
modo uniforme. - remove excess grease. betätifen, um das Fett gleichmäßig
- togliere l’eccesso di grasso zu verteilen.
- Das überschüssige Fett entfernen.
14
MRT 1440-1640 EASY 50
25
15
SMONTAGGIO E RIMONTAGGIO DEL BRACCIO
TELESCOPICO COMPLETO
DISASSEMBLING AND REASSEMBLING THE ENTIRE

TELESCOPIC BOOM
AUSBAU UND WIEDEREINBAU DES KOMPLETTEN

TELESKOPAUSLEGERS
MRT 1440-1640 EASY

IT-EN-DE
50 MRT 1440-1640 EASY
IT EN DE
SMONTAGGIO COMPLETO DEL DISASSEMBLING THE ENTIRE KOMPLETTER AUSBAU DES

BRACCIO BOOM AUSLEGERS
Das Kabel des Aufwicklers des

Staccare il cavo dell’avvolgitore del Disconnect “M.S.S.” winder cable from the Sicherheitssystems “M.S.S.” von der Platte
“M.S.S.” dal piatto presente sul braccio II° plate present on the 2nd extension boom auf dem 2. Auszug abtrennen (Abb. 1 -
sfilo (Fig. 1 - Rif. A). (Fig. 1 - Ref. A). Bez. A).
Smontare l’avvolgitore (Fig. 2 - Rif. B) del Dismantle the winder (Fig. 2 - Ref. B) of Den Aufwickler (Abb. 2 - Bez. B) des
“M.S.S.” con la relativa staffa (Fig. 2 - the “M.S.S.” with the relative bracket (Fig. “M.S.S.” mit dazugehörigem Bügel (Abb. 2
Rif. C) nella parte anteriore sinistra del 2 - Ref. C) in the front left part of the exter- - Bez. C) im vorderen Teil links des exter-
braccio esterno. nal boom. nen Auslegerarms ausbauen.
Scollegare il tubo per il drenaggio dall’in- Disconnect the drainage pipe from the Die Rücklaufleitung aus der
nesto rapido sul lato destro della testa del quick-release coupling on the right side at Schnellkupplung auf der rechten Seite des
braccio (Fig. 3 - Rif. D). the top of the boom (Fig. 3 - Ref. D). Auslegerkopfs abtrennen (Abb. 3 - Bez.
D).
Aprire la scatola per presa cestello e libe- Open the basket socket box and free the
rare i cavi dalle fascette sulla testa del cables from the clamps on the boom head
braccio (Fig. 4 - Rif. E). (Fig. 4 - Ref. E). Den Kasten für die Steckdose der Bühne
öffnen und die Kabel von den
Kabelbindern auf dem Auslegerkopf befrei-
en (Abb. 4 - Bez. E).
Scollegare i cavi elettrici (Fig. 5 - Rif. A) Disconnect the electric wiring (Fig. 5 - Ref.
dalla presa multispina (Fig. 5 - Rif. B) del A) from the multipin socket (Fig. 5 - Ref. B)
cestello. of the basket. Die elektrischen Kabel (Abb. 5 - Bez. A)
aus der Mehrfachsteckdose (Abb. 5 - Bez.
B) der Bühne abklemmen.
Smontare la fascetta di blocco dei cavi Dismantle the clamp blocking the electric
elettrici e del tubo idraulico sulla canalina wires and hydraulic tube on the duct (Fig. Den Kabelbinder zum Blockieren der elek-
(Fig. 6 - Rif. C). 6 - Ref. C). trischen Kabel und der hydraulischen
Leitung auf dem Kabelkanal entfernen
Sfilare il tubo idraulico per il drenaggio dal- Extract the hydraulic drainage pipe through (Abb. 6 - Bez. C).
l’apertura sulla testa del braccio (Fig. 6 - the opening in the boom head (Fig. 6 -
Rif. D). Ref. D). Die hydraulische Rücklaufleitung aus der
Öffnung auf dem Auslegerkopf heraus-
ziehen (Abb. 6 - Bez. D).
Liberare dalla guaina protettiva (Fig. 7 - Free from the protective sheath (Fig. 7 -
Rif. E) i cavi elettrici e il tubo idraulico per Ref. E) the electric wires and the hydraulic Die elektrischen Kabel und die hydrauli-
il drenaggio all’uscita anteriore della cana- drainage pipe at the front outlet of the sche Rücklaufleitung am vorderen
lina. channel. Ausgang des Kabelkanals von der
Schutzhülle (Abb. 7 - Bez. E) befreien.
Nella parte posteriore della canalina stac- In the rear part of the channel disconnect Im hinteren Teil des Kabelkanals die
care la catena portatubi svitando le viti the tubeholder chain by unscrewing the Schlauchtragekette abtrennen, indem man
(Fig. 8 - Rif. F). screws (Fig. 8 - Ref. F). die Schrauben losdreht (Abb. 8 - Bez. F).
2
MRT 1440-1640 EASY 50
1 2
3 4
A C
D
B
5 6
E F
7 8
3
50 MRT 1440-1640 EASY
IT EN DE
Dalla parte posteriore della canalina sfilare From the rear part of the channel extract Die elektrischen Kabel und die hydrauli-
i cavi elettrici, il tubo idraulico (Fig. 9 - the electric wires, the hydraulic tube (Fig. 9 sche Leitung (Abb. 9 - Bez. A) auf der
Rif. A) e stendere la catena portatubi. - Ref. A) and stretch the tubeholder chain. Rückseite des Kabelkanals herausziehen
und die Schlauchtragekette auslegen.
Togliere la canalina (Fig. 10 - Rif. B) nella Remove the channel (Fig. 10 - Ref. B) in Den Kabelkanal (Abb. 10 - Bez. B) im vor-
parte anteriore del braccio smontando gli the front part of the boom by removing the deren Teil des Auslegers entfernen, indem
appositi perni (Fig. 10 - Rif. C/D) sulle for- pins (Fig. 10 - Ref. C/D) on the forks. man die entsprechenden Bolzen (Abb. 10
celle. - Bez. C/D) auf den Gabeln entfernt.
Smontare la fascetta (Fig. 11 - Rif. E) di Dismantle the clamps (Fig. 11 - Ref. E) Den Kabelbinder (Abb. 11 - Bez. E) zum
blocco dei cavi elettrici e del tubo idraulico blocking the cables and the hydraulic tube Blockieren der elektrischen Kabel und der
sul tubolare supporto catena. on the chain support tube. hydraulischen Leitung auf dem Ketten-
tragerohr entfernen.
Sfilare i cavi elettrici e il tubo idraulico dalla Extract the electric wires and hydraulic Die elektrischen Kabel und die hydrauli-
parte anteriore della catena portatubi (Fig. tube from the front of the tubeholder chain sche Leitung aus dem vorderen Teil der
12 - Rif. F). (Fig. 12 - Ref. F). Schlauchtragekette herausziehen (Abb. 12
- Bez. F).
Nella parte posteriore del tubolare liberare In the rear part of the tube, free the electric Die elektrischen Kabel und die hydrauli-
i cavi elettrici e il tubo idraulico togliendo il wires and the hydraulic tube, after remov- sche Leitung im hinteren Teil des Rohrs
collare (Fig. 13 - Rif. A) e tutte le fascette ing the collar (Fig. 13- Ref. A) and all the befreien, indem man den Anschlagbund
(Fig. 13 - Rif. B). clamps (Fig. 13 - Ref. B). (Abb. 13 - Bez. A) und alle Kabelbinder
(Abb. 13 - Bez. B) entfernt.
Liberare dalla guaina (Fig. 14 - Rif. C) i Free from the sheath (Fig. 14 - Ref. C) the Die Kabelhülle (Abb. 14 - Bez. C) der elek-
cavi elettrici e il tubo idraulico per il dre- electric wires and the hydraulic drainage trischen Kabel und der hydraulischen
naggio. pipe. Rücklaufleitung entfernen.
Staccare la spina multipresa elettrica (Fig. Disconnect the basket multipin electric Die elektrische Mehrfachsteckdose (Abb.
15 - Rif. D) per il cestello dal piastrino por- plug (Fig. 15 - Ref. D) from the plugholder 15 - Bez. D) für die Bühne von der
taspina (Fig. 15 - Rif. E). plate (Fig. 15 - Ref. E). Steckertrageplatte (Abb. 15 - Bez. E)
abklemmen.
Smontare il piastrino (Fig. 15 - Rif. E) per Dismantle the plate (Fig. 15 - Ref. E) for Die Platte (Abb. 15 - Bez. E) für die
presa elettrica nella parte posteriore destra the electric socket in the right rear part of Steckdose im hinteren Teil rechts am
del braccio esterno. the external boom. externen Ausleger ausbauen.
Sfilare completamente, dalla parte poste- Completely remove the cables for the bas- Die Kabel für die Bühnensteckdose und
riore del tubolare portacatena (Fig. 16 - ket socket and the hydraulic drainage pipe die hydraulische Rücklaufleitung am
Rif. F) i cavi per la presa cestello e il tubo at the top of the boom, from the back of Auslegerkopf von hinten ganz aus dem
idraulico per il drenaggio in testa al brac- the tubeholder chain (Fig. 16 - Ref. F). Kettentragerohr herausziehen (Abb. 16 -
cio. Bez. F).
4
MRT 1440-1640 EASY 50
⇪
A
D
9 10
⇪ F
11 12
A
B
C
B
B
B
13 14
F
⇪
15 16
5
50 MRT 1440-1640 EASY
IT EN DE
Smontare la catena portatubi togliendo le Dismantle the tubeholder chain after Die Schlauchtragekette ausbauen, indem
viti (Fig. 17 - Rif. A) nella parte anteriore removing the screws (Fig. 17 - Ref. A) in man die Schrauben (Abb. 17 - Bez. A) im
del tubolare portacatene. the front part of the chainholder tube. vorderen Teil des Kettentragerohrs ent-
fernt.
Smontare il pattino (Fig. 18 - Rif. B) bascu- Dismantle the pivot pad (Fig. 18 - Ref. B) Den auf der Gabel des 1. Auszugs kippend
lante sulla forcella del I° sfilo. on the 1st extension fork. befestigten Gleitschuh (Abb. 18 - Bez. B)
ausbauen.
Smontare le forcelle di supporto canalina Dismantle the channel support fork on the Die Tragegabeln des Kabelkanals auf dem
su I° e II° sfilo (Fig. 19 - Rif. C/D). 1st and 2nd extension (Fig. 19 - Ref. C/D). 1. und 2. Auszug ausbauen (Abb. 19 -
Bez. C/D).
Smontare il tubolare (Fig. 20 - Rif. E) Dismantle the chainholder tube (Fig. 20 - Das Kettentragerohr (Abb. 20 - Bez. E) auf
portacatene sul lato destro del braccio Ref. E) on the right side of the external der rechten Seite des externen Auslegers
esterno. boom ausbauen.
Smontaggio del braccio 2° sfilo dal 1° Dismantle the 2nd extension boom from Ausbau des 2. Auszugs aus dem 1.
sfilo the 1st extension. Auszug
Smontare la protezione martinetto 1° sfilo Dismantle the 1st extension cylinder guard Den Zylinderschutz des 1. Auszugs am
in testa al braccio telescopico (Fig. 21 - at the top of the telescopic boom (Fig. 21 - Kopf des Teleskopauslegers (Abb. 21 -
Rif. A). Ref. A). Bez. A) ausbauen.
Scollegare i tubi in ferro dalla valvola mar- Disconnect the iron tubes from the tilting Die Eisenrohre vom Ventil des Schwenk-
tinetto di brandeggio (Fig. 22 - Rif. B). cylinder valve (Fig. 22 - Ref. B). zylinders abtrennen (Abb. 22 - Bez. B).
Svitare la ghiera (Fig. 23 - Rif. C) di bloc- Unscrew the ring nut (Fig. 23 - Ref. C) for Die Ringmutter (Abb. 23 - Bez. C) zur
caggio perno incernieramento (Fig. 23 - locking the pivot pin (Fig. 23 - Ref. D) on Blockierung des Kippbolzens (Abb. 23 -
Rif. D) lato stelo martinetto brandeggio con the tilting cylinder rod side with quick- Bez. D) auf der Schaftseite des
attacco rapido. release coupling. Schwenkzylinders mit Schnellkupplung los-
Sfilare il perno incernieramento (Fig. 23 - Extract the pivot pin (Fig. 23 - Ref. D) on schrauben.
Rif. D) lato stelo martinetto brandeggio con the tilting cylinder rod side with quick- Den Kippbolzen (Abb. 23 - Bez. D) auf der
attacco rapido. release coupling. Schaftseite des Schwenkzylinders mit
Schnellkupplung herausziehen.
Assicurare l’attacco rapido al carro ponte o Secure the quick-release coupling to a Die Schnellkupplung am Laufkran oder
ad un elevatore. bridge crane or elevator. dem Gabelstapler absichern.
Svitare la vite (Fig. 24 - Rif. E) di bloccag- Unscrew the screws (Fig. 24 - Ref. E) for Die Schraube (Abb. 24 - Bez. E) zur
gio perno di incernieramento attacco rapi- locking quick-release coupling pivot pin Blockierung des Kippbolzens an der
do con braccio 2° sfilo. with 2nd extension boom. Schnellkupplung des 2. Auszugs los-
Sfilare il perno (Fig. 24 - Rif. F) di incernie- Extract the pivot pin (Fig. 24 - Ref. F) for schrauben.
ramento attacco rapido con braccio 2° quick-release coupling with 2nd extension Den Kippbolzen (Abb. 24 - Bez. F) der
sfilo. boom. Schnellkupplung mit dem 2. Auszug her-
ausziehen.
6
MRT 1440-1640 EASY 50
A
A
17 18
19 20
A
B
21 22
E
D
C F
23 24
7
50 MRT 1440-1640 EASY
IT EN DE
Assicurare il martinetto brandeggio (Fig. Secure the tilting cylinder (Fig. 25 - Ref. A) to a Den Schwenkzylinder (Abb. 25 - Bez. A)
25 - Rif. A) al carro ponte o un elevatore. bridge crane or elevator. am Laufkran bzw. dem Gabelstapler absi-
chern.
Svitare la vite di bloccaggio (Fig. 25 - Rif. Unscrew locking screws of (Fig. 25 - Ref. B) 2nd Die Feststellschraube (Abb. 25 - Bez. B)
B) perno di incernieramento martinetto di extension boom tilting cylinder pivot pin. des Kippbolzens am Schwenkzylinder des
brandeggio a braccio 2° sfilo. 2. Auszugs abschrauben.
Extract the pivot pin (Fig. 25 - Ref. C) for quick-
Sfilare il perno (Fig. 25 - Rif. C) di incernie- Den Kippbolzen (Abb. 25 - Bez. C) des
ramento martinetto di brandeggio a braccio release coupling with 2nd extension boom. Schwenkzylinders am 2. Auszug heraus-
2° sfilo. Remove the tilting cylinder (Fig. 25 ziehen.
Togliere il martinetto di brandeggio (Fig. 25

- Rif. A) dalla sede del braccio 2° sfilo. - Ref. A) from the 2nd extension boom housing. Den Schwenkzylinder (Abb. 25 - Bez. A)
aus der Aufnahme im 2. Auszug entfernen.
Die Eisenrohre (Abb. 26 - Bez. D) von den

Dismantle the iron tubes from the hoses (Fig. 26
Smontare i tubi in ferro (Fig. 26 - Rif. D) Schläuchen (Abb. 26 - Bez. E) trennen.
- Ref. D) (Fig. 26 - Ref. E).
dai flessibili (Fig. 26 - Rif. E).
Scollegare i tubi optional dai raccordi pas- Disconnect the optional tubes from the through- Die Zusatzschläuche von den wanddurch-
saparete (Fig. 27 - Rif. F) e liberarli dal connectors (Fig. 27 - Ref. F) and free them from führenden Anschlüssen (Abb. 27 - Bez. F)
collare (Fig. 27 - Rif. G). the collar (Fig. 27 - Ref. G). abklemmen und sie vom Anschlagbund
(Abb. 27 - Bez. G) freigeben.
Smontare la guida tubi flessibili (Fig. 28 - Dismantle the hose guide (Fig. 28 - Ref. H). Die Schlauchführung (Abb. 28 - Bez. H)
Rif. H). ausbauen.
Die Schläuche vom Zylinder des 2.

Scollegare i tubi flessibili dal martinetto 2° Disconnect the hoses from the 2nd extension Auszugs abtrennen (Abb. 28 - Bez. I).
cylinder (Fig. 28 - Ref. I).
sfilo (Fig. 28 - Rif. I).
Scollegare il tubo flessibile dal martinetto Disconnect the hose from the 1st exten- Den Schlauch vom Zylinder des 1.
1° sfilo (Fig. 29 - Rif. A). sion cylinder (Fig. 29 - Ref. A). Auszugs (Abb. 29 - Bez. A) abtrennen.
Collegare il tubo flessibile (Fig. 29 - Rif. B) Connect the hose (Fig. 29 - Ref. B) from Den Schlauch (Abb. 29 - Bez. B) vom
dal tubo in ferro (Fig. 29 - Rif. C). the iron tube (Fig. 29 - Ref. C). Eisenrohr (Abb. 29 - Bez. C) abtrennen.
Smontare i collari che fissano il tubo in Dismantle the collars fixing the iron tube to Die Anschlagbünde entfernen, die das
ferro al braccio (Fig. 30 - Rif. D). the boom (Fig. 30 - Ref. D). Eisenrohr am Ausleger befestigen (Abb. 30
- Bez. D).
Scollegare il tubo in ferro (Fig. 30 - Rif. E) Disconnect the iron tube (Fig. 30 - Ref. E)
dal tubo flessibile (Fig. 30 - Rif. F) all’inter- from the flexible tube (Fig. 30 - Ref. F) Das Eisenrohr (Abb. 30 - Bez. E) vom
no del braccio. inside the boom. Schlauch (Abb. 30 - Bez. F) innerhalb des
Auslegers abtrennen.
Scollegare i tubi in ferro (Fig. 31 - Rif. G) Disconnect the iron tubes (Fig. 31 - Ref. Die Eisenrohre (Abb. 31 - Bez. G) von den
dai tubi flessibili all’interno del braccio (Fig. G) from the flexible tubes inside the boom Schläuchen innerhalb des Auslegers
31 - Rif. H). (Fig. 31 - Ref. H). (Abb. 31 - Bez. H) trennen.
Sfilare i tubi flessibili dal retro del braccio Remove the flexible tubes from the back of Die Schläuche von der Rückseite des
seguendo la sequenza I, L, M, N, O, P the boom by following the sequence I, L, Auslegers her herausziehen, und zwar in
(Fig. 32). M,N,O,P (Fig. 32). der Reihenfolge I, L, M, N, O, P (Abb. 32).
8
MRT 1440-1640 EASY 50
C B
E
E
D
D
25 26
I I
F F
27 28
D
F
E
C
29 30
H
H P M
H O N
H
H
G G
G G L
I
G
31 32
9
50 MRT 1440-1640 EASY
IT EN DE
Smontare i tubi idraulici dal blocco valvola Dismantle the hydraulic pipes from the 1st Die hydraulischen Leitungen vom
del martinetto 1° sfilo (Fig. 33 - Rif. A). extension cylinder valve block (Fig. 33 - Ventilblock des Zylinders des 1. Auszugs
Ref. A). abtrennen (Abb. 33 - Bez. A).
Smontare i raccordi 90° dai tubi in ferro
(Fig. 33 - Rif. B). Dismantle e the 90° connectors from the Die 90° Anschlüsse aus den Eisenrohren
iron tubes (Fig. 33 - Ref. B). abziehen (Abb. 33 - Bez. B).
Smontare dal braccio i raccordi a 90° (Fig. Dismantle the 90° connectors from the Die 90° Anschlüsse aus dem Ausleger ent-
34 - Rif. C). boom (Fig. 34 - Ref. C). fernen (Abb. 34 - Bez. C).
Scollegare il tubo in ferro dal supporto Disconnect the iron tube from the valve Das Eisenrohr vom Träger des Ventils auf
della valvola sul martinetto 1° sfilo (Fig. 35 support on 1st extension cylinder valve dem Zylinders des 1. Auszugs abtrennen
- Rif. D). (Fig. 35 - Ref. D). (Abb. 35 - Bez. D).
Dismantle from the external boom the iron Die Eisenrohre an den Seiten des
Smontare dal braccio esterno i tubi in ferro
tubes on the sides of the 1st extension Zylinders des 1. Auszugs ausbauen, indem
ai lati del martinetto 1° sfilo liberandoli dai
cylinder by freeing them from the collars man die auf der Rückseite von den
collari lato posteriore (Fig. 35 - Rif. E) e
on the back (Fig. 35 - Ref. E) and front Anschlagbünden (Abb. 35 - Bez. E) und
lato anteriore (Fig. 36 - Rif. F), (Fig. 37 -
(Fig. 36 - Ref. F), (Fig. 37 - Ref. 10 - Page 10). auf der Vorderseite von den
Rif. A - Pag. 10).
Anschlagbünden (Abb. 36 - Bez. F), (Abb.
37 - Bez. A - Seite 10) befreit.
Liberare i tubi in ferro dai collari lungo il Free the iron tubes from the collars along Die Eisenrohre aus den Anschlagbünden
braccio esterno (Fig. 35 - Rif. G - Pag. 9) the external boom (Fig. 35 - Ref. G - Page längs des externen Auslegers befreien
e (Fig. 38 - Rif. B). 9) and (Fig. 38 - Ref. B). (Abb. 35 - Bez. G - Seite 9) und (Abb. 38
- Bez. B).
Sfilare il braccio 2° sfilo fino al raggiungi- Extend the 2nd extension boom till it Den 2. Auszug herausziehen, bis man das
mento del foro sul braccio esterno di reaches the hole on the external boom to Loch auf dem externen Auslegerarm
accesso al perno di incernieramento marti- access the 2nd extension cylinder pivoting erreicht, das Zugang zum Kippbolzen des
netto 2° sfilo lato posteriore (Fig. 39 - Rif. pin at the back (Fig. 39 - Ref. C). Zylinders des 2. Auszugs auf der
C). Rückseite gibt (Abb. 39 - Bez. C).
Togliere i seeger dalla sede del perno (Fig. Remove the snap-ring from the pin hous- Die Seegerringe aus dem Bolzensitz ent-
39 - Rif. D). ing (Fig. 39 - Ref. D). fernen (Abb. 39 - Bez. D).
Sfilare il perno di incernieramento marti- Extract the 2nd extension cylinder pivot pin Den Kippbolzen des Zylinders des 2.
netto 2° sfilo lato posteriore (Fig. 39 - Rif. on the back (Fig. 39 - Ref. E). Auszugs auf der Rückseite herausziehen
E). (Abb. 39 - Bez. E).
Sfilare il braccio 2° sfilo fino al raggiungi- Extend the 2nd extension boom to reach Den 2. Auszug herausziehen, bis man den
mento del perno di incernieramento marti- the 2nd extension cylinder pivot pin on the Kippbolzen des Zylinders des 2. Auszugs
netto 2° sfilo lato anteriore (Fig. 40). front (Fig. 40). auf der Vorderseite erreicht (Abb. 40).
Togliere il seeger dalla sede del perno Remove the snap-ring from the pin hous- Die Seegerringe aus dem Bolzensitz ent-
(Fig. 40 - Rif. F). ing (Fig. 40 - Ref. F). fernen (Abb. 40 - Bez. F).
Sfilare il perno di incernieramento martinetto 2° Extract the 2nd extension cylinder pivot pin Den Kippbolzen des Zylinders des 2.
sfilo lato anteriore (Fig. 40 - Rif. G). on the front (Fig. 40 - Ref. G). Auszugs auf der Vorderseite herausziehen
(Abb. 40 - Bez. G).
10
MRT 1440-1640 EASY 50
B C
A
A
33 34
G
D
F
F
E
E
35 36
B
B
A
B
37 38
D
F
E
G
39 40
11
50 MRT 1440-1640 EASY
IT EN DE
Con l’uso del carro ponte o un Using a bridge crane or elevator, remove Den Zylinder des 2. Auszugs mit dem
elevatore togliere il martinetto 2° sfilo the 2nd extension cylinder from the boom. Laufkran bzw. dem Gabelstapler entfernen.
dal braccio.
N.B. Mantenere i tubi flessibili sopra N.B. Keep the flexible tubes above the 2nd Anm.: Während des Herausziehens sind
alla canalina del martinetto 2° sfilo extension cylinder channel during the die Schläuche über dem Kabelkanal des
durantel’estrazione (Fig. 41). extraction (Fig. 41). Zylinders des 2. Auszugs zu halten
(Abb. 41).
Prestare attenzione a contrassegnare Make sure all the pads and shims that are Besonders darauf achten, dass die
tutti i pattini ed eventuali spessori che removed from the telescopic boom are Gleitschuhe und die etwaigen Beilagen,
vengono smontati dal braccio marked, so that they can be refitted die aus dem Teleskopausleger ausgebaut
telescopico per rimontarli correctly. werden, korrekt markiert werden, um sie
correttamente. wieder richtig einbauen zu können.
Alle Auszüge mit der Hilfe eines

Rientrare completamente gli sfili con Retract the extensions completely using a Gabelstaplers wieder vollständig einfahren
l’aiuto di un carrello elevatore. lift truck. lassen.
Smontare tutti i pattini lato posteriore Dismantle all the pads on the back of the Alle Gleitschuhe auf der Rückseite des 2.
del braccio 2° sfilo e i rispettivi spes- 2nd extension and the respective shims Auszugs mit den dazugehörigen Beilagen
sori (Fig. 42 - Rif. A). (Fig. 42 - Ref. A). ausbauen (Abb. 42 - Bez. A).
Sfilare il braccio 2° sfilo di circa 0,5 Extend the 2nd extension boom by about Den 2. Auszug um ca. 0,5 Meter aus dem
metri dal braccio 1° sfilo. 0.5 m from the 1st extension boom. 1. Auszug herausziehen.
Smontare tutti i pattini lato anteriore Dismantle all the pads on the front side of Alle Gleitschuhe auf der Vorderseite des 1.
del braccio 1° sfilo e i rispettivi spes- the 1st extension boom and the respective Auszugs mit den dazugehörigen Beilagen
sori (Fig. 42 - Rif. B). shims (Fig. 42 - Ref. B). ausbauen (Abb. 42 - Bez. B).
Con l’uso del carro ponte o un eleva- Using a bridge crane or elevator, extend Unter Benutzung des Laufkrans bzw. des
tore sfilare il braccio 2° sfilo dal brac- the 2nd extension boom from the 1st Gabelstaplers den 2. Auszug aus dem 1.
cio 1° sfilo (Fig. 43 - Rif. C) prestando extension boom (Fig. 43 - Ref. C) taking
Auszug herausziehen (Abb. 43 - Bez. C),
attenzione ai tubi idraulici nella cana- care to avoid the hydraulic pipes in the
wobei auf die hydraulischen Leitungen im
lina. channel.
Kabelkanal zu achten ist.
Smontare il tassello sul lato superiore Dismantle the insert on the upper back of Den Dübel oben auf der Rückseite des 2.
posteriore del braccio 2° sfilo the 2nd extension boom (Fig. 44 - Ref. D). Auszugs entfernen (Abb. 44 - Bez. D).
(Fig. 44 - Rif. D).
Die 4 Schläuche im Kabelkanal von der
Sfilare i 4 tubi nella canalina dal retro Extract the four tubes in the channel from Rückseite des 2. Auszugs her herauszie-
del braccio 2° sfilo (Fig. 44). the back of the 2nd extension boom hen (Abb. 44).
(Fig. 44).
12
MRT 1440-1640 EASY 50
ANTERIORE POSTERIORE
FRONT REAR
FRONT RÜCK
B A
41 42
C
D
43 44
B FRONT REAR
A FRONT RÜCK
A
C
C
F E
D
45 46

47 48
13
50 MRT 1440-1640 EASY
IT EN DE
Smontaggio del braccio 1° sfilo Dismantling the 1st extension Ausbau des 1. Auszugs aus dem
dal braccio esterno boom from the external boom externen Auslegerarm
Assicurare il martinetto 1° sfilo al Secure the 1st extension boom to a bridge Den Zylinder des 1. Auszugs am Laufkran
carro ponte o un elevatore. crane or elevator. oder dem Gabelstapler absichern.
Con l’apposito attrezzo togliere i Using a special tool, remove the snap Mit dem dazu bestimmten Werkzeug die
seeger dalla sede del perno rings from the pin housing (Fig. 45 - Ref. A). Seegerringer aus dem Bolzen herausneh-
(Fig. 45 - Rif. A). men (Abb. 45 - Bez. A).
Sfilare il perno di incernieramento marti- Extract the front 2nd extension cylinder Den Kippbolzen des Zylindes des 2.
pivot pin (Fig. 45 - Ref. B). Auszugs auf der Vorderseite herausziehen
netto 2° sfilo lato anteriore
(Abb. 45 - Bez. B).
(Fig. 45 - Rif. B).
Using a special tool, remove the snap Mit dem dazu bestimmten Werkzeug die
Con l’apposito attrezzo togliere i see-
rings from the pin housing (Fig. 45 - Ref. Seegerringe aus dem Bolzen herausneh-
ger dalla sede del perno C). men (Abb. 45 - Bez. C).
(Fig. 45 - Rif. C).
Den Kippbolzen des Zylindes des 2.
Sfilare il perno di incernieramento marti- Extract the back 2nd extension cylinder Auszugs auf der Rückseite herausziehen
netto 2° sfilo lato posteriore pivot pin (Fig. 45 - Ref. D). (Abb. 45 - Bez. D).
(Fig. 45 - Rif. D).
Unter Benutzung des Laufkrans oder des
Con l’uso del carro ponte o un eleva- Using a bridge crane or elevator, remove Gabelstaplers den Zylinder des 1. Auszugs
tore togliere il martinetto 1° sfilo dalla the 1st extension cylinder from its housing aus seinem Sitz im Teleskopausleger ent-
sede sul braccio telescopico. on the telescopic boom. fernen.
Smontare tutti i pattini lato posteriore Dismantle all the pads on the back of the Alle Gleitschuhe des Rückseite des 1.
del braccio 1° sfilo e i rispettivi spes- 1st extension boom and the respective Auszugs und die dazugehörigen Beilagen
sori (Fig. 46 - Rif. E). shims (Fig. 46 - Ref. E). ausbauen (Abb. 46 - Bez. E).
Sfilare il braccio 1° sfilo di circa 0,5 Extend the 1st extension boom by about Den 1. Auszug um circa 0,5 Meter aus
metri dal braccio esterno. 0.5 m from the external boom. dem externen Auslegerarm herausziehen.
Smontare tutti i pattini lato anteriore Dismantle all the pads from the front of the Alle Gleitschuhe der Vorderseite des exter-
del braccio esterno e i rispettivi spes- external boom and the respective shims nen Auslegerarms und die dazugehörigen
(Fig. 46 - Ref. F). Beilagen ausbauen (Abb. 46 - Bez. F).
sori (Fig. 46 - Rif. F).
Using a bridge crane or elevator, remove Unter Benutzung eines Laufkrans bzw.
Con l’uso del carro ponte o un eleva-
the 1st extension boom from the external eines Gabelstaplers den 1. Auszug auf
tore sfilare il braccio 1° sfilo dal brac-
boom (Fig. 47 - Ref. G). dem externen Auslegerarm herausziehen
cio esterno (Fig. 47 - Rif. G). (Abb. 47 - Bez. G).
14
MRT 1440-1640 EASY 50
FRONT REAR
B FRONT RÜCK
A
A
C
C
F E
D
45 46

47
15
50 MRT 1440-1640 EASY
IT EN DE
RIMONTAGGIO DEL BRACCIO REASSEMBLING THE ENTIRE TELE- WIEDEREINBAU DES KOMPLETTEN
TELESCOPICO COMPLETO TELESKOPAUSLEGERS
SCOPIC BOOM
ACHTUNG: Jedes Mal, wenn ein Gleitschuh an
ATTENZIONE: Ogni volta che si deve fis- ATTENTION: Each time it is necessary to der Struktur des Auslegers befestigt werden
sare il pattino alla struttura del braccio si fix the pad to the boom frame, proceed as muss, sind die folgenden Montageanleitungen
consigliano le seguenti modalità di mon- follows (Fig. 1) :
taggio (Fig. 1) : zu beachten (Abb. 1):
- insert pad (A) in the working position. - DenGleitschuh(A)inseinenArbeitssitzeinführen.
- inserire il pattino (A) nella sede di lavoro.
- tighten fixing screws (B) leaving a gap of - Die Befestigungsschraube (B) anziehen,
- avvitare la vite di fissaggio (B) lasciando
una distanza di circa 4-5 mm dalla about 4-5 mm from the pad operating wobei ein Abstand von circa 4-5 mm von der
superficie di lavoro del pattino. surface. Arbeitsfläche des Gleitschuhs zu lassen ist.
- bloccare la vite con un dado autobloc- - block the screw using a self-locking nut (C). - Die Schraube mit einer selbstsperrenden
cante (C). Mutter (C) blockieren.
Rimontaggio del braccio 1° sfilo Reassembling the 1st extension boom Wiedereinbau des 1. Auszugs
Il gioco tra i pattini e gli elementi del Clearance between the pads and boom DasSpielzwischendenGleitschuhenundden
braccio é di circa 1 mm. Dopo la elements is about 1 mm. After adjustment, ElementendesAuslegersbeträgtcirca1mm.Nachder
regolazione é importante verificare che check to ensure that there is no excessive Einstellungisteswichtigzuprüfen,dasswährenddes
non si produca del gioco o del blocco
eccessivo durante il rientro o play or block during extension or retraction Aus-undEinfahrensderAuszügekeinSpielentsteht
l’uscita degli sfili. of the boom. odereinzufesterSitzbesteht.
Montare tutti i pattini del braccio 1° sfilo, Fit all the pads of the 1st extension boom, Alle Gleitschuhe des 1. Auszugs der
lato posteriore (Fig. 2 - Rif. D). on the back (Fig. 2 - Ref. D). Rückseite montieren (Abb. 2 - Bez. D).
Ingrassare le superfici interne del braccio Grease the inner surfaces of the external
esterno dove lavoreranno i pattini del 1° sfilo. boom in which the 1st extension pads Die Innenfläche des externen
operate. Auslegerarms schmieren, wo die
Con l’uso del carro ponte o un elevatore
inserire il braccio 1° sfilo nel braccio Using a bridge crane or elevator, insert the Gleitschuhe des 1. Auszugs arbeiten.
esterno lasciandolo fuori di circa 0,5 metri. 1st extension boom in the external boom,
leaving it projecting out by about 0.5 m. Unter Benutzung eines Laufkrans bzw.
Montare gli spessori alti 20 mm e i pattini
nella parte inferiore del braccio esterno, eines Gabelstaplers den 1. Auszug in den
Fit the 20 mm thick shims and the pads in
lato anteriore (Fig. 2 - Rif. E). the lower part of the external boom, at the externen Auslegerarm einstecken und ihn
front (Fig. 2 - Ref. E). circa 0,5 Meter überstehen lassen.
Assicurarsi che il perno di articolazione
braccio esterno (Fig. 3 - Rif. F) sia perfet-
Make sure the external boom pivot pin Die 20 mm hohen Beilagen und die
tamente parallelo alla parte anteriore inter-
na 1° sfilo (Fig. 3 - Rif. G). (Fig. 3 - Ref. F) is perfectly parallel to the Gleitschuhe im unteren Teil des externen
1st extension internal front part (Fig. 3 - Auslegerarms auf der Vorderseite montie-
Spessorare, se necessario, i pattini nella Ref. G). ren (Abb. 2 - Bez. E).
parte inferiore del braccio esterno, lato
anteriore (Fig. 2 - Rif. E). Fit shims if necessary, on the pads in the
Sicherstellen, dass der Gelenkbolzen des
Bloccare i pattini con le viti di fissaggio. front of the external boom, front (Fig. 2 -
externen Auslegerarms (Abb. 3 - Bez. F)
Ref. E).
vollkommen parallel zum inneren Vorderteil
Lock the pads using fixing screws. des 1. Auszugs steht (Abb. 3 - Bez. G).
Die Gleitschuhe im unteren Teil des exter-

nen Arms auf der Vorderseite bei Bedarf
mit Beilagen versehen (Abb. 2 - Bez. E).
Die Gleitschuhe mit den Befestigungs-

schrauben blockieren.
16
MRT 1440-1640 EASY 50
FRONT REAR
A FRONT RÜCK
4-5mm E D
Superficie del braccio
Surfaces of the boom
OberflächeAusleger
1 2
17
50 MRT 1440-1640 EASY
IT EN DE
Inserire i pattini nella parte superiore del braccio Insert the pads in the upper part of the external Die Gleitschuhe in den oberen Teil des
esterno, lato anteriore, spessorarli se necessario boom, in front, fit shims if necessary, and lock in externen Auslegerarms auf der Vorderseite
e bloccarli (Fig. 4 - Rif. A). place (Fig. 4 - Ref. A). stecken, bei Bedarf mit Beilagen versehen
und anziehen (Abb. 4 - Bez. A).
Centrare il braccio 1° sfilo in rapporto al braccio Align the 1st extension boom with respect to the Den 1. Auszug im Bezug zum externen
esterno. Auslegerarm zentrieren.
external boom.
Inserire i pattini laterali B e C nella parte bassa Die seitlichen Gleitschuhe B und C in den
anteriore del braccio 1° sfilo, spessorarli se Insert side pads B and C in the lower front part of
vorderen Teil unten des 1. Auszugs ein-
necessario e bloccarli (Fig. 5). 1st extension boom, fitting shims if necessary, stecken, bei Bedarf mit Beilagen versehen
Inserire i pattini D e E nella parte alta, spessorarli and block them in place (Fig. 5). und anziehen (Abb. 5).
se necessario e bloccarli (Fig. 5). Insert pads D and E in the upper part, fitting Die Gleitschuhe D und E in den oberen
shims if necessary, and block them in place Teil einstecken, bei Bedarf mit Beilagen
N.B. Gli spessori dei pattini B, C, D, E, versehen und anziehen (Abb. 5).
(Fig. 5).
possono essere diversi. Anm.: Die Beilagen der Gleitschuhe B, C,
N.B. Different shims may be used for pads B, C, D, E können verschieden groß sein.
D, and E.
Rientrare completamente il braccio 1° sfilo nel Den 1. Auszug wieder ganz in den exter-
braccio esterno. nen Auslegerarm einfahren.
Retract the 1st extension boom completely into
Assicurarsi che i due pattini (Fig. 5 - Rif. F) the external boom. Sicherstellen, dass die beiden Gleitschuhe
posteriore superiore del braccio 1° sfilo siano (Abb. 5 - Bez. F) hinten oben am 1.
Auszug gut an der oberen Fäche des
ben aderenti alla superficie alta del braccio ester- Make sure the two rear upper pads (Fig. 5 - Ref. externen Auslegerarms anliegen und bei
no spessorando se necessario. F) of the 1st extension boom adhere perfectly to Bedarf Beilagen benutzen.
the upper surface of the external boom, fitting
Bloccare con un morsetto la parte superiore del Den oberen Teil des Teleskopauslegers auf
shims, if necessary.
braccio telescopico, lato posteriore (Fig. 5 - Rif. der Rückseite (Abb. 5 - Bez. G) mit einer
G) per montare i pattini inferiori (Fig. 5 - Rif. H) Spannbacke blockieren, um die unteren
spessorando se necessario. Block the upper part of the telescopic boom by Gleitschuhe (Abb. 5 - Bez. H) zu montie-
means of a clamp, at the back (Fig. 5 - Ref. G) ren. Bei Bedarf Beilagen benutzen.
Bloccare i pattini con le viti di fissaggio. to fit the lower pads (Fig. 5 - Ref. H), using
Die Gleitschuhe mit den
shims, if necessary. Befestigungsschrauben blockieren.
Togliere il morsetto.
Block the pads in place using fixing screws.
Die Spannbacke entfernen.
Centrare il braccio 1° sfilo in rapporto al braccio Remove the clamp.
esterno. Den 1. Auszug auf den externen
Spessorare se necessario i pattini laterali (Rif. I e Align the 1st extension boom with respect to the Auslegerarm zentrieren.
Die seitlichen Gleitschuhe (Bez. I und L -
L - Fig. 6) nella parte bassa poseriore del braccio external boom. Abb. 6) im hinteren Teil unten des 1.
1° sfilo, e bloccarli. If necessary, fit shims on side pads I and L in the Auszugs bei Bedarf mit Beilagen versehen
lower back of the 1st extension boom, and lock und blockieren.
them in place (Fig. 6).
N.B. Gli spessori dei pattini I, L, possono N.B. different shims may be used for the I, and L Anm.: Die Beilagen der Gleitschuhe I, L,
essere diversi. pads. können verschieden groß sein.
Con l’uso del carro ponte o un elevatore Using a bridge crane or elevator, insert the Unter Benutzung eines Laufkrans bzw.
inserire il martinetto 1° sfilo nell’apposita 1st extension cylinder in its housing on the eines Gabelstaplers den Zylinder des 1.
sede sul braccio telescopico. telescopic boom. Auszugs in die Aufnahme auf dem
Teleskopausleger stecken.
Ingrassare il perno di incernieramento Grease the base side 1st extension cylin-
martinetto 1° sfilo lato fondello (Fig. 7 - Rif. der pivot pin (Fig. 7 - Ref. A) and insert it Den Kippbolzen des 1. Auszugs auf der
A) e inserirlo nell’apposito foro nel braccio in the hole provided in the external boom. Seite der Bodenplatte (Abb. 7 - Bez. A)
esterno. schmieren und in das entsprechende Loch
Using the tool provided, fit the snap ring in im externen Auslegerarm stecken.
Con l’apposito attrezzo montare nella sede the pin housing (Fig. 7 - Ref. B).
del perno i seeger (Fig. 7 - Rif. B). Die Seegerringe (Abb. 7 - Bez. B) mit dem
Grease the rod side 1st extension cylinder dafür bestimmten Werkzeug in den Sitz im
Ingrassare il perno di incernieramento pivot pin (Fig. 7 - Ref. C) and insert it in Bolzen montieren.
martinetto 1° sfilo lato stelo (Fig. 7 - Rif. C) the hole provided in the 1st extension
e inserirlo nell’apposito foro del braccio 1° boom. Den Kippbolzen des Zylinder des 1.
sfilo. Auszugs auf der Schaftseite (Abb. 7 - Bez.
Using the tool provided, fit the snap rings C) schmieren und in das entsprechende
Con l’apposito attrezzo montare nella sede in the pin housing (Fig. 7 - Ref. D). Loch im 1. Auszug stecken.
del perno i seeger (Fig. 7 - Rif. D).
Die Seegerringe (Abb. 7 - Bez. D) mit dem
dafür bestimmten Werkzeug in den Sitz im
Bolzen montieren.
18
MRT 1440-1640 EASY 50
ANTERIORE POSTERIORE ANTERIORE POSTERIORE

FRONT REAR FRONT REAR
FRONT RÜCK FRONT RÜCK
D E F F
G
A
H
B C
4 5
FRONT REAR
FRONT RÜCK C
D
D
B
B
A
I L
6 7
19
50 MRT 1440-1640 EASY
IT EN DE
Montaggio del braccio 2° sfilo nel Assembling the 2nd extension boom in Montage des 2. Auszugs in den 1.
1° sfilo the 1st extension Auszug
Appoggiare il braccio 2° sfilo su due cavalletti Rest the 2nd extension boom on two Den 2. Auszug mit dem nach unten zeigenden
stands with the “TS” connection facing Anschluss des “TS” auf zwei Böcke legen.
con l’attacco del “TS” rivolto verso il basso.
downwards.
Auf jedem Schlauch für die hydraulischen
Segnare un riferimento su ogni tubo flessibile per Steuerungen von Schwenkung und Optionen
i comandi idraulici del brandeggio e optional a Mark a reference on each flexible tube for
ausgehend vom 90° Anschluss eine Markierung
partire dal raccordo 90° (Fig. 8). the tilting and optional hydraulic controls
anbringen (Abb. 8).
starting from the 90° connector (Fig. 8).
Legare insieme i 4 tubi flessibili per i comandi Die 4 Schläuche für die hydraulischen
idraulici del brandeggio e optional ed infilarli all’in- Steuerungen der Schwenkung und der Optionen
terno della canalina del braccio 2° sfilo dal retro Tie the four flexible tubes for the tilting and zusammenbinden und in den Kabelkanal des 2.
del braccio all’attacco rapido fino al raggiungi- optional hydraulic controls together and pass Auszugs stecken, und zwar von der Rückseite
mento del riferimento in corrispondenza del tas- them through the 2nd extension boom chan- des Auslegers an der Schnellkupplung bis zum
sello (Fig. 9 - Rif. A). nel from the back of the boom to quick- Erreichen des Bezugs auf der Höhe des Dübels
release coupling, till the reference mark on (Abb. 9 - Bez. A).
Assicurarsi che tutti i tubi siano orientati con il the insert is reached (Fig. 9 - Ref. A).
raccordo 90° rivolto verso l’alto (Fig. 10) e fissarli Sicherstellen, dass alle Schläuche so ausgerich-
con il tassello sul lato uperiore posteriore del Make sure that all the tubes are oriented tet sind, dass der 90° Anschluss nach oben zeigt
braccio 2° sfilo (Fig. 9 - Rif. B). with the 90° connector facing upwards (Abb. 10) und sie mit dem Dübel auf der oberen
(Fig.10) and fix them by means of the Seite hinten am 2. Auszug befestigen (Abb. 9 -
Inserire la restante parte all’interno del braccio 2° insert on the upper back of the 2nd exten- Bez. B).
sfilo (Fig. 11). sion boom (Fig. 9 - Ref. B).
Den restlichen Teil in das Inneres des 2.
Auszugs stecken (Abb. 11).
Montare tutti i pattini del braccio 2° sfilo, lato Insert the remaining part into the 2nd
extension boom (Fig. 11).
posteriore (Fig. 12 - Rif. A)
Alle Gleitschuhe des 2. Auszugs auf der
Fit all the pads of the 2nd extension boom, at the Rückseite montieren (Abb. 12 - Bez. A)
Ingrassare le superfici interne del braccio 1° sfilo
dove lavoreranno i pattini del braccio 2° sfilo. back (Fig. 12 - Ref. A)
Die Innenflächen des 1. Auszugs dort schmie-
Grease the inner surfaces of the 1st extension ren, wo die Gleitschuhe des 2. Auszugs arbeiten
Con l’uso del carro ponte o un elevatore inserire werden.
il braccio 2° sfilo nel braccio 1° sfilo lasciandolo boom where the pads of the 2nd extension
fuori di circa 0,5 metri. boom will operate. Mit der Hilfe eines Laufkrans bzw. eines
Gabelstaplers den 2. Auszug in den 1. Auszug
Montare gli spessori alti 3 mm e i pattini nella Using a bridge crane or elevator, insert the 2nd stecken, ihn aber um circa 0,5 Meter überstehen
parte inferiore del braccio 1° sfilo, lato anteriore lassen.
extension boom in the 1st extension boom, leav-
(Fig. 12 - Rif. B). ing it to project out by about 0.5 m. 3 mm hohe Beilagen und die Gleitschuhe im
unteren Teil des 1. Auszugs auf der Vorderseite
Assicurarsi che il perno di articolazione montieren (Abb. 12 - Bez. B).
Fit the 3 mm thick shims and the pads in the
braccio esterno (Fig. 13 - Rif. C) sia perfet-
lower part of the 1st extension boom, at the front
tamente parallelo al perno di incerniera- Sicherstellen, dass der Gelenkbolzen des exter-
mento “TS” sul braccio 2° sfilo (Fig. 13 - (Fig. 12 - Ref. B). nen Auslegerarms (Abb. 13 - Bez. C) vollkom-
Rif. D). men parallel zum Kippbolzen “TS” auf dem 2.
Make sure the external boom pivot pin (Fig. 13 - Auszug steht (Abb. 13 - Bez. D).
Spessorare, se necessario, i pattini nella parte Ref. C) is perfectly parallel to the “TS” pivot pin
on the 2nd extension boom (Fig. 13 - Ref. D). Die Gleitschuhe im unteren Teil des 1. Auszugs
inferiore del braccio 1° sfilo, lato anteriore auf der Vorderseite bei Bedarf mit Beilagen ver-
(Fig. 12 - Rif. B). sehen (Abb. 12 - Bez. B).
If necessary, fit shims to the pads in the lower
part of the 1st extension boom, in front (Fig. 12 -
Bloccare i pattini con le viti di fissaggio. Die Gleitschuhe mit den Befestigungsschrauben
Ref. B). blockieren.
Rientrare completamente il braccio 2° sfilo nel Lock the pads in place using fixing screws. 2. Auszug ganz in 1. Auszug einschieben.
braccio 1° sfilo.
Retract the 2nd extension boom completely into Sicherstellen, dass die beiden Gleitschuhe
Assicurarsi che i due pattini (Fig. 14 - Rif. the 1st extension boom. (Abb. 14 - Bez. E) hinten oben des 2. Auszugs
E) posteriore superiore del braccio 2° sfilo ganz an der oberen Oberfläche des 1. Auszugs
siano ben aderenti alla superficie alta del Ensure that the two pads (Fig. 14 - Ref. E) in the anliegen. Bei Bedarf Beilagen verwenden.
braccio 1° sfilo spessorando se necessario. upper back of the 2nd extension boom adhere
Den oberen Teil des Teleskopauslegers auf der
perfectly to the upper surface of the 1st exten- Rückseite (Abb. 14 - Bez. F) mit einer
Bloccare con un morsetto la parte superio- sion boom, and fit shims, if necessary. Spannbacke blockieren und die unteren
re del braccio telescopico, lato posteriore Gleitbacken (Abb. 14 - Bez. G) bei Bedarf mit
(Fig. 14 - Rif. F) per spessorare i Block the upper part of the telescopic boom Beilagen versehen.
pattini inferiori (Fig. 14 - Rif. G) se necessario. using a clamp, at the back (Fig. 14 - Ref.
F) fitting shims on the lower pads (Fig.14- Die Gleitschuhe mit den Befestigungsschrauben
Bloccare i pattini con le viti di fissaggio. Ref. G) if necessary. blockieren.
Block the pads in place using fixing screws. Die Spannbacke entfernen.
Togliere il morsetto.
Remove the clamp.
20
MRT 1440-1640 EASY 50
A
A
MRT 1440-1640 = 4,87 mt A
A
8 9
10 11
13
B A C
D
12
FRONT REAR
FRONT RÜCK
E E
F
14
21
50 MRT 1440-1640 EASY
IT EN DE
Centrare il braccio 2° sfilo in rapporto al braccio Align the 2nd extension boom with respect Den 2. Auszug auf den 1. Auszug zentrie-
1° sfilo. to the 1st extension boom. ren. Die seitlichen Gleitschuhe (Bez. A und
Spessorare se necessario i pattini laterali (Rif. A If necessary, fit shims on lateral pads A B - Abb. 15) im unteren Teil hinten auf dem
e B - Fig. 15) nella parte bassa poseriore del and B in the lower back of the 1st exten- 1. Auszug bei Bedarf mit Beilagen verse-
braccio 1° sfilo, e bloccarli. sion boom, and lock the pads in place hen und sie dann blockieren.
(Fig. 15).
N.B. Gli spessori dei pattini A, B, possono
essere diversi. N.B. different shims may be used for pads Anm.: Die Beilagen der Gleitschuhe A, B,
A and B. können verschieden groß sein.
Sfilare circa 0,5 metri il braccio 2° sfilo dal
braccio 1° sfilo. Extend the 2nd extension boom by about Den 2. Auszug um circa 0,5 Meter aus
0.5 m from the 1st extension boom. dem 1. Auszug herausziehen.
Inserire i pattini nella parte superiore del braccio Insert the pads in the upper part of 1st
1° sfilo, lato anteriore, spessorarli se necessario extension boom, in the front, use shims if Die Gleitschuhe im oberen Teil des 1.
e bloccarli (Fig. 16 - Rif. C). necessary, and lock them in place (Fig. 16 Auszugs auf der Vorderseite einstecken
- Ref. C). und bei Bedarf mit Beilagen versehen. Sie
dann blockieren(Abb. 16 - Bez. C).
Centrare il braccio 2° sfilo in rapporto al braccio Align the 2nd extension boom with respect
1° sfilo. to the 1st extension boom. Den 2. Auszug auf den 1. Auszug
Inserire i pattini laterali (Rif. D e E - Fig. 17) nella Insert the lateral pads D and E in the front zentrieren.
parte bassa anteriore del braccio 1° sfilo, spes- lower part of the 1st extension boom, Die seitlichen Gleitschuhe (Bez. D und E -
sorarli se necessario e bloccarli. using shims if necessary, and block them Abb. 17) in den unteren Teil vorn des 1.
Inserire i pattini (Rif. F e G - Fig. 17) nella parte in place (Fig. 17). Auszugs bei Bedarf mit Beilagen versehen
alta, spessorarli se necessario e bloccarli. Insert pads F and G in the upper part und sie blockieren.
using shims if necessary, and block them Die Gleitschuhe (Bez. F und G - Abb. 17)
N.B. Gli spessori dei pattini D, E, F, G, in place (Fig. 17). im oberen Teil einstecken, die bei Bedarf
possono essere diversi. mit Beilagen versehen und blockieren.
N.B. Different shims may be used for pads
D, E, F and G. Anm.: Die Beilagen der Gleitschuhe D, E,
F, G können verschieden groß sein.
Sfilare la restante parte dei 4 tubi inseriti prece- Extract the remaining part of the four tubes
dentemente dal retro del braccio 2° sfilo tenen- inserted earlier from the back of the 2nd Die vorher eingesteckten restlichen 4
doli ai lati del braccio (Fig. 18). extension boom, keeping them along the Schläuche von der Rückseite des 2.
sides of the boom (Fig. 18). Auszugs her herausziehen und sie an den
Seiten des Auslegers halten (Abb. 18).
Con l’uso del carro ponte o un elevatore inserire
il martinetto 2° sfilo dentro al braccio telescopico.
Using a bridge crane or elevator, insert the
2nd extension cylinder into the telescopic Mit der Hilfe des Laufkrans bzw. des
N.B. Mantenere i tubi flessibili sopra alla Gabelstaplers den Zylinder des 2. Auszugs
canalina del martinetto 2° sfilo durante boom.
in den Teleskopausleger einstecken.
l’inserimento (Fig. 19).
N.B. Keep the flexible tubes above the 2nd
extension cylinder channel during the inser- Anm.: Die Schläuche während dieses
tion (Fig. 19). Vorgangs über dem Kabelkanal des
Zylinders des 2. Auszugs halten (Abb. 19).
Ingrassare il perno di incernieramento martinetto
2° sfilo lato stelo (Fig. 20 - Rif. A) e inserirlo nel- Grease the rod side 2nd extension cylinder
l’apposito foro del braccio 2° sfilo. pivot pin (Fig. 20 - Ref. A) and insert it in the Den Kippbolzen des Zylinders des 2.
hole provided in the 2nd extension boom. Auszugs auf der Schaftseite (Abb. 20 -
Bez. A) schmieren ind die das entspre-
Montare nelle sedi del perno gli anelli seeger Fit the snap rings in the pin housing chende Loch im 2. Auszug stecken.
(Fig. 20 - Rif. B). (Fig. 20 - Ref. B).
Die Seegerringe in die Bolzen montieren
Retract the 2nd extension boom into 1st (Abb. 20 - Bez. B).
Rientrare il braccio 2° sfilo nel braccio 1° sfilo fino extension boom till the base side 1st exten-
all’allineamento del foro del perno di incerniera- sion cylinder pivot pin hole is perfectly lined Den 2. Auszug in den 1. Auszug einfahren,
mento martinetto 1° sfilo lato fondello. up. bis das Loch des Kippbolzens des
Zylinders des 1. Auszugs auf der Seite der
Grease the base side 1st extension cylinder Bodenplatte ausgerichtet ist.
Ingrassare il perno di incernieramento martinetto pivot pin (Fig. 20 - Ref. C) and insert it in the
1° sfilo lato fondello (Fig. 20 - Rif. C) e inserirlo hole provided in the 1st extension boom. Den Kippbolzen des Zylinders des 1.
nell’apposito foro nel braccio 1° sfilo. Auzugs auf der Bodenseite schmieren
(Abb. 20 - Bez. C) und in das entsprechen-
Fit the snap rings in the pin housing de Loch im 1. Auszug stecken.
Montare nelle sedi del perno gli anelli seeger (Fig. 20 - Ref. D).
(Fig. 20 - Rif. D). Die Seegerringe in die Bolzen montieren
(Abb. 20 - Bez. D).
Fit the respective iron tubes on the sides of
Montare i rispettivi tubi in ferro ai lati del martinet- the 1st extension cylinder and fix them to Die entsprechenden Eisenrohre an den
to 1° sfilo e fissarli al braccio esterno tramite gli the external boom by means of special col- Seiten des Zylinders des 1. Auszugs mon-
appositi collari lato anteriore (Fig. 21 - Rif. E), lars in front (Fig. 21 - Ref. E), (Fig. 22 - Ref. tieren und sie mit den Anschlagbünden der
(Fig. 22 - Rif. F) e lato posteriore (Fig. 23 - Rif. A F) and at the back (Fig. 23 - Ref. A - Page 25). Vorderseite (Abb. 21 - Bez. E), (Abb. 22 -
- Pag. 25). Bez. F) und der Rückseite (Abb. 23 - Bez.
A - Seite 20) am externen Auslegerarm
befestigen.
22
MRT 1440-1640 EASY 50
ANTERIORE POSTERIORE ANTERIORE POSTERIORE

FRONT REAR FRONT REAR
FRONT RÜCK FRONT RÜCK
C
A
B
15 16
FRONT REAR
FRONT RÜCK
G
F
E
D
17 18
A
B
B
D
C
19 20
E
E
F
21 22
23
50 MRT 1440-1640 EASY
IT EN DE
Fissare i tubi in ferro al centro del braccio Fix the iron tubes to the middle of the Die Eisenrohre am Mittelpunkt des exter-
esterno tramite gli appositi collari (Fig. 23 - external boom using collars (Fig. 23 - Ref. nen Auslegerarms mit den entsprechenden
Rif. B) e (Fig. 24 - Rif. C). B) and (Photo 24 - Ref. C). Anschlagbünden (Abb. 23 - Bez. B) und
(Abb. 24 - Bez. C) befestigen.
Collegare il tubo in ferro al supporto della Connect the iron tube to the valve support Das Eisenrohr am Träger des Ventils auf
valvola sul martinetto 1° sfilo (Fig. 23 - Rif. on the 1st extension cylinder (Fig. 23 - dem Zylinder des 1. Auszugs befestigen
D). Ref. D). (Abb. 23 - Bez. D).
Montare sul braccio i raccordi a 90° (Fig. Fit the 90° connectors on the boom (Fig. Die 90° Anschlüsse am Auslegerarm mon-
25 - Rif. E). 25 - Ref. E). tieren (Abb. 25 - Bez. E).
Collegare i tubi idraulici alla valvola del Connect the hydraulic pipes to the 1st Die hydraulischen Leitungen am Ventil des
martinetto 1° sfilo (Fig. 26 - Rif. F) e ai rac- extension cylinder valve (Fig. 26 - Ref. F) Zylinders des 1. Auszugs (Abb. 26 - Bez.
cordi a 90° (Fig. 26 - Rif. G). and the 90° connections (Fig. 26 - Ref. G). F) und an den 90° Anschlüssen befestigen
(Abb. 26 - Bez. G).
Montare i raccordi 90° sui tubi in ferro (Fig. Fit the 90° connectors on the iron tube
26 - Rif. H). (Fig. 26 - Ref. H). Die 90° Anschlüsse an den Eisenrohren
befestigen (Abb. 26 - Bez. H).
Inserire i tubi flessibili dal retro del braccio Insert the flexible tubes through the back Die Schläuse von der Rückseite des
seguendo la sequenza (Rif. A, B, C, D - of the boom following sequence A, B, C, D Auslegers einstecken, und zwar in der vor-
Fig. 27) collegandoli ai tubi in ferro (Fig. 27) connecting them to the iron tubes gesehenen Reihenfolge (Bez. A, B, C, D -
seguendo sempre la sequenza (Rif. E, F, using sequence E, F, G, H (Fig. 28). Abb. 27), indem man die immer in der vor-
G, H Fig. 28). gesehenenen Reihenfolge (Bez. E, F, G, H
Abb. 28) an den Eisenrohren anschließt.
Inserire i tubi flessibili dal retro del braccio Insert the flexible tube from the back of the Die Schläuche von der Rückseite des
seguendo la sequenza (Rif. I, L - Fig. 29). boom by following sequence I, L (Fig. 29). Auslegers einstecken, und zwar in der vor-
gesehenen Reihenfolge (Bez. I, L - Abb.
29).
Collegare il flessibile (Fig. 29 - Rif. I) al Connect the flexible tube (Fig. 29 - Ref. I) Den Schlauch (Abb. 29 - Bez. I) an das
tubo in ferro (Fig. 30 - Rif. M). to the iron tube (Fig. 30 - Ref. M). Eisenrohr (Abb. 30 - Bez. M) anschließen.
24
MRT 1440-1640 EASY 50
B
D C
C
C
A
A C
23 24
E H
G
G
F
F
25 26
F
G
A E H
C
27 28
L M
I
29 30
25
50 MRT 1440-1640 EASY
IT EN DE
Collegare il tubo flessibile (Fig. 29 - Rif. L Connect the flexible tube (Fig. 29 - Ref. L - Den Schlauch (Abb. 29 - Bez. L Seite 19)
Pag. 19) al tubo in ferro (Fig. 31- Rif. A). Page 21) to the iron tube (Fig. 31- Ref. A). am Eisenrohr (Abb. 31- Bez. A) ansch-
ließen.
Fissare il tubo in ferro al braccio tramite gli Fix the iron tube to the boom by means of
appositi collari (Fig. 31 - Rif. B). collars (Fig. 31 - Ref. B). Das Eisenrohr am Ausleger mit den dafür
vorgesehenen Anschlagbünden befestigen
(Abb. 31 - Bez. B).
Collegare il tubo flessibile al martinetto 1° Connect the flexible tube to the 1st exten-
sfilo (Fig. 32 - Rif. C). sion cylinder (Fig. 32 - Ref. C). Den Schlauch am Zylinder des 1. Auszugs
anschließen (Abb. 32 - Bez. C).
Collegare il tubo in ferro (Fig. 32 - Rif. D) Connect the iron tube (Fig. 32 - Ref. D) to
al tubo flessibile (Fig. 32 - Rif. E). the flexible tube (Fig. 32 - Ref. E). Das Eisenrohr (Abb. 32 - Bez. D) am
Schlauch (Abb. 32 - Bez. E) anschließen.
Collegare i tubi flessibili al martinetto 2° Connect the flexible tubes to the 2nd Die Schläuche am Zylinder des 2. Auszugs
sfilo (Fig. 33 - Rif. F). extension cylinder (Fig. 33 - Ref. F). anschließen (Abb. 33 - Bez. F).
Montare la guida tubi flessibili (Fig. 33 - Fit the flexible tubes guide (Fig. 33 - Ref. G). Die Schlauchführung montieren (Abb. 33 -
Rif. G). Bez. G).
Collegare i tubi optional ai raccordi passa- Connect the optional tubes to the through- Die Schläuche der Optionen an den wand-
parete (Fig. 34 - Rif. H) e bloccarli con connectors (Fig. 34 - Ref. h) and block them durchführenden Anschlüssen (Abb. 34 -
l’apposito collare (Fig. 34 - Rif. I). by means of the collar (Fig. 34 - Ref. I). Bez. H) anschließen und mit dem dafür
vorgesehehen Anschlagbund blockieren
(Abb. 34 - Bez. I).
Montare i tubi in ferro orientati verso i rac- Fit the iron tubes oriented towards the
cordi attacchi rapidi (Fig. 35 - Rif. A/B) : quick-release couplings (Fig. 35 - Ref. A/B) : Die Eisenrohre in Richtung auf die
- montare il tubo in ferro (Fig. 35 - Rif. A) - fit the iron tube (Fig. 35 - Ref. A) with the Anschlüsse der Schnellkupplungen mon-
col flessibile (Fig. 36 - Rif. C); flexible tube (Fig. 36 - Ref. C); tieren (Abb. 35 - Bez. A/B) :
- montare il tubo in ferro (Fig. 35 - Rif. B) - fit the iron tube (Fig. 35 - Ref. B) with the - Das Eisenrohr (Abb. 35 - Bez. A) mit dem
col flessibile (Fig. 36 - Rif. D). flexible tube (Fig. 36 - Ref. D). Schlauch (Abb. 36 - Bez. C) montieren;
- das Eisenrohr (Abb. 35 - Bez. B) mit dem
Schlauch (Abb. 36 - Bez. D) montieren.
Inserire nella sede del braccio telescopico Insert the tilting cylinder in the telescopic
il martinetto di brandeggio (Fig. 37). boom housing (Fig. 37).
Den Schwenkzylinder in seine Aufnahme
im Teleskopausleger stecken (Abb. 37).
Avvitare i tubi in ferro circa di 2 giri di filet- Tighten the iron tube by about two turns of
to alla valvola sul martinetto di brandeggio: the thread to the valve on the tilting cylin- Die Eisenrohre circa um 2 Gewinde-
- montare il tubo in ferro (Fig. 35 - Rif. A) der: umdrehungen am Ventil auf dem
col raccordo (Fig. 38 - Rif. E); - fit the iron tube (Fig. 35 - Ref. A) with the Schwenkzylinder anschrauben:
- montare il tubo in ferro (Fig. 35 - Rif. B) connection (Fig. 38 - Ref. E); - Das Eisenrohr (Abb. 35 - Bez. A) mit dem
col raccordo (Fig. 38 - Rif. F). - fit the iron tube (Fig. 35 - Ref. B) with the Anschluss (Abb. 38 - Bez. E) montieren;
connection (Fig. 38 - Ref. F). - das Eisenrohr (Abb. 35 - Bez. B) mit dem
Anschluss (Abb. 38 - Bez. F) montieren.
26
MRT 1440-1640 EASY 50
D
A
31 32
F F H H
33 34
C D
B
A
35 36
37 38
27
50 MRT 1440-1640 EASY
IT EN DE
Ingrassare il perno di incernieramento Grease the tilting cylinder pivot pin to the 2nd Den Kippbolzen des Schwenkzylinders
martinetto di brandeggio a braccio 2° sfilo extension boom (Fig. 39 -Ref. A) and insert it am 2. Auszug (Abb. 39 -Bez. A) schmieren
(Fig. 39 -Rif. A) e inserirlo nell’apposito in the hole provided. und in das entsprechende Loch stecken.
foro.
Avvitare la vite di fermo perno Tighten the pin stop screws (Fig. 39 - Ref. B). Die Feststellschraube des Bolzens anzie-
(Fig. 39 - Rif. B). hen (Abb. 39 - Bez. B).
Con l’ausilio del carro ponte inserire Using a bridge crane, insert the quick- Mit der Hilfe des Laufkrans die
l’attacco rapido nella sede sul braccio 2° release coupling in the housing on the 2nd Schnellkupplung in die Aufnahme im 2.
sfilo. extension boom. Auszug stecken.
Grease the pivot pin for quick-release cou- Den Kippbolzen der Schnellkupplung mit
Ingrassare il perno di incernieramento pling with 2nd extension boom (Fig. 40 - 2. Auszug (Abb. 40 - Bez. C) schmieren
attacco rapido con braccio 2° sfilo (Fig. 40 Ref. C) and insert it in the hole provided. und in das entsprechende Loch stecken.
- Rif. C) e inserirlo nell’apposito foro. Tighten the quick-release coupling pivot Die Feststellschraube des Kippbolzens der
Avvitare la vite di bloccaggio perno incerniera- pin locking screw (Fig. 40 - Ref. D). Schnellkupplung anschrauben (Abb. 40 -
mento attacco rapido (Fig. 40 - Rif. D). Bez. D).
Grease the tilting cylinder rod side pivot Den schaftseitigen Kippbolzen des
Ingrassare il perno di incernieramento lato pin with quick-release coupling and insert it Schwenkzylinders mit der Schnellkupplung
stelo martinetto brandeggio con attacco in the hole provided (Fig. 41 - Ref. E). schmieren und in das entsprechende Loch
rapido e inserirlo nell’apposito foro (Fig. 41 Tighten the cylinder pivot pin lock nut (Fig. stecken (Abb. 41 - Bez. E).
- Rif. E). 41 - Ref. F). Die Ringmutter zum Blockieren des
Avvitare la ghiera di bloccaggio perno Zylinderkippbolzens anschrauben (Abb. 41
incernieramento martinetto (Fig. 41 - Rif. F). - Bez. F).
Fit the iron tubes correctly to the valve on Die Eisenrohre am Ventil auf dem
Serrare correttamente i tubi in ferro alla the tilting cylinder (Fig. 42 - Ref. G). Schwenkzylinder korrekt anziehen (Abb.
valvola sul martinetto di brandeggio (Fig. 42 - Bez. G).
42 - Rif. G).
Fit the 1st extension cylinder guard at the Den Schutz des Zylinders des 1. Auszugs
Montare la protezione martinetto 1° sfilo in top of the telescopic boom (Fig. 43 - Ref. A). am Kopf des Teleskopauslegers montieren
testa al braccio telescopico (Fig. 43 - Rif. A). (Abb. 43 - Bez. A).
Fit the chainholder tube (Fig. 44 - Ref. B) Das Kettentragerohr (Abb. 44 - Bez. B) auf
Montare il tubolare portacatene (Fig. 44 - on the left side of the external boom. der rechten Seite des externen
Rif. B) sul lato destro del braccio esterno. Auslegerarms montieren.
Fit the duct support forks on the 1st and Die Traggabeln des Kabelkanals auf dem
Montare le forcelle di supporto canalina su 2nd extension (Fig. 45 - Ref. C). 1. und 2. Auszug montieren (Abb. 45 -
I° e II° sfilo (Fig. 45 - Rif. C). Bez. C).
IMPORTANT: Fit the gaskets on the ends WICHTIG: In den Kettentragerohren die
IMPORTANTE: Nei tubolari portacatena of the chainholder tubular elements to kantenabdeckenden Dichtungen an den
mettere delle guarnizioni copribordo alle cover the edges as these can cut through Rohrenden anbringen, welche die hydrauli-
estremità che si potrebbero rivelare the hydraulic tubes (Fig. 45 - Ref. D). schen Leitungen beschädigen könnten
taglienti per i tubi idraulici (Fig. 45 - Rif. D). (Abb. 45 - Bez. D).
Montare il pattino basculante (Fig. 46 - Rif. Fit the pivoting pad (Fig. 46 - Ref. E) on Den kippenden Gleitschuh (Abb. 46 - Bez.
E) sulla forcella del I° sfilo. the 1st extension fork. E) auf der Gabel des 1. Auszugs montie-
ren.
28
MRT 1440-1640 EASY 50
A B
C
39 40
E G
41 42
43 44
E
C
45 46
29
50 MRT 1440-1640 EASY
IT EN DE
Montare la catena portatubi fissandola Fit the tubeholder chain by fixing it in the Die Schlauchtragekette montieren und am
nella parte anteriore del tubolare portaca- front part of the chainholder tube (Fig. 47). vorderen Teil des Kettentragerohr befesti-
tene (Fig. 47). gen (Abb. 47).
Stendere completamente la catena porta- Stretch the tubeholder chain completely on Die Schlauchtragekette ganz im
tubi sul tubolare portacatene (Fig. 48). the chainholder tube (Fig. 48). Kettentragerohr auslegen (Abb. 48).
Infilare all’interno del tubolare, da dietro

(Fig. 49), i cavi per la presa cestello e il Insert the cables for the basket socket and Von hinten her (Abb. 49) die Kabel für die
tubo idraulico per il drenaggio in testa al the hydraulic drainage tube at the top of Steckdose der Bühne und die hydraulische
braccio. the boom into the tube (Fig. 49), form the Leitung für den Rücklauf am Kopf des
back. Auslegerarms in das Rohr stecken.
Farli uscire dalla parte anteriore e stenderli When it comes out from the front part, Sie auf der Vorderseite austreten lassen
(Fig. 50). extend it (Fig. 50). und verliegen (Ann. 50).
Montare il piastrino (Fig. 51 - Rif. A) per Fit the plate (Fig. 51 - Ref. A) for the elec- Die Platte (Abb. 51 - Bez. A) für die elektri-
presa elettrica nella parte posteriore destra trical socket at the back on the right side of sche Steckdose rechts im hinteren Teil des
del braccio esterno. the external boom externen Auslegerarms montieren.
Attaccare la spina multipresa elettrica (Fig. Connect the basket electric multipin socket Die Mehrfachsteckdose (Abb. 51 - Bez. B)
51 - Rif. B) per il cestello all’apposito pia- (Fig. 51 - Ref. B) to the plate provided für die Bühne an der dafür bestimmten
strino (Fig. 51 - Rif. A). (Fig. 51 - Ref. A). Platte anschließen (Abb. 51 - Bez. A).
Proteggere con una guaina (Fig. 52 - Rif. Protect the electric cables by means of a Die elektrischen Kabel mit einer Kabelhülle
C) i cavi elettrici, raggruppandoli, per un sheath (Fig. 52 - Ref. C) grouping them schützen (Abb. 52 - Bez. C) , wobei man
tratto di circa 40-50 cm all’uscita anteriore together to a section about 40-50 cm at sie über eine Strecke von circa 40-50 cm
del tubolare. Fare la stessa operazione the outlet in front of the tube. Repeat the am vorderen Rohrausgang zusammenfas-
con il tubo idraulico per il drenaggio. operation with the hydraulic drainage tube. st. Den gleichen Vorgang mit der hydrauli-
schen Rücklaufleitung vornehmen.
Nella parte posteriore del tubolare blocca- Block the electric cables and the hydraulic Die elektrischen Kabel und die hydrauli-
re i cavi elettrici e il tubo idraulico con il tube at the back of the tube by means of sche Leitung mit dem Anschlagbund (Abb.
collare (Fig. 53 - Rif. D) le fascette (Fig. 53 the collar (Fig. 53 - Ref. D) and clamps 53 - Bez. D) und den Kabelbindern (Abb.
- Rif. E). (Fig. 53- Ref. E). 53 - Bez. E) im hinteren Teil des Rohrs
befestigen.
Nella parte anteriore infilare i cavi elettrici Insert the electric cables and hydraulic Die elektrischen Kabel und die hydrauli-
e il tubo idraulico all’interno della catena tube through the tubeholder chain in the sche Leitung im vorderen Teil in das
portatubi (Fig. 54 - Rif. F). front (Fig. 54 - Rif. F). Innere der Schlauchtragekette stecken
(Abb. 54 - Bez. F).
30
MRT 1440-1640 EASY 50
47 48

49 50
B
C
51 52

E
D
E
E
E
E
F
E
53 54
31
50 MRT 1440-1640 EASY
IT EN DE
Montare la fascetta (Fig. 55 - Rif. A) per Fit the clamp (Fig. 55 - Ref. A) to block the Den Kabelbinder (Abb. 55 - Bez. A) zum
bloccare i cavi elettrici e il tubo idraulico electric cables and hydraulic tube on the Blockieren der elektrischen Kabel und die
sul tubolare supporto catena. chain support tube. hydraulische Leitung auf dem
Kettentragerohr montieren.
Montare la canalina (Fig. 56 - Rif. B) con Fit the channel (Fig. 56 - Ref. B) using the Den Kabelkanal (Abb. 56 - Bez. B) mit den
gli appositi perni (Fig. 56 - Rif. C/D) sulle pins provided (Fig. 56 - Ref. C/D) on the dafür bestimmten Bolzen (Abb. 56 - Bez.
forcelle nella parte anteriore del braccio. forks in the front of the boom. C/D) auf den Gabeln im vorderen Teil des
Auslegerarms montieren.
Nella parte posteriore della canalina infila- Insert the electric cables and hydraulic Die elektrischen Kabel und die hydrauli-
re i cavi elettrici e il tubo idraulico tube in the back of the channel (Fig. 57 - sche Leitung (Abb. 57 - Bez. E) in den
(Fig. 57 - Rif. E). Rif. E). hinteren Teil des Kabelkanals stecken.
Nella parte posteriore della canalina fissa- Fix the tubeholder chain by means of Die Schlauchtragekette mit den Schrauben
re la catena portatubi con le viti screws (Fig. 58 - Ref. F) in the back of the (Abb. 58 - Bez. F) im hinteren Teil des
(Fig. 58 - Rif. F). channel. Kabelkanals befestigen.
Die elektrischen Kabel mit einer Kabelhülle

Proteggere con una guaina (Fig. 59 - Rif. Protect the electric cables with a sheath
(Abb. 59 - Bez. A) schützen und sie auf
A) i cavi elettrici, raggruppandoli, per un (Fig. 59 - Ref. A) grouping them to a sec-
eine Stecke von circa 90-100 cm am vor-
tratto di circa 90-100 cm all’uscita anteriore tion about 90-100 cm long at the front out-
deren Ausgang des Kabelkanals zusam-
della canalina. Fare la stessa operazione let from the duct. Repeat the operation
menfassen. Den gleichen Vorgang auf der
con il tubo idraulico per il drenaggio in with the hydraulic drainage tube at the top
hydraulischen Leitung für den Rücklauf am
testa al braccio. of the boom.
Kopf des Auslegerarms vornehmen.
Infilare il tubo idraulico per il drenaggio Pass the hydraulic drainage tube through Die hydraulische Rücklaufleitung in die
nell’apposita apertura sulla testa al braccio the opening at the top of the boom (Fig. dafür vorgesehene Öffnung am Kopf des
(Fig. 60- Rif. B); montare la fascetta di 60- Ref. B); fit the clamp for blocking the Auslegerarms stecken (Abb. 60- Bez. B);
blocco dei cavi elettrici e del tubo idraulico electric cables and hydraulic tube on the den Kabelbinder zur Befestigung der elek-
sulla canalina (Fig. 60- Rif. C). channel (Fig. 60- Ref. C). trischen Kabel und der hydraulischen
Leitung auf dem Kabelkanal montieren
(Abb. 60- Bez. C).
Montare la scatola per presa cestello sul Fit the basket socket box on the left side of Den Kasten für die Bühnensteckdose auf
lato sinistro della testa (Fig. 61 - Rif. D). the head (Fig. 61 - Ref. D). der linken Kopfseite montieren (Abb. 61 -
Bez. D).
Eseguire il collegamento dei cavi elettrici Connect the electric cables (Fig. 62 - Ref. Den Anschluss der elektrischen Kabel
(Fig. 62 - Rif. E) con la presa multispina E) with the basket multipin plug (Abb. 62 - Bez. E) an der Mehrfach-
del cestello (Fig. 62 - Rif. F). (Fig. 62 - Ref. F). steckdose der Bühne vornehmen (Abb. 62
- Bez. F).
32
MRT 1440-1640 EASY 50
A
B
55 56
F

F
E
57 58
C
B
59 60
E
F
61 62
33
50 MRT 1440-1640 EASY
IT EN DE
Chiudere la scatola per presa cestello e Close the basket socket box and secure Das Gehäuse der Steckdose der Bühne
assicurare i cavi con delle fascette (Fig. 63 the cables by means of clamps (Fig. 63 - schließen und die Kabel mit Kabelbindern
- Rif. A) alla testa del braccio. Ref. A) to the top of the boom. (Abb. 63 - Bez. A) am Kopf des
Auslegerarms absichern.
Collegare il tubo per il drenaggio all’inne- Connect the drainage tube to the quick- Die Rücklaufleitung an der Schnell-
sto rapido sul lato destro in testa al braccio coupling on the right side at the top of the kupplung auf der rechten Seite am Kopf
(Fig. 64 - Rif. B). boom (Fig. 64 - Ref. B). des Auslegerarms anschließen (Abb. 64 -
Bez. B).
Montare l’avvolgitore del “M.S.S.” (Fig. 65 - Fit the “M.S.S.” winder (Fig. 65 - Ref. C) Den Aufwickler des Sicherheitssystems
Rif. C) con la relativa staffa (Fig. 65 - Rif. with the relative bracket (Fig. 65 - Ref. D) “M.S.S.” (Abb. 65 - Bez. C) mit dem dazu-
D) nella parte anteriore sinistra del braccio in the left front of the external boom. gehörigen Bügel (Abb. 65 - Bez. D) im vor-
esterno. deren Teil links auf dem externen
Auslegerarm montieren.
Fissare il cavo dell’avvolgitore del “M.S.S.” Fix the “M.S.S.” winder cable to the plate Das Kabel des Aufwicklers des Sicher-
al piatto presente sul braccio II° sfilo (Fig. present on the 2nd extension boom heitssystems “M.S.S.” an der Platte auf
66 - Rif. E). (Fig. 66 - Ref. E). dem 2. Auszug befestigen
(Abb. 66 - Bez. E).
Anm.: Die Eichung des Sicherheitssystems

N. B. La taratura del sistema di sicurezza N. B. Calibration of the“MSS” safety
“MSS” muss durch autorisiertes Personal
“MSS” deve essere eseguita da personale system must be carried out by authorized
von Manitou vorgenommen werden.
autorizzato Manitou. Manitou personnel.
34
MRT 1440-1640 EASY 50
63 64
65 66
35
SMONTAGGIO E RIMONTAGGIO DEL BRACCIO
TELESCOPICO COMPLETO
DISASSEMBLING AND REASSEMBLING ENTIRE

TELESCOPIC BOOM
AUSBAU UND WIEDEREINBAU DES KOMPLETTEN

TELESKOPAUSLEGERS
MRT 1840 EASY

IT-EN-DE
50 MRT 1840 EASY
IT EN DE
SMONTAGGIO DEL BRACCIO DISASSEMBLING ENTIRE AUSBAU DES KOMPLETTEN

TELESCOPICO COMPLETO TELESCOPIC BOOM TELESKOPAUSLEGERS
Smontaggio impianto idraulico e Disassembling boom hydraulic system Ausbau der hydraulischen Anlage und
impianto elettrico del braccio (tavole 5- and electrical system (Tables 5-6-7-8) der elektrischen Anlage des Ausleger-
6-7-8) arms (Tafeln 5-6-7-8)
Dopo avere appoggiato il braccio telesco- Rest the telescopic boom horizontally on Nach dem Auflegen des Teleskop-
pico su due cavalletti in posizione orizzon- two stands, disconnect the hydraulic pipes auslegers in horizontaler Position auf zwei
tale, scollegare i tubi idraulici (Rif. A-Fig. 1) (Ref. A-Fig. 1) from the valve block on the Böcke die hydraulischen Leitungen (Bez. A
dal blocchetto valvola sul cilindro di bran- tilting cylinder and mark them to ensure - Abb. 1) vom Ventilblock auf dem
deggio e contrassegnarli per il corretto correct reassembly. Schwenkzylinder abtrennen und sie für
rimontaggio. den korrekten Wiedereinbau markieren.
Scollegare i tubi idraulici (Rif. B-Fig. 2) Disconnect the hydraulic pipes (Ref. B-Fig.
2) from the quick-release couplings on the Die hydraulischen Leitungen(Bez. B-Abb.
dagli innesti rapidi sul lato sinistro in testa 2) von den Schnellkupplungen auf der lin-
al braccio (Rif. C-Fig. 2) e contrassegnarli left side on the boom head (Ref. C-Fig. 2)
and mark them to ensure correct reassem- ken Seite am Kopf des Auslegers abtren-
per il corretto rimontaggio. nen (Bez. C-Abb. 2) und sie für den kor-
bly.
rekten Wiedereinbau markieren.
Scollegare il tubo dall’innesto rapido sul Disconnect the pipe from the quick-release
coupling on the right side of the boom Die Leitung von der Schnellkupplung auf
lato destro della testa del braccio e con- der rechten Seite des Auslegerkopfs
trassegnarlo per il corretto rimontaggio. head and mark it to ensure correct
reassembly. abtrennen sie für den korrekten
Wiedereinbau markieren.
Staccare il cavo dell’avvolgitore del Disconnect the “M.S.S.” winder cable from
the ring (Ref. D-Fig. 3) on the 1st exten- Das Kabel des Aufwickels des
“M.S.S.” dall’anello (Rif. D-Fig. 3) presente Sicherheitssystems “M.S.S.” vom Ring
sul braccio I° sfilo. sion boom.
(Bez. D-Abb. 3) auf dem 1. Auszug abtren-
nen.
Smontare l’avvolgitore (Rif. E-Fig. 4) del Dismantle the “M.S.S.” winder (Ref. E-Fig.
Den Aufwickler (Bez. E-Abb. 4) von
“M.S.S.” con la relativa staffa (Rif. F-Fig. 4) 4) with relative bracket (Ref. F-Fig. 4) in
“M.S.S.” mit dem dazugehörigen Bügel
nella parte anteriore sinistra del braccio the front on the left side of the outside
(Bez. F-Abb. 4) im vorderen Teil links des
esterno. boom.
externen Auslegersarms ausbauen.
Scollegare le connessioni elettriche a tenu- Disconnect the watertight electric connec-

Die abgedichteten elektrischen Anschlüsse
ta stagna dei microinterruttori sugli attacchi tions of the microswitches on the chain fit-
der Mikroschalter auf den Anschlüssen der
delle catene nella parte anteriore superiore tings in the upper front part of the boom
Ketten im vorderen Teil oben des
del braccio ed eliminare la fascettatura and remove the band (Ref. A-Fig. 5).
Auslegers abtrennen und die Kabelbinder
(Rif. A-Fig. 5). beseitigen (Bez. A-Abb. 5).
Dismantle the brackets of the microswitch-
Smontare le staffe dei microinterruttori (Rif. es (Ref. B-Fig. 5) and the relative striker
Die Bügel der Mikroschalter (Bez. B-Abb.
B-Fig. 5) e i relativi riscontri (Rif. C-Fig. 5), plates (Ref. C-Fig. 5), in the upper front
5) und der dazugehörigen Anschläge (Bez.
nella parte anteriore superiore del braccio. part of the boom.
C-Abb. 5) im vorderen Teil oben des
Auslegers ausbauen.
Aprire la scatola per presa cestello e scol- Open the basket socket box and discon-
legare i cavi elettrici dalla presa (Rif. D- nect the wiring from the socket
Den Kasten der Bühnensteckdose öffnen
Fig. 6). (Ref. D-Fig. 6).
und die elektrischen Kabel von der
Steckdose abklemmen (Bez. D-Abb. 6).
Sfilare i cavi elettrici dalla scatola (Rif. D- Remove the electric wiring from the box
Fig. 7) e liberarli dalle fascette (Rif. F-Fig. (Ref. D-Fig. 7) and free them from the
Die elektrischen Kabel aus dem Kasten
7). bands (Ref. F-Fig. 7).
herausziehen (Bez. D-Abb. 7) und von den
Kabelbindern befreien (Bez. F-Abb. 7).
Liberare i cavi elettrici e i tubi idraulici dalle Free the electric wiring and hydraulic pipes
guaine protettive (Rif. G-Fig. 8) e sfilare i from the protective sheaths (Ref. G-Fig. 8)
Die elektrischen Kabel und die hydrauli-
tubi idraulici dal foro superiore della testa and extract the hydraulic pipes through the
schen Leitungen von den Schutzhüllen
del braccio (Rif. H-Fig. 8). upper opening on the boom head
befreien (Bez. G-Abb. 8) und die hydrauli-
(Ref. H-Fig. 8).
sche Leitung aus dem oberen Loch des
Auslegerkopfs herausziehen
(Bez. H-Abb. 8).
2
MRT 1840 EASY 50
A C
A
B
C
B
1 2
3 4
C C
C
B
A
B
5 6
F G
H
E
7 8
3
50 MRT 1840 EASY
IT EN DE
Nei passaggi tra tubolari portacatene e Free the electric wiring from the bands, in An den Übergangsstellen zwischen
catene portatubi, liberare i cavi elettrici the passages between the chain holder Kettentragerohren und Schlauch-
dalle fascette (Rif. A-Fig. 9). tubes and tube holder chains (Ref. A-Fig. trageketten die elektrischen Kabel von den
9). Kabelbindern befreien (Bez. A-Abb. 9).
Liberare i tubi idraulici dal tubolare porta- Free the hydraulic pipes from the 3rd Die hydraulischen Leitungen vom
catena III° sfilo (Rif. B-Fig. 10) smontando extension chain holder tube (Ref. B-Fig. Kettentragerohr des 3. Auszugs befreien
il collare di fermo (Rif. C e D-Fig. 10). 10) by dismantling the stop collar (Ref. C (Bez. B-Abb. 10), indem man den
and D-Fig. 10). Anschlagbund ausbaut (Bez. C und D-
Abb. 10).
Staccare la terza catena portatubi (Rif. E-
Fig. 11) nella parte posteriore del tubolare Detach the third tube holder chain (Ref. E- Die dritte Schlauchtragekette (Bez. E-Abb.
(Rif. F-Fig. 11). Fig. 11) in the rear part of the tube (Ref. F- 11) auf der Rückseite des Rohrs abtrennen
Fig. 11). (Bez. F-Abb. 11).
Sfilare i cavi elettrici (Rif. G-Fig. 12) per il

cestello ed i tubi idraulici (Rif. H-Fig. 12) Extract the electric wiring (Ref. G-Fig. 12) Die elektrischen Kabel (Bez. G-Abb. 12)
dal tubolare portacatene (Rif. I-Fig. 12). for the basket and hydraulic pipes (Ref. H- für die Bühne und die hydraulischen
Fig. 12) from the chain holder tube (Ref. I- Leitungen (Bez. H-Abb. 12) aus dem
Smontare il tubolare dal braccio III° sfilo Fig. 12). Kettentragerohr herausziehen (Bez. I-Abb.
(Rif. A-Fig. 13). 12).
Smontare i collari di bloccaggio (Rif. B-Fig. Dismantle the tube from the 3rd extension Das Rohr aus dem 3. Auszug ausbauen
14) dei raccordi a gomito (Rif. C e D-Fig. boom (Ref. A-Fig. 13). (Bez. A-Abb. 13).
14) dalla piastra di fissaggio sul tubolare
portacatena II° sfilo (Rif. E-Fig. 14).
Scollegare i tubi in ferro (Rif. C e D-Fig. Dismantle the stop collars (Ref. B-Fig. 14) Die blockierenden Anschlagbünde (Bez. B-
14) dai tubi idraulici all’interno della terza of the elbow joints (Ref. C and D-Fig. 14) Abb. 14) der Knieanschlüsse (Bez. C und
catena portatubi (Rif. F e G-Fig. 15); scol- from the fixing plate on 2nd extension D-Abb. 14) von der Befestigungsplatte auf
legare i tubi in ferro (Rif. C e D-Fig. 14) dai chain holder tube (Ref. E-Fig. 14). dem Kettentragerohr 2. Auszug ausbauen
tubi idraulici all’interno del tubolare porta- Disconnect the iron pipes (Ref. C and D- (Bez. E-Abb. 14).
catena II° sfilo (Rif. H-Fig. 15). Fig. 14) from the hydraulic pipes inside the Die Eisenrohre (Bez. C und D-Abb. 14)
Durante questa operazione contrassegna- third tube holder chain (Ref. F e G-Fig. von den hydraulischen Leitungen innerhalb
re i tubi idraulici per il corretto rimontaggio. 15); disconnect the iron tubes (Ref. C and der dritten Schlauchtragekette abtrennen
D-Fig. 14) from the hydraulic pipes inside (Bez. F und G-Abb. 15); die Eisenrohre
the 2nd extension chain holder tube (Ref. (Bez. C und D-Abb. 14) von den hydrauli-
Sfilare i cavi elettrici (Rif. I-Fig. 15) dalla H-Fig. 15). schen Leitungen innerhalb des
terza catena portatubi verso il “TS”. During this operation, mark the hydraulic Kettentragerohrs des 2. Auszugs abtren-
pipes to ensure correct reassembly. nen (Bez. H-Abb. 15).
Während dieses Vorgangs die hydrauli-
Smontare la terza catena portatubi (Rif. L- Extract the electric wiring (Ref. I-Fig. 15) schen Leitungen für den korrekten
Fig. 16) dal tubolare portacatena (Rif. M- from the third tube holder chain to the Wiedereinbau markieren.
Fig. 16) togliendo le apposite viti (Rif. N- “TS”.
Fig. 16). Die elektrischen Kabel (Bez. I-Abb. 15)
aus der dritten Schlauchtragekette zum
Dismantle the third tube holder chain (Ref. “TS” herausziehen.
L-Fig. 16) from the chain holder tube (Ref.
M-Fig. 16) after removing the screws (Ref. Die dritte Schlauchtragekette (Bez. L-Abb.
N-Fig. 16). 16) aus dem Kettentragerohr (Bez. M-Abb.
16) ausbauen, indem man die entspre-
chenden Schrauben entfernt (Bez. N-Abb.
16).
4
MRT 1840 EASY 50
A A A
C
B
A A
D
9 10

E
G
F I
H
11 12
A E
C
D
13 14
F
G
L
G
G N
F
M
I I
H H H
H H
15 16
5
50 MRT 1840 EASY
IT EN DE
Smontare la seconda catena portatubi (Rif. Remove the second tube holder chain Die zweite Schlauchtragekette (Bez. A-
A-Fig. 17) nella parte posteriore del tubola- (Ref. A-Fig. 17) in the rear part of the Abb. 17) auf der Rückseite des
re portacatena (Rif. B-Fig. 17). chain holder tube (Ref. B-Fig. 17). Kettentragerohrs ausbauen(Bez. B-Abb.
17).
Sfilare i cavi elettrici e i tubi idraulici dal Extract the electric wiring and hydraulic Die elektrischen Kabel und die hydrauli-
tubolare portacatene (Rif. C-Fig. 18). pipes from the chain holder tube (Ref. C- schen Leitungen aus dem Kettentragerohr
Fig. 18). herausziehen (Bez. C-Abb. 18).
Smontare il tubolare portacatene (Rif. D- Remove the chain holder tube (Ref. D-Fig. Das Kettentragerohr (Bez. D-Abb. 19) aus
Fig. 19) dal braccio II° sfilo. 19) from the 2nd extension boom. dem 2. Auszug ausbauen.
Sfilare i cavi elettrici (Rif. E-Fig. 20) dalla Extract the electric wiring (Ref. E-Fig. 20) Die elektrischen Kabel (Bez. E-Abb. 20)
seconda catena portatubi verso il “TS”. from the second tube holder chain to the aus der zweiten Schlauchtragekette zum
“TS”. “TS” herausziehen.
Smontare i collari di bloccaggio (Rif. A-Fig. Dismantle the stop collars (Ref. A-Fig. 21) Die Anschlagbünde (Bez. A-Abb. 21) der
21) dei raccordi a gomito (Rif. B e C-Fig. of the elbow joints (Ref. B and C-Fig. 21) Knieanschlüsse (Bez. B und C-Abb. 21)
21) dalla piastra di fissaggio sul tubolare from the fixing plate on the 1st extension von der Befestigungsplatte auf dem
portacatena I° sfilo (Rif. D-Fig. 21). chain holder tube (Ref. D-Fig. 21). Kettentragerohr 1. Auszug ausbauen (Bez.
Scollegare i tubi in ferro (Rif. B e C-Fig. Disconnect the iron tubes (Ref. B and C- D-Abb. 21).
21) dai tubi idraulici all’interno della secon- Fig. 21) from the hydraulic pipes inside the Die Eisenrohre (Bez. B und C-Abb. 21)
da catena portatubi (Rif. E-Fig. 21); scolle- second tube holder chain (Ref. E-Fig. 21); von den hydraulischen Leitungen innerhalb
gare i tubi in ferro (Rif. B e C-Fig. 21) dai disconnect the iron tubes (Ref. B and C- der zweiten Schlauchtragekette abtrennen
tubi idraulici all’interno del tubolare porta- Fig. 21) from the hydraulic pipes inside the (Bez. E-Abb. 21); die Eisenrohre (Bez. B
catena I° sfilo (Rif. F-Fig. 21). 1st extension chain holder tube (Ref. F- und C-Abb. 21) von den hydraulischen
Durante questa operazione contrassegna- Fig. 21). Leitungen innerhalb des Kettentragerohrs
re i tubi idraulici per il corretto rimontaggio. During this operation, mark the hydraulic des 1. Auszugs abtrennen (Bez. F-Abb.
pipes to ensure correct reassembly. 21).
schen Leitungen für den korrekten
Smontare la seconda catena portatubi (Rif. Dismantle the second tube holder chain Die zweite Schlauchtragekette (Bez. G-
G-Fig. 22) dal tubolare portacatena (Rif. H- (Ref. G-Fig. 22) from the chain holder tube Abb. 22) aus dem Kettentragerohr (Bez. H-
Fig. 22) togliendo le apposite viti (Rif. I-Fig. (Ref. H-Fig. 22) after removing the screws Abb. 22) ausbauen, indem man die ent-
22). (Ref. I-Fig. 22). sprechenden Schrauben entfernt (Bez. I-
Abb. 22).
Liberare dalle fascette il cavo (Rif. 22A- Free the clamp around the cable (Ref. Das Kabel (Bez. 22A-Abb. 23) für den
Fig. 23) per il microinterruttore sul bilance- 22A-Fig. 23) for the microswitch on the 1st Mikroschalter auf dem einzelnen Kipphebel
re singolo dell’attacco catene al braccio extension boom chain connection single des Kettenanschlusses auf dem 1. Auszug
I° sfilo. equaliser. von den Kabelbindern befreien.
6
MRT 1840 EASY 50

C
B
17 18
D

E
19 20
E E E
E E
G
A
D
F B
C I
21 H 22
22A
23
7
50 MRT 1840 EASY
IT EN DE
Smontare la prima catena portatubi (Rif. A- Dismantle the first tube holder chain (Ref. Die erste Schlauchtragekette (Bez. A-Abb.
Fig. 24) nella parte posteriore del tubolare A-Fig. 24) in the rear part of the chain 24) auf der Rückseite des
portacatena (Rif. B-Fig. 24). holder tube (Ref. B-Fig. 24). Kettentragerohrs entfernen (Bez. B-Abb.
24).
Sfilare i cavi elettrici, il cavo per il microin- Extract the electric wiring, the cable for the Die elektrischen Kabel, das Kabel für den
terruttore dell’attacco catene sul bilancere microswitch from the chain connection on Mikroschalter des Kettenanschlusses auf
singolo e i tubi idraulici dal tubolare porta- the single equaliser and the hydraulic dem einzelnen Kipphebel und die hydrauli-
catene (Rif. C-Fig. 25). pipes from the chain holder tube (Ref. C- schen Leitungen aus dem Kettentragerohr
Fig. 25). (Bez. C-Abb. 25) herausziehen.
Smontare il tubolare portacatene (Rif. D- Dismantle the chain holder tube (Ref. D- Das Kettentragerohr (Bez. D-Abb. 26) aus
Fig. 26) dal braccio I° sfilo. Fig. 26) from the 1st extension boom. dem 1. Auszug ausbauen.
Sfilare i cavi elettrici (Rif. E-Fig. 27) dalla Extract the electric wiring (Ref. E-Fig. 27) Die elektrischen Kabel (Bez. E-Abb. 27)
prima catena portatubi verso il “TS”. from the first tube holder chain towards the aus der ersten Schlauchtragekette zum
Liberare dalle fascette i cavi (Rif. 22A e “TS”. Free the clamp around the cables “TS” herausziehen. Die Kabel (Bez. 22A
22B-Fig. 27) per i microinterruttori degli (Ref. 22A and 22B-Fig. 27) for the chain und 22B-Abb. 27) für die Mikroschalter der
attacchi catene sui bilanceri. connector microswitches on the equalisers. Kettenanschlüsse auf den Kipphebeln von
den Kabelbindern befreien.
Smontare i collari di bloccaggio (Rif. A-Fig. Dismantle the stop collars (Ref. A-Fig. 28) Die Anschlagbünde (Bez. A-Abb. 28) der
28) dei raccordi a gomito (Rif. B e C-Fig. of the elbow joints (Ref. B and C-Fig. 28) Knieanschlüsse (Bez. B und C-Abb. 28)
28) dalla piastra di fissaggio sul tubolare from the fixing plate on the external boom von der Befestigungsplatte auf dem
portacatena braccio esterno chain holder tube (Ref. D-Fig. 28). Kettentragerohr des externen
(Rif. D-Fig. 28). Disconnect the iron tubes (Ref. B and C- Auslegerarms ausbauen (Bez. D-Abb. 28).
Scollegare i tubi in ferro (Rif. B e C-Fig. Fig. 28) from the hydraulic pipes from Die Eisenrohre (Bez. B und C-Abb. 28)
28) dai tubi idraulici all’interno della prima inside the first tube holder chain (Ref. E- von den hydraulischen Leitungen innerhalb
catena portatubi (Rif. E-Fig. 28); scollegare Fig. 28); disconnect the iron tubes (Ref. B der ersten Schlauchtragekette abtrennen
i tubi in ferro (Rif. B e C-Fig. 28) dai tubi and C-Fig. 28) from the hydraulic pipes (Bez. E -Abb. 28); die Eisenrohre (Bez. B
idraulici all’interno del tubolare portacatena inside the external boom chain holder tube und C-Abb. 28) von den hydraulischen
braccio esterno (Rif. F-Fig. 28). (Ref. F-Fig. 28). Leitungen innerhalb des Kettentragerohrs
Durante questa operazione contrassegna- During this operation, mark the hydraulic des externen Auslegersarms abtrennen
re i tubi idraulici per il corretto rimontaggio. pipes to ensure correct reassembly. (Bez. F-Abb. 28).
schen Leitungen für den korrekten
Smontare la prima catena portatubi (Rif. Dismantle the first tube holder chain (Ref. Die erste Schlauchtragekette (Bez. G-Abb.
G-Fig. 29) dal tubolare portacatena (Rif. H- G-Fig. 29) from the chain holder tube (Ref. 29) vom Kettentragerohr (Bez. H-Abb. 29)
Fig. 29) togliendo le apposite viti (Rif. I-Fig. H-Fig. 29) after removing the screws (Ref. ausbauen, indem man die entsprechenden
29). I-Fig. 29). Schrauben entfernt (Bez. I-Abb. 29).
Liberare dal braccio esterno i tubi idraulici Release the hydraulic pipes and electric Die hydraulischen Leitungen und die elek-
e i cavi elettrici togliendo le staffe (Rif. L- wires from the external boom after remov- trischen Kabel vom externen Auslegerarm
Fig. 30). ing the brackets (Ref. L-Fig. 30). befreien, indem man die Bügel entfernt
(Bez. L-Abb. 30).
Sfilare i tubi idraulici e i cavi elettrici dal Extract the hydraulic pipes and electric Die hydraulischen Leitungen und die elek-
tubolare portacatena (Fig. 31). wiring from the chain holder tube (Fig. 31). trischen Kabel aus dem Kettentragerohr
(ABB. 31) herausziehen.
8
MRT 1840 EASY 50

C
B
24 25
22A

22B
D
26 27
E E
E E
E
A
G
I
I
H
B
D
F
28 29
I
I

30 31
9
50 MRT 1840 EASY
IT EN DE
Smontare la spina multipresa (Rif. A-Fig. Remove the basket multipin plug (Ref. A- Den Mehrfachstecker (Bez. A-Abb. 32) für
32) per il cestello dal piastrino (Rif. B-Fig. Fig. 32) from the plate (Ref. B-Fig. 32). die Bühne von der Platte (Bez. B-Abb. 32)
32). entfernen.
Remove the plate (Ref. B-Fig. 32) for the
Smontare il piastrino (Rif. B-Fig. 32) per electric socket in the rear part on the right Die Platte (Bez. B-Abb. 32) für die
presa elettrica nella parte posteriore destra of the external boom. Steckdose auf der Rückseite rechts vom
del braccio esterno. externen Auslegerarm ausbauen.
Togliere il collare (Rif. C-Fig. 33) e smonta- Remove the collar (Ref. C-Fig. 33) and Den Anschlagbund (Bez. C-Abb. 33) ent-
re i tubi idraulici di collegamento al cilindro dismantle the hydraulic pipes connected to fernen und die hydraulischen Leitungen
di sfilo (Rif. D e E-Fig. 33). the extension cylinder (Ref. D and E-Fig. zur Verbindung am Zylinders des Auszugs
33). (Bez. D und E-Abb. 33) ausbauen.
Smontare i tubi idraulici in sequenza (Rif. Dismantle the hydraulic pipes in sequence Die hydraulischen Leitungen in der vorge-
F, G, H, I, L, M, N-Fig. 34) dai raccordi (Ref. F, G, H, I, L, M, N-Fig. 34) from the sehenen Reihenfolge (Bez. F, G, H, I, L, M,
passaparete. connectors. N-Abb. 34) von den wanddurchführenden
Contrassegnare i tubi per il corretto Mark the pipes to ensure their correct Anschlüssen abtrennen.
rimontaggio. reassembly. Die Leitungen für den korrekten
Smontare il tubolare portacatene (Rif. O- Dismantle the chain holder tube (Ref. O- Das Kettentragerohr (Bez. O-Abb. 35) auf
Fig. 35) sul lato destro del braccio esterno. Fig. 35) on the right side of the external der rechten Seite des externen
boom. Auslegerarms ausbauen.
Togliere i raccordi passaparete nella aletta Remove the connectors in the perforated Die wanddurchführenden Anschlüsse im
forata nella parte posteriore del braccio fin in the rear part of the outside boom gelochten Flügel auf der Rückseite des
esterno (Fig. 36). (Fig. 36). externen Auslegerarms entfernen (Abb.
36).
Smontaggio dei martinetti dal braccio Dismantling the cylinders from the Ausbau der Zylinder aus dem Ausleger
(tavola 5-6) boom (Tables 5-6) (Tafel 5-6)
Assicurare il cilindro di brandeggio (Rif. A- Secure the tilting cylinder (Ref. A-Fig. 37) Den Schwenkzylinder (Bez. A-Abb. 37) am
Fig. 37) al carro ponte o un elevatore. to a bridge crane or elevator. Laufkran oder dem Gabelstapler ab-
Svitare la vite (Rif. B-Fig. 37) di bloccaggio Unscrew the screws (Ref. B-Fig. 37) for sichern.
perno di incernieramento cilindro di bran- the locking the tilting cylinder pivot pin of Die Schraube (Bez. B-Abb. 37) zum
deggio del braccio III° sfilo. the 3rd extension boom. Blockieren des Kippbolzens des
Schwenkzylinders des 3. Auszugs los-
schrauben.
Sfilare il perno (Rif. C-Fig. 37) di incernie- Extract the 3rd extension boom tilting cylin-
ramento cilindro di brandeggio al braccio der (Ref. C-Fig. 37) pivot pin. Den Kippbolzen (Bez. C-Abb. 37) des
III° sfilo. Remove the tilting cylinder (Ref. A-Fig. 37) Schwenkzylinders am 3. Auszug heraus-
Togliere il cilindro di brandeggio (Rif. A-Fig. from the 3rd extension boom seat. ziehen.
37) dalla sede del braccio III° sfilo. Den Schwenkzylinder (Bez. A-Abb. 37)
With the boom extended by about 25÷30 aus dem Sitz im 3. Auszug entfernen.
A braccio sfilato di circa 25÷30 cm, svitare cm, unscrew the lock nuts and nuts on the
i controdadi e i dadi sui tiranti per le cate- tie rods for the chains for extending the Wenn der Ausleger circa 25-30 cm heraus-
ne di uscita bracci (Rif. D e E-Fig. 38) fino boom (Ref. D and E-Fig. 38) up against gezogen ist, die Gegenmuttern und
contro le coppiglie. the split pins. Muttern auf den Zugstangen für die
Ausfahrketten der Ausleger (Bez. D und E-
Abb. 38) bis gegen die Sicherungssplinte
losschrauben.
Svitare controdadi e dadi dei tiranti delle Unscrew the lock nuts and nuts of the tie Die Gegenmuttern und Muttern der
catene per il rientro del braccio II° sfilo rods of the chains for retracting the 2nd Gestänge der Ketten zum Einfahren des 2.
(Rif. F-Fig. 39) fino contro le coppiglie. extension boom (Ref. F-Fig. 39) up against Auszugs (Bez. F-Abb. 39) bis gegen die
the split pins. Sicherungssplinte losschrauben.
10
MRT 1840 EASY 50
32 E D 33
L M N O
H I
G
F
34 35
A
36 37
D D
D D
F F
38 39
11
50 MRT 1840 EASY
IT EN DE
Svitare controdado e dado sul tirante della Unscrew the lock nut and nut on the tie Die Gegenmutter und die Mutter auf dem
catena di rientro del braccio III° sfilo (Rif. rod of the chain for retracting the 3rd Gestänge der Einfahrkette des 3. Auszugs
A-Fig. 40) fino contro le coppiglie. extension boom (Ref. A-Fig. 40) up against (Bez. A-Abb. 40) bis gegen die
the split pins. Sicherungssplinte losschrauben.
Togliere le viti (Rif. B-Fig. 41) di bloccaggio Remove the screws (Ref. B-Fig. 41) for Die Schrauben (Bez. B-Abb. 41) zum
perni incernieramento cilindro sfilo al brac- locking the 1st extension boom cylinder Blockieren der Kippbolzen des Schwenk-
cio I° sfilo. pivot pins. zylinders zum Ausfahren des 1. Auszugs
entfernen.
Con l’ausilio di un estrattore sfilare i perni Using an extractor, remove the 1st exten- Mit der Hilfe eines Abziehers die Kipp-
di incernieramento cilindro sfilo al braccio sion boom extension cylinder pivot pin bolzen des Zylinders zum Ausfahren des
I° sfilo (Rif. C-Fig. 42). (Ref. C-Fig. 42). 1. Auszugs (Bez. C-Abb. 42) heraus-
ziehen.
Togliere i seeger (Rif. D-Fig. 42) e sfilare il Remove the snap rings (Ref. D-Fig. 42) Die Seegerringe (Bez. D-Abb. 42) entfer-
perno (Rif. E-Fig. 43) di incernieramento and extract the pivot pin (Ref. E-Fig. 43) nen und den Kippbolzen (Bez. E-Abb. 43)
tra cilindro di sfilo e braccio esterno. between the extension cylinder and out- zwischen dem Ausfahrzylinder und dem
side boom. externen Auslegerarm herausziehen.
Con l’ausilio di un carroponte o un elevato- Use a bridge crane or an elevator to

re togliere il cilindro di sfilo dal braccio remove the extension cylinder from the Mit der Hilfe eines Laufkrans oder
(Fig. 44). boom (Fig. 44). Gabelstaplers den Ausfahrzylinder vom
Auslegerarm entfernen (Abb. 44).
Smontaggio del I, II e III braccio dal Dismantling the 1st, 2nd and 3rd exten- Ausbau des 1., 2. und 3. Auszugs vom
braccio esterno (tavola 4) sion from outside boom (Table 4) externen Auslegerarm (Tafel 4)
Prestare attenzione a contrassegnare tutti i Make sure all the pads with the relative Darauf achten, dass alle Gleitschuhe mit
pattini con i relativi spessori che verranno shims that are dismantled from den dazugehörigen Beilagen, die aus dem
smontati dal braccio telescopico per the telescopic boom are marked, Teleskopausleger ausgebaut werden, mar-
rimontarli correttamente. to ensure correct reassembly. kiert werden, um sie korrekt wiedereinbau-
en zu können.
Smontare i pattini posteriori fissati al I° Dismantle the rear pads fixed to the 1st Die hinteren Gleitschuhe, die am 1.
sfilo con i relativi spessori (Rif. A-Fig. 45). extension with the relative shims (Ref. A- Auszug mit den dazugehörigen Beilagen
Fig. 45). montiert sind, ausbauen (Bez. A-Abb. 45).
Liberare le 6 catene per la fuoriuscita dei Free the six chains that draw out the Die 6 Ketten zum Ausfahren der
bracci smontando i bilanceri (Rif. B e C- booms, by dismantling the equalisers (Ref. Auslegerarme freigeben, indem man die
Fig. 46) nella parte anteriore superiore del B and C-Fig. 46) in the upper front part of Kipphebel (Bez. B und C-Abb. 46) auf der
braccio. the boom. Vorderseite oben des Auslegers ausbaut.
12
MRT 1840 EASY 50
B
A
40 41

E
42 43
A A
A A

A A
44 45
46
13
50 MRT 1840 EASY
IT EN DE
Smontare la carrucola (Rif. A-Fig. 47) nella Dismantle the pulley (Ref. A-Fig. 47) in the Die Rolle (Bez. A-Abb. 47) auf der
parte anteriore superiore del braccio II° upper front part of the 2nd extension boom Vorderseite oben am 2. Auszug ausbauen,
sfilo sfilando il perno (Rif. B-Fig. 47). by removing the pin (Ref. B-Fig. 47). indem man den Bolzen (Bez. B-Abb. 47)
herauszieht.
Smontare le carrucole (Rif. C-Fig. 48) nella Dismantle the pulleys (Ref. C-Fig. 48) in Die Rollen (Bez. C-Abb. 48) auf der
parte anteriore superiore del braccio I° sfilo the upper front part of the 1st extension Vorderseite oben am 1. Auszug ausbauen,
sfilando il perno (Rif. D-Fig. 48). boom by removing the pin (Ref. D-Fig. 48). indem man den Bolzen herauszieht (Bez.
D-Abb. 48).
Smontare il pattino (Rif. E-Fig. 49) per lo Remove the extension cylinder sliding Den Gleitschuh (Bez. E-Abb. 49) zum
scorrimento del cilindro di sfilo e svincolare track pad (Ref. E-Fig. 49) and release the Gleiten des Ausfahrzylinders ausbauen
dal braccio II° sfilo i pettini (Rif. F-Fig. 49) connector comb (Ref. F-Fig. 49) of the 2nd und die Kämme (Bez. F-Abb. 49) zum
di attacco delle catene di rientro del II° sfilo extension retraction chain from the 2nd Anschluss der Einfahrketten des 2.
(Rif. G-Fig. 49). extension boom (Ref. G-Fig. 49). Auszugs (Bez. G-Abb. 49) vom 2. Auszug
freigeben.
Smontare la carrucola (Rif. H-Fig. 50) nella Dismantle the pulley (Ref. H-Fig. 50) in the Die Rolle (Bez. H-Abb. 50) auf der
parte posteriore del braccio I° sfilo. rear part of the 1st extension boom. Rückseite des 1. Auszugs ausbauen.
Con l’ausilio del carroponte o di un eleva- Using a bridge crane or elevator, extend Mit der Hilfe eines Laufkrans oder
tore sfilare di circa 20÷30 cm il braccio I° the 1st extension boom by about 20÷30 Gabelstaplers den 1. Auszug circa 20-30
sfilo dal braccio esterno. cm from the outside boom. cm aus dem externen Auslegerarm her-
ausziehen.
Smontare i pattini anteriori laterali superiori Remove the upper front side pads fixed to
fissati al braccio esterno (Rif. A-Fig. 51) the outside boom (Ref. A-Fig. 51) with the Die vorderen seitlichen oberen
con i relativi spessori. relative shims. Gleitschuhe, die am exterenen
Auslegerarm befestigt sind (Bez. A-Abb.
51) mit den entsprechenden Beilagen aus-
bauen.
Sollevare il braccio I° sfilo con l’ausilio di Lift the 1st extension boom using a bridge
un carroponte o di un elevatore e smonta- crane or elevator and dismantle the lower Den 1. Auszug mit der Hilfe eines
re i pattini anteriori inferiori (Rif. B-Fig. 52) front pads (Ref. B-Fig. 52) of the outside Laufkrans oder Gabelstaplers heben und
braccio esterno con i relativi spessori (Rif. boom with the relative shims (Ref. C-Fig. die vorderen unteren Gleitschuhe (Bez. B-
C-Fig. 52). 52). Abb. 52) des externen Auslegerarms mit
den dazugehörigen Beilagen ausbauen
(Bez. C-Abb. 52).
Con l’ausilio di un carroponte o di un ele- Using a bridge crane or an elevator, Mit der Hilfe eines Laufkrans oder
vatore, sfilare i bracci I°, II° e III° sfilo dal remove the 1st, 2nd and 3rd extension Gabelstaplers den 1., 2. und 3. Auszug
braccio esterno (Fig. 53). booms from the outside boom (Fig. 53). aus dem externen Auslegerarm heraus-
ziehen (Abb. 53).
Togliere le due coppiglie (Rif. D-Fig. 54) e Remove the two split pins (Ref. D-Fig. 54) Die beiden Sicherungssplinte (Bez. D-Abb.
svitare completamente dadi e controdadi and unscrew nuts and locknuts (Ref. E- 54) entfernen und die Muttern und
(Rif. E-Fig. 54), liberare le catene per il Fig. 54), completely, free the chains for Gegenmuttern (Bez. E-Abb. 54) ganz los-
rientro del braccio II° sfilo nella parte ante- retracting the 2nd extension boom in the schrauben, die Ketten für das Einfahren
riore inferiore del braccio esterno. lower front part of the outside boom. des 2. Auszugs auf der Vorderseite unten
des externen Auslegerarms freigeben.
14
MRT 1840 EASY 50
A
C
C
47 48
F F
G G
49 50
A
A
C
C
A
51 52
53 54
15
50 MRT 1840 EASY
IT EN DE
Smontaggio del II° e III° sfilo dal braccio Dismantling the 2nd and 3rd extension Ausbau des 2. und 3. Auszugs aus dem
I° sfilo (tavola 3) from the 1st extension boom (Table 3) 1. Auszug (Tafel 3)
Liberare la catena di rientro (Rif. A-Fig. 55) Free the retraction chain (Ref. A-Fig. 55) Die Einfahrkette (Bez. A-Abb. 55) des 3.
del braccio III° sfilo nella parte posteriore from the 3rd extension boom in the rear Auszugs auf der Rückseite der
dei bracci. part of the booms. Auslegerarme freigeben.
Smontare dalla catena il pettine Dismantle the combs (Ref. B-Fig. 56) from Den Kamm von der Kette befreien (Bez. B-
(Rif. B-Fig. 56). the chain. Abb. 56).
Sollevare il braccio II° sfilo all’interno del Lift the 2nd extension boom inside the 1st Den 2. Auszug innerhhalb des 1. Auszugs
braccio I° sfilo con l’ausilio di un crick extension boom using a hydraulic jack. mit der Hilfe einer hydraulischen Winde
idraulico. Smontare i pattini posteriori infe- Dismantle the lower and side rear pads heben. Die hinteren, unteren und seitlichen
riori e laterali (Rif. C-Fig. 57) con i relativi (Ref. C-Fig. 57) with the relative shims Gleitschuhe (Bez. C-Abb. 57) mit den
spessori fissati al braccio II° sfilo. fixed to the 2nd extension boom. dazugehörigen Beilagen, die am 2. Auszug
befestigt sind, entfernen.
Togliere il crick all’interno del braccio I° Remove the jack inside the 1st extension Die Winde innerhalb des 1. Auszugs ent-
sfilo e smontare i pattini posteriori superiori boom and dismantle the upper rear pads fernen und die hinteren oberen
(Rif. D-Fig. 58) fissati al braccio II° sfilo. (Ref. D-Fig. 58) fixed to the 2nd extension Gleitschuhe ausbauen (Bez. D-Abb. 58),
boom. die am 2. Auszug befestigt sind.
Risollevare il braccio II° sfilo all’interno del Lift the 2nd extension boom inside the 1st Den 2. Auszug innerhalb des 1. Auszugs
braccio I° sfilo con l’ausilio di un crick extension boom again using the hydraulic mit der Hilfe einer hydraulischen Winde
idraulico per sfilare la catena dalla sede jack to extract the chain where the pulley erneut heben, um die Kette aus ihrem Sitz
della carrucola (Rif. A-Fig. 59). is situated (Ref. A-Fig. 59). an der Rolle herauszuziehen (Bez. A-Abb.
59).
Smontare il blocchetto anteriore di fissag- Dismantle the front filling block fixing the Den vorderen Befestigungsblock der
gio della catena di rientro del III° sfilo tra- 3rd extension retraction chain by means of Einfahrkette des 3. Auszugs mit den ent-
mite le apposite viti (Rif. B-Fig. 60) ed the screws provided (Ref. B-Fig. 60) and sprechenden Schrauben (Bez. B-Abb. 60)
estrarre la catena tirandola verso il “TS”. extract the chain pulling it towards the ausbauen und die Kette entfernen, indem
Ad operazione terminata togliere il crick. “TS”. man sie in Richtung auf den “TS” heraus-
When the operation is complete, remove zieht.
the jack. Nach diesem Vorgang die Winde entfer-
nen.
Smontare i pattini anteriori laterali e supe- Dismantle the side and upper front pads Die vorderen, seitlichen und oberen
riori (Rif. C-Fig. 61) con i relativi spessori (Ref. C-Fig. 61) with the relative shims Gleitschuhe (Bez. C-Abb. 61) mit den
fissati al braccio I° sfilo. fixed to the 1st extension boom. dazugehörigen Beilagen ausbauen, die am
1. Auszug befestigt sind.
Sollevare la parte anteriore del braccio II° Lift the front part of the 2nd extension Den vorderen Teil des 2. Auszugs mit
sfilo con l’ausilio di un carroponte o un ele- boom using a bridge crane or elevator, to einem Laufkran oder einem Gabelstapler
vatore, per smontare i pattini anteriori infe- dismantle the lower front pads with the rel- heben, um die vorderen unteren
riori con i relativi spessori (Rif. D-Fig. 62) ative shims (Ref. D-Fig. 62) fixed to the 1st Gleitschuhe mit den entsprechenden
fissati al braccio I° sfilo. extension boom. Beilagen auszubauen (Bez. D-Abb. 62),
die am 1. Auszug befestigt sind.
16
MRT 1840 EASY 50
55 56
57 58
B B
B
A
59 60
D
D
61 62
17
50 MRT 1840 EASY
IT EN DE
Fare passare le quattro catene (Rif. A-Fig. Pass the four chains (Ref. A-Fig. 63) for Die vier Ketten (Bez. A-Abb. 63) für das
63) per l’uscita del braccio II° sfilo all’inter- extending the 2nd extension boom through Ausfahren des 2. Auszugs in das Innere
no delle aperture nella parte anteriore the opening in the top front part of the 1st der Öffnungen im Vordereteil des 1.
superiore del braccio I° sfilo (Rif. B-Fig. extension boom (Ref. B-Fig. 63), and Auszugs stecken (Bez. B-Abb. 63) und sie
63), e stenderle completamente sul brac- extend them completely on the 2nd exten- ganz auf dem 2. Auszug verlegen (Bez. C-
cio II° sfilo (Rif. C-Fig. 63). sion boom (Ref. C-Fig. 63). Abb. 63).
Legare le catene al braccio II° sfilo (Rif. D- Secure the chains to the 2nd extension Die Ketten am 2. Auszug festbinden (Bez.
Fig. 64). boom (Ref. D-Fig. 64). D-Abb. 64).
Con l’ausilio del carroponte o un elevatore Using a bridge crane or elevator, extend Mit der Hilfe eines Laufkrans oder eines
sfilare i bracci II° e III° sfilo dal braccio I° the 2nd and 3rd extension booms from the Gabelstaplers den 2. und 3. Auszug aus
sfilo (Fig. 64) tenendo ben tese le catene 1st extension boom (Fig. 64) keeping the dem 1. Auszug (Abb. 64) herausziehen,
appoggiate sulla parte superiore. chains resting on the upper part properly wobei man die auf der oberen Seite lie-
tightened. genden Ketten gut gespannt hält.
Smontaggio del braccio I° sfilo dal brac- Dismantling the 1st extension boom Ausbau des 1. Auszugs aus dem 2.
cio II° sfilo (tavole 1 e 2) from the 2nd extension boom (Tables 1-2) Auszug (Tafeln 1 und 2)
Smontare la carrucola (Rif. E-Fig. 65), Dismantle the pulley (Ref. E-Fig. 65), in Die Rolle (Bez. E-Abb. 65) auf der
nella parte posteriore del braccio II° sfilo. the rear part of the 2nd extension boom. Rückseite des 2. Auszugs ausbauen.
Fare uscire di 20÷30 cm il braccio III° sfilo Extend the 3rd extension boom from the Den 3. Auszug um 20-30 cm aus dem 2.
dal braccio II° sfilo e smontare i pattini 2nd extension boom by about 20÷30 cm Auszug herausfahren lassen und die seit-
laterali (Rif. F-Fig. 66) coi relativi spessori out and dismantle the lateral pads (Ref. F- lichen Gleitschuhe (Bez. F-Abb. 66) mit
fissati al braccio III° sfilo nella parte Fig. 66) with the relative shims fixed to the den dazugehörigen Beilagen ausbauen,
posteriore. 3rd extension boom in the rear part. die am 3. Auszug auf der Rückseite be-
festigt sind.
Smontare i pattini anteriori laterali e supe- Dismantle the side and upper front pads Die vorderen, seitlichen und oberen
riori (Rif. A-Fig. 67) con i relativi spessori (Ref. A-Fig. 67) with the relative shims Gleitschuhe (Bez. A-Abb. 67) mit den
fissati al braccio II° sfilo. fixed to the 2nd extension boom. dazugehörigen Beilagen ausbauen, die am
2. Auszug befestigt sind.
Sollevare il braccio III° sfilo nella parte Lift the 3rd extension boom in the front Den 3. Auszug auf der Vorderseite mit der
anteriore con l’ausilio di un carroponte o part using a bridge crane or elevator to Hilfe eines Laufkrans oder Gabelstaplers
un elevatore per smontare i pattini anteriori dismantle the lower front pads (Ref. B-Fig. heben, um die vorderen unteren
inferiori (Rif. B-Fig. 68) con i relativi spes- 68) with the relative shims fixed to the 2nd Gleitschuhe (Bez. B-Abb. 68) mit den
sori fissati al braccio II° sfilo. extension boom. dazugehörigen Beilagen auszubauen, die
am 2. Auszug befestigt sind.
Legare le catene al braccio III° sfilo (Rif. Secure the chains to the 3rd extension Die Ketten am 3. Auszug anbinden (Bez.
C-Fig. 69). boom (Ref. C-Fig. 69). C-Abb. 69).
Con l’ausilio del carroponte o di un eleva- Using a bridge crane or elevator, extend Mit der Hilfe eines Laufkrans oder eines
tore sfilare il braccio III° sfilo dal braccio II° the 3rd extension boom from the 2nd Gabelstaplers den 3. Auszug aus dem 2.
sfilo (Fig. 70) tenendo ben tese le catene extension boom (Fig. 70) keeping the Auszug (Abb. 70) herausziehen, wobei die
appoggiate sulla parte superiore, le quali chains resting on the upper part well auf der oberen Seite liegenden Ketten gut
potrebbero incastrarsi. stretched, to prevent their jamming. gespannt zu halten sind, weil sie sich ver-
heddern könnten.
18
MRT 1840 EASY 50
A A
D

B B

C C 63 64
F
F
65 66
A B
B
67 68
69 70
19
50 MRT 1840 EASY
IT EN DE
Smontare i pettini di attacco superiore Dismantle the upper connector comb in the Die oberen Anschlusskämme im vorderen
nella parte anteriore delle quattro catene di front part of the four chains of the 2nd Teil der vier Ausfahrketten des 2. Auszugs
uscita del braccio II° sfilo (Rif. A-Fig. 71). extension boom extension (Ref. A-Fig. 71). ausbauen (Bez. A-Abb. 71).
Smontare i tiranti di attacco (Rif. B-Fig. 72) Dismantle the tie rods (Ref. B-Fig. 72) con- Die Anschlussgestänge (Bez. B-Abb. 72)
per le catene di uscita del braccio II° sfilo, necting the 2nd extension boom extension für die Ausfahrketten des 2. Auszugs aus-
sfilandoli dagli appositi fori in coda al brac- chains, extracting them from the openings bauen, indem man sie aus den Löchern
cio II° sfilo. provided at the tail end of the 2nd exten- am unteren Ende des 2. Auszugs heraus-
sion boom. zieht.
Smontare i tiranti di attacco (Rif. C-Fig. 73) Dismantle the tie rods (Ref. C-Fig. 73) Die Anschlusszugstange (Bez. C-Abb. 73)
per le catene di uscita del braccio III° sfilo, connecting the 3rd extension boom exten- für die Ausfahrketten des 3. Auszugs aus-
sfilandoli dagli appositi fori in coda al brac- sion chains, extracting them through the bauen, indem man sie aus den Löchern
cio III° sfilo. openings at the tail end of the 3rd exten- am unteren Ende des 3. Auszugs heraus-
sion boom. zieht.
Scollegare fra loro i due pettini di attacco Detach the two upper chain connection Die beiden oberen Anschlusskämme der
superiore catene (Rif. D-Fig. 74) smontan- combs (Ref. D-Fig. 74) dismantling the pair Ketten (Bez. D-Abb. 74) voneinander tren-
do la coppia di bilanceri singoli (Rif. E-Fig. of single equalisers (Ref. E-Fig. 74). nen, indem man das Paar der einzelnen
74). Kipphebel ausbaut (Bez. E-Abb. 74).
20
MRT 1840 EASY 50
71 72
D D
C
73 74
21
50 MRT 1840 EASY
IT EN DE
MONTAGGIO DEL BRACCIO ASSEMBLING THE ENTIRE MONTAGE DES KOMPLETTEN

TELESCOPICO COMPLETO TELESCOPIC BOOM TELESKOPAUSLEGERS
Vorbereitungen
Operazioni preliminari Preliminary operations
Die Metallstruktur vorbereiten, indem man
Preparare la carpenteria verificando la cor- Prepare the structural work checking the
die korrekte Ausführung der
retta esecuzione dei fori filettati; eliminare correct drilling of the threaded holes;
Gewindebohrungen prüft; Grate von den
le bave dalle boccole per i perni, smeriglia- remove the burrs from the bushings for the
Buchsen für die Bolzen entfernen, etwaige
re eventuali colate di saldatura in corri- pins, and smooth welding drips in the pad
Schweissperlen auf der Höhe der
spondenza degli alloggiamenti per i pattini. seating.
Aufnahmen der Gleitschuhe abschmirgeln.
Premontare i tiranti di attacco per le catene Preassemble the chain connector tie rods
Die Zugstangen für den Kettenanschluss
(Rif. A-Fig. 1) avvitandoli ai pettini (Rif. B- (Ref. A-Fig. 1) screwing them to the combs
vormontieren (Bez. A-Abb 1), indem man sie
Fig. 1) e bloccandoli con il contro dado (Ref. B-Fig. 1) and locking them in place
an den Kämmen anschraubt (Bez. B-Abb. 1)
(Rif. C-Fig. 1). by means of the lock nut (Ref. C-Fig. 1).
und mit der Gegenmutter blockiert (Bez. C-
Abb. 1).
Premontaggio braccio III° sfilo (tavola 1) Preassembling the 3rd extension boom
Vormontage des 3. Auszugs (Tafel 1)
(Table 1)
Stendere le due catene (Rif. D-Fig. 2) di
Die beiden Ketten (Bez. D-Abb. 2) zum
uscita del braccio III° sfilo sul braccio. Extend the two 3rd extension boom exten-
Ausfahren des 3. Auszugs auf dem Ausleger
sion chains (Ref. D-Fig. 2) on the boom.
verlegen.
Die Kämme (Bez. E-Abb. 3) des oberen

Montare i pettini (Rif. E-Fig. 3) di attacco Fit the upper connecting combs (Ref. E-
Anschlusses im vorderen Teil der zwei ver-
superiore nalla parte anteriore delle due Fig. 3) in the front part of the two stretched
legten Ketten montieren.
catene distese. chains.
Die beiden oberen Anschlusskämme der

Collegare fra loro i pettini di attacco supe- Connect the two chain upper connecting
Ketten (Bez. F-Abb. 4) mit dem Paar der
riore catene (Rif. F-Fig. 4) con la coppia di combs (Ref. F-Fig. 4) to one another with
einzelnen Kippbolzen (Bez. G-Abb. 4) mit-
bilanceri singoli (Rif. G-Fig. 4). the pair of single equalisers (Ref. G-Fig. 4).
einander verbinden.
Die Kämme der Anschlusszugstangen (Bez.

Montare i pettini dei tiranti di attacco (Rif. Fit the connecting tie rods combs (Ref. A-
A-Abb. 5) an den Ketten der Rückseite des
A-Fig. 5) alle catene lato posteriore braccio Fig. 5) to the 3rd extension boom rear side
3. Auszugs montieren (Bez. B-Abb. 5).
III° sfilo (Rif. B-Fig. 5). chains (Ref. B-Fig. 5).
Die Zugstangen für den Anschluss der
Inserire i tiranti di attacco per le catene Insert the connecting tie rods for the
Ketten (Bez. C-Abb. 5) in die entsprechen-
(Rif. C-Fig. 5) negli appositi fori in coda al chains (Ref. C-Fig. 5) in the holes provided
den Löcher am unteren Ende des 3.
braccio III° sfilo ed avvitare il dado e con- at the tail end of 3rd extension boom and
Auszugs einstecken und die Mutter und
trodado (Rif. D-Fig. 5) fino ad inserire la screw on the nut and lock nut (Ref. D-Fig.
Gegenmutter anziehen (Bez. D-Abb. 5), bis
coppiglia di sicurezza (Rif. E-Fig. 5). 5) to insert the safety split pin (Ref. E-Fig.
der Sicherungssplint einrastet (Bez. E-Abb.
5).
5).
Die Ebenheit der Basis für die oberen

Verificare la planarità della base per i patti- Check the planarity of the base for the
Gleitschuhe (Seife Bez. F-Abb. 6) auf der
ni superiori (saponette Rif. F-Fig. 6) nella upper pads (saponette Ref. F-Fig. 6) in the
Rückseite vom 3. Auszug prüfen, ggf.
parte posteriore del braccio III° sfilo, even- rear part of 3rd extension boom, and
schmirgeln.
tualmente smerigliare. smooth, if necessary.
Vormontage des 2. Auszugs (Tafel 2)

Premontaggio braccio II° sfilo (tavola 2) Preassembling the 2nd extension boom
(Table 2)
Die Ketten (Bez. G-Abb. 7) zum Ausfahren
Stendere sul braccio le catene (Rif. G-Fig. Stretch the 2nd extension boom extension
des 2. Auszugs auf dem Ausleger verlegen.
7) di uscita del braccio II° sfilo. chains on the boom (Ref. G-Fig. 7).
Fit the connecting tie rod combs (Ref. H-

Die Kämme der Anschlusszugstangen
Montare i pettini dei tiranti di attacco (Rif. Fig. 8) to the 2nd extension boom rear
(Bez. H-Abb. 8) an den Ketten auf der
H-Fig. 8) alle catene lato posteriore brac- side chains (Ref. I-Fig. 8).
Rückseite des 2. Auszugs montieren (Bez.
cio II° sfilo (Rif. I-Fig. 8). Insert the chain connecting tie rods (Ref.
I-Abb. 8).
Inserire i tiranti di attacco per le catene L-Fig. 8) in the openings provided at the
Die Anschlusszugstangen für die Ketten
(Rif. L-Fig. 8) negli appositi fori in coda al tail end of the 2nd extension boom (Fig. 8)
(Bez. L-Abb. 8) in die entsprechenden
braccio II° sfilo (Fig. 8) ed avvitare il dado and screw on the nut and lock nut (Ref. M-
Löcher am unteren Ende des 2. Auszugs
e controdado (Rif. M-Fig. 8) fino ad inseri- Fig. 8) till the split pin (Ref. N-Fig. 8) is
stecken (Abb. 8) und die Mutter und
re la coppiglia di sicurezza (Rif. N-Fig. 8). inserted.
Gegenmutter anschrauben (Bez. M-Abb.
8), bis der Sicherungssplint einrastet (Bez.
N-Abb. 8).
22
MRT 1840 EASY 50
A
D D
1 2
F F
E G
E
3 4
Superfici complanari
Surfaces in the same plane
B
A
F
C
F
E 5 6
M I
L H
N
G
G G G
7 8
23
50 MRT 1840 EASY
IT EN DE
Montare i pettini (Rif. A-Fig. 9) di attacco Fit the upper connecting combs (Ref. A- Die Kämme (Bez. A-Abb. 9) für den oberen
superiore nella parte anteriore delle 4 cate- Fig. 9) in the front part of the four Anschluss auf der Vorderseite der 4 ver-
ne distese e tenderle manualmente. stretched chains, stretching them manual- legten Ketten montieren und sie von Hand
ly. spannen.
Assicurare le catene distese sul braccio Secure the chains stretched on the 3rd Die auf dem 3. Auszug und dem 2. Auszug
III° sfilo e sul braccio II° sfilo con del extension boom and 2nd extension boom verlegten Ketten mit gummiertem
nastro di carta gommata (Rif. B-Fig. 10), with rubberised adhesive tape (Ref. B-Fig. Papierband absichern (Bez. B-Abb. 10),
per evitare che durante le operazioni suc- 10), to prevent the chains falling off the um zu vermeiden, dass die Ketten bei den
cessive di montaggio le catene possano boom during subsequent assembly opera- anschließenden Montageschritten vom
cadere dal braccio. tions. Auslegerarm fallen können.
Ingrassare internamente il braccio II° sfilo Grease the inside of the 2nd extension Den 2. Auszug innen schmieren (Abb. 11)
(Fig. 11) (vedi tabella “Lubrificanti” sul boom (Fig. 11) (See “Lubricants” Table in (siehe Tabelle “Schmierstoffe” in der
manuale Uso e Manutenzione). the Use and Maintenance Manual). Betriebs- und Wartungsanleitung).
Inserimento del braccio III° sfilo nel Inserting the 3rd extension boom in the Einstecken des 3. Auszugs in den 2.
braccio II° sfilo (tavola 1-2) 2nd extension boom (Tables 1-2) Auszug (Tafel 1-2)
Con l’ausilio del carroponte o un elevatore Using a bridge crane or elevator, insert the Mit der Hilfe des Laufkrans oder eines
inserire il braccio III° sfilo all’interno del 3rd extension boom into the 2nd extension Gabelstaplers den 3. Auszug in das Innere
braccio II° sfilo (Fig. 12), lasciandolo fuori boom (Fig. 12), leaving out a 30÷35 cm des 2. Auszugs stecken (Abb. 12), wobei
man ihn 30-35 cm überstehen lässt, um
per un tratto di 30÷35 cm per facilitare il section to facilitate assembly of the front
die Montage der vorderen Gleitschuhe zu
montaggio dei pattini anteriori. pads.
vereinfachen.
Ogni volta che si deve fissare il pattino alla Each time the pad is to be fixed to the Jedes Mal, wenn man den Gleitschuh an
struttura del braccio si consiglia la seguen- boom structure, proceed as follows der Struktur des Auslegers befestigen
te procedura (Fig. 13): (Fig. 13): muss, ist die folgende Prozedur zu be-
achten (Abb. 13):
Posizionare il pattino (A) nella sede di Position pad (A) in the work seat; Den Gleitschuh (A) in seinen Arbeitssitz
lavoro; Tighten fixing screw (B) leaving a distance positionieren.
Avvitare la vite di fissaggio (B) lasciando of 4-5 mm between the end of the screw Die Befestigungsschraube (B) anziehen,
una distanza di 4-5 mm dall’estremità della and the pad operating surface; wobei ein Abstand von circa 4-5 mm von
vite alla superficie di lavoro del pattino; Block the screw by means of self-locking der Arbeitsfläche des Gleitschuhs zu las-
Bloccare la vite con un dado autobloccante nut (C). sen ist.
(C).
Die Schraube mit einer selbstsperrenden
Mutter (C) blockieren.
Montare i pattini superiori (Rif. D-Fig. 14) Fit the upper pads (Ref. D-Fig. 14) fixed to
fissati al braccio II° sfilo nella parte anterio- the 2nd extension boom in the front part
re e sollevare con il carroponte o un eleva- and, using a bridge crane or elevator, lift Die oberen Gleitschuhe montieren (Bez.
tore il braccio III° sfilo fino a battuta (Fig. the 3rd extension boom till it fits flush (Fig. D-Abb. 14), die am 2. Auszug auf der
14). 14). Vorderseite montiert sind, und dem 3.
Auszug mit einem Laufkran oder
Gabelstapler bis zum Anschlag heben
(Abb. 14).
Montare i pattini anteriori inferiori (Rif. E- Fit the lower front pads (Ref. E-Fig. 15) Die vorderen unteren Gleitschuhe (Bez. E-
Fig. 15) con i relativi spessori fissati al with the relative shims fixed to the 2nd Abb. 15) mit den dazugehörigen Beilagen
braccio II° sfilo nella parte anteriore in extension boom in the front part in such a montieren, die am 2. Auszug auf der
modo che non vi siano giochi eccessivi. way that there is no excessive play. Vorderseite befestigt sind, damit nicht zu
viel Spiel entsteht.
Calare il braccio III° sfilo lasciandolo ada- Lower the 3rd extension boom letting to
Den 3. Auszug senken, wobei man ihn auf
giare sui pattini fissati al II° sfilo. come to rest on the pads fixed to the 2nd
die Gleitschuhe senkt, die am 2. Auszug
extension.
befestigt sind.
24
MRT 1840 EASY 50
9 10
11 12

A
C
D
B
D
4-5mm
superficie del braccio
boom surface
13 14
E
E
15
25
50 MRT 1840 EASY
IT EN DE
Assicurarsi, con l’ausilio di una livella,che il Using a spirit level, make sure the “TS” Mit Hilfe einer Wasserwaage sicherstellen,
perno di incernieramento “TS” (Rif. A-Fig. (Ref. A-Fig. 16) of 3rd extension boom is dass der Kippbolzen “TS” (Bez. A-Abb. 16)
16) del braccio III° sfilo sia perfettamente perfectly parallel to the outside front sur- des 3. Auszugs vollkommen parallel zur
parallelo alla superficie anteriore esterna face of the 2nd extension boom (Ref. B- externen Vorderfläche des 2. Auszugs
del braccio II° sfilo (Rif. B-Fig. 17). Fig. 17). steht (Bez. B-Abb. 17).
Spessorare, se necessario, i pattini inferiori If necessary, fit shims to the lower pads Die unteren Gleitschuhe, die am 2. Auszug
fissati al braccio II° sfilo nella parte anterio- fixed to 2nd extension boom in the front an der Vorderseite befestigt sind, eventuell
re (Rif. E-Fig. 15-Pag. 23). part (Ref. E-Fig. 15-Pag. 23). mit Beilagen ausgleichen (Bez. E-Abb. 15-
Seite 23).
Centrare il braccio III° sfilo in rapporto al Align the 3rd extension boom in relation to Den 3. Auszug im Bezug zum 2. Auszug
braccio II° sfilo nella parte anteriore : the 2nd extension boom in the front part : auf der Vorderseite zentrieren:
- inserire i pattini laterali nella parte bassa, - insert the side pads at the bottom, fitting - Die seitlichen Gleitschuhe im unteren Teil
spessorando se necessario e fissandoli shims if necessary and fixing them to einstecken, sie bei Bedarf mit Beilagen
al braccio II° sfilo (Rif. C-Fig. 18); the 2nd extension boom (Ref. C-Fig. versehen und am 2. Auszug befestigen
- inserire i pattini laterali nella parte alta, 18); (Bez. C-Abb. 18).
spessorando se necessario e fissandoli - insert the side pads at the top, fitting - Die seitlichen Gleitschuhe im oberen Teil
al braccio II° sfilo (Rif. D-Fig. 18). shims if necessary and fixing them to einstecken, sie bei Bedarf mit Beilagen
the 2nd extension boom (Ref. D-Fig. versehen und am 2. Auszug befestigen
18). (Bez. D-Abb. 18).
Cospargere di grasso il braccio III° sfilo Smear grease on the 2nd extension boom Den 3. Auszug mit Fett einpinseln (Abb.
con un pennello (Fig. 18) (vedi tabella using a brush (Fig. 18) (See “Lubricants” 18) (siehe Tabelle “Schmierstoffe” in der
“Lubrificanti” sul manuale Uso e Table in the Use and Maintenance Betriebs- und Wartungsanleitung).
Manutenzione). Manual).
Fare rientrare di qualche cm il braccio III° Retract the 3rd extension boom by a few Den 3. Auszug um ein paar Zentimeter in
sfilo all’interno del braccio II° sfilo e cm into the 2nd extension boom and fit all den 2. Auszug einfahren lassen und alle
montare tutti i pattini posteriori fissati al the rear pads fixed to the 3rd extension hinteren Gleitschuhe montieren, die am 3.
braccio III° sfilo spessorando se necessa- boom, if necessary (Ref. A-Fig. 19). Auszug befestigt sind, um sie bei Bedarf
rio (Rif. A-Fig. 19). mit Beilagen zu versehen (Bez. A-Abb.
19).
Montare la carrucola (Rif. B-Fig. 20) nella Fit the pulley (Ref. B-Fig. 20) in the rear Die Rolle (Bez. B-Abb. 20) im hinteren Teil
parte posteriore del braccio II° sfilo, inseri- part of the 2nd extension boom, insert des 2. Auszugs montieren, den Kippbolzen
re il perno di incernieramento (Rif. C-Fig. pivot pin (Ref. C-Fig. 20) locking it by einstecken (Bez. C-Abb. 20) und mit der
20) bloccandolo all’apposita vite (Rif. D- means of the screw provided (Ref. D-Fig. entsprechenden Schraube blockieren
Fig. 20). 20). (Bez. D-Abb. 20).
Ingrassare il perno della carrucola (vedi Grease the pulley pin (See “Lubricants” Den Bolzen der Rolle schmieren (siehe
tabella “Lubrificanti” sul manuale Uso e Table in the Use and Maintenance Tabelle “Schmierstoffe” in der Betriebs-
Manutenzione). Manual). und Wartungsanleitung).
Verificare la planarità, nella parte posterio- Check the planarity of the surface in the Im hinteren Teil oben des 2. Auszugs die
re superiore del braccio II° sfilo, della upper top part of the 2nd extension boom, Ebenheit der Flächen prüfen, wo die
superficie dove andranno posizionati i pat- on which the pads will be positioned. Gleitschuhe angeordnet werden. Eventuell
tini. Eventualmente smerigliare (Rif. E-Fig. Smooth, if necessary (Ref. E-Fig. 21). schmirgeln (Bez. E-Abb. 21).
21).
26
MRT 1840 EASY 50
16 17
A A
D
A A
A A
18 19
Superfici complanari
Surfaces in the same plane
B E
E
D
20 21
27
50 MRT 1840 EASY
IT EN DE
Premontaggio braccio I° sfilo (tavola 3) Preassembling 1st extension boom Vormontage 1. Auszug (Tafel 3)
(Table 3)
Stendere la catena per il rientro del III°
sfilo (Rif. A-Fig. 22) all’interno del braccio Spread the chain for retracting 3rd exten- Die Kette zum Einfahren des 3. Auszugs
I° sfilo. Per compiere questa operazione è sion (Ref. A-Fig. 22) into the 2nd extension (Bez. A-Abb. 22) innerhalb des 1. Auszugs
possibile procedere legando la catena boom. To carry out this operation, proceed verlegen. Um diesen Vorgang auszu-
all’etremità di un’asta adeguatamente by securing the chain to the end of a suit- führen, kann man die Kette am Ende einer
lunga. ably long rod. Stange mit angemessener Länge anbin-
den.
Montare il tirante (Rif. B-Fig. 23) con il Fit the tie rod (Ref. B-Fig. 23) with the rela- Die Zugstange (Bez. B-Abb. 23) mit dem
relativo pettine (Rif. C-Fig. 23) all’estremità tive combs (Ref. C-Fig. 23) to the front end dazugehörigen Kamm (Bez. C-Abb. 23)
anteriore della catena (Rif. D-Fig. 23). of the chain (Ref. D-Fig. 23). am vorderen Kettenende montieren (Bez.
D-Abb. 23).
Nella parte anteriore del braccio I° sfilo, In the front part of the 1st extension boom,
verificare la giusta corrispondenza tra bat- check the alignment between the stop and Im vorderen Teil des 1. Auszugs auf richti-
tuta e fori del blocchetto (Rif. E-Fig. 23) holes on the block (Ref. E-Fig. 23) for fix- ges Übereinstimmen zwischen Anschlag
per il fissaggio del tirante catena rientro III° ing the 3rd extension retraction chain tie und Löchern im Block (Bez. E-Abb. 23) für
sfilo. rod. die Befestigung der Zugstange für die
Einfahrkette des 3. Auszugs prüfen.
Legare un cavetto all’etremità posteriore Tie a cable to the rear end of the 3rd Ein Kabel am hinteren Ende der
della catena di rientro del braccio III° sfilo extension boom retraction chain (Ref. F- Einfahrkette des 3. Auszugs anbinden
(Rif. F-Fig. 24) e tenderla manualmente. Fig. 24) and stretch it manually. (Bez. F-Abb. 24) und die Kette von Hand
spannen.
Sfilare leggermente l’attacco anteriore Slightly extract the front connection of the Den vorderen Anschluss der Einfahrkette,
della catena di rientro adagiata all’interno retraction chain resting inside the 1st die im Inneren des 1. Auszugs liegt, leicht
del braccio I° sfilo (Fig. 25). extension boom (Fig. 25). herausziehen (Abb. 25).
Inserimento dei bracci II° e III° sfilo Inserting the 2nd and 3rd extension Einstecken des 2. und 3. Auszugs in
nel braccio I° sfilo (tavola 3) booms in the 1st extension boom (Table 3) den 1. Auszug (Tafel 3)
Con l’ausilio del carroponte o un elevatore With the help of a bridge crane or elevator, Mit der Hilfe des Laufkrans oder des
Inserire i bracci II° e III° sfilo all’interno del insert 2nd and 3rd booms into 2nd exten- Gabelstaplers den 2. und 3. Auszug in das
braccio I° sfilo (Fig. 29) lasciandoli fuori sion boom (Fig. 29) leaving out a section Innere des 1. Auszugs (Abb. 29) stecken
per un tratto di circa 30÷35 cm per facilita- of about 30÷35 cm to facilitate assembly of und eine Strecken von circa 30-35 cm
re il montaggio dei pattini anteriori. the front pads. überstehen lassen, um die Montage der
vorderen Gleitschuhe zu vereinfachen.
Fare passare le catene (Rif. A-Fig. 27), Pass the chains (Ref. A-Fig. 27), previous- Die zuvor auf dem 2. Auszug verlegten
precedentemente adagiate sul braccio II° ly resting on the 2nd extension boom Ketten (Bez. A-Abb. 27) in die vorderen
sfilo, all’interno delle aperture anteriori inside the upper front openings of 2nd Öffnungen oben auf dem 1. Auszug
superiori del braccio I° sfilo (Rif. B-Fig. 27). extension boom (Ref. B-Fig. 27). stecken (Bez. B-Abb. 27).
Montare, il pattino anteriore superiore (Rif. Fit the upper front pad (Ref. C-Fig. 28) Den vorderen oberen Gleitschuh (Bez. C-
C-Fig. 28) fissato al braccio I° sfilo nella fixed to 1st extension boom in the front Abb. 28), der am 1. Auszug im vorderen
parte anteriore e sollevare con il carropon- part and lift the 2nd and 3rd extension Teil montiert ist, montieren und den 2. und
te o un elevatore i bracci II° e III° sfilo fino booms using a bridge crane or elevator, till 3. Auszug mit dem Laufkran oder einem
a battuta. they fit flush. Gabelstapler bis zum Anschlag heben.
Die unteren Gleitschuhe (Bez. D-Abb. 29)

Fit the lower pads (Ref. D-Fig. 29) with mit den dazugehörigen Beilagen montieren
Montare i pattini inferiori (Rif. D-Fig. 29) their shims (Ref. E-Fig. 29) fixed to the 1st (Bez. E-Abb. 29), die am 1. Auszug im vor-
con gli appositi spessori (Rif. E-Fig. 29) fis- extension boom in the front part in such a deren Teil befestigt sind, damit kein zu
sati al braccio I° sfilo nella parte anteriore way that there is no excessive play. großes Spiel vorliegt.
in modo che non vi siano giochi eccessivi. Lower the 2nd and 3rd extension booms Den 2. und 3. Auszug senken, bis er auf
Calare il braccio II° e III° sfilo lasciandoli letting them come to rest on the pads fixed den Gleitschuhen aufliegt, die am 1.
adagiare sui pattini fissati al I° sfilo. to the 1st extension. Auszug befestigt sind.
28
MRT 1840 EASY 50

C
E
A 22 23
24 25
A
A

B B
26 27
D
C
E
28 29
29
50 MRT 1840 EASY
IT EN DE
Con l’ausilio di una livella assicurarsi che il Using a spirit level, make sure that the Mit Hilfe einer Wasserwaage sicherstellen,
perno di incernieramento “TS” (Rif. A-Fig. “TS” pivot pin “TS” (Ref. A-Fig. 30) of the dass der Kippbolzen “TS” (Bez. A-Abb. 30)
30) del braccio III° sfilo sia perfettamente 3rd extension boom is perfectly parallel to des 3. Auszugs vollkommen parallel zur
parallelo alla superficie anteriore esterna the outside front surface of the 1st exten- externen Vorderfläche des 1. Auszugs
del braccio I° sfilo (Rif. B-Fig. 31). sion boom (Ref. B-Fig. 31). steht (Bez. B-Abb. 31).
Spessorare, se necessario, i pattini inferiori If necessary, fit shims to the lower pads Die unteren Gleitschuhe, die am 2. Auszug
fissati al braccio I° sfilo nella parte anterio- fixed to the 1st extension boom in the front an der Vorderseite befestigt sind, eventuell
re (Rif. D-Fig. 29-Pag. 27). part (Ref. D-Fig. 29-Pag. 27). mit Beilagen ausgleichen (Bez. D-Abb. 29-
Seite 27).
Centrare i bracci II° e III° sfilo in rapporto Align 2nd and 3rd extension booms to the Den 2. und 3. Auszug im Bezug zum 1.
al braccio I° sfilo nella parte anteriore : 1st extension boom in the front part : Auszug auf der Vorderseite zentrieren:
- inserire i pattini laterali nella parte bassa, - insert the side pads in the lower part, fit- - Die seitlichen Gleitschuhe im unteren Teil
spessorando se necessario e fissandoli ting shims to them if necessary, and fix einstecken, sie bei Bedarf mit Beilagen
al braccio I° sfilo (Rif. C-Fig. 32); them to the 1st extension boom (Ref. C- versehen und am 1. Auszug befestigen
- inserire i pattini laterali nella parte alta, Fig. 32); (Bez. C-Abb. 32).
spessorando se necessario e fissandoli - insert the side pads in the top part, fitting - Die seitlichen Gleitschuhe im oberen Teil
al braccio I° sfilo (Rif. D-Fig. 32). shims to them if necessary, and fix them einstecken, sie bei Bedarf mit Beilagen
to the 1st extension boom (Ref. D-Fig. versehen und am 1. Auszug befestigen
32). (Bez. D-Abb. 32).
Cospargere di grasso il braccio III° sfilo
con un pennello (vedi tabella “Lubrificanti” Smear the 3rd extension boom with grease Den 3. Auszug mit Fett einpinseln (siehe
sul manuale Uso e Manutenzione). using a brush (See “Lubricants” Table in Tabelle “Schmierstoffe” in der Betriebs-
the Use and Maintenance Manual). und Wartungsanleitung).
Legare il blocchetto anteriore il fissaggio

della catena in modo che non possa cade- Tie the front block to the chain to prevent it Den vorderen Block zur Befestigung der
re a terra durante le operazioni successive falling to the ground during subsequent Kette so anbringen, dass er während der
(Rif. E-Fig. 33). operations (Ref. E-Fig. 33). anschließenden Vorgänge nicht hinfallen
kann (Bez. E-Abb. 33).
Sollevare il braccio II° sfilo all’interno del I° Lift the 2nd extension boom inside the 1st Den 2. Auszug innerhalb des 1. Auszugs
sfilo aon l’ausilio di un crick idraulico nella extension boom using a hydraulic jack in mit der Hilfe einer hydraulischen Winde im
parte posteriore (Rif. A-Fig. 34). the rear part (Ref. A-Fig. 34). hinteren Teil heben (Bez. A-Abb. 34).
Con l’aiuto del cavo precedentemente Using the cable previously tied to the Mit der Hilfe des zuvor an der Kette ange-
legato alla catena, farla passare all’interno chain, pass it through the opening in the bundenen Kabels sie in die Öffnung im
dell’apertura nella parte posteriore inferiore lower rear part of the 2nd extension boom, hinteren Teil unten des 2. Auszugs gleiten
del braccio II° sfilo, dove è alloggiata la where the pulley is housed (Ref. B-Fig. lassen, wo sich die Rolle befindet (Bez. B-
carrucola (Rif. B-Fig. 34). 34). Abb. 34).
Fissare al blocchetto anteriore il fissaggio Fix the chain fastening to the front block by Die Befestigung der Kette mit den dazu
della catena tramite le apposite viti (Rif. C- means of the screws provided (Ref. C-Fig. vorgesehehen Schrauben am vorderen
Fig. 35). 35). Block befestigen (Bez. C-Abb. 35).
Togliere il crick all’interno del braccio I° Remove the jack from inside the 1st exten- Die Winde aus dem Inneren des 1.
sfilo e montare i pattini posteriori superiori sion boom and fit the 2nd extension boom Auszugs herausnehmen und die hinteren,
e laterali braccio II° sfilo (Rif. D-Fig. 36). top and side pads (Ref. D-Fig. 36). oberen und seitlichen Gleitsschuhe des 2.
Auszugs montieren (Bez. D-Abb. 36).
Risollevare il braccio II° sfilo all’interno del Lift the 2nd extension boom again into the Den 2. Auszug innerhalb des 1. Auszugs
braccio I° sfilo con l’ausilio del crick idrauli- 1st extension boom using the hydraulic mit der Hilfe einer hydraulischen Winde
co e montare i pattini posteriori inferiori jack and fit the lower rear pads (Ref. E-Fig. wieder heben und die hinteren unteren
(Rif. E-Fig. 37) con i relativi spessori. 37) together with the relative shims. Gleitschuhe mit den dazugehörigen
Beilagen montieren (Bez. E-Abb. 37).
30
MRT 1840 EASY 50
30 31
32 33
A C C
B
34 35
D
D
36 37
31
50 MRT 1840 EASY
IT EN DE
Togliere il crick idraulico all’interno del Remove the hydraulic jack from inside the Die hydraulische Winde aus dem 1.
braccio I° sfilo e montare il pettine (Rif. A- 1st extension boom and fit the combs (Ref. Auszug herausnehmen und den Kamm
Fig. 38) per il fissaggio posteriore della A-Fig. 38) for rear fixing of the 3rd exten- (Bez. A-Abb. 38) für die hintere
catena (Rif. B-Fig. 38) di rientro del brac- sion boom retraction chain (Ref. B-Fig. Befestigung der Einfahrkette (Bez. B-Abb.
cio III° sfilo. 38). 38) des 3. Auszugs montieren.
Fissare il pettine con la catena nella parte Fix the combs with the chain in the rear Den Kamm mit der Kette im hinteren Teil
posteriore del braccio III° sfilo (Rif. C-Fig. part of the 3rd extension boom (Ref. C-Fig. des 3. Auszugs befestigen (Bez. C-Abb.
39). 39). 39).
Richiudere completamente su se stessi i 3 Fold the three extension booms down Die 3 bisher montierten Auszüge unterein-
bracci sfilo finora montati fra loro, tenendo assembled together, keeping the chain ander ganz schließen, wobei die Ketten
tese le catene per evitare che si incastrino. stretched to prevent it getting jammed. gespannt zu halten sind, damit sie sich
nicht verheddern.
Premontaggio braccio esterno Preassembling the outside boom (Table Vormontage des externen Auslegerarms
(tavola 4) 4) (Tafel 4)
Dopo avere ingrassato internamente le After greasing the inside walls of the out- Nach dem Schmieren der Innenwände des
pareti del braccio esterno, stendervi le side boom, stretch out the 2nd extension externen Auslegerarms die Ketten (Bez. D-
catene (Rif. D-Fig. 40) per il rientro del boom retraction chains (Ref. D-Fig. 40). Abb. 40) für das Einfahren des 2. Auszugs
braccio II° sfilo. darin verlegen.
Montare i tiranti (Rif. E-Fig. 41) con i relati- Fit the tie rods (Ref. E-Fig. 41) with the rel- Die Zugstangen (Bez. E-Abb. 41) mit den
vi pettini (Rif. F-Fig. 41) all’estremità ante- ative combs (Ref. F-Fig. 41) to the front dazugehörigen Kämmen (Bez. F-Abb. 41)
riore delle catene (Rif. G-Fig. 41). end of the chains (Ref. G-Fig. 41). am vorderen Ende der Ketten montieren
(Bez. G-Abb. 41).
Inserire i tiranti di attacco negli appositi fori Insert the connecting tie rods in the holes Die Zugstangen des Anschlusses in den
nella parte anteriore inferiore del braccio provided in the lower front part of the out- entsprechenden Löchern im vorderen Teil
esterno (Fig. 42-43) ed avvitare il dado e side boom (Fig. 42-43) and fit the nut and unten am externen Auslegerarm (Abb. 42-
controdado (Rif. A-Fig. 43) fino ad inserire lock nut (Ref. A-Fig. 43) to insert the check 43) einstecken und die Mutter und
la coppiglia di sicurezza (Rif. B-Fig. 43). pin (Ref. B-Fig. 43). Gegenmutter anziehen (Bez. A-Abb. 43),
bis der Sicherungssplint einrastet (Bez. B-
Abb. 43).
Montare i pettini (Rif. C-Fig. 44) all’estre- Fit the combs (Ref. C-Fig. 44) to the rear Die Kämme (Bez. C-Abb. 44) am hinteren
mità posteriore delle catene (Rif. D-Fig. end of the chains (Ref. D-Fig. 44) and Ende der Ketten montieren (Bez. D-Abb.
44) e tendere quest’ultime verso il poste- stretch these towards the rear of the out- 44) und die Ketten zum hinteren Teil des
riore del braccio esterno. side boom. externen Auslegerarms spannen.
32
MRT 1840 EASY 50
A C
38 39
D
D
G
E
40 41
42 43
D D
C C
44
33
50 MRT 1840 EASY
IT EN DE
Inserire dei bracci I°, II° e III° sfilo Insert the 1st, 2nd and 3rd exten- Einstecken des 1., 2. und 3. Auszugs in
nel braccio sion booms in the outside boom den externen Auslegerarm (Tafel 4)
esterno (tavola 4) (Table 4)
Mit der Hilfe eines Laufkrans oder eines
Con l’ausilio di un carroponte o un elevato- Using a bridge crane or elevator, insert the Gabelstaplers den 1., 2. und 3. Auszug in
re, infilare i bracci I°, II° e III° sfilo all’inter- 1st, 2nd and 3rd extension booms into the das Innere des externen Auslegerarms
no del braccio esterno (Fig. 45) lasciandoli outside boom (Fig. 45) leaving out a sec- stecken (Abb. 45), wobei man sie um eine
fuori per un tratto di circa 30÷35 cm per tion about 30÷35 cm long to facilitate Strecke von circa 30-35 cm überstehen
facilitare il montaggio dei pattini anteriori. assembly of the front pads. lässt, um die Montage der vorderen
Gleitschuhe zu vereinfachen.
Mit der Hilfe eines Laufkrans oder eines

Con l’ausilio di un carroponte o di un ele- Using a bridge crane or elevator, lift the Gabelstaplers den 1., 2. und 3. Auszug
vatore sollevare i bracci I°, II° e III° sfilo 1st, 2nd and 3rd extension booms to fit the heben, um die unteren Gleitschuhe zu
per montare i pattini inferiori fissati al brac- lower pads fixed to the outside boom (Ref. montieren, die am externen Auslegerarm
cio esterno (Rif. A-Fig. 46) nella parte A-Fig. 46) in the front part. (Bez. A-Abb. 46) auf der vorderen Seite
anteriore. Let the 1st, 2nd and 3rd extension booms montiert sind.
Lasciare adagiare i bracci I°, II° e III° sfilo rest on the lower pads fixed to the outside Den 1., 2. und 3. Auszug auf den unteren
sui pattini inferiori fissati al braccio esterno boom, and using a spirit level, make sure Gleitschuhen aufliegen lassen, die am
e con l’ausilio di una livella assicurarsi che the outside boom pivot pin (Ref. B-Fig. 47) externen Auslegerarm befestigt sind, und
il perno di incernieramento braccio esterno is perfectly parallel to the “TS” (Ref. C-Fig. mit der Hilfe einer Wasserwaage feststel-
(Rif. B-Fig. 47) sia perfettamente parallelo 48) of the 3rd extension boom. len, dass der Kippbolzen des externen
al perno di incernieramento “TS” (Rif. C- If necessary, fit shims to the lower pads Auslegerarms (Bez. B-Abb. 47) vollkom-
Fig. 48) del braccio III° sfilo. fixed to the outside boom in the front part men parallel zum Kippbolzen “TS” (Bez. C-
Spessorare, se necessario, i pattini inferiori (Ref. D-Fig. 46). Abb. 48) des 3. Auszugs steht.
fissati al braccio esterno nella parte ante- Die unteren Gleitschuhe, die am externen
riore (Rif. D-Fig. 46). Auslegerarm im vorderen Teil befestigt
sind, bei Bedarf mit Beilagen versehen
(Bez. D-Abb. 46).
Montare i pattini superiori (Rif. A-Fig. 49) Fit the top pads (Ref. A-Fig. 49) with the
con i relativi spessori fissati al braccio relative shims fixed to the outside boom in Die oberen Gleitschuhe (Bez. A-Abb. 49)
esterno nella parte anteriore. the front part. mit den entsprechenden Beilagen montie-
ren, die am externen Auslegerarm auf der
Centrare i bracci I°, II° e III° sfilo in rappor- Align the 1st, 2nd and 3rd extension Vorderseite befestigt sind.
to al braccio esterno nella parte anteriore : booms to the outside boom in the front
- inserire i pattini laterali nella parte bassa, part : Den 1., 2. und 3. Auszug im Bezug zum
spessorando se necessario e fissandoli - insert the side pads in the lower part, fit- externen Auslegerarm auf der Vorderseite
al braccio esterno (Rif. B-Fig. 49); ting shims if necessary, and fixing them zentrieren:
- inserire i pattini laterali nella parte alta, to the outside boom (Ref. B-Fig. 49); - Die seitlichen Gleitschuhe im unteren Teil
spessorando se necessario e fissandoli - insert the side pads at the top, fitting einstecken, bei Bedarf mit Beilagen ver-
al braccio esterno (Rif. C-Fig. 49). shims if necessary, and fixing them to sehen und am externen Auslegerarm
the outside boom (Ref. C-Fig. 49). befestigen (Bez. B-Abb. 49);
- Die seitlichen Gleitschuhe in den oberen
Con l’ausilio del carroponte o un elevatore Using a bridge crane or elevator, close the Teil einstecken, bei Bedarf mit Beilagen
chiudere quasi completamente il braccio assembled boom almost completely (Fig. versehen und am externen Auslegerarm
assemblato (Fig. 50), fino ad avere coas- 50), till the holes of the bushings present in befestigen (Bez. C-Abb. 49).
sialità dei fori delle boccole presenti nella the rear part of the outside boom and 1st
parte posteriore del braccio esterno e del extension boom are perfectly coaxial (Ref.
braccio I° sfilo (Rif. D-Fig. 51). D-Fig. 51). Mit der Hilfe des Laufkrans oder eines
Gabelstaplers den zusammengebauten
Sollevare il braccio I° sfilo nella parte Lift the 1st extension boom in the rear part Ausleger fast ganz schließen (Abb. 50), bis
posteriore all’interno del braccio esterno into the outside boom placing a pad tem- die Koaxialität zwischen den Löchern der
sottoponendovi provvisoriamente un patti- porarily under it (Ref. E-Fig. 52). This will Buchsen im hinteren Teil des Auslegers
no (Rif. E-Fig. 52). In questo modo si libe- release the chains (Ref. F-Fig. 52). und des 1. Auszugs besteht (Bez. D-Abb.
reranno le catene (Rif. F-Fig. 52). 51).
Montare la carrucola (Rif. G-Fig. 52) nella Fit the pulley (Ref. G-Fig. 52) in the rear Den 1. Auszug im hinteren Teil innerhalb
parte posteriore del braccio I° sfilo bloc- part of the 1st extension boom locking the des externen Auslegerarms heben und
cando il perno (Rif. H-Fig. 52) tramite pin (Ref. H-Fig. 52) by means of the screw provisorisch einen Gleitschuh dazwischen
l’apposita vite (Rif. I-Fig. 52). provided (Ref. I-Fig. 52). legen (Bez. E-Abb. 52). Auf diese Weise
werden die Ketten freigegeben (Bez. F-
Ingrassare il perno della carrucola (vedi Grease the pulley pin (See the “Lubricants” Abb. 52).
tabella “Lubrificanti” sul manuale Uso e Table in the Use and Maintenance
Manutenzione). Manual). Die Rolle (Bez. G-Abb. 52) im hinteren Teil
des 1. Auszugs montieren und den Bolzen
(Bez. H-Abb. 52) mit der entsprechenden
Schraube blockieren (Bez. I-Abb. 52).
Den Bolzen der Rolle schmieren (siehe

Tabelle “Schmierstoffe” in der Betriebs-
und Wartungsanleitung).
34
MRT 1840 EASY 50
D
D
45 46
47 48

A
A
C

B
49 50
D
H
E
G
I
F F
51 52
35
50 MRT 1840 EASY
IT EN DE
Fissare i pettini (Rif. A-Fig. 53) delle 2 Fix the combs (Ref. A-Fig. 53) of the two Die Kämme (Bez. A-Abb. 53) der 2 Ketten
catene al braccio II° sfilo. chains to the 2nd extension boom. am 2. Auszug montieren.
Montare il pattino (Rif. B-Fig. 53) per lo Fit the extension cylinder track pad (Ref. Den Kamm (Bez. B-Abb. 53) für das
scorrimento del cilindro di sfilo. B-Fig. 53). Gleiten des Auszugszylinders montieren.
Montare le carrucole (Rif. C-Fig. 54) nella Fit the pulleys (Ref. C-Fig. 54) in the upper Die Rollen (Bez. C-Abb. 54) im vorderen
parte anteriore superiore del braccio I° sfilo front part of the 1st extension boom lock- Teil oben am 1. Auszug montieren, indem
bloccando il perno (Rif. D-Fig. 54) tramite ing the pin (Ref. D-Fig. 54) by means of man den Bolzen (Bez. D-Abb. 54) mit der
l’apposita vite (Rif. E-Fig. 54). the screw provided (Ref. E-Fig. 54). Schraube (Bez. E-Abb. 54) blockiert.
Ingrassare il perno delle carrucole (vedi Grease the pulley pin (See the “Lubricants” Den Bolzen der Rollen schmieren (siehe
tabella “Lubrificanti” sul manuale Uso e Table in the Use and Maintenance Tabelle “Schmierstoffe” in der Betriebs-
Manutenzione). Manual). und Wartungsanleitung).
Montare la carrucola (Rif. F-Fig. 55) nella Fit the pulley (Ref. F-Fig. 55) in the upper Die Rolle (Bez. F-Abb. 55) am vorderen
parte anteriore superiore del braccio II° front part of the 2nd extension boom lock- Teil oben am 2. Auszug montieren, indem
sfilo bloccando il perno (Rif. G-Fig. 55) tra- ing the pin (Ref. G-Fig. 55) by means of man den Bolzen (Bez. G-Abb. 55) mit der
mite l’apposita vite (Rif. H-Fig. 55). the screw provided (Ref. H-Fig. 55). entsprechenden Schraube (Bez. H-Abb.
55) blockiert.
Grease the pulley pin (See the “Lubricants”
Ingrassare il perno della carrucola (vedi Table in the Use and Maintenance Den Bolzen der Rolle schmieren (siehe
tabella “Lubrificanti” sul manuale Uso e Manual). Tabelle “Schmierstoffe” in der Betriebs-
Manutenzione). und Wartungsanleitung).
Die 6 Ketten zum Ausfahren der

Fissare le 6 catene per la fuoriuscita dei Fix the six chains for drawing out the Auslegerarme mit den entsprechenden
bracci attraverso gli appositi bilanceri (Rif. booms through the equalisers provided for Kipphebeln befestigen (Bez. I-Abb. 56).
I-Fig. 56). the purpose (Ref. I-Fig. 56).
Montaggio dei martinetti sul Assembling the cylinders on the boom Montage der Zylinder auf dem
braccio (tavola 5) (Table 5) Auslegerarm (Tafel 5)
Controllare che sul cilindro di sfilo siano Check to ensure the rollers (Ref. A-Fig. Sicherstellen, dass auf dem Auszugs-
montati correttamente i rulli (Rif. A-Fig. 57), 57), and valve block (Ref. B-Fig. 57) are zylinder die Rollen (Bez. A-Abb. 57), der
la slitta (Rif. B-Fig. 57) e il blocco valvola fitted correctly on the extension cylinders Schlitten (Bez. B-Abb. 57) und der
(Rif. C-Fig. 58). (Ref. C-Fig. 58). Ventilblock (Bez. C-Abb. 58) korrekt mon-
tiert sind.
Con l’ausilio di un carroponte o un elevato- Using a bridge crane or elevator, insert the Mit der Hilfe eines Laufkrans oder
re inserire il cilindro di sfilo (Rif. D-Fig. 59) extension cylinder (Ref. D-Fig. 59) into the Gabelstaplers den Auszugzylinder (Bez. D-
all’interno del braccio mantenendo il bloc- boom keeping the valve block (Ref. E-Fig. Abb. 59) in das Innere des Auslegers
co valvole (Rif. E-Fig. 60) rivolto verso il 60) facing downwards. stecken, wobei der Ventilblock (Bez. E-
basso. Abb. 60) nach unten zeigen muss.
36
MRT 1840 EASY 50
B
C
A A C
53 54
I
F
H
G I
55 56
B
A
57 58
D

59 60
37
50 MRT 1840 EASY
IT EN DE
Centrare i fori delle boccole presenti sul Align the bushing holes on the 1st exten- Die Löcher der Buchsen, die auf dem 1.
braccio I° sfilo con le sedi dei perni sulla sion boom with the pin seats on the exten- Auszug vorhanden sind, mit den Sitzen der
camicia del cilindro di sfilo (Fig. 61). sion cylinder liner (Fig. 61). Bolzen auf der Laufbuchse des
Auszugszylinders zentrieren (Abb. 61).
Inserire i perni di incernieramento (Rif. A- Insert the pivot pin (Ref. A-Fig. 62) Die Kippbolzen (Bez. A-Abb. 62) zwischen
Fig. 62) tra cilindro di sfilo e braccio I° sfilo between the extension cylinder and 1st des Auszugszylinder und den 1. Auszug
e fissare i perni con le viti (Rif. B-Fig. 63) extension boom and fix the pins by means stecken und die Bolzen mit den Schrauben
al cilindro. of screws (Ref. B-Fig. 63) to the cylinder. (Bez. B-Abb. 63) am Zylinder befestigen.
Inserire il perno di incernieramento (Rif. C- Insert the pivot pin (Ref. C-Fig. 64) Den Kippbolzen (Bez. C-Abb. 64) zwi-
Fig. 64) tra cilindro di sfilo e braccio ester- between the extension cylinder and out- schen Auszugszylinder und externem
no e fissarlo con i seeger (Rif. D-Fig. 64). side boom and fix by means of snap rings Auslegerarm einstecken und mit den
N.B. Se necessario, sollevare il cilindro di (Ref. D-Fig. 64). Seegerringen befestigen (Bez. D-Abb. 64).
sfilo, con l’ausilio del carroponte o un ele- N.B. If necessary, lift the extension cylinder Anm.: Falls erforderlich, den
vatore, per centrare il foro di incerniera- by means of a bridge crane or elevator, to Auszugszylinder mit der Hilfe des
mento col braccio esterno. align the pivot hole with the outside boom. Laufkrans oder eines Gabelstaplers heben,
Ingrassare il perno del cilindro di sfilo (vedi Grease the extension cylinder pin (See the um das Scharnierloch auf den externen
tabella “Lubrificanti” sul manuale Uso e “Lubricants” Table in the Use and Auslegerarm zu zentrieren.
Manutenzione). Maintenance Manual). Den Bolzen des Auszugszylinders schmie-
ren (siehe Tabelle “Schmierstoffe” in der
Betriebs- und Wartungsanleitung).
Montare i pattini inferiori (Rif. A-Fig. 65) Fit the lower pads (Ref. A-Fig. 65) with the Die unteren Gleitschuhe (Bez. A-Abb. 65)
con i relativi spessori fissati al braccio relative shims fixed to the outside boom in mit den entsprechenden Beilagen montie-
esterno nella parte posteriore. the rear part. ren, die am externen Auslegerarm im hin-
teren Teil befestigt sind.
Montare i pattini superiori (Rif. B-Fig. 66) e Fit the upper (Ref. B-Fig. 66) and side Die oberen (Bez. B-Abb. 66) und die seit-
laterali (Rif. C-Fig. 66), con i relativi spes- (Ref. C-Fig. 66), pads, with the relative lichen Gleitschuhe (Bez. C-Abb. 66) mit
sori fissati al braccio esterno nella parte shims fixed to the outside boom in the rear den entsprechenden Beilagen montieren,
posteriore. part. die am externen Auslegerarm im hinteren
Teil befestigt sind.
Con l’ausilio del carroponte o di un eleva- Using a bridge crane or elevator, insert the Mit der Hilfe des Laufkrans oder eines
tore inserire il cilindro di brandeggio (Rif. tilting cylinder (Ref. D-Fig. 67) in the 3rd Gabelstaplers den Schwenkzylinder (Bez.
D-Fig. 67) nella sede del braccio III° sfilo. extension boom seat. D-Abb. 67) in den Sitz im 3. Auszug ein-
Inserire il perno di incernieramento (Rif. E- Insert the tilting cylinder pivot pin (Ref. E- stecken.
Fig. 67) cilindro di brandeggio e bloccarlo Fig. 67) and block it by means of the Den Kippbolzen (Bez. E-Abb. 67) des
tramite l’apposita vite (Rif. F-Fig. 67). screw (Ref. F-Fig. 67). Schwenkzylinders einstecken und mit der
Ingrassare il perno di incernieramento Grease the tilting cylinder pivot pin (See entsprechenden Schraube (Bez. F-Abb.
cilindro di brandeggio (vedi tabella the “Lubricants” Table in the Use and 67) blockieren.
“Lubrificanti” sul manuale Uso e Maintenance Manual). Den Kippbolzen des Schwenkzylinders
Manutenzione). schmieren (siehe Tabelle “Schmierstoffe”
in der Betriebs- und Wartungsanleitung).
38
MRT 1840 EASY 50
61 62

B
63 64
B B
C C
65 66
D
67
39
50 MRT 1840 EASY
IT EN DE
Registrazione del braccio Adjusting the boom Einstellung des Auslegers
Con l’ausilio di una centralina idraulica, Using a hydraulic unit, connect the two Mit der Hilfe einer hydraulischen
collegare due tubi al cilindro di sfilo. pipes to the extension cylinder. Krafteinheit zwei Leitungen am
Eseguire il comando di rientro braccio fino Retract the boom up to the extension cylin- Auszugszylinder befestigen.
a fine corsa del cilindro di sfilo. der end-of-stroke. Den Befehl zum Einfahren des Auslegers
bis zum Anschlag des Auszugszylinders
erteilen.
Avvitare completamente il dado sul tirante Tighten the nut on the 3rd extension boom Die Mutter auf der Zugstange der
della catena di rientro braccio III° sfilo (Rif. retraction chain completely (Ref. A-Fig. 68) Einfahrkette des 3. Auszugs (Bez. A-Abb.
A-Fig. 68) fino al contatto della battuta di ight up to the end of travel up to the stop 68) ganz bis zum Kontakt mit dem
fine corsa (Rif. B-Fig. 69). (Ref. B-Fig. 69). Anschlag festschrauben (Bez. B-Abb. 69).
Ottenuto il contatto della piastra di fine When the end-of-travel plate makes con- Nach Erhalten des Kontakts mit der
corsa, creare un pretensionamento della tact, create pre-stretching of the chain by Anschlagplatte eine Vorspannung der
catena avvitando ulteriormente il dado di 5 tightening the nut further by 5 mm and Kette schaffen, indem man die Mutter um
mm e bloccarlo col controdado. block it by means of the lock nut. weitere 5 mm anschraubt und mit der
Gegenmutter blockiert.
Ripetere la medesima procedura anche Repeat the same procedure for the 2nd Die gleiche Prozedur auch für die
per i tiranti di rientro braccio II° sfilo (Rif. extension boom retraction tie rods (Ref. C- Zugstangen zum Einfahren des 2. Auszugs
C-Fig. 70), controllando le piastre di fine Fig. 70), cchecking the end-of-travel plates wiederholen (Bez. C-Abb. 70), wobei man
corsa (Rif. D-Fig. 71). (Ref. D-Fig. 71). die Anschlagsplatten prüft (Bez. D-Abb.
71).
Avvitare in modo uniforme i dadi sui tiranti Tighten the 3rd extension boom (Ref. A- Die Muttern auf den Zugstangen der
delle catene di uscita braccio III° sfilo (Rif. Fig. 72) and 2nd extension boom (Ref. B- Ausfahrketten des 3. Auszugs (Bez. A-
A-Fig. 72) e braccio II° sfilo (Rif. B-Fig. 72) Fig. 72) retraction chain tie rod nuts uni- Abb. 72) und dem 2. Auszug (Bez. B-Abb.
fino a quando, sfilando il braccio, non si formly till the correct tension is achieved, 72) gleichmäßig anziehen, bis man beim
raggiunge la corretta tensione (Fig. 73-74): when the boom is extended (Fig. 73-74): Ausfahren des Auslegers die richtige
Spannung erhält (Abb. 73-74):
H1 ≤ 80 mm H1 ≤ 80 mm
1st extension boom 1. Auszug
H1 ≤ 80 mm
Braccio I° sfilo
H1 ≤ 100 mm H1 ≤ 100 mm
Minimum measurement : Mindestwert:
H1 ≤ 100 mm
misura minima :
misura massima : Maximum measurement : Max. Wert:
H2 ≤ 80 mm H2 ≤ 80 mm
2nd extension boom 2. Auszug
H2 ≤ 80 mm
Braccio II° sfilo
H2 ≤ 100 mm H2 ≤ 100 mm
Minimum measurement : Mindestwert:
H2 ≤ 100 mm
misura minima :
misura massima : Maximum measurement : Max. Wert:
40
MRT 1840 EASY 50
B
A
68 69
C C
70 71
H1
A A A A
B B
72 73
H2
74
41
50 MRT 1840 EASY
IT EN DE
Verificare che i pettini di attacco delle cate- Check to ensure that the connecting Sicherstellen, dass die Anschlusskämme
ne superiori siano allineati (Fig. 75 e Fig. combs of the upper chains are aligned der oberen Ketten ausgerichtet sind (Abb.
76). Se queste condizioni non si verificano (Fig. 75 and Fig. 76). If this is not the case, 75 und Abb. 76). Wenn diese Bedingungen
agire sui dadi dei tiranti posteriori (Rif. A e adjust the nuts on the rear tie rods (Ref. A nicht vorliegen, die Muttern der hinteren
B-Fig. 77). and B-Fig. 77). Zugstangen betätigen (Bez. A und B-Abb.
77).
Stringere tutti i controdadi sui tiranti di Tighten all the lock nuts on the chain con- Alle Gegenmuttern auf den Zugstangen
attacco catene (Fig. 77). nector tie rods (Fig. 77). zum Anschluss der Ketten anziehen (Abb.
77).
Sfilare completamente il braccio per Extend the boom completely to grease it Den Ausleger ganz herausziehen, um ihn
ingrassarlo su tutta la lunghezza in corri- along the entire length on the pads and auf der ganzen Länge auf der Höhe der
spondenza dei pattini e lubrificare le cate- lubricate the chains (See the “Lubricants” Gleitschuhe zu schmieren, und die Ketten
ne (vedi tabella “Lubrificanti” sul manuale Table in the Use and Maintenance schmieren (siehe Tabelle “Schmierstoffe”
Uso e Manutenzione). Manual). in der Beteriebs- und Wartungsanleitung).
Richiudere il braccio lasciandolo sfilato per Close the boom leaving it extended out by Den Ausleger wieder zusammenfahren, bis
una lunghezza di circa 10÷20 cm. about 10÷20 cm. man einen Überstand von circa 10-20 cm
erhält.
Montaggio impianto idraulico e impian- Assembling the hydraulic and electrical Montage der hydraulischen Anlage und
to elettrico sul braccio (tavole 5-6-7-8) system on the boom (Tables 5-6-7-8) der elektrischen Anlage auf dem
Ausleger (Tafel 5-6-7-8)
Preparare i tubi idraulici “9-11-12-13” Prepare hydraulic pipes “9-11-12-13”
(tav.6) con i raccordi “19” (tav.6); infilarli (Tab.6) with unions “19” (Tab.6); insert into Die hydraulischen Leitungen “9-11-12-13”
nelle catene portatubi (Rif. A-Fig. 78) the tube holder chains (Ref. A-Fig. 78) (Tafel 6) mit den Anschlüssen “19” (Tafel 6)
numerandoli (1, 2 = brandeggio; 3, 4 = numbering them (1, 2 = tilting; 3, 4 = vorbereiten; die in die Schlauchtrageketten
optional; 5 = drenaggio) e appoggiare le optional; 5 = drainage) and rest the chains stecken (Bez. A-Abb. 78) und nummerie-
catene a terra (Fig. 78). on the ground (Fig. 78). ren (1, 2 = Schwenken; 3, 4 = Optionen; 5
= Rücklauf) und die Ketten am Boden
ablegen (Abb. 78).
Montare i raccordi passaparete nella aletta Fit the connectors in the perforated fin in Die wanddurchführenden Anschlüsse im
forata nella parte posteriore del braccio the rear part of the outside boom (Fig. 79). gelochten Flügel in der Rückseite des
esterno (Fig. 79). externen Auslegerarms montieren (Abb.
79).
Montare il tubolare portacatene sul lato Fit the chain holder tube on the right side Das Kettentragerohr auf der rechten Seite
destro del braccio esterno (Rif. B-Fig. 80). of the outside boom (Ref. B-Fig. 80). des externen Auslegerarms montieren
(Bez. B-Abb. 80).
In tutti i tubolari portacatena mettere delle Fit gaskets on the edges of all the chain In allen Kettetragerohren kantenabdecken-
guarnizioni copribordo alle estremità per holder tubes, to prevent breakage of the de Dichtungen auf den Rihrenden
evitare rotture dei tubi idraulici (Rif. C-Fig. hydraulic pipes (Ref. C-Fig. 81). strecken, damit die hydraulischen
81). Leitungen nicht beschädigt werden
(Bez. C-Abb. 81).
42
MRT 1840 EASY 50
Allineamento pettini Allineamento pettini

Alignment combs Alignment combs
75 76
A A A A
A A A
B B
77 78
79 80
C
C
81
43
50 MRT 1840 EASY
IT EN DE
Montare i tubi idraulici di comando bran- Fit the tilting control hydraulic pipes “1-2” Die hydraulischen Leitungen des
deggio “1-2” (Fig. 82) in corrispondenza (Fig. 82) to the connectors (Ref. A and B- Schwenkbefehls “1-2” (Abb. 82) auf der
dei raccordi passaparete (Rif. A e B-Fig. Fig. 82) and mark the pipes with the corre- Höhe der wanddurchführenden Anschlüsse
82) e contrassegnare i tubi con i numeri sponding numbers. (Bez. A und B-Abb. 82) montieren und die
corrispondenti. Leitungen mit den entsprechenden
Nummern markieren.
Montare i tubi idraulici comando sfilo “10- Fit the extension control hydraulic pipes Die hydraulischen Leitungen zur
11” (Fig. 83) sul cilindro di sfilo (Rif. C e D- “10-11” (Fig. 83) on extension cylinder Steuerung des Ausfahrens “10-11” (Abb.
Fig. 83), ai passaparete (Rif. E e F-Fig. 82) (Ref. C and D-Fig. 83), to the connector 83) auf dem Auszugszylinder (Bez. C und
e assicurarli con il collare (Rif. G-Fig. 83). (Ref. E and F-Fig. 82) and secure by D-Abb. 83) an den wanddurchführenden
means of collar (Ref. G-Fig. 83). Anschlüssen (Bez. E und F-Abb. 82) befe-
stigen und mit dem Anschlagbund absi-
chern (Bez. G-Abb. 83).
Montare i tubi idraulici comando optional Fit the optional control hydraulic pipes “3- a
“3-4” (Fig. 82) in corrispondenza dei rac- 4” (Fig. 82) to the connector (Ref. H and I- Die hydraulischen Leitungen zum
cordi passaparete (Rif. H e I-Fig. 82) e Fig. 82) and mark the pipes with the corre- Ansteuern der Optionen “3-4” (Abb. 82) auf
contrassegnare i tubi con i numeri corri- sponding numbers. der Höhe der wanddurchführenden
spondenti. Anschlüsse (Bez. H und I-Abb. 82) montie-
ren und die Leitungen mit den entspre-
chenden Nummern kennzeichnen.
Montare il tubo idraulico per il drenaggio Fit the hydraulic drainage pipe “5” (Fig. 82) Die hydraulische Rücklaufleitung “5” (Abb.
“5” (Fig. 82) in corrispondenza del passa- to connector (Ref. L-Fig. 82) and mark the 82) auf der Höhe des wanddurchführenden
parete (Rif. L-Fig. 82) e contrassegnare il pipes with the corresponding numbers. Anschlusses (Bez. L-Abb. 82) montieren
tubo con il numero corrispondente. und mit der entsprechenden Nummer
kennzeichnen.
Montare i microinterruttori con le relative Fit the microswitches with the relative Die Mikroschalter mit den entsprechenden
staffe e i relativi riscontri sui bilanceri nella brackets and the relative striker plates on Bügeln und den entsprechenden
parte anteriore superiore del braccio ester- the equalisers in the upper front part of the Anschlägen auf den Kipphebeln im vorde-
no (Rif. M-Fig. 84) e braccio I° sfilo (Rif. N- outer boom (Ref. M-Fig. 84) and 1st exten- ren Teil oben am externen Auslegerarm
Fig. 84). sion boom (Ref. N-Fig. 84). (Bez. M-Abb. 84) und dem 1. Auszug (Bez.
N-Abb. 84) montieren.
Infilare all’interno del tubolare i cavi per la Insert into the tube the cables for the bas- Die Kabel für die Steckdose der Bühne
presa cestello (Rif. A-Fig. 85) e il cavo per ket socket (Ref. A-Fig. 85) and the cable (Bez. A-Abb. 85) und das Kabel für die bei-
la coppia di microinterruttori sugli attacchi for the pair of microswitches on the chain den Mikroschalter an den
catene al braccio esterno (Rif. B-Fig. 85). connections to the outside boom (Ref. B- Kettenanschlüssen am externen
Fig. 85). Auslegerarm in das Rohrinnere stecken
(Bez. B-Abb. 85).
Montare il piastrino per presa elettrica Fit the electric socket plate in the right rear Die Platte für den Stecker im hinteren Teil
nella parte posteriore destra del braccio part of the outside boom (Ref. C-Fig. 86). des externen Auslegerarms montieren
esterno (Rif. C-Fig. 86). (Bez. C-Abb. 86).
Attaccare la spina multipresa elettrica (Rif. Connect the multipin electric socket (Ref. Die Mehfachsteckdose (Bez. D-Abb. 86)
D-Fig. 86) per il cestello al piastrino (Rif. D-Fig. 86) for the basket to the plate (Ref. für die Bühne an der Platte (Bez. C-Abb.
C-Fig. 86). C-Fig. 86). 86) befestigen.
Infilare i tubi idraulici “1-2-3-4-5” (Fig. 87), Insert the hydraulic pipes “1-2-3-4-5” (Fig. Die hydraulischen Leitungen “1-2-3-4-5”
precedentemente fissati ai raccordi passa- 87), already fixed to the connectors, inside (ABB. 87), die man zuvor an den wand-
parete, all’interno del tubolare portacatena the chain holder tube (Ref. E-Fig. 87-88) in durchführenden Anschlüssen befestigt
(Rif. E-Fig. 87-88) in sequenza come sequence as shown in Fig. 88. hatte, in das Innere des Kettentragerohrs
mostrato in Fig. 88. (Bez. E-Abb. 87-88) stecken, und zwar in
der Reihenfolge von Abb. 88.
44
MRT 1840 EASY 50
G
L I H F E B A
11 10
10 2 1
3 11
D C
82 83
M N
M
N
B
M
A
84 85
C
1
2
3

4
D 5 E
86 87
4 3 2 1
5
88
45
50 MRT 1840 EASY
IT EN DE
Montare la prima catena portatubi (Rif. A- Fit the first tube holder chain (Ref. A-Fig. Die erste Schlauchtragekette (Bez. A-Abb.
Fig. 89) sul tubolare portacatena fissando- 89) on the chain holder tube fixing it by 89) am Kettentragerohr montieren und mit
lo con le apposite viti (Rif. B-Fig. 89). means of the screws provided (Ref. B-Fig. den entsprechenden Schrauben befestigen
89). (Bez. B-Abb. 89).
Collegare i raccordi a gomito (Rif. C-Fig. Connect the elbow joints (Ref. C-Fig. 90) Die Knieanschlüsse (Bez. C-Abb. 90) an
90) ai tubi dentro al tubolare (Rif. D-Fig. to the pipes inside the tube (Ref. D-Fig. den Leitungen im Rohr anschließen (Bez.
90) e sucessivamente ai tubi dentro la 90) and subsequently to the pipes inside D-Abb. 90) und anschließend an den
catena (Rif. E-Fig. 90) seguendo la the chain (Ref. E-Fig. 90) following the Leitungen in der Kette (Bez. E-Abb. 90).
sequenza dall’interno braccio verso sequence from inside the boom to the out- Dabei die Reihenfolge vom Inneren des
l’esterno alternando i raccordi lunghi coi side alternating the long and short connec- Auslegers nach außen befolgen, wobei
corti (Fig. 90). tors (Fig. 90). man die langen mit den kurzen
Fissare i raccordi con i collari (Rif. F-Fig. Fix the connectors with the collars (Ref. F- Anschlüssen abwechselt (Abb. 90).
90) al tubolare porta catena. Fig. 90) to the chain holder tube. Die Anschlüsse mit den Anschlagbünden
(Bez. F-Abb. 90) am Kettentragerohr befe-
stigen.
Infilare i cavi elettrici nella catena portatubi Insert the electric wires in the tube holder Die elektrischen Kabel in die
(Rif. G-Fig. 91). Il cavo “22A” (tav.8) per il chain (Ref. G-Fig. 91). Pass cable “22A” Schlauchtragekette (Bez. G-Abb. 91)
microinterruttore dell’attacco catene sul (Tab.8) for the microswitch of the chain stecken. Das Kabel “22A” (Tafel 8) für den
bilancere singolo (Rif. H-Fig. 92) viene connection on the single equaliser (Ref. H- Mikroschalter des Kettenanschlusses auf
fatto passare all’interno della catena porta- Fig. 92) into the tube holder chain (Fig. dem einzelnen Kipphebel (Bez. H-Abb. 92)
tubi (Fig. 91); il cavo “22B” (tav.8) per la 91); clamp cable “22B” (Tab.8) for the pair wird durch das Inntere der
coppia di microinterruttori dell’attacco cate- of microswitches for the chain connection Schlauchtragekette (Abb. 91) durchgeführt;
ne sul bilancere doppio (Rif. I-Fig. 92) on the double equaliser (Ref. I-Fig. 92) das Kabel “22B” (Tafel 8) für die beiden
viene fascettatto direttamente al braccio directly to the outside boom (Fig. 91). Mikroschalter des Kettenanschlusses auf
esterno (Fig. 91). dem doppelten Kipphebel (Bez. I-Abb. 92)
wird direkt am externen Auslegerarm mit
Kabelbindern befestigt (Abb. 91).
Fissare al braccio esterno i tubi idraulici “1- Fix hydraulic pipes “1-2-3-4-5” (Tab.6), Die hydraulischen Leitungen “1-2-3-4-5”
2-3-4-5” (tav.6), i cavi elettrici (Rif. A e electric wires (Ref. A and “22B”-Fig. 93) to (Tafel 6) und die elektrischen Kabel (Bez.
“22B”-Fig. 93) con le apposite staffe (Rif. the outside boom, using the brackets pro- A und “22B”-Abb. 93) mit den entsprechen-
B-Fig. 93). vided (Ref. B-Fig. 93). den Bügeln (Bez. B-Abb. 93) am externen
Auslegerarm befestigen.
Montare il tubolare portacatene I° sfilo sul Fit the 1st extension chain holder tube on Das Kettentragerohr des 1. Auszugs auf
braccio I° sfilo (Rif. C-Fig. 94). the 1st extension boom (Ref. C-Fig. 94). dem 1. Auszug montieren (Bez. C-Abb.
94).
Infilare i cavi elettrici, il cavo “22A” (tav.8) e Insert the electric wiring, cable “22A” Die elektrischen Kabel, das Kabel “22A”
i tubi idraulici dalla catena portatubi al (Tab.8) and the hydraulic pipes from the (Tafel 8) und die hydraulischen Leitungen
tubolare portacatene I° sfilo (Fig. 95). tube holder chain to the 1st extension von der Schlauchtragekette zum
chain holder tube (Fig. 95). Kettentragerohr des 1. Auszugs einstecken
(Abb. 95).
Fissare la catena portatubi (Rif. D-Fig. 96) Fix the tube holder chain (Ref. D-Fig. 96) Die Schlauchtragekette (Bez. D-Abb. 96)
al tubolare portacatena (Rif. E-Fig. 96). to the chain holder tube (Ref. E-Fig. 96). am Kettentragerohr (Bez. E-Abb. 96) befe-
stigen.
46
MRT 1840 EASY 50
E E
E E
E
A F
B
B
D
89 90
I
H
22A
I
22B

G
G
G
91 92
B B
93 94
D

95 96
47
50 MRT 1840 EASY
IT EN DE
Fascettare il cavo “22A” (tav.8) al braccio Clamp cable “22A” (Tab.8) to the 1st Das Kabel “22A” (Tafel 8) am 1. Auszug
I° sfilo (Fig. 97). extension boom (Fig. 97). mit Kabelbindern befestigen (Abb. 97).
Montare la seconda catena portatubi sul Fit the second tube holder chain on the 1st Die zweite Schlauchtragekette auf dem
tubolare portacatena I° sfilo fissandolo con extension chain holder tube fixing it by Kettentragerohr des 1. Auszugs montieren,
le apposite viti (Rif. A-Fig. 98). means of the screws provided (Ref. A-Fig. indem man sie mit den entsprechenden
98). Schrauben befestigt (Bez. A-Abb. 98).
Collegare i raccordi a gomito (Rif. B-Fig. Connect the elbow joints (Ref. B-Fig. 99) Die Knieanschlüsse (Bez. B-Abb. 99) an
99) ai tubi dentro al tubolare (Rif. C-Fig. to the pipes inside the tube (Ref. C-Fig. den Leitungen im Rohr anschließen (Bez.
99) e sucessivamente ai tubi dentro la 99) and subsequently the tubes inside the C-Abb. 99) und danach an den Leitungen
catena (Rif. D-Fig. 99) seguendo la chain (Ref. D-Fig. 99) following the in der Kette (Bez. D-Abb. 99). Dabei die
sequenza dall’interno braccio verso sequence from inside the boom outwards, Reihenfolge vom Inneren des Auslegers
l’esterno alternando i raccordi lunghi coi alternating long and short connectors (Fig. nach außen befolgen und die langen mit
corti (Fig. 99). 99). den kurzen Anschlüssen abwechseln (Abb.
Fissare i raccordi con i collari (Rif. E-Fig. Fix the connectors by means of the collars 99).
99) al tubolare porta catena. (Ref. E-Fig. 99) to the chain holder tube. Die Anschlüsse mit den Anschlagbünden
(Bez. E-Abb. 99) am Kettentragerohr befe-
stigen.
Infilare i cavi elettrici nella seconda catena Insert the electric wiring in the second tube
portatubi (Rif. F-Fig. 100). holder chain (Ref. F-Fig. 100).
Die elektrischen Kabel in die zweite
Schlauchtragekette stecken (Bez. F-Abb.
100).
Montare il tubolare portacatene II° sfilo sul Fit the 2nd extension chain holder tube on
braccio II° sfilo (Rif. A-Fig. 101). the 2nd extension boom (Ref. A-Fig. 101). Das Kettentragerohr des 2. Auszugs auf
den 2. Auszug montieren (Bez. A-Abb.
101).
Infilare i cavi elettrici e i tubi idraulici dalla Insert the electric wiring and hydraulic Die elektrischen Kabel und die hydrauli-
seconda catena portatubi al tubolare porta- pipes from the second tube holder chain to schen Leitungen von der zweiten
catene II° sfilo (Fig. 102). the 2nd extension chain holder tube (Fig. Schlauchtragekette zum Kettentragerohr
102). des 2. Auszugs stecken (Abb. 102).
Fissare la seconda catena portatubi (Rif. Fix the second tube holder chain (Ref. B- Die zweite Schlauchtragekette (Bez. B-
B-Fig. 103) al tubolare portacatena (Rif. C- Fig. 103) to the chain holder tube (Ref. C- Abb. 103) am Kettentragerohr befestigen
Fig. 103). Fig. 103). (Bez. C-Abb. 103).
Montare la terza catena portatubi (Rif. D- Fit the third tube holder chain (Ref. D-Fig. Die dritte Schlauchtragekette (Bez. D-Abb.
Fig. 104) sul tubolare portacatena II° sfilo 104) on the 2nd extension chain holder 104) am Kettentragerohr des 2. Auszugs
(Rif. E-Fig. 104) fissandolo con le apposite tube (Ref. E-Fig. 104) fixing it by means of (Bez. E-Abb. 104) montieren und mit den
viti (Rif. F-Fig. 104). the screws provided (Ref. F-Fig. 104). entsprechenden Schrauben (Bez. F-Abb.
104) befestigen.
48
MRT 1840 EASY 50
22A
A
97 98

D D D
D D
F
D A

C B
99 100
A

101 102
F
B
103 104
49
50 MRT 1840 EASY
IT EN DE
Infilare i cavi elettrici nella terza catena Insert the electric wiring in the third tube Die elektrischen Kabel in die dritte
portatubi (Rif. A-Fig. 105). holder chain (Ref. A-Fig. 105). Schlauchtragekette (Bez. A-Abb. 105)
stecken.
Montare il tubolare portacatene III° sfilo sul Fit the 3rd extension chain holder tube on Das Kettentragerohr des 3. Auszugs auf
braccio III° sfilo (Rif. B-Fig. 106). the 3rd extension boom (Ref. B-Fig. 106). dem 3. Auszug (Bez. B-Abb. 106) montie-
ren.
Infilare i cavi elettrici e i tubi idraulici dalla Insert the electric wiring and hydraulic Die elektrischen Kabel und die hydrauli-
terza catena portatubi al tubolare portaca- pipes from the third tube holder chain to schen Leitungen von der dritten
tene III° sfilo (Fig. 107). the 3rd extension chain holder tube (Fig. Schlauchtragekette zum Kettentragerohr
107). des 3. Auszugs stecken (Abb. 107).
Fissare la terza catena portatubi (Rif. C- Fix the third tube holder chain (Ref. C-Fig. Die dritte Schlauchtragekette (Bez. C-Abb.
Fig. 108) al tubolare portacatena III° sfilo 108) to the 3rd extension chain holder tube 108) am Kettentragerohr des 3. Auszugs
(Rif. D-Fig. 108). (Ref. D-Fig. 108). (Bez. D-Abb. 108) befestigen.
Proteggere con una guaina i cavi elettrici Protect the electric wiring for the basket by Die elektrischen Kabel für die Bühne (Bez.
per il cestello (Rif. A-Fig. 109) e posiziona- means of a sheath (Ref. A-Fig. 109) and A-Abb. 109) mit einer Kabelhülle schützen
re i tubi idraulici sul tubolare portacatena position the hydraulic pipes on the chain und die hydraulischen Leitungen auf dem
con l’apposito collare (Rif. B-Fig. 109) holder tube by means of the collar provid- Kettentragerohr mit dem entsprechenden
lasciandoli liberi per lo scorrimento e ed (Ref. B-Fig. 109) leaving them free for Anschlagbund (Bez. B-Abb. 109) anord-
l’orientamento. sliding and orientation. nen, wobei man sie frei lässt, um damit sie
gleiten und ausgerichtet werden können.
Montare i raccordi idraulici a 90° con gli Fit the hydraulic connections at 90° with Die 90° Anschlüsse mit den
innesti rapidi (maschio) sul lato sinistro quick-release couplings (male) on the left Schnellkupplungen (Innenteil) auf der lin-
(Rif. C-Fig. 110) e (femmina) sul lato side (Ref. C-Fig. 110) and (female) on the ken Seite (Bez. C-Abb. 110) und
destro (Rif. D-Fig. 111) della testa del brac- right side (Ref. D-Fig. 111) of the boom (Außenteil) auf der rechten Seite (Bez. D-
cio. head. Abb. 111) des Auslegerkopfs montieren.
Proteggere con una guaina i tubi per il With a sheath protect tilting pipes (already Die Leitungen für das Schwenken (vorher
brandeggio (precedentemente numerati) numbered) “1, 2” (Ref. E-Fig. 112) and nummeriert) “1, 2” (Bez. E-Abb. 112) mit
“1, 2” (Rif. E-Fig. 112) e infilarli nel foro insert them in the opening on top of the einer Hülle schützen und in das obere
superiore della testa del braccio (Rif. F- boom head (Ref. F-Fig. 112). Loch auf dem Auslegerkopf stecken (Bez.
Fig. 112). F-Abb. 112).
50
MRT 1840 EASY 50

A A
105 106

C
D
107 108
A
B
C
109 110
D
E
111 112
51
50 MRT 1840 EASY
IT EN DE
Collegare i tubi idraulici “1, 2” (Fig. 113) al Connect hydraulic pipes “1, 2” (Fig. 113) to Die hydraulischen Leitungen “1, 2” (Abb.
blocchetto valvola sul cilindro di brandeg- the valve block on the tilting cylinder (Ref. 113) am Ventilblock auf dem
gio (Rif. A-Fig. 113). A-Fig. 113). Schwenkzylinder (Bez. A-Abb. 113) ansch-
ließen.
Proteggere con una guaina i tubi per Protect optional pipes “3, 4” (Fig. 114) with Die Leitungen der Optionen “3, 4” (Abb.
l’optional “3, 4” (Fig. 114), infilarli nel foro a sheath, insert them in the opening on top 114) mit einer Hülle schützen, sie in das
superiore della testa del braccio e collegar- of the boom head and connect them to the obere Loch am Auslegerkopf stecken und
li agli innesti rapidi (Rif. B-Fig. 114) sul lato quick-release couplings (Ref. B-Fig. 114) an den Schnellkupplern (Bez. B-Abb. 114)
sinistro della testa del braccio. on the left side of the boom head. auf der linken Seite des Auslegerkopfs
anschließen.
Proteggere con una guaina il tubo per il Protect drain pipe “5” with a sheath, insert Die Rücklaufleitung “5” mit einer Hülle
drenaggio “5”, infilarlo nel foro superiore it through the opening on top of the boom schützen, in das obere Loch am
della testa del braccio e collegarlo all’inne- head and connect it to the quick-release Auslegerkopf stecken und mit dem
sto rapido sul lato destro della testa del coupling on the right side on the boom Schnellkuppler auf der rechten Seite des
braccio (Rif. C-Fig. 115). head (Ref. C-Fig. 115). Auslegerkopfs verbinden (Bez. C-Abb.
115).
Collegare i raccordi a gomito (Rif. D-Fig. Connect the elbow joints (Ref. D-Fig. 116) Die Knieanschlüsse (Bez. D-Abb. 116) an
116) ai tubi dentro al tubolare (Rif. E-Fig. to the pipes inside the tube (Ref. E-Fig. den Leitungen im Rohr (Bez. E-Abb. 116)
116) e sucessivamente ai tubi dentro la 116) and subsequently to the pipes inside anschließen und anschließend an den
catena (Rif. F-Fig. 116) seguendo la the chain (Ref. F-Fig. 116) by following the Leitungen in der Kette (Bez. F-Abb. 116).
sequenza dall’interno braccio verso sequence from inside the boom outwards, Dabei die Reihenfolge vom Inneren des
l’esterno alternando i raccordi lunghi coi alternating long and short connectors (Fig. Auslegers nach außen befolgen und die
corti (Fig. 116). 116). langen mit den kurzen Anschlüssen
Fissare i raccordi con i collari (Rif. G-Fig. Fix the connectors with collars (Ref. G-Fig. abwechseln (Abb. 116).
116) al tubolare porta catena. 116) to the chain holder tube. Die Anschlüsse mit den Anschlagbünden
(Bez. G-Abb. 116) am Kettentragerohr
befestigen.
Nei passaggi tra tubolari portacatene e In the passages between the chain holder An den Übergangsstellen zwischen
catene portatubi, fermare i cavi elettrici ai tube and tube holder chain, secure the Kettentragerohren und Schlauchtrage-
tubi idraulici tramite delle fascette (Rif. A- electric wire to the hydraulic pipes by ketten die elektrischen Kabel an den
Fig. 117). means of clamps (Ref. A-Fig. 117). hydraulischen Leitungen mit den
Kabelbindern befestigen (Bez. A-Abb.
117).
Stringere completamente il collare del Tighten the 3rd extension chain holder Den Anschlagbund des Kettentragerohrs
tubolare portacatena III° sfilo (Rif. B-Fig. tube collar completely (Ref. B-Fig. 118). des 3. Auszugs ganz anziehen (Bez. B-
118). Abb. 118).
Montare la scatola (Rif. C-Fig. 119) per Fit the box (Ref. C-Fig. 119) for the basket Den Kasten (Bez. C-Abb. 119) für die
presa cestello sul lato sinistro della testa. socket on the left side on the head. Steckdose der Bühne auf der linken
Kopfseite montieren.
Eseguire il collegamento dei cavi elettrici Make the electric wiring connections in the
nella presa multispina del cestello (Rif. D- basket multipin socket (Ref. D-Fig. 119). Den Anschluss der elektrischen Kabel an
Fig. 119). der Mehrfachsteckdose für die Bühne
(Bez. D-Abb. 119) vorgenommen.
Chiudere la scatola per presa cestello (Rif. Close the basket socket box (Ref. E-Fig. Den Kasten für die Steckdose der Bühne
E-Fig. 120) e fascettare il cavo elettrico sul 120) and clamp the electric cable on the schließen (Bez. E-Abb. 120) und das elek-
fianco sinistro della testa braccio III° sfilo left side of the 3rd extension boom head trische Kabel auf der linken Seite des
(Rif. F-Fig. 120). (Ref. F-Fig. 120). Kopfs am 3. Auszug (Bez. F-Abb. 120) mit
Kabelbindern befestigen.
52
MRT 1840 EASY 50
2
B
1
4
A B
3
113 114
D
C
F
5
E
115 116
A A A
A A A A B
A A
A A
117 118
C F
D
F
119 120
53
50 MRT 1840 EASY
IT EN DE
Fascettare il cavo elettrico assieme alle Clamp the electric wire together with the Das elektrische Kabel zusammen mit den
guaine di protezione dei tubi comando tilting control, optional and drainage pipe Schutzhüllen der Leitungen für die
brandeggio, optional e drenaggio (Rif. A- sheaths (Ref. A-Fig. 121). Schwenksteuerung, der Optionen und des
Fig. 121). Rücklaufs (Bez. A-Abb. 121) mit
Kabelbindern verbinden.
Connettere i microinterruttori dei bilancieri Connect the 2nd and 3rd extension chain Die Mikroschalter der Kipphebel der Ketten
catene II° sfilo e III° sfilo (Rif. B-Fig. 122) e equaliser microswitches (Ref. B-Fig. 122) des 2. und des 3. Auszugs (Bez. B-Abb.
fascettare i cavi. and clamp the cables. 122) verbinden und die Kabel mit
Kabelbindern versehen.
Montare l’avvolgitore del “M.S.S.” (Rif. C- Fit the “M.S.S.” winder (Ref. C-Fig. 123) Den Aufwickler des Sicherheitssystems
Fig. 123) con la relativa staffa nella parte with the relative bracket in the front left “M.S.S.” (Bez. C-Abb. 123) mit dem ent-
anteriore sinistra del braccio esterno (Rif. part of the outside boom (Ref. D-Fig. 123). sprechenden Bügel im vorderen Teil links
D-Fig. 123). des externen Auslegerarms montieren
(Bez. D-Abb. 123).
Fissare il cavo dell’avvolgitore del “M.S.S.” Fix the “M.S.S.” winder cable to the ring on Das Kabel des Aufwickels des
all’anello presente sul braccio I° sfilo (Rif. the 1st extension boom (Ref. E-Fig. 124). Sicherheitssystems “M.S.S.” an den Ring
E-Fig. 124). befestigen, der auf dem 1. Auszug vorhan-
N. B. Calibration of the“MSS” safety sys- den ist (Bez. E-Abb. 124).
N. B. La taratura del sistema di sicurezza tem must be carried out by authorized
“MSS” deve essere eseguita da personale Manitou personnel. Anm.: Die Eichung des Sicherheitssystems
autorizzato Manitou. “MSS” muss durch autorisiertes Manitou-
Personal vorgenommen werden.
54
MRT 1840 EASY 50
121 122
123 124
TAVOLA/TABLE/TAFEL 1
17
20
24
21 9 1
40
22 18
15 24
15 22 21
12
16
14 2 10 13
41
39
33
10 42
37
3-4
3-4
28 29 35
2
25 10 38
27 36 34
7-8 14 31
7-8 30
26 6
5 10 32
10 11
12
55
50 MRT 1840 EASY
IT EN DE
22
25 11
23 9 18
2
21 19
33 8
22 3-4
3-4
23 9
36 24 9
37 27 2 2
38 26 3-4 8
2
53 42 12 1 3-4
41
14 5
17 5
13 15
9
56 39 16
34 9 2 6-7 34
6-7
15
30 3-4 53
29 48
31
45
28
29 46
30 24 48 47
32 3-4
43
26 2
52
42
50 51 3-4 9
3-4
49 34 41 40
42 35
2
2 9
10
49 41 13
14 11
20 44
20
22
18 14
4
52 16 9-10
3 4
12
28 19 17 5 2
52 23
53 30
29 5 9-10
12 21
15 4
8
4 5 3
9-10 5 15
6 4
9-10
15 1 7-56 6
11 7-56
4 11 54
38 38 55 13
15
4 5
24 25
9-10
27
9-10 26
33 5
32
4
51
15
9-10
31
32 5
33 4
35 37
36 5 14
56
MRT 1840 EASY 50
21
11 19
17 41
21
15 10 2 2
7 8 3-4 8
2
49
3-4
3-4 3-4
11 2 6
13 20 6
16 18 5
5 3-4
8 2
1 41
2
3-4
27 26 9
28 33
32 23 26
26
27
28
26
25
22 23 24
31
29
43
30
8
45
44
22
12
21
7
7 6
20
26 19
24
11 18
27 8
10
26 9
13 24
15
14 27
17 25
13 1
16 23
11 2
10 25 3
4 5
57
50 MRT 1840 EASY
IT EN DE
29
28 27 26 13
10
30
24
41
25 10
13
12
22
23
20
10 40
20 33
19 44 10 13 20
10 12 10
15
16 45 203
42
17
19 43
18
10 19 37
10 36 35
13 12 13 15 45 34
16 46 35
17 33 34
19 18 1
2
11 10 RI 33
38
19 39
10
2
32
1 31
14
32
32
30 31
10
1 11
6 2 3
5
8
7
4
VEDI TAVOLA
VOIR PLANCHE
SEE DRAWING 1500 15
SEHEN SEITE
VER DIBUJO
58
MRT 1840 EASY 50
4 3
3 6
4 1 8
4
5
5 1
3 2 5
8 2 6 12
9
10
2
4 4 14 7
17
9 5
5 7 11
13
17 18
20 16
15
19
21
15
22-A
22-B
14
15
16
59
SMONTAGGIO E RIMONTAGGIO
COLLETTORE IDRAULICO DI ROTAZIONE
DISASSEMBLING AND REASSEMBLING

ROTATION HYDRAULIC MANIFOLD
AUSBAU UND WIEDEREINBAU

DES ROTATIONSVERTEILERS
MRT 1440-1640-1840 EASY

IT-EN-DE
70 MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO DEL COLLETTORE DISASSEMBLING ROTATION AUSBAU DES

IDRAULICO DI ROTAZIONE HYDRAULIC MANIFOLD ROTATIONSVERTEILERS
- Posizionare la macchina su una superfi- - Position the vehicle on level ground and - Die Maschine auf einer ebenen Fläche
cie piana e sollevare completamente il raise the telescopic boom completely. abstellen und den Teleskopausleger
braccio telescopico. ganz heben.
- Spegnere il motore termico e scollegare i - Switch off the engine and disconnect the - Den Verbrennungsmotor abstellen und
morsetti della batteria. battery terminals. die Batterieklemmen abtrennen.
- Smontare il coperchio (Rif. A-Fig. 1). - Remove the cover (Ref. A-Fig. 1). - Den Deckel ausbauen (Bez. A-Abb. 1).
- Smontare le fascette di gomma (Rif. B- - Remove the rubber bands (Ref. B-Fig. 2). - Die Kabelbinder aus Gummi entfernen
Fig. 2).
(Bez. B-Abb. 2).
- Scollegare il cablaggio elettrico dalla sca- - Disconnect the electric wiring from the-
tola di controls junction box “C21” (Ref. C- - Die elektrische Verkabelung von der
derivazione carro “C21” (Rif. C-Fig. 3) e Fig. 3) and the support on the oil tank Abzweigdose der Bedienelemente (Bez.
dal supporto sul serbatoio olio “C17- “C17-C18” (Ref. D-Fig. 2). C-Abb. 3) und dem Träger auf dem
C18” (Rif. D-Fig. 2). Ölbehälter abtrennen (Bez. D-Abb. 2).
- Tagliare le fascette a stringa (Rif. A-Fig. - Cut the string band (Ref. A-Fig. 4).
4). - Die einfachen Kabelbinder durchschnei-
den (Bez. A-Abb. 4).
- Scollegare il cablaggio elettrico (Rif. B- - Disconnect the electric wiring (Ref. B-Fig.
Fig. 4) dalla cabina posizionato sotto il 4) from the cab positioned under the - Die elektrische Verkabelung (Bez. B-Abb.
cruscotto stabilizzatori “C1.-C2”. outriggers control panel.“C1.-C2” 4) von der Kabine unter dem
Armaturenbrett der Stabilisatoren
abtrennen.
- Smontare le orecchiette di trascinamento - Dismantle the hydraulic rotation collector
collettore di rotazione idraulico (Rif. C- drive tabs (Ref. C-Fig. 4). - Die Mitnehmeransätze des Rotations-ver-
Fig. 4). teilers abmontieren (Bez. C-Abb. 4).
- Alle Leitungen vom Rotationsverteiler

- Disconnect all the pipes from the abtrennen (siehe Tabelle ROTATIONS-
- Scollegare tutti i tubi dal collettore di
hydraulic rotation manifold (see VERTEILER).
rotazione idraulico (vedere tebella
COLLETTORE ROTANTE IDRAULICO). HYDRAULIC ROTARY MANIFOLD
Table). - Den elektrischen Teil des Rotations-
verteilers mit einem Gabelstapler oder
einem Laufkran absichern, die
- Assicurare il collettore di rotazione idrauli- - Secure the hydraulic/electric manifold to Befestigungsschrauben (Bez. D-Abb. 5)
a bridge crane or an elevator, unscrew losdrehen und es aus der Maschine her-
co/elettrico ad un elevatore o un carro
the fixing screws (Ref. D-Fig. 5) and ausnehmen.
ponte, svitare le viti di fissaggio (Rif. D-
Fig. 5) e rimuoverlo dalla macchina. remove it from the vehicle.
2
MRT 1440-1640-1840 EASY 70
D
A
B
FIG. 1 FIG. 2
C 17
C1 8
A
FIG. 3
C
C1
C2 FIG. 4
D

D
FIG. 5
3
70 MRT 1440-1640-1840 EASY
IT EN DE
- A banco aprire le connessioni “C17-C18- - On the workbench, open the connections - Die Anschlüsse auf der Werkbank öffnen
C21” e sfilare le spinette dalle loro sedi. “C17-C18-C21”and remove the pins und die Stecker aus ihren Sitzen her-
(TAVOLA 1). from their housing. (TABLE 1) ausziehen. (TAFEL 1)
- Svitare le viti di fissaggio collettore di - Unscrew the electric rotation manifold fix- - Die Befestigungsschraube des elektri-
rotazione elettrico. ing screws. schen Rotationsverteilers losschrauben.
- Si raccomanda di lubrificare il cablaggio - We recommend lubrication of the electric - Es empfiehlt sich, die elektrische
wiring with oil or grease before removing Verkabelung vor dem Herausziehen des
elettrico con olio o grasso prima di sfila-
the cable clamp from the hydraulic rota- Kabelbaums aus dem Rotations-
re il fascio del cavo dal collettore di rotation manifold (failure to observe this rec- verteilermit Öl oder Fett zu schmieren
zione idraulico (la non osservanza di ommendation can damage the electric (wenn man diese Empfehlung nicht
questa lubrificazione può generare lesio- wiring).(TABLE 1) beachtet, kann es zu Beschädigungen
ni al cablaggio elettrico). (TAVOLA 1) an der elektrischen Verkabelung kom-
men). (TAFEL 1)
4
MRT 1440-1640-1840 EASY 70
TAVOLA/ TABLE/ TAFEL 1
COLLETTORE ROTANTE ELETTRICO

ROTARY ELECTRIC MANIFOLD
ELEKTRISCHEN ROTATIONSVERTEILERS
GREAS E
CABLAGGIO ELETTRICO
ELECTRIC CABLAGE
ELEKTRISCHE VERKABELUNG
C1
C2
COLLETTORE ROTANTE IDRAULICO

ROTARY HYDRAULIC MANIFOLD
ROTATIONSVERTEILER
C 18
GREAS E GREAS E
7
C1
C2
C21
1
C17
C18
5
70 MRT 1440-1640-1840 EASY
IT EN DE
COLLETTORE ROTANTE IDRAULICO ROTARY HYDRAULIC MANIFOLD ROTATIONSVERTEILER
1) - Scarico 1) - Exhaust 1) - Auslauf
2) - Scarico 2) - Exhaust 2) - Auslauf
3) - Alimentazione cambio (lenta/veloce) 3) - Gear (slow/fast) power supply 3) - Versorgung Schaltgetriebe (lang-
sam/schnell)
4) - Alimentazione acceleratore 4) - Accelerator power supply
4) - Versorgung Gaspedal
5) - Alimentazione cambio (lenta/veloce) 5) - Gear (slow/fast) power supply
5) - Versorgung Schaltgetriebe (lang-
6) - Libero 6) - Free sam/schnell)
7) - Alimentazione freno di servizio 7) - Front axle hand brake and parking 6) - Unbelegt
ponte anteriore e stazionamento brake power supply
7) - Versorgung Betriebsbremse
8) - Alimentazione freno di servizio 8) - Rear axle hand brake power supply Vorderachse und Feststellbremse
ponte posteriore
9) - Gear (fast/slow) solenoid valve 8) - Versorgung Betriebsbremse
9) - Alimentazione elettrovalvola cambio power supply - parking brake sole- Hinterachse
(lenta/veloce) - elettrovalvola noid valve - hand brake pump
freno di stazionamento - pompa 9) - Versorgung Magnetventil
freno di servizio 10) - Inching power supply Schaltgetriebe (langsam/schnell) -
Magnetventil der
10) - Alimentazione inching 11) - Free Feststellbremse - Pumpe der
Betriebsbremse
11) - Libero 12) - Steering types solenoid valve power
supply 10) - Versorgung Inching
12) - Alimentazione elettrovalvola tipi di
sterzata 13) - Front steering cylinder power supply 11) - Unbelegt
13) - Alimentazione martinetto sterzo 14) - Turret rotation power supply 12) - Versorgung Magnetventile
anteriore Lenktypen
15) - Turret rotation power supply
14) - Alimentazione rotazione torretta 13) - Versorgung vorderer Lenkzylinder
16) - Movements valve system - outrigger
15) - Alimentazione rotazione torretta power supply 14) - Versorgung Turmrotation
16) - Alimentazione distributore 17) - Power steering - movement valve 15) - Versorgung Turmrotation
movimenti-stabilizzatori system power supply
16) - Versorgung Steuergerät
17) - Alimentazione Bewegungen - Stabilisatoren
idroguida - distributore movimenti
17) - Versorgung Hydrolenkung -
Steuergerät Bewegungen
6
MRT 1440-1640-1840 EASY 70
A s
s
s
1
3
4
5
t B
6
7
8
10
11 1 3
10 12
17 4
9 13
A
5
16 14
8 6
2 15
7
13 12
11
14
10
B
15
9
16
17
7
70 MRT 1440-1640-1840 EASY
IT EN DE
RIMONTAGGIO DEL COLLETTORE REASSEMBLING ROTATION WIEDEREINBAU DES ROTATIONS-VER-

IDRAULICO DI ROTAZIONE HYDRAULIC MANIFOLD TEILERS
- Con l'uso del carro ponte o un elevatore - Using a bridge crane or elevator, fit the - Den Rotationsverteiler mit der Hilfe des
montare il colletore idraulico di rotazione rotation hydraulic manifold (Ref. A-Fig. Laufkrans bzw. eines Gabelstaplers
(Rif. A-Fig. 1) nell'apposita sede sul 1) in its housing on the vehicle chassis. (Bez. A-Abb. 1) in seiner Aufnahme im
telaio della macchina. Fahrgestell der Maschine montieren.
- Tighten the fixing screws (Ref. B-Fig. 1).
- Avvitare le viti di fissaggio (Rif. B-Fig. 1). - Die Befestigungsschrauben anziehen
- Fit the rotary electric manifold drive sup- (Bez. B-Abb. 1).
- Montare il supporto di trascinamento del port (Ref. C-Fig. 2).
collettore elettrico rotante (Rif. C-Fig. 2).
- Fit the rotary electric manifold drive - Den Mitnehmerträger des Rotations-
- Montare la flangia di trascinamento del flange (Ref. D-Fig. 2). verteilers montieren (Bez. C-Abb. 2).
collettore elettrico rotante (Rif. D-Fig. 2).
- Insert the electric wiring (Ref. E-Fig. 3) - Den Mitnehmerflansch des Rotations-ver-
- Inserire il cablaggio elettrico (Rif. E-Fig. from the top towards the bottom into the teilers montieren (Bez. D-Abb. 2).
3) dall'alto verso il basso nel foro pas- through hole of the rotary hydraulic man-
sante del collettore idraulico rotante (Rif. ifold (Ref. F-Fig. 2). - Die elektrische Verkabelung (Bez. E-Abb.
F-Fig. 2). 3) von oben nach unten durch das
- We recommend lubricating the electric durchgehende Loch im Rotations-
- Si raccomanda di lubrificare il cablaggio wiring with oil or grease before inserting verteiler stecken (Bez. F-Abb. 2).
elettrico con olio o grasso prima di the cable clamp in the hydraulic rotation
inserire il fascio del cavo nel collettore di manifold (failure to observe this recom- - Es empfiehlt sich, die elektrische
rotazione idraulico (la non osservanza di mendation can damage the electric Verkabelung mit Öl oder Fett zu schmie-
questa lubrificazione può generare lesio- wiring). ren, bevor man das Kabel in das
ni al cablaggio elettrico). Rotationsverteiler steckt (Die
- Match the holes on the support to the Nichtbeachtung dieser Empfehlung kann
- Fare combaciare i fori del supporto alle rotary electric manifold fixing screws zu Beschädigungen der elektrischen
viti di fissaggio collettore elettrico rotante (Ref. G-Fig. 3). Verkablung führen).
(Rif. G-Fig. 3).
- Die Löcher des Trägers mit den
- Match the electric manifold drive coupling Befestigungsschrauben des Rotations-
- Fare combaciare l'attacco di trascina- (Ref. A-Fig. 4) with its flange; rotate the verteilers in Überdeckung bringen (Bez.
mento del collettore elettrico (Rif. A-Fig. electric element (Ref. B-Fig. 5) to insert G-Abb. 3).
4) con l'apposita flangia; ruotare the drive coupling correctly.
l'elemento elettrico (Rif. B-Fig. 5) per
inserire l'attacco di trascinamento corretta- - Den Mitnehmeranschluss des elektri-
mente - Tighten the rotary electric manifold fixing schen Verteilers (Bez. A-Abb. 4) mit dem
screws with the drive support, crosswise Flansch in Deckung bringen; das elektri-
- Avvitare le viti di fissaggio, del collettore to prevent incorrect blocking. sche Element (Bez. B-Abb. 5) drehen,
elettrico rotante con il supporto di trasci- um den Mitnehmeranschluss korrekt ein-
namento, in modo incrociato per evitare zustecken.
che venga bloccato scorrettamente. - Fit the rotary electric manifold safety side
plate. - Die Befestigungsschrauben des elektri-
- Montare la lamiera di protezione laterale schen Rotationsverteilers so überkreuz
del collettore elettrico rotante. - Reconnect the rotation manifold hydraulic am Mitnehmerträger anschrauben, dass
pipes correctly (see HYDRAULIC ein falsches Blockieren vermieden wird.
- Ricollegare i tubi idraulici al collettore di ROTARY MANIFOLD Table).
rotazione correttamente (vedere tebella - Das seitliche Schutzblech des elektri-
COLLETTORE ROTANTE IDRAULICO). schen Rotationsverteilers montieren.
- Fit the hydraulic rotation manifold drive
tabs (Ref. C-Fig. 6). - Die hydraulischen Leitungen wieder kor-
- Montare le orecchiette di trascinamento rekt am Rotationsverteiler anschließen
collettore di rotazione idraulico (Rif. C- (siehe Tabelle ROTATIONSVER-
Fig. 6). - Reconnect the electric wiring of the elec- TEILER).
tric rotation manifold to the cab (Ref. D-
- Ricollegare il cablaggio elettrico dal col- Fig. 6) positioned beneath the outriggers
lettore di rotazione elettrico alla cabina control panel ”C1-C2”. - Die Mitnehmerabsätze des Rotations-ver-
(Rif. D-Fig. 6) posizionato sotto il cru- teilers montieren (Bez. C-Abb. 6).
scotto stabilizzatori.”C1-C2” - Block the hydraulic pipes and electric
wiring with string bands (Ref. E-Fig. 6). - Die elektrische Verkabelung vom
- Bloccare i tubi idraulici ed il cablaggio Rotationsverteiler zur Kabine wieder
elettrico con delle fascette a stringa (Rif. anschließen (Bez. D-Abb. 6), die sich
E-Fig. 6). unter dem Armaturenbrett der
Stabilisatoren befindet.
- Die hydraulischen Leitungen und die

elektrische Verkabeluung mit
Kabelbindern blockieren (Bez. E-Abb. 6).
8
MRT 1440-1640-1840 EASY 70
B
C
A
FIG. 1 FIG. 2
B
E
G
FIG. 3 FIG. 4
B D
E
C
FIG. 5
C1
C2 FIG. 6
9
70 MRT 1440-1640-1840 EASY
IT EN DE
- Riconnettere le spinette nelle loro sedi - Reconnect the pins in the connector C17, - Die Stecker wieder in die Aufnahme in
dei connettori C17, C18, C21.(TAVOLA 2) C18, C21 seats. (TABLE 2) den Steckverbindern C17, C18, C21 ein-
rasten lassen.(TAFEL 2)
- Ricollegare il cablaggio elettrico dal - Reconnect the electric wiring from the
collettore di rotazione elettrico alla electric rotation manifold to the controls - Die elektrische Verkabelung vom elektri-
scatola di derivazione comandi junction box (Ref. A-Fig. 7) and the sup- schen Teil des Rotationsverteilers zur
(Rif. A-Fig. 7) e al supporto sul serbatoio port on the oil tank (Ref. B-Fig. 8). Abzweigdose der Bedienelemente (Bez.
olio (Rif. B-Fig. 8). A-Abb. 7) und zum Träger auf dem
Ölbehälter (Bez. B-Abb. 8) wieder
- Bloccare il fascio elettrico al telaio della - Block the electric bundle to the vehicle anschließen.
macchina con delle fascette di gomma chassis using rubber bands (Ref. C-Fig.
(Rif. C-Fig. 8). 8).
- Den Kabelstrang am Fahrgestell der
- Montare il coperchio (Rif. D-Fig. 9). - Fit the cover (Ref. D-Fig. 9). Maschine mit Gummikabelbindern be-
festigen (Bez. C-Abb. 8).
- Ricollegare i morsetti della batteria. - Reconnect the battery terminals.
- Den Deckel wieder montieren (Bez. D-

Abb. 9).
- Die Batterieklemmen wieder anschließen.
10
MRT 1440-1640-1840 EASY 70
TAVOLA/ TABLE/ TAFEL 2
C18
C1
7
1
C2
A C
FIG.7
C1 7
C1 8 FIG. 8
FIG. 9
11
70 MRT 1440-1640-1840 EASY
IT
CONNETTORE “C17” (FEMMINA)
NR. CORRISP. CABLAGGIO DESCRIZIONE

A Bianco 012 Strumento livello combustibile
B Bianco 013 Spia stabilizzatori sfilati
C Bianco 015 Segnale marcia lenta-veloce inserita
D Bianco 023 Spia allineamento ponte anteriore
E Bianco 017 Elettrovalvola esclusione circuito idraulico
F Bianco 002 Segnale stabilizzatori appoggiati
G Bianco 008 Elettrovalvola stabilizzatore posteriore destro
H Bianco 009 Elettrovalvola stabilizzatore posteriore sinistro
J Bianco 011 Elettrovalvola stabilizzatore anteriore sinistro
K Bianco 003 Elettrovalvola stabilizzatore anteriore destro
L Bianco 004 Elettrovalvola rientro stabilizzatori
M Bianco 006 Elettrovalvola trave posteriore destra
N Bianco 005 Elettrovalvola trave posteriore sinistra
P Bianco 007 Elettrovalvola trave anteriore destra
R Bianco 010 Elettrovalvola trave anteriore sinistra
S Blu Luci di direzione destre
T Blu nero Luci di direzione sinistre
U Bianco 040 Elettrovalvola freno stazionamento
V ---- ----
CONNETTORE “C18” (MASCHIO)

A Marrone sez. 2,5 (044) Positivo batteria
B Marrone sez. 2,5 (044) Positivo batteria
C Marrone sez. 2,5 (044) Positivo batteria
D Marrone sez. 2,5 (044) Positivo batteria
E Blu sez. 2,5 (041) Negativo batteria (solo con staccabatteria)
F Blu sez. 2,5 (041) Negativo batteria (solo con staccabatteria)
G Blu sez. 2,5 (041) Negativo batteria (solo con staccabatteria)
H Blu sez. 2,5 (041) Negativo batteria (solo con staccabatteria)
I Nero sez. 2,5 (043) Massa telaio
J Nero sez. 2,5 (043) Massa telaio
K Nero sez. 2,5 (043) Massa telaio
L Nero sez. 2,5 (043) Massa telaio
1 Bianco 016 Spia allineamento ponte posteriore
2 Bianco 018 Elettrovalvola, relè e cicalino retromarcia
3 Giallo marrone Elettrovalvola, relè e cicalino retromarcia
4 Bianco 022 Spia intasamento filtro aria
5 Bianco 028 Elettrovalvola marcia avanti
6 Bianco 024 Elettrovalvola sterzatura granchio
7 Bianco 025 Elettrovalvola sterzatura concentrica
8 ---- ----
9 Bianco 026 Luci di direzione destre
10 ---- ----
11 Bianco 027 Luci di direzione sinistre
12 ---- ----
13 Bianco 034 Spia carica batteria
14 Bianco 035 Spia bassa pressione olio motore
15 Bianco 038 Spia eccessiva temperatura acqua motore
16 Bianco 036 Elettrovalvola arresto motore
17 Marrone 1,5 Elettrovalvola arresto motore
18 Bianco 039 Eccitazione relè pompa emergenza
19 ---- ----
CONNETTORE “C21” (FEMMINA)

1 Bianco 042 Positivo per scatola logica e sistema antiribaltamento
2 ---- ----
A Bianco 001 Eccitazione relè luci anabbaglianti e abbaglianti
B Bianco 014 Eccitazione relè elettrovalvola generale stabilizzatori
C Bianco 019 Segnale consenso avviamento
D Bianco 020 Segnale proximity 55°
E Bianco 021 Luci di posizione
F Bianco 029 Elettrovalvola di livellamento
G Bianco 030 Elettrovalvola di livellamento
H Bianco 031 Eccitazione relè termoavviatore
J Bianco 032 Eccitazione relè servizi
K Bianco 033 Eccitazione relè avviamento
L Bianco 037 Elettrovalvola bloccaggio ponte posteriore
M Giallo marrone Elettrovalvola, relè e cicalino retromarcia
12
MRT 1440-1640-1840 EASY 70
EN
CONNECTOR “C17” (FEMALE)
No. CORRESP. WIRING DESCRIPTION

A White 012 Fuel level instrument
B White 013 Outriggers extended indicator
C White 015 Slow-fast gearbox engaged signal
D White 023 Front axle alignment indicator
E White 017 Hydraulic circuit cut-out solenoid valve
F White 002 Outriggers supported signal
G White 008 Right rear outrigger solenoid valve
H White 009 Left rear outrigger solenoid valve
J White 011 Right front outrigger solenoid valve
K White 003 Left rear outrigger solenoid valve
L White 004 Outriggers retraction solenoid valve
M White 006 Right rear boom solenoid valve
N White 005 Left rear boom solenoid valve
P White 007 Right front boom solenoid valve
R White 010 Left front boom solenoid valve
S Blue Right direction lights
T Blue Black Left direction lights
U White 040 Parking brake solenoid valve
V ---- ----
CONNECTOR “C18” (MALE)

A Brown cross.sec. 2 5 (044) Battery positive
B Brown cross.sec. 2 5 (044) Battery positive
C Brown cross.sec. 2 5 (044) Battery positive
D Brown cross.sec. 2 5 (044) Battery positive
E Blue cross.sec. 2 5 (041) Battery negative (only with battery disconnector)
F Blue cross.sec. 2 5 (041) Battery negative (only with battery disconnector)
G Blue cross.sec. 2 5 (041) Battery negative (only with battery disconnector)
H Blue cross.sec. 2 5 (041) Battery negative (only with battery disconnector)
I Black cross.sec. 2 5 (043) Chassis ground
J Black cross.sec. 2 5 (043) Chassis ground
K Black cross.sec. 2 5 (043) Chassis ground
L Black cross.sec. 2 5 (043) Chassis ground
1 White 016 Rear axle alignment indicator
2 White 018 Solenoid valve, relay and reverse gear buzzer
3 Yellow brown Solenoid valve, relay and reverse gear buzzer
4 White 022 Air filter clogged indicator
5 White 028 Forward gear solenoid valve
6 White 024 Crab steering solenoid valve
7 White 025 Concentric steering solenoid valve
8 ---- ----
9 White 026 Right direction lights
10 ---- ----
11 White 027 Left direction lights
12 ---- ----
13 White 034 Battery charge indicator
14 White 035 Engine oil pressure low indicator
15 White 038 Engine water temperature excessive indicator
16 White 036 Engine stop solenoid valve
17 Brown 1 5 Engine stop solenoid valve
18 White 039 Emergency pump relay excitation
19 ---- ----
CONNECTOR “C21” (FEMALE)

1 White 042 Positive for anti-tipping system and logic box
2 ---- ----
A White 001 Dimmed headlights and high-beam headlights relay
excitation
B White 014 Outriggers main solenoid valve relay excitation
C White 019 Start-up permissive signal
D White 020 55° proximity signal
E White 021 Position lights
F White 029 levelling solenoid valve
G White 030 levelling solenoid valve
H White 031 Thermal starter relay excitation
J White 032 Services relay excitation
K White 033 Start-up relay excitation
L White 037 Rear axle block solenoid valve
M Yellow brown Solenoid valve, relay and reverse gear buzzer
13
70 MRT 1440-1640-1840 EASY
DE
STECKVERBINDER “C17” (STECKBUCHSE)
NR. ENTSPR. VERKABELUNG BESCHREIBUNG

A Weiß 012 Kraftstoffstandanzeige
B Weiß 013 Kontrollanzeige Stabilisatoren ausgefahren
C Weiß 015 Signal langsamer-schneller Gang eingelegt
D Weiß 023 Kontrollanzeige Ausrichtung Vorderachse
E Weiß 017 Magnetventil Ausschaltung hydr. Kreislauf
F Weiß 002 Signal Stabilisatoren aufgestellt
G Weiß 008 Magnetventil Stabilisator hinten rechts
H Weiß 009 Magnetventil Stabilisator hinten links
J Weiß 011 Magnetventil Stabilisator vorn links
K Weiß 003 Magnetventil Stabilisator vorn rechts
L Weiß 004 Magnetventil Stabilisatoren eingefahren
M Weiß 006 Magnetventil Balken hinten rechts
N Weiß 005 Magnetventil Balken hinten links
P Weiß 007 Magnetventil Balken vorn rechts
R Weiß 010 Magnetventil Balken vorn links
S Blau Blinklichter rechts
T Blau schwarz Blinklichter links
U Weiß 040 Magnetventil Feststellbremse
V ---- ----
STECKVERBINDER “C18” (STECKERTEIL)

A Braun Querschn. 2,5 (044) Positiv Batterie
B Braun Querschn. 2,5 (044) Positiv Batterie
C Braun Querschn. 2,5 (044) Positiv Batterie
D Braun Querschn. 2,5 (044) Positiv Batterie
E Blau Querschn. 2,5 (041) Negativ Batterie (nur mit Batterieabtrenner)
F Blau Querschn. 2,5 (041) Negativ Batterie (nur mit Batterieabtrenner)
G Blau Querschn. 2,5 (041) Negativ Batterie (nur mit Batterieabtrenner)
H Blau Querschn. 2,5 (041) Negativ Batterie (nur mit Batterieabtrenner)
I Schwarz Querschn. 2,5 (043) Masse Fahrgestell
J Schwarz Querschn. 2,5 (043) Masse Fahrgestell
K Schwarz Querschn. 2,5 (043) Masse Fahrgestell
L Schwarz Querschn. 2,5 (043) Masse Fahrgestell
1 Weiß 016 Kontrollanzeige Ausrichtung Hinterachse
2 Weiß 018 Magnetventil, Relais und Summer Rückwärtsgang
3 Gelb braun Magnetventil, Relais und Summer Rückwärtsgang
4 Weiß 022 Kontrollanzeige Verstopfung Luftfilter
5 Weiß 028 Magnetventil Vorwärtsgang
6 Weiß 024 Magnetventil Hundegang
7 Weiß 025 Magnetventil Allradlenkung
8 ---- ----
9 Weiß 026 Blinker rechts
10 ---- ----
11 Weiß 027 Blinker links
12 ---- ----
13 Weiß 034 Ladestromkontrollanzeige
14 Weiß 035 Kontrollanzeige niedriger Druck Motoröl
15 Weiß 038 Kontrollanzeige zu hohe Temperatur Wassertemperatur
16 Weiß 036 Magnetventil Motorabstellung
17 Braun 1,5 Magnetventil Motorabstellung
18 Weiß 039 Erregung Relais Hilfspumpe
19 ---- ----
STECKVERBINDER “C21” (STECKBUCHSE)

1 Weiß 042 Positiv für Logikbox und Sicherheitssystem
2 ---- ----
A Weiß 001 Erregung Relais Fernlicht und Abblendlicht
B Weiß 014 Erregung Relais allgemeines Magnetventil Stabilsatoren
C Weiß 019 Signal Startfreigabe
D Weiß 020 Signal Näherungsschalter 55°
E Weiß 021 Standlicht
F Weiß 029 Magnetventil Nivellierung
G Weiß 030 Magnetventil Nivellierung
H Weiß 031 Erregung Relais Thermostarter
J Weiß 032 Erregung Relais Wartungsfunktionen
K Weiß 033 Erregung Relais Starten
L Weiß 037 Magnetventil Sperre Hinterachse
M Gelb braun Magnetventil, Relais und Summer Rückwärtsgang
14
SCHEMI IDRAULICI
HYDRAULIC SYSTEMS
HYDRAULISCHE SCHALTPLÄNE
MRT 1440-1640-140 EASY

IT-EN-DE
2
Schema impianto idraulico dei movimenti
Moviment hydraulic system 70
Hydrauliknanlage der bewegungsablaufe
MRT 1440 - 1640 (400°)
IT EN DE
SCHEMA IMPIANTO IDRAULICO DEI MOVIMENTI MOVIMENT HYDRAULIC SYSTEM HYDRAULIKNANLAGE DER BEWEGUNGSABLAUFE
M.R.T = Motore rotazione torretta M.R.T = Motor Turmrotation

V.B. = Valvola di blocco e controllo movimenti M.R.T = Mast turning motor V.B. = Sperr- und Steuerventil Bewegungen
P = Pompa doppia ad ingranaggi V.B. = Locking and balancing valve P = Doppel Zahnradpumpe
D.F = Divisore di flusso Danfoss per impianto sterzo P = Double gear pump D.F = Strommengenteiler Danfoss für Lenkung
D = Distributore Danfoss D.F = Danfoss flow divider for steering system D = Wegeventil Danfoss
R = Serbatoio olio D = Danfoss valve system R = Ölbehälter
F.A. = Filtro aspirazione R = Oil tank F.A. = Saugfilter
F.R. = Filtro scarico F.A. = Intake filter F.R. = Ablassfilter
V.A. = Cilindro accessorio F.R. = Exhaust filter V.A. = Zubehörzylinder
V.L. = Cilindro sollevamento V.A. = Accessory cylinder V.L. = Hubzylinder
MRT 1440 - 1640 (400°)
V.T.I = Cilindro 1° sfilo V.L. = Lifting cylinder V.T.I = Zylinder 1. Auszugstufe

V.T.II = Cilindro 2° sfilo V.T.I = 1st extension cylinder V.T.II = Zylinder 2. Auszugstufe
V.I = Cilindro brandeggio V.T.II = 2nd extension cylinder V.I = Schwenkzylinder
V.C = Cilindro di compensazione V.I = Tilting cylinder V.C = Kompensationszylinder
C.S.P. = Valvola sicurezza pilotata V.C = Compensating cylinder C.S.P. = Vorgesteuertes Sicherheitsventil
C.S.P.D. = Valvola sicurezza pilotata doppia C.S.P. = Piloted safety valve C.S.P.D. = Vorgesteuertes doppeltes Sicherheitsventil
E.S. = Elettrovalvola selettrice per gli stabilizzatori C.S.P.D. = Double piloted safety valve E.S. = Magnetventil für Stützenwahl
M.V. = Motore ventola E.S. = Selector solenoid valve for outriggers M.V. = Lüftermotor
I = Idroguida M.V. = Fan motor I = Hydrolenkung
S.T. = Stabilizzatori I = Power steering system S.T. = Stützen
F.M. = Filtro mandata S.T. = Outriggers F.M. = Filter in Druckleitung
E.. A.S = Elettrovalvola alimentazione stabilizzatori F.M. = Delivery filter E.. A.S = Magnetventil Versorgung Stabilisatoren
E.. T.M.D = Elettrovalvola taglio movimenti distributore E.. A.S = Stabilizers power supply solenoid valve E.. T.M.D = Magnetventil Schnitt Bewegungen Steuergeräte
E.. T.M.D = Distributor movements cut solenoid valve
70
3
4
MRT 1440 - 1640 (360°)
IT EN DE

C.R = Collettore idraulico rotante V.B. = Locking and balancing valve C.R = Ölsammelleitung Rotation
P = Pompa doppia ad ingranaggi C.R = Rotating hydraulic manifold P = Doppel Zahnradpumpe
D.F = Divisore di flusso Danfoss per impianto sterzo P = Double gear pump D.F = Strommengenteiler Danfoss für Lenkung
MRT 1440 - 1640 (360°)

V.T.II = Cilindro 2° sfilo V.T.I = 1st extension cylinder V.T.II = Zylinder 2. Auszugstufe
V.I = Cilindro brandeggio V.T.II = 2nd extension cylinder V.I = Schwenkzylinder
C.S.P.D. = Valvola sicurezza pilotata doppia C.S.P. = Piloted safety valve C.S.P.D. = Vorgesteuertes doppeltes Sicherheitsventil
E.S. = Elettrovalvola selettrice per gli stabilizzatori C.S.P.D. = Double piloted safety valve E.S. = Magnetventil für Stützenwahl
M.V. = Motore ventola E.S. = Selector solenoid valve for outriggers M.V. = Lüftermotor
I = Idroguida M.V. = Fan motor I = Hydrolenkung
S.T. = Stabilizzatori I = Power steering system S.T. = Stützen
F.M. = Filtro mandata S.T. = Outriggers F.M. = Filter in Druckleitung
E.. A.S = Elettrovalvola alimentazione stabilizzatori F.M. = Delivery filter E.. A.S = Magnetventil Versorgung Stabilisatoren
E.. T.M.D = Elettrovalvola taglio movimenti distributore E.. A.S = Stabilizers power supply solenoid valve E.. T.M.D = Magnetventil Schnitt Bewegungen Steuergeräte
70
5
6
MRT 1840 (400°)
IT EN DE

P = Pompa doppia ad ingranaggi V.B. = Locking and balancing valve P = Doppel Zahnradpumpe
D.F = Divisore di flusso Danfossper impianto sterzo P = Double gear pump D.F = Strommengenteiler Danfoss für Lenkung
MRT 1840 (400°)

V.I = Cilindro brandeggio V.T.I = 1st extension cylinder V.I = Schwenkzylinder
E.S. = Elettrovalvola selettrice per gli stabilizzatori C.S.P. = Piloted safety valve E.S. = Magnetventil für Stützenwahl
M.V. = Motore ventola E.S. = Selector solenoid valve for outriggers Arbeitshydraulik
I = Idroguida M.V. = Fan motor M.V. = Lüftermotor
S.T. = Stabilizzatori I = Power steering system I = Hydrolenkung
F.M. = Filtro mandata S.T. = Outriggers S.T. = Stützen
E.. A.S = Elettrovalvola alimentazione stabilizzatori F.M. = Delivery filter F.M. = Filter in Druckleitung
E.. T.M.D = Elettrovalvola taglio movimenti distributore E.. A.S = Stabilizers power supply solenoid valve E.. A.S = Magnetventil Versorgung Stabilisatoren
E.. T.M.D = Distributor movements cut solenoid valve E.. T.M.D = Magnetventil Schnitt Bewegungen Steuergeräte
70
7
8
MRT 1840 (360°)
IT EN DE

C.R = Collettore idraulico rotante V.B. = Locking and balancing valve C.R = Ölsammelleitung Rotation
P = Pompa doppia ad ingranaggi C.R = Rotating hydraulic manifold P = Doppel Zahnradpumpe
D.F = Divisore di flusso Danfossper impianto sterzo P = Double gear pump D.F = Strommengenteiler Danfoss für Lenkung
MRT 1840 (360°)
V.I = Cilindro brandeggio V.T.I = 1st extension cylinder V.I = Schwenkzylinder
E.S. = Elettrovalvola selettrice per gli stabilizzatori C.S.P. = Piloted safety valve E.S. = Magnetventil für Stützenwahl
M.V. = Motore ventola E.S. = Selector solenoid valve for outriggers Arbeitshydraulik
I = Idroguida E = Hydraulic circuit cut-out solenoid valve M.V. = Lüftermotor
S.T. = Stabilizzatori M.V. = Fan motor I = Hydrolenkung
F.M. = Filtro mandata I = Power steering system S.T. = Stützen
E.. A.S = Elettrovalvola alimentazione stabilizzatori S.T. = Outriggers F.M. = Filter in Druckleitung
E.. T.M.D = Elettrovalvola taglio movimenti distributore F.M. = Delivery filter E.. A.S = Magnetventil Versorgung Stabilisatoren
E.. A.S = Stabilizers power supply solenoid valve E.. T.M.D = Magnetventil Schnitt Bewegungen Steuergeräte
70
9
Schema impianto idraulico stabilizzatori
10
Outrigger hydraulic system 70
Hydrauliknanlage - abstutzungen
MRT 1440 - 1640-1840
IT EN DE
SCHEMA IMPIANTO IDRAULICO STABILIZZATORI OUTRIGGER HYDRAULIC SYSTEM OUTRIGGER HYDRAULIC SYSTEM
VS =Outrigger lifting-lowering cylinder VS = Hubzylinder - Senkung Abstützung

V.S. = Cilindro di sollevamento - discesa stabilizzatore R = Oil tank R = Ölbehälter
F.A. = Saugfilter
R = Serbatoio olio F.A. = Intake filter
F.R. = Ablassfilter
F.A. = Filtro aspirazione F.R. = Exhaust filter
P. = Pumpe
F.R. = Filtro scarico P. = Pump
G.E.S. = Gruppe Magnetventile Stützen
P. = Pompa G.E.S. = Outrigger solenoid valve unit
L.P. = Druckbegrenzungs-ventil
G.E.S. = Gruppo elettrovalvole L.P. = Pressure limiting valve E.S. = Magnetventil zur Wahl Stützen
stabilizzatori E.S. = Outrigger selector solenoid valve PH =Hidrostatische pumpe
MRT 1440 - 1640-1840
L.P. = Valvola limitatrice di pressione PH =Hydrostatic pump M. = Wärmebilanz

E.S. = Elettrovalvola selettrice stabilizzatori M. = Thermal relais motor DF =Stromteiler
P.H. = Popma idrostatica DF =Flow divider D = Wegeventil
M = Motore termico D = Valve system C.D. = Hydrolenkung
D.F. = Divisore di flusso C.D. = Power steering F.M. = Filter in Druckleitung
D = Distributore F.M. = Delivery filter P . R = Druckschalter
C.D. = Idroguida P . R = Pressure switch E. A.S. = Magnetventil Versorgung Stabilisatoren
F.M. = Filtro mandata E. A.S = Stabilizers power supply solenoid valve C . S = Sicherheitsventil
P . R = Pressostato C . S = Relief valve
E. A.S. = Elettrovalvola alimentazione stabilizzatori
C . S = Valvola sicurezza
70
11
12
Impianto idraulico freno/acceleratore/blocco ponte posteriore/comando cambio/sterzo
Brake/accelerator/front axle locking/gearbox control/steering hydraulic system 70
Hydraulikanlage bremse/beschleuniger/achsensperre vorne/getriebesteuerung/lenkung
MRT 1440 - 1640-1840 (400°)
IT EN DE
LEGENDA IMPIANTO IDRAULICO FRENO/ACCELERATORE KEY TO BRAKE/ACCELERATOR/FRONT AXLE

/BLOCCO PONTE POSTERIORE/COMANDO LOCKING/GEARBOX CONTROL/STEERING HYDRAULIC LEGENDE HYDRAULIKANLAGE BREMSE / BESCHLEUNIGER /
CAMBIO/STERZO SYSTEM ACHSENSPERRE VORNE / GETRIEBESTEUERUNG /
LENKUNG
V.B.P. = Valvola blocco ponte posteriore V.B.P. = Rear axle locking valve
V.B.P.A. = Cilindro blocco ponte posteriore V.B.P.A. = Rear axle locking cylinder V.B.P. = Sperrventil Hinterachse
F.D.A.V. = Freni a dischi anteriore F.D.A.V. = Front axle disk brakes V.B.P.A. = Sperrzylinder Hinterachse
M = Motore termico M = Internal combustion engine F.D.A.V. = Vordere Scheibenbremsen
P.H. = Pompa idrostatica P.H. = Hydrostatic pump M = Verbrennungsmotor
V.C.L.R. = Cilindro comando lenta-veloce V.C.L.R. = Fast-slow control cylinder P.H. = Hydrostatische Pumpe
V.F.P. = Cilindro comando freno di stazionamento V.F.P. = Parking brake control cylinder V.C.L.R. = Steuerzylinder Fahrstufe langsam-schnell
P.F. = Pedale freno P.F. = Brake pedal V.F.P. = Sterzylinder Handbremse
P.C.A. = Pedale comando acceleratore R = Brake fluid reservoir P.F. = Bremspedal
P.A. = Pedale acceleratore M.C. = Brake pump R = Bremsflüssigkeitsbehälter
R = Serbatoio liquido freno V.S.L.R. = Slow-fast selector valve M.C. = Bremspumpe
MRT 1440 - 1640-1840 (400°)
M.C. = Pompa freno R.C.F.P. = Parking brake control cock V.S.L.R. = Ventil für Fahrstufenwahl langsam-schnell
V.S.L.R. = Valvola selettrice lenta-veloce P. = Double gear pump R.C.F.P. = Steuerhahn Handbremse
R.C.F.P. = Rubinetto comando freno di stazionamento F.A. = Intake filter P. = Doppelt Zahnradpumpe
P. = Pompa doppia ingranaggi F.R. = Drain filter F.A. = Saugfilter
F.A. = Filtro aspirazione D.F. = Flow divider F.R. = Ablassfilter
F.R. = Filtro scarico E = Solenoid valve D.F. = Flussmengenteiler
D.F. = Divisore di flusso V.D. = Steering cylinders E = Magnetventil
E = Elettrovalvola I.D. = Steering pump V.D. = Lenkzylinder
V.D. = Cilindri sterzo S = Oil tank I.D. = Lenkpumpe
I.D. = Pompa sterzo F.M = Delivery filter S = Ölbehälter
S = Serbatoio olio D = Valvr system F.M = Filter in Druckleitung
F.M = Filtro mandata D = Wegeventil
D = Distributore
70
13
14
Impianto idraulico freno/acceleratore/blocco ponte posteriore/comando cambio/sterzo
Brake/accelerator/front axle locking/gearbox control/steering hydraulic system
70
Hydraulikanlage bremse/beschleuniger/achsensperre vorne/getriebesteuerung/lenkung
MRT 1440 - 1640-1840 (360°)
IT EN DE
LEGENDA IMPIANTO IDRAULICO FRENO/ACCELERATORE KEY TO BRAKE/ACCELERATOR/FRONT AXLE

/BLOCCO PONTE POSTERIORE/COMANDO LOCKING/GEARBOX CONTROL/STEERING HYDRAULIC LEGENDE HYDRAULIKANLAGE BREMSE / BESCHLEUNIGER /
CAMBIO/STERZO SYSTEM ACHSENSPERRE VORNE / GETRIEBESTEUERUNG /
LENKUNG
V.B.P. = Valvola blocco ponte posteriore V.B.P. = Rear axle locking valve
V.B.P.A. = Cilindro blocco ponte posteriore V.B.P.A. = Rear axle locking cylinder V.B.P. = Sperrventil Hinterachse
F.D.A.V. = Freni a dischi anteriore F.D.A.V. = Front axle disk brakess V.B.P.A. = Sperrzylinder Hinterachse
M = Motore termico M = Internal combustion engine F.D.A.V. = Vordere Scheibenbremsen
V.C.A. = Cilindro comando acceleratore V.C.A. = Accelerator control cylinder M = Verbrennungsmotor
P.H. = Pompa idrostatica P.H. = Hydrostatic pump V.C.A. = Steuerzylinder Fahrstufe
C.R. = Collettore idraulico di rotazione C.R. = Hydraulic manifold for swivelling action P.H. = Hydrostatische Pumpe
V.C.L.R. = Cilindro comando lenta-veloce V.C.L.R. = Fast-slow control cylinder C.R. = Ölsammelleitung Rotation
V.F.P. = Cilindro comando freno di stazionamento V.F.P. = Parking brake control cylinder V.C.L.R. = Steuerzylinder Fahrstufe langsam-schnell
P.F. = Pedale freno P.F. = Brake pedal V.F.P. = Sterzylinder Handbremse
P.C.A. = Pedale comando acceleratore P.C.A. = Accelerator control pedal P.F. = Bremspedal
MRT 1440 - 1640-1840 (360°)
P.A. = Pedale acceleratore P.A. = Accelerator pedal P.C.A. = Steuerpedal Fahstufe

R = Serbatoio liquido freno R = Brake fluid reservoir P.A. = Gaspedal
M.C. = Pompa freno M.C. = Brake pump R = Bremsflüssigkeitsbehälter
V.S.L.R. = Valvola selettrice lenta-veloce V.S.L.R. = Slow-fast selector valve M.C. = Bremspumpe
R.C.F.P. = Rubinetto comando freno di stazionamento R.C.F.P. = Parking brake control cock V.S.L.R. = Ventil für Fahrstufenwahl langsam-schnell
P. = Pompa tripla a ingranaggi P. = Double gear pump R.C.F.P. = Steuerhahn Handbremse
F.A. = Filtro aspirazione F.A. = Intake filter P. = Dopellt Zahnradpumpe
F.R. = Filtro scarico F.R. = Drain filter F.A. = Saugfilter
D.F. = Divisore di flusso D.F. = Flow divider F.R. = Ablassfilter
E = Elettrovalvola E = Solenoid valve D.F. = Flussmengenteiler
V.D. = Cilindri sterzo V.D. = Steering cylinders E = Magnetventil
I.D. = Pompa sterzo I.D. = Steering pump V.D. = Lenkzylinder
S = Serbatoio olio S = Oil tank I.D. = Lenkpumpe
F.M = Filtro mandata F.M = Delivery filter S = Ölbehälter
D = Distributore D = Valve system F.M = Filter in Druckleitung
D = Wegeventil
70
15
Impianto idraulico trasmissione
16
Transmission hydraulic system 70
Hydraulikanlage - antrieb
MRT 1440 - 1640-1840 (400°)
IT EN DE
LEGENDA IMPIANTO IDRAULICO TRASMISSIONE

KEY TO TRANSMISSION HYDRAULIC SYSTEM LEGENDE HYDRAULIKANLAGE - ANTRIEB
M = Motore Perkins 1104D-44 T
P.I. = Pompa a cilindrata variabile A4 VG 56DA M = 1104D-44 T Perkins engine M = Perkins-Motor 1104D-44 T
R = Serbatoio olio idraulico P.I. = A4 VG 56DA variable P.I.. = Verstellpumpe A4 VG 56DA
V.I. = Valvola inching displacement pump R = Hydraulikölbehälter
M.I. = Motore a cilindrata variabile R = Hydraulic oil tank V.I. = Inch-Ventil
A6 VG 107DA V.I. = Inching valve M.I. = Verstellmotor A6 VG 107DA
F.A. = Filtro aspirazione M.I. = A6 VG 107DA variable F.A. = Saugfilter
F.R. = Filtro scarico displacement engine F.R. = Ablassfilter
F.A. = Intake filter
F.R. = Drain filter
MRT 1440 - 1640-1840 (400°)
70
17
18
Impianto idraulico trasmissione
Transmission hydraulic system 70
Hydraulikanlage - antrieb
MRT 1440 - 1640-1840 (360°)
IT EN DE
LEGENDA IMPIANTO IDRAULICO TRASMISSIONE

KEY TO TRANSMISSION HYDRAULIC SYSTEM LEGENDE HYDRAULIKANLAGE - ANTRIEB
M = Motore Perkins 1104C-44 T
P.I. = Pompa a cilindrata variabile A4 VG 56DA M = 1104C-44 T Perkins engine M = Perkins-Motor 1104C-44 T
R = Serbatoio olio idraulico P.I. = A4 VG 56DA variable P.I.. = Verstellpumpe A4 VG 56DA
V.I. = Valvola inching displacement pump R = Hydraulikölbehälter
M.I. = Motore a cilindrata variabile R = Hydraulic oil tank V.I. = Inch-Ventil
A6 VG 107DA V.I. = Inching valve M.I. = Verstellmotor A6 VG 107DA
F.A. = Filtro aspirazione M.I. = A6 VG 107DA variable F.A. = Saugfilter
F.R. = Filtro scarico displacement engine F.R. = Ablassfilter
C.R. = Collettore idraulico di rotazione F.A. = Intake filter C.R. = Ölsammelleitung Rotation
F.R. = Drain filter
C.R. = Hydraulic manifold for swivelling action
MRT 1440 - 1640-1840 (360°)
70
19
SMONTAGGIO DEL SERBATOIO
TANK DISASSEMBLING
AUSBAU DES BEHÄLTERS
MRT 1440-1640-1840 EASY

IT-EN-DE
70 MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO DEL SERBATOIO TANK DISASSEMBLING AUSBAU DES BEHÄLTERS
SMONTAGGIO DEL SERBATOIO DELL’O- DISASSEMBLING HYDRAULIC OIL AUSBAU DES BEHÄLTERS DES
LIO IDRAULICO E DEL COMBUSTIBILE HYDRAULIKÖLS UND DES KRAFT-
AND FUEL TANK STOFFS
- Posizionare la macchina su una superficie
- Position the vehicle on level ground, turn - Die Maschine auf einer ebenen Fläche
piana, ruotare la torretta a 180°, e spegne- abstellen, den Turm auf 180° drehen
re il motore termico. the turret through 180°, and switch off
the engine. und den Verbrennungsmotor abstellen.
- Vuotare il serbatoio conformemente alla - Den Behälter so entleeren, wie es in der

descrizione del manuale uso e manuten- - Empty the tank according to the proce- Beschreibung der Betriebs- und
zione. dure described in the use and mainte- Wartungsanleitung steht.
nance manual.
- Den Deckel ausbauen (Bez. A-Abb. 1).
- Smontare il coperchio, (Rif. A-Fig. 1).
- Remove the cover (Ref. A-Fig. 1). - Die 3 Stufen des Aufstiegs ausbauen
- Smontare i 3 gradini della scaletta, (Rif. B- (Bez. B-Abb. 1).
Fig. 1). - Remove the three steps (Ref. B-Fig. 1).
- Das vordere Gehäuse ausbauen (Bez. C-
- Smontare il carter anteriore, (Rif. C-Fig. 1). - Remove the front guard (Ref. C-Fig. 1). Abb. 1).
- Smontare il comando dell’acceleratore a - Den Handgaszug ausbauen, der am

- Dismantle the control of the hand accel- Behälter befestigt ist (Bez. D-Abb. 2).
mano fissato al serbatoio, (Rif. D-Fig. 2).
erator fixed to the tank (Ref. D-Fig. 2).
- Disconnect the fuel intake and return - Die Saug- und Rücklaufleitung des
- Scollegare i tubi d’aspirazione e di ritorno Kraftstoffs abtrennen, die auf dem
del combustibile montati sull’indicatore di pipes fitted on the level indicator (Ref. A- Standanzeiger montiert sind (Bez. A-
livello, (Rif. A-Fig. 3). Fig. 3). Abb. 3).
- Staccare la connessione elettrica - Detach the electric wiring of the fuel level - Den elektrischen Anschluss des
indicator (Ref. B-Fig. 3). Kraftstoffstandanzeigers abtrennen (Bez.
dell’indicatore del livello del combustibile, B-Abb. 3).
(Rif. B-Fig. 3).
- Unscrew the oil vent filter (Ref. C-Fig. 3) - Den Filter der Ölentlüftung losschrauben
- Svitare il filtro dello sfiato olio, (Rif. C-Fig. 3) and screw on the eyebolt to secure the (Bez. C-Abb. 3) und eine Kranöse ein-
e avvitare un occhiello per assicurare il ser- tank to a bridge crane or an elevator. schrauben, um den Behälter am
batoio al carro ponte o un elevatore. Laufkran oder einem Gabelstapler abzu-
sichern.
- Disconnect the electric sockets (Ref. D-
- Scollegare le prese elettriche (Rif. D-Fig. 3)
Fig. 3) and the support on the tank (Ref. - Die Steckdosen (Bez. D-Abb. 3) und den
ed il supporto sul serbatoio (Rif. E-Fig. 3).
E-Fig. 3). Träger auf dem Behälter abtrennen
(Bez. E-Abb. 3).
- Svitare la fascetta che sostiene i cavi
elettrici dal telaio (Rif. F-Fig. 3). - Unscrew the clamp used to fix the elec-
- Die Kabelschelle losschrauben, welche
tric cables to the chassis (Ref. F-Fig. 3). die Kabel vom Fahrgestell trägt (Bez. F-
Abb. 3).
- Svitare il collettore di ritorno olio montato sul
filtro di scarico, (Rif. G-Fig. 4). - Unscrew the oil return manifold fitted on - Die Sammelleitung des rücklaufenden
the exhaust filter (Ref. G-Fig. 4). Öls losschrauben, die auf den Auslauf-
filter montiert ist (Bez. G-Abb. 4).
- Smontare la scatola dei relays svitando le
viti, (Rif. H-Fig. 4). - Dismantle the relays box by unscrewing - Die Relaisbox ausbauen, indem man die
the screws (Ref. H-Fig. 4). Schrauben losdreht (Bez. H-Abb. 4).
- Svitare le viti di fissaggio del collettore al - Die Befestigungsschrauben der

telaio, (Rif. I-Fig. 5). Sammelleitung am Fahrgestell aus-
- Unscrew the screws fixing the manifold to schrauben (Bez. I-Abb. 5).
the chassis (Ref. I-Fig. 5).
- Smontare l’indicatore di vuoto, (Rif. L-Fig. - Den Anzeiger für Behälter leer ausbauen
5). (Bez. L-Abb. 5).
- Dismantle the vacuum indicator (Ref. L-
-Scollegare i tubi d’aspirazione dell’olio idrau- Fig. 5).
- Die Ansaugleitungen des hydraulischen
lico montati sul serbatoio, (Rif. A, B, C, D- Öls abtrennen, die auf dem Behälter
Fig. 6). - Disconnect the hydraulic oil intake piping montiert sind (Bez. A, B, C, D-Abb. 6).
(Nota: il tubo “C” non è presente nel fitted on the tank (Ref. A, B, C, D-Fig. (Anm.: Die Leitung “C” ist im Modell
modello MRT 1432-1542-1742; il tubo “D” 6). MRT 1432-1542-1742 nicht vorhanden;
(N.B.: pipe “C” is not present in model die Leitung “D” ist nur in den Versionen
è presente solo nelle versioni mit Klimaanlage vorhanden).
equipaggiate di aria condizionata). MRT 1432-1542-1742; pipe “D” is pre-
- Scollegare i tubi idraulici d’aspirazione sul fil- sent only in the versions fitted with air - Die hydraulischen Ansaugleitung auf dem
tro dell’olio di trasmissione, (Rif. E-Fig. 6). conditioning). Filter des hydraulischen Öls abtrennen
(Bez. E-Abb. 6).
- Scollegare il tubo idraulico di ritorno - Disconnect the hydraulic intake pipes on
dell’olio dal radiatore, (Rif. F-Fig. 6). - Die hydraulische Leitung des vom
the transmission oil filter (Ref. E-Fig. 6). Kühler zurücklaufenden Öls abtren-
nen (Bez. F-Abb. 6).
- Scollegare il tubo idraulico di drenaggio del
- Disconnect the radiator oil hydraulic
motore rotazione, (Rif. G-Fig. 6) - Die hydraulische Rücklaufleitung des
return pipe (Ref. F-Fig. 6).
Umdrehungsmotors abtrennen (Bez.
- Scollegare il tubo idraulico di ritorno G-Abb. 6)
dell’olio dalla pompa idrostatica, (Rif. H-Fig. - Disconnect the rotation motor hydraulic
6). drainage pipe (Ref. G-Fig. 6) - Die hydraulische Rücklaufleitung des
Öls von der hydrostatischen Pumpe
- Disconnect the hydrostatic pump oil abtrennen (Bez. H-Abb. 6).
hydraulic return pipe (Ref. H-Fig. 6)
2
MRT 1440-1640-1840 EASY 70
FIG. 1 FIG. 2
G
E
B
C
D
H
FIG. 3 FIG. 4
F
H E
I
L D
C
FIG. 5 FIG. 6
3
70 MRT 1440-1640-1840 EASY
IT EN DE
- Smontare la fascetta della marmitta dal - Dismantle the tank silencer clamp (Ref. I- - Die Rohrschelle des Auspufftopfs vom
serbatoio (Rif. I-Fig. 7). Fig. 7). Behälter abmontieren (Bez. I-Abb. 7).
- Svitare le viti lato anteriore (Rif. A-Fig. 8) - Unscrew the front (Ref. A-Fig. 8) and rear - Die Schrauben auf der Vorderseite (Bez.
e lato posteriore (Rif. B-Fig. 9) del ser- (Ref. B-Fig. 9) screws on the tank. A-Abb. 8) und der Hinterseite (Bez. B-
batoio. Abb. 9) des Behälters losschrauben.
- Svitare la vite lato interno del serbatoio al - Unscrew the screw fixing the tank to the - Die Schraube auf der Innenseite des
telaio, (Rif. C-Fig. 10). chassis on the inner side (Ref. C-Fig. 10). Behälters am Fahrgestell abschrauben
(Bez. C-Abb. 10).
- Togliere il serbatoio. - Remove the tank. - Den Behälter entfernen.
4
MRT 1440-1640-1840 EASY 70
FIG. 7 FIG. 8
A
C
B
FIG. 9 FIG. 10
5
CONTROLLO PRESSIONI
PRESSURE CONTROL
PRÜFUNG DER DRÜCKE
MRT 1440-1640-1840 EASY

IT-EN-DE
70 MRT 1440-1640-1840 EASY
IT EN DE
CONTROLLO PRESSIONI PRESSURE CONTROL PRÜFUNG DER DRÜCKE
Per controllare le pressioni si deve utilizza- To check the pressure, use a suitable Um die Drücke zu prüfen, ist ein geeignetes
re un manometro appropriato, l’olio deve pressure gauge; the oil temperature must Manometer zu benutzen, das Öl muss eine
essere ad una temperatura di circa 60°, il be about 60°, the engine must be at maxi- Temperatur von circa 60° aufweisen, der
motore termico deve essere al massimo Verbrennungsmotor muss bei max. Touren lau-
mum operating speed for all checks except
dei giri per tutti i controlli tranne per il con- fen, das gilt für alle Prüfungen, mit Ausnahme
those for checking rotation, which must be
trollo della rotazione che va effettuato al
done at minimum speed. der Prüfung der Drehung, die bei
minimo dei giri.
Mindestdrehzahl ausgeführt wird.
FIG./ABB. 1
D
C
2
MRT 1440-1640-1840 EASY 70
Nuovo distributore danfoss 5 elementi-New Danfoss 5 elements valve system-Neues Steuergerät Danfoss 5 Elemente
FIG./ABB. 4
OPTIONAL-OPTIONEN
BRANDEGGIO-TILTING-SCHWENKEN
ROTAZIONE-SLEWING-DREHUNG
SFILO-EXTENSION-AUSFAHREN
SOLLEVAMENTO-LIFT-HEBEN
3
70 MRT 1440-1640-1840 EASY
IT EN DE
CONTROLLO DELLE PRESSIONI CHECKING PRESSURE PRÜFUNG DER DRÜCKE
Movimenti braccio. Boom movements. Auslegerbewegungen

Pompa P1: Effettuare il controllo dalla Pomp P1: Check pressure through intake Pumpe P1: Je nach Modell die Prüfung von
presa di pressione “A” della figura 1,2 o 3 “A” in Figure 1,2 or 3 depending on the Druckanschluss “A” der Abbildung 1,2 oder
a seconda del modello ed agire sulla val model and act on the distributor valve to 3 vornehmen und zum Einstellen des
vola nel distributore per regolare la pressione. adjust the pressure. Drucks das Ventil im Steuergerät benutzen.
CONTROLLO PRESSIONI VALORE REGOLAZIONE
- Pressione distributore principale Danfoss 275-280b limitatore principale del distributore Danfoss
- Sfilo lato stelo 230b valvola anti-urto pre-regolata
- Brandeggio e compensazione lato stelo 250-260b valvola anti-urto pre-regolata
- Rotazione torretta 110-120b limitatore di pressione sul blocco
al min. rpm d’alimentazione di motore
- Direzione (Sterzo) 175b al max limitatore di pressione nel corpo
dell’idroguida Danfoss
PRESSURE CHECK VALUE ADJUSTMENT
- Danfoss main valve system pressure 275-280b Danfoss main valve system limiter
- Rod side extension 230b valvola anti-urto pre-regolata
- Rod side tilting and compensation 250-260b valvola anti-urto pre-regolata
- Rod side tilting and compensation 110-120b pressure limiter on block
at min. rpm motor power supply
- Direction (Steering) 175b at max pressure limiter in Danfoss power steering body
PRÜFUNG DER DRÜCKE WERT EINSTELLUNG
- Druck Hauptsteuergerät Danfoss 275-280b Hauptdruckbegrenzer Steuergerät Danfoss

- Auszug Schaftseite 230b voreingestelltes Antischockventil
- Schwenken und Ausgleich Schaftseite 250-260b voreingestelltes Antischockventil
- Turmdrehung 110-120b Druckbegrenzer auf Block der
bei Mind.drehzahl Motorversorgung
- Lenkung 175b max. Druckbegrenzer auf Körper der Hydrolenkung
Danfoss
4
MRT 1440-1640-1840 EASY 70
IT EN DE
Gruppo stabilizzatori. Outriggers unit. Gruppe Stabilisatoren
La pressione è uguale a quella del distri- The pressure is equal to that of the main Der Druck ist der gleiche wie im
butore principale. valve system. Hauptsteuergerät.
MRT 1542-1742 MRT 1542-1742 MRT 1542-1742

Pompa P2: Effettuare il controllo dalla Pomp P2: Check pressure through intake Pumpe P2: Die Prüfung vom Druckanschluss
presa di pressione “A” della figura 2 “A” in Figure 2 “A” der Abbildung 2 vornehmen.
CONTROLLO PRESSIONI VALORE REGOLAZIONE
- circuito stabilizzatori 170b al min. rpm agire sulla valvola posta prima del distributore
250b al max. rpm del gruppo stabilizzatori (vedere rif. P - fig. 5).
- outriggers circuit 170b at min. rpm act on valve located in front of valve system
250b at max. rpm of outriggers unit (see ref. P - fig. 5).
PRÜFUNG DER DRÜCKE WERT EINSTELLUNG
- Kreislauf Stabilisatoren 170b bei Min.Drehz. Ventil vor Steuergerät der Gruppe
250b bei max. Drehz. Stabilisatoren verwenden (s. Bez. P - Abb. 5).
FIG./ABB. 5
P
5
70 MRT 1440-1640-1840 EASY
IT EN DE
Motore ventola. Fan motor. Motor Lüfterrad

Pompa P3: Effettuare il controllo dalla Pomp P3: Check the pressure through Pumpe P3: Die Prüfung je nach Modell am
presa di pressione “C” di figura 1,2 o 3 a intake “C” of Figure 1,2 or 3 depending on Druckanschluss “C” von Abbildung 1,2
seconda del modello. the model. oder 3 vornehmen.
CONTROLLO PRESSIONE VALORE REGOLAZIONE
Velocità rotazione 3200 min-1 120b circa La registrazione della velocità in funzione della pressione è
Velocità rotazione 2000 min-1 50b circa
automatica ed è regolata da una valvola all’interno del motore - ventola.
Rotation speed e 3200 min-1 approx. 120b Adjustment of the speed according to the pressure is automatic
Rotation speed 2000 min-1 approx. 50b and is regulated by a valve inside the fan motor.
DRUCKPRÜFUNG WERT EINSTELLUNG
Drehgeschwindigk. 3200 min-1 120b circa Die Einstellung der Geschwindigkeit je nach Druck ist automa-
Drehgeschwindigk. 2000 min-1 50b circa tisch und wird durch ein Ventil im Motor des Lüfterrads geregelt.
La ventola è di tipo aspirante. The fan is of the suction type. Das Lüfterrad ist ein Saugrad.
Nota: Per facilitare il controllo della velo- Note: To facilitate checking of high speeds, Anm.: Um die Steuerung der höchsten
cità più elevata effettuare un ponte sulla bridge the temperature probe (FIG. 8). Geschwindigkeit zu vereinfachen, eine
sonda di temperatura (FIG. 8). Schaltbrücke auf dem Temperaturfühler
vornehmen (ABB. 8).
FIG./ABB. 8
6
MRT 1440-1640-1840 EASY 70
Pompa di sovralimentazione sulla Booster pump on hydrostatic Aufladepumpe auf hydrostatischem

trasmissione idrostatica. transmission. Getriebe
Pompa P4: Effettuare il controllo dalla Pomp P4: Check the pressure through Pumpe P4: Die Prüfung je nach dem
presa di pressione “D” di figura 1,2 o intake “D” of Figure 1,2 or 3 depending on Modell auf dem Druckanschluss “D” von
3 a seconda dei modelli. the model. Abbildung 1,2 oder 3 vornehmen.
CONTROLLO PRESSIONE VALORE REGOLAZIONE

- Freno stazionamento 40b sul limitatore di pressione
sovralimentazione
- Servo freno 40b (vedere capitolo trasmissione idrostatica).
- Comando cambio di velocità (lenta e veloce) 40b

- Parking brake 40b On boost pressure limiter
- Servo brake 40b (see Hydrostatic transmission Chapter).
- Speed change command (slow/fast) 40b
DRUCKPRÜFUNG WERT EINSTELLUNG
- Feststellbremse 40b auf Druckbegrenzer

Ausladung
- Betriebsbremse 40b (siehe Kapitel hydrostatisches Getriebe)
- Geschwindigkeitsaschaltung (langsam und schnell) 40b
Per MRT 1432 la pressione é di 30b. For MRT 1432 the pressure is 30b. Für MRT 1432 beträgt der Druck 30 bar.
7
POSIZIONE DEI COMPONENTI IDRAULICI
POSITION OF HYDRAULIC COMPONENTS
POSITION DER HYDRAULISCHEN KOMPONENTEN
MRT 1440-1640 (400°)
IT-EN-DE
TRASMISSIONE IDROSTATICA E BLOCCO ASSALE POSTERIORE- HYDROSTATIC TRANSMISSION AND REAR AXLE BLOCK -
HYDROSTATISCHES GETRIEBE UND SPERRE DER HINTERACHSE
BY PASS DI RAFFREDDAMENTO IMPIANTO IDROSTATICO

HYDROSTATIC SYSTEM COOLING BY PASS
KÜHL- BY PASS HYDROSTATISCHE ANLAGE ELECTROVALVOLE BLOCCAGGIO OSCILLAZIONE PONTE POSTERIORE
POMPA TRASMISSIONE A 4 VG 71 DA
TRANSMISSION PUMP A 4 VG 71 DA REAR AXLE SWING BLOCKAGE SOLENOID VALVE
GETRIEBEPUMPE A 4 VG 71 DA MAGNETVENTILE PENDELSPERRE HINTERACHSE
MRT 1440-1640-1840 EASY
MARTINETTO
BLOCCAGGIO
OSCILLAZIONE
PONTE
POSTERIORE
REAR AXLE
SWING BLOCK-
ING CYLINDER
SPERR-
ZYLINDER
PENDELUNG
HINTERACHSE
MOTORE IDROSTATICO A 6 VM 107 DA

HYDROSTATIC MOTOR A 6 VM 107 DA FILTRO ASPIRAZIONE POMPA SOVRALIMENTAZIONE TRASMISSIONE
HYDROSTATISCHER MOTOR A 6 VM 107 DA TRANSMISSION BOOSTER PUMP SUCTION FILTER
1
70
FILTER SAUGLEITUNG PUMPE AUFLADUNG GETRIEBE

2
70
IMPIANTO IDRAULICO FRENANTE E CAMBIO - BRAKING AND GEAR HYDRAULIC SYSTEM - HYDRAULISCHE BREMSANLAGE UND GETRIEBE
SERBATOIO OLIO FRENI ED

ACCELERATORE
ACCELERATOR AND
BRAKES OIL TANK
A
B
ÖLBEHÄLTER BREMSE UND
GASPEDAL T P
SERVO FRENO
SERVO BRAKE
SERVOBREMSE
B T
T A
P
B
A
P
MRT 1440-1640-1840 EASY
IMPIANTO IDRAULICO CIRCUITO PRINCIPALE E VENTOLA - OUTRIGGERS CIRCUIT HYDRAULIC SYSTEM -
HYDRAULISCHE ANLAGE HAUPTKREISLAUF UND LÜFTERRAD
LIMITATORE PRESSIONE POMPA ALIMENTAZIONE MOTORE VENTILATORE

OUTRIGGERS E.S. SOLENOID VALVE
DRUCKBEGRENZER ZUFUHRPUMPE MOTOR LÜFTERRAD
¬
MRT 1440-1640-1840 EASY
C1
P
C2
LIMITATORE PRESSIONE
STABILIZZATORI
OUTRIGGERS PRESSURE
LIMITER ELETTROVALVOLA E. S. PER STABILIZZATORI
FAN MOTOR FEED PUMP PRESSURE LIMITER
DRUCKBEGRENZER STABI- DRUCKBEGRENZER STABILISATOREN
LISATOREN
3
70
4
70
IMPIANTO IDRAULICO CIRCUITO VENTOLA - FAN CIRCUIT HYDRAULIC SYSTEM - HYDRAULISCHE ANLAGE KREISLAUF LÜFTERRAD
LIMITATORE PRESSIONE MOTORE IDRAULICO

VENTILATORE
FAN HYDRAULIC MOTOR PRESSURE LIMITER
DRUCKBEGRENZER HYDRAULISCHER
MOTOR LÜFTERRAD
MOTORE IDRAULICO - HYDRAULIC MOTOR - HYDRAULISCHER MOTOR

MRT 1440-1640-1840 EASY
IMPIANTO IDRAULICO CIRCUITO STABILIZZATORI - OUTRIGGERS CIRCUIT HYDRAULIC SYSTEM -
HYDRAULISCHE ANLAGE KREISLAUF STABILISATOREN
ELETTRO-DISTIBUTORE PER
STABILIZATORI SITUATO LATO ANTERIORE DESTRO
DEL TELAIO
ELECTRO-DISTRIBUTOR FOR
OUTRIGGERS SITUATED ON RIGHT FRONT OF CHASSIS
ELEKTRO-STEUERGERÄT FÜR
STABILISATOREN VORN RECHTS AM GESTELL
MRT 1440-1640-1840 EASY
A
A
A
A
T
P
C2
ELETTROVALVOLA E. S. PER STABILIZZATORI SITUATA SUL TELAIO DAVANTI LA CABINA

3 E. S. SOLENOID VALVE FOR OUTRIGGERS SITUATED ON CHASSIS IN FRONT OF CAB
MARTINETTO SALITA/DISCESA STABILIZZATORI MAGNETVENTIL E. S. FÜR STABILISATOREN AUF GESTELL VOR KABINE
2 OUTRIGGERS LIFT/LOWER CYLINDER
5
70
ZYLINDER HEBEN/SENKEN STABILISATOREN

6
70
IMPIANTO IDRAULICO CIRCUITO ROTAZIONE TORRETTA - TURRET ROTATION CIRCUIT HYDRAULIC SYSTEM -
HYDRAULISCHE ANLAGE KREISLAUF TURMDREHUNG
RIDUTTORE DI ROTAZIONE CON FRENO
ROTATION REDUCTION GEAR WITH BRAKE
DREHGETRIEBE MIT BREMSE
MANDATA ALIMENTAZIONE DEGLI IMPIANTI AUSILIARI
DELIVERY INFEED OF AUXILIARY SYSTEMS
DRUCKLEITUNG VERSORGUNG HILFSANLAGEN
MOTORE DI ROTAZIONE
ROTATION MOTOR
INCHING-VENTIL
C3
V2
V1
VALVOLA INCHING
INCHING VALVE C2
INCHING-VENTIL
LIMITTATORI PRESSIONE ROTAZIONE

VALVOLA DI BILANCIAMENTO ROTATION PRESSURE LIMITERS
BALANCING VALVE DRUCKBEGRENZER DREHUNG
MRT 1440-1640-1840 EASY
AUSGLEICHSVENTIL
IMPIANTO IDRAULICO CIRCUITO STERZO - STEERING CIRCUIT HYDRAULIC SYSTEM - HYDRAULISCHE ANLAGE LENKUNG
DIVISORE DI FLUSSO DANFOSS OLS80

DANFOSS OLS80 FLOW DIVIDER
FLUSSMENGENTEILER DANFOSS OLS80
MRT 1440-1640-1840 EASY
A B
P
T
ELETTROVALVOLA DI SELEZIONE DEL TIPO DI STERZATA

SITUATA SULLA PARTE POSTERIORE DEL TELAIO
SOLENOID VALVE FOR SELECTING TYPE OF STEERING,

SITUATED ON REAR OF CHASSIS
MAGNETVENTIL WAHL DES LENKTYPS HINTEN AM

IDROGUIDA DANFOSS
GESTELL
DANFOSS POWER STEERING
7
70
HYDROLENKUNG DANFOSS
8
70
IMPIANTO IDRAULICO CIRCUITO ALIMENTAZIONE BRACCIO - BOOM POWER SUPPLY CIRCUIT HYDRAULIC SYSTEM -
HYDRAULISCHE ANLAGE KREISLAUF VERSORGUNG AUSLEGERARM
DISTRIBUTORE PRINCIPALE DANFOSS PVG32

DANFOSS PVG32 MAIN VALVE SYSTEM
HAUPTSTEUERGERÄT DANFOSS PVG32
T
MRT 1440-1640-1840 EASY
IMPIANTO IDRAULICO CIRCUITO SOLLEVAMENTO-COMPENSAZIONEALIMENTAZIONE BRACCIO
BOOM POWER SUPPLY LIFT-COMPENSATION CIRCUIT HYDRAULIC SYSTEM
HYDRAULISCHE ANLAGE KREISLAUF HEBEN-AUSGLEICH VERSORGUNG ARM
MARTINETTO DI COMPENSAZIONE
COMPENSATION CYLINDER
MARTINETTO DI SOLLEVAMENTO
AUSGLEICHSZYLINDER
LIFT CYLINDER
HUBZYLINDER
MRT 1440-1640 EASY
9
70
10
IMPIANTO IDRAULICO CIRCUITO BRACCIO TELESCOPICO - TELESCOPIC BOOM CIRCUIT HYDRAULIC SYSTEM -
HYDRAULISCHE ANLAGE KREISLAUF TELESKOPAUSLEGER 70-
MARTINETTO 1° SFILO
1ST EXTENSION CYLINDER
ZYLINDER 1. AUSZUG
BRACCIO ESTERNO
EXTERNAL BOOM
EXTERNER AUSLEGERARM
MARTINETTO 2° SFILO
2ND EXTENSION CYLINDER
ZYLINDER 2. AUSZUG
MRT 1440-1640 EASY
HYDRAULISCHE ANLAGE KREISLAUF TELESKOPAUSLEGER
MRT 1440-1640 EASY
1
2
MARTINETTO D’INCLINAZIONE FORCHE

FORK TILTING CYLINDER
GABELNEIGE-ZYLINDER
11
70
12
70
IMPIANTO IDRAULICO CIRCUITO SOLLEVAMENTO-COMPENSAZIONEALIMENTAZIONE BRACCIO
BOOM POWER SUPPLY LIFT-COMPENSATION CIRCUIT HYDRAULIC SYSTEM
HYDRAULISCHE ANLAGE KREISLAUF HEBEN-AUSGLEICH VERSORGUNG ARM
MARTINETTO DI COMPENSAZIONE
COMPENSATION CYLINDER
MARTINETTO DI SOLLEVAMENTO
AUSGLEICHSZYLINDER
LIFT CYLINDER
HUBZYLINDER
MRT 1840 EASY
MRT 1840 EASY
MARTINETTO SFILO
EXTENSION CYLINDER
ZYLINDER AUSZUG
BRACCIO ESTERNO
EXTERNAL BOOM
EXTERNER AUSLEGERARM
13
70
14
70
MARTINETTO D’INCLINAZIONE FORCHE

FORK TILTING CYLINDER
GABELNEIGE-ZYLINDER
1
2
MRT 1840 EASY
SMONTAGGIO E RIMONTAGGIO MARTINETTO
INCLINAZIONE STABILIZZATORI
DISASSEMBLING AND REASSEMBLING OUTRIGGERS

TILTING CYLINDER
AUSBAU UND WIEDEREINBAU DES

STABILISATORENNEIGUNGSZYLINDERS
MRT 1440-1640-1840 EASY

IT-EN-DE
70 MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO MARTINETTO DISMANTLING OUTRIGGERS AUSBAU DES STABILISATOREN-

SALITA E DISCESA STABILIZZATORI UP/DOWN CYLINDER HEBE- UND -SENKZYLINDERS
1) Per smontare il martinetto inclinazione è 1) To dismantle the tilting cylinder, remove 1) Zum Ausbau des Neigungszylinders ist
necessario smontare il parafango onde the mudguard to prevent accidental der Kotflügel auszubauen, um ein
evitare rotture accidentali. unbeabsichtigtes Beschädigen zu ver-
breakage.
meiden.
2) Dai comandi in cabina portare il piede
2) Using the cab controls, bring the outrig- 2) Mit den Bedienelementen in der
dello stabilizzatore vicino al suolo.
ger feet close to the ground. Kabinen den Fuß des Stabilisators in
Bodennähe bringen.
3) Agganciare con un carro ponte o un ele-
vatore il braccio dello stabilizzatore 3) Hook the foot side outrigger boom to a
3) Den Stabilisatorarm auf der Fußseite mit
lato piede. bridge crane or elevator. einem Laufkran oder Gabelstapler
absichern.
4) Svitare la vite di fermo e sfilare il perno 4) Unscrew the stop screws and extract
(Rif. A-Fig. 1). the pin (Ref. A-Fig. 1). 4) Die Feststellschraube losschrauben und
den Bolzen herausziehen
5) Adagiare il braccio stabilizzatori lato (Bez. A-Abb. 1).
5) Rest the left foot side outrigger arm on
piede al suolo. the ground. 5) Den Stabilisatorenarm auf der Fußseite
am Boden abstellen.
6) Dai comandi in cabina rientrare comple-
6) Using the cab controls, retract the out-
tamente lo stelo dello stabilizzatore. 6) Mit den Bedienelementen in der
rigger rod completely.
Kabinen den Stabilisatorenschaft ganz
7) Smontare i tubi idraulici posti sulla val- einfahren.
vola del martinetto inclinazione stabiliz- 7) Dismantle the hydraulic pipes on the
zatori outriggers tilting cylinder valve 7) Die hydraulischen Leitungen auf dem
Ventil des Stabilisatorenneigezylinders
8) Chiudere gli orifizi con appositi tappi ausbauen.
8) Cap the holes to prevent dirt from
onde evitare che possano entrare entering. 8) Die Öffnungen mit den Stopfen ver-
eventuali sporcizie.
schließen, damit kein Schmutz ein-
9) Secure the cylinder to a bridge crane or dringt.
9) Assicurare il martinetto ad un carro
an elevator by means of the band pro-
ponte o un elevatore con apposita 9) Den Zylinder mit einem Gurt an einem
vided.
fascia. Laufkran oder Gabelstapler absichern.
10) Svitare la vite di fermo e sfilare il perno 10) Unscrew the stop screws and extract 10) Die Feststellschraube losschrauben
(Rif. B-Fig. 1) the pin (Ref. B-Fig. 1) und den Bolzen herausziehen (Bez. B-
Abb. 1)
11) Estrarre il martinetto dalla sede. 11) Extract the cylinder from its seating.
11) Den Zylinder aus seiner Aufnahme her-
ausziehen.
RIMONTAGGIO: Eseguire le operazioni REASSEMBLY: Follow disassembly WIEDEREINBAU: Die Vorgänge

(con procedura inversa) allo smontaggio operations from Point 1 to No. 11 umgekehrter Reihenfolge zum Ausbau)
dal punto n° 11 al n° 1. (in reverse order). von Punkt 11 bis Punkt 1 ausführen.
2
MRT 1440-1640-1840 EASY 70
FIG. 1
3
NORME GENERALI PER LO SMONTAGGIO MARTINETTI
CYLINDERS DISASSEMBLY
ALLGEMEINE NORMEN FÜR DEN AUSBAU
DER ZYLINDER
MRT 1440-1640-1840-1840 EASY

IT-EN-DE
MRT 1440-1640-1840-1840 70
- SMONTAGGIO E RIMONTAGGIO DELLO STELO COMPLETO

- REMOVAL AND REASSEMBLY OF THE COMPLETE STEM 1
- AUSBAU UND WIEDEREINBAU DES KOMPLETTEN SCHAFTS
- SMONTAGGIO E RIMONTAGGIO DEL PISTONE E DELLA

GHIERA DI CHIUSURA
- REMOVAL AND REASSEMBLY OF THE PISTON AND LOCKING RING ....................3
- AUSBAU UND WIEDEREINBAU VON KOLBEN UND VERSCHLUSSMUTTER
- SMONTAGGIO E RIMONTAGGIO GUARNIZIONI DEL PISTONE

- REMOVAL AND REASSEMBLY OF THE PISTON SEALS AND RING 5
- AUSBAU UND WIEDEREINBAU DER KOLBENRINGE
- SMONTAGGIO E RIMONTAGGIO GUARNIZIONI DELLA

GHIERA DI CHIUSURA
- REMOVAL AND REASSEMBLY OF THE LOCKING RING SEALS AND RING............6
- AUSBAU UND WIEDEREINBAU DER VERSCHLUSSMUTTERDICHTUNGEN
- APPLICAZIONE DEL FRENAFILETTI

- APPLICATION OF THE THREAD LOCKING MATERIAL 8
- ANBRINGUNG DER SCHRAUBENSICHERUNG
- TAVOLE DEI MARTINETTI

- CYLINDERS DRAWINGS 9
- TAFELN DER ZYLINDER
3
70 MRT 1440-1640-1840-1840 EASY
IT EN DE
SMONTAGGIO E RIMONTAGGIO REMOVAL AND REASSEMBLY OF AUSBAU UND WIEDEREINBAU
DELLO STELO COMPLETO THE COMPLETE STEM DES KOMPLETTEN SCHAFTS
REMOVAL AUSBAU
SMONTAGGIO
- Den Zylinder in einen Schraubstock mit
- Place the cylinder in a vice fitted with
- Mettere il martinetto in una morsa dotata Backenschutz stecken.
false jaws. - Den Zylinder vorsichtig einspannen,
di copriganasce. - Tighten the vice, ensuring that the body damit sein Körper nicht verformt wird.
- Stringere moderatamente il martinetto per
does not get distorted. - Die Verschlussmutter “B” (Abb. 1) mit
evitare di deformare il corpo.
- Sbloccare la ghiera di chiusura “B” (Fig. - Free locking ring B (Fig. 1) using a span- einem Stirnlochschlüssel freigeben.
1) con una chiave a pioli. ner wrench. - Sollte das Freigeben der Ringmutter
- In caso di difficoltà nello sbloccare la - If you find it difficult to free the ring, see Schwierigkeiten machen, im Abschnitt
ghiera, si prega di consultare il para- subsection "REMOVAL" in section "AUSBAU" des Kapitels “Anbringung der
grafo "SMONTAGGIO" al capitolo Schraubensicherung” nachlesen.
“APPLICATION OF THE THREAD
“Applicazione del frenafiletti”. - Die Verschlussmutter ganz losdrehen “B”
LOCKING MATERIAL”.
- Svitare completamante la ghiera di chiu- (Abb. 1).
- Completely unscrew locking ring B (Fig. 1). - Den Schaft ganz aus dem Gehäuse des
sura “B” (Fig. 1). - Extract the complete stem from the cylin- Zylinders herausziehen.
- Estrarre lo stelo completo dal corpo del
der body.
martinetto.
ANM.: ZYLINDER MIT GROSSER LÄNGE.
NOTA: PER MARTINETTI DI GRANDE NOTE : VERY LONG CYLINDERS - Den Schaft maximal um 200 mm heraus-
LUNGHEZZA. - Take out the stem over 200 mm maxi- ziehen.
- Estrarre lo stelo per un massimo di 200 mum. - Die Verschlussmutter um eine halbe
mm. Umdrehung lockern (allmählich und
- Give a half turn to the locking ring to
- Svitare la ghiera di chiusura di un mezzo ruckfrei drehen).
loosen it (very slowly and evenly).
giro (Operazione da eseguire gradual- - Den Schaft um circa 2500 mm herauszie-
- Take out the stem by about 2500 mm. hen.
mente, senza scosse). - Support the stem end to prevent it from - Den Schaft am Ende festhalten, um
- Estrarre lo stelo per circa 2500 mm.
weighing on the locking ring (Fig. 2). Belastung der Verschlussmutter zu ver-
- Sostenere lo stelo dall’estremità per evi-
tare sforzi sulla ghiera di chiusura - Carry on unscrewing the locking ring. If meiden (Abb. 2).
(Fig. 2). the effort is excessive, lift and lower the - Die Verschlussmutter weiter abdrehen.
- Continuare a svitare la ghiera di chiusu- stem to reduce the friction. Bei zu hoher Belastung den Schaft
ra. Se lo sforzo è troppo grande, solle- heben und dann senken, um die
vare e poi abbassare lo stelo per dimi- Reibung zu verringern.
muire l’attrito.
Non forzare mai per svitare: rischio di Never force the ring when unscrewing it Das Losschrauben nicht erzwingen:
grippaggio. as this could cause it to seize. Festfressgefahr.
CONTROLLO INSPECTION KONTROLLE

- Togliere il grasso e pulire l’interno del - Degrease and clean the cylinder - Das Fett entfernen und den Zylinder
martinetto. chamber. innen reinigen.
- Controllare visivamente che il corpo del - Visually inspect the cylinder chamber, - Sichtprüfung ausführen, dass das
martinetto sia privo di rigature, bave, Zylindergehäuse keine Rillen, Grate,
there should be no scratches, burrs, oxi-
ossidazione… Roststellen aufweist.
disation, etc...
RIMONTAGGIO REASSEMBLY WIEDEEINBAU

- Applicare olio idraulico sulle guarnizioni
- Apply hydraulic oil on the piston seals - Mit einem Pinsel hydraulisches Öl auf die
del pistone per mezzo di un pennello. and ring, using a brush. Kolbenringe auftragen.
- Rimontare lo stelo completo nel corpo del - Den Schaft ganz in das Zylindergehäuse
- Reassemble the complete stem inside
martinetto “C” (Fig. 1). “C” einfahren lassen (Abb. 1).
- Fare attenzione a non rovinare le guarni- cylinder body C (Fig. 1). - Darauf achten, dass die Kolbenringe
zioni quando si passa sulla maschiatura - Ensure that the seals are not damaged nicht beschädigt werden, wenn man
del corpo del martinetto. while passing through the inside thread über die Gewindebohrung auf dem
- Applicare olio idraulico sulle guarnizioni in the cylinder body. Zylindergehäuse gelangt.
esterne della ghiera di chiusura. - Apply hydraulic oil to the outside seals on - Auf die Außendichtungen der
- Applicare il frenafiletti Loctite 222 (Vedere the locking ring. Verschlussmutter hydraulisches
capitolo “Applicazione del frenafiletti”) - Apply Loctite 222 (See section “APPLI- Öl auftragen.
sulla ghiera di chiusura (Fig. 3). - Die Schraubenicherung Loctite 222
CATION OF THE THREAD LOCKING
- Avvitare la ghiera. (siehe Kapitel “Anbringung der
- Bloccare con una chiave a pioli e con MATERIAL”) on the locking ring (Fig. 3). Schraubensicherung”) auf die
una chiave dinamometrica alla coppia di - Screw the ring in. Verschlussmutter auftragen (Abb. 3).
serraggio indicata (Fig. 4). - Block using a spanner wrench and a - Die Ringmutter anschrauben.
- Fare compiere un giro allo stelo per torque wrench, see table for the tighten- - Mit einem Stirnlochschlüssel blockieren
consentire il posizionamento delle ing torque (Fig. 4). und mit einem Drehmomentschlüssel
guarnizioni. zum angegebenen Anzugsmoment
- Give one turn to the screw to ensure that anziehen (Abb. 4).
the seals are correctly positioned. - Den Schaft eine Umdrehung ausführen
lassen, damit die Kolbenringe richtig
einrasten.
NOTA REMARK
- Si consiglia di provare il martinetto - We advise completing a hydraulic test of ANMERKUNG
idraulicamente prima di rimontarlo sulla the cylinder before reassembling it on - Bevor man den Hydraulikzylinder wieder
macchina. the machine. auf der Maschine einbaut, sollte er
- Effettuare alcune uscite e rientri dello
- Operate the stem several times in both getestet werden.
stelo.
directions. - Den Schaft verschiedene Male ein- und
ausfahren.
4
MRT 1440-1640-1840-1840 70
“B”
“A” “C” “D”
FIG./ABB. 1 FIG./ABB. 2
Frenafiletti COPPIA DI SERRAGGIO CAMICIA

Loctite LOCKING RING TIGHTENING TORQUE
Camicia Schraubensicherung
ANZUGSMOMENT LAUFBUCHSE
Locking ring
Laufbuchse
Stelo
Stem
Schaft
Coppia in Nm
Torque in N.m
Drehmoment in Nm
Guarnizioni-Seal-Dichtungen
FIG./ABB. 3
Filettature-Thread-Gewinde
FIG./ABB. 4
5
70 MRT 1440-1640-1840-1840 EASY
IT EN DE

DEL PISTONE E DELLA GHIERA DI THE PISTON AND LOCKING RING DES KOLBENS UND DER VER-
CHIUSURA SCHLUSSMUTTER
SMONTAGGIO REMOVAL AUSBAU
- Mettere lo stelo in una morsa dotata di - Place the stem in a vice fitted with false - Den Schaft in einen Schraubstock mit
copriganasce. jaws. Backenschutz stecken.
- Stringere per evitare la rotazione del - Tighten so as to stop it turning. - Anziehen, um die Rotation der Gruppe zu
gruppo. - Loosen nut D (Fig. 1) and unscrew it vermeiden.
- Sbloccare il dado “D” (Fig. 1) e svitarlo completely - Die Mutter “D” (Abb. 1) freigeben und sie
completamente per mezzo di una chiave using a box wrench. Or, depending on mit einem Ringschlüssel ganz los-
poligonale oppure, a seconda della ver- the version, remove locking screw 6 schrauben oder, je nach der Version, die
sione, rimuovere la vite a spillo “E” (Fig. (Fig. 1) using a hexagonal wrench. Nadelschraube “E” (Abb. 1) mit einem
1) con l’ausilio di una chiave esagonale. NOTE : Locking ring E (Fig. 1) is fitted Sechskantschlüssel entfernen.
usingLoctite, then blocked by striking it
with achisel.
- Smontare il pistone “C” (Fig. 2) tirandolo - Remove piston C (Fig. 2) by pulling it out - Den Kolben “C” (Abb. 2) ausbauen,
manualmente oppure, secondo la ver- manually or, depending on the version, indem man ihn von Hand herauszieht
sione, svitando il pistone “F” (Fig. 1) con by unscrewing piston F (Fig. 1) using a oder, je nach Version,den Kolben “F”
l’ausilio di una chiave a pioli. hook wrench. (Abb. 1) mit einem Stirnlochschlüssel
- Smontare la ghiera “B” (Fig. 3) facendola - Remove locking ring B (Fig. 3) by sliding losschrauben.
scorrere lungo lo stelo. it alongthe stem. - Die Ringmutter “B” (Abb. 3) ausbauen,
indem man sie auf dem Schaft gleiten
lässt.
CONTROLLO INSPECTION
- Con l’ausilio di un comparatore, controlla- - Check that the stem is straight over its KONTROLLE
re la linearità dello stelo su tutta la lun- whole length, using a comparator (Fig. - Mit Hilfe einer Meßuhr den Schaft auf der
ghezza (Fig. 4). 4). gesamten Länge auf Linearität prüfen
- Controllare che lo stelo non sia sbreccia- - Check that the stem is not scaling, cor- (Abb. 4).
to, corroso o rigato. roded or scratched. - Sicherstellen, dass der Schaft nicht
abbröckelt, Korrosion oder Rillen auf-
weist.
RIMONTAGGIO REASSEMBLY WIEDEREINBAU
- Rimontare la ghiera “B” (Fig. 5) sullo - Reassemble locking ring B (Fig. 5) on - Die Ringmutter “B” (Abb. 5) auf den
stelo “A” (Fig. 5). stem A (Fig. 5). Schaft “A” (Abb. 5) montieren.
- Rimontare il pistone “C” (Fig. 1) sullo - Reassemble piston C (Fig. 1) on the - Den Kolben “C” (Abb. 1) wieder auf den
stelo. stem. Schaft montieren.
- Avvitare e bloccare il dado “D” (Fig. 1) - Screw and lock nut D (Fig. 1) using a box - Die Mutter “D” (Abb. 1) mit einem
con una chiave poligonale e una chiave wrench and a torque wrench. See the Ringschlüssel anziehen und mit einem
dinamometrica alla coppia di serraggio table for the tightening torque (Fig. 6). Drehmomentschlüssel beim angegebe-
indicata (Fig. 6) oppure, a seconda della Or, depending on the version, screw pis- nen Anzugsmoment anziehen (Abb. 6)
versione, riavvitare il pistone “F” (Fig. 1) ton F (Fig. 1) using a spanner wrench oder je nach der Version den Kolben
con una chiave a pioli (vedere coppia di (see tightening torque Fig. 6) and block “F” (Abb. 1) mit einem Stirnlochschlüssel
serraggio Fig. 6) e bloccarlo con una it with locking screw E (Fig. 1). (siehe Anzugsmoment Abb. 6) anziehen
vite a spillo “E” (Fig. 1). und mit der Nadelschraube “E” blockie-
ren (Abb. 1).
NOTA: NOTE : ANMERKUNG:

- Il montaggio della vite a spillo deve - The locking screw should be fitted - Die Montage der Nadelschraube ist unter
essere eseguito applicando loctite using Loctite 243, see section E. Anbringung von Loctite 243 vorzuneh-
243, vedere capitolo “Applicazione del - Tightening torque for the screw : 20 Nm. men, siehe Kapitel “Anbringung der
frenafiletti”. - Strike with a chisel to drive the screw Schraubensicherung”.
- Coppia di serraggio della vite = 20 Nm. - Anzugsmoment der Schraube = 20 Nm.
into the metal.
- Dare un colpo di scalpello per ricaccia- - Einen Meißelschlag geben, um das
re il metallo sulla vite. Metall wieder auf die Schraube
anzustauchen.
6
MRT 1440-1640-1840-1840 70
“B” “B”
“A” “C”
“A” “C” “F”
“D” “E”
Comparatore
Comparator
“B” Meßuhr
“A”
“A”
COPPIA DI SERRAGGIO PISTONE

PISTON TIGHTENING TORQUE
ANZUGSMOMENT KOLBEN
“B”
Coppia in Nm
Torque in N.m
Drehmoment in Nm
“A”
FIG./ABB. 5 Filettature-Thread-Gewinde
FIG./ABB. 6
7
70 MRT 1440-1640-1840-1840 EASY
IT EN DE

GUARNIZIONI DEL PISTONE THE PISTON SEALS AND RING DER DICHTUNGEN AUF DEM
KOLBEN
NOTA: NOTE : Anm.:

Non usare in nessun caso utensili taglienti Never use cutting or sharp tools (screw Auf keinen Fall schneidende Werkzeuge
(Cacciaviti, lame, etc.) per il montaggio e drivers, blades, etc.) when assembling and (Schraubenzieher, Klingen etc.) für den
lo smontaggio delle guarnizioni. removing seals. Ein- und Ausbau der Dichtungen verwen-
Si consiglia di lavorare su banchi puliti, Ensure that there are no chippings on the den. Man sollte auf saubenen, spanfreien
senza trucioli. work bench. Werkbänken arbeiten.

- Die Dichtungen vom Kolben entfernen
- Togliere le guarnizioni dal pistone - Remove the piston seals and ring
(Abb. 1 oder 2).
(Fig. 1 o 2). (Fig. 1 or 2).
- Achtung: Vermeiden, die Kanten und die
- Attenzione: evitare di danneggiare gli - Take care not to damage the edges or
Rillen zu beschädigen.
spigoli e le gole. the bottom of the grooves.

- Togliere il grasso e pulire il pistone. - Degrease and clean the piston. - Das Fett entfernen und den Kolben reini-
- Controllare che le gole e le superfici - Check that the groove bottoms and sides gen.
siano lisce ed esenti da rigature. are smooth, and without scratches. - Sicherstellen, dass die Rillen und die
- Le gole non devono avere corpi estranei. - There should be no extraneous bodies in Oberflächen glatt und nicht gerillt sind.
the grooves. - In den Rillen dürfen keine Fremdkörper
vorhanden sein.
REASSEMBLY WIEDEREINBAU
RIMONTAGGIO
- Fit the seals and ring as in Fig. 1 or 2. - Die Dichtungen wie bei der Montage
- Posizionare le guarnizioni seguendo il
- When fitting the outside seals, open them anordnen (Abb. C1 oder C2).
montaggio (Fig. 1 o 2).
sufficiently to slip them into the grooves - Für die Montage der externen
- Per il montaggio delle guarnizioni
while ensuring that they do not break. Dichtungen sind diese so weit wie erfor-
esterne, aprirle quanto basta, in modo da
- The inside ring should be fitted by hand. derlich zu öffnen, um sie in die Rillen zu
poterle inserire nelle gole senza
setzen, ohne dass sie Schaden
romperle.
nehmen.
- La guarnizione interna deve essere
- Die interene Dichtung ist von Hand zu
montata manualmente.
montieren.
8
MRT 1440-1640-1840-1840 70
Guarnizioni Guarnizioni
Seals Seals
Dichtungen Dichtungen
Anello OR Anello OR
O-Ring O-Ring
O-Ring
FIG./ABB. 1 O-Ring
FIG./ABB. 2
9
70 MRT 1440-1640-1840-1840 EASY
IT EN DE

GUARNIZIONI DELLA GHIERA DI THE SEALS AND RINGS ON THE DER DICHTUNGEN DER VER-
CHIUSURA LOCKING SCHLUSSMUTTER
NOTA: NOTE : ANMERKUNG:

Non usare in nessun caso utensili taglienti Never use cutting or sharp tools Auf keinen Fall schneidende Werkzeuge
(Cacciaviti, lame, etc.) per il montaggio e (screw drivers, blades, etc.) when (Schraubenzieher, Klingen etc.) für den
lo smontaggio delle guarnizioni. assembling and removing seals. Ein- und Ausbau der Dichtungen verwen-
Si consiglia di lavorare su banchi puliti, Ensure that there are no chippings on den. Man sollte auf saubenen, spanfreien
senza trucioli. the work bench. Werkbänken arbeiten.
- Togliere le guarnizioni della ghiera di - Remove the locking ring seals and rings. - Die Dichtungen von der Verschlussmutter
chiusura. - Take care not to damage the edges or entfernen.
- Attenzione: evitare di danneggiare gli spi- the bottom of the grooves. - Achtung: Vermeiden, die Kanten und die
goli e le gole. Rillen zu beschädigen.

- Togliere il grasso e pulire la ghiera di - Degrease and clean the locking ring. - Das Fett entfernen und die
chiusura. - Check that the groove bottoms and sides Verschlussmutter reinigen.
- Controllare che le gole e le superfici are smooth, and without scratches. - Sicherstellen, dass die Rillen und die
siano lisce ed esenti da rigature. - There should be no extraneous bodies in Oberflächen glatt und nicht gerillt sind.
- Le gole non devono avere corpi estranei. the grooves. - In den Rillen dürfen keine Fremdkörper
- Infilare la ghiera sullo stelo facendola - Thread the bare ring on the stem and vorhanden sein.
correre su tutta la lunghezza. slide it over its whole length. - Die Verschlussmutter auf den Schaft
- Il gioco non deve essere eccessivo, ma - The gap should not be excessive, but it stecken und auf der ganzen Länge glei-
non si deve nemmeno bloccare rigida- should not grip either. tern lassen.
mente la ghiera. - Das Spiel darf nicht zu groß sein, aber
die Verschlussmutter darf auch nicht
starr sitzend montiert werden.
- Posizionare le guarnizioni seguendo il - Fit the seals and rings as in Fig. 1. The - Die Dichtungen gemäß der Montage von
montaggio riportato in Fig. 1. lips of the stem seal should face the Abb. 1 anordnen. Die Dichtlippen müs-
Le labbra della guarnizione devono pressure side. sen in Richtung der Druckseite zeigen.
essere orientate lato pressione. - When fitting the stem seal, first introduce - Für die Montage der Schaftdichtung ist
- Per il montaggio della guarnizione dello it in the groove, holding it back either sie in die Rille zu stecken, wobei man
stelo, inserirla nella gola tenendola con with your thumb or a bit (item F) with no sie mit dem Daumen oder einer
il pollice o con un puntale “F” (Fig. 2) sharp edges (Fig. 2). Bolzenspitze “F” (Abb. 2) hält, die keine
che non abbia spigoli vivi. - Push it into the groove with the other scharfen Kanten haben darf.
- Spingere la guarnizione nella gola con hand or a smooth die (item G) (Fig. 3). If - Die Dichtung mit der anderen Hand oder
l’altra mano o con un punzone liscio “G” the seal is too tight, dip it into hydraulic mit einer glatten Bolzenspitze “G” in die
(Fig. 3). Se la resistenza della guarnizio- oil heated to 50°C. Rille drücken (Abb. 3). Wenn die
ne è notevole, la si può ridurre metten- Fit scraper ring D (Fig. 1) using a plug Dichtung einen zu großen Widerstand
dola a bagno in olio idraulico alla tempe- and a mallet. O-rings A and C (Fig. 1) abgibt, kann man ihn verringern, indem
ratura di 50°C. and extrusion proof ring B (Fig. 1) will be man sie bei einer Temperatur von 50° C
Posizionare il raschiaolio “D” (Fig. 1) fitted by hand. ein Bad mit hydraulischem Öl legt.
servendosi di un tampone e di un maz- Den Ölabstreifring “D” (Abb. 1) mit
zuolo. Montare manualmente gli O-ring einem Dorn und einem Hammer positio-
“A” e “C” (Fig. 1) e la guarnizione anti- nieren. Die O-Ringe “A” und “C” (Abb. 1)
estrusione Pos. “B” (Fig. 1). und den Stützring Pos. “B” (Abb. 1) von
Hand montieren.
10
MRT 1440-1640-1840-1840 70
“C” “B” Guarnizione

“A” Seal
Dichtung
“D”
Puntale “F”
Bit“F”
“E” FIG./ABB. 1 Bolzenspitze “F” FIG./ABB. 2
Punzone “G”
Plug “G”
Stempel “G”
Puntale “F”
Bit “F”
Bolzenspitze “F” FIG./ABB. 3
11
70 MRT 1440-1640-1840-1840 EASY
IT EN
APPLICAZIONE DEL FRENAFILETTI APPLICATION OF THE THREAD LOCKING MATERIAL
CARATTERISTICHE CHARACTERISTICS
Frenafiletti leggero Loctite 222 Light thread locking material (Loctite 222)
Applicazione sulle filettature della ghiera di chiusura. Application on the locking ring threads.
Senza Attivatore
Without activation agent
Tempo di lavorabilità 10 - 30 min.
Handling time 10 - 30 minutes
Tempo di messa in funzione 3 - 6 ore
Use time 3 - 6 hours
(Martinetto in pressione)
(Placing of the cylinder under pressure)
Con Attivatore N Loctite
With N Loctite activation agent
Tempo di lavorabilità 10 - 20 min.
Tempo di messa in funzione 2 - 4 ore Handling time 10 - 20 minutes
(Martinetto in pressione) Use time 2 - 4 hours

Resistenza al taglio 1,5 - 4 N/mm 2 (Placing of the cylinder under pressure)
Shearing strength 15.4 - 4 N/mm2
Medium thread locking material (Loctite 243)

Frenafiletti medio Loctite 243
Application on the M8 screws to lock the pistons.

Applicazione su viti M8 per bloccaggio pistoni.
Senza Attivatore Without activation agent
Tempo di lavorabilità 10 - 20 min. Handling time 10 - 20 minutes

Tempo di messa in funzione 3 - 6 ore Use time 3 - 6 hours
(Martinetto in pressione) (Placing of the cylinder under pressure)
Con Attivatore N Loctite With N Loctite activation agent
Tempo di lavorabilità 5 - 15 min. Handling time 5 - 15 minutes
Tempo di messa in funzione 2 - 4 ore Use time 2 - 4 hours
(Martinetto in pressione) (Placing of the cylinder under pressure)
Resistenza al taglio 5 - 7,5 N/mm2
Shearing strength 5 - 7.5 N/mm2
REMOVAL
SMONTAGGIO
If the parts fitted with locking material cannot be removed using
Se i componenti montati con frenafiletti non possono essere standard tools, we recommend
sbloccati con utensili standard, si consiglia di scaldare la zona heating the glued area to T = 250°C, preferably using a hot air
incollata alla temperatura T = 250°C usando preferibilmente una pistol rather than a blowpipe.
pistola ad aria calda invece di un cannello.
NOTA REMARK
Se la temperatura è vicina a 0°C si consiglia, durante il montag- If the temperature is near 0°C, we recommend using a Loctite
gio, di usare un attivatore Loctite in modo da ridurre il tempo di activation agent for the assembly,
polimerizzazione. in addition, this will limit the polymerisation time.
12
MRT 1440-1640-1840-1840 70
DE
ANBRINGUNG DER SCHRAUBENSICHERUNG
EIGENSCHAFTEN
Loctite 222 - niedrigfeste Schraubensicherung
Auftragung auf den Gewinden der Verschlussmutter.

Ohne Aktivator
Zeit der Bearbeitbarkeit 10 - 30 min.
Zeit bis Funktionsaufnahme 3 - 6 Stunden
(Zylinder unter Druck)
Mit Aktivator N Loctite
Scherfestigkeit 1,5 - 4 N/mm2
Loctite 243 - mittelfeste Schraubensicherung
Auftragung auf Schrauben M8 zur Kolbenblockierung.

Ohne Aktivator
Mit Aktivator N Loctite
Scherfestigkeit 5 - 7,5 N/mm2
AUSBAU
Wenn die mit der Schraubensicherung montieren Komponenten

nicht mit Standardwerkzeugen freigegeben werden können, emp-
fiehlt es sich, den verklebten Bereich auf die Temperatur T =
250°C zu erhitzen, am besten unter Benutzung einer
Heißluftpistole anstatt eines Brenners.
ANMERKUNG
Wenn die Temperatur in der Nähe von 0°C liegt, empfiehlt es
sich, während der Montage einen Loctite-Aktivator zu benutzen,
um die Aushärtungszeiten zu verringern.
13
70 MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO MARTINETTO DISASSEMBLING LIFT AUSBAU DES HUBZYLINDERS

SOLLEVAMENTO (MRT 1440-1640- CYLINDER (MRT 1440-1640- (MRT 1440-1640-1840)
1840) 1840) Erforderliche Werkzeuge:
Attrezzi necessari: - 1 Hakenschlüssel (für Ringmuttern)
Tools required:
- 1 chiave ad uncino (per ghiere) - 1 Steckschlüssel von 4 mm
- 1 pin wrench (for ring nuts)
- 1 chiave a brugola di 4mm - 1 4mm Allen wrench
AUSBAU
SMONTAGGIO
DISASSEMBLY - Den Kopf Bez. 16 mit der Hilfe des
- Svitare la testata Rif. 16 con l’aiuto della Hakenschlüssels losschrauben, nach-
chiave ad uncino dopo aver agito sul - Unscrew head Ref. 16 using the pin dem man den Lappen der Laufbuchse
gelockert hat, der in den Kopfsitz einge-
lembo della camicia ribattuto ad incastro wrench after acting on the edge of the schlagen worden ist.
nella sede della testata. cylinder liner riveted in the head seating. - Aus der Laufbuchse des Zylinders die
- Estrarre dalla camicia del martinetto - Extract the liner of rod assembly cylinder Baugruppe Schaft Bez. 8 + Kolben Bez. 6
l’assemblaggio stelo Rif. 8 + pistone Rif. 6. Ref. 8 + piston Ref. 6. herausziehen.
- Smontare la vite a brugola Rif. 2 (chiave - Dismantle the Allen screws Ref. 2 (using - Die Inbusschraube Bez. 2 (mit
a brugola di 4mm) del pistone. a 4mm Allen wrench) of the piston. Steckschlüssel von 4 mm) des Kolbens
- ATTENZIONE vite bloccata con loctite - ATTENTION screw locked using Loctite losdrehen.
- ACHTUNG Schraube mit Loctite abgesi-
(vedi capitolo “Norme generali per lo (see Chapter “General rules for disas- chert (siehe Kapitel “Allgemeine Normen
smontaggio martinetti”). sembling cylinders”). zum Ausbau der Zylinder”).
- Svitare il pistone Rif. 6 del martinetto con - Unscrew the piston Ref. 6 of the cylinder - Den Kolben Bez. 6 des Zylinders mit der
l’aiuto di una chiave ad uncino. using a pin wrench. Hilfe eines Hakenschlüssels losschrauben.
- Togliere il pistone Rif. 6 del martinetto e - Remove the piston Ref. 6 of the cylinder - Den Kolben Bez. 6 des Zylinders und den
la testata Rif. 16 dallo stelo. and the head Ref. 16 from the rod. Kopf Bez. 16 aus dem Schaft ausbauen.
- Smontare le guarnizioni Rif. 4 e 5 e gli - Dismantle the gaskets Ref. 4 and 5 and - Die Dichtungen Bez. 4 und 5 und die
Leitringe Bez. 3 des Kolbens ausbauen.
anelli di guida Rif. 3 del pistone. guide rings Ref. 3 of the piston. - Die Dichtungen Bez. 11, 12 und 15, die
- Smontare le guarnizioni Rif. 11, 12 e 15, - Dismantle gaskets Ref. 11, 12 and 15, Leitringe Bez. 14 und die Dichtungen
gli anelli di guida Rif. 14 e le guarnizioni guide rings Ref. 14 and gaskets Ref. 13 Bez. 13 und 17 des Kopfs ausbauen.
Rif. 13 e 17 della testata. and 17 of the head. - Den Zustand des Ventils, des Ventilsitzes
- Verificare lo stato della valvola, della - Check the condition of the valve, the und der Feder prüfen.
sede della valvola e della molla. valve seat and the spring. - Die Dichtungen und die Komponenten
- Cambiare le guarnizioni e i componenti - Replace the gaskets and components, if ersetzen, falls erforderlich (siehe Kapitel
“Allgemeine Normen für den Ausbau der
se necessario (vedi capitolo “Norme necessary (see Chapter “General rules Zylinder”).
generali per lo smontaggio martinetti”). for disassembling cylinders”). - Auf die Richtung des Wiedereinbaus
- ATTENZIONE al senso di rimontaggio. - ATTENTION to the direction of ACHTEN.
reassembly.
WIEDEREINBAU
RIMONTAGGIO REASSEMBLY Umgekehrte Richtung des Ausbaus.
Operazione inversa dello smontaggio. Anm.:
Nota: Operation reverse of disassembly. - Der Außenlappen der Laufbuchse muss
Note : in eine der Einschlagstellen auf dem Kopf
- Si rammenta che il lembo esterno della
- Remember that the outside edge of the eingeschlagen werden.
camicia deve essere ribattuto in una delle - Die Montage der Inbusschraube ist mit
cylinder liner must be riveted in one of the
sedi ad incastro presenti sulla testata. seating present on the head. der Schraubensicherung Loctite vorzuneh
- Il montaggio della vite a brugola deve - Assembly of the Allen screw must be men.
essere effettuata con loctite blocca filetti. - Die Dichtungen mit hydraulischem Öl ein
done using thread-locking Loctite. schmieren (siehe Kapitel “Allgemeine
- Spalmare le guarnizioni di olio idraulico - Smear hydraulic oil on the gaskets (see Normen für den Ausbau der Zylinder”).
(vedi capitolo “Norme generali per lo Chapter “General rules for disassembling
cylinders”).
14
MRT 1440-1640-1840 EASY 70
SMONTAGGIO MARTINETTO DI DISASSEMBLING TILTING AUSBAU DES SCHWENKZYLIN-

BRANDEGGIO CYLINDER DERS
Attrezzi necessari: Tools required: Erforderliche Werkzeuge:
- 1 chiave ad uncino (per ghiere) - 1 pin wrench (for ring nuts) - 1 Hakenschlüssel (für Ringmuttern)
- 1 chiave a brugola di 4mm - 1 4mm Allen wrench - 1 Steckschlüssel von 4 mm
AUSBAU
SMONTAGGIO DISASSEMBLY
- Den Kopf Bez. 10 mit der Hilfe des
- Svitare la testata Rif. 10 con l’aiuto della - Unscrew head Ref. 10 using the pin
Hakenschlüssels losschrauben, nachdem
chiave ad uncino dopo aver agito sul wrench after acting on the edge of the
man den Lappen der Laufbuchse gelockert
lembo della camicia ribattuto ad incastro cylinder liner riveted in the head seating.
hat, der in den Kopfsitz eingeschlagen wor-
- Extract the liner of rod assembly cylinder
nella sede della testata. den ist.
Ref. 7 + piston Ref. 6.
- Estrarre dalla camicia del martinetto - Aus der Laufbuchse des Zylinders die
- Dismantle the Allen screws Ref. 2 (using
l’assemblaggio stelo Rif. 7 + pistone Rif. 6. Baugruppe Schaft Bez. 7 + Kolben Bez. 6
a 4mm Allen wrench) of the piston.
- Smontare la vite a brugola Rif. 2 (chiave herausziehen.
- ATTENTION screw locked using Loctite
a brugola di 4mm) del pistone. - Die Inbusschraube Bez. 2 (mit Steckschlüssel
(see Chapter “General rules for disas-
- ATTENZIONE vite bloccata con loctite von 4 mm) des Kolbens losdrehen.
sembling cylinders”).
- ACHTUNG Schraube mit Loctite abgesichert
(vedi capitolo “Norme generali per lo - Unscrew the piston Ref. 6 of the cylinder
(siehe Kapitel “Allgemeine Normen zum
smontaggio martinetti”). using a pin wrench.
Ausbau der Zylinder”).
- Svitare il pistone Rif. 6 del martinetto con - Remove the piston Ref. 6 of the cylinder
- Den Kolben Bez. 6 des Zylinders mit der Hilfe
l’aiuto di una chiave ad uncino. and the head Ref. 10 from the rod.
eines Hakenschlüssels losschrauben.
- Togliere il pistone Rif. 6 del martinetto e - Dismantle the gaskets Ref. 4 and 5 and
- Den Kolben Bez. 6 des Zylinders und den Kopf
la testata Rif. 10 dallo stelo. guide rings Ref. 3 of the piston.
Bez. 10 aus dem Schaft ausbauen.
- Smontare le guarnizioni Rif. 4 e 5 e gli - Dismantle gaskets Ref. 11, 12 and 14,
- Die Dichtungen Bez. 4 und 5 und die Leitringe
anelli di guida Rif. 3 del pistone. guide rings Ref. 15 and gaskets Ref. 13
Bez. 3 des Kolbens ausbauen.
- Smontare le guarnizioni Rif. 11, 12 e 14, and 16 of the head.
- Die Dichtungen Bez. 11, 12 und 14, die
- Check the condition of the valve, the
gli anelli di guida Rif. 15 e le guarnizioni Leitringe Bez. 15 und die Dichtungen Bez. 13
valve seat and the spring.
Rif. 13 e 16 della testata. und 16 des Kopfs ausbauen.
- Replace the gaskets and components, if
- Verificare lo stato della valvola, della - Den Zustand des Ventils, des Ventilsitzes und
necessary (see Chapter “General rules
sede della valvola e della molla. der Feder prüfen.
for disassembling cylinders”).
- Cambiare le guarnizioni e i componenti - Die Dichtungen und die Komponenten erset-
- ATTENTION to the direction of reassem-
se necessario (vedi capitolo “Norme zen, falls erforderlich (siehe Kapitel
bly.
“Allgemeine Normen für den Ausbau der
generali per lo smontaggio martinetti”).
Zylinder”).
- ATTENZIONE al senso di rimontaggio.
- Auf die Richtung des Wiedereinbaus ACHTEN.
Operazione inversa dello smontaggio. Operation reverse of disassembly. Umgekehrte Richtung des Ausbaus.
Nota: Note : Anm.:
- Si rammenta che il lembo esterno della - Remember that the outside edge of the - Der Außenlappen der Laufbuchse muss
camicia deve essere ribattuto in una delle cylinder liner must be riveted in one of the in eine der Einschlagstellen auf dem Kopf
sedi ad incastro presenti sulla testata. seating present on the head. eingeschlagen werden.
- Il montaggio della vite a brugola deve - Assembly of the Allen screw must be - Die Montage der Inbusschraube ist mit
essere effettuata con loctite blocca filetti. done using thread-locking Loctite. der Schraubensicherung Loctite vorzunehmen.
- Spalmare le guarnizioni di olio idraulico - Smear hydraulic oil on the gaskets (see - Die Dichtungen mit hydraulischem Öl ein
(vedi capitolo “Norme generali per lo Chapter “General rules for disassembling schmieren (siehe Kapitel “Allgemeine
smontaggio martinetti”). cylinders”). Normen für den Ausbau der Zylinder”).
15
70 MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO MARTINETTO DISASSEMBLING COMPENSATION AUSBAU DES AUSGLEICHSZYLIN-

COMPENSAZIONE CYLINDER DERS
Erforderliche Werkzeuge:
Tools required:
- 1 chiave ad uncino (per ghiere) - 1 Steckschlüssel von 4 mm
- 1 4mm Allen wrench
- 1 chiave a brugola di 4mm
AUSBAU
SMONTAGGIO DISASSEMBLY
- Den Kopf Bez. 10 mit der Hilfe des
- Svitare la testata Rif. 10 con l’aiuto della - Unscrew head Ref. 10 using the pin Hakenschlüssels losschrauben, nach-
wrench after acting on the edge of the dem man den Lappen der Laufbuchse
chiave ad uncino dopo aver agito sul gelockert hat, der in den Kopfsitz einge-
lembo della camicia ribattuto ad incastro cylinder liner riveted in the head seating.
schlagen worden ist.
nella sede della testata. - Extract the liner of rod assembly cylinder - Aus der Laufbuchse des Zylinders die
Ref. 7 + piston Ref. 6. Baugruppe Schaft Bez. 7 + Kolben Bez.
- Estrarre dalla camicia del martinetto
- Dismantle the Allen screws Ref. 2 (using 6 herausziehen.
l’assemblaggio stelo Rif. 7 + pistone Rif. 6.
a 4mm Allen wrench) of the piston. - Die Inbusschraube Bez. 2 (mit
- Smontare la vite a brugola Rif. 2 (chiave - ATTENTION screw locked using Loctite Steckschlüssel von 4 mm) des Kolbens
a brugola di 4mm) del pistone. (see Chapter “General rules for disas- losdrehen.
- ATTENZIONE vite bloccata con loctite sembling cylinders”). - ACHTUNG Schraube mit Loctite abgesi-
(vedi capitolo “Norme generali per lo - Unscrew the piston Ref. 6 of the cylinder chert (siehe Kapitel “Allgemeine Normen
smontaggio martinetti”). zum Ausbau der Zylinder”).
using a pin wrench. - Den Kolben Bez. 6 des Zylinders mit der
- Svitare il pistone Rif. 6 del martinetto con - Remove the piston Ref. 6 of the cylinder Hilfe eines Hakenschlüssels losschrau-
l’aiuto di una chiave ad uncino. and the head Ref. 10 from the rod. ben.
- Togliere il pistone Rif. 6 del martinetto e - Dismantle the gaskets Ref. 4 and 5 and - Den Kolben Bez. 6 des Zylinders und
la testata Rif. 10 dallo stelo. guide rings Ref. 3 of the piston. den Kopf Bez. 10 aus dem Schaft aus-
- Smontare le guarnizioni Rif. 4 e 5 e gli - Dismantle gaskets Ref. 11, 12 and 14, bauen.
guide rings Ref. 15 and gaskets Ref. 13 - Die Dichtungen Bez. 4 und 5 und die
anelli di guida Rif. 3 del pistone. Leitringe Bez. 3 des Kolbens ausbauen.
- Smontare le guarnizioni Rif. 11, 12 e 14, and 16 of the head.
- Die Dichtungen Bez. 11, 12 und 14, die
gli anelli di guida Rif. 15 e le guarnizioni - Check the condition of the valve, the Leitringe Bez. 15 und die Dichtungen
valve seat and the spring. Bez. 13 und 16 des Kopfs ausbauen.
Rif. 13 e 16 della testata.
- Replace the gaskets and components, if - Die Dichtungen und die Komponenten
- Cambiare le guarnizioni e i componenti
necessary (see Chapter “General rules ersetzen, falls erforderlich (siehe Kapitel
se necessario (vedi capitolo “Norme for disassembling cylinders”). “Allgemeine Normen für den Ausbau der
generali per lo smontaggio martinetti”). - ATTENTION to the direction of reassembly Zylinder”).
- ATTENZIONE al senso di rimontaggio. - Auf die Richtung des Wiedereinbaus
ACHTEN.
Operazione inversa dello smontaggio. Operation reverse of disassembly.
Note : Umgekehrte Richtung des Ausbaus.
Nota:
- Remember that the outside edge of the Anm.:
- Si rammenta che il lembo esterno della
cylinder liner must be riveted in one of the - Der Außenlappen der Laufbuchse muss
camicia deve essere ribattuto in una delle seating present on the head. in eine der Einschlagstellen auf dem Kopf
sedi ad incastro presenti sulla testata. - Assembly of the Allen screw must be eingeschlagen werden.
- Il montaggio della vite a brugola deve done using thread-locking Loctite. - Die Montage der Inbusschraube ist mit
essere effettuata con loctite blocca filetti. - Smear hydraulic oil on the gaskets (see der Schraubensicherung Loctite vorzunehmen.
- Spalmare le guarnizioni di olio idraulico Chapter “General rules for disassembling
cylinders”). - Die Dichtungen mit hydraulischem Öl ein
(vedi capitolo “Norme generali per lo schmieren (siehe Kapitel “Allgemeine
smontaggio martinetti”). Normen für den Ausbau der Zylinder”).
16
MRT 1440-1640-1840 EASY MRT 1440-1640-1840-1840 EASY 70
SMONTAGGIO MARTINETTO 1° DISASSEMBLING 1st EXTENSION AUSBAU ZYLINDER 1. AUSZUG

SFILO (MRT 1440-1640-1840) CYLINDER (MRT 1440-1640-1840) (MRT 1440-1640-1840)
Attrezzi necessari: Tools required: Erforderliche Werkzeuge:
- 1 chiave ad uncino (per ghiere) - 1 pin wrench (for ring nuts) - 1 Hakenschlüssel (für Ringmuttern)
SMONTAGGIO DISASSEMBLY AUSBAU
- Svitare la testata Rif. 23 con l’aiuto della chiave - Unscrew head Ref. 23 using the pin wrench - Den Kopf Bez. 23 mit der Hilfe des
after acting on the edge of the cylinder liner riv- Hakenschlüssels losschrauben, nachdem
ad uncino dopo aver agito sul lembo della
eted in the head seating. man den Lappen der Laufbuchse gelockert
camicia ribattuto ad incastro nella sede della
- Extract the liner of rod assembly cylinder Ref. hat, der in den Kopfsitz eingeschlagen wor-
testata. den ist.
- Estrarre dalla camicia del martinetto 16 + piston Ref. 10.
- Aus der Laufbuchse des Zylinders die
l’assemblaggio stelo Rif. 16 + pistone Rif. 10. - Dismantle the Allen screws Ref. 11 (using a
Baugruppe Schaft Bez. 16 + Kolben Bez. 10
- Smontare la vite a brugola Rif. 11 (chiave a 4mm Allen wrench) of the piston. herausziehen.
brugola di 4mm) del pistone. - ATTENTION screw locked using Loctite (see - Die Inbusschraube Bez. 11 (mit Steckschlüssel
- ATTENZIONE vite bloccata con loctite (vedi Chapter “General rules for disassembling von 4 mm) des Kolbens losdrehen.
capitolo “Norme generali per lo smontaggio mar- cylinders”). - ACHTUNG Schraube mit Loctite abgesichert
tinetti”). - Unscrew the piston Ref. 10 of the cylinder (siehe Kapitel “Allgemeine Normen zum
- Svitare il pistone Rif. 10 del martinetto con using a pin wrench. Ausbau der Zylinder”).
l’aiuto di una chiave ad uncino. - Remove the piston Ref. 10 of the cylinder and - Den Kolben Bez. 10 des Zylinders mit der Hilfe
- Togliere il pistone Rif. 10 del martinetto e la the head Ref. 23 from the rod. eines Hakenschlüssels losschrauben.
testata Rif. 23 dallo stelo. - Dismantle gaskets Ref. 6 and guide rings Ref. - Den Kolben Bez. 10 des Zylinders und den
- Smontare la guarnizione Rif. 6 e gli anelli di 5 of the piston. Kopf Bez. 23 aus dem Schaft ausbauen.
guida Rif. 5 del pistone. - Dismantle sealing ring Ref. 14 and extract - Die Dichtung Bez. 6 und die Leitringe Bez. 5
- Smontare l’anello di tenuta Rif. 14 e sfilare il spacer Ref. 15. des Kolbens ausbauen.
- Dismantle gaskets Ref. 19, 20 and 22, guide - Den Dichtungsring Bez. 14 ausbauen und
distanziale Rif. 15.
rings Ref. 18 and gaskets Ref. 21 and 24 of den Distanzring Bez. 15 herausziehen.
- Smontare le guarnizioni Rif. 19, 20 e 22, gli
the head. - Die Dichtungen Bez. 19, 20 und 22, die
anelli di guida Rif. 18 e le guarnizioni Rif. 21 e Leitringe Bez. 18 und die Dichtungen Bez. 21
24 della testata. - Unscrew valve Ref. 12 after removing the snap
und 24 des Kopfs ausbauen.
- Svitare la valvola Rif. 12 dopo aver tolto l’anello ring Ref. 1.
- Das Ventil Bez. 12 ausschrauben, nachdem
elastico Rif. 1. - Check the condition of the valve, the valve seat man den Sprengring Bez. 1 entfernt hat.
- Verificare lo stato della valvola, della sede della and the spring. - Den Zustand des Ventils, des Ventilsitzes und
valvola e della molla. - Replace the gaskets and components, if nec- der Feder prüfen.
- Cambiare le guarnizioni e i componenti se essary (see Chapter “General rules for disas- - Die Dichtungen und die Komponenten erset-
necessario (vedi capitolo “Norme generali per sembling cylinders”). zen, falls erforderlich (siehe Kapitel
lo smontaggio martinetti”). - ATTENTION to the direction of reassembly. “Allgemeine Normen für den Ausbau der
- ATTENZIONE al senso di rimontaggio. Zylinder”).
REASSEMBLY - Auf die Richtung des Wiedereinbaus ACHTEN.
RIMONTAGGIO
Operation reverse of disassembly. WIEDEREINBAU
Operazione inversa dello smontaggio. Note :
Nota: - Remember that the outside edge of the cylin- Umgekehrte Richtung des Ausbaus.
der liner must be riveted in one of the seating Anm.:
- Si rammenta che il lembo esterno della camicia
present on the head. - Der Außenlappen der Laufbuchse muss in eine
deve essere ribattuto in una delle sedi ad
- Assembly of the Allen screw must be done der Einschlagstellen auf dem Kopf eingeschla
incastro presenti sulla testata. gen werden.
- Il montaggio della vite a brugola deve essere using thread-locking Loctite.
- Die Montage der Inbusschraube ist mit der
effettuata con loctite blocca filetti. - Smear hydraulic oil on the gaskets (see
Schraubensicherung Loctite vorzunehmen.
- Spalmare le guarnizioni di olio idraulico (vedi Chapter “General rules for disassembling - Die Dichtungen mit hydraulischem Öl ein
capitolo “Norme generali per lo smontaggio cylinders”). schmieren (siehe Kapitel “Allgemeine Normen
martinetti”). für den Ausbau der Zylinder”).
17
70 MRT 1440-1640-1840-1840 EASY MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO MARTINETTO 2° DISASSEMBLING 2nd EXTEN- AUSBAU DES ZYLINDERS 2.

SFILO (MRT 1440-1640-1840) SION CYLINDER (MRT 1440- AUSZUG (MRT 1440-1640-1840)
1640-1840)
Attrezzi necessari: Erforderliche Werkzeuge:
Tools required:
- 1 chiave ad uncino (per ghiere) - 1 Hakenschlüssel (für Ringmuttern)
SMONTAGGIO DISASSEMBLY AUSBAU
- Svitare la testata Rif. 21 con l’aiuto della chiave - Unscrew head Ref. 21 using the pin - Den Kopf Bez. 21 mit der Hilfe des
ad uncino dopo aver agito sul lembo della wrench after acting on the edge of the Hakenschlüssels losschrauben, nachdem man
camicia ribattuto ad incastro nella sede della cylinder liner riveted in the head seating. den Lappen der Laufbuchse gelockert hat, der in
testata. - Extract the liner of rod assembly cylinder den Kopfsitz eingeschlagen worden ist.
- Estrarre dalla camicia del martinetto Ref. 12 + piston Ref. 3. -Aus der Laufbuchse des Zylinders die Baugruppe
l’assemblaggio stelo Rif. 12 + pistone Rif. 3. - Dismantle the Allen screws Ref. 8 (using Schaft Bez. 12 + Kolben Bez. 3 herausziehen.
- Smontare la vite a brugola Rif. 8 (chiave a bru- a 4mm Allen wrench) of the piston. - Die Inbusschraube Bez. 8 (mit Steckschlüssel von
gola di 4mm) del pistone. - ATTENTION screw locked using Loctite 4 mm) des Kolbens losdrehen.
- ATTENZIONE vite bloccata con loctite (vedi -ACHTUNG Schraube mit Loctite abgesichert
(see Chapter “General rules for disas-
capitolo “Norme generali per lo smontaggio mar- sembling cylinders”). (siehe Kapitel “Allgemeine Normen zumAusbau
tinetti”). - Unscrew the piston Ref. 3 of the cylinder der Zylinder”).
- Svitare il pistone Rif. 3 del martinetto con l’aiuto using a pin wrench. - Den Kolben Bez. 3 des Zylinders mit der Hilfe
di una chiave ad uncino. - Remove the piston Ref. 3 of the cylinder eines Hakenschlüssels losschrauben.
- Togliere il pistone Rif. 3 del martinetto e la testa- - Den Kolben Bez. 3 des Zylinders und den Kopf
and the head Ref. 21 from the rod.
ta Rif. 21 dallo stelo. Bez. 21 aus dem Schaft ausbauen.
- Dismantle gaskets Ref. 5 and guide rings
- Smontare la guarnizione Rif. 5 e gli anelli di - Die Dichtung Bez. 5 und die Leitringe Bez. 6 des
Ref. 6 of the piston.
guida Rif. 6 del pistone. Kolbens ausbauen.
- Dismantle sealing ring Ref. 14 and
- Smontare l’anello di tenuta Rif. 14 e sfilare il - Den Dichtungsring Bez. 14 ausbauen und den
extract spacer Ref. 15.
distanziale Rif. 15. Distanzring Bez. 15 herausziehen.
- Dismantle gaskets Ref. 17, 18 and 20,
- Smontare le guarnizioni Rif. 17, 18 e 20, gli - Die Dichtungen Bez. 17, 18 und 20, die Leitringe
guide rings Ref. 16 and gaskets Ref. 19
anelli di guida Rif. 16 e le guarnizioni Rif. 19 e Bez. 16 und die Dichtungen Bez. 19 und 22 des
and 22 of the head.
22 della testata. Kopfs ausbauen.
- Unscrew valve Ref. 24 after removing the
- Svitare la valvola Rif. 24 dopo aver tolto l’anello - Das Ventil Bez. 24 ausschrauben, nachdem man
snap ring Ref. 2.
elastico Rif. 2. den Sprengring Bez. 2 entfernt hat.
- Verificare lo stato della valvola, della sede della - Den Zustand des Ventils, des Ventilsitzes und der
valvola e della molla. Feder prüfen.
- Replace the gaskets and components, if
- Cambiare le guarnizioni e i componenti se - Die Dichtungen und die Komponenten ersetzen,
necessario (vedi capitolo “Norme generali per falls erforderlich (siehe Kapitel “Allgemeine
lo smontaggio martinetti”). Normen für denAusbau der Zylinder”).
- ATTENTION to the direction of reassembly.
- ATTENZIONE al senso di rimontaggio. -Auf die Richtung des WiedereinbausACHTEN.

Operazione inversa dello smontaggio. Operation reverse of disassembly. Umgekehrte Richtung desAusbaus.
Nota: Note : Anm.:
- Si rammenta che il lembo esterno della camicia - Remember that the outside edge of the - DerAußenlappen der Laufbuchse muss in eine
deve essere ribattuto in una delle sedi ad cylinder liner must be riveted in one of the der Einschlagstellen auf dem Kopf eingeschla
incastro presenti sulla testata. seating present on the head. gen werden.
- Il montaggio della vite a brugola deve essere - Assembly of the Allen screw must be - Die Montage der Inbusschraube ist mit der
effettuata con loctite blocca filetti. done using thread-locking Loctite. Schraubensicherung Loctite vorzunehmen.
- Spalmare le guarnizioni di olio idraulico (vedi - Smear hydraulic oil on the gaskets (see - Die Dichtungen mit hydraulischem Öl ein
capitolo “Norme generali per lo smontaggio Chapter “General rules for disassembling schmieren (siehe Kapitel “Allgemeine Normen
martinetti”). cylinders”). für denAusbau der Zylinder”).
18
MRT 1440-1640-1840 EASY 70
SMONTAGGIO MARTINETTO DISASSEMBLING OUTRIGGERS AUSBAU STABILISATORENZY-

STABILIZZATORI (MRT 1440- CYLINDER (MRT 1440-1640- LINDER (MRT 1440-1640-1840)
1640-1840)
1840) Erforderliche Werkzeuge:
- 1 chiave ad uncino (per ghiere) Tools required: - 1 Steckschlüssel von 4 mm
- 1 chiave a brugola di 4mm - 1 pin wrench (for ring nuts)
- 1 4mm Allen wrench
SMONTAGGIO AUSBAU
DISASSEMBLY - Den Kopf Bez. 10 mit der Hilfe des
- Svitare la testata Rif. 10 con l’aiuto della chiave Hakenschlüssels losschrauben, nach-
ad uncino dopo aver agito sul lembo della - Unscrew head Ref. 10 using the pin dem man den Lappen der Laufbuchse
camicia ribattuto ad incastro nella sede della wrench after acting on the edge of the gelockert hat, der in den Kopfsitz einge-
testata. cylinder liner riveted in the head seating. schlagen worden ist.
- Estrarre dalla camicia del martinetto - Extract the liner of rod assembly cylinder - Aus der Laufbuchse des Zylinders die
l’assemblaggio stelo Rif. 7 + pistone Rif. 6. Ref. 7+ piston Ref. 6. Baugruppe Schaft Bez. 7 + Kolben Bez.
- Smontare la vite a brugola Rif. 2 (chiave a bru- - Dismantle the Allen screws Ref. 2 (using 6 herausziehen.
gola di 4mm) del pistone. a 4mm Allen wrench) of the piston. - Die Inbusschraube Bez. 2 (mit
Steckschlüssel von 4 mm) des Kolbens
- ATTENZIONE vite bloccata con loctite (vedi - ATTENTION screw locked using Loctite
losdrehen.
capitolo “Norme generali per lo smontaggio mar- (see Chapter “General rules for disas-
- ACHTUNG Schraube mit Loctite abgesi-
tinetti”). sembling cylinders”). chert (siehe Kapitel “Allgemeine Normen
- Svitare il pistone Rif. 6 del martinetto con l’aiuto - Unscrew the piston Ref. 6 of the cylinder zum Ausbau der Zylinder”).
di una chiave ad uncino. using a pin wrench. - Den Kolben Bez. 6 des Zylinders mit der
- Togliere il pistone Rif. 6 del martinetto e la testa- - Remove the piston Ref. 6 of the cylinder Hilfe eines Hakenschlüssels losschrauben.
ta Rif. 10 dallo stelo. and the head Ref. 10 from the rod. - Den Kolben Bez. 6 des Zylinders und
- Smontare le guarnizioni Rif. 4 e 5 e gli anelli di - Dismantle the gaskets Ref. 4 and 5 and den Kopf Bez. 10 aus dem Schaft aus-
guida Rif. 3 del pistone. guide rings Ref. 3 of the piston. bauen.
- Dismantle gaskets Ref. 11, 12 and 14, - Die Dichtungen Bez. 4 und 5 und die
- Smontare le guarnizioni Rif. 11, 12 e 14, gli
guide rings Ref. 15 and gaskets Ref. 13 Leitringe Bez. 3 des Kolbens ausbauen.
anelli di guida Rif. 15 e le guarnizioni Rif. 13 e
and 16 of the head. - Die Dichtungen Bez. 11, 12 und 14, die
16 della testata. Leitringe Bez. 15 und die Dichtungen
- Verificare lo stato della valvola, della sede della Bez. 13 und 16 des Kopfs ausbauen.
valvola e della molla.
- Cambiare le guarnizioni e i componenti se
FIG./ABB. 5 the gaskets and components, if
- Replace - Den Zustand des Ventils, des Ventilsitzes
und der Feder prüfen.
necessario (vedi capitolo “Norme generali per - Die Dichtungen und die Komponenten
lo smontaggio martinetti”). ersetzen, falls erforderlich (siehe Kapitel
- ATTENTION to the direction of reassem- “Allgemeine Normen für den Ausbau der
- ATTENZIONE al senso di rimontaggio. bly. Zylinder”).
- Auf die Richtung des Wiedereinbaus
ACHTEN.
RIMONTAGGIO WIEDEREINBAU
REASSEMBLY
Operazione inversa dello smontaggio. Umgekehrte Richtung des Ausbaus.
Nota: Operation reverse of disassembly. Anm.:
Note : - Der Außenlappen der Laufbuchse muss
- Si rammenta che il lembo esterno della camicia
in eine der Einschlagstellen auf dem Kopf
deve essere ribattuto in una delle sedi ad - Remember that the outside edge of the
eingeschlagen werden.
incastro presenti sulla testata. cylinder liner must be riveted in one of the
- Die Montage der Inbusschraube ist mit
- Il montaggio della vite a brugola deve essere seating present on the head. der Schraubensicherung Loctite vorzunehmen.
effettuata con loctite blocca filetti. - Assembly of the Allen screw must be - Die Dichtungen mit hydraulischem Öl ein
- Spalmare le guarnizioni di olio idraulico (vedi done using thread-locking Loctite. schmieren (siehe Kapitel “Allgemeine
capitolo “Norme generali per lo smontaggio - Smear hydraulic oil on the gaskets (see Normen für den Ausbau der Zylinder”).
martinetti”). Chapter “General rules for disassembling
cylinders”).
19
70 MRT 1440-1640-1840 EASY
IT EN DE
SMONTAGGIO MARTINETTO DISASSEMBLING REAR AXLE AUSBAU DES SPERRZYLIN-

BLOCCAGGIO ASSE BLOCK CYLINDER DERS DER HINTERACHSE
POSTERIORE
SMONTARE DISASSEMBLY AUSBAU
- Estrarre dalla camicia del martinetto lo - Extract the liner of the rod cylinder Ref. 7. - Die Laufbuchse des Zylinders vom Schaft
stelo Rif. 7. - Dismantle gaskets Ref. 3, anti-extrusion Bez. 7 abziehen.
- Smontare la guarnizione Rif. 3, le guarni- seals Ref. 4, 5 and guide rings Ref. 6 of - Die Dichtung Bez. 3, die Stützringe Bez.
zioni anti-estrusione Rif. 4, 5 e gli anelli cylinder Ref. 2. 4, 5 und die Leitringe Bez. 6 des
di guida Rif. 6 del cilindro Rif. 2. - Replace the gaskets and components, if Zylinders Bez. 2 ausbauen.
- Cambiare le guarnizioni e i componenti necessary (see Chapter “General rules for - Die Dichtungen und Komponenten erset-
se necessario (vedi capitolo “Norme disassembling cylinders”). zen, wenn es erforderlich ist (siehe
generali per lo smontaggio martinetti”). Kapitel “Allgemeine Normen für den
Ausbau der Zylinder”).
Operazione inversa dello smontaggio. Operation reverse to disassembly. Umgekehrte Richtung des Ausbaus.
Nota: Note : Anm.:
- Spalmare le guarnizioni di olio idraulico - Smear the gaskets with hydraulic oil - Die Dichtungen mit hydraulischem Öl ein
(vedi capitolo “Norme generali per lo (see Chapter “General rules for schmieren (siehe Kapitel “Allgemeine
smontaggio martinetti”). disassembling cylinders”). Normen für den Ausbau der Zylinder”).
20
PROCEDURA SPURGO ARIA MARTINETTO
COMANDO ACCELERATORE
ACCELERATOR CONTROL JACK AIR BLEED PROCEDURE
ENTLÜFTEN DES GASPEDALSTEUERZYLINDERS
MRT 1440-1640-1840 EASY

IT-EN-DE
MRT1440-1640-1840 EASY 70
IT EN DE
PROCEDURA SPURGO ARIA ACCELERATOR CONTROL JACK ENTLÜFTEN DES GASPEDAL-

MARTINETTO COMANDO AIR BLEED PROCEDURE STEUERZYLINDERS
ACCELERATORE
- Motore spento. - Engine off. - Motor abgestellt.
- Mantenere il martinetto comando accele- - Keep the accelerator control jack with the - Den Gaspedalsteuerzylinder mit der
ratore con la vite di spurgo verso l’alto bleeder screw facing up (Detail 1- Photo 1). Entlüftungsschraube nach oben zeigend
(Dettaglio 1-Foto 1). halten (Ausschnitt 1-Bild 1).
- Press the accelerator pedal several
- Schiacciare più volte il pedale dell’accele- times, keep it pressed and loosen the - Das Gaspedal mehrmals betätigen, es
ratore, mantenerlo premuto e svitare la bleeder screw to release the air, tighten durchgetreten halten und die
vite dello spurgo per fare uscire l’aria, the screw and repeat the same opera- Entlüftungsschraube losschrauben, um
riavvitare la vite e ripetere la stessa tion until oil flows out without air bub- die Luft austreten zu lassen, die
operazione finché l’olio esca senza bolle bles. up (Detail 1- Photo 1). Schraube wieder anziehen und den glei-
d’aria.(Dettaglio 1-Foto 1).. chen Vorgang wiederholen, bis blasen-
freies Öl ausläuft. (Ausschnitt 1-Bild 1)
- Verificare che lo stelo del martinetto fuo- - Make sure that the jack stem sticks out
riesca completamente fino alla battuta completely up to the mechanical striker, - Sicherstellen, dass der Schaft des
meccanica, percettibile anche dal rumore which can also be heard by the mecha- Zylinders bis zum mechanischen
meccanico.(Dettaglio A-Foto 1).. nical noise. (Detail A- Photo 1) Anschlag vollkommen austritt, was man
auch an dem mechanischen Geräusch
- IMPORTANTE: Effettuare la registrazione - IMPORTANT: Adjust the two limit swit- feststellen kann. (Ausschnitt A-Bild 1)
dei due fine corsa (regime del minimo - ches (idle - maximum rpm) using the
regime del massimo) tramite la forcella fork screwed onto the accelerator con- - WICHTIG: Die Einstellung der beiden
avvitata sullo stelo del martinetto trol jack stem. (Detail 2- Photo 2) Endanschläge (Leerlauf - max.
comando acceleratore. (Dettaglio 2-Foto 2). Drehzahl) mit der Gabel vornehmen, die
auf dem Schaft des
Gaspedalsteuerzylinders aufgeschraubt
ist.(Ausschnitt 2-Bild 2)
FIG. 1 FIG. 2
3
SMONTAGGIO E RIMONTAGGIO RIDUTTORE ROTAZIONE
DISASSEMBLING AND REASSEMBLING ROTATION
REDUCTION GEAR
AUSBAU UND WIEDEREINBAU DES DREHGETRIEBES
MRT 1440-1640-1840 EASY

IT-EN-DE
MRT 1440-1640-1840 EASY 70
- SOSTITUZIONE MOTORIDUTTORE
- REPLACE THE GEARMOTO ...............................................................................................................4
- ERSETZEN DES GETRIEBEMOTORS
- RIEMPIMENTO OLIO E VERIFICA LIVELLO

- OIL FILLING AND LEVEL CHECKING ......................................................................................................6
- ÖLEINFÜLLEN UND STANDPRÜFUNG
- PROCEDURA REGOLAZIONE MOTORE ROTAZIONE TORRETTA

- TURRET ROTATION MOTOR REGULATION PROCEDURE ...................................................................8
- EINSTELLUNG DES MOTORS DER TURMDREHUNG
- REGISTRAZIONE VALVOLA REGOLAZIONE TEMPO DI INTERVENTO FRENO

STATICO RIDUTTORE ROTAZIONE
- ADJUSTING ROTATION REDUCTION GEAR STATIC BRAKE ACTION TIME
ADJUSTMENT VALVE..............................................................................................................................10
- EINSTELLUNG REGELVENTIL ANSPRECHZEIT STATISCHE BREMSE
DREHGETRIEBE
- PROCEDURA REGOLAZIONE ROTAZIONE COL CESTELLO MONTATO

- ROTATION ADJUSTMENT PROCEDURE WITH BASKET MOUNTED..................................................12
- EINSTELLUNG DER DREHUNG MIT MONTIERTER BÜHNE
70 MRT 1440-1640-1840 EASY
IT EN DE
SOSTITUZIONE MOTORIDUTTORE REPLACE THE GEARMOTOR ERSETZEN DES GETRIEBEMOTORS
Posizionare la macchina su un suolo Die Maschine auf einer ebenen Fläche

Place the machine on a flat ground
piano, quindi sfilare completamente le travi abstellen, die Balken der Stabilisatoren
and stabilize it; shut down the engine. dann ganz ausfahren und die Maschine
degli stabilizzatori e stabilizzare la macchi-
na. stabilisieren.
Arrestare il motore termico. Remove the silencer and the end Den Verbrennungsmotor abstellen.
piping of the exhaust pipe.
Smontare la marmitta e la tubazione termi- Den Auspufftopf und das Endrohr des
nale di scarico. Remove the feeding pipe (Ref. A, Auspuffs ausbauen.
Photo 1), the delivery pipe (Ref. B,
Scollegare il tubo di alimentazione (Rif. A- Die Einlassleitung (Bez. A-Abb. 1), die
Photo 1) and the motor’s drainage Auspuffleitung des Motors (Bez. B-Abb. 1),
Fig. 1), il tubo di scarico motore (Rif. B-Fig.
1), il tubo relativo al drenaggio del motore pipe (Ref. C, Photo 1) and the feeding die Leitung des Motorrücklaufs (Bez. C-
(Rif. C-Fig. 1) e il tubo relativo all’alimenta- pipe of the negative brake (Ref. D, Abb. 1) und die Leitung zur Versorgung
zione freno negativo (Rif. D-Fig. 1). Photo 1). der negativen Bremse (Bez. D-Abb. 1)
abtrennen.
Attenzione: per evitare la fuoriuscita di Warning: to prevent oil leaking from Achtung: Um das Auslaufen von Öl aus
olio dal serbatoio montare dei tappi the tank, fit some caps at the end of dem Behälter zu vermeiden, die
all’estremità dei tubi. the pipes. Leitungsenden mit Stopfen ver
schließen.
Svitare le 10 viti M12x60 (Rif. E-Fig. 1) per
To remove the gearmotor, unscrew the
smontare il motoriduttore. Die 10 Schrauben M12x60 (Bez. E-Abb. 1)
10 M12 x 60 screws (Ref. E, Photo 1). losdrehen, um den Getriebemotor auszu-
bauen.
Attenzone: l’operazione in questione Warning: the above operation Achtung: Dieser Vorgang ist mit maximaler
richiede la massima cautela in quanto il requires the maximum care, Vorsicht auszuführen, weil der
motoriduttore ha un peso di circa Getriebemotor ein Gewicht von circa 80 kg
as the gearmotor weighs about
80Kg.; posizionare pertanto un crick hat. Daher einen Wagenheber mit einem
80 kg, put a crick with a chock Stopfen positionieren, der für dieses
con un tappo opportuno per sostenere
il peso (Fig. 2). to support the weight. Gewicht geeignet ist (Abb. 2).
Separare il motore dal riduttore svitando le To remove the motor from the reduc- Den Motor von Getriebe trennen. Dazu die
4 viti (Rif. F-Fig. 1). tion gear unscrew the 4 screws (Ref. 4 Schrauben losdrehen (Bez. F-Abb. 1).
F, Photo 1).
Montare il motore idraulico al nuovo Fit the motor to the new reduction Den Hydraulikmotor am neuen Getriebe
riduttore posizionando il lato alimenta- gear, pay attention to the position of montieren, wobei man die Seite für die
zione del motore in corrispondenza the feeding side of the motor: this Motorversorgung auf der Höhe des
della zona compresa fra lo scarico side must be between the filler cap Bereichs zwischen Ölauslauf (Bez. G-Abb.
olio (Rif. G-Fig. 3) e lo spacco del (Ref. G, Photo 3) and the U groove 3) und Getriebespalt anordnet (Bez. H-
riduttore (Rif. H-Fig. 3) per permettere (Ref. H, Photo 3) to allow an easy link
un facile collegamento dei tubi. Abb. 3), um den einfachen Anschluss der
to the pipes.
Leitungen zu gestatten.
Effettuare il riempimento dell’olio del Fill the new reduction gear and the Getriebe und Motor bei Bedarf mit Öl füllen
riduttore e del motore, se necessario motor (if necessary) with oil as descri- (siehe Seite 4).
(vedi pag.4). bed on page 4.
4
MRT 1440-1640-1840 EASY 70
D
D
F
C
B
FIG. 1
H FIG. 3 CRICK
FIG. 2
5
70 MRT 1440-1640-1840 EASY
IT EN DE
RIMONTAGGIO MOTORIDUTTORE ASSEMBLING THE GEARMOTOR WIEDEREINBAU DES GETRIEBE-

MOTORS
Rimontare il motoriduttore sulla macchina Fit the gearmotor on the machine using
utilizzando il crick e fissandolo attraverso the same crick, screw the 10 M 12x60 with Den Getriebemotor unter Benutzung eines
le 10 viti M12x60. con una coppia di ser- a torque of 120 Nm. Wagenhebers wieder auf der Maschine
raggio di 120 Nm. einbauen und die 10 Schrauben M12x60
mit einem Anzugsmoment von 120 Nm
anziehen.
NOTA: l’orientamento angolare del NOTE: the angular orientation of the
riduttore deve essere tale da ottenere gearmotor must be such as to obtain a Anm.: Die Winkelstellung des Getriebes
un’accoppiamento senza gioco fra coupling without play between the muss so aussehen, dass man eine
pignone e ralla. Per questa operazione pinion and the thrust bearing. spielfreie Passung zwischen Ritzel und
fare riferimento a quanto di seguito Kranz erhält. Für diesen Vorgang die
spiegato. The point of maximum eccentricity (Ref. A, folgende Beschreibung beachten.
Photo 4) can be distinguished by a U groo-
Il punto di massima eccentricità é in corri- ve on the fixing flange. Die Stelle der maximalen Exzentrizität ent-
spondenza dello spacco indicato in (Rif. A- spricht dem Schlitz (Bez. A-Abb. 4).
Fig. 4). Position the gearmotor as illustrated in
Photo 5, with hole (Ref. B, Photos 4 and 5) Den Getriebemotor anordnen, wie in der
Posizionare il motoriduttore come illustrato corresponding with hole (Ref. C, Photo 5) Abb. 5 gezeigt ist, mit dem Loch (Bez. B-
in Fig. 5, con il foro (Rif. B-Fig. 4 e 5) in of the chassis. Abb. 4 und 5) auf der Höhe des Lochs
corrispondenza del foro (Rif. C-Fig. 5) del If necessary, turn the gearmotor clockwise (Bez. C-Abb. 5) im Gestell.
telaio. to bring it to hole (Ref. B, Photo 5) to cor- Bei Bedarf im Uhrzeigersinn drehen, bis
Ruotare, se necessario, in senso orario respond with hole (Ref. D or E, Photo 5) of das Loch (Bez. B-Abb. 4) auf der Höhe
portando il foro (Rif. B-Fig. 4) in corrispon- the chassis in order to further reduce the von Loch (Bez. D oder E-Abb. 5) des
denza del foro (Rif. D o E-Fig. 5) del telaio play between the thrust bearing and the Gestells steht, um das Spiel zwischen
per ridurre ulteriormente il gioco tra ralla e pinion. Kranz und Ritzel noch weiter zu verrin-
pignone. gern.
The filler/vent cap (Ref. F, Photo 5) may be
Il tappo di carico e sfiato (Rif. F-Fig. 5) può positioned according to assembly Der Einfüll- und Entlüftungsstopfen (Bez.
essere posizionato in base alle esigenze di requirements in any of the four holes F-Abb. 5) kann je nach dem Einbau-
montaggio in uno qualunque dei 4 fori positioned at 90° from each other (Ref. A, gegebenheiten in einem beliebigen der 4
posizionati a 90° uno dall’altro (Rif. A Fig. Photo 5 oil filling). Löcher angeordnet werden, die einen
6 Riempimento olio). Abstand von 90° voneinander haben (Bez.
A Abb. 6 Öleinfüllen).
RIEMPIMENTO OLIO E VERIFICA OIL FILLING AND LEVEL ÖLEINFÜLLEN UND

LIVELLO CHECKING STANDPRÜFUNG
Riempimento olio riduttore. Reduction gear oil filling. Öleinfüllung in das Getriebe.
Rimuovere il tappo (Rif. B-Fig. 6) e riempi- Remove the cap (Ref. B, Photo 6) and fill Den Stopfen (Bez. B-Abb. 6) abnehmen Öl
re con olio tipo SHELL DONAX TD (quan- with oil type SHELL DONAX TD (oil quan- der Sorte SHELL DONAX TD (Ölmenge 2
tità olio 2 LT.) tity 2 LT.) Liter) einfüllen.
Il controllo del livello d’olio deve essere The checking of the oil level must be done Die Prüfung des Ölstands ist durch eines
eseguito tramite uno dei fori (Rif. C-Fig. 6). through one of the holes (Ref. C, Photo 6). der Löcher vorzunehmen (Bez. C-Abb. 6).
Rimuovere il tappo (Rif. D-Fig. 6) e riempi- Remove the cap (Ref. D, Photo 6) and fill Den Stopfen (Bez. D-Abb. 6) entfernen
re con olio tipo SHELL TELLUS T 46 with oil type SHELL TELLUS T 46 (quantity und mit Öl der Sorte SHELL TELLUS T 46
(quantità olio 0,3 LT.). oil 0,3 LT.). (Ölmenge 0,3 Liter) füllen.
Rif. A - Fori nei quali può essere posiziona- Ref. A - The holes in which the filler/vent Bez. A - Löcher, in denen der Einfüll- und
to il tappo di carico e sfiato. cap can be positioned. Entlüftungsstopfen angebracht werden
kann.
6
MRT 1440-1640-1840 EASY 70
C
E D
B
B
FIG. 4 FIG. 5
A
A A
FIG. 6
7
70 MRT 1440-1640-1840 EASY
IT EN DE
PROCEDURA REGOLAZIONE TURRET ROTATION MOTOR REGU- EINSTELLUNG DES MOTORS DER
MOTORE ROTAZIONE TORRETTA LATION PROCEDURE TURMDREHUNG
REGOLAZIONE DECELERAZIONE ROTATION DECELERATION EINSTELLUNG DER DREHUNGSAB-

ROTAZIONE REGULATION BREMSUNG
Per la regolazione della rotazione della tor- To regulate the rotation of the turret, use Für die Einstellung der Turmdrehung
retta occorre agire sulle due valvole Rif. A the two valves Ref. A and Ref. B in FIG. 7. benutzt man die beiden Ventile Bez. A und
e Rif. B della FIG. 7. The valve block Ref. B is meant for Bez. B von Abb. 7.
Il blocco valvola RIF. B è adibito al control- hydraulic control of the dynamic braking. Der Ventilblock Bez. B dient zur hydrauli-
lo idraulico della frenatura dinamica. In the above-mentioned block, the valves schen Steuerung der dynamischen
Nel suddetto blocco le valvole sono tarate are calibrated in such a way as to have Bremsung.
in modo da avere una frenatura ottimale optimum braking of rotation and a starting In diesem Block sind die Ventile so einge-
della rotazione e una coppia di spunto torque suitable for all conditions of use. stellt, dass man eine hervorragende
Bremsung der Drehbewegung und ein
adatta in qualunque condizione di utilizzo.
Anlaufdrehmoment erhält, das für alle
Einsatzverhältnisse geeignet ist.
Per effettuarne regolazione agire nel modo To make the adjustment, proceed as fol- Um die Einstellung vorzunehmen, geht
seguente : lows: man folgendermaßen vor:
1 - Svitare la vite a brugola Rif. C e avvita- 1 - Unscrew Allen screw Ref. C and com- 1 - Die Innensechskantschraube Bez. C
re completamente il pomolo Rif. D pletely tighten knob Ref. D of valve losschrauben und den Drehgriff Bez.
della valvola Rif. A (FIG. 7 - 8). Ref. A (FIG. 7 - 8). D des Ventils Bez. A (Abb. 7 - 8)
2 - Porre il motore termico al massimo dei 2 - Set the engine rotating at maximum ganz anziehen.
giri. speed.
3 - Sfilare completamente il braccio in 2 - Den Verbrennungsmotor auf max.
3 - Extend the boom completely in the
posizione orizzontale. horizontal position. Touren bringen.
4 - Effettuare la rotazione della torretta in 4 - Rotate the turret clockwise and check 3 - Den Auslegerarm in der horizontalen
senso orario e verificare che rila- to ensure that when the manipulator Position ganz ausfahren.
sciando il manipolatore la frenata non is released, the braking is not 4 - Die Turmdrehung in der Uhrzeiger-
sia eccessivamente brusca : lo spa- excessive: the stop space must be richtung vornehmen und prüfen, dass
zio d’arresto deve essere circa 1 about 1 m. beim Loslassen des Manipulators der
metro.
Bremsvorgang nicht zu plötzlich statt-
findet: Der Bremsweg muss circa 1
Meter ausmachen.
8
MRT 1440-1640-1840 EASY 70
FIG. 7
A
D
FIG. 8
9
70 MRT 1440-1640-1840 EASY
IT EN DE
Note: Note: Anm.:

- Se l’arresto della rotazione è troppo -If the rotation stops very brusquely, the - Wenn die Drehung zu abrupt unterbro-
brusco occorre regolare la valvola Rif. E valve Ref. E (FIG. 9) must be adjusted by chen wird, ist das Ventil Bez. E (Abb.
(FIG. 9) allentando il controdado e slackening the lock nut and unscrewing the 9) einzustellen, indem man die
svitando la vite a brugola di 1/4 di giro Allen screw through one quarter of a turn Gegenmutter lockert und die
(90°). (90°).
- Verificare la rotazione con il manipolatore Innensechskantschraube um 1/4
in cabina e in caso di risultato non Umdrehung (90°) lockert.
- Check the rotation with the manipulator in - Die Drehung mit dem Manipulator in der
soddisfacente, procedere nuovamente
the cab, and if it is found to be unsati sfac- Kabine prüfen und, wenn das Resultat
come al punto precedente.
tory, repeat the previous point again. nicht zufriedenstellend ausfällt, erneut
5 -Per la rotazione in senso opposto wie unter dem vorstehenden Punkt vor-
(antiorario) operare in modo analogo alla 5 - For rotation in the opposite direction
gehen.
descrizione del punto 3, andando ad (anticlockwise) operate in a similar manner
agire sulla valvola Rif. F (FIG. 9). as described at point 3, acting on valve
5 - Für die Drehung in der entgegenge-
Ref. F (FIG. 9).
setzten Richtung (Gegenuhrzeigersinn)
VERIFICA DELLA COPPIA DI auf analoge Weise vorgehen, wie unter
CHECKING ROTATION TORQUE
ROTAZIONE Punkt 3 beschrieben ist, aber unter
Benutzung des Ventils Bez. F (Abb. 9).
- Posizionare la macchina su un piano - Position the machine on a horizontal sur PRÜFUNG DES DREHMOMENTS
orizzontale con gli stabilizzatori face with the front outriggers lowere
anteriori completamente abbassati e completely and the rear outriggers just - Die Maschine auf einer ebenen Fläche
quelli posteriori solo appoggiati al terreno. resting on the ground. abstellen, wobei die vorderen Stabilisa-
- Unscrew knob Ref. D to bring it to the toren ganz ausgefahren werden und die
- Svitare il pomolo Rif. D per riportarlo hinteren am Boden abgesetzt werden.
initial position (Fig. 7) and lock it using
nella posizione iniziale (Fig. 7) e
bloccarlo con la vite a brugola Rif. C. the Allen screw Ref. C. - Den Drehgriff Bez. D losschrauben, um
ihn dann wieder in die Ausgangs-
- With the boom closed and horizontal, lift position zu bringen (Abb. 7) und mit
- A braccio tutto chiuso e orizzontale, der Innensechskantschrauben Bez. C
sollevare da terra il carico massimo di the maximum machine capacity load off
zu blockieren.
portata della macchina. the ground.
- Mit ganz eingefahrenem und horizontal
- Compiere una rotazione di 360° della - Rotate the turret through 360° both stehendem Auslegerarm die höchst-
torretta in senso sia orario che antiorario. clockwise and anticlockwise. zulässige Last der Maschine vom
Boden abheben.
- Se necessario, per un ulteriore verifica, - If necessary, for a further check, fit the - Den Turm eine Vollumdrehung von 360°
montare il manometro sulla presa di pressure gauge on the valve system im Uhrzeigersinn und im entgegen-
pressione del distributore e controllare pressure intake and check to ensure that gesetzten Sinn ausführen lassen.
che la pressione risulti dello stesso valore the pressure value is the same in both
in entrambi i sensi di rotazione durante la directions of rotation during the - Falls erforderlich, für eine weitere
manovra (vedi capitolo “Controllo Kontrolle ein Manometer auf demn
movement (see “Pressure Check” Druckanschluss des Steuergeräts mon-
pressioni”).
tieren und prüfen, ob der Druck
während der Drehung in beiden
Richtungen den gleichen Wert aufweist
(siehe Kapitel “Prüfung der Drücke”).
REGISTRAZIONE VALVOLA REGO- ADJUSTING ROTATION REDUCTION
LAZIONE TEMPO DI INTERVENTO GEAR STATIC BRAKE ACTION TIME EINSTELLUNG DES REGELVENTILS
FRENO STATICO RIDUTTORE ADJUSTMENT VALVE DER ANSPRECHZEIT DER STATISCHEN
ROTAZIONE BREMSE DES DREHGETRIEBES
La valvola (Fig. 10) è regolata in modo otti- The valve (Fig. 10) is adjusted in an opti- Das Ventil (Abb. 10) wird optimal mit mit
male con la tacca “2” del pomolo “D” di mum manner with notch “2” of adjustment der Kerbe “2” des Drehgriffs “D” zur
registrazione in corrispondenza della tacca knob “D” lined up with notch “A” indicated Einstellung der Übereinstimmung der
“A” indicata sulla zona del corpo della val- on the valve body area. Kerbe “A” geregelt, die auf dem Körper
vola stessa. des gleichen Ventils angezeigt ist.
Per anticipare o ritardare il tempo di inter- To anticipate or delay the rotation reduc- Um die Ansprechzeit der statischen
vento del freno statico del riduttore rotazio- tion gear static brake action time, act on Bremse des Drehgetriebes zu verfrühen
ne, si agisce sulla suddetta valvola nel the above valve as follows (FIG. 8): oder zu verzögern, benutzt man das Ventil
modo seguente (FIG. 8): auf die folgende Weise (Abb. 8):
- Svitando il pomolo “D” si anticipa - Unscrew “D” to advance brake action - Beim Losschrauben des Drehgriffs “D”
l’intervento del freno con ilrisultato di with the result of obtaining a more hasty wird das Ansprechen der Bremse ver-
ottenere un arresto della rotazione piu rotation stop. früht, wobei man eine plötzlichere
repentino. Anhaltung der Drehung erhält.
- Avvitando il pomolo si ritarda invece - Tightening the knob will delay the brake - Beim Anschrauben des Drehgriffs ver-
l’intervento del freno e si ottiene un action and the result is thus a more spätet man das Ansprechen der
arresto della rotazione più graduale. gradual rotation stop. Bremse, so dass man ein allmäh-
licheres Anhalten der Drehung erhält.
- A operazione ultimata bloccare - When the operation is complete, tighten
nuovamente la vite a brugola “C” (Fig. 8-10). - Wenn der Vorgang abgeschlossen ist, die
again using Allen screw “C” (Fig. 8-10)
Innensechskantschraube “C” (Abb. 8-
10) wieder anziehen.
10
MRT 1440-1640-1840 EASY 70
E D
FIG. 9 FIG. 10
11
70 MRT 1440-1640-1840 EASY
IT EN DE
PROCEDURA REGOLAZIONE ROTATION ADJUSTMENT PROCE- EINSTELLUNG DER DREHUNG MIT

ROTAZIONE COL CESTELLO DURE WITH BASKET MOUNTED
MONTIERTER BÜHNE
MONTATO
REGOLAZIONE ROTAZIONE ADJUSTING ROTATION DREHUNGSEINSTELLUNG

Innerhalb der elektronischen Logikbox, die
All'interno della scatola logica elettronica The “Danfoss” flow regulator for rotation
sich hinter der Kabine befindet, ist der
situata dietro la cabina è alloggiato il rego- speed, controlled from the basket, is hou-
sed inside the electronic logic box situated Durchflussmengenregler "Danfoss" für die
latore di flusso "Danfoss" per la velocità di
rotazione comandata dal cestello (Il regola- behind the cab (The regulator is mounted Drehgeschwindigkeit angebracht, die von
tore è quello montato in posizione orizzon- in the horizontal position Ref. A-Fig. 12). der Bühne geregelt wird (der Regler ist
tale Rif. A-Fig. 12). der, der in horizontaler Position montiert
ist, Bez. A-Abb. 12).
La registrazione va effettuata col motore Adjustment must be made with the engine Die Einstellung ist bei Verbrennungsmotor
termico a 1000 min-1 (accelerare al massi- at 1000 min-1 (accelerate hand lever Ref. mit 1000 min-1 (Beschleunigung mit dem
mo la leva a mano Rif. B-Fig. 11) : B-Fig. 11 to the maximum) : Handgashebel bis zum Höchstwert, Bez.
B-Abb. 11) vorzunehmen:
- Sollevare il braccio telescopico di circa 45° - Raise the telescopic boom by about 45°
- Den Teleskopausleger um circa 45°
- Sfilare il braccio per una lunghezza pari a - Extend the boom to a length equal to
heben
about half the total travel.
circa la metà della corsa totale.
- Den Auslegeraum um circa die Hälfte des
- Effettuare la rotazione della torretta gesamten Hubs ausfahren.
- Rotate the turret clockwise using the
tramite la pulsantiera del cestello in
basket pushbutton and ensure that the
senso orario e verificare che la velocità di rotation speed is about 0.7 m/sec (if - Die Turmdrehung mit der Schalttafel der
rotazione sia circa 0,7 mt/sec necessary, use register "R1"). Bühne im oder entgegen dem
(se necessario agire sul registro "R1"). Uhrzeigersinn ausführen und sicherstel
len, dass die Drehgeschwindigkeit circa
- Ripetere l'operazione in senso antiorario - Repeat the operation anticlockwise and 0,7 m/s beträgt (falls erforderlich mit der
e verificare che la velocità di rotazione ensure that the rotation speed is about Stellvorrichtung "R1" ändern).
sia circa 0,7 mt/sec (se necessario 0.7 m/sec (if necessary, use
agire sul registro "R2"). register "R2"). - Den Vorgang im Gegenuhrzeigersinn
wiederholen und prüfen, dass die
Drehgeschwindigkeit circa 0,7 m/s
beträgt (falls erforderlich mit der
Stellvorrichtung "R2" ändern).
12
MRT 1440-1640-1840 EASY 70
FIG. 11
MRT ROTAZIONE CONTINUA 360°

MRT CONTINUOS ROTATION 360°
MRT DAUERDREHUNG 360°
MRT ROTAZIONE LIMITATA 400°

MRT LIMITED ROTATION 400°
MRT BESCHRÄNKTE DREHUNG 400°
R1 R2
MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX MIN MAX
BRANDEGGIO A
SOLLEVAMENTO
ROTAZIONE
FIG. 12
13
SCHEMI ELETTRICI
ELECTRICAL SYSTEM
STROMLAUFPLÄNE
MRT 1440-1640-1840 EASY

IT-EN-DE
MRT 1440 - 1640-1840 4
MRT EASY
(400°)
3
4 MRT 1440 - 1640-1840
Scatola Fusibili e Relè in cabina - Fuse and Relay box in cab
Scatola Fusibili e Relè carro - Fuse and Relay box on truck
4
MRT 1440 - 1640-1840 4
5
4 MRT 1440 - 1640-1840
6
MRT 1440 - 1640-1840 4
7
4 MRT 1440 - 1640-1840
8
MRT 1440 - 1640-1840 4
9
10
4
MRT EASY
1440, 1640, 1840
(400°)
euro 3 motore perkins

ELECTRIC DRAWING
MRT 1440 - 1640-1840
MRT 1440 - 1640-1840 4
11
12
4
MRT EASY
1440, 1640, 1840
(400°)

ELECTRIC DRAWING
MRT 1440 - 1640-1840
MRT 1440 - 1640-1840 4
13
4 MRT 1440 - 1640-1840
14
MRT 1440 - 1640-1840 4
15
4 MRT 1440 - 1640-1840
16
MRT 1440 - 1640-1840 4
17
4 MRT 1440 - 1640-1840
18
MRT 1440 - 1640-1840 4
19
4 MRT 1440 - 1640-1840
20
MRT 1440 - 1640-1840 4
21
4 MRT 1440 - 1640-1840
22
MRT 1440 - 1640-1840 4
23
4 MRT 1440 - 1640-1840
24
MRT 1440 - 1640-1840 4
25
4 MRT 1440 - 1640-1840
26
MRT 1440 - 1640-1840 4
27
4 MRT 1440 - 1640-1840
28
MRT 1440 - 1640-1840 4
29
4 MRT 1440 - 1640-1840
30
MRT 1440 - 1640-1840 4
31
4 MRT 1440 - 1640-1840
32
MRT 1440 - 1640-1840 4
33
4 MRT 1440 - 1640-1840
34
MRT 1440 - 1640-1840 4
35
4 MRT 1440 - 1640-1840
36
MRT 1440 - 1640-1840 4
37
4 MRT 1440 - 1640-1840
38
MRT 1440 - 1640-1840 4
39
4 MRT 1440 - 1640-1840
40
MRT 1440 - 1640-1840 4
41
4 MRT 1440 - 1640-1840
42
MRT 1440 - 1640-1840 4
43
MRT 1440 - 1640-1840 4
MRT EASY
(360°)
45
4 MRT 1440 - 1640-1840
Scatola Fusibili e Relè in cabina - Fuse and Relay box in cab
Scatola Fusibili e Relè carro - Fuse and Relay box on truck
46
MRT 1440 - 1640-1840 4
Scatola Fusibili e Relè in cabina - Fuse and Relay box in cab / Scatola Fusibili e Relè carro - Fuse and Relay box on truck
47
4 MRT 1440 - 1640-1840
48
MRT 1440 - 1640-1840 4
49
4 MRT 1440 - 1640-1840
50
MRT 1440 - 1640-1840 4
51
52
4
MRT EASY
1440, 1640, 1840
(360°)

ELECTRIC DRAWING
MRT 1440 - 1640-1840
MRT 1440 - 1640-1840 4
53
4 MRT 1440 - 1640-1840
54
MRT 1440 - 1640-1840 4
55
4 MRT 1440 - 1640-1840
56
MRT 1440 - 1640-1840 4
57
4 MRT 1440 - 1640-1840
58
MRT 1440 - 1640-1840 4
59
4 MRT 1440 - 1640-1840
60
MRT 1440 - 1640-1840 4
61
4 MRT 1440 - 1640-1840
62
MRT 1440 - 1640-1840 4
63
4 MRT 1440 - 1640-1840
64
MRT 1440 - 1640-1840 4
65
4 MRT 1440 - 1640-1840
66
MRT 1440 - 1640-1840 4
67
4 MRT 1440 - 1640-1840
68
MRT 1440 - 1640-1840 4
69
4 MRT 1440 - 1640-1840
70
MRT 1440 - 1640-1840 4
71
4 MRT 1440 - 1640-1840
72
MRT 1440 - 1640-1840 4
73
4 MRT 1440 - 1640-1840
74
MRT 1440 - 1640-1840 4
75
4 MRT 1440 - 1640-1840
76
MRT 1440 - 1640-1840 4
77
4 MRT 1440 - 1640-1840
78
MRT 1440 - 1640-1840 4
79
4 MRT 1440 - 1640-1840
80
MRT 1440 - 1640-1840 4
81
4 MRT 1440 - 1640-1840
82
MRT 1440 - 1640-1840 4
83
4 MRT 1440 - 1640-1840
84
MRT 1440 - 1640-1840 4
85
4 MRT 1440 - 1640-1840
86
CABLAGGI
CABLES
MRT 1440-1640-1840 EASY

IT-EN
SCATOLA LOGICA
LOGIC BOX
LOGIKBOX
MRT 1440-1640-1840 EASY

IT-EN-DE
SCATOLA LOGICA
80-8-8-M96 IT
U9
+
+
DL3
+
POWER
+
+
+
+
+
+
+
+
+
+
+
+
DL 13
+
+
+
+
+
+
+
+
+
+
+
+
4
3
2
1
DL 37
5
DL 24
DL 40
JP1
DL 18
+
8 12 16 20 24
7 11 15 19 23
6 10 14 18 22
9 13 17 21
DL 31
+
DL 16
DL 38
DL 14 DL 43
+
+
DL 9 DL 36
DL 2
DL 1
DL 28
+
10
11
12
DL 18
7
8
9
+
DL 25
JP4
4
5
6
DL46
1
2
3
DL 32
DL 27
DL 30
DL 20
DL 34
4
5
6
17/04/2002
MANITOU 5.2.1
JP6
2
1
3
DL 35 DL 19
DL 8 DL 22
DL 33 +
+
+
DL 44
DL 5
DL 29
DL 6
DL 7 DL 26
10
11
12
7
8
9
JP3
4
5
6
DL 4
1
2
DL 23
3
+
DL 12
DL 21
DL 15
3
2
1
DL 42
JP5
6
5
4
DL 11
DL 42 DL 17
DL 10 DL 41
10 7
11 8
12 9
6
JP2
DL 39
5 2
3
4 1
DL 31 Security off Security on
850 850
MR T 1 MR T 1
TURBO TURBO
DL 40
+/- 5°
DL 30
850 850
MR T 1 MR T 1
TURBO TURBO
DL 39
MAX +/- 5°
2 2
1 3 1 3
DL 1 DL 22
4 4
Off
5
On 5
400° 400°
LOCK LOCK
DL 2 DL 24 N
400° 400° T T
P P
DL 9 N DL 18
DL 8 N DL 16
DL 13
< 3 mt MR T 1
850
TUR BO
> 3 mt MR T 1
850
TUR BO
DL 43 Off Off
DL 28
2
1 3
4
DL 12 DL 27
5
MR T
DL 25
TURBO
I
PUSH (Off)
0 (On)
0 1
1
DL 35 DL 45
2 2
1 3 1 3
DL 34 DL 20
4
5
4
5 Off
On
LOCK LOCK
DL 5 DL 19
0 (Off) 0
1(On) 1 kg
DL 4 DL 44
kg
DL 7 DL 29
BUTTON BUTTON
DL 6 DL 26 OPTIONAL OPTIONAL
(On) (Off)
S TOP S TOP
DL 33 DL 23
E ME R G E NC Y E ME R G E NC Y
ALARM MSS (Off) ALARM MSS (On)
DL 32 DL 21
DL 15
850
MR T 1 850
TURBO
MR T 1
TURBO
DL 42
+/- 5°
DL 14 DL 17
DL 11 DL 41
On Off
DL 10 DL 36
On Off
DL 37
DL 38 Off Off DL 46
Significato led sulla scheda logica
Nome led verdi Descrizione Acceso Spento

di input
DL31 Chiave di esclusione sicurezze Chiave inserita Chiave
disinserita
DL30 Proximity di massima salita braccio Massima altezza Massima altezza
(disabilita la manovra di salita) raggiunta non raggiunta
DL 1 Proximity N°1 per la gestione della Non legge la cam Legge la cam
rotazione limitata (Segnale da I 11)
DL 2 Proximity N°2 per la gestione della Non legge la cam Legge la cam
rotazione limitata (Segnale da I 50)
DL 9 Micro manipolatore cabina Manipolatore Manipolatore in
E’ l’ingresso di un comando qualsiasi dalla non in posizione posizione di
cabina di riposo riposi
DL 8 Micro manipolatore cestello Manipolatore Manipolatore in
E’ l’ingresso di un comando qualsiasi dalla non in posizione posizione di
pulsantiera cestello di riposo riposi
DL 13 Proximity per sentire i 3 mt di altezza del Braccio sotto i 3 Braccio sopra i 3
braccio (Segnale da I 37) mt mt
DL 12 Proximity per bloccaggio ponte posteriore Ponte posteriore Ponte posteriore
(Segnale da I 60 per braccio alto e I 7 per libero bloccato
rotazione torretta)
DL 35 Segnale per consenso manovre da cestello o Consenso Consenso
da radiocomando manovre presente manovre
(Si ottiene premendo il pulsante rosso sul mancante
manipolatore della pulsantiera )
DL 34 Segnale presenza radiocomando Radiocomando Radiocomando
(Si attiva col pulsante “Radiocomando” sul presente non presente
cruscotto “Stabilizzatori”)
DL 5 Segnale presenza cestello Cestello non Cestello presente
(Si attiva inserendo la pulsantiera sulla presente
scatola in testa al braccio)
DL 4 Segnale da chiave di salvataggio Chiave di Chiave di
salvataggio salvataggio non
attivata attivata
DL 7 Segnale di micro sovraccarico cestello Micro non Micro
intervenuto intervenuto intervenuto
DL 6 Segnale cestello a pendolo (A+B oppure Braccio cestello Braccio cestello
3D)con braccio abbassato abbassato non abbassato
(Permette la salita stabilizzatori )
(Segnale da I 39)
DL 33 Selezione tra cestello normale e pendoli Cestelli a Cestello normale
pendolo
DL 32 Segnale da antiribaltamento Antiribaltamento Antiribaltamento
non intervenuto intervenuto
DL 15 Segnale stabilizzatori in appoggio sul suolo Stabilizzatori Stabilizzatori non
appoggiati in appoggio
DL 14 Proximity per lettura braccio tutto rientrato Braccio rientrato Braccio non
(Segnale da I 36) rientrato
DL 11 Segnale per comando uscita o Comando attivo Comando non
abbassamento stabilizzatori. attivo
DL 10 Segnale per comando rientro o Comando attivo Comando non
sollevamento stabilizzatori. attivo
DL 38 Input non usato (deve essere spento)
DL 37 Input non usato (deve essere spento)

DL 40 Proximity 1 per identificazione stato di Il Proximity Il Proximity non
macchina frontale dentro 5° legge la cam legge la cam
Viene usato anche per fare il reset della
rotazione assieme a centrcab2
DL 39 Proximity 1 per identificazione stato di Il Proximity Il Proximity non
macchina frontale dentro 5° legge la cam legge la cam
Viene usato anche per fare il reset della
rotazione assieme a centrcab1
Nome led rossi Descrizione Acceso Spento
DL 22 Uscita usata per attivare la lampada rossa Lampada rossa Lampada rossa
sulla pulsantiera accesa sulla spenta
pulsantiera
DL 24 Uscita che porta l'alimentazione al Alimentazione Alimentazione
distributore Danfoss. Si attiva quando la fornita non fornita
macchina fa fisicamente un movimento.
DL 18 Uscita che va al sistema di antiribaltamento Macchina metà Macchina non
per segnalare che la macchina è stabilizzata stabilizzata stabilizzata
(non distingue se gli stabilizzatori sono
completamente sfilati o no)
DL 16 Uscita per pilotaggio valvola uscita o Rientro Stabilizzatori
rientro stabilizzatori. Funzione assieme alla fermi o in uscita
generale che viene eccitata
DL 43 Uscita libera non utilizzata (deve essere
spenta)
DL 28 Questi 3 led sono associati a tre relè che Abilitati Abilitati
gestiscono lo scambio dei movimenti sfilo, movimenti da movimenti da
optional, brandeggio, rotazione, cestello o da cabina
DL 27 sollevamento, da cestello o radiocomando a radiocomando
cabina. Quando scambiano i movimenti sul
cestello o sul radio, si attivano solamente se
DL 25 tutte le condizioni che richiede il cestello o
il radiocomando sono presenti (compreso il
consenso manovre)
DL 45 Questa uscita serve ad alimentare la Alimentazione al Alimentazione al
pulsantiera e il cestello. L'alimentazione al cestello tolta cestello fornita
cestello viene tolta quando si inserisce la
chiave di salvataggio
DL 20 Questa uscita va alla pulsantiera per Micro o Micro o
accendere la spia gialla e il buzzer. Segnala antiribaltamento antiribaltamento
la condizione di micro sovraccarico intervenuti non intervenuti
intervenuto con un segnale continuo,
mentre segnala la condizione di
antiribaltamento intervenuto tramite un
segnale intermittente
DL 19 Questa uscita attiva l'elettrovalvola per il Elettrovalvola Elettrovalvola
basculamento dei cestello a pendolo. eccitata non eccitata
DL 44 Questa uscita va a simulare l'ingresso del Micro di Micro
micro di sovraccarico. Si attiva solamente sovraccarico non sovraccarico
se con il segnale di presenza cestello basso intervenuto intervenuto
(cestello presente) viene a mancare il
segnale normale chiuso del micro di
sovraccarico
DL 29 Questo segnale si attiva quando il Sfilo abilitato Sfilo disabilitato
movimento di sfilo è abilitato. E il segnale
proveniente dal manipolatore ha un valore
significativo per compiere il movimento.
DL 26 Questo segnale si attiva quando il Optional abilitato Optional
movimento di optional è abilitato. E il disabilitato
segnale proveniente dal manipolatore ha un
valore significativo per compiere il
movimento.
DL 23 Segnale proveniente dal fungo di Fungo di Fungo di
emergenza sul cestello. Normale chiuso emergenza non emergenza
premuto premuto
DL 21 Uscita per segnalazione in cabina Ponte posteriore Ponte posteriore
(lampeggiante) di ponte posteriore bloccato bloccato non bloccato
(lampeggiante)
DL 42 Uscita che va al sistema antiribaltamento Macchina in Macchina non in
per segnalare la condizione di macchina in posizione posizione
posizione frontale entro i 5° centrale frontale
DL 17 Uscita per pilotaggio valvola generale per Valvola generale Valvola generale
comando stabilizzatori, travi e livellamento abilitata disabilitata
DL 41 Uscita che va ad abilitare o meno la Livellamento Livellamento
funzione di livellamento abilitato disabilitato
DL 36 Simulazione della presenza uomo quando si Presenza uomo Presenza uomo
lavora da cestello o da radiocomando non simulata simulata
DL 46 Questo led segnala se la macchina sta Movimenti Movimenti non
lavorando con velocità movimenti limitata limitati limitati
o veloce
8 7 6 5 4 3 2 1
SCHEDA MANITOU 5 STANDARD

M1/[1..12]
M2/[1..6]
D D
SEZIONE USCITE 2 SEZIONE CONNETTORI SEZIONE INGRESSI 1
SEZIONE MICROPROCESSORE
IN1 BRACAB BRACAB PONTSLOW PONTSLOW
IN2 SOLCAB SOLCAB SELCES SELCES
BUS/[0..7] IN3 IN3 OPTCAB OPTCAB MICROSV MICROSV
IN4 IN4 SFICAB SFICAB MANCES MANCES
SEL[1..3] OUTSW IN5 ROTCAB ROTCAB MANCAB MANCAB
ROTLIN1 BRACES BRACES INSTA INSTA
M2/[1..6] ROTLIN2 SOLCES SOLCES OUTSTA OUTSTA
OPTCES OPTCES BLPOPOS BLPOPS
BUS/[0..7]
AN_[1..5] RESET SFICES SFICES LIMSAL LIMSAL

SEL[1..3]
ROTCES ROTCES LIMSFILO LIMSFILO

EVOPT EVOPT STAUSC STAUSC
SCH_MANITOU_5_STANDARD_1_5_1 EVSFI EVSFI CHSALV CHSALV
PREUOM1 PREUOM1
SEZIONE I/O PREUOM2 PREUOM2 M1/[1..12]
C_R7 PRECES PRECES
POSRAD POSRAD SCH_MANITOU_5_STANDARD_1_5_10
C
BUS/[0..7] RESET C_R8 PENDOLO PENDOLO C
MICROSV MICROSV
M1/[1..12] ALIMCES ALIMCES
R_1_2_3 CHSALV CHSALV SEZIONE INGRESSI 2
SEL[1..3]
SCH_MANITOU_5_STANDARD_1_5_5
M2/[1..6] ESCSAL ESCSAL
ROTLIN1 CHIPAT CHIPAT
OUT[1..22] ROTLIN2 ANTIRIB ANTIRIB
AN_[1..5]
CES23M CES23M
SCH_MANITOU_5_STANDARD_1_5_3 EVROT POSRAD POSRAD
SEZIONE USCITE 1 EVSOL CONCES CONCES
EVBRA
SEZIONE MODULO PORTATA 1 M2/[1..6]
C_R7 PENINT PENINT
SISTANTIR SISTANTIR
OUT[1..22] IN1 C_R8 EVRIE_STA EVRIE_STA SCH_MANITOU_5_STANDARD_1_5_11
GENSTA GENSTA
AN_[1..5] EVBRA R_1_2_3 MOVCES MOVCES
MARINS MARINS
SCH_MANITOU_5_STANDARD_1_5_7 OUTSW ARRMOT ARRMOT
B B
SPIAPBL SPIAPBL
DISTRDANF DISTRDANF
SEZIONE MODULO PORTATA 2 OUT[1..22] PULARR PULARR SEZIONE INGRESSI 3
SCH_MANITOU_5_STANDARD_1_5_4 SCH_MANITOU_5_STANDARD_1_5_6
OUT[1..22] IN2 ESCSAL
CHIPAT
AN_[1..5] EVSOL SEZIONE ALIMENTAZIONE ANTIRIB
CES23M
POSRAD
SCH_MANITOU_5_STANDARD_1_5_8 CONCES
M2/[1..6]
SEZIONE MODULO PORTATA 3
OUT[1..22] IN5
AN_[1..5] EVROT AUTEL s.r.l. SASSUOLO (MO) -ITALY- Via Tagliamento 45 TEL. 0536/802104 e-mail autel@aeautel.it
A Document Code: Description: Size A

SCH_MANITOU_5_STANDARD_1_5_9 SCH1112-00-01/01 SCHEDA CONTROLLO MANITOU 5 STANDARD CON LIMITATORI DI PORTATA A4
OUT[1..22] PRJ References: File Name: Customer: Customer-Ref.:

PJ1112-00-01 SCH_MANITOU_5_STANDARD_1_5.OPJ MANITOU MANITOU
Rev Designed by: Checked by: Approved by:

1.5 PONTI FEDERICA MAZZACANI CLAUDIO MAZZACANI CLAUDIO
Revision Date: Thursday, September 06, 2001 Sheet 1 of 13

8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
R1 +IC AN_[1..5]
470 +5V +5V AN_[1..5]
ROTLIN1
Y1 R2
+ C1 C2 4MHz 10K +IC +IC
DL1 10uF 16VL 0.1uF
LED VERDE 3MM +5V U4 U4 U1
PC3 14 12 AN_1 U2A D1 R101
X X0
4
R3 13 AN_2 R4 LMC6482 1N4004 100K 1%
D 2.2K R9 PC4 X1 10K 1% R7 R8 D
15 - 2
10M Y AN_3 1K 10K 1%
2 1
R5 R10 PC5 Y0 AN_4
4 1 + 3 IN_3
470 10K Z Y1
M3/1 5 AN_5 R6
Z0 M2/2 100 R103
8
3
Z1
4
6
C6 +IC 16 C3 100K 1%
33pF VDD D2 0.1uF
6
U3A C4 INH +IC 1N4004
11 OUTSW
TLP504A 10nF A
8 10
VSS B
7 9
C5 +5V VEE C
33pF R231 +IC +IC
3
R11 U4 4053 27K 1%

470 68HC705P9
28
U2B D3 R104
ROTLIN2
4
27 10 BUS/0 R12 LMC6482 1N4004 100K 1%
VCC
OSC1 PA0 BUS/1 10K 1% R14 R15
26 9 - 6
DL2 OSC2 PA1 BUS/2 1K 10K 1%
8 7
LED VERDE 3MM +5V PA2 BUS/3
1 7 + 5 IN_4
RESET PA3 BUS/4
C 2 6 C
R16 +5V IRQ/VPP PA4 BUS/5 R13
5
2.2K PA5 BUS/6 100 R107
8
4
PA6 BUS/7 C7 100K 1%
3
R17 R18 PA7 D4 0.1uF
470 10K CS 23 11 MOSI BUS/[0..7] +IC 1N4004
PD5 PB5/SDO BUS/[0..7]
+5V M2/7 25 12 MISO SEL[1..3]
PD7/TCAP PB6/SDI SEL[1..3]
13 SK
PB7/SCK
1
C9 24 22 SEL1
0.1uF U3B C8 TCMP PC0 SEL2 +IC +IC
21
U6 TLP504A 10nF PC1 SEL3
20
PC2 PC3
19
PC3/AN3 PC4 U5A D5 R19
18
PC4/AN2
4
+5V PC5 LMC6482 1N4004 10K 1%
2
17
PC5/AN1 M2/5 R22
14 16 - 2
+5V VSS PC6/AN0 VREF 1K
15 1
+ C10 PC7/VRH + 3
10uF 16VL R20
U6 100 R21
8
R24 100
8
B B
4.7K + C11
VCC
1 7 C12 C13 R25 R232 C14 D6 0.1uF

RST ST +5V 1uF 50VL 10nF 4.99K 1% 27K 1% 0.1uF +IC +IC 1N4004
2 6
C15 +5V TD RST
100pF 3 5 1 2 U5B R23
TOL RST RESET
8
LMC6482 4.99K 1%
GND
+ 5
U7A +5V +5V 7
C16 C17 74HC14 - 6
U6 47nF 47nF
4
MAX1232 + C22 C23

10uF 16VL 0.1uF
4
U8
U8 U8 N.B. R231 E R232 NELLA VERSIONE
MISO 4 8
M2/[1..7] M3/[1..5] DO VC +5V MANITOU 7 SONO 4.99K 1%
M2/[1..7] M3/[1..5]
CS 1
CS
6 AUTEL s.r.l. SASSUOLO (MO) -ITALY- Via Tagliamento 45 TEL. 0536/802104 e-mail autel@aeautel.it
M2/1 M3/1 SK ORG
2
M2/2 M3/2 SIC
M2/3 M3/3 MOSI 3 5
DI GND SCH1112-00-01/01 SCHEDA MANITOU 5 - SEZIONE MICROPROCESSORE A4
M2/4 M3/4
M2/5 M3/5
M2/6 R26 R27 PRJ References: File Name: Customer: Customer-Ref.:
93C46
M2/6 10K 10K PJ1112-00-01 SCH_MANITOU_5_STANDARD_1_5.OPJ MANITOU MANITOU

Revision Date: Wednesday, September 05, 2001 Sheet 2 of 13

8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
+12E
D D
C24 + D7
470uF 25VL 1N4004
D8 R28 L1 U9
F1 1N4004 2.2 2W 330uH L4940V5 +5V
1A
1 3
+VBATT IN VO1
GND
RV1 RV2 C26 + C27 C28 + C25 R29
27Z1 27Z1 100uF 50VL 0.1uF 0.1uF 47uF 16VL 680
2
C C
R30
2.2 1/2W
DL3
LED ROSSO 3MM
+IC
1
C29 +
47uF 25VL C30 D9 DZ1
0.1uF 1N4004 15V 1/2W
2
B B
AUTEL s.r.l. SASSUOLO (MO) -ITALY- Via Tagliamento 45 TEL. 0536/802104 e-mail autel@aeautel.it
SCH1112-00-01/01 SCHEDA MANITOU 5 - SEZIONE ALIMENTAZIONI A4
PRJ References: File Name: Customer: Customer-Ref.:



8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
+5V
M1/[1..13] BUS/[0..7] OUT[1..22]

M1/[1..12] BUS/[0..7] OUT[1..8]
20
M1/1 18 2 BUS/0 U17
VCC
M1/2 B1 A1 BUS/1 BUS/0 OUT1
17 3 3 2
M1/3 B2 A2 BUS/2 BUS/1 D0 Q0 OUT2
16 4 4 5
15 5 7 6
D M1/5 B4 A4 BUS/4 BUS/3 D2 Q2 OUT4 D
14 6 8 9
13 7 13 12
12 8 14 15
M1/8 B7 A7 BUS/7 U7B BUS/6 D5 Q5 OUT7
11 9 17 16
B8 A8 74HC14 BUS/7 D6 Q6 OUT8
18 19
D7 Q7
19
GND
+ + + + + + + + G
1 1
DIR OC
3 4 11
G
10
U16 74HC373
74HC245 C39
C31 C32 C33 C34 C35 C36 C37 C38 4.7KpF
1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL R79 R80 R81 R82 R83 R84 R85 R86
+5V 4.7K 4.7K 4.7K 4.7K 4.7K 4.7K 4.7K 4.7K U19
BUS/0 3 2 OUT9
U18 BUS/1 D0 Q0 OUT10
4 5
74HC245 BUS/2 D1 Q1 OUT11
20
7 6
BUS/3 D2 Q2 OUT12
8 9
M1/9 BUS/0 BUS/4 D3 Q3 OUT13
18 2 13 12
VCC
M1/10 B1 A1 BUS/1 +5V BUS/5 D4 Q4 OUT14
17 3 14 15
C 16 4 17 16 C
15 5 18 19
M2/1 B4 A4 BUS/4 +5V C92 U7C D7 Q7
14 6
M2/3 B5 A5 BUS/5 0.1uF 74HC14
13 7 1
M2/4 B6 A6 BUS/6 U42 U42 OC
12 8 5 6 11
M2/6 B7 A7 BUS/7 74HC245 G
11 9
20
M2/2 B8 A8 C48 74HC373
M2/5 19 BUS/0 2 18 M3/1 4.7KpF
GND
VCC
+ + + + + + + + G BUS/1 A1 B1 M3/2
1 3 17
DIR BUS/2 A2 B2 M3/3
4 16
BUS/3 A3 B3 M3/4
5 15
10 BUS/4 A4 B4 M3/5
6 14
BUS/5 A5 B5
7 13
C40 C41 C42 C43 C44 C45 C46 C47 BUS/6 A6 B6
8 12 U20
1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL BUS/7 A7 B7 BUS/0 OUT17
9 11 3 2
A8 B8 + + + + + BUS/1 D0 Q0 OUT18
4 5
BUS/2 D1 Q1 OUT19
19 7 6
GND
M2/[1..6] G BUS/3 D2 Q2 OUT20
M2/[1..6] 1 8 9
M3/[1..5] DIR BUS/4 D3 Q3 OUT21
M3/[1..5] 13 12
BUS/5 D4 Q4 OUT22
14 15
10
+5V +5V +5V +5V C49 C86 C90 C89 C91 BUS/6 D5 Q5
B 17 16 B
M3/1 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL 1uF 50VL BUS/7 D6 Q6
18 19
M3/2 D7 Q7
C50 C52 C53 C54 M3/3 1
0.1uF 0.1uF 0.1uF 0.1uF M3/4 OC
9 8 11
U21 U18 U16 U17 M3/5 G
U7D C55 74HC373
74HC14 4.7KpF
+5V R87
SEL[1..3] 1M
SEL[1..3]
U21 RESET 11 10 +5V +5V
RESET
74HC138
16
R88 U7E
SEL1 1 15 1K D13 + 74HC14 C51 C59
VCC
SEL2 A Y0 1N4148 C56 0.1uF 0.1uF

2 14
SEL3 B Y1 1uF 50VL U20 U19
3 13
C Y2
12
Y3
11
RESET Y4
6 10
G1 Y5 AUTEL s.r.l. SASSUOLO (MO) -ITALY- Via Tagliamento 45 TEL. 0536/802104 e-mail autel@aeautel.it
4 9
GND
G2A Y6
A 5 7 A
R89 R90 R91 G2B Y7 Document Code: Description: Size
4.7K 4.7K 4.7K SCH1112-00-01/01 SCHEDA MANITOU 5 - SEZIONE I/O A4
C57 C58 C20
8
4.7KpF 4.7KpF 4.7KpF PRJ References: File Name: Customer: Customer-Ref.:



8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
K2 DL17 +5V
DL16 R92 FBR51 12V LED 3MM ROSSO K3
LED 3MM ROSSO 1.5K 5 R93 FBR51 12V
3 1.5K 5
+VBATT DL46
4 EVRIE_STA +VBATT 3
1 4 LED ROSSO 3MM
+12E GENSTA
2 1
+12E
2
D D
OUT[1..22] K4 R279
OUT[1..22] 470
FBR51 12V
DL18 R94
LED 3MM ROSSO 1.5K 5 R280
U22 3 10K
OUT1 +VBATT OUT14 Q13
1 16 4 SISTANTIR
OUT2 IN1 OUT1 K5 BC847
2 15 1
OUT3 IN2 OUT2 +12E R95 FBR51 12V
3 14 2
OUT4 IN3 OUT3 DL19 1.5K
4 13 5
OUT5 IN4 OUT4 LED 3MM ROSSO
5 12 3
OUT6 IN5 OUT5 +VBATT
6 11 4 MOVCES
OUT7 IN6 OUT6
7 10 1
IN7 OUT7 +12E R255
2
8 9 DL41 1.5K
GND COM +12E
LED 3MM ROSSO K18
ULN2003D1 FBR51 12V
D35 2
1N4004 1
K6 +12E
4
OUT9 FBR51 12V OUTLIV
C 3 C
R96 +VBATT
5
1.5K 5
D34 3 K7
1N4004 +VBATT R97 FBR51 12V DL42
4
PENINT 1.5K LED 3MM ROSSO
1 5
OUT10 +12E R256
2 +VBATT 3
DL21 4 1.5K
DL20 LED 3MM ROSSO SPIAPBL K19
U23 1
OUT16 LED 3MM ROSSO +12E FBR51 12V
1 16 C_R8 2
OUT8 IN1 OUT1
2 15 2
IN2 OUT2
3 14 +12E 1
OUT11 IN3 OUT3
4 13 4
OUT17 IN4 OUT4 OUTCC
5 12 C_R7 3
OUT20 IN5 OUT5 K8 +12E +VBATT
6 11 R_1_2_3 5
OUT21 IN6 OUT6 FBR51 12V
7 10 OUTSW
OUT12 IN7 OUT7 R99
OUT13 8 9 1.5K 5
GND COM +12E
OUT14 3
+VBATT R257
ULN2003D1 4
MARINS 1.5K
B 1 B
+12E
2
K20
DL22 D32 FBR51 12V
LED 3MM ROSSO 1N4004
DL43 5
LED 3MM ROSSO 3
K10 +VBATT
4
FBR51 12V OUTRL
1
R100 2
1.5K 5
+VBATT 3
R98 4 OUT22 Q12
1.5K DISTRDANF BC847
1
+12E R258
2
10K
K9 DL24
FBR51 12V LED 3MM ROSSO
DL23 5
LED 3MM ROSSO ARRMOT AUTEL s.r.l. SASSUOLO (MO) -ITALY- Via Tagliamento 45 TEL. 0536/802104 e-mail autel@aeautel.it
+V 3
A 4 +12E +12E A
Document Code: Description: Size
1 SCH1112-00-01/01 SCHEDA MANITOU 5 - SEZIONE USCITE 1 A4
PULARR 2
C60 C85
0.1uF 0.1uF PRJ References: File Name: Customer: Customer-Ref.:
U22 U23 PJ1112-00-01 SCH_MANITOU_5_STANDARD_1_5.OPJ MANITOU MANITOU

D14 1.5 PONTI FEDERICA MAZZACANI CLAUDIO MAZZACANI CLAUDIO
1N4004
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
K11
FBR244 12V
BRACAB
IN_1
BRACES R102 DL25
1.5K LED 3MM ROSSO
SOLCAB
IN_2
D SOLCES D
+12E
+12E +12E
K12
FBR244 12V R233
R235 10K
OPTCAB 1.2K D27 R234 DZ2 +12E
IN_3
1N4004 1K 8.2V 1/2W
OPTCES R105 DL27
1.5K LED 3MM ROSSO Q10 K1
SFICAB R237 BC807 FBR51 12V
IN_4
10K
SFICES Q11
PRECES 5 PREUOM2
+12E BC847
PREUOM1 3
4
1
C88 R236 2
0.1uF 47K
K15
C FBR244 12V R109 D12 C
R106 1.5K 1N4004
1.5K DL26
LED 3MM ROSSO D28
EVOPT 1N4004
DL36
+12E LED 3MM ROSSO
C_R7 POSRAD
K14
FBR244 12V C87 R238
0.1uF 4.7K
EVSFI
R110
1.5K DL29
LED 3MM ROSSO
D31
+12E 1N4004 +12E
C_R8
PENDOLO
B B
K13
FBR244 12V
R259
ROTCAB D30 1.5K D33
IN_5
1N4004 1N4004
ROTCES R108 DL28
1.5K LED 3MM ROSSO
MICROSV
DL44 K16
+12E LED 3MM ROSSO FBR244
R_1_2_3
CHSALV
K21 R260
FBR51 12V D29 1.5K
1N4004 AUTEL s.r.l. SASSUOLO (MO) -ITALY- Via Tagliamento 45 TEL. 0536/802104 e-mail autel@aeautel.it
A 2 A
4
3
+V DL45 PRJ References: File Name: Customer: Customer-Ref.:
ALIMCES 5
LED 3MM ROSSO PJ1112-00-01 SCH_MANITOU_5_STANDARD_1_5.OPJ MANITOU MANITOU


8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
JP2
JP1 CONNETTORE 12 POLI
CONNETTORE 24 POLI C22
C14 +VBATT
1 CONCES
JP2 PIN1 = "CONCES" SEGNALE DI CONSENSO MANOVRA DA RADIOCOMANDO
1 LIMSAL 2 BRACES
JP1 PIN1 = "LIMSAL" SEGNALE BRACCIO SOTTO I DUE METRI JP2 PIN2 JP4 PIN5-8 = "BRACES" INGRESSO DANFOSS BRANDEGGIO DA RADIOCOMANDO
2 SFICAB 3 POSRAD
JP1 PIN2 = "SFICAB" INGRESSO DANFOSS DI SFILO CABINA JP2 PIN3-10 = "POSRAD" ALIMENTAZIONE RADIOCOMANDO
3 INP_FR2 4 CENTRCAB2
JP1 PIN3 = "INP_FR2" INPUT LIBERO JP2 PIN4 = "CENTRCAB2" SEGNALE DI CABINA CENTRATA
4 CENTCAB1 5 OPTCES
D JP1 PIN4 = "CENTCAB1" SEGNALE DI CABINA CENTRATA (1/2) JP2 PIN5 JP4 PIN12 = "OPTCES" INGRESSO DANFOSS DI OPTIONAL DA RADIOCOMANDO D
5 LIMSFILO 6 SOLCES
JP1 PIN5 = "LIMSFILO" SEGNALE BRACCIO RIENTRATO JP2 PIN6 JP4 PIN2 = "SOLCES" INGRESSO DANFOSS SOLLEVAMENTO DA RADIOCOMANDO
6 INP_FR1 7
JP1 PIN6 = "INP_FR1" INPUT LIBERO JP2 PIN7 = MASSA
7 CHIPAT 8 PULARR
JP1 PIN7 = "CHIPAT" SEGNALE CHIAVE PAT JP2 PIN8 = "PULARR" PULSANTE DI ARRESTO MOTORE DA RADIOCOMANDO
8 POSRAD 9 PORTLEFT-L
JP1 PIN8 = "POSRAD" SEGNALE RADIOCOMANDO INSERITO JP2 PIN9 JP4 PIN6 = "SFICES" INGRESSO DANFOSS DI SFILO DA RADIOCOMANDO
9 DISTRDANF 10
JP1 PIN9 = "DISTRDANF" ALIMENTAZIONE DISTRIBUTORI DANFOSS JP2 PIN3-10 = "POSRAD" ALIMENTAZIONE RADIOCOMANDO
10 MANCAB 11 MANCES
JP1 PIN10 = ""MANCAB" SEGNALE MICRO DA MANIPOLATORE CABINA JP2 PIN11 JP4 PIN7 = "MANCES" SEGNALE MICRO MANIPOLATORE DA RADIOCOMANDO
11 BRACAB 12 ROTCES
JP1 PIN11 = "BRACAB" INGRESSO DANFOSS DI BRANDEGGIO DA CABINA JP2 PIN12 JP4 PIN9 = "ROTCES" INGRESSO DANFOSS DI ROTAZIONE DA RADIOCOMANDO
12 ROTLIN2
JP1 PIN12 = "ROTLIN2" SEGNALE PROXIMITY LIMITAZIONE ROTAZIONE TORRETTA
13 SISTANTIR
JP1 PIN13 = "SISTANTIR" SEGNALE AL PAT DI MACCHINA STABILIZZATA
14 JP1 PIN14 JP5 PIN6 = "+VBATT" ALIMENTAZIONE POSITIVA SEZIONATA DA ECONOMIZZATORE
15 SOLCAB
JP1 PIN15 = "SOLCAB" INGRESSO DANFOSS DI SOLLEVAMENTO DA CABINA
16 ROTLIN1
JP1 PIN16 = "ROTLIN1" SEGNALE DI PROXIMITY LIMITAZIONE ROTAZIONE TORRETTA
17 ANTIRIB
JP1 PIN17 = "ANTIRIB" SEGNALE ANTIRIBALTAMENTO
18 OUTRL
JP1 PIN18 = "OUTRL" USCITA A RELE' LIBERA JP3
19 OPTCAB
JP1 PIN19 = "OPTCAB" INGRESSO DANFOSS DI OPTIONAL DA CABINA CONNETTORE 12 POLI
20 PREUOM1
JP1 PIN20 = "PREUOM1" CONTATTO MICRO PRESENZA UOMO C13
21 EVRIE_STA
JP1 PIN21 = "EVRIE_STA" ELETTROVALVOLA RIENTRO STABILIZZATORI
22 ESCSAL
JP1 PIN22 = "ESCSAL" SEGNALE BRACCIO MASSIMA ALTEZZA
23 ROTCAB 1 EVBRA
JP1 PIN23 = "ROTCAB" INGRESSO DANFOSS DI ROTAZIONE DA CABINA JP3 PIN1 = "EVBRA" USCITA DANFOSS BRANDEGGIO
24 PREUOM2 2 STAUSC
C JP1 PIN24 = "PREUOM2" CONTATTO MICRO PRESENZA UOMO JP3 PIN2 = "STAUSC" SEGNALI STABILIZZATORI USCITI C
3 OUTSTA
JP3 PIN3 = "OUTSTA" SEGNALE PER COMANDO USCITA STABILIZZATORI
4 EVROT
JP3 PIN4 = "EVROT" USCITA DANFOSS ROTAZIONE
5 BLPOPOS
JP3 PIN5 = "BLPOPOS" SEGNALE BLOCCAGGIO PONTE POSTERIORE
6 CHSALV
JP3 PIN6 = "CHSALV" SEGNALE CHIAVE SALVATAGGIO
7 EVSFI
JP3 PIN7 = "EVSFI" USCITA DANFOSS SFILO
8 PENDOLO
JP4 JP3 PIN8 = "PENDOLO" SEGNALE PENDOLO ELETTRONICO
9 SPIAPBL
CONNETTORE 12 POLI JP3 PIN9 = "SPIAPBL" SPIA LAMPEG. SEGNALAZIONE PONTE POSTERIORE BLOCCATO
10 EVSOL
C15 JP3 PIN10 = "EVSOL" USCITA DANFOSS SOLLEVAMENTO
11 EVOPT
JP3 PIN11 = "EVOPT" USCITA DANFOSS OPTIONAL
12 ARRMOT
JP3 PIN12 = "ARRMOT" SEGNALE DI ARRESTO MOTORE
1 OPTCES
JP4 PIN12 JP2 PIN5 = "OPTCES" INGRESSO DANFOSS OPTIONAL DA CESTELLO
2 CES23M
JP4 PIN11 = "CES23M" SEGNALE DI CESTELLO A PENDOLO PRESENTE
3 ALIMCES
JP4 PIN10 = "ALIMCES" ALIMENTAZIONE CESTELLO
4 ROTCES
JP4 PIN9 JP2 PIN12 = "ROTCES" INGRESSO DANFOSS DI ROTAZIONE DA CESTELLO
5 BRACES
JP4 PIN5-8 JP2 PIN 2 = "BRACES" INGRESSO DANFOSS DI BRANDEGGIO DA CESTELLO
6 MANCES
JP4 PIN7 JP2 PIN11 = "MANCES" SEGNALE MICRO MANIPOLATORE DA CESTELLO
7 SFICES
JP4 PIN6 JP2 PIN9 = "SFICES" INGRESSO DANFOSS DI SFILO DA CESTELLO
8 JP4 PIN5-8 JP2 PIN 2 = "BRACES" INGRESSO DANFOSS BRANDEGGIO DA CESTELLO
9 CONCES
JP4 PIN4 = "CONCES" SEGNALE CONSENSO DA CESTELLO
10 PRECES
B JP4 PIN3 = "PRECES" SEGNALE DI PRESENZA CESTELLO B
11 SOLCES
JP4 PIN2 JP2 PIN6 = "SOLCES" INGRESSO DANFOSS SOLLEVAMENTO DA CESTELLO
12 PULARR
JP4 PIN1 = "PULARR" PULSANTE DI ARRESTO MOTORE DA CESTELLO
JP5
CONNETTORE 6 POLI
C13 +VBATT
1 GENSTA
JP5 PIN1 = "GENSTA" ELETTROVALVOLA GENERALE STABILIZZATORI
2 OUTCC
JP5 PIN2 = "OUTCC" SEGNALE DI SEGNALAZIONE PAT DI CABINA CENTRATA
3 JP5 PIN3 = MASSA
4 INSTA
JP6 JP5 PIN4 = "INSTA" SEGNALE PER COMANDO INGRESSO STABILIZZATORI
5 OUTLIV
CONNETTORE 6 POLI JP5 PIN5 = "OUTLIV" SEGNALE PER ABILITAZIONE LIVELLAMENTO
C15 +V 6 JP1 PIN14 JP5 PIN6 = "+VBATT" ALIMENTAZIONE POSITIVA SEZIONATA ECONOMIZZATORE
JP6 PIN1 = "MARINS" SEGNALE DI ABILITAZIONE CESTELLO (SPIA ROSSA)

1 MARINS
JP6 PIN2 = "MOVCES" SEGNALE PER VALVOLA MOVIMENTO CESTELLO BASCULANTE
2 MOVCES
JP6 PIN3 = "SELCES" SEGNALE DI CESTELLO A PENDOLO IN SELLA
3 SELCES
JP6 PIN4 = "+V" INGRESSO PER ALIMENTAZIONE CESTELLO
JP6 PIN5 = "MICROSV" SEGNALE DI MICRO SOVRACCARICO
5 MICROSV
A JP6 PIN6 = "PENINT" SEGNALE PENDOLO INTERVENUTO (CONTINUA) A
6 PENINT Document Code: Description: Size
O ANTIRIBALTAMENTO INVERTITO (INTERMITTENTE)
SCH1112-00-01/01 SCHEDA MANITOU 5 - SEZIONE CONNETTORI A4

PJ1112-00-01/01 SCH_MANITOU_5_STANDARD_1_5.OPJ MANITOU MANITOU


8 7 6 5 4 3 2 1
5 4 3 2 1
+IC
+IC
J1
R261 PONTICELLO R265
1 R112 R111 220
+IC 1.5K 1% 6.8K 1%
R114 U25A
4
10K U24 LMC6482
R113 U25B 12 14 2 -
X0 X
4
D D15 15K 1% LMC6482 R115 13 1 D
1N4004 R117 6.8K 1% X1
6 - 15 3 +
15K 1% Y
7 2
Y0
IN1 5 + 1 4
R119 Y1 Z R118
8
R116 10K 5 1.5K 1% C61
15K 1% C62 C63 J2 Z0 0.1uF
8
3
0.1uF 0.1uF PONTICELLO Z1 +IC
16
R262 VDD +IC
6
1 +IC INH
11
+IC A
10 8
R120 B VSS R121 R125
9 7
D16 10K 1% C VEE 10K 1% 10K 1% +IC
1N4004 U26A 4053
8
LMC6482
3 + D17
1 AN_1 U26B 1N4004
4
2 - AN_2 +IC LMC6482 R122
R263 AN_3 6 - 100
1 AN_4 7 EVBRA
+IC AN_5 R124
4
C 5 + C
U27A 10K
4093 C64
R123 R264 0.1uF D18
8
4.99K 1% 1.5K 1% AN_[1..5] 1 1N4004
AN_[1..5]
3
+IC 2 R126 R127 +IC
10K 100
R129 Q1 OUT14
10K 1% R130 BC847
U28A 10K U27B OUT[1..22]
OUT[15..21]
4
LM393 4093 R128

R131 2 - 10K C65
3.3K 1% 1 5 10nF
3 + 4 +IC +IC OUT1
6 OUT2
OUT3
R132 R133 OUT4
8
C66 10K 10K OUT5

10nF R134 OUT6
B +IC 1M 1% U27C OUT7 B
4093 OUT8
R135 +IC OUT9
1K 1% 9 OUT10
10 12 OUT11
R136 8 11 OUT12
U28B 10K 13 OUT13
4
LM393 OUT14
R140 6 - OUT15
3.3K 1% 7 Q2 U27D OUT16
5 + R137 R138 BC847 4093 OUT17
100 10K OUT18
OUT19 Q3 OUT19
BC847 OUT20
8
C68 OUT21
10nF R139 C67 OUT22
+IC 10K 10nF
R266 R141
A 1.5K 1% 1M 1% A
+IC +IC Document Code: Description: Size
SCH1112-00-01/01 SCHEDA MANITOU 5 - SEZIONE MODULO 1 A4
1
R142 + + PRJ References: File Name: Customer: Customer-Ref.:

10K 1% C18 C19 PJ1112-00-01 SCH_MANITOU_5_STANDARD_1_5.OPJ MANITOU MANITOU
47uF 16VL 47uF 16VL
2

5 4 3 2 1
5 4 3 2 1
+IC
J3 +IC
PONTICELLO
R169 R271
15K 1% R168 R167 220
+IC 1.5K 1% 6.8K 1%
R170 U33A
4
10K U32 LMC6482
R267 U33B 12 14 2 -
X0 X
4
D D19 1 LMC6482 R171 13 1 D
1N4004 R173 6.8K 1% X1
6 - 15 3 +
15K 1% Y
7 2
Y0
IN2 5 + 1 4
R175 Y1 Z R174
8
R172 10K 5 1.5K 1% C69
15K 1% C70 C71 J4 Z0 0.1uF
8
3
16
R268 VDD +IC
6
1 +IC INH
11
+IC A
10 8
R176 B VSS R177 R181
9 7
D20 10K 1% C VEE 10K 1% 10K 1% +IC
1N4004 U34A 4053
8
LMC6482
3 + D21
1 AN_2 U34B 1N4004
4
2 - AN_1 +IC LMC6482 R178
R269 AN_3 6 - 100
1 AN_4 7 EVSOL
C +IC 4 AN_5 R180 5 + C
U35A 10K
4093 C72
R179 R270 0.1uF D22
8
4.99K 1% 1.5K 1% AN_[1..5] 1 1N4004
AN_[1..5]
3
+IC 2 R182 R183 +IC
10K 100
R185 Q4 OUT14
10K 1% R186 BC847
U36A 10K U35B OUT[1..22]
OUT[15..21]
4
LM393 4093 R184

R187 2 - 10K C73
3.3K 1% 1 5 10nF
3 + 4 +IC +IC OUT1
6 OUT2
OUT3
R188 R189 OUT4
8
C74 10K 10K OUT5

10nF R190 OUT6
B +IC 1M 1% OUT7 B
OUT8
+IC OUT9
9 OUT10
R191 10 12 OUT11
1K 1% R192 8 11 OUT12
U36B 10K U35C 13 OUT13
4
LM393 4093 OUT14

R196 6 - OUT15
3.3K 1% 7 Q5 U35D OUT16
5 + R193 R194 BC847 4093 OUT17
100 10K OUT18
OUT18 Q6 OUT19
BC847 OUT20
8
C76 OUT21
10nF R195 C75 OUT22
+IC 10K 10nF
R272 R197
A 1.5K 1% 1M 1% A
R198 PRJ References: File Name: Customer: Customer-Ref.:

10K 1% PJ1112-00-01 SCH_MANITOU_5_STANDARD_1_5.OPJ MANITOU MANITOU


5 4 3 2 1
5 4 3 2 1
+IC
J5 +IC
PONTICELLO
R273 R278
1 R200 R199 220
+IC 1.5K 1% 6.8K 1%
R202 U38A
4
R201 10K U37 LMC6482
15K 1% U38B 12 14 2 -
X0 X
4
D D23 LMC6482 R203 13 1 D
1N4004 R204 R205 6.8K 1% X1
6 - 15 3 +
15K 1% 15K 1% Y
7 2
Y0
IN5 5 + 1 4
R207 Y1 Z R206
8
1
10K 5 1.5K 1% C77
C78 C79 J6 Z0 0.1uF
8
+ 3
0.1uF 22uF 25VL PONTICELLO Z1 +IC
16
R208 VDD +IC
6
1 +IC INH
2
11
+IC A
10 8
R274 B VSS
9 7
D24 10K 1% C VEE R209 R213
1N4004 U39A 4053 10K 1% 10K 1% +IC
8
LMC6482
3 +
1 AN_5 D25
2 - AN_1 U39B 1N4004
4
R211 AN_2 +IC LMC6482 R210
1 AN_3 6 - 100
+IC AN_4
4
C 7 EVROT
C
R212 5 +
U40A 10K
R275 R217 4093
4.99K 1% 1.5K 1% AN_[1..5] C80 D26
8
AN_[1..5]
1 0.1uF 1N4004
+IC 3
2 R214 R215 +IC
R276 10K 100
10K 1% R218 Q7 OUT14
U41A 10K U40B BC847 OUT[1..22]
OUT[15..21]
4
LM393 4093
R219 2 - R216
3.3K 1% 1 5 10K C81
3 + 4 +IC +IC 10nF OUT1
6 OUT2
OUT3
R220 R221 OUT4
8
C82 10K 10K OUT5

10nF R222 OUT6
B +IC 1M 1% OUT7 B
OUT8
+IC OUT9
9 OUT10
R223 10 12 OUT11
1K 1% R224 8 11 OUT12
U41B 10K U40C 13 OUT13
4
LM393 4093 OUT14

R228 6 - OUT15
3.3K 1% 7 Q8 U40D OUT16
5 + R225 R226 BC847 4093 OUT17
100 10K OUT18
OUT15 Q9 OUT19
BC847 OUT20
8
C84 OUT21
10nF R227 C83 OUT22
+IC 10K 10nF
R277 R229
A 1.5K 1% 1M 1% A



5 4 3 2 1
5 4 3 2 1
R31 R32
470 470
CHSALV
R33 R34
470 470
PRECES
R35 R36
D 470 470 D
SELCES
R37 R38
470 470
PENDOLO +5V +5V +5V +5V +5V +5V
R39 R40
470 470
R41 R42 R43 R44 R45 R46
MANCES 2.2K 2.2K 2.2K 2.2K 2.2K 2.2K
R47 R48
470 470
MANCAB
7
DL4 LED 3MM VERDE R49 R50 R51 R52 R53 R54
DL5 LED 3MM VERDE U10A 10K U10B 10K U11A 10K U11B 10K U12A 10K U12B 10K
DL6 LED 3MM VERDE TLP504A TLP504A TLP504A TLP504A TLP504A TLP504A
DL7 LED 3MM VERDE
C DL8 LED 3MM VERDE C
M1/8
M1/9
M1/11
M1/12
DL9 LED 3MM VERDE
3
8
M1/7
M1/10
R55 R56 M1/[1..12]
470 470 M1/[1..12]
INSTA
M1/5
R57 R58
M1/1
M1/2
M1/3
M1/4
M1/6
470 470
OUTSTA
R59 R60
470 470
BLPOPS
R61 R62
470 470
LIMSAL
B R63 R64 B
470 470 +5V +5V +5V +5V +5V +5V
LIMSFILO
R77 R78 R66 R65 R67 R68 R69 R70 R71 R72 R73 R74 R75 R76
470 470 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K
STAUSC
DL10 LED 3MM VERDE

4
7
DL11 LED 3MM VERDE
DL12 LED 3MM VERDE
DL13 LED 3MM VERDE U13A U13B U14A U14B U15A U15B
DL15 LED 3MM VERDE
3
8
SCH1112-00-01/01 SCHEDA MANITOU 5 - SEZIONE INGRESSI 1 A4



5 4 3 2 1
5 4 3 2 1
M2/[1..6]
D M2/[1..6] D
M2/1
M2/2
M2/3
M2/4
M2/5
M2/6
DL30
R143 LED 3MM VERDE R144
470 470
ESCSAL
DL31
470 470
CHIPAT
DL32
470 470
ANTIRIB
C DL33 C
470 470
CES23M
DL34
470 470
POSRAD
+5V +5V +5V +5V +5V +5V
DL35
470 470 R153 R154 R155 R156 R157 R158 R159 R160 R161 R162 R163 R164
2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K
CONCES
4
7
B B
U29A U29B U30A U30B U31A U31B

TLP504A TLP504A TLP504A TLP504A TLP504A TLP504A
3
8



1.5 PONTI FEDERICA MAZZACANI CLAUDIO MAZZACANI CLADIO

5 4 3 2 1
5 4 3 2 1
D M3/[1..5] D
M3/[1..5]
M3/1
M3/2
M3/3
M3/4
M3/5
DL40
470 470
CENTRCAB1
DL39
470 470
CENTRCAB2
DL38
C R246 LED 3MM VERDE R245 C
470 470
INP_FR1
+5V +5V +5V +5V
DL37
470 470 R241 R242 R244 R243 R248 R247 R253 R254
2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K
INP_FR2
6
U43B U43A U44B U44A
TLP504A TLP504A TLP504A TLP504A
B B
5
5 4 3 2 1
ELECTRONIC BOX
80-8-8-M96 EN
U9
+
+
DL3
+
POWER
+
+
+
+
+
+
+
+
+
+
+
+
DL 13
+
+
+
+
+
+
+
+
+
+
+
+
4
3
2
1
DL 37
5
DL 24
DL 40
JP1
DL 18
+
8 12 16 20 24
7 11 15 19 23
6 10 14 18 22
9 13 17 21
DL 31
+
DL 16
DL 38
DL 14 DL 43
+
+
DL 9 DL 36
DL 2
DL 1
DL 28
+
10
11
12
DL 18
7
8
9
+
DL 25
JP4
4
5
6
DL46
1
2
3
DL 32
DL 27
DL 30
DL 20
DL 34
4
5
6
17/04/2002
MANITOU 5.2.1
JP6
2
1
3
DL 35 DL 19
DL 8 DL 22
DL 33 +
+
+
DL 44
DL 5
DL 29
DL 6
DL 7 DL 26
10
11
12
7
8
9
JP3
4
5
6
DL 4
1
2
DL 23
3
+
DL 12
DL 21
DL 15
3
2
1
DL 42
JP5
6
5
4
DL 11
DL 42 DL 17
DL 10 DL 41
10 7
11 8
12 9
6
JP2
DL 39
5 2
3
4 1
850 850
MR T 1 MR T 1
TURBO TURBO
DL 40
+/- 5°
DL 30
850 850
MR T 1 MR T 1
TURBO TURBO
DL 39
MAX +/- 5°
2 2
1 3 1 3
DL 1 DL 22
4 4
Off
5
On 5
400° 400°
LOCK LOCK
DL 2 DL 24 N
400° 400° T T
P P
DL 9 N DL 18
DL 8 N DL 16
DL 13
< 3 mt MR T 1
850
TUR BO
> 3 mt MR T 1
850
TUR BO
DL 43 Off Off
DL 28
2
1 3
4
DL 12 DL 27
5
MR T
DL 25
TURBO
I
PUSH (Off)
0 (On)
0 1
1
DL 35 DL 45
2 2
1 3 1 3
DL 34 DL 20
4
5
4
5 Off
On
LOCK LOCK
DL 5 DL 19
0 (Off) 0
1(On) 1 kg
DL 4 DL 44
kg
DL 7 DL 29
BUTTON BUTTON
(On) (Off)
S TOP S TOP
DL 33 DL 23
DL 32 DL 21
DL 15
850
MR T 1 850
TURBO
MR T 1
TURBO
DL 42
+/- 5°
DL 14 DL 17
DL 11 DL 41
On Off
DL 10 DL 36
On Off
DL 37
DL 38 Off Off DL 46
Logical box’s led description
Input green led Description On Off

DL31 Key to cut out security Turned key Normal position
DL30 Max height reached Proximity Max height Max height not
reached reached
DL 1 Rotation limitation Proximity N°1 ( I 11) Rotation enabled Rotation’s end
DL 2 Rotation limitation Proximity N°2 ( I 50) Rotation enabled Rotation’s end
DL 9 Manipulator cab’s micro input Moved Manipulator in

manipulator home position
DL 8 Manipulator basket’s micro Moved Manipulator in
manipulator home position
DL 13 3 Meters height proximity Boom under 3 Boom over 3
meters meters
DL 12 Rear axle locking proximity Rear axle free Rear axle locked
DL 35 Input to activate movement from basket or Movement Movement

remote control (Obtained pushing the red consent consent not
button on manipulator) present
DL 34 Remote-control presence input Remote control Remote control
activated not activated
DL 5 Basket presence input Basket Basket connected
(Obtained with the connection of the disconnected
basket’s plug)
DL 4 Input from the basket’s rescue key Turned key Normal position
DL 7 Input from overload basket micro Overload not Overload

present
DL 6 Input from pendulum basket’s boom Lowered boom Boom not
lowered (I 39) lowered
DL 33 Input to distinguish basket Pendulum basket Orh basket
DL 32 Input from M.S.S system M.s.s. alarm off M.s.s. alarm on
DL 15 Input from outriggers on ground Outriggers on Outriggers not on

ground ground
DL 14 Boom retracted proximity Boom retracted Boom not
(I 36) retracted
DL 11 Input to control the exit or the lowering of Input on Input off
outriggers.
DL 10 Input to control the lift or the reentry Input on Input off
lowering of outriggers.
DL 38 Free input (Must be off) X
DL 37 Free input (Must be off) X
DL 40 Cab center 1 proximity (less than 5°) Cab centered Cab rotated
DL 39 Cab center 1 proximity (less than 5°) Cab centered Cab rotated
Red led Description On Off

DL 22 Exit used to activate the red light on the Red light on Red light off
basket’s push-button panel
DL 24 Exit used to give power supply to danfoss . Power on Power off
DL 18 Exit used to signal to the MSS system that Machine on Machine on

the machine is on outriggers outriggers wheels
DL 16 Exit to control the exit or the reentry of the Reentry Exit or stationary
outriggers
DL 43 Free exit (Must be off) X
DL 28 This 3 led are connected to 3 relais that Movements from Movements from
changes the movement of: telescope, basket’ or cab
DL 27 optional, tilting, rotation, lifting from remote control
DL 25 basket or remote-control to the cab
DL 45 This exit gives power supply to the basket’s Power not given Power given
push-button panel
DL 20 This exit is used to light the yellow warning Overload or Mss Basket not
light of the push-button panel and to alarm on overload or Mss
activate the buzzer. The signal is alarm off
continuous when the basket is overload and
flickering when MSS is on alarm
DL 19 This exit activates the electrovalve of the Electrovalve Electrovalve not
pendulum basket tilting activated activated
DL 44 This exit simulate the overload micro . Not overload Overload
DL 29 This exit is activate when is possibile to Telescope Telescope not

telescope the boom, and the manipulator is activated possible
moved.
DL 26 This exit is activate when is possibile to use Optional Optional
the optional, and the manipulator is moved. activated deactivated
DL 23 Input coming from emergency red Red-button not Red-button
emergency button pushed pushed
DL 21 Exit used to activate the rear axle locking Rear axle locked Rear axle not
yellow light locked
DL 42 Exit that give the information to Mss Frontal position 360° position
system that the cab is on frontal position
DL 17 Exit used to control the general valve for Valve activated Valve not
moving outriggers. activated
DL 41 Exit used to activate the levelling Levelling Levelling not
enabled enabled
DL 36 Man’presence Man not present Man’s presence
DL 46 This led indicate the movement’s speed Slow Fast

8 7 6 5 4 3 2 1

M1/[1..12]
M2/[1..6]
D D
BUS/[0..7]

SEL[1..3]

PREUOM1 PREUOM1
C_R7 PRECES PRECES
C
MICROSV MICROSV
SEL[1..3]
AN_[1..5]
CES23M CES23M
EVBRA
C_R7 PENINT PENINT
SISTANTIR SISTANTIR
GENSTA GENSTA
MARINS MARINS
B B
SPIAPBL SPIAPBL
DISTRDANF DISTRDANF
CHIPAT
CES23M
POSRAD
M2/[1..6]
OUT[1..22] IN5




8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
R1 +IC AN_[1..5]
470 +5V +5V AN_[1..5]
ROTLIN1
Y1 R2
DL1 10uF 16VL 0.1uF
PC3 14 12 AN_1 U2A D1 R101
X X0
4
R3 13 AN_2 R4 LMC6482 1N4004 100K 1%
D 2.2K R9 PC4 X1 10K 1% R7 R8 D
15 - 2
10M Y AN_3 1K 10K 1%
2 1
R5 R10 PC5 Y0 AN_4
4 1 + 3 IN_3
470 10K Z Y1
M3/1 5 AN_5 R6
Z0 M2/2 100 R103
8
3
Z1
4
6
C6 +IC 16 C3 100K 1%
33pF VDD D2 0.1uF
6
11 OUTSW
TLP504A 10nF A
8 10
VSS B
7 9
C5 +5V VEE C
33pF R231 +IC +IC
3
R11 U4 4053 27K 1%

470 68HC705P9
28
U2B D3 R104
ROTLIN2
4
27 10 BUS/0 R12 LMC6482 1N4004 100K 1%
VCC
OSC1 PA0 BUS/1 10K 1% R14 R15
26 9 - 6
8 7
1 7 + 5 IN_4
RESET PA3 BUS/4
C 2 6 C
5
2.2K PA5 BUS/6 100 R107
8
4
PA6 BUS/7 C7 100K 1%
3
R17 R18 PA7 D4 0.1uF
470 10K CS 23 11 MOSI BUS/[0..7] +IC 1N4004
+5V M2/7 25 12 MISO SEL[1..3]
13 SK
PB7/SCK
1
C9 24 22 SEL1
21
20
PC2 PC3
19
18
PC4/AN2
4
+5V PC5 LMC6482 1N4004 10K 1%
2
17
PC5/AN1 M2/5 R22
14 16 - 2
15 1
+ C10 PC7/VRH + 3
10uF 16VL R20
U6 100 R21
8
R24 100
8
B B
4.7K + C11
VCC
1 7 C12 C13 R25 R232 C14 D6 0.1uF

2 6
C15 +5V TD RST
100pF 3 5 1 2 U5B R23
TOL RST RESET
8
LMC6482 4.99K 1%
GND
+ 5
U7A +5V +5V 7
C16 C17 74HC14 - 6
U6 47nF 47nF
4
MAX1232 + C22 C23

10uF 16VL 0.1uF
4
U8
MISO 4 8
M2/[1..7] M3/[1..5]
CS 1
CS
M2/1 M3/1 SK ORG
2
M2/2 M3/2 SIC
M2/3 M3/3 MOSI 3 5
M2/4 M3/4
M2/5 M3/5
93C46


8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
+12E
D D
C24 + D7
470uF 25VL 1N4004
D8 R28 L1 U9
F1 1N4004 2.2 2W 330uH L4940V5 +5V
1A
1 3
+VBATT IN VO1
GND
RV1 RV2 C26 + C27 C28 + C25 R29
27Z1 27Z1 100uF 50VL 0.1uF 0.1uF 47uF 16VL 680
2
C C
R30
2.2 1/2W
DL3
LED ROSSO 3MM
+IC
1
C29 +
0.1uF 1N4004 15V 1/2W
2
B B



8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
+5V
M1/[1..13] BUS/[0..7] OUT[1..22]

M1/[1..12] BUS/[0..7] OUT[1..8]
20
M1/1 18 2 BUS/0 U17
VCC
17 3 3 2
16 4 4 5
15 5 7 6
14 6 8 9
13 7 13 12
12 8 14 15
11 9 17 16
18 19
D7 Q7
19
GND
+ + + + + + + + G
1 1
DIR OC
3 4 11
G
10
U16 74HC373
74HC245 C39
C31 C32 C33 C34 C35 C36 C37 C38 4.7KpF
+5V 4.7K 4.7K 4.7K 4.7K 4.7K 4.7K 4.7K 4.7K U19
BUS/0 3 2 OUT9
4 5
20
7 6
BUS/3 D2 Q2 OUT12
8 9
18 2 13 12
VCC
17 3 14 15
C 16 4 17 16 C
15 5 18 19
M2/1 B4 A4 BUS/4 +5V C92 U7C D7 Q7
14 6
M2/3 B5 A5 BUS/5 0.1uF 74HC14
13 7 1
M2/4 B6 A6 BUS/6 U42 U42 OC
12 8 5 6 11
M2/6 B7 A7 BUS/7 74HC245 G
11 9
20
M2/2 B8 A8 C48 74HC373
M2/5 19 BUS/0 2 18 M3/1 4.7KpF
GND
VCC
+ + + + + + + + G BUS/1 A1 B1 M3/2
1 3 17
4 16
BUS/3 A3 B3 M3/4
5 15
10 BUS/4 A4 B4 M3/5
6 14
BUS/5 A5 B5
7 13
C40 C41 C42 C43 C44 C45 C46 C47 BUS/6 A6 B6
8 12 U20
9 11 3 2
A8 B8 + + + + + BUS/1 D0 Q0 OUT18
4 5
BUS/2 D1 Q1 OUT19
19 7 6
GND
M2/[1..6] G BUS/3 D2 Q2 OUT20
M2/[1..6] 1 8 9
M3/[1..5] DIR BUS/4 D3 Q3 OUT21
M3/[1..5] 13 12
BUS/5 D4 Q4 OUT22
14 15
10
+5V +5V +5V +5V C49 C86 C90 C89 C91 BUS/6 D5 Q5
B 17 16 B
18 19
M3/2 D7 Q7
C50 C52 C53 C54 M3/3 1
0.1uF 0.1uF 0.1uF 0.1uF M3/4 OC
9 8 11
U21 U18 U16 U17 M3/5 G
U7D C55 74HC373
74HC14 4.7KpF
+5V R87
SEL[1..3] 1M
SEL[1..3]
U21 RESET 11 10 +5V +5V
RESET
74HC138
16
R88 U7E
SEL1 1 15 1K D13 + 74HC14 C51 C59
VCC
SEL2 A Y0 1N4148 C56 0.1uF 0.1uF

2 14
3 13
C Y2
12
Y3
11
RESET Y4
6 10
4 9
GND
G2A Y6
A 5 7 A
C57 C58 C20
8



8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
K2 DL17 +5V
3 1.5K 5
+VBATT DL46
1 4 LED ROSSO 3MM
+12E GENSTA
2 1
+12E
2
D D
OUT[1..22] K4 R279
OUT[1..22] 470
FBR51 12V
DL18 R94
U22 3 10K
1 16 4 SISTANTIR
2 15 1
3 14 2
4 13 5
5 12 3
6 11 4 MOVCES
OUT7 IN6 OUT6
7 10 1
IN7 OUT7 +12E R255
2
8 9 DL41 1.5K
GND COM +12E
LED 3MM ROSSO K18
ULN2003D1 FBR51 12V
D35 2
1N4004 1
K6 +12E
4
C 3 C
R96 +VBATT
5
1.5K 5
D34 3 K7
4
1 5
OUT10 +12E R256
2 +VBATT 3
DL21 4 1.5K
U23 1
1 16 C_R8 2
OUT8 IN1 OUT1
2 15 2
IN2 OUT2
3 14 +12E 1
OUT11 IN3 OUT3
4 13 4
5 12 C_R7 3
6 11 R_1_2_3 5
7 10 OUTSW
OUT12 IN7 OUT7 R99
OUT13 8 9 1.5K 5
GND COM +12E
OUT14 3
+VBATT R257
ULN2003D1 4
MARINS 1.5K
B 1 B
+12E
2
K20
DL22 D32 FBR51 12V
DL43 5
LED 3MM ROSSO 3
K10 +VBATT
4
FBR51 12V OUTRL
1
R100 2
1.5K 5
+VBATT 3
R98 4 OUT22 Q12
1
+12E R258
2
10K
K9 DL24
DL23 5
+V 3
A 4 +12E +12E A
PULARR 2
C60 C85

1N4004
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
K11
FBR244 12V
BRACAB
IN_1
BRACES R102 DL25
1.5K LED 3MM ROSSO
SOLCAB
IN_2
D SOLCES D
+12E
+12E +12E
K12
FBR244 12V R233
R235 10K
IN_3
1N4004 1K 8.2V 1/2W
OPTCES R105 DL27
IN_4
10K
SFICES Q11
PRECES 5 PREUOM2
+12E BC847
PREUOM1 3
4
1
C88 R236 2
0.1uF 47K
K15
C FBR244 12V R109 D12 C
R106 1.5K 1N4004
1.5K DL26
LED 3MM ROSSO D28
EVOPT 1N4004
DL36
+12E LED 3MM ROSSO
C_R7 POSRAD
K14
FBR244 12V C87 R238
0.1uF 4.7K
EVSFI
R110
1.5K DL29
LED 3MM ROSSO
D31
+12E 1N4004 +12E
C_R8
PENDOLO
B B
K13
FBR244 12V
R259
ROTCAB D30 1.5K D33
IN_5
1N4004 1N4004
ROTCES R108 DL28
1.5K LED 3MM ROSSO
MICROSV
DL44 K16
R_1_2_3
CHSALV
K21 R260
FBR51 12V D29 1.5K
A 2 A
4
3
ALIMCES 5


8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
JP2
C14 +VBATT
1 CONCES
1 LIMSAL 2 BRACES
2 SFICAB 3 POSRAD
4 CENTCAB1 5 OPTCES
5 LIMSFILO 6 SOLCES
6 INP_FR1 7
7 CHIPAT 8 PULARR
9 DISTRDANF 10
10 MANCAB 11 MANCES
11 BRACAB 12 ROTCES
12 ROTLIN2
13 SISTANTIR
15 SOLCAB
16 ROTLIN1
17 ANTIRIB
18 OUTRL
19 OPTCAB
20 PREUOM1
21 EVRIE_STA
22 ESCSAL
23 ROTCAB 1 EVBRA
24 PREUOM2 2 STAUSC
3 OUTSTA
4 EVROT
5 BLPOPOS
6 CHSALV
7 EVSFI
8 PENDOLO
9 SPIAPBL
10 EVSOL
11 EVOPT
12 ARRMOT
1 OPTCES
2 CES23M
3 ALIMCES
4 ROTCES
5 BRACES
6 MANCES
7 SFICES
9 CONCES
10 PRECES
11 SOLCES
12 PULARR
JP5
CONNETTORE 6 POLI
C13 +VBATT
1 GENSTA
2 OUTCC
3 JP5 PIN3 = MASSA
4 INSTA
5 OUTLIV

1 MARINS
2 MOVCES
3 SELCES
5 MICROSV



8 7 6 5 4 3 2 1
5 4 3 2 1
+IC
+IC
J1
1 R112 R111 220
+IC 1.5K 1% 6.8K 1%
R114 U25A
4
10K U24 LMC6482
R113 U25B 12 14 2 -
X0 X
4
D D15 15K 1% LMC6482 R115 13 1 D
1N4004 R117 6.8K 1% X1
6 - 15 3 +
15K 1% Y
7 2
Y0
IN1 5 + 1 4
R119 Y1 Z R118
8
R116 10K 5 1.5K 1% C61
15K 1% C62 C63 J2 Z0 0.1uF
8
3
16
R262 VDD +IC
6
1 +IC INH
11
+IC A
10 8
R120 B VSS R121 R125
9 7
D16 10K 1% C VEE 10K 1% 10K 1% +IC
1N4004 U26A 4053
8
LMC6482
3 + D17
1 AN_1 U26B 1N4004
4
2 - AN_2 +IC LMC6482 R122
R263 AN_3 6 - 100
1 AN_4 7 EVBRA
+IC AN_5 R124
4
C 5 + C
U27A 10K
4093 C64
R123 R264 0.1uF D18
8
4.99K 1% 1.5K 1% AN_[1..5] 1 1N4004
AN_[1..5]
3
+IC 2 R126 R127 +IC
10K 100
R129 Q1 OUT14
10K 1% R130 BC847
U28A 10K U27B OUT[1..22]
OUT[15..21]
4
LM393 4093 R128

R131 2 - 10K C65
3.3K 1% 1 5 10nF
3 + 4 +IC +IC OUT1
6 OUT2
OUT3
R132 R133 OUT4
8
C66 10K 10K OUT5

10nF R134 OUT6
4093 OUT8
R135 +IC OUT9
1K 1% 9 OUT10
10 12 OUT11
R136 8 11 OUT12
U28B 10K 13 OUT13
4
LM393 OUT14
R140 6 - OUT15
3.3K 1% 7 Q2 U27D OUT16
5 + R137 R138 BC847 4093 OUT17
100 10K OUT18
OUT19 Q3 OUT19
BC847 OUT20
8
C68 OUT21
10nF R139 C67 OUT22
+IC 10K 10nF
R266 R141
A 1.5K 1% 1M 1% A
1

47uF 16VL 47uF 16VL
2

5 4 3 2 1
5 4 3 2 1
+IC
J3 +IC
PONTICELLO
R169 R271
15K 1% R168 R167 220
+IC 1.5K 1% 6.8K 1%
R170 U33A
4
10K U32 LMC6482
R267 U33B 12 14 2 -
X0 X
4
D D19 1 LMC6482 R171 13 1 D
1N4004 R173 6.8K 1% X1
6 - 15 3 +
15K 1% Y
7 2
Y0
IN2 5 + 1 4
R175 Y1 Z R174
8
R172 10K 5 1.5K 1% C69
15K 1% C70 C71 J4 Z0 0.1uF
8
3
16
R268 VDD +IC
6
1 +IC INH
11
+IC A
10 8
R176 B VSS R177 R181
9 7
D20 10K 1% C VEE 10K 1% 10K 1% +IC
1N4004 U34A 4053
8
LMC6482
3 + D21
1 AN_2 U34B 1N4004
4
2 - AN_1 +IC LMC6482 R178
R269 AN_3 6 - 100
1 AN_4 7 EVSOL
C +IC 4 AN_5 R180 5 + C
U35A 10K
4093 C72
R179 R270 0.1uF D22
8
4.99K 1% 1.5K 1% AN_[1..5] 1 1N4004
AN_[1..5]
3
+IC 2 R182 R183 +IC
10K 100
R185 Q4 OUT14
10K 1% R186 BC847
U36A 10K U35B OUT[1..22]
OUT[15..21]
4
LM393 4093 R184

R187 2 - 10K C73
3.3K 1% 1 5 10nF
3 + 4 +IC +IC OUT1
6 OUT2
OUT3
R188 R189 OUT4
8
C74 10K 10K OUT5

10nF R190 OUT6
B +IC 1M 1% OUT7 B
OUT8
+IC OUT9
9 OUT10
R191 10 12 OUT11
1K 1% R192 8 11 OUT12
U36B 10K U35C 13 OUT13
4
LM393 4093 OUT14

R196 6 - OUT15
3.3K 1% 7 Q5 U35D OUT16
5 + R193 R194 BC847 4093 OUT17
100 10K OUT18
OUT18 Q6 OUT19
BC847 OUT20
8
C76 OUT21
10nF R195 C75 OUT22
+IC 10K 10nF
R272 R197
A 1.5K 1% 1M 1% A



5 4 3 2 1
5 4 3 2 1
+IC
J5 +IC
PONTICELLO
R273 R278
1 R200 R199 220
+IC 1.5K 1% 6.8K 1%
R202 U38A
4
R201 10K U37 LMC6482
15K 1% U38B 12 14 2 -
X0 X
4
D D23 LMC6482 R203 13 1 D
1N4004 R204 R205 6.8K 1% X1
6 - 15 3 +
15K 1% 15K 1% Y
7 2
Y0
IN5 5 + 1 4
R207 Y1 Z R206
8
1
10K 5 1.5K 1% C77
C78 C79 J6 Z0 0.1uF
8
+ 3
16
R208 VDD +IC
6
1 +IC INH
2
11
+IC A
10 8
R274 B VSS
9 7
D24 10K 1% C VEE R209 R213
1N4004 U39A 4053 10K 1% 10K 1% +IC
8
LMC6482
3 +
1 AN_5 D25
2 - AN_1 U39B 1N4004
4
R211 AN_2 +IC LMC6482 R210
1 AN_3 6 - 100
+IC AN_4
4
C 7 EVROT
C
R212 5 +
U40A 10K
R275 R217 4093
4.99K 1% 1.5K 1% AN_[1..5] C80 D26
8
AN_[1..5]
1 0.1uF 1N4004
+IC 3
2 R214 R215 +IC
R276 10K 100
10K 1% R218 Q7 OUT14
U41A 10K U40B BC847 OUT[1..22]
OUT[15..21]
4
LM393 4093
R219 2 - R216
3.3K 1% 1 5 10K C81
3 + 4 +IC +IC 10nF OUT1
6 OUT2
OUT3
R220 R221 OUT4
8
C82 10K 10K OUT5

10nF R222 OUT6
B +IC 1M 1% OUT7 B
OUT8
+IC OUT9
9 OUT10
R223 10 12 OUT11
1K 1% R224 8 11 OUT12
U41B 10K U40C 13 OUT13
4
LM393 4093 OUT14

R228 6 - OUT15
3.3K 1% 7 Q8 U40D OUT16
5 + R225 R226 BC847 4093 OUT17
100 10K OUT18
OUT15 Q9 OUT19
BC847 OUT20
8
C84 OUT21
10nF R227 C83 OUT22
+IC 10K 10nF
R277 R229
A 1.5K 1% 1M 1% A



5 4 3 2 1
5 4 3 2 1
R31 R32
470 470
CHSALV
R33 R34
470 470
PRECES
R35 R36
D 470 470 D
SELCES
R37 R38
470 470
R39 R40
470 470
R41 R42 R43 R44 R45 R46
MANCES 2.2K 2.2K 2.2K 2.2K 2.2K 2.2K
R47 R48
470 470
MANCAB
7
DL7 LED 3MM VERDE
M1/8
M1/9
M1/11
M1/12
DL9 LED 3MM VERDE
3
8
M1/7
M1/10
R55 R56 M1/[1..12]
470 470 M1/[1..12]
INSTA
M1/5
R57 R58
M1/1
M1/2
M1/3
M1/4
M1/6
470 470
OUTSTA
R59 R60
470 470
BLPOPS
R61 R62
470 470
LIMSAL
B R63 R64 B
470 470 +5V +5V +5V +5V +5V +5V
LIMSFILO
R77 R78 R66 R65 R67 R68 R69 R70 R71 R72 R73 R74 R75 R76
470 470 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K
STAUSC
DL10 LED 3MM VERDE

4
7
DL11 LED 3MM VERDE
DL12 LED 3MM VERDE
DL15 LED 3MM VERDE
3
8



5 4 3 2 1
5 4 3 2 1
M2/[1..6]
D M2/[1..6] D
M2/1
M2/2
M2/3
M2/4
M2/5
M2/6
DL30
470 470
ESCSAL
DL31
470 470
CHIPAT
DL32
470 470
ANTIRIB
C DL33 C
470 470
CES23M
DL34
470 470
POSRAD
+5V +5V +5V +5V +5V +5V
DL35
470 470 R153 R154 R155 R156 R157 R158 R159 R160 R161 R162 R163 R164
2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K
CONCES
4
7
B B

3
8




5 4 3 2 1
5 4 3 2 1
D M3/[1..5] D
M3/[1..5]
M3/1
M3/2
M3/3
M3/4
M3/5
DL40
470 470
CENTRCAB1
DL39
470 470
CENTRCAB2
DL38
470 470
INP_FR1
+5V +5V +5V +5V

DL37
470 470 R241 R242 R244 R243 R248 R247 R253 R254
2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K
INP_FR2
1
6
U43B U43A U44B U44A
B B
2
5




5 4 3 2 1
LOGIKBOX
80-8-8-M96 DE
U9
+
+
DL3
+
POWER
+
+
+
+
+
+
+
+
+
+
+
+
DL 13
+
+
+
+
+
+
+
+
+
+
+
+
4
3
2
1
DL 37
5
DL 24
DL 40
JP1
DL 18
+
8 12 16 20 24
7 11 15 19 23
6 10 14 18 22
9 13 17 21
DL 31
+
DL 16
DL 38
DL 14 DL 43
+
+
DL 9 DL 36
DL 2
DL 1
DL 28
+
10
11
12
DL 18
7
8
9
+
DL 25
JP4
4
5
6
DL46
1
2
3
DL 32
DL 27
DL 30
DL 20
DL 34
4
5
6
17/04/2002
MANITOU 5.2.1
JP6
2
1
3
DL 35 DL 19
DL 8 DL 22
DL 33 +
+
+
DL 44
DL 5
DL 29
DL 6
DL 7 DL 26
10
11
12
7
8
9
JP3
4
5
6
DL 4
1
2
DL 23
3
+
DL 12
DL 21
DL 15
3
2
1
DL 42
JP5
6
5
4
DL 11
DL 42 DL 17
DL 10 DL 41
10 7
11 8
12 9
6
JP2
DL 39
5 2
3
4 1
850 850
MR T 1 MR T 1
TURBO TURBO
DL 40
+/- 5°
DL 30
850 850
MR T 1 MR T 1
TURBO TURBO
DL 39
MAX +/- 5°
2 2
1 3 1 3
DL 1 DL 22
4 4
Off
5
On 5
400° 400°
LOCK LOCK
DL 2 DL 24 N
400° 400° T T
P P
DL 9 N DL 18
DL 8 N DL 16
DL 13
< 3 mt MR T 1
850
TUR BO
> 3 mt MR T 1
850
TUR BO
DL 43 Off Off
DL 28
2
1 3
4
DL 12 DL 27
5
MR T
DL 25
TURBO
I
PUSH (Off)
0 (On)
0 1
1
DL 35 DL 45
2 2
1 3 1 3
DL 34 DL 20
4
5
4
5 Off
On
LOCK LOCK
DL 5 DL 19
0 (Off) 0
1(On) 1 kg
DL 4 DL 44
kg
DL 7 DL 29
BUTTON BUTTON
(On) (Off)
S TOP S TOP
DL 33 DL 23
DL 32 DL 21
DL 15
850
MR T 1 850
TURBO
MR T 1
TURBO
DL 42
+/- 5°
DL 14 DL 17
DL 11 DL 41
On Off
DL 10 DL 36
On Off
DL 37
DL 38 Off Off DL 46
Bedeutung der LED-Anzeigen auf der Logikplatine
Name grüner Beschreibung An Aus

LED-Anzeigen
der Eingänge
DL31 Schlüssel zur Ausschaltung der Schlüssel steckt Schlüssel
Sicherheiten abgezogen
DL30 Näherungsschalter max. Auslegerhub Max. Höhe Max. Höhe nicht
(sperrt Hubvorgang) erreicht erreicht
DL 1 Näherungsschalter Nr. 1 für Steuerung Kurve nicht Kurve wird
beschränkter Drehung (Signal von I 11) erfasst erfasst
DL 2 Näherungsschalter Nr. 2 für Steuerung Kurve nicht Kurve wird
beschränkter Drehung (Signal von I 50) erfasst erfasst
DL 9 Mikroschalter Vierwegschalter Kabine Vierwegschalter Vierwegschalter
Ist der Eingang eines beliebigen nicht in in Ruhestellung
Bedienelements der Kabine Ruhestellung
DL 8 Mikroschalter Vierwegschalter Bühne Vierwegschalter Vierwegschalter
Ist der Eingang eines beliebigen nicht in in Ruhestellung
Bedienelements der Druckknopftafel Bühne Ruhestellung
DL 13 Näherungsschalter zum Erfassen der 3 m Ausleger Ausleger über 3
Auslegerhöhe (Signal von I 37) unterhalb der 3 m m Höhe
DL 12 Näherungsschalter für Sperre Hinterachse Hinterachse frei Hinterachse
(Signal von I 60 für Ausleger oben und I 7 gesperrt
für Turmdrehung)
DL 35 Signal für Freigabesignal Manöver von Freigabesignal Freigabesignal
Bühne oder Fernbedienung Manöver liegt Manöver fehlt
(Wird erhalten, wenn man die rote Taste auf vor
Vierwegschalter der Druckknopftafel
drückt)
DL 34 Signal Fernbedienung vorhanden Fernbedienung Fernbedienung
(Wird mit Taste „Fernbedienung“ auf vorhanden nicht vorhanden
Armaturenbrett „Stabilisatoren“ aktiviert)
DL 5 Signal Bühne vorhanden Bühne nicht Bühne vorhanden
(Wird durch Anschließen der vorhanden
Druckknopftafel im Gehäuse am
Auslegerkopf aktiviert)
DL 4 Signal von Sicherheitsschlüssel Sicherheits- Sicherheits-
schlüssel schlüssel nicht
aktiviert aktiviert
DL 7 Signal von Mikroschalter Überlastung Mikroschalter hat Mikroschalter hat
Bühne hat angesprochen nicht angesprochen
angesprochen
DL 6 Signal Pendelbühne (A+B oder 3D) mit Ausleger Bühne Ausleger Bühne
gesenktem Ausleger gesenkt nicht gesenkt
(Gestattet das Heben der Stabilisatoren)
(Signal von I 39)
DL 33 Wahl zwischen normaler und Pendelbühne Pendelbühne Normale Bühne
DL 32 Signal von Sicherungssystem Sicherungs- Sicherungs-

system hat nicht system hat
angesprochen angesprochen
DL 15 Signal Stabilisatoren stehen am Boden Stabilisatoren Stabilisatoren
sind abgestellt sind nicht
abgestellt
DL 14 Näherungsschalter für Erfassen Ausleger Ausleger Ausleger nicht
ganz eingefahren eingefahren eingefahren
(Signal von I 36)
DL 11 Signal für Befehl Stabilisatoren ausfahren Befehl aktiv Befehl nicht
oder senken. aktiv
DL 10 Signal für Befehl Stabilisatoren einfahren Befehl aktiv Befehl nicht
oder heben. aktiv
DL 38 Input nicht benutzt (muss aus sein)
DL 37 Input nicht benutzt (muss aus sein)
DL 40 Näherungsschalter 1 für Identifikation Näherungs- Näherungsschalt

Zustand von Maschine frontal eingefahren schalter erfasst er erfasst Kurve
5° Kurve nicht
Wird auch benutzt, um Reset der Drehung
zusammen mit centrcab2 zu machen
DL 39 Näherungsschalter 1 für Identifikation Näherungs- Näherungsschalt
Zustand von Maschine frontal eingefahren schalter erfasst er erfasst Kurve
5° Kurve nicht
Wird auch benutzt, um Reset der Drehung
zusammen mit centrcab1 zu machen
Name rote Beschreibung An Aus

LED-Anzeigen
DL 22 Ausgang wird benutzt, um die rote Leuchte Rote Leuchte auf Rote Leuchte aus
auf Druckknopftafel zu aktivieren Druckknopftafel
an
DL 24 Ausgang, der die Versorgung zum Versorgung wird Versorgung wird
Steuergerät Danfoss bringt. Wird aktiviert, geliefert nicht geliefert
wenn die Maschine eine tatsächliche
Bewegung ausführt.
DL 18 Ausgang, der zum Sicherungssystem geht, Maschine halb Maschine nicht
um zu melden, dass die Maschine stabilisiert stabilisiert
stabilisiert ist (unterscheidet nicht, ob die
Stabilisatoren ganz ausgefahren sind oder
nicht)
DL 16 Ausgang für Vorsteuerung Ventil zum Aus- Eingefahren Stabilisatoren
oder Einfahren der Stabilisatoren. stehen still oder
Funktioniert zusammen mit allgemeinem, fahren aus
der erregt wird.
DL 43 Ausgang frei, nicht benutzt (muss aus sein)
DL 28 Diese 3 LED-Anzeigen sind drei Relais Bewegungen von Bewegungen von

zugeordnet, welche den Wechsel der Bühne oder Kabine
Bewegungen Ausfahren, Option, Fernbedienung freigegeben
DL 27 Schwenken, Drehen, Heben von der Bühne freigegeben
oder mit der Fernbedienung oder aus der
Kabine ansteuern. Wenn man die
DL 25 Bewegungen aus der Bühne oder mit
Fernbedienung umschaltet, werden diese
nur dann aktiviert, wenn alle Bedingungen
vorliegen, welche die Bühne oder die
Fernbedingungen verlangen (einschließlich
Freigabesignal für Manöver)
DL 45 Dieser Ausgang dient zur Versorgung der Versorgung der Versorgung der
Druckknopftafel und der Bühne. Die Bühne Bühne wird
Versorgung der Bühne wird ausgeschaltet, ausgeschaltet geliefert
wenn man den Sicherungsschlüssel
einsteckt.
DL 20 Dieser Ausgang geht zur Druckknopftafel, Mikroschalter Mikroschalter
um die gelbe Kontrollanzeige und den oder Sicherungs- oder Sicherungs-
Summer einzuschalten. Meldet den Zustand system haben system haben
Mikroschalter für Überlastung hat angesprochen nicht
angesprochen mit einem Dauersignal, angesprochen
während der Zustand Sicherungssystem hat
angesprochen durch ein aussetzendes Signal
gemeldet wird.
DL 19 Dieser Ausgang aktiviert das Magnetventil Magnetventil Magnetventil
für das Schwenken der Pendelbühnen. erregt nicht erregt
DL 44 Dieser Ausgang simuliert den Eingang des Mikroschalter für Mikroschalter für
Mikroschalters für Überlastung. Er wird nur Überlastung hat Überlastung hat
aktiviert, wenn bei Signal Vorhandensein nicht angesprochen
Bühne unten (Bühne vorhanden) das Signal angesprochen
(Öffnerkontakt) des Mikroschalters für
Überlastung ausfällt.
DL 29 Dieses Signal wird aktiviert, wenn die Auszug Auszug nicht

Ausfahrbewegung freigegeben ist. Und das freigegeben freigegeben
Signal, das vom Vierwegschalter kommt,
einen signifikanten Wert hat, um die
Bewegung auszuführen.
DL 26 Dieses Signal wird aktiviert, wenn die Option Option nicht
Bewegung der Option freigegeben ist. Und freigegeben freigegeben
das Signal, das vom Vierwegschalter
kommt, einen signifikanten Wert hat, um
die Bewegung auszuführen.
DL 23 Signal von der Pilz-Schlagtaste auf der Pilz-Schlagtaste Pilz-Schlagtaste
Bühne. Öffnerkontakt. nicht gedrückt gedrückt
DL 21 Ausgang für Meldung in Kabine (blinkend) Hinterachse Hinterachse nicht
für Hinterachse blockiert blockiert (blinkt) blockiert
DL 42 Ausgang, der zum Sicherungssystem geht, Maschine in Maschine nicht
um den Zustand Maschine in frontaler zentraler Position in frontaler
Position innerhalb von 5° zu melden Position
DL 17 Ausgang zur Vorsteuerung des Hauptventils Hauptventil Hauptventil nicht
für Ansteuerung von Stabilisatoren, Balken freigegeben freigegeben
und Nivellierung.
DL 41 Ausgang zur Freigabe oder Nichtfreigabe Nivellierung Nivellierung
der Nivellierfunktion. freigegeben nicht freigegeben
DL 36 Simulation von Mann-vorhanden, wenn Mann-vorhanden Mann-vorhanden
man von der Bühne oder mit der nicht simuliert simuliert
Fernbedienung arbeitet
DL 46 Diese LED-Anzeige meldet, ob die Bewegungen Bewegungen
Maschine mit beschränkten Bewegungen beschränkt nicht beschränkt
oder schnell arbeitet.
8 7 6 5 4 3 2 1

M1/[1..12]
M2/[1..6]
D D
BUS/[0..7]

SEL[1..3]

PREUOM1 PREUOM1
C_R7 PRECES PRECES
C
MICROSV MICROSV
SEL[1..3]
AN_[1..5]
CES23M CES23M
EVBRA
C_R7 PENINT PENINT
SISTANTIR SISTANTIR
GENSTA GENSTA
MARINS MARINS
B B
SPIAPBL SPIAPBL
DISTRDANF DISTRDANF
CHIPAT
CES23M
POSRAD
M2/[1..6]
OUT[1..22] IN5




8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
R1 +IC AN_[1..5]
470 +5V +5V AN_[1..5]
ROTLIN1
Y1 R2
DL1 10uF 16VL 0.1uF
PC3 14 12 AN_1 U2A D1 R101
X X0
4
R3 13 AN_2 R4 LMC6482 1N4004 100K 1%
D 2.2K R9 PC4 X1 10K 1% R7 R8 D
15 - 2
10M Y AN_3 1K 10K 1%
2 1
R5 R10 PC5 Y0 AN_4
4 1 + 3 IN_3
470 10K Z Y1
M3/1 5 AN_5 R6
Z0 M2/2 100 R103
8
3
Z1
4
6
C6 +IC 16 C3 100K 1%
33pF VDD D2 0.1uF
6
11 OUTSW
TLP504A 10nF A
8 10
VSS B
7 9
C5 +5V VEE C
33pF R231 +IC +IC
3
R11 U4 4053 27K 1%

470 68HC705P9
28
U2B D3 R104
ROTLIN2
4
27 10 BUS/0 R12 LMC6482 1N4004 100K 1%
VCC
OSC1 PA0 BUS/1 10K 1% R14 R15
26 9 - 6
8 7
1 7 + 5 IN_4
RESET PA3 BUS/4
C 2 6 C
5
2.2K PA5 BUS/6 100 R107
8
4
PA6 BUS/7 C7 100K 1%
3
R17 R18 PA7 D4 0.1uF
470 10K CS 23 11 MOSI BUS/[0..7] +IC 1N4004
+5V M2/7 25 12 MISO SEL[1..3]
13 SK
PB7/SCK
1
C9 24 22 SEL1
21
20
PC2 PC3
19
18
PC4/AN2
4
+5V PC5 LMC6482 1N4004 10K 1%
2
17
PC5/AN1 M2/5 R22
14 16 - 2
15 1
+ C10 PC7/VRH + 3
10uF 16VL R20
U6 100 R21
8
R24 100
8
B B
4.7K + C11
VCC
1 7 C12 C13 R25 R232 C14 D6 0.1uF

2 6
C15 +5V TD RST
100pF 3 5 1 2 U5B R23
TOL RST RESET
8
LMC6482 4.99K 1%
GND
+ 5
U7A +5V +5V 7
C16 C17 74HC14 - 6
U6 47nF 47nF
4
MAX1232 + C22 C23

10uF 16VL 0.1uF
4
U8
MISO 4 8
M2/[1..7] M3/[1..5]
CS 1
CS
M2/1 M3/1 SK ORG
2
M2/2 M3/2 SIC
M2/3 M3/3 MOSI 3 5
M2/4 M3/4
M2/5 M3/5
93C46


8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
+12E
D D
C24 + D7
470uF 25VL 1N4004
D8 R28 L1 U9
F1 1N4004 2.2 2W 330uH L4940V5 +5V
1A
1 3
+VBATT IN VO1
GND
RV1 RV2 C26 + C27 C28 + C25 R29
27Z1 27Z1 100uF 50VL 0.1uF 0.1uF 47uF 16VL 680
2
C C
R30
2.2 1/2W
DL3
LED ROSSO 3MM
+IC
1
C29 +
0.1uF 1N4004 15V 1/2W
2
B B



8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
+5V
M1/[1..13] BUS/[0..7] OUT[1..22]

M1/[1..12] BUS/[0..7] OUT[1..8]
20
M1/1 18 2 BUS/0 U17
VCC
17 3 3 2
16 4 4 5
15 5 7 6
14 6 8 9
13 7 13 12
12 8 14 15
11 9 17 16
18 19
D7 Q7
19
GND
+ + + + + + + + G
1 1
DIR OC
3 4 11
G
10
U16 74HC373
74HC245 C39
C31 C32 C33 C34 C35 C36 C37 C38 4.7KpF
+5V 4.7K 4.7K 4.7K 4.7K 4.7K 4.7K 4.7K 4.7K U19
BUS/0 3 2 OUT9
4 5
20
7 6
BUS/3 D2 Q2 OUT12
8 9
18 2 13 12
VCC
17 3 14 15
C 16 4 17 16 C
15 5 18 19
M2/1 B4 A4 BUS/4 +5V C92 U7C D7 Q7
14 6
M2/3 B5 A5 BUS/5 0.1uF 74HC14
13 7 1
M2/4 B6 A6 BUS/6 U42 U42 OC
12 8 5 6 11
M2/6 B7 A7 BUS/7 74HC245 G
11 9
20
M2/2 B8 A8 C48 74HC373
M2/5 19 BUS/0 2 18 M3/1 4.7KpF
GND
VCC
+ + + + + + + + G BUS/1 A1 B1 M3/2
1 3 17
4 16
BUS/3 A3 B3 M3/4
5 15
10 BUS/4 A4 B4 M3/5
6 14
BUS/5 A5 B5
7 13
C40 C41 C42 C43 C44 C45 C46 C47 BUS/6 A6 B6
8 12 U20
9 11 3 2
A8 B8 + + + + + BUS/1 D0 Q0 OUT18
4 5
BUS/2 D1 Q1 OUT19
19 7 6
GND
M2/[1..6] G BUS/3 D2 Q2 OUT20
M2/[1..6] 1 8 9
M3/[1..5] DIR BUS/4 D3 Q3 OUT21
M3/[1..5] 13 12
BUS/5 D4 Q4 OUT22
14 15
10
+5V +5V +5V +5V C49 C86 C90 C89 C91 BUS/6 D5 Q5
B 17 16 B
18 19
M3/2 D7 Q7
C50 C52 C53 C54 M3/3 1
0.1uF 0.1uF 0.1uF 0.1uF M3/4 OC
9 8 11
U21 U18 U16 U17 M3/5 G
U7D C55 74HC373
74HC14 4.7KpF
+5V R87
SEL[1..3] 1M
SEL[1..3]
U21 RESET 11 10 +5V +5V
RESET
74HC138
16
R88 U7E
SEL1 1 15 1K D13 + 74HC14 C51 C59
VCC
SEL2 A Y0 1N4148 C56 0.1uF 0.1uF

2 14
3 13
C Y2
12
Y3
11
RESET Y4
6 10
4 9
GND
G2A Y6
A 5 7 A
C57 C58 C20
8



8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
K2 DL17 +5V
3 1.5K 5
+VBATT DL46
1 4 LED ROSSO 3MM
+12E GENSTA
2 1
+12E
2
D D
OUT[1..22] K4 R279
OUT[1..22] 470
FBR51 12V
DL18 R94
U22 3 10K
1 16 4 SISTANTIR
2 15 1
3 14 2
4 13 5
5 12 3
6 11 4 MOVCES
OUT7 IN6 OUT6
7 10 1
IN7 OUT7 +12E R255
2
8 9 DL41 1.5K
GND COM +12E
LED 3MM ROSSO K18
ULN2003D1 FBR51 12V
D35 2
1N4004 1
K6 +12E
4
C 3 C
R96 +VBATT
5
1.5K 5
D34 3 K7
4
1 5
OUT10 +12E R256
2 +VBATT 3
DL21 4 1.5K
U23 1
1 16 C_R8 2
OUT8 IN1 OUT1
2 15 2
IN2 OUT2
3 14 +12E 1
OUT11 IN3 OUT3
4 13 4
5 12 C_R7 3
6 11 R_1_2_3 5
7 10 OUTSW
OUT12 IN7 OUT7 R99
OUT13 8 9 1.5K 5
GND COM +12E
OUT14 3
+VBATT R257
ULN2003D1 4
MARINS 1.5K
B 1 B
+12E
2
K20
DL22 D32 FBR51 12V
DL43 5
LED 3MM ROSSO 3
K10 +VBATT
4
FBR51 12V OUTRL
1
R100 2
1.5K 5
+VBATT 3
R98 4 OUT22 Q12
1
+12E R258
2
10K
K9 DL24
DL23 5
+V 3
A 4 +12E +12E A
PULARR 2
C60 C85

1N4004
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
K11
FBR244 12V
BRACAB
IN_1
BRACES R102 DL25
1.5K LED 3MM ROSSO
SOLCAB
IN_2
D SOLCES D
+12E
+12E +12E
K12
FBR244 12V R233
R235 10K
IN_3
1N4004 1K 8.2V 1/2W
OPTCES R105 DL27
IN_4
10K
SFICES Q11
PRECES 5 PREUOM2
+12E BC847
PREUOM1 3
4
1
C88 R236 2
0.1uF 47K
K15
C FBR244 12V R109 D12 C
R106 1.5K 1N4004
1.5K DL26
LED 3MM ROSSO D28
EVOPT 1N4004
DL36
+12E LED 3MM ROSSO
C_R7 POSRAD
K14
FBR244 12V C87 R238
0.1uF 4.7K
EVSFI
R110
1.5K DL29
LED 3MM ROSSO
D31
+12E 1N4004 +12E
C_R8
PENDOLO
B B
K13
FBR244 12V
R259
ROTCAB D30 1.5K D33
IN_5
1N4004 1N4004
ROTCES R108 DL28
1.5K LED 3MM ROSSO
MICROSV
DL44 K16
R_1_2_3
CHSALV
K21 R260
FBR51 12V D29 1.5K
A 2 A
4
3
ALIMCES 5


8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
JP2
C14 +VBATT
1 CONCES
1 LIMSAL 2 BRACES
2 SFICAB 3 POSRAD
4 CENTCAB1 5 OPTCES
5 LIMSFILO 6 SOLCES
6 INP_FR1 7
7 CHIPAT 8 PULARR
9 DISTRDANF 10
10 MANCAB 11 MANCES
11 BRACAB 12 ROTCES
12 ROTLIN2
13 SISTANTIR
15 SOLCAB
16 ROTLIN1
17 ANTIRIB
18 OUTRL
19 OPTCAB
20 PREUOM1
21 EVRIE_STA
22 ESCSAL
23 ROTCAB 1 EVBRA
24 PREUOM2 2 STAUSC
3 OUTSTA
4 EVROT
5 BLPOPOS
6 CHSALV
7 EVSFI
8 PENDOLO
9 SPIAPBL
10 EVSOL
11 EVOPT
12 ARRMOT
1 OPTCES
2 CES23M
3 ALIMCES
4 ROTCES
5 BRACES
6 MANCES
7 SFICES
9 CONCES
10 PRECES
11 SOLCES
12 PULARR
JP5
CONNETTORE 6 POLI
C13 +VBATT
1 GENSTA
2 OUTCC
3 JP5 PIN3 = MASSA
4 INSTA
5 OUTLIV

1 MARINS
2 MOVCES
3 SELCES
5 MICROSV



8 7 6 5 4 3 2 1
5 4 3 2 1
+IC
+IC
J1
1 R112 R111 220
+IC 1.5K 1% 6.8K 1%
R114 U25A
4
10K U24 LMC6482
R113 U25B 12 14 2 -
X0 X
4
D D15 15K 1% LMC6482 R115 13 1 D
1N4004 R117 6.8K 1% X1
6 - 15 3 +
15K 1% Y
7 2
Y0
IN1 5 + 1 4
R119 Y1 Z R118
8
R116 10K 5 1.5K 1% C61
15K 1% C62 C63 J2 Z0 0.1uF
8
3
16
R262 VDD +IC
6
1 +IC INH
11
+IC A
10 8
R120 B VSS R121 R125
9 7
D16 10K 1% C VEE 10K 1% 10K 1% +IC
1N4004 U26A 4053
8
LMC6482
3 + D17
1 AN_1 U26B 1N4004
4
2 - AN_2 +IC LMC6482 R122
R263 AN_3 6 - 100
1 AN_4 7 EVBRA
+IC AN_5 R124
4
C 5 + C
U27A 10K
4093 C64
R123 R264 0.1uF D18
8
4.99K 1% 1.5K 1% AN_[1..5] 1 1N4004
AN_[1..5]
3
+IC 2 R126 R127 +IC
10K 100
R129 Q1 OUT14
10K 1% R130 BC847
U28A 10K U27B OUT[1..22]
OUT[15..21]
4
LM393 4093 R128

R131 2 - 10K C65
3.3K 1% 1 5 10nF
3 + 4 +IC +IC OUT1
6 OUT2
OUT3
R132 R133 OUT4
8
C66 10K 10K OUT5

10nF R134 OUT6
4093 OUT8
R135 +IC OUT9
1K 1% 9 OUT10
10 12 OUT11
R136 8 11 OUT12
U28B 10K 13 OUT13
4
LM393 OUT14
R140 6 - OUT15
3.3K 1% 7 Q2 U27D OUT16
5 + R137 R138 BC847 4093 OUT17
100 10K OUT18
OUT19 Q3 OUT19
BC847 OUT20
8
C68 OUT21
10nF R139 C67 OUT22
+IC 10K 10nF
R266 R141
A 1.5K 1% 1M 1% A
1

47uF 16VL 47uF 16VL
2

5 4 3 2 1
5 4 3 2 1
+IC
J3 +IC
PONTICELLO
R169 R271
15K 1% R168 R167 220
+IC 1.5K 1% 6.8K 1%
R170 U33A
4
10K U32 LMC6482
R267 U33B 12 14 2 -
X0 X
4
D D19 1 LMC6482 R171 13 1 D
1N4004 R173 6.8K 1% X1
6 - 15 3 +
15K 1% Y
7 2
Y0
IN2 5 + 1 4
R175 Y1 Z R174
8
R172 10K 5 1.5K 1% C69
15K 1% C70 C71 J4 Z0 0.1uF
8
3
16
R268 VDD +IC
6
1 +IC INH
11
+IC A
10 8
R176 B VSS R177 R181
9 7
D20 10K 1% C VEE 10K 1% 10K 1% +IC
1N4004 U34A 4053
8
LMC6482
3 + D21
1 AN_2 U34B 1N4004
4
2 - AN_1 +IC LMC6482 R178
R269 AN_3 6 - 100
1 AN_4 7 EVSOL
C +IC 4 AN_5 R180 5 + C
U35A 10K
4093 C72
R179 R270 0.1uF D22
8
4.99K 1% 1.5K 1% AN_[1..5] 1 1N4004
AN_[1..5]
3
+IC 2 R182 R183 +IC
10K 100
R185 Q4 OUT14
10K 1% R186 BC847
U36A 10K U35B OUT[1..22]
OUT[15..21]
4
LM393 4093 R184

R187 2 - 10K C73
3.3K 1% 1 5 10nF
3 + 4 +IC +IC OUT1
6 OUT2
OUT3
R188 R189 OUT4
8
C74 10K 10K OUT5

10nF R190 OUT6
B +IC 1M 1% OUT7 B
OUT8
+IC OUT9
9 OUT10
R191 10 12 OUT11
1K 1% R192 8 11 OUT12
U36B 10K U35C 13 OUT13
4
LM393 4093 OUT14

R196 6 - OUT15
3.3K 1% 7 Q5 U35D OUT16
5 + R193 R194 BC847 4093 OUT17
100 10K OUT18
OUT18 Q6 OUT19
BC847 OUT20
8
C76 OUT21
10nF R195 C75 OUT22
+IC 10K 10nF
R272 R197
A 1.5K 1% 1M 1% A



5 4 3 2 1
5 4 3 2 1
+IC
J5 +IC
PONTICELLO
R273 R278
1 R200 R199 220
+IC 1.5K 1% 6.8K 1%
R202 U38A
4
R201 10K U37 LMC6482
15K 1% U38B 12 14 2 -
X0 X
4
D D23 LMC6482 R203 13 1 D
1N4004 R204 R205 6.8K 1% X1
6 - 15 3 +
15K 1% 15K 1% Y
7 2
Y0
IN5 5 + 1 4
R207 Y1 Z R206
8
1
10K 5 1.5K 1% C77
C78 C79 J6 Z0 0.1uF
8
+ 3
16
R208 VDD +IC
6
1 +IC INH
2
11
+IC A
10 8
R274 B VSS
9 7
D24 10K 1% C VEE R209 R213
1N4004 U39A 4053 10K 1% 10K 1% +IC
8
LMC6482
3 +
1 AN_5 D25
2 - AN_1 U39B 1N4004
4
R211 AN_2 +IC LMC6482 R210
1 AN_3 6 - 100
+IC AN_4
4
C 7 EVROT
C
R212 5 +
U40A 10K
R275 R217 4093
4.99K 1% 1.5K 1% AN_[1..5] C80 D26
8
AN_[1..5]
1 0.1uF 1N4004
+IC 3
2 R214 R215 +IC
R276 10K 100
10K 1% R218 Q7 OUT14
U41A 10K U40B BC847 OUT[1..22]
OUT[15..21]
4
LM393 4093
R219 2 - R216
3.3K 1% 1 5 10K C81
3 + 4 +IC +IC 10nF OUT1
6 OUT2
OUT3
R220 R221 OUT4
8
C82 10K 10K OUT5

10nF R222 OUT6
B +IC 1M 1% OUT7 B
OUT8
+IC OUT9
9 OUT10
R223 10 12 OUT11
1K 1% R224 8 11 OUT12
U41B 10K U40C 13 OUT13
4
LM393 4093 OUT14

R228 6 - OUT15
3.3K 1% 7 Q8 U40D OUT16
5 + R225 R226 BC847 4093 OUT17
100 10K OUT18
OUT15 Q9 OUT19
BC847 OUT20
8
C84 OUT21
10nF R227 C83 OUT22
+IC 10K 10nF
R277 R229
A 1.5K 1% 1M 1% A



5 4 3 2 1
5 4 3 2 1
R31 R32
470 470
CHSALV
R33 R34
470 470
PRECES
R35 R36
D 470 470 D
SELCES
R37 R38
470 470
R39 R40
470 470
R41 R42 R43 R44 R45 R46
MANCES 2.2K 2.2K 2.2K 2.2K 2.2K 2.2K
R47 R48
470 470
MANCAB
7
DL7 LED 3MM VERDE
M1/8
M1/9
M1/11
M1/12
DL9 LED 3MM VERDE
3
8
M1/7
M1/10
R55 R56 M1/[1..12]
470 470 M1/[1..12]
INSTA
M1/5
R57 R58
M1/1
M1/2
M1/3
M1/4
M1/6
470 470
OUTSTA
R59 R60
470 470
BLPOPS
R61 R62
470 470
LIMSAL
B R63 R64 B
470 470 +5V +5V +5V +5V +5V +5V
LIMSFILO
R77 R78 R66 R65 R67 R68 R69 R70 R71 R72 R73 R74 R75 R76
470 470 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K
STAUSC
DL10 LED 3MM VERDE

4
7
DL11 LED 3MM VERDE
DL12 LED 3MM VERDE
DL15 LED 3MM VERDE
3
8



5 4 3 2 1
5 4 3 2 1
M2/[1..6]
D M2/[1..6] D
M2/1
M2/2
M2/3
M2/4
M2/5
M2/6
DL30
470 470
ESCSAL
DL31
470 470
CHIPAT
DL32
470 470
ANTIRIB
C DL33 C
470 470
CES23M
DL34
470 470
POSRAD
+5V +5V +5V +5V +5V +5V
DL35
470 470 R153 R154 R155 R156 R157 R158 R159 R160 R161 R162 R163 R164
2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K
CONCES
4
7
B B

3
8




5 4 3 2 1
5 4 3 2 1
D M3/[1..5] D
M3/[1..5]
M3/1
M3/2
M3/3
M3/4
M3/5
DL40
470 470
CENTRCAB1
DL39
470 470
CENTRCAB2
DL38
470 470
INP_FR1
+5V +5V +5V +5V

DL37
470 470 R241 R242 R244 R243 R248 R247 R253 R254
2.2K 10K 2.2K 10K 2.2K 10K 2.2K 10K
INP_FR2
1
6
U43B U43A U44B U44A
B B
2
5




5 4 3 2 1
CABLAGGI PULSANTIERA CESTELLI
BASKET REMOTE CONTROL CABLES
VERKABELUNGEN DRUCKKNOPFTAFEL BÜHNEN
MRT 1440-1640-1840 EASY

IT-EN-DE
Tavola pulsantiera 1 / Table remote control 1 / Tafel druckknopftafel 1
MICRO DOOR
MICRO SPORTELLO
MICRO OVERLOADING
MICRO SOVRACCARICO
EV SBLOCCO OSCILLAZIONE
CESTELLO PEND 3D
EV OSCILLATION RELEASE
BASKET PENDULUM 3D
MRT 1440-164-1840 EASY
PULSANTE ARRESTO D'EMERGENZA -

EMERGENCY BUTTON
ARRESTO MOTORE - STOP ENGINE
N.A. BUTTON
START MOTORE - START ENGINE
N.A. BUTTON
AVVISATORE ACUSTICO - KLAXON
SEGNALE DI PENDOLO O ANTIRIBALTAMENTO- INPUT PENDULUM OR SAFETY SISTEM

- EV OSCILLATION BASKET PENDULUM 3D
SPIA DI DIFETTO - ERROR LIGHT

- N.A. BUTTON
POMPA EMERGENZA - EMERGENCY PUMP
1
80
2
80
Tavola pulsantiera 2 / Table remote control 2 / Tafel druckknopftafel 2
SOLLEVAMENTO - LIFTING
SFILO - EXTENDING
ROTAZIONE - ROTATION
3 POSITIONS
BRANDEGGIO - TILTING
SELECTOR LEVER
MICROINTERRUTTORE MANIPOLATORE -
MICROSWITCH JOYSTICK
CONSENSO MANOVRE -
MOVEMENTS CONSENT
SEGNALE CESTELLO 3D INSERITO -

ACTIVE 3D BASKET SIGNAL
POSITION 1
POSITION 2
POSITION 3
POSITION 4
POSITION 5
5 POSITIONS ROTATING SELECTOR

SOL. CEST. 3D - LIFTING PEND 3D
EV ROT. CEST 3D - ROTATION PEN. 3D
EV BRAND. CEST 3D - TILTING PEN. 3D

MRT 1440-164-1840 EASY
INDICE
1 CONVENZIONI ..................................................................................................... 3
2 CONFORMITÀ ...................................................................................................... 3
3 DESCRIZIONE RADIOCOMANDO ............................................................................. 4
4 AVVERTENZE PER L’INSTALLAZIONE DEL RADIOCOMANDO ........................................ 4
5 AVVERTENZE PER L’USO DEL RADIOCOMANDO ........................................................ 6
Italiano
6 AVVERTENZE PER LA MANUTENZIONE ORDINARIA DEL RADIOCOMANDO ................... 6
7 AVVERTENZE PER LA MANUTENZIONE STRAORDINARIA ............................................ 8
8 DOCUMENTAZIONE .............................................................................................. 8
9 UNITÀ TRASMITTENTE E SUO FUNZIONAMENTO ....................................................... 9
10 UNITÀ RICEVENTE .............................................................................................. 11
11 PROCEDURA DI TARATURA USCITE PROPORZIONALI (REMOTE SET UP) .................... 12
12 FREQUENZE RADIO ............................................................................................ 14
13 DIAGNOSTICA ................................................................................................... 15
14 DATI TECNICI .................................................................................................... 16
INDEX
1 CONVENTIONS .................................................................................................. 17
2 CONFORMITY ..................................................................................................... 17
3 RADIO REMOTE CONTROL DESCRIPTION ............................................................... 18
4 WARNINGS REGARDING INSTALLATION ................................................................ 18
5 WARNINGS REGARDING USE ............................................................................... 20
English
6 WARNINGS REGARDING ROUTINE MAINTENANCE .................................................. 20
7 WARNINGS REGARDING SPECIAL MAINTENANCE ................................................... 22
8 DOCUMENTATION .............................................................................................. 22
9 TRANSMITTING UNIT AND HOW IT WORKS ........................................................... 23
10 RECEIVING UNIT ................................................................................................ 25
11 PROPORTIONAL OUTPUT SETTING PROCEDURE (REMOTE SET UP) ............................ 26
12 RADIO FREQUENCIES ......................................................................................... 28
13 DIAGNOSTIC ..................................................................................................... 28
14 TECHNICAL DATA ............................................................................................... 30
INHALT
1 KONVENTIONEN ................................................................................................. 31
2 KONFORMITÄT ................................................................................................... 31
3 BESCHREIBUNG DER FUNKFERNSTEUERUNG ......................................................... 32
4 WARNUNGEN BEI DER INSTALLATION DER FUNKFERNSTEUERUNG ........................... 32
5 WARNUNGEN ZUM GEBRAUCH DER FUNKFERNSTEUERUNG ..................................... 34
Deutsch
6 WARNUNGEN ZUR NORMALE WARTUNG DER FUNKFERNSTEUERUNG ........................ 35

7 WARNUNGEN ZUR AUßERGEWOHNLICHE WARTUNG DER FUNKFERNSTEUERUNG ....... 36
8 DOKUMENTATION .............................................................................................. 36
9 DIE SENDEEINHEIT UND IHR BETRIEB .................................................................. 37
10 EMPFANGSEINHEIT ............................................................................................ 39
11 EICHVERFAHREN PROPORTIONALE AUSGÄNGE (REMOTE SET UP) ............................ 40
12 FUNKFREQUENZEN ............................................................................................. 42
13 FEHLERSUCHE ................................................................................................... 43
14 TECHNISCHE DATEN ........................................................................................... 44
-1-
LIPROMU2
SOMMARIE
1 CONVENZIONS .................................................................................................. 45
2 CONFORMITE ..................................................................................................... 45
3 CARACTERISTIQUES DE LA RADIOCOMMANDE ....................................................... 46
4 CONSEIL POUR L’INSTALLATION DE LA RADIOCOMMANDE ...................................... 46
5 CONSEILS POUR L’UTILISATION DE LA RADIOCOMMANDE ....................................... 48
Français
6 CONSEILS POUR L’ENTRETIEN ORDINAIRE DE LA RADIOCOMMANDE ........................ 48
7 CONSEILS POUR L’ENTRETIEN EXTRAORDINAIRE DE LA RADIOCOMMANDE ............... 50
8 DOCUMENTATION .............................................................................................. 50
9 UNITÉ DE TRANSMISSION ET SON FONCTIONNEMENT ............................................ 51
10 UNITE DE RECEPTION ......................................................................................... 53
11 PROCÉDURE DE RÉGLAGE DES SORTIES PROPORTIONNELLES (REMOTE SET UP) ....... 54
12 FRÉQUENCES RADIO .......................................................................................... 56
13 DIAGNOSTIC ..................................................................................................... 57
14 FICHE TECHNIQUE ............................................................................................. 58
ÍNDICE
1 CONVENCIONES ................................................................................................ 59
2 CONFORMITÀ .................................................................................................... 59
3 DESCRIPTCIÓN DEL RADIOMANDO ....................................................................... 60
4 ADVERTENCIAS PARA LA INSTALACIÓN DEL RADIOMANDO ..................................... 60
5 ADVERTENCIAS PARA LA UTILIZACIÓN DEL RADIOMANDO ...................................... 62
Español
6 ADVERTENCIAS PARA LA MANUTENCIÓN ORDINARIA DEL RADIOMANDO .................. 62
7 ADVERTENCIAS PARA LA EXTRAORDINARIA MANUTENCIÓN DEL RADIOMANDO ......... 64
8 DOCUMENTACIÓN .............................................................................................. 64
9 UNIDAD TRANSMISORA Y SU FUNCIONAMIENTO .................................................... 65
10 UNIDAD RECEPTORA .......................................................................................... 67
11 PROCESO DE REGULACIÓN DE LAS SALIDAS PROPORCIONALES (REMOTE SET UP) .... 68
12 FRECUENCIAS RADIO ......................................................................................... 70
13 DIAGNÓSTICA ................................................................................................... 71
14 DATOS TËCNICOS .............................................................................................. 72
-2-
LIPROMU2
1 CONVENZIONI
Il carattere grassetto viene usato per i testi da leggere con particolare at-
tenzione.
Questo simbolo contraddistingue tutte le indicazioni e le informazioni di

estrema importanza: la mancata osservanza di queste provoca situazioni di
grave pericolo a persone o cose.
Questo simbolo contraddistingue tutte le indicazioni e le informazioni impor-

tanti che riguardano il funzionamento.
2 CONFORMITÀ
Il radiocomando PRO-M della serie C26 PRO è conforme alla Direttiva R&TTE
99/05/CE e ai suoi requisiti essenziali.
Il radiocomando è inoltre conforme alle norme riportate nella dichiarazione di confor-
mità CE allegata a questo manuale.
Nei Dati Tecnici (vedere capitolo 14) sono indicate le caratteristiche delle funzioni di
sicurezza secondo la EN 954-1.
Si ricorda che in taluni stati si devono rispettare leggi che regola-

mentano l’uso e/o il possesso di un radiocomando (vedere l’allegato
“Limitazioni & Autorizzazioni”).
Possono esistere delle limitazioni nazionali di utilizzo delle frequen-

ze dato che non sono ancora armonizzate negli stati europei.
Verificare prima dell’uso che il radiocomando lavori in una banda di
frequenze che è permessa dalle leggi nazionali che regolamentano
le radiocomunicazioni.
Come richiesto dalla Direttiva Macchine e dalle relative norme armonizzate, è neces-
sario effettuare per ogni macchina un’analisi dei rischi: pertanto, in caso di utilizzo di
un radiocomando, occorre valutare all’interno di questa analisi se la macchina può es-
sere radiocomandata o meno.
La responsabilità di questa analisi è del costruttore della macchina stessa e/o di chi
decide l’installazione e l’uso del radiocomando.
Autec non potrà assumersi alcuna responsabilità se questa analisi dei rischi
non è stata effettuata in maniera corretta e se il radiocomando è installato
su applicazioni diverse da quelle consentite:
APPLICAZIONI CONSENTITE
Macchine di sollevamento e movimentazione installate esclusiva-
mente su automezzi dove l’alimentazione elettrica proviene da una
batteria (per esempio: gru idrauliche, pompe di calcestruzzo . . .)
APPLICAZIONI NON CONSENTITE

- macchine installate in ambienti che necessitano di apparecchiatu-
re con caratteristiche antideflagranti
- macchine alimentate in AC
- macchine dove l’alimentazione in DC non proviene da batteria
- macchine in cui l’analisi dei rischi, per la verifica della conformità
del radiocomando all'applicazione, non sia possibile o abbia dato
esito negativo o incerto
Per garantire il corretto utilizzo del radiocomando, devono essere sempre rispettate
tutte le prescrizioni vigenti sulla sicurezza del lavoro e sulla prevenzione degli infor-
tuni sul lavoro. Inoltre, si devono sempre osservare tutte le leggi nazionali relative
all’uso sia della macchina che del radiocomando vigenti nel singolo stato dove il siste-
ma è utilizzato.
Autec non potrà assumersi alcuna responsabilità se il radiocomando è utiliz-
zato in condizioni lavorative non a norma.
LIPROMU2
-3- Italiano
3 DESCRIZIONE RADIOCOMANDO
Un radiocomando è utilizzato per comandare

macchine da posizione remota. Esso è costitui-
to da una unità trasmittente portatile da cui
l’operatore può comandare a distanza la mac-
china e da un’unità ricevente installata a bordo
della macchina stessa. L’unità trasmittente in-
via un messaggio codificato, attraverso una
trasmissione a radiofrequenza. In questo mes-
saggio è presente un valore detto indirizzo (ad-
dress) che consente all’unità ricevente di Unità
decodificare esclusivamente i messaggi prove- Ricevente
nienti dalla propria unità trasmittente (quella
che possiede lo stesso indirizzo).
Ciò esclude che un’interferenza possa attivare
un qualsiasi comando. Infatti, se la trasmissio- Unità
ne a radiofrequenza risulta disturbata, errata o Trasmittente
interrotta, l’unità ricevente arresta autonoma-
mente l’intero sistema.
4 AVVERTENZE PER L’INSTALLAZIONE DEL RADIOCOMANDO

L'installazione deve essere eseguita esclusivamente da personale
qualificato, secondo le disposizioni di legge del Paese in cui si effet-
tua l'operazione. Solo una corretta installazione può assicurare il
necessario grado di sicurezza durante il successivo utilizzo del ra-
diocomando.
Indicazioni
generali Collegare il Radiocomando alla macchina rispettando le caratteristiche di funziona-
mento della stessa: non si devono eludere i circuiti di sicurezza previsti sul ra-
diocomando e/o presenti nella macchina.
La semplice configurabilità del cablaggio della unità ricevente permette una installa-
zione senza dover intervenire sulla macchina: non modificare il quadro elettrico della
macchina senza autorizzazione del costruttore.
Togliere l’alimentazione dall’unità ricevente scollegando tutte le

connessioni elettriche ogni volta che si effettua una saldatura sulla
macchina.
Installazione
L'unità ricevente deve essere posta in posizione tale da favorire la ricezione
dei segnali emessi dall'unità trasmittente. Pertanto, essa deve essere montata
verticalmente (antenna verso l’alto). L'unità ricevente deve inoltre essere facilmente
accessibile per permettere di operarvi in condizioni sicure.
Se l’unità ricevente risulta coperta da strutture metalliche o installata all'interno di
quadri metallici, utilizzare il relativo kit-prolunga per antenna esterna.
L’antenna non deve mai essere in contatto con parti metalliche.
È vietato forare il contenitore della unità ricevente. Tale azione compromette

il grado di protezione agli agenti esterni (IP65).
Per ridurre l’effetto delle vibrazioni create dall’automezzo sull’unità ricevente, adotta-
re sempre dei blocchi antivibrazioni.
È opportuno posizionare l’unità ricevente lontana da fonti di calore (tubi di scappa-

mento, alternatori ecc.).
Cablaggio
La maggior parte delle macchine prevede il collegamento dell’unità ricevente attraver-
so una spina multipla che, in caso di necessità, permette di scollegare in modo rapido
il radiocomando per sostituirlo con un comando a cavo. Anche dove la macchina non
è così predisposta, è sempre consigliato l'utilizzo di questa tecnica di collegamento.
-4-
LIPROMU2
L'affidabilità dell'installazione è legata alla qualità del cablaggio: pertanto, si consiglia
di realizzarlo secondo le migliori regole utilizzando cavo multipolare o cavi singoli di
sezione adeguata alle correnti in gioco e con caratteristiche di non propagazione
alla fiamma (per maggior sicurezza riferirsi alla norma EN 60204-1).
Nel caso di collegamenti esterni all’unità ricevente si consiglia di utilizzare cavi a pro-
tezione antiolio.
L’alimentazione dell’unità ricevente deve obbligatoriamente passa-

re attraverso un interruttore per consentire di togliere l'alimenta-
zione durante le operazioni di installazione, di cablaggio e/o di
manutenzione. Per ottenere il miglior funzionamento del radioco-
mando, connettere l’unità ricevente immediatamente a valle dell’in-
terruttore generale della macchina.
È sempre opportuno controllare il valore dell’alimentazione anche sotto il massimo ca-

rico in modo da verificarne le massime variazioni (i valori limite di scostamento tolle-
rati sono riportati sia nei Dati Tecnici che sulla scheda tecnica del Radiocomando).
Fluttuazioni di tensione dell’alimentazione dell’unità ricevente oltre

i valori limite possono compromettere il regolare funzionamento del
radiocomando.
I radiocomandi della serie C26-PRO sono dotati di circuiti di protezione contro i mo-
vimenti involontari dalla posizione di riposo degli attuatori (funzione di SAFETY).
Tale protezione è efficace se nell'unità ricevente il comune dei comandi di movimento
è ricavato dalla serie del contatto di STOP e del contatto di SAFETY (che si chiude
quando un comando di movimento viene trasmesso). Viceversa, il comune dei co-
mandi di selezione può non essere in serie al contatto di SAFETY.
Esempio di
cablaggio
Tarature
uscite Autec fornisce il radiocomando con i valori di taratura delle uscite
proporzionali proporzionali già preimpostati. Durante l’installazione questi valori
devono essere verificati ed eventualmente modificati secondo le ne-
cessità di funzionamento della macchina (vedere capitolo 11).
Verifiche e
collaudi Alla fine dell'installazione e del cablaggio è sempre necessario:
- verificare che, azionando il pulsante di STOP del radiocomando, avvenga la messa
in sicurezza della macchina (mediante azione diretta sulla elettrovalvola generale
del circuito principale), lo spegnimento eventuale del motore e, se presente,
l’apertura del teleruttore principale in modo da togliere tensione.
- accertarsi dell'esatta corrispondenza tra le manovre effettuate dalla macchina e i
comandi dell'unità trasmittente (questa corrispondenza è riportata nella scheda tecnica)
- controllare il funzionamento del circuito di sicurezza (un modo semplice è quello
di togliere il fusibile F3, alloggiato sulla scheda base della Unità Ricevente, e verificare
che in queste condizione nessun comando di movimento possa essere effettuato; alla
fine inserire nuovamente il fusibile F3 e assicurarsi del corretto funzionamento)
L'istallatore deve inoltre compilare e/o verificare le due copie presenti della
scheda tecnica dove è riportato lo schema di cablaggio tra l’unità ricevente
e la macchina. La prima copia della scheda tecnica è inserita all’interno
dell’unità ricevente, la seconda è allegata al manuale d’uso. L’installatore
deve porre la data di messa in funzione dell'impianto con timbro e firma in
ciascuna delle due copie.
LIPROMU2
-5- Italiano
5 AVVERTENZE PER L’USO DEL RADIOCOMANDO
L’uso del radiocomando è consentito solo ad operatori che:
- abbiano letto e capito il presente manuale,
- siano qualificati ed addestrati,
- conoscano bene il sistema “radiocomando + macchina”.
Autec non potrà assumersi alcuna responsabilità se il radiocomando

è installato su applicazioni diverse da quelle consentite e se è utiliz-
zato in condizioni lavorative non a norma.
Ogni volta che si accende l’unità trasmittente, verificare che il pul-

sante di STOP funzioni correttamente e che il suo azionamento in-
terrompa istantaneamente i movimenti della macchina.
In caso contrario, non utilizzare il radiocomando.
L’operatore deve sempre controllare che entrambe le unità siano in-

tegre e che le guarnizioni, i soffietti ed i cappucci degli attuatori
(joystick, selettori, pulsanti) siano integri. In caso contrario, il ra-
diocomando non deve essere utilizzato prima di essere riparato.
Per lavorare in modo efficace e per prevenire eventuali situazioni di

emergenza, occorre scegliere una posizione che permetta di:
- rimanere all’interno del raggio d’azione del radiocomando (vedere
capitolo 14)
- seguire a vista in ogni momento la macchina, i suoi movimenti e
l’eventuale carico.
Durante il fun-
zionamento L’operatore dovrà:
- spegnere l’unità trasmittente ogni volta che sospende il lavoro
- non lasciare MAI incustodita l’unità trasmittente con la chiave
d’accensione inserita
- evitare di lavorare con la batteria vicina all’esaurimento.
L’operatore non dovrà mai accendere o azionare l’unità trasmittente

se non per iniziare a lavorare. È infatti possibile creare un collega-
mento radioelettrico anche al di fuori del raggio d’azione e da posti
chiusi, facendo in tal modo eseguire dei comandi non voluti alla
macchina radiocomandata.
In caso di
pericolo Nel caso si verifichi una condizione di pericolo, l’operatore deve in-
tervenire immediatamente azionando il pulsante di STOP che inter-
rompe istantaneamente i movimenti della macchina.
Poiché non tutti i pericoli sono causati dal sistema “radiocomando +

macchina”, l’operatore dovrà prestare attenzione anche nei casi
d’emergenza che si verificano nella zona di lavoro. Anche in questo
caso, l’operatore dovrà intervenire immediatamente azionando il
pulsante di STOP.
In caso di
guasto In presenza di un qualunque guasto o di parti danneggiate del ra-
diocomando, si DEVE mettere fuori servizio il sistema “radiocoman-
do + macchina” fino alla completa eliminazione del problema.
Eventuali guasti possono essere riparati esclusivamente da perso-
nale autorizzato Autec, utilizzando soltanto pezzi di ricambio origi-
nali.
6 AVVERTENZE PER LA MANUTENZIONE ORDINARIA DEL RA-

DIOCOMANDO
Durante tutte le operazioni di manutenzione ordinaria del radioco-
mando e della macchina, togliere la batteria dall’unità trasmittente
e sconnettere la spina di collegamento dall’unità ricevente.
-6-
LIPROMU2
Tutti gli interventi di controllo e di manutenzione del radiocomando vanno verificati e
registrati dal Responsabile della Manutenzione della macchina.
La manutenzione ordinaria secondo le indicazioni contenute in que-

sto manuale è fondamentale per il funzionamento sicuro del radio-
comando.
Dopo ogni intervento di manutenzione, verificare sempre che i co-

mandi inviati dalla unità trasmittente attivino esclusivamente le
manovre previste.
Indicazioni
riassuntive Le indicazioni che seguono sono da considerarsi come le minime indispensabili per il
funzionamento sicuro e corretto del radiocomando.
Particolari applicazioni possono richiedere interventi di manutenzione ordinaria più
specifici e con tempistiche diverse.
In nessun caso, queste indicazioni possono assumere carattere contrattuale, sostituire
le norme e le leggi in materia di sicurezza del lavoro e limitare le responsabilità dell’ac-
quirente e dell’utilizzatore del radiocomando.
Tutte le indicazioni riportate devono essere eseguite ad ogni messa in servi-
zio della macchina e del radiocomando.
Componente Periodicità
Ogni Ogni 3 Ogni 6 Ogni 12
giorno mesi mesi mesi
Unità trasmittente X
Unità ricevente X
Funzionalità elettrica X
Conduttori elettrici esterni X
Se durante un intervento di manutenzione ordinaria si evidenzias-

sero delle anomalie, mettere fuori servizio il sistema “macchina+ra-
diocomando” seguendo le indicazioni riportate (vedere capitolo 7).
Unità
trasmittente
È necessario ogni giorno:
1. rimuovere la polvere o accumuli di altro materiale dall'unità trasmittente: per pulire
non usare mai solventi o prodotti infiammabili/corrosivi e non utilizzare idropulitrici
ad alta pressione o apparecchi a vapore.
2. immagazzinare l'unità trasmittente in ambienti puliti ed asciutti.
3. verificare che le guarnizioni, i soffietti ed i cappucci dei joystick, selettori e pulsanti
siano integri, morbidi ed elastici
4. accertarsi che la sede d'alloggiamento e i contatti della batteria siano sempre puliti
5. controllare che l'unità trasmittente sia strutturalmente integra.
6. verificare che i simboli del pannello siano ben visibili ed eventualmente sostituire
il pannello stesso
7. controllare la leggibilità e l'integrità della targhetta identificativa
Unità
ricevente È necessario ogni tre mesi:
1. rimuovere la polvere o accumuli di altro materiale dall'unità ricevente: per pulire
non usare mai solventi o prodotti infiammabili/corrosivi e non utilizzare idropulitrici
ad alta pressione o apparecchi a vapore.
2. controllare che l'unità ricevente sia strutturalmente integra.
3. verificare l’integrità e la connessione del cablaggio interno all’unità ricevente
4. verificare che i simboli del pannello siano ben visibili ed eventualmente sostituire
il pannello stesso
5. controllare la leggibilità e l'integrità della targhetta identificativa
Funzionalità
elettrica È necessario ogni 6 mesi:
1. verificare il corretto funzionamento dei contatti di tutti i relè dell'unità ricevente,
controllando la chiusura del contatto all'attivazione della corrispondente manovra e
apertura del contatto alla disattivazione della manovra
2. verificare la corretta corrispondenza tra comandi inviati e manovre eseguite.
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Conduttori
elettrici È necessario ogni 12 mesi:
esterni 1. verificare l'integrità del cavo di collegamento tra unità ricevente e macchina in tutta
la tua lunghezza.
2. verificare l’integrità e il collegamento delle spine e delle prese di collegamento
3. verificare ed eventualmente sostituire le fascette o altri sistemi di fissaggio
4. verificare che la guaina del cavo di collegamento non presenti deterioramenti, so-
prattutto in corrispondenza dei pressacavi
5. verificare l’integrità della spine e delle prese di collegamento.
7 AVVERTENZE PER LA MANUTENZIONE STRAORDINARIA

Durante tutte le operazioni di manutenzione straordinaria del radio-
comando e della macchina, togliere la batteria dall’unità trasmitten-
te e sconnettere la spina di collegamento dall’unità ricevente.
.
Eventuali guasti possono esclusivamente essere riparati da perso-
nale autorizzato (interpellare il Servizio Assistenza), utilizzando
soltanto pezzi di ricambio originali Autec.
Per rendere possibile un intervento più veloce ed efficace, devono essere comunicati
i dati del radiocomando:
- numero di matricola
- data di acquisto (riportata sul certificato di garanzia)
- anomalia riscontrata
- indirizzo e numero di telefono del luogo in cui è utilizzato (e il nome del responsabile
da contattare)
- ditta fornitrice.
Prima di far intervenire i tecnici del Servizio Assistenza, è opportuno aver
letto e capito in tutte le sue parti il presente manuale, verificando di aver
eseguito correttamente tutte le istruzioni riportate.
8 DOCUMENTAZIONE
La documentazione allegata al radiocomando industriale è sempre
composta almeno da:
- manuale d'istruzioni ed avvertenze
- manuale del caricabatterie
- dichiarazione di conformità CE
- certificato di garanzia
- scheda tecnica del radiocomando
- allegato "Limitazioni & Autorizzazioni".
Verificare che siano presenti questi allegati: in caso contrario farne

richiesta ad Autec specificando il numero di matricola del radioco-
mando.
Manuale
d'uso Il presente manuale è parte integrante del radiocomando e delle sue funzioni
di sicurezza ed ha l'obiettivo di fornire le principali indicazioni necessarie all'instal-
lazione, uso e manutenzione del radiocomando.
Tutte le operazioni d'installazione, uso e manutenzione devono tassativa-

mente essere effettuate da personale qualificato e adeguatamente addestra-
to rispetto alle normative e alle leggi di riferimento.
Pertanto, è necessario che il presente manuale sia stato letto e capito in ogni parte
almeno dal proprietario del radiocomando, dall'installatore del radiocomando,
dall'operatore/utilizzatore del radiocomando, dal responsabile ed addetto della manu-
tenzione e dal responsabile ed addetto della sicurezza del cantiere.
Per le istruzioni ed avvertenze relative alla macchina comandata dal radio-
comando, seguire quanto indicato dal costruttore della macchina stessa.
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LIPROMU2
In caso di danneggiamento o smarrimento del presente manuale, chiederne copia ad
Autec specificando il numero di matricola del radiocomando ad esso legato.
Le informazioni contenute nel presente manuale sono soggette a modifiche senza
preavviso e non rappresentano un impegno da parte della ditta Autec. Per nessun mo-
tivo possono essere riprodotte, in qualsiasi forma o mezzo parti del libretto senza il
permesso scritto di Autec srl (inclusa registrazione e fotocopia).
Certificato di
garanzia Le condizioni che regolano la garanzia del radiocomando sono riportate sul "Certifica-
to di Garanzia" contenuto nel presente manuale. Le parti elettroniche con 3 anni
di garanzia sono: MTX_____, MRX_____, RD97_____, RI_____ e CH_____.
Scheda
tecnica La scheda tecnica rappresenta lo schema di cablaggio dell'unità ricevente con la mac-
china. Deve essere compilata e controllata dall'installatore il quale ha la responsabilità
del corretto cablaggio. L'installatore, inoltre, deve firmare la scheda tecnica che deve
sempre rimanere allegata al manuale d'uso (nel caso in cui la si utilizzi per pratiche
amministrative tenerne sempre una copia).
Targhette
identificazioneI dati di identificazione e di omologazione del radiocomando sono riportati su apposite
targhette presente nell’unità trasmittente e ricevente.
Tali targhette NON DEVONO essere né rimosse dalla loro posizione né alte-
rate o rovinate per nessun motivo. La rimozione comporta l'immediata deca-
denza della garanzia.
9 UNITÀ TRASMITTENTE E SUO FUNZIONAMENTO
L A E A attuatori (a joystick o a selettore)
B pulsante di STOP
C pulsante di START / clacson
D chiave d’accensione
H E selettore rpm +/-
F selettore velocità
G batteria
H targhetta d’identificazione
L led di segnalazione (verde e rosso)

D
C G
F
B
Accensione ed
avviamento Accertarsi che la chiave d’accensione sia nella posizione “O”, inserire la
batteria nell’apposita sede senza forzare. Verificare che né il pulsante di
stop né gli attuatori siano azionati.
Girare la chiave d’accensione in posizione “I” e azionare il pulsante di
START fino a quando il led verde inizia a lampeggiare.
L’accensione avviene solo se la batteria è sufficientemente carica e

se tutti gli attuatori sono disinseriti.
Comandi
Si possono far eseguire i comandi alla macchina radiocomandata solo dopo che il col-
legamento radioelettrico tra unità trasmittente e ricevente è avvenuto (segnalato
dall’accensione della spia ENABLE presente nell’unità ricevente (vedere capitolo 10)).
Azionare gli attuatori relativi alle manovre che si intendono comandare.
Tutti i comandi protetti dalla funzione SAFETY sono approvati in categoria 3 secondo
la EN 954 - 1 per la protezione dei movimenti non voluti dalla posizione di riposo
(UMFS - Unintended Movement From Standstill).
Alcuni dei comandi disponibili nell’unità trasmittente sono i seguenti:

Clacson
Con unità trasmittente accesa premendo il pulsante di START, si aziona il clacson/al-
larme della macchina.
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STOP
Per arrestare immediatamente la macchina, premere il pulsante di STOP: l’unità tra-
smittente si spegne automaticamente.
Per riprendere a lavorare, ruotare nel verso indicato il pulsante di STOP e ripetere la
procedura di accensione ed avviamento.
Il pulsante di STOP va utilizzato ogni volta che c’è la necessità di ar-

restare immediatamente la macchina per il verificarsi di una qualun-
que condizione di pericolo.
Il circuito di STOP è approvato in categoria 4 secondo la EN 954 -1.

RPM +/-
Questo selettore ha una doppia funzione:
1) durante il normale funzionamento: serve per aumentare (rpm +) o di-
minuire (rpm -) i giri del motore della macchina
2) durante la fase di taratura REMOTE SET UP: vedere capitolo 11
Selettore
velocità Può essere presente un selettore di velocità che serve a far funzionare la macchina a
velocità diverse a seconda delle necessità lavorative. Esso può essere a due, tre o
quattro posizioni che abilitano rispettivamente due, tre e quattro livelli di velocità.
Cambio
frequenza In caso di interferenza o di conflitto con altri impianti radio, è possibile cambiare la
frequenza radio a cui si lavora.
Con unità trasmittente accesa ed avviata, occorre mantenere azionato il pulsante di
START per 5-6 secondi: un prolungato bip accompagnato dall’accensione di entrambi
i led di segnalazione indicherà l’avvenuto cambio di frequenza. Durante questa ope-
razione l’unità ricevente si spegne: per riprendere a lavorare premere nuovamente il
pulsante di START come una normale operazione di avviamento.
Segnalazioni
led Alcune condizioni di funzionamento dell’unità trasmittente vengono evidenziate da
due led di segnalazione (uno di colore verde e uno di colore rosso).
Tipo di Led
segnalazione
verde rosso
Lampeggio funzionamento /
lento normale
Avviso che Avviso che
Lampeggio veloce la batteria è quasi la batteria
scarica è scarica
Luce Comando inserito
continua / durante
all’avviamento * l’avviamento
Luce continua e simul- Cambio frequenza
tanea di entrambi i led avvenuto
* accompagnata da un segnale acustico
Quando la batteria ha erogato circa il 90% della sua carica, il led verde aumenta la
velocità di lampeggio per preavvisare che occorre provvedere alla ricarica. Se si con-
tinua ad utilizzare il radiocomando, circa 3 minuti prima che la batteria esaurisca la
sua carica, il led rosso inizia a lampeggiare e contemporaneamente interviene un av-
visatore acustico. In presenza di questa situazione portare immediatamente la mac-
china in stato di sicurezza, spegnere l’unità trasmittente e mettere in ricarica la
batteria (o sostituirla con una già carica).
Spegnimento
Girare la chiave d’accensione in posizione “O”.
Ricordarsi di estrarre sempre la chiave d’accensione e di riporla in un luogo sicuro.
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Spegnimento
automatico Lo spegnimento dell’unità trasmittente può anche avvenire automaticamente quan-
do:
- la batteria non è sufficientemente carica e/o
- il radiocomando non viene utilizzato da circa 3 minuti e mezzo (la funzione di auto-
spegnimento può essere disabilitata rivolgendosi a personale autorizzato Autec).
Ricarica della
batteria Togliere la batteria dell’unità trasmittente ed inserirla nell’apposita sede del carica-
batterie.
La ricarica in corso viene segnalata dall’accensione della spia “ON CHARGING”. La fine
carica viene segnalata dall’accensione della spia “END OF CHARGE”.
La ricarica della batteria deve avvenire con una temperatura ambiente compresa fra
+5°C e +45°C.
Per tutte le istruzioni, le avvertenze e i dati tecnici delle batterie e

del caricabatterie vedere il relativo libretto fornito.
10 UNITÀ RICEVENTE
A
P
G G
B B
C C
F L
M
N
G G
A antenna B spia POWER
B spia POWER C spia ENABLE
C spia ENABLE H modulo RI97-08
D spina di collegamento L fusibile F1
E targhetta identifitiva M fusibile F2
F targhetta dati tecnici N fusibile F3
G viti di chiusura P led interni
Segnalazioni
esterne La spia POWER indica la presenza (se accesa) o meno (se spenta) di alimentazione
nell’unità ricevente.
La spia ENABLE indica l’avvenuto collegamento (se accesa) o la mancanza di collega-
mento (se spenta) tra l’unità trasmittente e l’unità ricevente.
Pertanto, con unità ricevente alimentata, il corretto funzionamento è segnalato da:
- POWER e ENABLE accese fisse, con unità trasmittente avviata
- POWER accesa fissa ed ENABLE spenta, con unità trasmittente non avviata.
LIPROMU2
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Segnalazioni
interne I led presenti visualizzano l’avvenuto inserimento di un relè: quando un led si accende
indica che è attivato il relativo relè al comando riportato nel seguente schema (pre-
sente anche nel lato interno del coperchio dell’unità ricevente):
SAFETY
Per proteggere il sistema dai movimenti involontari dovuti ad eventuali guasti del ra-
diocomando, il radiocomando è dotato di una funzione di sicurezza chiamata SAFETY.
Tale funzione controlla costantemente la posizione di riposo (neutra) degli attuatori
di movimento nell’unità trasmittente ed è disponibile in uscita sul relè di SAFETY
nell’unità ricevente.
FLOW
Azionando un comando di movimento, si attiva anche la funzione di FLOW: essa co-
manda l’elettrovalvola che mette in pressione l’olio nel circuito idraulico primario del
distributore
T.S.
Il T.S. (TIMED STOP) è il comando che spegne il motore diesel della macchina: esso
rimane attivato per 10 secondi dopo l’attivazione del pulsante di STOP.
Fusibili
I tre fusibili presenti all’interno dell’unità ricevente hanno le seguenti caratteristiche:
Fusibile Funzione Caratteristiche tecniche
F1 protezione del POWER SUPPLY 4A (32Vdc, autofuse)
F2 protezione del circuito di STOP 10A (32Vdc, autofuse)
F3 protezione del circuito di SAFETY 10A (32Vdc, autofuse)
11 PROCEDURA DI TARATURA USCITE PROPORZIONALI

(REMOTE SET UP)
La procedura di taratura delle uscite proporzionali deve essere ese-
guita solo da personale qualificato ed addestrato e deve essere effet-
tuata rispettando tutte le avvertenze presenti nei capitoli 4, 5, 6 e 7.
Informazioni
sul modulo Le uscite proporzionali del modulo RI97-08____ sono tarate ai valori riportati nella
RI97-08 scheda tecnica. Il numero della scheda tecnica relativa al radiocomando viene ripor-
tato nell’etichetta presente sulla memoria dati (K2)).
C3 C1 C2 S L P
C1 connettore per le uscite proporzionali
C2 connettore per le uscite proporzionali ausiliare
C3 connettore per l’alimentazione
C4 connettore per la chiave di taratura
C5 connettore per il collegamento alla scheda bus
L led verde
K1 chiave di taratura
K2 memoria dati
P pulsante di ripristino taratura iniziali
C5 C4 K1 K2 S selettore rotativo
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Non lasciare mai inserita la chiave di taratura K1 durante il funzio-
namento del radiocomando: essa è necessaria solo durante la fase
di taratura e, quando inserita, abilita soltanto un comando propor-
zionale alla volta.
Per ripristinare i valori delle uscite proporzionali iniziali (cioè quelli indicati nella sche-
da tecnica), inserire la chiave di taratura e premere il pulsante di ripristino P finché il
led verde L smette di lampeggiare assumendo la segnalazione di luce continua.
Nel caso di sostituzione del modulo, per mantenere gli stessi valori presenti nelle usci-
te proporzionali, spostare la memoria dati K2 dal modulo vecchio a quello nuovo.
Preparazione
alla taratura 1. Assicurarsi che l’unità trasmittente sia spenta.
2. Togliere l’alimentazione all’unità ricevente.
3. Aprire l’unità ricevente ed inserire la chiave di taratura K1 nel connettore C4.
4. Fornire alimentazione all’unità ricevente. ATTENZIONE: Da questo momento, fino
alla fine della taratura non toccare l’unità ricevente (si rischia di perdere i settaggi
impostati)
5. Nell’unità trasmittente girare la chiave di accensione nella posizione “I” e premere
il pulsante di START.
6. Girare la chiave d’accensione nella posizione “ “ (REMOTE SET UP).
Taratura
7. Selezionare i parametri da tarare mediante il selettore rotativo S presente nel modulo
RI97-08: impostare la taratura agendo nel selettore RPM+/- presente nell’unità trasmit-
tente (dove il + serve ad aumentare il valore che si sta tarando e il - a diminuirlo).
Nei moduli con uscite in tensione sono possibili le tarature nelle po-
sizioni 1, 2, 3, 4 e 5. Nei moduli con uscite in corrente (PWM) sono
possibili le tarature nelle posizioni 0, 1, 3 e 4
Durante la taratura, muovendo il joystick fuori dalla posizione di ri-

poso, un colpo di clacson/allarme di circa 0,5 secondi segnala che si
è in zona di taratura del minimo.
Le tarature vanno eseguite per ogni singola posizione del selettore

di velocità presente nell’unità trasmittente.
Tarature nei
moduli con Posizione 1: minimi e massimi Z2-Z7
uscite in ten- Con il selettore rotativo S in posizione 1 si regolano il valore massimo e minimo di
sione tensione dei due semiassi di ogni joystick. Procedere come di seguito:
1. Per fissare il valore massimo, portare il joystick alla massima escursione sul se-
miasse da tarare. Mantenendo questa posizione, agire sul selettore RPM+/- presente
nell’unità trasmittente e impostare il valore desiderato.
2. Per fissare il valore minimo, portare il joystick immediatamente fuori dalla posizio-
ne di riposo sul semiasse da tarare. Mantenendo questa posizione, agire sul selettore
RPM+/- presente nell’unità trasmittente e impostare il valore desiderato.
Posizione 2: tensione della posizione di riposo del joystick
Con il selettore rotativo S in posizione 2 si regola il valore della tensione corrispon-
dente alla posizione di riposo del joystick. Normalmente questo valore non dovrebbe
essere modificato. Se necessario, procedere come di seguito:
- portare un joystick qualsiasi immediatamente fuori dalla posizione di riposo
- mantenendo tale posizione, agire sul selettore RPM+/- presente nell’unità trasmit-
tente e impostare il valore desiderato.
Posizioni 3 e 4: minimi e massimi Z8 e Z9
Con il selettore rotativo S in posizione 3 e 4 si regolano i valori minimo e massimo di
tensione rispettivamente delle uscite ausiliarie Z8 e Z9. Procedere come di seguito:
1. Per fissare il valore massimo, ruotare la manopola (presente nell’unità trasmitten-
te) relativa al comando Z8 (o Z9) completamente in senso orario. Mantenendo questa
posizione, agire sul selettore RPM+/- presente nell’unità trasmittente e impostare il
valore desiderato.
2. Per fissare il valore minimo, ruotare la manopola (presente nell’unità trasmittente)
relativa al comando Z8 (o Z9) completamente in senso antiorario. Mantenendo questa
valore desiderato.
Posizione 5: inversione dei semiassi
Con il selettore rotativo S in posizione 5 si inverte la direzione dei semiassi. Procedere
come di seguito:
LIPROMU2
- 13 - Italiano
- portare il joystick relativo all’asse da invertire immediatamente fuori dalla posizione
di riposo
- mantenendo questa posizione, agire sul selettore RPM+/- presente nell’unità tra-
smittente spostandola nella posizione + per invertire la direzione dei semiassi o nella
posizione - per ripristinare la direzione dei semiassi.
Taratura nei
moduli con Posizione 0: frequenza del segnale PWM
uscite in cor- Con il selettore rotativo S in posizione 0, si regola la frequenza del segnale PWM (cor-
rente (PWM) rente). Normalmente questo valore non dovrebbe essere modificato. Se necessario
procedere come di seguito:
- portare un joystock fuori dalla posizione di riposo;
- mantenendo questa posizione, agire sul selettore RPM+/- presente nell’unità tra-
smittente per modificare il valore desiderato.
Posizione 1: minimi e massimi Z2-Z7
Con il selettore rotativo S in posizione 1 si regolano il valore massimo e minimo del
segnale dei due semiassi di ogni joystick. Procedere come di seguito:
1. Per fissare il valore massimo, portare il joystick alla massima escursione sul se-
miasse da tarare. Mantenendo questa posizione, agire sul selettore RPM+/- presente
nell’unità trasmittente e impostare il valore desiderato.
2. Per fissare il valore minimo, portare il joystick immediatamente fuori dalla posizio-
ne di riposo sul semiasse da tarare. Mantenendo questa posizione, agire sul selettore
RPM+/- presente nell’unità trasmittente e impostare il valore desiderato.
Posizioni 3 e 4: minimi e massimi Z8 e Z9
Con il selettore rotativo S in posizione 3 e 4 si regolano i valori minimo e massimo di
tensione rispettivamente delle uscite ausiliarie Z8 e Z9. Procedere come di seguito:
1. Per fissare il valore massimo, ruotare la manopola (presente nell’unità trasmitten-
te) relativa al comando Z8 (o Z9) completamente in senso orario. Mantenendo questa
valore desiderato
2. Per fissare il valore minimo, ruotare la manopola (presente nell’unità trasmittente)
relativa al comando Z8 (o Z9) completamente in senso antiorario. Mantenendo questa
valore desiderato.
Memorizza-
zione della ta-8. Spegnere l’unità trasmittente per memorizzare le tarature.
ratura 9. Togliere alimentazione all’unità ricevente.
10. Estrarre la chiave di taratura K1.
11. Chiudere l’unità ricevente e fornirle alimentazione.
12 FREQUENZE RADIO
Le frequenze radio programmate nel radiocomando appartengono all’insieme delle
frequenze ammesse dalle normative europee in vigore al momento dell’immissione in
mercato.
Verificare nell’allegato “Limitazioni & Autorizzazioni” eventuali li-

mitazioni esistenti nel paese d’utilizzo del radiocomando.
Un radiocomando può essere programmato in modalità di SCANSIONE AUTOMATICA

o di SELEZIONE MANUALE.
Scansione
automatica Normalmente, un radiocomando viene programmato dal costruttore in questa moda-
lità: può funzionare quindi in una qualunque delle frequenze disponibili. In caso di in-
terferenza o di conflitto con altri impianti, tale modalità consente di spostare la
frequenza di lavoro (vedi “Cambio della frequenza di lavoro”) senza dover intervenire
all’interno né dell’unità trasmittente né dell’unità ricevente.
Selezione
manuale
Per impostare questa modalità di funzionamento della frequenza ra-
dio di lavoro, contattare esclusivamente personale autorizzato Autec.
Un radiocomando che opera in modalità di selezione manuale consente di lavorare ad

una specifica frequenza. Per impostare questa frequenza occorre settare i dip switch
presenti nel modulo trasmittente e ricevente.
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13 DIAGNOSTICA
Nel caso in cui “radiocomando + macchina” non si avvii, è opportuno controllare se il
problema interessa il radiocomando o la macchina. Perciò prima di qualunque verifica,
collegare il posto comando a cavo: se la macchina non si avvia, il problema interessa
la macchina stessa.
Se invece la macchina si avvia regolarmente solo se azionata da posto comando a ca-
vo, il problema riguarda il radiocomando. In tal caso, effettuare i seguenti controlli.
Diagnostica
unità trasmit- Il led di segnalazione Il led di segnalazione
tente verde è acceso Il led di segnalazione
verde è acceso
con luce rosso è acceso
con luce
intermittente veloce? con luce fissa?
intermittente lenta?
Disattivare gli attua-

Effettuare Inserire una batteria tori e/o il pulsante di
la diagnostica sicuramente carica. STOP eventualmente
dell’unità ricevente.
inseriti.
Se l’unità trasmittente
non si accende in modo
corretto, CHIAMA-
RE ASSISTENZA
Diagnostica
unità riceven- La spina di collegamen- Agganciare corretta-
te La spia mente la spina di col-
to tra unità ricevente e
POWER legamento ed avviare
macchina è connessa
è accesa? il radiocomando.
correttamente?
Togliere tensione Sostituire il fusibile.

all’unità ricevente ed Controllare
aprirla. Il fusibile F1 è i collegamenti
integro? d’alimentazione.
CHIAMARE Ridare tensione

ed avviare
ASSISTENZA
il radiocomando.
La spia Effettuare la proce-

ENABLE deura di cambio fre-
è accesa? quenza. La macchina
si avvia?
Togliere tensione Sostituire i fusibili.

all’unità ricevente e Ridare tensione
aprirla. I fusibili F2- ed avviare
F3 sono integri? il radiocomando.
CHIAMARE
ASSISTENZA
LIPROMU2
- 15 - Italiano
14 DATI TECNICI
Generali
Frequenza di lavoro ...................................................... 433.050 - 434.790 MHz
............................................................................................ 869.7 - 870 MHz
Canali radio utilizzabili a 433 MHz ................................................................. 64
Canali radio utilizzabili a 870 MHz ................................................................. 12
Canalizzazione utilizzata ......................................... 25 kHz (opzionale 12.5 kHz)
Distanza di Hamming ................................................................................. 8
Probabilità di mancanza rilevazione errore .............................................. <10-11
Raggio di azione tipico .......................................................................... 150 m
Tempo di emergenza passiva .......................................................... 0.5/1.5 sec
Tempo di risposta dei comandi ....................................................... 70 - 120 ms
Tempo di risposta dello STOP ......................................................... 70 - 120 ms
Categoria funzioni di sicurezza secondo la EN 954 - 1

Protezione dello STOP ........................................................................... Cat. 4
Protezione dei movimenti non voluti dalla posizione di riposo degli attuatori ..... Cat.3
Unità
trasmittente Numero comandi disponibili ..................... 6+2 analogici+12 on/off + start + stop
Antenna ............................................................................................. interna
Tipo di modulazione ............................................................................... GFSK
Potenza a 433 MHz............................................................................. <10 mW
Potenza a 870 MHz.............................................................................. < 5 mW
Alimentazione: pacco batteria .............................................. NiMH 7.2V - 1.3 Ah
Tensione di spegnimento ........................................................................ 6.0 V
Autonomia con batteria carica (a 20°C) ........................................... circa 10 ore
Tempo preavviso batteria quasi scarica .......................................... circa 15 min.
Tempo preavviso batteria scarica .................................................... circa 3 min.
Temperatura di lavoro ......................................................... (-20°C) - (+55°C)
Custodia ..................................................................................... PA6 fg 20%
Grado di protezione ................................................................................. IP65
Dimensioni ........................................................................ (236x160x173) mm
Peso (con batteria) .................................................................................. 2 kg
Unità
ricevente Tensione di alimentazione ................................................... 8 - 30 Vdc (< 40W)
Antenna ................................................................................... a stilo esterna
Portata contatti del relè STOP e SAFETY ........................................ 10 A (30 Vdc)
Portata contatti dei relè dei comandi di movimento .......................... 4 A (30 Vdc)
Portata contatti dei relè dei comandi di selezione ............................. 6 A (30 Vdc)
Sensibilità ricevitore ..................................................... 0,5µV per 20 dB SINAD
Temperatura di lavoro ......................................................... (-20°C) - (+70°C)
Custodia ..................................................................................... PA6 fg 20%
Grado di protezione ................................................................................. IP65
Dimensioni ......................................................................... (180x230x95) mm
Peso ................................................................................................... 2.8 kg
Dima di foratura .......................................................................... A = 148 mm
B = 116 mm
C = 253 mm
D = 253 mm
Caricabatte-
rie e batterie Dati tecnici riportati su apposito libretto
- 16 -
LIPROMU2
1 CONVENTIONS
Any pieces of text written in bold should be read very carefully.
This symbol highlights extremely important indications and information whi-

ch, if not observed, can create seriously dangerous situations for people or
things.
This symbol highlights all important indications and information that deal
with operation.
2 CONFORMITY
The C26 PRO series PRO-M radio remote control is in conformity with the
R&TTE 99/05/EC Directive and its essential requirements.
The radio remote control is also in conformity with the norms given in the EC confor-
mity declaration that is included in this manual.
In Technical Data (see chapter 14) there are the characteristics of safety functions
according with EN 954-1.
It should be remembered that in some countries rules which control

the use and/or possession of a radio remote control must be res-
pected (see the enclosed "Limitations & Authorisations").
Some national limitations may be present for the use of frequencies

which have not yet been harmonised in European countries. Before
using the radio remote control, verify that it works in a frequency
band which is allowed by national radiocommunication laws.
As required by the Machines Directive and relative harmonised standards, all machi-
nes must undergo a risk analysis; therefore it is necessary to evaluate, within the li-
mits of this analysis, if the machine can be radio remote controlled.
The machine producer and/or the person who decides upon radio remote control use
and installation is responsible for this analysis.
Autec cannot be held responsible if the risk analysis is not carried out cor-
rectly and if the radio remote control is installed on applications that are dif-
ferent from those permitted:
PERMITTED APPLICATIONS:
Hoisting and moving machines installed exclusively on vehicles that
use a battery as electrical power supply source (for example:
hydraulic cranes, concrete pumps . . .)
FORBIDDEN APPLICATIONS
- machines installed in areas where equipment with explosion-proof
characteristics are being used
- AC supplied machines
- machines using a DC supply that does not come from a battery
- machines where risk analysis regarding verification of radio remo-
te control conformity to the application is not possible or has given
a negative or uncertain result.
To guarantee correct radio remote control operation, all current regulations regarding
safety at work and accident prevention should be respected. All current user country
national laws regarding the use of both the machine and the radio remote control
MUST ALWAYS be respected.
Autec cannot be held responsible if the radio remote control is used in un-
lawful working conditions.
LIPROMU2
- 17 - English
3 RADIO REMOTE CONTROL DESCRIPTION
Industrial radio remote controls are used to

command machines from a distance. Each in-
dustrial radio remote control is made up of a
portable transmitting unit, from which the user
can remotely control the machine, and a recei-
ving unit installed on board the machine itself.
The transmitting unit sends a coded message

over radio frequency transmission. This mes-
sage contains a value called address, which lets Receiving
the receiving unit decode only the messages unit
coming from its own transmitting unit (the one
that has the same address).
This ensures that no interference can activate
any command. If the radio frequency transmis- Transmitting
sion is disturbed, incorrect or interrupted, the unit
receiving unit autonomously stops the whole
system.
4 WARNINGS REGARDING INSTALLATION

Installation must only be carried out by qualified people and in ac-
cordance with installation country rules. Only a correct installation
can ensure the necessary level of safety during subsequent radio re-
mote control use.
General
indications Respect the machine operational characteristics when connecting the Radio remote
control. The safety circuits on the radio remote control and/or present on the
machine should not be bypassed (or excluded).
The receiving unit wiring can be configured very easily, therefore it can be installed
without having to modify the machine. Do not modify the machine electric panel
without the machine manufacturer authorisation.
Disconnect the receiving unit by detaching all the electrical connec-

tions each time the machine is welded.
Installation
The receiving unit must be placed in a position that favours reception of the
signals issued by the transmitting unit. It should therefore be assembled verti-
cally (antenna upwards). The receiving unit should also be easily accessible to permit
working in safe conditions.
If the receiving unit is covered by metal structures or installed inside metal panels,
use the relative extension kit for external antennas.
The antenna must never come into contact with metal parts.
It is forbidden to pierce the receiving unit container. Doing so compromises

the protection degree against external agents (level IP65).
The vehicle creates vibrations, therefore antivibration blocks must always be used to
reduce the effect that these vibrations have on the receiving unit.
The receiving unit must be positioned away from heat sources (exhaust pipes, alter-
nators, etc.)
Wiring
Most machines are connected to the receiving unit by multiple-pole plugs which let
the radio remote control be disconnected quickly whenever necessary and replaced
by a cable command. This connecting technique is advisable even if the machine is
not originally equipped for it.
- 18 -
LIPROMU2
The reliability of the installation is largely dependent on the quality of the wiring, and
connections should therefore be made to the highest standards using multi-core or
single-core cables of suitable cross-sectional area for the current to be carried. Ca-
bles should also be flame retardant (for futher information refer to EN 60204 - 1).
Cables with anti-oil protection should be used for connections external to the re-
ceiving unit.
The receiving unit power supply must pass through a switch to per-
mit power disconnection during installation, wiring and/or mainte-
nance operations.
To improve radio remote control operation, connect the receiving
unit immediately downstream of the machine main switch.
It is always advisable to check the supply voltage even under maximum load; in this
way the maximum variations can be verified (the limit values of tolerated deviation
are given both in the Technical Data and on the technical card of the Radio remote
control).
Receiving unit supply voltage fluctuations that exceed the limit va-
lues can compromise regular radio remote control operation.
The C26-PRO series radio remote controls are equipped with circuits that protect
against involuntary movements from the actuator rest position (SAFETY function).
This protection is available if the movement commands common of the receiving unit
is in serial with the STOP contact and SAFETY contact (which close when a movement
command is transmitted). On the contrary, the selection command common can not
be in series with the SAFETY contact.
Example of
wiring
Proportional
output Autec supplies the radio remote control with the proportional ou-
setting tput values already set depending on type of valves. During instal-
lation, these values must be verified and, if necessary, modified
according to how the machine is to user’s working preference (see
chapter 11).
Testing
When installation and wiring have been completed, always do the following:
- make sure that when the radio remote control STOP pushbutton is pressed the ma-
chine goes into a situation of safety (through direct action on the general solenoid
valve of the main circuit), the motor possibly switches off and, if present, the
main line contactor opens to remove voltage.
- make sure that the manoeuvres carried out by the machine and which have been
commanded by the transmitting unit correspond exactly (this correspondence is gi-
ven in the technical data sheet)
- check safety circuit operation (a simple way of doing this is to remove fuse F3,
housed on the main board of the Receiving Unit. Make sure that in these conditions
no movement command can be carried out, then insert the F3 fuse again and check
correct operation)
The installer must also compile and/or verify the two copies of the technical
data sheet, where the wiring layout between the receiving unit and the ma-
chine is given. The first copy of the technical card is inside the receiving unit,
the second is annexed to the user's manual. The installer must put the date
of installation, the sign and the stamp on both copies.
LIPROMU2
- 19 - English
5 WARNINGS REGARDING USE
The radio remote control can only be used by operators who:
- have read and understood this manual,
- are qualified and trained,
- know the "radio remote control + machine" system well.
Autec cannot be held responsible if the radio remote control is in-

stalled on applications other than those permitted and if used in ir-
regular working conditions.
Each time the transmitting unit is powered, make sure that the
STOP pushbutton operates correctly and that, when pressed, machi-
ne movement is interrupted instantly.
If it doesn’t happen, do not use the radio remote control.
The operator should always control that both units are whole and
that the gaskets, bellows and hoods of the actuators (joysticks, se-
lectors, pushbutton) are whole. If not, the radio remote control mu-
stn’t be used before being repaired.
To work efficiently and to prevent possible emergency situations, it

is necessary to select a position from where it is possible to:
- remain inside the typical working range of the radio remote control
(see chapter 14)
- visibly follow the machine, its movements and a possible load at
all times.
During
operation The operator must:
- switch off the transmitting unit each time work is stopped
- NEVER leave the transmitting unit unattended with the starting
key inserted
- avoid working if the battery is almost flat.
The operator should never switch on or activate the transmitting

unit unless ready to start working. A radio link can be created even
outside the active range and from enclosed places, making the radio
remote controlled machine carry out undesired commands.
In case of
danger If a danger situation arises, the operator must intervent immedia-
tely by pressing the STOP button, which instantly interrupts machi-
ne movement.
As not all dangers are caused by the “radio remote control + machi-
ne” system, the operator should be careful even when emercency
situations are present in the work area. The operator should, also in
this case, intervene manually by activating the STOP command.
In case of
fault In case of faults or damaged parts, ALWAYS STOP the “radio remote
control + machine” system until the problem has been solved.
Any damaged part can ONLY be replaced by authorised Autec per-
sonnel and only using original Autec spare parts.
6 WARNINGS REGARDING ROUTINE MAINTENANCE

While carrying out routine and special maintenance on the radio re-
mote control and the machine, remove the battery from the tran-
smitting unit and disconnect the connection plug from the receiving
unit.
All control and maintenance interventions carried out on the radio remote control
must be verified and recorded by the person in charge of carrying out maintenance
on the machine.
- 20 -
LIPROMU2
According to the indications given in this manual, routine mainte-
nance is fundamental for using the radio remote control safely.
After each maintenance intervention, always make sure that only

the expected manoeuvres are carried out when the relative com-
mands are sent by the transmitting unit.
Prescriptions
summary The prescriptions that follow should be considered as the minimum necessary for safe
and correct radio remote control operation.
Special applications may need more specific routine maintenance interventions to be
carried out at different periods.
These indications can never become a contract, replace regulations and laws regar-
ding safety at work and limit the responsibilities of the purchaser and user of the radio
remote control.
All the mentioned prescriptions must be carried out each time the machine
and the radio remote control put into service.
Component Interval
Daily Every 3 Every 6 Every 12
months months months
Transmitting unit X
Receiving unit X
Electrical operation X
External electric conductors X
If irregularities are noted while carrying out routine maintenance,

put the "machine+radio remote control" system out of order, fol-
lowing the indications given (see chapter 7).
Transmitting
unit The following must be done daily:
1. remove dust or accumulations of other material from the transmitting unit. Never
use solvents or flammable/corrosive materials to clean, and do not use high pressure
water cleaners or steam cleaners.
2. store the transmitting unit in clean and dry areas.
3. make sure that the transmitting unit gaskets, joystick bellows, selectors caps and
pushbuttons are intact, soft and elastic
4. make sure that the battery seat and the battery contacts are always clean
5. make sure that the transmitting unit are structurally integral
6. make sure that the panel symbols can be easily recognised. If necessary, replace the
panel.
7. check identification plate readability and integrity
Receiving
unit The following must be done every 3 months:
1. remove dust or accumulations of other material from the receiving unit. Never use
solvents or flammable/corrosive materials to clean, and do not use high pressure wa-
ter cleaners or steam cleaners.
2. make sure that the receiving unit are structurally integral
3. verify the integrity and connection of the internal wiring to the receiving unit
4. make sue that the panel symbols can be easily seen. If necessary, replace the panel.
5. check identification plate readability and integrity
Electrical
operation The following must be done every 6 months:
1. make sure that all the relay contacts of the receiving unit operate correctly, con-
trolling contact closing when the corresponding manoeuvre is enabled and contact
opening when the manoeuvre is disabled.
2. verify the correct correspondence between the commands that are sent and the
manoeuvres that are carried out.
External
electric The following must be done every 12 months:
conductors 1. verify integrity along the full length of the cable which connects the receiving unit
to the machine.
2. verify the integrity and the electrical connection of the plugs and the connection socket
LIPROMU2
- 21 - English
3. verify and if necessary replace the strips or other fixing systems
4. make sure that the connecting cable has not deteriorated, above all near the cable
entry
5. verify the integrity of the plugs and the connection sockets
7 WARNINGS REGARDING SPECIAL MAINTENANCE

While carrying out special maintenance on the radio remote control
and the machine, remove the battery from the transmitting unit and
disconnect the connecting plug from the receiving unit.
.
Any fault should be repaired by authorised Autec personnel (contact
Service), using original Autec spare parts only.
The following radio remote control data must be communicated in order to make in-
terventions faster and more reliable:
- serial number
- purchase date (given on the guarantee certificate)
- problem found
- address and telephone number of the place where the device is being used (with the
name of the person to contact)
- supplier.
It is better to have read and understood all parts of this manual, and made
sure that all the instructions it contains have been followed correctly before
contacting the Service technicians.
8 DOCUMENTATION
The minimum documentation indicated below is always supplied
with the industrial radio remote control:
- instruction and warnings manual
- battery charger manual
- a CE conformity declaration
- a guarantee certificate
- the radio remote control technical data sheet
- the enclosed “Limitations & Authorisations”.
Make sure that these documents are present. If they are not, please
please ask them to Autec, specifying the radio remote control serial
number.
Instruction
and warnings This manual is an integral part of the radio remote control and its safety functions and
manual gives the main information necessary for installing, using and carrying out mainte-
nance on the radio remote control.
All installation, usage and maintenance operations must be carried out

exclusively by qualified technicians who are suitably trained in relevant nor-
ms and laws.
At least the radio remote control owner, installer, user and the person in charge of its
maintenance must therefore read and understand each part of this manual.
Follow the instructions and warnings given by the machine producer regar-
ding the machine controlled by the radio remote control.
If this manual is lost or damaged, ask for a copy from Autec. Please specify the serial
number of the relative radio remote control.
The information contained in this manual is subject to modification without notice and
is not binding.
No parts of this manual may be reproduced by any means without the written per-
mission of Autec (including recording and photocopying).
- 22 -
LIPROMU2
Warrantly
The conditions of warranty applicable to the radio remote control are specified in the
"Warranty Certificate" in the manual.
The electronic components which have a 3 year guarantee are: MTX_____,
MRX_____, RD97____, RI97____ and CH97____.
Technical
data sheet The technical data sheet shows the wiring system between the receiving unit and the
machine. It should be filled out and checked by the installer, who has the responsi-
bility of a correct wiring.
Once all necessary checks have taken place the installer must undersign the technical
data sheet, which must be kept with the user's manual (always keep a copy of this
data sheet in case it could be required).
Identification
plates The radio remote control identification data are written on a technical data plate both
on the transmitting unit and on the receiving unit.
The plates MUST NOT be removed from where they are placed or damaged.
In this case, the warranty will be forfeited.
9 TRANSMITTING UNIT AND HOW IT WORKS
A E
L A actuators (joystick or selector)
B STOP push button
C START / clacson push putton
D starting key
H E selector rpm +/-
F speed selector
G battery
H identification plate
L two signalling leds (green and red)

D
C
F G
Power on and
starting Check that the starting key is in position “O”, insert the battery in its hou-
sing without force. Check that the STOP push button has not been pressed
and that none of the actuactors have been out of neutral position.
Turn the key to “I” and activate START push button and release it when
the green light starts to flash.
The transmitting unit only switches on if the battery is charged

enough and if all the actuators are inactive.
Commands
It is possible to control the radio remote machine only after the transmitting unit has
been radio linked to the receiving unit (signalled by the lighting up of the ENABLE pilot
light on the receiving unit (see chapter 10)).
Activate the actuators that carry out the moves to be made.
All commands protected by the SAFETY function are approved category 3 of EN 954
- 1 against the undesired movements when in the standstill position (UMFS - Unin-
tended Movement From Standstill).
Some transmitting unit commands are given below:

Clacson
With the transmitting unit switched on, press the START pushbutton: the machine
horn/alarm activates.
LIPROMU2
- 23 - English
STOP
To immediately stop the machine, press the STOP pushbutton: the transmitting unit
switches off automatically.
To start working again, rotate the STOP button in the direction indicated and repeat
the power on and starting procedures.
The STOP pushbutton must be used each time the machine has to be
stopped immediately because of a danger situation.
The STOP circuit is approved in category 4 according to the EN 954 -1.

RPM +/-
This selector works in two ways:
1) during normal operation: increases (rpm +) or decreases (rpm -) the
machine motor turns
2) during the setting up phase REMOTE SET UP: see chapter 11
Speed
selector A speed selector may be present, which makes the machine operate at different spe-
eds as necessary. This selector can have two, three or four positions which respec-
tively activate two, three or four speed levels.
Frequency
change In case of interference or conflict with other radio systems, it is possible to change
the radio frequency being used.
With the transmitting unit powered and started, keep the START pushbutton pressed
for 5-6 seconds: a prolonged beep accompanied by the switching on of both signalling
leds indicate that the frequency has changed. During this operation the receiving unit
switches off: press the START pushbutton again to start working normally.
LED
signals
Some transmitting unit operating conditions are signalled by two signalling leds (one
green and one red):
Type Led
of signal
green red
Slow normal /
flashing operation
Warning Warning
Quick flashing that the battery is that the battery
almost not charged is not charged
Continuos Command
light during / operated during
power on * the power on
Both lights steadily Frequency
lit simultaneously * changed
* accompanied by an acoustic signal
When the battery is approximately 90% discharged, the green light will start flashing
at a faster rate to inform the operator that the battery requires recharging. If the ope-
rator continues to use the radio control, approximately 3 minutes before the battery
is fully discharged, the red light will start flashing and an acoustic alarm will sound.
In this situation, the operator must return the machine to a condition of safety (by
pressing the stop button), switch off the transmitting unit, and recharge the battery
or fit a fully charged battery.
Power off
Turn the ignition key to "O".
Always remember to extract the starting key and put it in a safe place.
- 24 -
LIPROMU2
Automatic
power off The transmitting unit can switch off automatically when:
- the battery is not charged enough and/or
- the radio remote control has not been used for 3 and a half minutes (to deactivate
automatic switching off, please contact Autec authorised personnel).
Recharging
the battery Remove the battery from the transmitting unit and insert in the battery charger.
The "ON CHARGING" light will illuminate to indicate that the battery is being charged.
Once the battery is fully charged, the "END OF CHARGE" light will illuminate. Battery
charging should be performed at an ambient temperature within the range +5°C to
+45°C.
See the supplied booklet for all instructions, warnings and technical
data regarding the batteries and the battery changer.
10 RECEIVING UNIT
A
P
G G
B B
C C
F L
M
N
G G
A antenna B POWER light
B POWER light C ENABLE light
C ENABLE light H RI97-08 module
D connection plug L fuse F1
E identification plate M fuse F2
F technical data plate N fuse F3
G closing screws P internal led
External
signalling The POWER light indicates the presence (on) or not (off) of the power supply in the
receiving unit
The ENABLE light indicates that the connection between the transmitting unit and the
receiving unit is enabled (on) or disabled (off).
When the receiving unit is powered, proper operation is indicated when :
- POWER and ENABLE lights on, with transmitting unit on;
- POWER light on and ENABLE off, with transmitting unit off.
LIPROMU2
- 25 - English
Internal
signalling The leds that are present show when a relay has activated: when a led switches on,
this means that the relative command relay given in the following drawing (also pre-
sent inside the receiving lid cover) has been activated:
SAFETY
The radio remote control is equipped with a safety function called SAFETY which pro-
tects the system from involuntary movements caused by possible radio remote con-
trol faults.
This function constantly controls the rest position (neutral) of the movement actua-
tors in the transmitting unit and is available on the receiving unit SAFETY relay ou-
tput.
FLOW
Activating a movement command also activates the FLOW function: this commands
the solenoid valve which puts the oil in the hydraulic circuit of the main distributor
under pressure.
T.S.
T.S. (TIMED STOP) is the command that switches off the machine diesel motor: it re-
mains active for 10 seconds after the STOP pushbutton has been pressed.
Fuse
The three fuses inside the receiving unit have the following characteristics:
Fuse Function Technical Data
F1 POWER SUPPLY circuit guard 4A (32Vdc, autofuse)
F2 STOP circuit guard 10A (32Vdc, autofuse)
F3 SAFETY circuit guard 10A (32Vdc, autofuse)
11 PROPORTIONAL OUTPUT SETTING PROCEDURE (REMOTE

SET UP)
The proportional outputs must only be set by qualified and trained
personnel who respect all the warnings given in chapters 4, 5, 6 and
7.
Information
about RI97-08 The proportional outputs of RI97-08____ module are programmed at the values gi-
module ven on the relevant technical data sheet. The identification number of the technical
data sheet for each radio remote control is written on data memory (K2))
C3 C1 C2 S L P
C1 connector for the proportional outputs
C2 connector for the auxiliar proportional outputs
C3 connector for the power supply
C4 connector for the calibration key
C5 connector for the coonection to the bus board
L green led
K1 calibration key
K2 data memory
P initial values reset push button
C5 C4 K1 K2 S rotaty switch
- 26 -
LIPROMU2
Never leave the K1 calibration key inserted during radio remote
control use. The key is only needed during the calibration phase
and, when inserted, only one proportional command can be activa-
ted at a time.
To reset the initial proportional output values (i.e. those given in the technical data
sheet), with calibration key K1 inserted, just keep reset button P pressed until the
green led L stops flashing and remains lit.
To keep the same settings in case of module replacement, move the K2 memory from
the old module to the new one.
Preparation
for setting 1. Make sure that the transmitting unit is switched off.
2. Disconnect the power from the receiving unit.
3. Open the receiving unit and insert the K1 settings key into the C4 connector.
4. Power the receiving unit. ATTENTION: From this moment onwards do not touch
the receiving unit until setting up has been completed (otherwise you risk losing the
settings that have already been set)
5. Turn the transmitting unit ignition key to "I" and press the START pushbutton.
6. Turn the starting key to the " " position (REMOTE SET UP).
Setting
7. Select the parameters to be set using the rotary switch S, which can be found on
the RI97-08 module, and the RPM+/- selector, which is present on the transmitting
unit (+ increases the value being set, - decreases it).
In modules with voltaged outputs it is possible to set positions 1, 2,

3, 4 and 5. In modules with current outputs (PWM) it is possible to
set positions 0, 1, 3 and 4.
If the joystick is moved out of its rest position during setting, the
horn/alarm sounds for 0.5 seconds, indicating that you are in the
minimum setting area.
Each single position of the speed selector present on the transmit-

ting unit must be set.
Setting mo-
dules with Position 1: minimum and maximum Z2-Z7
voltage outputWhen the rotary switch S is at 1, it is possible to regulate the maximum and minimum
voltage values of the two semiaxes of a joystick. Proceed as follows:
1. To set the maximum value, take the joystick to the maximum range of the semiaxis
to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining
same joystick position.
2. To set the minimum value, take the joystick just out of the rest position of the se-
miaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while
maintaining same joystick position.
Position 2: joystick standstill position voltage
When the rotary switch S is at 2 the voltage value which corresponds to the mecha-
nical rest position of the joystick can be regulated. Normally, this value shouldn’t be
modified. Proceed as follows:
- take any joystick out of the rest position
- use the toggle switch RPM +/- to modify the value while maintaining same joystick
position.
Positions 3 e 4: minimum and maximum Z8 and Z9
When the rotary switch S is at 3 and 4, it is possible to regulate the maximum and
minimum voltage values of auxiliary outputs Z8 and Z9 respectively. Proceed as fol-
lows:
1. To set the maximum value, turn the Z8 (or Z9) command knob (present in the
transmitting unit) fully clockwise. Use the toggle switch RPM +/- to modify the value
while maintaining same knob position.
2. To set the minimum value, turn the Z8 (or Z9) command knob (present in the tran-
smitting unit) fully counterclockwise. Use the toggle switch RPM +/- to modify the va-
lue while maintaining same knob position.
Position 5: semi-axis inversion
Semiaxis direction is inverted when the rotary switch S is at 5. Proceed as follows:
- take the joystick of the axis to be inverted out of the rest position
LIPROMU2
- 27 - English
- while maintaining this situation, use the toggle switch RPM +/- on the transmitting
unit. Move it to + in order to invert the semiaxis direction or to - in order to reset
the semiaxis direction.
Setting
modules with Position 0: PWM signal frequency
(PWM) cur- When the rotary switch S is at 0, the PWM (current) signal frequency can be adjusted.
rent outputs Normally this value shouldn’t be modified. If necessary, proceed as follows:
- take one joystick out of the rest position
- use the toggle switch RPM +/- to modify the value while maintaining same joystick
position.
Position 1: minimum and maximum Z2-Z7
When the rotary switch S is at 1, it is possible to regulate the maximum and minimum
voltage (or current) values of the two semiaxes of a joystick. Proceed as follows:
1. To set the maximum value, take the joystick to the maximum range of the semiaxis
to be calibrated. Use the toggle switch RPM +/- to modify the value while maintaining
same joystick position.
2. To set the minimum value, take the joystick just out of the rest position of the se-
miaxis to be calibrated. Use the toggle switch RPM +/- to modify the value while
maintaining same joystick position.
Positions 3 and 4: minimum and maximum Z8 and Z9
When the rotary switch S is at 3 and 4, it is possible to regulate the maximum and
minimum voltage values of auxiliary outputs Z8 and Z9 respectively. Proceed as fol-
lows:
1. To set the maximum value, turn the Z8 (or Z9) command knob (present in the
transmitting unit) fully clockwise. Use the toggle switch RPM +/- to modify the value
while maintaining same knob position.
2. To set the minimum value, turn the Z8 (or Z9) command knob (present in the tran-
smitting unit) fully counterclockwise. Use the toggle switch RPM +/- to modify the va-
lue while maintaining same knob position.
Saving the
setting 8. Switch off the transmitting unit to save the settings.
9. Disconnect power from the receiving unit.
10. Extract the K1 settings key.
11. Close the receiving unit and power it.
12 RADIO FREQUENCIES
The radio frequencies that are programmed in the radio remote control belong to the
frequencies permitted by the European norms that are permitted when the device is
put onto the market.
Check for possible user conutry limitations in “Limitations & Autho-

risations” enclosure.
A radio remote control can be programmed in AUTOMATIC SCAN or MANUAL SELEC-

TION.
Automatic
scan A radio remote control is normally programmed by the producer in the following man-
ner: it can therefore operate in any of the available frequencies. In cases of interfe-
rence or conflict with other systems, the working frequency can be moved (see
paragraph "Frequency change") without having to touch the inside of either the tran-
smitting or the receiving units.
Manual
selection Only contact Autec authorised personnel if the working radio fre-
quency has to be set in this manner.
Using the radio remote control in the manual selection mode makes it possible to
work at a specific frequency. To set this frequency, you must set the dip switches
present in the transmitting and receiving modules.
- 28 -
LIPROMU2
13 DIAGNOSTIC
If the "radio remote control + machine" does not start, you should check if the pro-
blem is caused by the radio remote control or the machine. Before doing anything
else, therefore, connect the wired control station: if the machine does not start, the
problem is caused by the machine.
If the machine starts normally but only if activated by the wired control station, the
problem lies in the radio remote control. In this case, carry out the following controls.
Diagnostic of
transmitting Is the green Is the green
unit signalling LED Is the red
signalling LED
on flashing signalling LED on
on flashing
quickly? with a steady light?
slowly?
Deactivate, if active,
Carry out Insert a battery the actuactor
receiving unit that is charged. and/or the STOP
diagnostic.
pushbutton.
If the transmitting unit

does not switch on cor-
rectly, CALL FOR
ASSISTANCE
Diagnostic of
receiving unit Is the connection plug Correctly insert
Is the POWER the connection plug
between the receiving
light and start the
unit and the machine
on? radio remote control.
connected correctly?
Disconnect
Replace the fuse.
the receiving unit
Check the power
and open it. Is the F1
supply connections.
fuse integral?
Power and restart

CALL FOR the radio
ASSISTANCE remote control.
Is the Carry out the

ENABLE frequency change
light on? procedure. Does the
machine start?
Disconnect Replace the fuse.

the receiving unit and Power and restart
open it. Are the F2-F3 the radio
fuses integral? remote control.
CALL FOR
ASSISTANCE
LIPROMU2
- 29 - English
14 TECHNICAL DATA
General
Frequency range .......................................................... 433.050 - 434.790 MHz
............................................................................................ 869.7 - 870 MHz
Programmable radio channel (433 MHz) ........................................................ 64
Programmable radio channel (870 MHz) ........................................................ 12
Channel spacing .......................................................... 25 kHz (option 12.5 kHz)
Hamming distance ..................................................................................... 8
Probability of non-recognition of error .................................................... <10-11
Typical working range ........................................................................... 150 m
Passive emergency time ................................................................. 0.5/1.5 sec
Time of reply to commands ........................................................... 70 - 120 ms
Time of reply to STOP ................................................................... 70 - 120 ms
Safety function category according to EN 954 - 1

STOP protection ..................................................................................... Cat. 4
Protection against unintended movements from standstill position
of the actuators ..................................................................................... Cat. 3
Transmitting
unit Number of available commands .................... 6+2 analog+12 on/off + start + stop
Antenna ............................................................................................. internal
Type of modulation ................................................................................. GFSK
Transmitting power (433 MHz) .............................................................<10 mW
Transmitting power (870 MHz) ............................................................. < 5 mW
Power supply: battery pack .................................................. NiMH 7.2V - 1.3 Ah
Turn off voltage .................................................................................... 6.0 V
Autonomy with fully charged battery (at 20°C) ............................. about 10 hours
Battery almost discharged prewarning time .................................. about 15 min.
Warning that the battery is discharged ........................................... about 3 min.
Working temperature ........................................................... (-20°C) - (+55°C)
Housing ...................................................................................... PA6 fg 20%
Protection grade ..................................................................................... IP65
Dimensions ...................................................................... (236x160x173) mm
Weight (with battery) .............................................................................. 2 kg
Receiving
unit Power supply ......................................................................8 - 30 Vdc (< 40W)
Antenna .............................................................................................external
Max switching capacity of STOP and SAFETY relay contacts ...............10 A (30 Vdc)
Max switching capacity of movement command relay contacts ........... 4 A (30 Vdc)
Max switching capacity of selection command relay contacts .............. 6 A (30 Vdc)
Sensitivity receiver ........................................................ 0,5µV per 20 dB SINAD
Working temperature ........................................................... (-20°C) - (+70°C)
Housing ....................................................................................... PA6 fg 20%
Protection grade ..................................................................................... IP65
Dimensions .........................................................................(180x230x95) mm
Weight ................................................................................................. 2.8 kg
Drilling template .......................................................................... A = 148 mm
B = 116 mm
C = 253 mm
D = 253 mm
Battery
charger and
battery Technical data inside dedicated booklet
- 30 -
LIPROMU2
1 KONVENTIONEN
Der fettgedruckte Text wird benutzt, wenn man möchte, dass der Text mit
besonderer Aufmerksamkeit gelesen wird.
Dieses Symbol kennzeichnet alle Angaben und Informationen besonderer

Wichtigkeit: Eine Nichtbeachtung dieser wichtigen Informationen verursa-
cht Situationen, die für Personen oder Gegenstände sehr gefährlich sein
können.
Dieses Symbol kennzeichnet alle wichtigen Angaben und Informationen, die

den Betrieb betreffen.
2 KONFORMITÄT
Die Funkfernsteuerung PRO-M der Serie C26 PRO stimmt mit der Vorschrift
R&TTE 99/05/CE und ihren wesentlichen Forderungen überein.
Die Funkfernsteuerung stimmt außerdem mit den Vorschriften der Konformitätse-
rklärung CE überein, die diesem Handbuch beigefügt ist.
Die Eigenschaften der Sicherheitsfunktionen nach der EN 954-1 befinden sich in den
Daten Blatt (siehe Kapitel 14).
Wir erinnern daran, dass man in einigen Ländern Gesetze befolgen muss,
die folgendes regeln den Gebrauch und/oder den Besitz einer Funk-
steuerung (siehe die Anlage "Beschränkungen & Genehmigungen").
Den die Nationalbeschränkungen für die Benutzung der Frequen-

zen, da noch keine harmonisierte Europäischen Arbeitsfrequenzen
existieren. Überprüfen, bevor der Benutzung, dass die Funksteue-
rung mit zugelassen Frequenzen für das Land der Inbetriebnahme
arbeitet.
Wie es von der Maschinenvorschrift und ihren entsprechenden Weisungen vorge-

sehen wird, ist es notwendig, für jede Maschine eine Risikoanalyse durchzuführen:
deshalb muß man im Falle der Verwendung einer Funkfernsteuerung innerhalb dieser
Analyse überprüfen, ob die Maschine ferngesteuert werden kann oder nicht.
Die Verantwortung dieser Analyse liegt beim Hersteller der Maschine und/oder bei
demjenigen, der die Installation und die Verwendung einer Funkfernsteuerung bestimmt.
Autec kann keine Verantwortung übernehmen, falls die Risikoanalyse nicht
korrekt ausgeführt wurde und wenn die Funkfernsteuerung für Anwendun-
gszwecke benutzt wird, die von den vorgesehenen abweichen:
ERLAUBTE ANWENDUNGSBEREICHE:
Hebe- und Transportmaschinen, ausschließlich auf Kraftfahrzeugen
installiert, die ausschließlich durch eine Batterie elektrisch gespeist
werden (zum Beispiel: Ladekrane, Betonpumpen . . .)
NICHT ERLAUBTE ANWENDUNGSBEREICHE

- Maschinen, die in Gegenden installiert sind, die Geräte mit explo-
sionssicheren Eigenschaften voraussetzen
- Maschinen, die mit Wechselstrom gespeist werden
- Maschinen, deren Gleichstromspeisung nicht von einer Batterie
stammt
- Maschinen, bei der die Risikoanalyse zur Überprüfung der Überein-
stimmung der Funkfernsteuerung bei der Anwendung nicht möglich
sein sollte oder ein negatives oder unsicheres Ergebnis erbracht
hat7
Um einen einwandfreien Betrieb der Funkfernsteuerung zu garantieren, müssen stets

alle Vorschriften zur Arbeitssicherheit und Unfallverhütung am Arbeitsplatz beachtet
werden. Außerdem MUß man stets alle geltenden staatlichen Gesetze bezüglich der
Benutzung der Maschine als auch der Funkfernsteuerung im einzelnen Zustand, in
dem das System benutzt wird, beachten.
Autec kann keine Verantwortung übernehmen, falls die Funkfernsteuerung
nicht unter vorschriftsgemäßen Arbeitsbedingungen verwendet wird.
LIPROMU2
- 31 - Deutsch
3 BESCHREIBUNG DER FUNKFERNSTEUERUNG
Die industriellen Funkfernsteuerungen werden be-
nutzt, um Maschinen aus entfernter Position zu
steuern. Jede industrielle Funkfernsteuerung be-
steht aus einer tragbaren Sendeeinheit, von der
der Bediener die Maschine aus Entfernung steuern
kann, sowie aus einer Empfangseinheit, die am
Rand der Maschine angebracht ist. Die Sende-
einheit sendet mittels einer Funkübertragung eine
kodierte Nachricht. In dieser Nachricht ist ein Wert
vorhanden, Adresse (address) genannt, der der
Empfangseinheit ermöglicht, ausschließlich die
Nachrichten zu dekodieren, die von der eigenen Empfängseinheit
Sendeeinheit stammen (die, die dieselbe Adresse
hat). Somit wird verhindert, dass eine Interferenz
einen jeglichen Befehl auslösen kann. Tatsächlich
hält die Empfangseinheit das gesamte System sel-
bst an, falls sich die Funkübertragung als gestört, Sendeeinheit
fehlerhaft oder unterbrochen herausstellen sollte.
4 WARNUNGEN BEI DER INSTALLATION DER FUNKFERN-

STEUERUNG
Die Installation darf ausschließlich von qualifiziertem Personal
gemäß der Bestimmungen des Landes, in dem sie vollzogen wird,
ausgeführt werden. Nur eine korrekte Installation kann den
notwendigen Sicherheitsgrad während des darauffolgenden Ge-
brauchs der Funkfernsteuerung garantieren.
Allgemeine
Angaben Man sollte die Funkfernsteuerung an die Maschine anschließen, indem man die Be-
triebseigenschaften derselben beachtet: man sollte die auf der Funkfernsteue-
rung vorgesehenen und/oder auf der Maschine vorhandenen Sicherheits-
schaltungen nicht ausschalten.
Die einfache Gestaltungsweise der Verkabelung der Empfangseinheit ermöglicht eine

Installation, ohne dabei die Maschine einbeziehen zu müssen: die Schalttafel der Ma-
schine darf ohne Genehmigung des Konstrukteurs nicht verändert werden.
Die Speisung muss jedesmal unterbrochen werden, wenn man auf

der Maschine schweißt, indem man alle elektrischen Anschlüsse
trennt.
Installation
Die Empfangseinheit muss so positioniert sein, dass sie den Empfang von Si-
gnalen der Sendeeinheit begünstigt. Aus diesem Grund darf sie nur senkrecht
montiert werden (Antenne nach oben). Die Empfangseinheit muss außerdem leicht
zugänglich sein, um zu ermöglichen, unter sicheren Bedingungen zu arbeiten.
Falls die Empfangseinheit durch Metallstrukturen bedeckt sein sollte oder im Inneren
eines Metallschrankes installiert sein sollte, benutzen Sie bitte die dafür vorgesehene
Kit-Verlängerungsschnur für die Außenantenne.
Die Antenne darf nie mit Metallteilen in Kontakt stehen.

Es ist verboten, den Behälter der Empfangseinheit zu lochen: der Schutzgrad
für äußere Einwirkungen (IP65) wird sonst gefährdet.
Um die Vibrationen zu verringern, die durch das Kraftfahrzeug auf der Empfang-
seinheit entstehen, sollte man stets Schwingungsdämpfer benutzen.
Man sollte die Empfangseinheit weit von Wärmequellen entfernt positionieren (z.B.
Auspuffrohre, Wechselstromgeneratoren usw.).
Verkabelung
Der größte Teil der Maschinen sieht den Anschluss der Empfangseinheit mittels Mehr-
fachstecker vor, der, falls notwendig, ermöglicht, die Funkfernsteuerung schnell zu
trennen, um sie durch eine Kabelsteuerung zu ersetzen. Auch wenn die Maschine ni-
cht dafür vorgesehen ist, empfiehlt es sich stets, diese Anschlusstechnik zu benutzen.
- 32 -
LIPROMU2
Die Zuverlässigkeit der Anlage ist eng mit der Qualität der Verkabelung verbunden.
Die Verkabelung muß nach den Regeln der Technik erfolgen. Es ist darauf zu achten,
daß mehradrige Kabel verwendet werden, die für die spezifizierte Stromaufnahme ge-
eignet sind und aus feuerfestem Material bestehen. An dieser Stelle wird auf die en-
tsprechenden Abschnitte der Norm DIN EN 60204 -1 verwiesen.
Im Falle von Außenverbindungen an die Empfangseinheit empfehlen wir, Kabel mit
Ölschutz zu verwenden.
Die Speisung der Empfangseinheit muss auf jeden Fall durch einen
Schalter geschehen, um somit zu ermöglichen, dass die Speisung
während den Installations-, Verkabelungs- und/oder Wartungsar-
beiten unterbrochen werden kann. Um die Funkfernsteuerung so
gut es geht benutzen zu können, sollte man die Empfangseinheit di-
rekt nach dem Hauptschalter der Maschine anschließen.
Es ist stets sinnvoll, den Speisewert auch bei maximaler Leistung zu kontrollieren, um
die maximalen Variationen überprüfen zu können (die zugelassenen Abweichung-
sgrenzwerte sind sowohl in den Technischen Angaben als auch auf dem Schaltplan
der Funkfernsteuerung aufgeführt).
Spannungsschwankungen der Speisung der Empfangseinheit über

den Grenzwerten können den regulären Betrieb der Funkfernsteue-
rung gefährden.
Die Funkfernsteuerungen der Serie C26-PRO sind mit Schutzschaltungen gegen un-
gewollte Bewegungen von der Ruheposition der Bedienungen aus versehen (SAFETY-
Funktion). Dieser Schutz ist nur dann wirksam, wenn die gemeinsame Leitung der
Bewegungssteuerungen in der Empfangseinheit durch die Serie des STOP- und des
SAFETY-Kontakts gebildet wird (so dass sie sich schließt, wenn eine Bewegungssteue-
rung übertragen wird). Dagegen könnte die gemeinsame Leitung der Auswahlsteue-
rungen mit dem SAFETY-Kontakt nicht in Serie sein.
Verkabelung-
sbeispiel
Eichung pro-
portionale Autec liefert die Funkfernsteuerung mit den Eichwerten der bereits
Ausgänge voreingestellten proportionalen Ausgängen. Während der Installa-
tion müssen diese Werte überprüft und eventuell geändert werden,
je nach Betriebsbedarf der Maschine (siehe Kapitel 11).
Am Ende der Installation und der Verkabelung ist es stets notwendig:

- zu überprüfen, ob sich beim Drücken des Not-Schalters der Funkfernsteuerung die
Sicherheitsvorrichtung der Maschine einschaltet (durch direkte Einwirkung auf das al-
lgemeine Elektroventil des Hauptkreislaufes), sich eventuell der Motor ausschaltet
und sich, falls vorhanden, der Hauptfernschalter öffnet, so dass die Spannung unter-
brochen wird.
- sich über die exakte Übereinstimmung zwischen den von der Maschine ausgeführten
Schaltungen und den Steuerungen der Sendeeinheit zu vergewissern (diese Überein-
stimmung ist auf dem Schaltplan aufgeführt).
- den Betrieb der Sicherheitsschaltung zu überprüfen (eine einfache Möglichkeit ist
es, die Sicherung F3, die sich auf der Grundkarte der Empfangseinheit befindet, abzu-
trennen, und nachzuprüfen, dass unter diesen Bedingungen keine Bewegungssteue-
rung ausgeführt werden kann; die Sicherung F3 daraufhin wieder einfügen und sich
über den richtigen Betrieb vergewissern)
Der Installateur muss außerdem die beiden vorhandenen Kopien des Schal-
tplans ausfüllen und/oder überprüfen, auf denen der Verkabelungsplan der
Empfangseinheit und der Maschine aufgeführt ist. Die erste Kopie des Schal-
LIPROMU2
- 33 - Deutsch
tplans ist im Inneren der Empfangseinheit eingefügt, die zweite Kopie ist
dem Gebrauchshandbuch beigelegt. Der Installateur muss das Datum der
Inbetriebnahme der Anlage mit Stempel und Unterschrift auf beide Kopien
setzen.
5 WARNUNGEN ZUM GEBRAUCH DER FUNKFERNSTEUE-

RUNG
Der Gebrauch der Funkfernsteuerung ist nur Arbeitern genehmigt, die:
- das vorliegende Handbuch gelesen und verstanden haben,
- qualifiziert und geschult sind,
- das System "Funkfernsteuerung + Maschine" gut kennen.
Autec kann keine Verantwortung übernehmen, falls die Funkfern-

steuerung auf Befestigungen installiert wurde, die von den gültigen
Vorschriften abweichen, und unter nicht vorschriftsgemäßen Arbei-
tsbedingungen benutzt wird.
Jedesmal, wenn man die Sendeeinheit einschaltet, muss man über-

prüfen, dass der Notschalter richtig funktioniert und dass sein An-
trieb die Bewegungen der Maschine sofort unterbricht.
Andernfalls die Funkfernsteuerung nicht benutzen.
Der Funkfernsteuerung folgende Punkte überprüfen beide Einheiten

sein unversehrt und die Dichtungen, Faltbalgen als auch die Kap-
pen der Betätigter (Meisterschalter, Drehschalter, Drucktasten)
sein unversehrt. Falls das nicht der Fall ist, die Funkfernsteuerung
muß bevor der Inbetriebnahme repariert werden.
Um wirksam arbeiten zu können und eventuellen Notfällen zuvor-

zukommen, sollte man eine Position wählen, die Folgendes ermöglicht:
- Im Inneren der Reichweite der Funkfernsteuerung zu bleiben
(siehe Kapitel 14)
- Die Maschine, ihre Bewegungen und die eventuelle Last in jedem
Moment mit den Augen zu verfolgen.
Während des
Betriebs Der Bediener muss:
- die Sendeeinheit jedesmal dann ausschalten, wenn er seine Arbeit unterbricht
- die Sendeeinheit NIEMALS unbewacht mit steckendem Zünd-
schlüssel lassen
- vermeiden, mit einer fast leeren Batterie zu arbeiten.
Der Bediener darf die Sendeeinheit nur dann einschalten oder akti-
vieren, wenn er zu arbeiten beginnen möchte. In der Tat ist es mö-
glich, eine Funkverbindung auch außerhalb der Reichweite und von
geschlossenen Orten aus aufzubauen, so dass ungewollte Steuerun-
gen die ferngesteuerte Maschine erreichen können.
In Notfall
Im Falle, daß sich eine Gefahrensituation ergibt, muß der Arbeiter
sofort eingreifen, indem er die STOP-Taste drückt, die sofort die
Bewegungen der Maschine zum Sillstand bringt.
Da nicht alle Gefahren durch das System “Funkfernsteuerung +Ma-

schine” verursacht werden, muß der Arbeiter auch auf die Notfälle
achten, die sich in der Arbeitszone ereignen. Auch in diesem Fall
muß der Arbeiter manuell eingreifen, indem er den STOP-Taste ak-
tiviert.
Im Schaden-
fall In einem jeglichen Defekt oder bei Entdeckung beschädigter Teile,
MUSS man das System “Funkfernsteuerung + Maschine” bis zur vol-
lständigen Beseitigung bestehenden Problems außer Betrieb set-
zen. Eventuelle Schäden können ausschließlich von autorisiertem
Autec-Personal repariert werden, indem sie nur Original-Ersatzteile
von Autec benutzen.
- 34 -
LIPROMU2
6 WARNUNGEN ZUR NORMALE WARTUNG DER FUNKFERN-
STEUERUNG
Während aller Wartungsarbeiten der Funkfernsteuerung und der
Maschine, muss man die Batterie aus der Sendeeinheit nehmen und
den Anschlussstecker von der Empfangseinheit trennen.
Alle Kontroll- und Wartungseingriffe der Funkfernsteuerung werden vom Verantwor-

tlichen für die Wartung der Maschine überprüft und registriert.
Die Wartung gemäß der in diesem Handbuch aufgeführten Anleitun-

gen ist wesentlicher Bestandteil für das sichere Funktionieren der
Funkfernsteuerung.
Nach jeglichem Eingriff nach der Installation muss man stets über-
prüfen, dass die von der Sendeeinheit gesendeten Steuerungen aus-
schließlich nur die vorgesehenen Bedienungen aktivieren.
Zusammen-
fassende An- Die nachfolgenden Anleitungen stellen den wesentlichen Bestandteil für ein sicheres
leitungen und korrektes Funktionieren der Funkfernsteuerung dar.
Besondere Anwendungen können etwas spezifischere Wartungseingriffe unterschie-
dlicher Dauer benötigen.
Diese Anleitungen sind auf keinen Fall vertragsgültig und können die Vorschriften
und die Gesetze bezüglich der Sicherheit am Arbeitsplatz nicht ersetzen sowie die Ve-
rantwortlichkeiten des Käufers und des Bedieners der Funkfernsteuerung nicht be-
grenzen.
Alle aufgeführten Anleitungen müssen bei jeder Inbetriebsetzung der Ma-
schine und der Funkfernsteuerung befolgt werden.
Komponente Periodizität
Jeden Alle 3 Alle 6 Alle 12
Tag Monate Monate Monate
Sendeeinheit X
Empfängseinheit X
Elektrische Funktionalität X
Externe elektrische Leiter X
Falls sich bei der Wartung Störungen ergeben sollten, muss man das
System "Maschine+Funkfernsteuerung" außer Betrieb setzen, in-
dem man die aufgeführten Anleitungen befolgt (siehe Kapitel 7).
Sendeeinheit
Man muss jeden Tag:
1. Staub und Anhäufungen anderen Materials von der Sendeeinheit entfernen: für die
Reinigung niemals entflammbare / korrosive Lösungsmittel oder Produkte benutzen
und keine Hochdruckwasserstrahler oder Dampfgeräte verwenden.
2. Die Sendeeinheit an sauberen und trockenen Orten lagern.
3. Überprüfen, dass die Gummidichtungen, die Gummibalgendichtungen und die Kap-
pen der Joysticks, die Wählschalter und die Druckknöpfe, die sich in der Sendeeinheit
befinden, unbeschädigt, weich und elastisch sind
4. Sich vergewissern, dass der Sitz und die KontaKte der Batterie sauber sind
5. Sich vergewissern, dass die Sendeeinheit vollständig sind.
6. Überprüfen, dass die Symbole des Paneels gut sichtbar sind und eventuell das Pa-
neel auswechseln
7. Kontrollieren, dass die Kennschilder gut lesbar und unversehrt sind
Empfäng-
seinheit Man muss alle 3 Monate:
1. Staub und Anhäufungen anderen Materials von der Empfängseinheit entfernen: für
die Reinigung niemals entflammbare / korrosive Lösungsmittel oder Produkte benut-
zen und keine Hochdruckwasserstrahler oder Dampfgeräte verwenden.
2. Sich vergewissern, dass die Empfängseinheit vollständig sind.
3. Die Verbindung und die interne Verkabelung in der Empfangseinheit überprüfen
4. Überprüfen, dass die Symbole des Paneels gut sichtbar sind und eventuell das Pa-
neel auswechseln
5. Kontrollieren, dass die Kennschilder gut lesbar und unversehrt sind
LIPROMU2
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Elektrische
FunktionalitätMan muss alle 6 Monate:
1. den korrekten Betrieb der Kontakte aller Relais der Empfangseinheit überprüfen, indem
man dabei die Schließung des Kontaktes bei der Aktivierung der entsprechenden Bedie-
nung und die Öffnung des Kontaktes bei der Deaktivierung der Bedienung kontrolliert.
2. die korrekte Übereinstimmung zwischen gesendeten Steuerungen und ausgeführ-
ten Bedienungen überprüfen.
Externe
elektrische Man muss alle 12 Monate:
Leiter 1. die Integrität des Anschlusskabels zwischen der Empfangseinheit und der Maschine
in seiner ganzen Länge überprüfen.
2. die Integrität und den Anschluss der Stecker und der Steckdosen überprüfen.
3. die Schellen überprüfen und diese oder andere Befestigungssysteme eventuell ersetzen.
4. überprüfen, dass der Mantel des Anschlusskabels keine Fäulnis aufweist, vor allem
in Übereinstimmung mit den Kabelpressen
5. die Integrität der Stecker und der Steckdosen überprüfen.
7 WARNUNGEN ZUR AUßERGEWOHNLICHE WARTUNG DER

FUNKFERNSTEUERUNG
Während aller Wartungsarbeiten der Funkfernsteuerung und der
Maschine, muss man die Batterie aus der Sendeeinheit nehmen und
den Anschlussstecker von der Empfangseinheit trennen.
.
Eventuelle Schäden können ausschließlich von autorisiertem Autec-
Personal (den Kundendienst anrufen) repariert werden, indem sie
nur Original-ersatzteile von Autec benutzen.
Um einen schnelleren und wirksameren Ablauf zu ermöglichen, müssen die Angaben

der Funkfernsteuerung mitgeteilt werden:
- Seriennummer
- Kaufdatum (auf dem Garantiezertifikat aufgeführt)
- festgestellte Störung
- Adresse und Telefonnummer des Ortes, an dem das Gerät benutzt wird (mit dem
Namen des verantwortlichen Ansprechpartners)
- Lieferfirma.
Bevor man die Techniker des Kundendienstes eingreifen lässt, ist es ratsam,
das vorliegende Handbuch vollständig gelesen und verstanden zu haben, indem
man überprüft, alle aufgeführten Anleitungen richtig ausgeführt zu haben.
8 DOKUMENTATION
Die der industriellen Funkfernsteuerung beigelegten Dokumenta-
tion besteht stets aus mindestens:
- einem Anleitungs- und Warnungshandbuch
- einem Handbuch des Akkus
- Konformitätserklärung CE
- der Garantieschein
- Technische Scha der Funkfernsteuerung
- Blatt "Beschränkungen & Genehmigungen".
Nachsehen, ob alle diese Anlagen vorhanden sind: anderenfalls Au-

tec darum bitten, indem Sie die Seriennummer der Funkfernsteue-
rung angeben.
Handbuch
Das vorliegende Handbuch ist wesentlicher Bestandteil der Funkfernsteue-
rung und seiner Sicherheitsfunktionen und hat die Absicht, die wichtigsten In-
formationen zu übermitteln, die für die Installation und die Wartung der
Funkfernsteuerung nötig sind.
Alle Installations-, Gebrauchs- und Wartungsarbeiten dürfen ausschließlich
nur von einem qualifizierten und in Hinblick auf die entsprechenden Vor-
schriften und Gesetze angemessen geschulten Personal ausgeführt werden.
Deshalb ist es notwendig, dass das vorliegende Handbuch wenigstens vom Eigentü-
mer der Funkfernsteuerung, vom Installateur der Funkfernsteuerung, vom Bediener/
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LIPROMU2
Benutzer der Funkfernsteuerung sowie vom Verantwortlichen und Angestellten für
die Wartung vollständig gelesen und verstanden worden ist.
Für die Anleitungen und Warnungen, die die von der Funkfernsteuerung ge-
steuerten Maschine betreffen, muss man so vorgehen, wie es vom Konstruk-
teur der Maschine angegeben wurde.
Im Falle einer Beschädigung oder eines Abhandenkommens der vorliegenden Ge-

brauchsanleitungen, ist es notwendig, eine weitere Kopie derselben von Autec zu er-
fragen. Dabei sollte man die Kennnummer der Funkfernsteuerung angeben.
Im Sinne ständiger Verbesserung aller Erzeugnisse der AUTEC s.r.l. behalten wir uns
Änderungen im Design und in den technischen Daten ohne vorhergehende Bekannt-
gabe vor. Ohne schriftliche Genehmigung der AUTEC s.r.l. darf diese Betriebsanlei-
tung in keiner Form, auch nur auszugsweise, reproduziert werden.
Garantie
Die Bedingungen, die die Garantie der Funkfernsteuerung regeln, sind auf dem "Ga-
rantieschein" aufgeführt, der dem vorliegenden Handbuch beigefügt ist.
Die elektronischen Teile mit 3 Jahren Garantie sind: MTX_____, MRX_____,
RD97____, RI97____ und CH97____.
Schaltplan
Der Schaltplan stellt die Verkabelung zwischen der Empfangseinheit und der Maschi-
ne dar. Er muß von dem Installateur ausgefüllt und kontrolliert werden, der die Ve-
rantwortung der korrekten Verkabelung trägt. Nachdem diese wichtigen Kontrollen
durchgeführt wurden, muß der Installateur die technische Karte unterschreiben, die
dem Handbuch beigefügt bleiben muß (im Falle, dass sie für Verwaltungszwecke ve-
rwendet wird, stets eine Kopie machen und aufbewahren).
Identifika-
tionsschild Die Daten der Identifikation und der Homologation der Funkfernsteuerung sind auf
einem geeigneten Schild aufgeführt, das sich sowohl auf der Sende- als auch auf der
Empfangseinheit befindet. Diese Schilder DÜRFEN auf keinen Fall von ihrem
Platz entfernt oder beschädigt werden, anderenfalls entfällt die Garantie.
9 DIE SENDEEINHEIT UND IHR BETRIEB
L A E A Bedienungen (Joystick oder Schalter)
B STOP Schalter
H C START / Alarm Drucktaste
D Zundschüssel
E Schalter rpm +/-
F Geschwindigkeisschalers
G Akku
H Identifikationsschild
L zwei Kontroll-Leds (grün und rot)

D
C
G
F
B
Einschaltung
und Start Stellen Sie sicher, daß der Schlüsselschalter zum Einschalten auf Position
"O" steht, und setzen Sie den Akku in die dafür vorgesehene Aufnahme
ohne dabei Druck auszuüben. Drehen Sie den Schlüsselschalter auf Posi-
tion "I "und betätigen Sie den START Taster/Schlüsselschalter. Dieser
kann losgelassen werden, sobald die grüne Kontrollampe aufleuchtet.
Die Einschaltung erfolgt nur dann, wenn die Batterie ausreichend

aufgeladen ist und wenn alle Bedienungen ausgeschaltet sind.
Befehle
Die ferngesteuerte Maschine kann nur dann die Steuerungen ausführen, nachdem
eine Funkverbindung zwischen Sende- und Empfangseinheit erfolgt ist (durch das Au-
fleuchten der Kontrolllampe ENABLE signalisiert, die sich in der Empfangseinheit be-
findet (siehe Kapitel 10)).
Die Bedienungen der Arbeitsschritte, die man ausführen möchte, aktivieren.
Alle von der Sicherheitsfunktion SAFETY geschützten Steuerungen sind gemäß der EN
954 - 1 für den Schutz der von der Ruheposition nicht gewollten Bewegungen in Ka-
tegorie 3 genehmigt (UMFS - Unintended Movement From Standstill).
LIPROMU2
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Einige der in der Sendeeinheit verfügbaren Bedienungen sind die folgenden:
Alarm
Bei eingeschalteter Sendeeinheit aktiviert sich der Clacson / Alarm der Maschine,
wenn man den START-Schalter drückt.
STOP
Um die Maschine umgehend anzuhalten, muss man den Stop-Schalter drücken: nach
einem kurzen Moment schaltet sich die Sendeeinheit automatisch aus.
Um mit der Arbeit fortzusetzen, muss man den Stop-Schalter in die angegebene Ri-
chtung drehen und das Zündungs- und Einschaltverfahren wiederholen.
Der Stop-Schalter wird jedesmal benutzt, wenn die Notwenigkeit

besteht, die Maschine umgehend anzuhalten, im Falle einer jegli-
chen Gefahrensituation.
Der Stop-Kreislauf ist bestätigt in der Kategorie 4 gemäß der EN 954 -1.
RPM +/-
Dieser Wählschalter hat eine doppelte Funktion:
1) während des normalen Betriebs: er dient dazu, die Umdrehungen der
Motors der Maschine zu erhöhen (rpm +) oder zu verringern (rpm -).
2) während der Eichung (REMOTE SET UP): siehe Kapitel 11
Geshwindi-
gkeitsschal- Es kann ein Geschwindigkeitsschalter vorhanden sein, der dazu dient, die Maschine
ters zu unterschiedlichen Geschwindigkeiten laufen zu lassen, je nach Arbeitsbedarf. Die-
ser Geschwindigkeitsschalter kann mit zwei, drei oder vier Positionen ausgestattet
sein, die entsprechend zwei, drei und vier Geschwindigkeitsniveaus ermöglichen.
Frequenzwe-
chsel Im Falle einer Interferenz oder einen Konflikts mit andern Funkanlagen besteht die
Möglichkeit, die Funkfrequenz, mit der man arbeitet, zu wechseln.
Mit eingeschalteter und gestarteter Sendeeinheit muss man den START-Schalter für
5-6 Sekunden gedrückt halten: ein längeres Piepen, gefolgt von der Einschaltung bei-
der Signalisierungs-Leds zeigt den erfolgten Frequenzwechsel an. Während dieses
Vorgangs schaltet sich die Empfangseinheit aus: um mit der Arbeit fortzufahren, er-
neut den START-Schalter drücken, wie bei einem normalen Startvorgang.
Signalisierun-
gen Led Einige Betriebskonditionen der Sendeeinheit werden von zwei Signalisierungs-LEDs
angezeigt (eine ist grün und eine ist rot).
Signaltyp Led
grün rot
Langsames normaler Betrieb /
Schnelles Ankündigung dass Ankündigung dass
Blinken Batterie fast leer ist Batterie leer ist
Licht blinkt immer noch Steuerbefehl
während des Einschaltens* / aktiviert
Dauerleuchten beider Frequenzwechsel
Led * erfolgt
* begleitet von einem akustichen Signal
Wenn der Akku ca.90% seiner Ladung aufgebraucht hat, erhöht sich die Blinkge-
schwindigkeit der grünen Kontrollampe des Senders. Wenn die Funkfernsteuerung
weiter benutzt wird, beginnt die rote Kontrollampe zu blinken. Gleichzeitig ertönt ein
akustisches Signal. Es verbleiben ca. 3 Minuten, um die Maschine in einen sicheren
Zustand zu bringen, den Sender auszuschalten und den Akku zu laden oder zu tau-
schen.
Ausschalten
Den Zündschlüssel auf die Position "O" drehen.
Man sollte nicht vergessen, den Zündschlüssel stets herauszuziehen und ihn an einen
sicheren Ort zu bringen.
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LIPROMU2
Automatische
Ausschalten Die Sendeeinheit kann auch automatisch erfolgen, wenn:
- die Batterie nicht ausreichend aufgeladen ist und/oder
- die Funkfernsteuerung für circa 3,5 Minuten nicht benutzt wird (Die Funktion der
Selbstausstellung kann ausgeschaltet werden, indem man sich an das autorisierte
Personal von Autec wendet).
Laden der
Akku Nehmen Sie den Akku aus der Aufnahme des Senders und setzen Sie ihn in die Auf-
nahme des Akkuladegerätes.
Der Ladevorgang wird dann durch die Kontrollampe "ON CHARGING" angezeigt. Das
Ende des Ladevorgangs wird von der Kontrollampe "END OF CHARGE" angezeigt. Der
Ladevorgang darf nur bei einer Temperatur von + 5°C bis + 45°C erfolgen.
Für alle Anleitungen, Warnungen und technische Angaben, die die

Batterien und den Akku betreffen, siehe mitgeliefertes Heft.
10 EMPFANGSEINHEIT
A
P
G G
B B
C C
F L
M
N
G G
A Antenne B POWER Lampe
B POWER Lampe C ENABLE Lampe
C ENABLE Lampe H RI97-08 Modul
D Verbindungsstecker L Sicherung F1
E Identificationsschild M Sicherung F2
F Technische angeben Schild N Sicherung F3
G Schließschraube P internal Leds
Innere Signali-
sierungen Die vorhandenen Leds zeigen die erfolgte Einschaltung eines Relais an: wenn sich
eine Led einschaltet, zeigt diese damit an, dass das Relais aktiviert wurde, das zur
der Steuerung gehört, die im folgenden Schema aufgeführt ist (auch auf der inneren
Seite des Deckels der Empfangseinheit vorhanden):
LIPROMU2
- 39 - Deutsch
Äußere Signa-
lisierungen POWER Lampe zeigt die Anwesenheit (eingeschaltet) oder die Nicht-Anwesenheit (au-
sgeschaltet) der Speisung in der Empfängereinheit an.
ENABLE Lampe zeigt die erfolgte Verbindung (eingeschaltet) oder den Verbindung-
smangel (ausgeschaltet) zwischen Sender- und Empfängereinheit an.
Der fehlerfreie Betrieb wird signalisiert durch:
- POWER und ENABLE fest eingeschaltet, mit eingeschalteter Sendereinheit;
- POWER fest eingeschaltet und ENABLE ausgeschaltet, mit ausgeschalteter Sende-
reinheit.
SAFETY
Um das System vor ungewollten Bewegungen zu schützen, die durch eventuelle
Schäden der Funkfernsteuerung verursacht werden könnten, ist die Funkfernsteue-
rung mit einer Sicherheitsfunktion namens SAFETY versehen.
Diese Funktion kontrolliert konstant die Ruheposition (neutral) der Bewegungsbedie-
nungen in der Sendeeinheit und ist im Ausgang auf dem SAFETY-Relais in der Em-
pfangseinheit verfügbar.
FLOW
Indem man eine Bewegungssteuerung aktiviert, aktiviert sich auch die FLOW-Funktion:
diese steuert das Elektroventil, das Öl im primären Wasserlauf des Verteilers spannt.
T.S.
Der T.S. (TIMED STOP) ist die Steuerung, die den Dieselmotor der Maschine ausschaltet:
dieser bleibt nach der Aktivierung des Not-Schalters 10 Sekunden lang aktiviert.
Sicherung
Die drei Sicherungen, die sich im Inneren der Empfangseinheit befinden, haben die
folgenden Eigenschaften:
Sicherung Beschreibung Technische Daten
F1 Schutz des POWER SUPPLY Stromkreises 4A (32Vdc, autofuse)
F2 Schutz des STOP Stromkreises 10A (32Vdc, autofuse)
F3 Schutz des SAFETY Stromkreises 10A (32Vdc, autofuse)
11 EICHVERFAHREN PROPORTIONALE AUSGÄNGE (REMOTE SET UP)

Das Eichverfahren der proportionalen Ausgänge darf nur von qualifi-
ziertem und geschultem Personal ausgeführt werden und nur unter Be-
achtung aller in den Kapiteln 4, 5, 6 und 7 aufgeführten Warnungen.
Informationen
über das Mo- Die proportionalen Ausgänge des Moduls RI97-08 _____ sind bei den Werten ange-
dul RI97-08 geben, die sich auf der beigefügten technischen Spezifikation befinden. Die Nummer
der die einzelne Anlage betreffenden technischen Spezifikation ist auf dem Etikett an-
gegeben, das sich auf dem Schlüssel zur Datenspeicherung (K2) befindet.
C3 C1 C2 S L P
C1 Verbinder für die proportionalen Ausgänge
C2 Verbinder für die proportionalen Hilfausgänge
C3 Verbinder für die Speisung
C4 Verbinder für die den Eichschüssel
C5 Verbinder für den Anschluss an die bus Karte
L grüne Led
K1 Datenspei cherung
K2 Datenspeicherung
P Rückstellschalter zur Rückstellung der anfän-
glichen Eichwerte
C5 C4 K1 K2 S Drehwählschalter
Den Eichschlüssel K1 niemals während des Betriebs der Funksteue-

rung stecken lassen: Er nützt nur in der Eichphase und befähigt,
wenn er steckt, jeweils nur einen proportionalen Befehl.
Im Falle, dass man die Werte der anfänglichen proportionalen Ausgänge zurückstellen
möchte (d.h. die in der technischen Spezifikation aufgeführten), genügt es, mit dem
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LIPROMU2
Eichschlüssel eingesetzt, den Rückstellknopf P gedrückt zu halten, bis die relative
grüne Led L zu Blinken aufhört und die Signalisierung des stetigen Lichts erfolgt. Im
Falle einer Ersetzung des Moduls genügt es, den Speicherschlüssel K2 vom alten Mo-
dul auf das neue Modul zu versetzen, um dieselben Werte, die sich in den proportio-
nalen Ausgängen befinden, zu behalten.
Vorbereitung
zur Eichung 1. Sich vergewissern, dass die Sendeeinheit ausgeschaltet ist.
2. Der Empfangseinheit die Spannung abtrennen.
3. Die Empfangseinheit öffnen und den Eichschlüssel K1 in den Verbinder C4 stecken.
4. Der Empfangseinheit Speisung geben. ACHTUNG: Ab diesem Moment bis zum Ende
der Eichung darf die Empfangseinheit nicht berührt werden (man riskiert ansonsten,
die eingestellten Werte zu verlieren)
5. In der Sendeeinheit den Zündschlüssel auf Position "I" drehen und den START-
Schalter drücken.
6. Den Zündschlüssel auf Position " " drehen (REMOTE SET UP).
Eichung
7. die zu eichenden Parameter mit dem Drehwählschalter S, der sich im Modul RI97-08 be-
findet, wählen, indem man den Wählschalter RPM+/- bedient, der sich in der Sendeeinheit
befindet (das + erhöht den Wert, den man gerade eicht, und das - verringert diesen Wert).
Bei den Modulen mit Ausgängen unter Spannung sind die Eichungen
in den Positionen 1, 2, 3, 4 und 5 möglich. Bei den Modulen mit Au-
sgängen unter Strom (Ampere) (PWM) sind die Eichungen in den
Positionen 0, 1, 3 und 4 möglich.
Während der Eichung, indem man den Joystick aus der Ruheposition
bringt, signalisiert ein Clacson / ein Alarm von circa 0,5 Sekunden
Dauer, dass man sich im Bereich der Mindesteichwerte befindet.
Die Eichungen werden für jede einzelne Position des Geschwindi-

gkeitsschalters durchgeführt, der sich in der Sendeeinheit befindet.
Eichungen in
den Modulen Position 1: Mindest- und Höchstwerte Z2-Z7
mit Ausgän- Mit dem Drehwählschalter in Position 1 stellt man den maximalen und den minimalen
gen unter Spannungswert der verschiedenen Achswellen eines Joysticks ein. Wie folgt vorgehen:
Spannung 1. Um den Höchstwert zu bestimmen, den Joystick zum maximalen Ausschlag auf der
zu eichenden Achswelle bringen. Indem man diese Position beibehält, den Kippschal-
ter RPM +/- betätigen, der sich in der Sendeeinheit befindet, um den gewünschten
Wert zuändern.
2. Um den Mindestwert zu bestimmen, den Joystick außerhalb der Ruheposition (nicht
über die Hälfte des Ausschlags) auf der zu eichenden Achswelle bringen. Indem man
diese Position beibehält, den Kippschalter RPM +/- betätigen, der sich in der Sende-
einheit befindet, um den gewünschten Wert zuändern.
Position 2: Spannung der Ruheposition des Joysticks
Mit dem Drehwählschalter in Position 2 stellt man den Spannungswert ein, der mit
der mechanischen Ruheposition des Joysticks übereinstimmt. Normalerweise dieser
Wert soll nicht geändert werden. Falls notwendig, man muß wie folgt vorgehen:
- Irgendeinen Joystick außerhalb der Ruheposition bringen.
- Indem man diese Position beibehält, den Kippschalter RPM +/- betätigen, der sich
in der Sendeeinheit befindet, um den gewünschten Wert zuändern.
Positionen 3 und 4: Mindest- und Höchstwerte Z8 und Z9
Mit dem Drehwählschalter in Position 3 und 4 stellt man die maximalen und minima-
len Spannungswerte bezüglich der Hilfsausgänge Z8 und Z9 ein. Wie folgt vorgehen:
1. Um den Höchstwert zu bestimmen, den Knopf (der sich in der Sendereinheit befin-
det) bezüglich der Steuerung Z8 (oder Z9) vollständig im Uhrzeigersinn drehen.
Indem man diese Position beibehält, den Kippschalter RPM +/- betätigen, der sich in
der Sendeeinheit befindet, um den gewünschten Wert zuändern.
2. Um den Mindestwert zu bestimmen, den Knopf (der sich in der Sendereinheit be-
findet) bezüglich der Steuerung Z8 (oder Z9) vollständig gegen den Uhrzeigersinn
drehen. Indem man diese Position beibehält, den Kippschalter RPM +/- betätigen,
der sich in der Sendeeinheit befindet, um den gewünschten Wert zuändern.
Position 5: Umkehr der Halbachsen
Mit dem Drehwählschalter in Position 5 kehrt man die Richtung der Achswellen um.
Wie folgt vorgehen:
- Den Joystick bezüglich der umzukehrenden Achse außerhalb der Ruheposition bringen
LIPROMU2
- 41 - Deutsch
in der Sendeeinheit befindet, indem man ihn in die Position + bringt, um die Ri-
chtung der Achswellen umzukehren, oder indem man ihn in die Position - bringt, um
die Richtung der Achswellen zurückzustellen.
Eichungen in
den Modulen Position 0: Frequenz des PWM-Signals
mit Ausgän- Mit dem Drehwählschalter in Position 0 stellt man die Frequenz des PWM-Signals ein.
gen unter Normalerweise dieser Wert soll nicht geändert werden. Falls notwendig, man muß wie
Strom (PWM) folgt vorgehen:
- Einen Joystick außerhalb der Ruheposition bringen.
in der Sendeeinheit befindet, um den gewünschten Wert zuändern.
Position 1: Mindest- und Höchstwerte Z2-Z7
Mit dem Drehwählschalter in Position 1 stellt man den maximalen und den minimalen
Spannungs- oder Stromwert (je nach Modul) der verschiedenen Achswellen eines
Joysticks ein. Wie folgt vorgehen:
1. Um den Höchstwert zu bestimmen, den Joystick zum maximalen Ausschlag auf der
zu eichenden Achswelle bringen. Indem man diese Position beibehält, den Kippschal-
ter RPM +/- betätigen, der sich in der Sendeeinheit befindet, um den gewünschten
Wert zuändern.
2. Um den Mindestwert zu bestimmen, den Joystick außerhalb der Ruheposition (nicht
über die Hälfte des Ausschlags) auf der zu eichenden Achswelle bringen. Indem man
diese Position beibehält, den Kippschalter RPM +/- betätigen, der sich in der Sende-
einheit befindet, um den gewünschten Wert zuändern.
Positionen 3 und 4: Mindest- und Höchstwerte Z8 und Z9
Mit dem Drehwählschalter in Position 3 und 4 stellt man die maximalen und minima-
len Spannungswerte bezüglich der Hilfsausgänge Z8 und Z9 ein. Wie folgt vorgehen:
1. Um den Höchstwert zu bestimmen, den Knopf (der sich in der Sendereinheit befin-
det) bezüglich der Steuerung Z8 (oder Z9) vollständig im Uhrzeigersinn drehen.
Indem man diese Position beibehält, den Kippschalter RPM +/- betätigen, der sich in
der Sendeeinheit befindet, um den gewünschten Wert zuändern.
2. Um den Mindestwert zu bestimmen, den Knopf (der sich in der Sendereinheit be-
findet) bezüglich der Steuerung Z8 (oder Z9) vollständig gegen den Uhrzeigersinn
drehen. Indem man diese Position beibehält, den Kippschalter RPM +/- betätigen,
der sich in der Sendeeinheit befindet, um den gewünschten Wert zuändern.
Speicherung
der Eichung 8. Die Sendeeinheit ausschalten, um die Eichungen zu speichern.
9. Der Empfangseinheit die Speisung nehmen.
10. Den Eichschlüssel K1 herausziehen.
11. Die Empfangseinheit zu machen und ihr Speisung geben.
12 FUNKFREQUENZEN
Die in der Funkfernsteuerung programmierten Funkfrequenzen gehören den von den
europäischen Vorschriften zugelassenen Frequenzen an, die in dem Moment gültig
waren, als das Gerät auf dem Markt eingeführt wurde.
In der diesem Handbuch beigefügten Anlage “Beschränkungen &

Genehmigungen” sollte man eventuelle Beschränkungen des be-
treffenden Landes überprüfen.
Eine Funkfernsteuerung kann sowohl in der Modalität der AUTOMATISCHEN ABTA-

STUNG als auch der MANUELLEN AUSWAHL arbeiten.
Automati-
sche Abta- Normalerweise wird eine Funkfernsteuerung vom Konstrukteur in dieser Modalität
stung programmiert und kann somit auf einer jeglichen verfügbaren Frequenz arbeiten. Im
Falle einer Interferenz oder eines Konflikts mit anderen Anlagen, ermöglicht diese Mo-
dalität, die Arbeitsfrequenz zu wechseln (siehe "Wechsel der Arbeitsfrequenz"), ohne
auf das Innere der Sendeeinheit oder der Empfangseinheit einwirken zu müssen.
Um diese Funktionsmodalität der Arbeitsfrequenz einzustellen, darf

man ausschließlich nur das genehmigte Autec-Personal kontaktieren.
Eine Funkfernsteuerung, die mit der manuellen Auswahlmodalität arbeitet, ermögli-

cht, in einer spezifischen Frequenz zu arbeiten. Um diese Frequenz einzustellen, muss
man die dip switch, die sich im Empfänger- und Sendemodul befinden, einstellen.
- 42 -
LIPROMU2
13 FEHLERSUCHE
Falls sich das System "Funkfernsteuerung + Maschine" nicht einschaltet, sollte man
kontrollieren, ob das Problem die Funkfernsteuerung oder die Maschine betrifft. De-
shalb sollte man vor jeglicher Überprüfung den Sendeplatz an ein Kabel anschließen:
sollte sich die Maschine nicht einschalten, betrifft das Problem die Maschine selbst.
Sollte sich die Maschine jedoch normal einschalten, weil sie vom verkabelten Sende-
platz aus aktiviert wurde, betrifft das Problem die Funksteuerung. In diesem Fall soll-
ten folgende Kontrollen durchgeführt werden.
Sende-
reinheit Feh- Ist die grüne Signali- Ist die rote Signalisie-
Ist die grüne Signali-
lersuche sierungs-Led mit lang- sierungs-Led mit sch- rungs-Led mit perma-
sam aufblinkend Licht nell aufblinkend Licht nentem Licht
eingeschaltet? eingeschaltet? eingeschalter?
Die Bedienungen and/

Die Fehlersuche
Eine aufgeladene oder den Not-Schalter,
der Empfangseinheit
Batterie einfügen. die eventuell eingeschal-
durchführen. .
tet sind, ausschalten.
Falls sich die Sende-

einheit nicht richtig
einschaltet, den Kun-
dendienst anrufen.
Empfäneger-
einheit Fehler-
suche Ist der Anschlussstec- Den Anschlussstecker
Ist die ker zwischen der Em- richtig anschließen und
KontrolllampePOWER pfangseinheit und der die Funkfernsteuerung
ingeschaltet? Maschine richtig ange- starten.
schlossen?
Der Empfangseinheit Die Sicherung erset-

die Spannung nehmen zen. Die Speiseverbin-
und sie öffnen. Ist die Si- dungen kontrollieren.
cherung F1 unversehrt?
DEN Erneut Spannung ge-

KUNDENDIENST ben und die Funkfern-
ANRUFEN steuerung starten.
Einen
Ist die Kontrolllampe
Frequenzwechsel
ENABLE
vornehmen. Schaltet
ingeschaltet?
sich die Maschine ein?
Der Empfangseinheit Die Sicherung ersetzen.

die Spannung nehmen Erneut Spannung ge-
und sie öffnen. Sind die
ben und die Funkfern-
Sicherungen F2-F3
unversehrt? steuerung starten.
DEN
KUNDENDIENST
ANRUFEN
LIPROMU2
- 43 - Deutsch
14 TECHNISCHE DATEN
Allgemeines
Arbeitsfrequenz ........................................................... 433.050 - 434.790 MHz
............................................................................................ 869.7 - 870 MHz
Verfügbare Kanäle (433 MHz) ...................................................................... 64
Verfügbare Kanäle (433 MHz) ..................................................................... 12
Kanalabstand .............................................................. 25 kHz (option 12.5 kHz)
Hamming- Distanz ..................................................................................... 8
Restfehler-Wahrscheinlichkeit ................................................................ <10-11
Arbeitsradius ......................................................................................... 150 m
Reaktionszeit passiver Nothalt/Stop .................................................. 0.5/1.5 Sek
Reaktionszeit Steuerbefehle..............................................................70÷120 ms
Reaktionszeit STOP .........................................................................70÷120 ms
Kategorie der Sicherheitsfunktionen nach der EN 954-1

Niveausicherheitsvorrichtung für Stopbefehl.............................................. Kat. 4
Niveausicherheitsvorrichtung für Steuerbefehlen gegen unbeabsichtigte Bewegungen
der Betätigungshebeln von Nullstellung .................................................... Kat. 3
Sendeeinheit
Anzahl der Ausgänge ............................ 6+2 Analogisch+12 on/off + start + stop
Antenne .............................................................................................. intern
Modulationstyp ..................................................................................... GFSK
ÜbertragengsleistungHF-Teil (433 MHz) .............................................. <10 mW
ÜbertragengsleistungHF-Teil (870 MHz) ................................................ < 5 mW
Versorgungsspannung: Akkupaket ........................................ NiMH 7.2V - 1.3 Ah
Abschaltspannung ................................................................................. 6.0 V
Laufzeitmit geladenem Akku (bei 20°C) ............................................. ca. 10 Std.
Ankündigungszeitraum Batterie fast leer .......................................... ca. 15 min.
Ankündigungszeitraum Batterie leer ................................................... ca. 3 min.
Arbietstemperatur ...................................................................... -20°C÷+55°C
Gehäusematerial .......................................................................... PA6 fg 20%
IP-Schutzgrad ........................................................................................ IP65
Abmessungen ................................................................... (236x160x173) mm
Gewicht (inkl. Akku) ................................................................................ 2 kg
Empfänge-
reinheit Versorgungsspannung ........................................................ 8 - 30 Vdc (< 40W)
Antenne ............................................................................................ externe
Leistung der Kontakte der STOP- und SAFETY-Relais ....................... 10 A (30 Vdc)
Leistung der Kontakte der Relais der Bewegungsteuerungen ............. 4 A (30 Vdc)
Leistung der Kontakte der Relais der Auswahlsteuerungen ................ 6 A (30 Vdc)
Sensibilità ricevitore ..................................................... 0,5µV per 20 dB SINAD
Arbietstemperatur ............................................................... (-20°C) - (+70°C)
Gehäusematerial .......................................................................... PA6 fg 20%
IP-Schutzgrad ......................................................................................... IP65
Abmessungen ..................................................................... (180x230x95) mm
Gewicht .............................................................................................. 2.8 kg
Lehre für die Bohrungen ................................................................ A = 148 mm
B = 116 mm
C = 253 mm
D = 253 mm
Akkuladege-
rät und Akku Die Technischen Daten sind in der eigens dazu bestimmten Gebrauchsanweisung en-
thalten.
- 44 -
LIPROMU2
1 CONVENZIONS
Les textes en caractère gras sont à lire avec une attention particulière.
Ce symbole distingue toutes les indications et les informations d’extrême

importance: le non respect de celles-ci provoque des situations de grave
danger pour les personnes ou pour les choses..
Ce symbole distingue toutes les indications et les informations importantes

concernant son fonctionnement.
2 CONFORMITE
La radiocommande PRO-M de la série C26 PRO est conforme à la Directive
R&TTE 99/05/CE et aux qualités essentielles requises.
La radiocommande est en outre conforme aux normes reportées dans la déclaration
de conformité CE jointe à ce manuel.
Parmi les données techniques (voir chapitre 14) sont indiquées les caractéristiques
des fonctions de sécurité selon la EN 954 - 1.
Nous vous rappelons que dans certains Etats, il faut respecter des
lois qui réglementent l’utilisation et/ou la possession d’une radio-
commande (voir l’annexe "Limitations & Autorisations").
Des limitations nationales à l'utilisation des fréquences peuvent

exister, lorsqu'elles n'ont pas encore été harmonisées à l'intérieur
des Etats européens. Avant l'utilisation , vérifier que la radiocom-
mande travaille dans une bande de fréquences admise par les lois
nationales qui règlent les radiocommunications.
Comme le demande la Directive Machines et les normes harmonisées correspondan-

tes, il est nécessaire d'effectuer une analyse des risques pour chaque machine: c'est
pourquoi, en cas d'utilisation d'une radiocommande, il faut évaluer à l'intérieur de
cette analyse si la machine peut être radiocommandée ou non.
Le constructeur de la machine et/ou la personne qui décide l'installation et l'utilisation
de la radiocommande est responsable de cette analyse.
Autec ne pourra assumer aucune responsabilité si cette analyse des risques
n'a pas étée effectuée de façon correcte et si la radiocommande est installée
sur des applications différentes de celles permises:
APPLICATIONS PERMISES
Machines de soulèvement et de manipulation installées exclusive-
ment sur des engins où l’alimentation électrique provient d’une bat-
terie (par exemple: grues hydrauliques, pompes à béton . . .)
APPLICATIONS NON PERMISES

- machines installées dans des milieux où les appareils ayant des ca-
ractéristiques antidéflagrantes sont nécessaires
- machines pour la manipulation, le soulèvement et le transport de
personnes
- machines alimentées en CA
- machines où l’alimentation en CD ne provient pas d’une batterie
- machines dans lesquelles l'analyse des risques, pour la vérification
de la conformité de la radiocommande à l'application, n'est pas pos-
sible ou a donné un essor négatif ou incertain
Pour garantir le fonctionnement correct de la radiocommande, toutes les prescrip-

tions en vigueur sur la sécurité et sur la prévention des accidents en milieu de travail
doivent toujours être respectées.
En outre, on DOIT toujours observer toutes les lois nationales en vigueur dans chaque
Etat où le système est utilisé aussi bien pour l’utilisation de la machine que pour celle
de la radiocommande.
Autec ne pourra assumer aucune responsabilité si la radiocommande est uti-
lisée dans des conditions de travail hors norme.
LIPROMU2
- 45 - Français
3 CARACTERISTIQUES DE LA RADIOCOMMANDE
Les radiocommandes industrielles sont utilisées

pour commander des machines de loin. Chaque
radiocommande industrielle est constituée
d'une unité de transmission portable, à partir
de laquelle l'opérateur peut commander la ma-
chine à distance, et d'une unité de réception in-
stallée à bord de la machine elle-même.
L’unité de transmission envoie un message co-
dé, à travers une transmission par fréquence
radio. Dans ce message, on trouve une valeur Unité de
appelée adresse qui permet à l’unité de récep- Reception
tion de décoder exclusivement les messages
provenant de sa propre unité de transmission
(celle qui possède la même adresse).
Ceci exclut qu’une interférence puisse activer Unité de
une quelconque commande. En effet, si la tran- Transmission
smission par fréquence radio est perturbée, er-
ronée ou interrompue, l'unité de réception
arrête tout le système de façon autonome.
4 CONSEIL POUR L’INSTALLATION DE LA RADIOCOMMANDE

L’installation doit être exécutée exclusivement par du personnel
qualifié, selon les dispositions du Pays dans lequel on effectue cette
opération. Seule une installation correcte peut assurer le degré de
sécurité nécessaire durant l’utilisation successive de la radiocom-
mande.
Indications
générales Brancher la Radiocommande à la machine en respectant les caractéristiques de fon-
ctionnement de cette dernière: il ne faut pas éluder les circuits de sécurité
prévus sur la Radiocommande et/ou sur la machine.
La possibilité de configurer simplement le câblage de l’Unité de réception permet une

installation sans devoir intervenir sur la machine: ne pas modifier le tableau électri-
que de la machine sans autorisation du constructeur.
Couper l’alimentation en débranchant toutes les connexions électri-

ques chaque fois que l’on effectue une soudure sur la machine.
Installation
L'unité de réception doit être placée dans une position telle à favoriser la ré-
ception des signaux émis par l'unité de transmission. Celle-ci doit donc être
montée verticalement (antenne vers le haut). L'unité de réception doit aussi être fa-
cilement accessible pour permettre d’y opérer en conditions de sécurité.
Si l’unité de réception est couverte par des structures métalliques ou installée à l'in-
térieur de tableaux métalliques, utiliser le kit - rallonge pour antenne externe prévu
à cet effet.
L’antenne ne doit jamais être en contact avec des parties métalliques.

Il est interdit de percer le boîtier de l’unité de réception. Cette action com-
promet le degré de protection contre les agents extérieurs (IP65).
Pour réduire l’effet des vibrations créées par l’engin sur l’unité de réception, toujours
adopter des cales contre les vibrations.
Il convient de placer l’unité de réception loin de sources de chaleur (tuyaux d’échap-

pement, alternateurs, etc.).
Câblage
La plupart des machines prévoient le branchement de l’unité de réception à l’aide
d’une fiche multiple qui, en cas de nécessité, permet de débrancher rapidement la ra-
diocommande pour la substituer par une commande par câble. Même là où la machine
n’est pas ainsi prédisposée, l’utilisation de cette technique de branchement est
toujours conseillée.
- 46 -
LIPROMU2
La fiabilité de l'installation est étroitement liée à la qualité du câblage; sa réalisation
doit donc s'effectuer dans les règles de l'art en utilisant un câble multipolaire ou des
câbles unipolaires ayant une section adaptée aux courants en jeu et des caractéri-
stiques pare-flammes; pour plus de sécurité, se référer à la norme EN60204 - 1.
En cas de branchements externes à l’unité de réception, nous conseillons d’utiliser
des câbles avec protection contre l’huile.
L’alimentation de l’unité de réception doit obligatoirement passer

par un interrupteur pour permettre de couper l'alimentation durant
les opérations d’installation, de câblage et/ou d’entretien.
Pour obtenir le meilleur fonctionnement possible de la radiocom-
mande, connecter l’unité de réception immédiatement en aval de
l’interrupteur général de la machine.
Il est toujours opportun de contrôler également la valeur de l’alimentation sous char-

ge maximale de façon à en vérifier les variations maximales (les valeurs limites
d’écart tolérées sont reportées dans les Données Techniques et sur la fiche technique
de la Radiocommande).
Des fluctuations de tension de l’alimentation de l’unité de réception

dépassant les valeurs limites peuvent compromettre le fonctionne-
ment régulier de la radiocommande.
Les radiocommandes de la série C26-PRO sont équipées de circuits de protection contre les
mouvements involontaires par la position de repos des actionneurs (fonction de SAFETY).
Cette protection est efficace si, dans l'unité de réception, le commun des commandes
de mouvement provient de la série du contact de STOP et du contact de SAFETY (qui
se ferme quand une commande de mouvement est transmise). Vice versa, le com-
mun des commandes de sélection peut n’être pas en série avec le contact de SAFETY.
Exemple de
câblage
Réglage
des sorties
proportion- Autec fournit la radiocommande avec des valeurs de réglage des
nelles sorties proportionnelles déjà programmées. Durant l’installation
ces valeurs doivent être vérifiées et éventuellement modifiées selon
les nécessités de fonctionnement de la machine (voir chapitre 11).
Vérifications
essais A la fin de l'installation et du câblage, il est toujours nécessaire de:
- vérifier qu’en actionnant le bouton de STOP de la radiocommande, la mise en sé-
curité de la machine (à l’aide d’une action directe sur l’électrovanne générale du
circuit principal), l’extinction éventuelle du moteur et, s’il est présent, l’ouvertu-
re du télérupteur principal aient lieu de façon à enlever la tension.
- s’assurer que les manoeuvres effectuées par la machine et les commandes de l'unité
de transmission correspondent exactement (cette correspondance est reportée
sur la fiche technique)
- contrôler le fonctionnement du circuit de sécurité (une façon simple est celle d’en-
lever le fusible F3, placé sur la carte principale de l’Unité de réception) et vérifier que
dans ces conditions aucune commande de mouvement ne puisse être effectuée; à la
fin insérer à nouveau le fusible F3 et s’assurer que le fonctionnement soit correct)
L'installateur doit aussi remplir et/ou vérifier les deux exemplaires présents
de la fiche technique là où l’on a reporté le schéma de câblage entre l’unité
de réception et la machine. Le premier exemplaire de la fiche technique est
inséré à l’intérieur de l’unité de réception, le deuxième est joint au manuel
d’utilisation. L’installateur doit inscrire la date de mise en fonction de l'in-
stallation avec son tampon et sa signature sur chacun des deux exemplaires.
LIPROMU2
- 47 - Français
5 CONSEILS POUR L’UTILISATION DE LA RADIOCOMMANDE
L’utilisation de la radiocommande est permise uniquement à des
opérateurs qui:
- ont lu et compris le présent manuel,
- sont qualifiés et formés,
- connaissent bien le système "radiocommande + machine".
Autec ne pourra être tenue responsable si la radiocommande est in-

stallée sur des applications différentes de celles qui sont permises
et si elle est utilisée en conditions de travail non aux normes.
Chaque fois que l'on allume l'unité de transmission, vérifier que le

bouton-poussoir de STOP fonctionne correctement et que son action-
nement interrompe instantanément les mouvements de la machine.
En cas contraire, ne pas utiliser la radiocommande.
Avant l'utilisation de la radiocommande, l'opérateur doit toujours

controler que les deux unités sont intègres et les garnitures, les
soufflets, et les capuchons des actionneurs (joystick, sélecteurs et
boutons-poussoirs) sont intègres. Le cas contraire, la radiocom-
mande ne doit pas etre utilisée avant d'avoir été réparée.
Pour travailler de façon efficace et pour prévenir d’éventuelles si-

tuations d’urgence, il faut choisir une position qui permette de:
- rester à l’intérieur du rayon d’action de la radiocommande (voir
chapitre )
- suivre visuellement et à tout moment la machine, ses mouvements
et l’éventuel chargement.
Durant le fonc-
tionnement L’opérateur devra:
- éteindre l’unité de transmission chaque fois qu’il suspend le travail
- ne JAMAIS laisser l’unité de transmission sans surveillance avec la
clé d’allumage insérée
- éviter de travailler avec la batterie presque épuisée.
L’opérateur ne devra jamais allumer ou actionner l’unité de tran-

smission sauf s’il commence à travailler. Il est en effet possible de
créer une liaison radioélectrique même en dehors du rayon d’action
et à partir d’endroits clos faisant ainsi exécuter des commandes non
voulues à la machine radiocommandée.
En cas de
danger Au cas où on constaterait une condition de danger, l’opérateur de-
vrait intervenir immédiatement en actionnant le bouton de STOP qui
interrompt instantanément les mouvements de la machine
Etant donné que tous les dangers ne sont pas causés par le système
“radiocommande + machine”, l’opérateur devra aussi être attentif
dans lescas d’urgence qui pourraient advenir dans la zone de tra-
vail. Dans ce cas-là aussi, l’opérateur devra intervenir manuelle-
ment actionnant la commande de STOP.
En cas de
panne Quel que soit le cas de panne ou de présence de parties endomma-
gées, on DOIT mettre hors sevice le système “radiocommande +
machine” jusqu’à complète élimination du problème existant.
Les éventuelles pannes pannes peuvent être réparées exclusive-
ment par du personnel autorisé Autec, en utilisant seulement des
pièces de rechange originales Autec.
6 CONSEILS POUR L’ENTRETIEN ORDINAIRE DE LA RADIO-

COMMANDE
Durant toutes les opérations d’entretien ordinaire de la radiocom-
mande et de la machine, enlever la batterie de l’unité de transmis-
sion et débrancher la fiche de branchement de l'unité de réception.
- 48 -
LIPROMU2
Toutes les interventions de contrôle et d'entretien de la radiocommande doivent être
vérifiées et enregistrées par le Responsable de l'Entretien de la machine.
L'entretien ordinaire d'après les indications contenues dans ce ma-

nuel est fondamental pour un fonctionnement sûr de la radiocom-
mande.
Après chaque intervention d’entretien, toujours vérifier que les

commandes envoyées par l'unité de transmission actionnent exclu-
sivement les manoeuvres prévues.
Indications
récapitulati- Les indications qui suivent doivent être considérées comme indications minimales in-
ves dispensables pour le fonctionnement sûr et correct de la radiocommande.
Certaines applications particulières peuvent demander des interventions d'entretien
ordinaire plus spécifiques et ayant des délais différents.
Ces indications ne peuvent en aucun cas assumer un caractère contractuel, remplacer
les normes et les lois en matière de sécurité du travail et limiter les responsabilités
de l'acheteur et de l'utilisateur de la radiocommande.
Toutes les indications reportées doivent être exécutées à chaque mise en
service de la machine et de la radiocommande.
Composant Périodicité
Tous les Tous les Tous les Tous les
jours 3 mois 6 mois 12 mois
Unité de transmission X
Unité de reception X
Fonctionnalité électrique X
Conducteurs électriques externes X
Si, durant une intervention d'entretien ordinaire, on remarque des

anomalies, mettre hors service le système "machine+radiocom-
mande" en suivant les indications reportées (voir chapitre 7).
Unité de
transmission Tous les jours, il faut:
1. Enlever la poussière ou accumulations d’autre matériel de l’unité de transmission:
pour nettoyer ne jamais utiliser de solvants ou de produits inflammables/corrosifs et
ne pas utiliser de nettoyeurs à jet d’eau à haute pression ou d’appareils à vapeur.
2. Emmagasiner l’unité de transmission dans un lieu propre et sec.
3. Vérifier que dans l’unité de transmission les garnitures, les soufflets et les capu-
chons des joysticks, des sélecteurs et des boutons-poussoirs soient intègres, souples
et élastiques
4. S’assurer que l’emplacement où est legée la batterie et les contacts de la batterie
soient propres.
5. Contrôler que l’unité de transmission soient intègres structurellement
6. Vérifier que les symboles du panneau soient bien visibles et, éventuellement, rem-
placer ce même panneau
7. Contrôler la lisibilité et l'intégrité de la plaquette d'identification
Unité de
réception Tous les 3 mois, il faut:
1. Enlever la poussière ou accumulations d’autre matériel de l’unité de réception:
pour nettoyer ne jamais utiliser de solvants ou de produits inflammables/corrosifs et
ne pas utiliser de nettoyeurs à jet d’eau à haute pression ou d’appareils à vapeur.
2. Contrôler que l’unité de réception soient intègres structurellement
3. Vérifier l'intégrité et la connexion du câblage interne à l'unité de réception
4. Vérifier que les symboles du panneau soient bien visibles et, éventuellement, rem-
placer ce même panneau
5. Contrôler la lisibilité et l'intégrité de la plaquette d'identification
Fonctionnali-
té électrique Tous les 6 mois, il faut:
1. Vérifier le fonctionnement correct des contacts de tous les relais de l'unité de ré-
ception en contrôlant la fermeture du contact lors de l'activation de la manoeuvre cor-
respondante et l'ouverture du contact lors de la désactivation de la manoeuvre
2. Vérifier la correspondance correcte entre commandes envoyés et manoeuvres exé-
cutées.
LIPROMU2
- 49 - Français
Conducteurs Tous les 12 mois, il faut:
électriques 1. Vérifier l'intégrité du câble de branchement entre unité de réception et machine
externes sur toute sa longueur.
2. Vérifier l'intégrité et le branchement des fiches et des prises de branchement
3. Vérifier et éventuellement remplacer les brides ou autres systèmes de fixation
4. Vérifier que la gaine du câble de branchement ne présente pas de détériorations,
surtout en face des serre-câbles
5. Vérifier l'intégrité de la fiche et des prises de branchement.
7 CONSEILS POUR L’ENTRETIEN EXTRAORDINAIRE DE LA RA-

DIOCOMMANDE
Durant toutes les opérations d’entretien extraordinaire de la radio-
commande et de la machine, enlever la batterie de l’unité de transmis-
sion et débrancher la fiche de branchement de l'unité de réception.
.
Les éventuelles pannes pannes peuvent être réparées exclusive-
ment par du personnel autorisé Autec, en utilisant seulement des
pièces de rechange originales Autec.
Pour rendre possible une intervention plus rapide et plus efficace, il faut communiquer
les données de la radiocommande:
- numéro de matricule
- date d’achat (reportée sur le certificat de garantie)
- anomalie constatée
- adresse et numéro de téléphone du lieu où elle est utilisée (avec le nom du respon-
sable à contacter)
- l’entreprise qui l’a fournie.
Avant de faire intervenir les techniciens du Service après-vente, il convient
d’avoir lu et compris toutes les parties du présent manuel en vérifiant d’avoir
exécuté correctement toutes les instructions reportées.
8 DOCUMENTATION
La documentation jointe à la radiocommande industrielle est
toujours composée d'au moins:
- manuel d'instructions et précautions
- manuel du chargeur de batteries
- déclaration de conformité CE
- certificat de garantie
- fiche technique de la radiocommande
- feuille "Limitations & Autorisations".
Vérifier que ces annexes soient présentes: en cas contraire, en faire

la demande à Autec en spécifiant le numéro de matricule de la ra-
diocommande.
Manuel d'in-
structions et Le présent manuel fait partie intégrante de la radiocommande et de ses fonctions de
précautions sécurité et a comme objectif de fournir les principales indications nécessaires à l’in-
stallation, l’utilisation et l’entretien de la radiocommande.
Toutes les opérations d'installation, d’utilisation et d’entretien doivent im-
pérativement être effectuées par du personnel qualifié et formé de façon ap-
propriée dans le respect des normes et des lois de référence.
Il est donc nécessaire que le présent manuel ait été lu et compris entièrement au mo-
ins par le propriétaire de la radiocommande, par l’installateur de la radiocommande,
par l’opérateur/utilisateur de la radiocommande, par le responsable et le préposé à
son entretien.
Pour les indications et les précautions concernant la machine commandé par
la radiocommande, suivre ce qui est indiqué par le constructeur de la machine.
En cas d'endommagement ou de perte du présent manuel, il est nécessaire d'en de-
mander une copie à Autec en spécifiant le numéro de matricule de la radiocommande
qui lui est associée.
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LIPROMU2
Les informations contenues dans le présent manuel sont sujettes à modifications sans
préavis et ne sont données qu'à titre indicatif (Document non contractuel). Toute re-
production ou représentation, intégrale ou partielle, sous quelque forme ou par quel-
que procédé que ce soit, de cet imprimé ne peut être faite sans le consentement
préalable de la société Autec.
Certificat de
garantie Les conditions qui réglementent la garantie de la radiocommande sont reportées sur
le "Certificat de Garantie" joint au présent manuel.
Les parties électroniques ayant 3 ans de garantie sont: MTX_____,
MRX_____, RD97____, RI97____ et CH97____.
Fiche
technique La fiche technique représente le schéma de câblage entre l’unité de réception et la ma-
chine. Elle doit être remplie et contrôlée par l’installateur qui est responsable du bon
câblage. Après avoir effectué ces vérifications nécessaires, l'installateur doit signer la
fiche technique qui doit rester annexée au manuel d'utilisation (au cas où on l'utilise-
rait pour des démarches administratives, toujours en conserver un exemplaire).
Plaque de
identification Les données d’identification et d’homologation de la radiocommande sont indiquées
sur la plaquette prévue à cet effet, aussi bien sur l’unité de transmission que sur l’uni-
té de réception.
Ces plaques NE DOIVENT pour aucune raison être enlevées de leur emplace-
ment ou abîmées, sous peine de faire déchoir la garantie.
9 UNITÉ DE TRANSMISSION ET SON FONCTIONNEMENT
L A E A actionneurs (joystick ou sélecteurs)
B bouton deSTOP
C bouton START / klaxon
D clé d’allumage
H E sélecteur rpm +/-
F sélecteur velocità
G batterie
H plaque d’identification
L voyant de signalisation (vert et

D rouge)
C
G
F
B
Allumage et
mise en marche
S'assurer que la clé d'allumage est en position “O”, mettre en place la bat-
terie dans son compartiment sans forcer. Vérifier que le poussoir de Stop
et qu'aucun actionneur n'est actionné.
Tourner la clé d'allumange en position “I” et actionner le poussoir ou le
selecteur de “START” jusqu’à quand le voyant vert commence à clignoter.
L’allumage s’effectue seulement si la batterie est suffisamment

chargée et si tous les actionneurs sont débranchés.
Commandes
Les commandes à la machine radiocommandée peuvent être exécutées uniquement
après que la liaison radioélectrique entre unité de transmission et unité de réception
a eu lieu (signalée par l’allumage du témoin ENABLE présent dans l’unité de réception
(voir chapitre 10)).
Agir sur les actionneurs correspondant à la manoeuvre qu’on entend commander.
Toutes les commandes protégées par la fonction SAFETY sont approuvées en catégo-
rie 3 selon la EN 954 - 1 pour la protection des mouvements non voulus de la position
de repos (UMFS - Unintended Movement From Standstill).
Quelques-unes des commandes disponibles dans l’unité de transmission sont les sui-
vantes:
LIPROMU2
- 51 - Français
Klaxon
Avec l’unité de transmission allumée et en appuyant sur le bouton de START, on ac-
tionne le klaxon/alarme de la machine.
STOP
Pour arrêter immédiatement la machine, appuyer sur le bouton de STOP: après quel-
ques instants, l’unité de transmission s’éteint automatiquement.
Pour reprendre le travail, tourner le bouton de STOP dans le sens indiqué et répéter
la procédure d’allumage et de démarrage.
Le bouton de STOP doit être utilisé chaque fois qu’il faut arrêter im-
médiatement la machine à cause d’une quelconque condition de
danger.
Le circuit de STOP est conforme aux qualité requises de la catégorie 4 d’après la EN 954-1
RPM +/-
Ce sélecteur a une double fonction:
1) durant le fonctionnement normal: il sert à augmenter (rpm +) ou dimi-
nuer (rpm -) les tours du moteur de la machine
2) durant la phase de réglage (REMOTE SET UP): voir le chapitre 11.
Sélecteur
de vitesse Il peut y avoir un sélecteur de vitesse qui sert à faire fonctionner la machine à des
vitesses différentes selon les besoins du travail. Il peut être à deux, trois ou quatre
positions qui habilitent respectivement deux, trois et quatre niveaux de vitesse.
Changement
de fréquence En cas d’interférence ou de conflit avec d’autres installations radio, il est possible de
changer la fréquence radio à laquelle on travaille.
Avec l’unité de transmission allumée et démarrée, il faut maintenir le bouton de
START actionné pendant 5-6 secondes: un bip prolongé accompagné de l’allumage
des deux led de signalisation indiquera que le changement de fréquence a eu lieu.
Durant cette opération, l’unité de réception s’éteint: pour reprendre le travail, ap-
puyer à nouveau sur le bouton de START comme une normale opération de démar-
rage.
Signalisa-
tions des led Certaines conditions de fonctionnement de l’unité de transmission sont mises en évi-
dence par deux led de signalisation (une de couleur verte et une de couleur rouge).
Type Voyant
de signal vert rouge
clignotement fonctionnement /
lent normal
Avis que la Avis que la
clignotement rapite batterie est presque batterie est déchar-
déchargée gée
commande
lumière continue* / enclenchée pedant l
a mise en marche
lumière permanent et changement
simultané des deux de fréquence
voyant advenu
* accompagnée par le signal acoustique
À 90% environ de l'état de décharge de la batterie, le rythme du clignotement du vo-

yant vert augmente pour signaler la nécessité de procéder à la recharge de la batterie.
Au cas où l'on continue à utiliser la radiocommande, 3 minutes environ avant la dé-
charge totale de la batterie, le voyant rouge commence à clignoter et une alarme so-
nore retentit en même temps. Dans cette situation, mettre la machine en état de
sécurité (en enfonçant le poussoir de stop), éteindre l'émetteur et procéder à la re-
charge de la batterie ou bien la remplacer par une autre déjà rechargée.
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LIPROMU2
Extinction
Tourner la clé d’allumage en position "O".
Se rappeler de toujours extraire la clé d’allumage et de la déposer en lieu sûr.
Extinction
automatique L’extinction de l’unité de transmission peut aussi se dérouler automatiquement
quand:
- la batterie n’est pas assez chargée et/ou
- la radiocommande n’est pas utilisée depuis environ 3 minutes et demie (la fonction d’ex-
tinction automatique peut être déshabilitée en s’adressant au personnel autorisé Autec).
Recharge de
la batterie Retirer la batterie de l'émetteur et la mettre dans le chargeur de batterie.
La charge en cours est signalée par l'allumage du témoin "ON CHARGING" (EN CHAR-
GE). La fin de charge est indiquée par l'allumage du témoin "END OF CHARGE" (FIN
DE CHARGE). La charge de la batterie doit se faire par une température ambiante
comprise entre +5°C et +45°C.
Pour toutes les instructions, les précautions et les données techni-

ques des batteries et du chargeur de batteries, voir le livret fourni
correspondant.
10 UNITE DE RECEPTION
A
P
G G
B B
C C
F L
M
N
G G
A antenne B témoin POWER
B témoin POWER C témoin ENABLE
C témoin ENABLE H module RI97-08
D fiche L fusible F1
E plaque d’identification M fusible F2
F donneé technique plaque N fusible F3
G vis de fermature P internal voyant
Signalisa-
tions externesLe témoin POWER indique la présence (allumé) ou non (éteint) d'alimentation dans l'uni-
té de réception.
Le témoin ENABLE indique que la liaison est effectuée (allumé) ou non (éteint) entre
l'unité de transmission et l'unité de réception.
Le fonctionnement correct est signalé par:
- POWER et ENABLE allumés de façon continue, avec unité de transmission allumée;
- POWER allumé de façon continue et ENABLE éteint, avec unité de transmission éteinte.
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- 53 - Français
Signalisa-
tions internes Les led présentes visualisent que l’un des relais s’est inséré: quand une led s’allume,
cela indique que le relais correspondant à la commande, reporté dans le schéma sui-
vant, est actionné (schéma présent également sur le côté interne du couvercle de
l’unité de réception):
SAFETY
Pour protéger le système contre les mouvements involontaires dus à d’éventuelles
pannes de la radiocommande, la même est équipée d'une fonction de sécurité ap-
pelée SAFETY. Cette fonction contrôle constamment la position de repos (neutre) des
actionneurs de mouvement dans l’unité de transmission et est disponible en sortie sur
le relais de SAFETY dans l’unité de réception.
FLOW
En actionnant une commande de mouvement, on actionne aussi la fonction de FLOW:
celle-ci commande l’électrovanne qui met l’huile sous pression dans le circuit hydrau-
lique primaire du distributeur.
T.S.
Le T.S. (TIMED STOP) est la commande qui éteint le moteur diesel de la machine: il
reste actif pendant 10 secondes après l’activation du bouton de STOP.
Fusibles
Les trois fusibles présents à l’intérieur de l’unité de réception ont les caractéristiques
suivantes:
Fusible Description Fiche tecnique
F1 protection de POWER SUPPLY 4A (32Vdc, autofuse)
F2 protection du circuit de STOP 10A (32Vdc, autofuse)
F3 protection du circuit de SAFETY 10A (32Vdc, autofuse)
11 PROCÉDURE DE RÉGLAGE DES SORTIES PROPORTION-

NELLES (REMOTE SET UP)
La procédure de réglage des sorties proportionnelles doit être exécu-
tée uniquement par du personnel qualifié et formé, et doit être effec-
tuée en respectant toutes les précautions présentes dans les
chapitres 4, 5, 6 et 7.
Information
sur le module Les sorties proportionnelles du module RI97-08____ sont indiquées aux valeurs présentes
RI97-08 sur la fiche technique jointe. Le numéro de la fiche technique correspondant à chaque in-
stallation est reporté sur l'étiquette présente sur la clé de mémoire des données (K2)).
C3 C1 C2 S L P C1 connecteur pour les sorties proportionnelles
C2 connecteur pour les sorties proportionelles

auxiliaires
C3 connecteur pour l’alimentation
C4 connecteur pour la clé deréglage
C5 connecteur pour le branchement à la carte bus
L LED verte
K1 clé de réglage
K2 clè de mémories des données
P bouton-poussoir de rétablissement des tara-

C5 C4 K1 ges initiaux
K2
S sélecteur rotatif
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LIPROMU2
Ne jamais laisser la clé de réglage K1 insérée durant le fonctionne-
ment de la radiocommande: elle sert seulement durant la phase de
réglage et, quand elle est insérée, elle habilite une seule commande
proportionnelle à la fois.
Pour rétablir les valeurs des sorties proportionnelles initiales (c'est-à-dire celles qui
sont indiquées sur la fiche technique), avec la clé de réclage insérée, appuyer sur le
bouton-poussoir de rétablissement P enclenché jusqu'à ce que la LED verte corre-
spondante L arrête de clignoter et assume la signalisation de lumière continue. En cas
de remplacement du module, pour garder les mêmes valeurs présentes dans les sor-
ties proportionnelles, il suffit de déplacer la clé de mémoire K2 du vieux module au
nouveau.
Préparation
au réglage 1. S’assurer que l’unité de transmission soit éteinte.
2. Couper l’alimentation à l’unité de réception.
3. Ouvrir l’unité de réception et insérer la clé de réglage K1 dans le connecteur C4.
4. Fournir l’alimentation à l’unité de réception. ATTENTION: A partir de ce moment-
là, jusqu’à la fin du réglage, ne pas toucher l’unité de réception (on risque de perdre
les mises au point programmées)
5. Dans l’unité de transmission, tourner la clé d’allumage dans la position "I" et ap-
puyer sur le bouton de START.
6. Tourner la clé d’allumage dans la position " " (REMOTE SET UP).
Réglage
7. Sélectionner les paramètres à régler à l’aide du sélecteur rotatif S présent sur le mo-
dule RI97-08 et en agissant sur le sélecteur RPM+/- présent dans l’unité de transmission
(où le + sert à augmenter la valeur qu’on est en train de régler et le – à la diminuer).
Dans les modules avec sorties sous tension, les réglages dans les posi-
tions 1, 2, 3, 4 et 5 sont possibles. Dans les modules avec sorties en cou-
rant (PWM), les réglages dans les positions 0, 1, 3 et 4 sont possibles.
Durant le réglage, en déplaçant le joystick hors de sa position de re-

pos, un coup de Klaxon/alarme d’environ 0,5 seconde signale qu’on
est en zone de réglage du minimum.
Les réglages doivent être exécutés pour chaque position du sé-

lecteur de vitesse présent dans l’unité de transmission.
Réglages
dans les mo- Position 1: minimums et maximums Z2-Z7
dules avec Avec le sélecteur rotatif en position 1 on règle la valeur maximale et minimale de ten-
sorties sous sion des différents demi- axes d'un joystick. Procéder ainsi:
tension 1. Pour fixer la valeur maximale, mettre le joystick à l'amplitude maximale sur le
demi-axe à régler. En gardant cette position, actionner le sélecteur à levier RPM +/
- présent dans l'unité de transmission pour modifier la valeur désirée.
2. Pour fixer la valeur minimale, mettre le joystick hors de la position de repos (pas
au-delà de la moitié de l'amplitude) sur le demi-axe à régler. En gardant cette posi-
tion, actionner le sélecteur à levier RPM +/- présent dans l'unité de transmission pour
modifier la valeur désirée.
Position 2: tension de la position de repos du joystick
Avec le sélecteur rotatif en position 2, on règle la valeur de la tension qui correspond
à la position mécanique de repos du joystick. Normalement cette valeur ne doit pas
être modifier. Si nécessaire, procder de la façon suivente:
- mettre un joystick quelconque hors de la position de repos
- en gardant cette position, actionner le sélecteur à levier RPM +/- présent dans l'uni-
té de transmission pour modifier la valeur désirée.
Positions 3 et 4: minimums et maximums Z8 et Z9
Avec le sélecteur rotatif en position 3 et 4, on règle les valeurs maximales et minima-
les de tension en fonction des sorties auxiliaires Z8 et Z9. Procéder ainsi:
1. Pour fixer la valeur maximale, tourner la manette présent dans l’unité de transmis-
sion, correspondant à la commande Z8 (ou Z9) à fond, dans le sens des aiguilles
d'une montre. En gardant cette position, actionner le sélecteur à levier RPM +/- pré-
sent dans l'unité de transmission pour modifier la valeur désirée.
2. Pour fixer la valeur minimale, tourner la manette, présent dans l’unité de tran-
smission, correspondant à la commande Z8 (ou Z9) à fond, dans le sens contraire des
aiguilles d'une montre. En gardant cette position, actionner le sélecteur à levier RPM
+/- présent dans l'unité de transmission pour modifier la valeur désirée.
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Position 5: inversion des demi-axes
Avec le sélecteur rotatif en position 5, on inverse la direction des demi-axes. Procéder
ainsi:
- mettre le joystick correspondant à l'axe à inverser hors de la position de repos
- en gardant cette position, actionner le sélecteur à levier RPM +/- présent dans l'uni-
té de transmission en la déplaçant dans la position + pour inverser la direction des
demi-axes ou dans la position - pour rétablir la direction des demi-axes.
Réglages
dans les mo- Position 0: fréquence du signal PWM
dules avec Avec le sélecteur rotatif en position 0 on règle la fréquence du signal PWM. Normalement
sorties en cette valeur ne doit pas être modifier. Si nécessaire, procder de la façon suivente:
courant - placer un joystick hors de la position de repos
(PWM) - en gardant cette position, actionner le sélecteur à levier RPM +/- présent dans l'uni-
té de transmission pour modifier la valeur désirée.
Position 1: minimums et maximums Z2-Z7
Avec le sélecteur rotatif en position 1 on règle la valeur maximale et minimale de ten-
sion des différents demi- axes d'un joystick. Procéder ainsi:
1. Pour fixer la valeur maximale, mettre le joystick à l'amplitude maximale sur le
demi-axe à régler. En gardant cette position, actionner le sélecteur à levier RPM +/
- présent dans l'unité de transmission pour modifier la valeur désirée.
2. Pour fixer la valeur minimale, mettre le joystick hors de la position de repos (pas
au-delà de la moitié de l'amplitude) sur le demi-axe à régler. En gardant cette posi-
tion, actionner le sélecteur à levier RPM +/- présent dans l'unité de transmission pour
modifier la valeur désirée.
Positions 3 et 4: minimums et maximums Z8 et Z9
Avec le sélecteur rotatif en position 3 et 4, on règle les valeurs maximales et minima-
les de tension en fonction des sorties auxiliaires Z8 et Z9. Procéder ainsi:
1. Pour fixer la valeur maximale, tourner la manette présent dans l’unité de transmis-
sion, correspondant à la commande Z8 (ou Z9) à fond, dans le sens des aiguilles
d'une montre. En gardant cette position, actionner le sélecteur à levier RPM +/- pré-
sent dans l'unité de transmission pour modifier la valeur désirée.
2. Pour fixer la valeur minimale, tourner la manette, présent dans l’unité de tran-
smission, correspondant à la commande Z8 (ou Z9) à fond, dans le sens contraire des
aiguilles d'une montre. En gardant cette position, actionner le sélecteur à levier RPM
+/- présent dans l'unité de transmission pour modifier la valeur désirée.
Mémorisation
du réglage 8. Eteindre l’unité de transmission pour mémoriser les réglages.
9. Couper l’alimentation à l’unité de réception.
10. Extraire la clé de réglage K1.
12 FRÉQUENCES RADIO
Les fréquences radio programmées dans la radiocommande appartiennent à l’ensem-
ble des fréquences admises par les normes européennes en vigueur au moment de
son introduction sur le marché.
Vérifier dans l’annexe “Limitations & Autorisations” de ce manuel

les éventuelles limitations dans le pays d’utilisation.
Une radiocommande peut être programmée en modalité de SCANSION AUTOMATI-

QUE ou de SÉLECTION MANUELLE.
Scansion
automatique Normalement, la radiocommande est programmée par le constructeur dans cette mo-
dalité: elle peut donc fonctionner dans une des fréquences disponibles quelconque. En
cas d’interférence ou de conflit avec d’autres installations, cette modalité permet de
déplacer la fréquence de travail (voir "Changement de la fréquence de travail") sans
devoir intervenir à l’intérieur ni de l’unité de transmission, ni de l’unité de réception.
Selection
manuelle Pour programmer cette modalité de fonctionnement de la fréquence
radio de travail, contacter exclusivement le personnel autorisé Autec.
Une radiocommande qui opère en modalité de sélection manuelle permet de travailler

à une fréquence spécifique. Pour programmer cette fréquence, il faut régler les dip
switch présents dans le module émetteur et récepteur.
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LIPROMU2
13 DIAGNOSTIC
Si la "radiocommande + machine" ne démarre pas, il faut contrôler si le problème
concerne la radiocommande ou la machine. Ainsi avant toute vérification, brancher le
poste de commande par câble: si la machine ne démarre pas, le problème concerne
la machine elle-même.
Si, au contraire la machine démarre régulièrement seulement si elle est actionnée à
partir du poste de commande par câble, le problème concerne la radiocommande.
Dans ce cas, effectuer les contrôles suivants.
Diagnostic
unité de tran- La led de signalisa- La led de signalisa- La led de signalisa-
smission tion verte est allumée tion verte est allumée tion rouge est allu-
de façon intermitten- de façon mée de façon
te lente? intermittente rapide? continue?
Désactiver les action-

Effectuer Insérer une batterie neurs et/ou le bouton
le diagnostic de véritablement de STOP éventuelle-
l'unité de réception. chargée ment insérés
Si l'unité de transmis-
sion ne s'allume pas de
façon correcte, APPE-
LER LE SERVICE
Diagnostic
unité de Brancher
La prise de branchement
rèception Le témoin correctement
entre l'unité de réception
POWER la prise et démarrer
et la machine est con-
est allumé? la radiocommande.
nectée correctement?
Togliere tensione Substituer le fusible.

all’unità ricevente ed Contrôler les
aprirla. Il fusibile F1 è branchements
integro? d'alimentation.
APPELER Remettre la tension

et
LE SERVICE
démarrer.
Le témoin Effectuer la procédu-

ENABLE re de changement de
est allumé? fréquence. La machi-
ne démarre?
Couper la tension à Substituer le fusibles.

l'unité de réception Remettre la tension
et l'ouvrir. Les fusibles et
F2 et F3 sont intègre? démarrer.
APPELER
LE SERVICE
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14 FICHE TECHNIQUE
Generali
Fréquence de fonctionnement ........................................ 433.050 - 434.790 MHz
............................................................................................ 869.7 - 870 MHz
Canaux radio utilisables (433 MHz) .............................................................. 64
Canaux radio utilisables (870 MHz) .............................................................. 12
Canalisation utilisée ................................................ 25 kHz (en option 12.5 kHz)
Distance de Hamming ................................................................................ 8
Probabilité de non déection des erreurs ................................................... <10-11
Rayon d’action typique............................................................................ 150 m
Temps d’urgence passive ................................................................. 0.5/1.5 sec
Temps de réponse des commandes .................................................. 70 - 120 ms
Temps de réponse de STOP ............................................................. 70 - 120 ms
Catégorie fonctions de sécurité selon la EN 954 - 1

Protection de STOP................................................................................. Cat. 3
Protection des mouvements non voulus de la position de zèro des actionneurs...... Cat. 4
Unité de
transmission Nombre de commandes disponibles ...... 6+2 analogiques+12 on/off + start + stop
Antenne ............................................................................................. interne
Type de modulation ............................................................................... GFSK
Puissance émetteur (433 MHz) ............................................................ <10 mW
Puissance émetteur (870 MHz) ............................................................. < 5 mW
Alimentation: piles ............................................................. NiMH 7.2V - 1.3 Ah
Tension d’extinction ............................................................................... 6.0 V
Autonomie avec batterie chargée (à 20°C) .................................... ca 10 heurres
Temps de préavis pour la batterie presque déchargée ......................... ca 15 min.
Temps de préavis pour la batterie déchargée ....................................... ca 3 min.
Température de service ....................................................... (-20°C) - (+55°C)
Boîtier ........................................................................................ PA6 fg 20%
Degré de protection ................................................................................. IP65
Dimensions ...................................................................... (263x160x173) mm
Poids (avec batterie) ............................................................................... 2 kg
Unité de
réception Tension d’alimentation ........................................................ 8 - 30 Vdc (< 40W)
Antenne ............................................................................................ externe
Pouvoit de contavts de relais STOP et SAFETY ................................ 10 A (30 Vdc)
Pouvoit de contavts de relais des commandes de mouvement ......... 4 A (30 Vdc)
Pouvoit de contavts de relais des commandes de sélection ............... 6 A (30 Vdc)
Sensibilité récepteur ..................................................... 0,5µV per 20 dB SINAD
Température de service ........................................................ (-20°C) - (+70°C)
Boîtier ........................................................................................ PA6 fg 20%
Degré de protection.................................................................................. IP65
Dimensions ........................................................................ (180x230x95) mm
Poids ................................................................................................... 2.8 kg
Schéma de parçage ..................................................................... A = 148 mm
B = 116 mm
C = 253 mm
D = 253 mm
Chargeur de
batterie et
batterie Données techniques (pour chargeur de batterie et batterie) indiqués dans l’exprés
cahier.
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LIPROMU2
1 CONVENCIONES
Las letras en negrita se emplean para los textos que hay que leer con par-
ticular atención.
Este símbolo caracteriza todas las indicaciones e informaciones de gran im-

portancia: el incumplimiento de éstas provoca situaciones de grave peligro
para las personas o cosas.
Este símbolo caracteriza todas las indicaciones y las informaciones impor-

tantes relacionadas al funcionamiento.
2 CONFORMITÀ
El radiomando PRO-M de la serie C26 PRO es conforme con la Directiva
R&TTE 99/05/CE y a sus requisitos fundamentales.
El radiomando además cumple las normas que se indican en la declaración de con-
formidad CE anexa a este manual.
Se recuerda que en algunos Estados se deben respetar leyes que re-

glamentan (ver anexo "Limitaciones y Autorizaciones").
Se pueden existir limitaciones nacionales de utilización de las fre-

cuencias, ya que no han sido armonizadas todavía en los estados eu-
ropeos. Comprobar, antes de su utilización, que el radiomando
funcione en una banda de frecuencia que autoricen las leyes nacio-
nales que regulen las radio comunicaciones.
Como requerido por la Directiva de Máquinas y de sus relativas armonizadas, hay que
realizar por cada máquina un análisis de los riesgos: por lo tanto, en caso de empleo
de un telemando, hay que valuar con el análisis de la máquina si la máquina se puede
teledirigir o no.
Este análisis es responsabilidad del fabricante de la máquina misma o de quién decide
instalar y utilizar el telemando.
Autec no se asume ninguna responsabilidad si este análisis de riesgos no se
ha efectuado de modo correcto y si el telemando ha sido instalado en aplica-
ciones diferentes de aquellas consentidas
APLICACIONES CONSENTIDAS
Máquinas de elevación y movilización instaladas exclusivamente en
vehículos que posean una alimentación eléctrica generada por una
batería ( por ejemplo: grúas hidráulicas, bombas de hormigón...)
APLICACIONES NO CONSENTIDAS
- en máquinas que hayan sido instaladas en ambientes en los que
sea necesarios equipamientos con características antideflagrante
- en máquinas que sean alimentadas con AC
- en máquinas donde la alimentación DC no provenga de una batería
- máquinas en las que el análisis de riesgos, realizada para la com-
probación de conformidad del radiomando en su aplicación, no sea
posible, haya resultado negativo o incierto
Para poder garantizar el funcionamiento correcto del telemando, se tienen que respe-
tar siempre todas las instrucciones sobre la seguridad en el trabajo y sobre la preven-
ción de accidentes en el trabajo. Además HAY que observar todas las leyes nacionales
relativas tanto al uso de la máquina como del telemando que estén en vigor en el
estado donde se utilice el sistema.
Autec no podrá asumirse alguna responsabilidad si se emplea el telemando
en condiciones de trabajo fuera norma.
LIPROMU2
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3 DESCRIPTCIÓN DEL RADIOMANDO
Los telemandos industriales se emplean para

radio-dirigir máquinas por control remoto.
Cada telemando industrial está constituido por
una unidad transmisora portátil, desde la que,
el operador puede dirigir a distancia la máquina
y por una unidad receptora instalada en la
máquina. La unidad transmisora manda un
mensaje codificado, a través de una transmi-
sión a radio frecuencia. En este mensaje se en-
cuentra un valor definido dirección (address) Unidad
que consiente a la unidad receptora descodifi- Receptora
car exclusivamente los mensajes que llegan de
la propia unidad transmisora (aquella que po-
see la misma dirección).
Esto excluye que una interferencia pueda acti- Unidad
var cualquier mando. De hecho, si la transmi- Transmissora
sión a radio frecuencia resulta disturbada,
equivocada o interrumpida la unidad receptora
detiene automáticamente todo el sistema.
4 ADVERTENCIAS PARA LA INSTALACIÓN DEL RADIOMANDO

La instalación tiene que ser efectuada exclusivamente por personal
cualificado, según las disposiciones del País en que se efectúe tal
operación. Sólo la correcta instalación puede asegurar el grado ne-
cesario de seguridad durante el próximo empleo del radiomando.
Indicaciones
generales Conectar el Radiomando a la máquina respetando las características de funciona-
miento de éste: no se deben excluir los circuitos de seguridad previstos para
el Radiomando o que se encuentren en la máquina.
La simple configuración del cableado de la Unidad Receptora permite su instalación

sin tener que intervenir en la máquina: no modificar el cuadro eléctrico de la máquina
sin autorización del constructor.
Desconectar la alimentación desconectando todas las conexiones

eléctricas cada vez que se efectúe una soldadura en la máquina.
Instalación
La unidad receptora se debe colocar de modo que favorezca la recepción de
las señales emitidas por la unidad transmisora. Por lo tanto, se debe montar
verticalmente (con la antena hacia arriba). La unidad receptora debe ser además
fácilmente accesible para permitir operaciones en modo seguro.
Si la unidad receptora se encontrase cubierta por estructuras metálicas o instalada al
interior de cuadros metálicos, emplear el kit-prolonga especial para antena externa.
La antena no debe entrar nunca en contacto con partes metálicas.
Se prohibe perforar el contenedor de la unidad receptora. Esta acción perju-

dica el grado de protección de los agentes externos (IP65).
Para reducir el efecto de vibración producido por el vehículo en la unidad receptora,

emplear siempre unos bloques antivibraciones.
Es oportuno colocar la unidad receptora lejos de fuentes de calor (tubos de escape,

alternadores, etc.).
Cableado
La mayor parte de la máquinas se tienen conectar a la unidad receptora con un en-
chufe múltiple que en caso de necesidad permita desconectar rápidamente el radio-
mando para sustituirlo con un mando con cable. Aun no estando la máquina
preparada para esto, se aconseja siempre, emplear esta técnica de conexión.
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LIPROMU2
La fiabilidad de la instalación depende en gran medida de la calidad del cableado, por
ello se recomienda el uso de cable multipolar o cables simples con una sección ade-
cuada a las corrientes en juego e ignífugos. Para mayor seguridad consultar la nor-
ma EN60204.
En el caso en que se efectúen conexiones externas a la unidad receptora se aconseja
emplear unos cables que estén protegidos contra el aceite.
La alimentación de la unidad receptora tiene que pasar obligatoria-

mente por un interruptor que consienta la desconexión de la alimen-
tación durante las operaciones de instalación, cableado y
manutención. Para poder obtener un mejor funcionamiento del ra-
diomando hay que conectar la unidad receptora inmediatamente
abajo del interruptor general de la máquina.
Conviene siempre comprobar el valor de la alimentación aunque bajo la máxima car-

ga para poder comprobar la variaciones máximas (los valores límite de recalenta-
mientos se encuentran en los Datos Técnicos de la ficha técnica del Radiomando).
Las oscilaciones de tensión en la alimentación de la unidad recepto-

ra que sobrepasen los valores límites pueden comprometer el fun-
cionamiento regular del radiomando
Los radiomandos de la serie C26-PRO están equipados con unos circuitos de protec-
ción contra los movimientos involuntarios en la posición de reposo de los actuadores
(función SAFETY). Esta protección es eficaz, si en la unidad receptora el común de los
mandos de movimiento se obtiene de la serie del contacto STOP y del contacto SA-
FETY (que se cierra cuando se transmite un mando de movimiento). Viceversa, el
común de los mandos de selección puede no estar en serie con el contacto SAFETY.
Ejemplo de
cableado
Regulociónes
salidas pro- Autec abastece el radiomando con los valores de tarado de las sali-
porcionales das proporcionales ya reguladas. Durante su instalación estos valo-
res deben ser comprobados y eventualmente modificados según las
necesidades de funcionamiento de la máquina (ver capítulo 11).
Verificaciones
y pruebas de Al fina de la instalación y del cableado es necesario siempre:
control - comprobar que cuando se accione el pulsador STOP del radiomando se accione la
protección de seguridad de la máquina (a través de la acción directa de la
electroválvula general del circuito principal), el eventual apagado del motor y, si
existe, la apertura del telerruptor principal que desconecte la tensión.
- cerciorarse que la correspondencia de las maniobras realizadas por la máquina y
los mandos de la unidad transmisora sean exactos (esta correspondencia se encuen-
tra en la ficha técnica)
-comprobar el funcionamiento del circuito de seguridad (un modo simple es el de
quitar el fusible F3, que se encuentra en la tarjeta principal de la Unidad Receptora y
verificar que ningún mando de movimiento pueda ser efectuado en estas condiciones;
al final insertar de nuevo el fusible F3 y asegurarse de su correcto funcionamiento).
El instalador tiene que rellenar y verificar las dos copias que se encuentran
en la ficha técnica y que ilustran el diagrama de cableado de efectuar entre
la unidad receptora y la máquina. La primera copia de la ficha técnica se en-
cuentra al interior de la unidad receptora, la segunda está anexa al manual
de uso. El instalador tiene que señalar la fecha de puesta en funcionamiento
del equipo, sellar y firmar cada copia.
LIPROMU2
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5 ADVERTENCIAS PARA LA UTILIZACIÓN DEL RADIOMANDO
L’utilización del radiomando está consentido sólo a operadores que:
- hayan leído y comprendido este manual,
- hayan sido cualificados y preparados,
- conozcan bien el sistema "radiomando + máquina".
Autec no puede asumirse ninguna responsabilidad si el radiomando

ha sido instalado en aplicaciones diversas de aquellas consentidas y
si se emplea en condiciones laborales fuera norma.
Cada vez que se encienda la unidad transmisora, hay que comprobar

que el pulsador STOP funcione correctamente, que su accionamien-
to interrumpa instantáneamente los movimientos de la máquina.
Si esto no se produjese, no utilizar el radiomando.
Es deber del operador comprobar que ambas unidades estén en per-

fectas condiciones, que las guarniciones, los fuelles y las capuchas
de los actuadores (joystick, selectores, pulsadores) estén en per-
fectas condiciones. Por el contrario, si esto no fuera así, no se debe
utilizar si antes no se ha reparado.
Para trabajar en modo eficaz y para poder prevenir posibles situa-

ciones de emergencia, es necesario elegir una posición que permita:
- permanecer al interior del radio de acción del radiomando (ver
capítulo 14)
- seguir en modo visual siempre la máquina, sus movimientos y su
eventual carga.
Durante el fun-
cionamineto El operador tendrá que:
- apagar la unidad transmisora cada vez que suspenda el trabajo
- no dejar NUNCA abandonada la unidad transmisora con la llave de
encendido insertada
- evitar trabajar con la batería casi agotada.
El operador no debe encender o accionar nunca la unidad transmisora

si no es para empezar a trabajar. De hecho, se puede crear una co-
nexión radioeléctrica aun fuera del radio de acción y de lugares cerra-
dos, pudiendo hacer ejecutar a la máquina radiodirigida indeseados.
En caso de
perigro En el caso en que se verificara una condición de peligro, el operador
tiene que intervenir inmediatamente presionando el pulsador de pa-
rada (STOP) que interrumpe instantáneamente los movimientos
que efectúaa la maquina.
Ya que no todos los peligros ser causando por el sistema “radioman-

do + máquina”, el operador tendrá que prestar atención aun en los
casos de emergencia que se verifiquen en la zona de trabajo. Aún en
este caso el operador tendrá que intervenir accionando el mando de
parada (STOP).
En caso di
avería En caso de averiá o presencia de partes deñadas HAY que poner fue-
ra de servicio el sistema “radiocomando+maquina” hasta eliminar
por compleo el problema existente.
Eventuales partes dañadas pueden ser sustituidas exclusivamente
por personal autorizado Autec, usando únicamente piezas de repue-
sto originales Autec.
6 ADVERTENCIAS PARA LA MANUTENCIÓN ORDINARIA

DEL RADIOMANDO
Durante todas las operaciones de manutención ordinaria del radio-
mando y de la máquina hay que quitar la batería de la unidad tran-
smisora y desconectar el enchufe de conexión de la unidad
receptora.
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LIPROMU2
Todas las intervenciones de control y de mantenimiento que se efectúen en el radio-
mando, se deben ser realizadas y registradas por el Responsable de Mantenimiento
de la máquina.
La manutención ordinaria según se indica en este manual, son fun-

damentales para obtener un funcionamiento seguro de la radioman-
do.
Se debe comprobar siempre, después de cada intervención sucesiva

a la instalación, que los mandos que transmite la unidad transmiso-
ra activen exclusivamente las maniobras previstas.
Resumen de
las Las indicaciones que siguen se deben considerar como las mínimas indispensables
indicaciones para un funcionamiento seguro y correcto del radiomando.
Aplicaciones particulares pueden requerir intervenciones de manutención ordinaria
más específicas en tiempos diferentes.
Por ningún motivo, estas indicaciones pueden asumir carácter contractual, sustituir
las normas y las leyes que conciernen la seguridad en el trabajo, y limitar las respon-
sabilidades del adquisidor y usuario del radiomando.
Todas las indicaciones que se señalan, se deben realizar, en cada puesta en
servicio de la máquina y del radiomando.
Componente Periodicidad
Cada Cada 3 Cada 6 Cada 12
día meses meses meses
Unidad transmissora X
Unidad receptora X
Función eléctrica X
Conductores eléctricos externos X
Si durante una intervención de mantenimiento se produjeran ano-

malías, poner fuera de servicio el sistema "máquima+radiomando"
siguiendo las indicaciones señaladas (ver capítulo 7).
Unidad
transmissora Es necesario cada día:
1. eliminar el polvo o acumulaciones de otros materiales de la unidad transmisora:
para limpiarlas no se debe emplear nunca disolventes o productos inflamables o cor-
rosivos y no se deben emplear hidrolimpiadoras a alta presión o aparatos de vapor.
2. almacenar la unidad transmisora en ambientes limpios y secos.
3. comprobar que en la unidad transmisora las guarniciones, los fuelles y caperuzas
de los joystick, selectores y pulsadores estén íntegros, suaves y elásticos
4. cerciorarse que el alojamiento y los contactos de la batería estén limpios
5. comprobar que la estructura de la unidad transmisora esté integra
6. comprobar que los símbolos del panel se vean bien, si no fuera así, sustituir el pa-
nel mismo.
7. comprobar que las placas de identificación sean bien legibles
Unidad
recptora Es necesario cada 3 meses:
1. eliminar el polvo o acumulaciones de otros materiales de la unidad receptora: para
limpiarlas no se debe emplear nunca disolventes o productos inflamables o corrosivos
y no se deben emplear hidrolimpiadoras a alta presión o aparatos de vapor.
2. comprobar que la estructura de la unidad receptora esté integra
3. comprobar la integridad y conexión del cableado interior de la unidad receptora
4. comprobar que los símbolos del panel se vean bien, si no fuera así, sustituir el pa-
nel mismo
5. comprobar que las placas de identificación sean bien legibles
Función
eléctrica Es necesario cada 6 meses:
1. comprobar que el funcionamiento de los contactos y de todos los relés de la unidad
receptora, comprobando el cierre del contacto para la activación de la maniobra cor-
respondiente, y la apertura del contacto para la desactivación de la maniobra
2. comprobar que correspondan los mandos transmitidos y las maniobras ejecutadas.
LIPROMU2
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Conductores
eléctricos ex- Es necesario cada 12 meses:
ternos 1. comprobar la integridad del cable de conexión entre la unidad receptora y la máqui-
na, en toda la longitud de éste.
2. comprobar la integridad y la conexión de los enchufes y de las tomas de conexión
3. Comprobar y eventualmente sustituir los zuncho u otros sistemas de fijación
4. comprobar que la guaina del cable de conexión no presente ningún desgaste, sobre
todo en proximidad de los recoge cables
5. comprobar la integridad de los enchufes y de las tomas de conexión
7 ADVERTENCIAS PARA LA EXTRAORDINARIA MANUTEN-

CIÓN DEL RADIOMANDO
Durante todas las operaciones de manutención extraordinaria del
radiomando y de la máquina hay que quitar la batería de la unidad
transmisora y desconectar el enchufe de conexión de la unidad re-
ceptora.
.
Eventuales partes dañadas pueden ser sustituidas exclusivamente
por personal autorizado Autec, usando únicamente piezas de repue-
sto originales Autec.
Para permitir una intervención rápida y eficaz se deben comunicar los datos del ra-
diomando:
- número de matrícula
- fecha de adquisición ( indicada en el certificado de garantía)
- anomalía encontrada
- dirección y número de teléfono del lugar donde se emplee (con el nombre del re-
sponsable que se debe contactar)
- empresa abastecedora
Antes de llamar los técnicos del Servicio de Asistencia es conveniente haber
leído y comprendido todas las partes de este manual, comprobando de haber
efectuado correctamente todas las instrucciones en él indicadas.
8 DOCUMENTACIÓN
La documentación que se adjunta al radiomando industrial, se com-
pone siempre de al menos:
- manual de instrucciones y advertencias
- la declaración de conformidad CE
- certificado de garantía
- ficha técnica
- anexo “Limitaciones & Autorizaciones”.
Comprobar que se hallen estos documentos anexos: si no fuera así,

solicitarlos a Autec especificando el número de matrícula del tele-
mando.
Manual de in-
strucciones y El presente manual forma parte integrante del radiomando y de sus funcio-
advertencias nes de seguridad y tiene como objetivo indicar las principales nociones que se de-
ben saber para la instalación, utilización y manutención del radiomando.
Todas las operaciones de instalación, utilización y manutención deben ser

efectuadas taxativamente por personal calificado y adecuadamente instrui-
do con respecto a las normativas y leyes de referencia. Por lo tanto, este ma-
nual lo deben haber leído y haber entendido cada parte por lo menos el propietario
del radiomando, el instalador del radiomando, el operador o usuario del radiomando,
el responsable o encargado de la manutención.
Por lo que concierne a las indicaciones y advertencias relativas a la máquina

dirigida por el telemando de radio, seguir las indicaciones del constructor de
la máquina.
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LIPROMU2
En caso de daño o perdida de este manual, hay que pedir una copia a Autec especi-
ficando el relativo número de matrícula del telemando de radio.
Las informaciones contenidas en el presente manual estan sujetas a modificaciones
sin previo aviso por parte de Autec. Bajo ningùn motivo puede ser reproducido, en
cualquier forma o medio, parte de este manual o el total del mismo sin el permiso
escrito de Autec.
Certificado de
garantía Las condiciones que regulan la garantía del radiomando se indican en el "Certificado
de Garantía" anexo a este manual. Las partes electrónicas con 3 años de garan-
tía son: MTX_____, MRX_____, RD97____, RI97____ y CH97____.
Ficha
técnica La ficha técnica representa el diagrama de conexionado entre la unidad de recepción
y la máquina. Esta tiene que ser rellenada y controlada por el instalador, éste tiene
la responsabilidad de efectuar el conexionado correcto. Efectuadas estas comproba-
ciones necesarias, el instalador tiene que firmar la ficha técnica que debe permanecer
anexa al manual de empleo (en el caso en que ésta se utilice para prácticas admini-
strativas hay que tener siempre una copia).
Placas de
identificatión Los datos de identificación y homologación del telemando están indicados en la ade-
cuada placa, ya sea sobre la unidad transmissora o sobre la unidad receptora.
Dichas placas NO SE TIENEN que quitar de su posición o dañar nunca por nin-
gún motivo, en caso contrario, la pena es la resolución de la garantía.
9 UNIDAD TRANSMISORA Y SU FUNCIONAMIENTO
L A E A actuadores (joystick o selector)
B pulsador de parada STOP
C pulsador de START / alarma
D llave de encendido
H E selector rpm +/-
F selectorde velocidad
G bateriá
H place de identificación
L led de señalización (verde y rojo)

D
C
G
F
B
Encendido y
activación Verificar que la llave de encendido está en posición "0" e introducir la ba-
tería en su sede sin forzarla. Verificar que el pulsador de parada y los ac-
tuadores no están accionados.
Girar la llave de encendido hasta la posición "I" y accionar el pulsador o
selector "START" hasta que el indicador verde (led), empiece a centellear.
Se enciende sólo si la batería está suficientemente recargada y si to-

dos los actuadores han sido desconectados.
Mandos
La máquina radiodirigida puede ejecutar los mandos sólo después de que la conexión
radioeléctrica entre la unidad transmisora y receptora se haya producido (que señala
el indicador luminoso ENABLE encendido que se encuentra en la unidad receptora (ver
capítulo 10)).
Accionar los actuadores que corresponden a las maniobras que se quieren ejecutar.
Todos los mandos que protege la función SAFETY están aprobados en la categoría 3
según la EN 954 - 1 para la protección de los movimientos involuntarios de la posición
de reposo.
Algunos mandos disponibles en la unidad transmisora son los siguientes:
Clacson
Con la unidad transmisora encendida si se presiona el pulsador START se acciona el
claxon o alarma de la máquina.
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STOP
Para detener inmediatamente la máquina presionar el pulsador STOP: después de un
instante la unidad transmisora se apagará automáticamente.
Para empezar de nuevo a trabajar girar en la dirección que se indica el pulsador STOP
y repetir el proceso de encendido y activación.
El pulsador STOP se tiene que emplear cada vez que se tenga que
detener inmediatamente la máquina a causa de cualquier situación
de peligro.
El circuito STOP es conforme con la categoría 4 según la EN 954-1.

RPM +/-
Este selector tiene un doble función:
1) durante un funcionamiento normal: sirve para aumentar (rpm +) o di-
sminuir (rpm -) los giros del motor de la máquina.
2) durante la fase de regulación (REMOTE SET UP): ver capítulo 11
Selector de
velocidad Puede existir un selector de velocidad que sirve para que la máquina funcione con di-
ferentes velocidades según las necesidades del trabajo. Este selector puede tener
dos, tres o cuatro posiciones que habilitan respectivamente dos, tres o cuatro niveles
de velocidad.
Cambio fre-
cuencia En caso de interferencia o conflicto con otros equipos radio se puede cambiar la fre-
cuencia radio con la que se está trabajando.
Con la unidad transmisora encendida y activada mantener accionado el pulsador
START por 5 - 6 segundos: un bip prolongado y acompañado del encendido de ambos
led de señalización indicarán que se ha producido el cambio de frecuencia. Durante
esta operación la unidad receptora se apaga: para poder empezar a trabajar hay que
presionar de nuevo el pulsador START como en una operación normal de activación.
Señalizacio-
nes led Algunas condiciones de funcionamiento de la unidad transmisora están evidenciadas
por dos led de señalización (uno de color verde y otro de color rojo).
Tipo Led
señal verde rojo
Centelleo funcionamiento /
lento normal
Centelleo Aviso que la bateriá Aviso que la
rápido casi descarga bateriá descarga
Luz continua mando activado
durante / durante el
el encendido * encendido
Luz continua y simultá- Cambio
nea de ambo Leds de frecuencia
* acompañada de una señal acústica
Cuando la batería ha suministrado aproximadamente el 90% de su carga, el led verde

con mayor frecuencia para indicarle al operador que es necesario recargarla. Si se
continúa a utilizarlo el Control Remoto, 3 minutos antes de que la batería se agote el
led rojo parpadea y se activa la señal acústica.
Cuando esto ocurre, colocar la máquina en condiciones de seguridad (accionando el
pulsador de parada), apagar la Unidad Transmisora y poner a recargar la batería o
sustituirla con una cargada.
Apagado
Girar la llave de encendido en la posición "O".
Hay que recordase siempre de extraer la llave de encendido y colocarla en un lugar
seguro.
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LIPROMU2
Apagado
automático El apagado de la unidad transmisora se puede producir automáticamente también
cuando:
- la batería no está suficientemente recargada y
- no se emplee el radiomando por unos 3 minutos y medio ( la función de apagado
automático se puede deshabilitar interpelando el personal autorizado Autec).
Recarga de la
batería Quitar la batería de la Unidad Transmisora e introducirla en la sede del cargador.
Mientras se está recargando la batería el testigo "ON CHARGING" permanece encen-
dido. El tiempo de recarga es de 8 a 10 horas aproximadamente. La recarga debe re-
alizarse con una temperatura ambiente entre +5 y +45 °C. Al finalizar el testigo "END
OF CHARGE" se enciende.
Para todas las instrucciones, las advertencias y los datos técnicos

de las baterías y del recargador de baterías ver el relativo manual
abastecido.
10 UNIDAD RECEPTORA
A
P
G G
B B
C C
F L
M
N
G G
A antena B señalización POWER
B señalización POWER C señalización ENABLE
C señalización ENABLE H modulo RI97-08
D enchufe L fusible F1
E place de identificación M fusible F2
F placa de datos técnicos N fusible F3
G tornillos de cierre P internal led
Señalizacio-
nes externas La señalización POWER indica la presencia (encendido) o no (apagado) de alimenta-
ción en la unidad receptora.
La señalización ENABLE verifica la conexión (encendido) o la falta de conexión (apa-
gado) entre la unidad transmisora y la unidad receptora.
El funcionamiento correcto se verifica cuando:
- POWER y ENABLE están encendidos y fijos, con la unidad transmisora encendida;
- POWER está encendido y fijo y ENABLE está apagado, con la unidad transmisora
apagada.
LIPROMU2
- 67 - Español
Segnalazioni
interne Los led presentes visualizan la inserción de un relé: cuando un led se enciende indica
que se ha activado el relé relativo al mando que se indica en el siguiente esquema
(presente también en el lado interior de la tapa de la unidad receptora):
SAFETY
Para proteger el sistema de posibles movimientos involuntarios debidos a eventuales
averías del radiomando, el radiomando está equipado con una función de seguridad
llamada SAFETY.
Dicha función controla constantemente la posición de reposo (neutra) de los actua-
dores de movimiento de la unidad transmisora y es disponible en la salida del relé
SAFETY de la unidad receptora.
FLOW
Accionado un mando de movimiento, se activa también la función FLOW: está dirige la
electroválvula que da presión al aceite del circuito hidráulico primario del distribuidor.
T.S.
El T.S. (TIMED STOP) es el mando que apaga el motor diesel de la máquina: este se
mantiene activo por 10 segundos después de la activación del pulsador STOP.
Fusibles
Los tres fusibles que se encuentran al interior de la unidad receptora tienen las si-
guientes características:
Fusible Función Datós Técnicos
F1 protección del POWER SUPPLY 4A (32Vdc, autofuse)
F2 protección del circuito di STOP 10A (32Vdc, autofuse)
F3 protección del circuito di SAFETY 10A (32Vdc, autofuse)
11 PROCESO DE REGULACIÓN DE LAS SALIDAS PROPORCIO-

NALES (REMOTE SET UP)
El proceso de regulación de las salidas proporcionales debe ser efec-
tuada sólo por personal cualificado y preparado y se debe realizar re-
spetando todas las advertencias que se hay en los capítulos 4, 5, 6 y 7.
Información
sobre el mo- Las salidas proporcionales del modulo RI97-08___ son ajustadas según cuanto indi-
dulo RI97-08 cado en la hoja técnica del equipo (el numero de la hoja técnica se indica también en
la llave de memorias datos (K2)).
C3 C1 C2 S L P C1 conector para las salidas proporcionales
C2 conector para las salidas proporcionales

auxliares
C3 conector para la alimentación
C4 conector para la llave de ajuste
C5 conector para la conexión con la tarjeta bus
L led verde
K1 llave de ajuste
K2 memoria de datos
P pulsador de restablecimiento regulaciones ini-

ciales
C5 C4 K1 K2 S selector rotativo
- 68 -
LIPROMU2
No dejar nunca insertada la llave de ajuste K1 durante el funciona-
miento del radiocontrol. Dicha llave sirve para la fase de ajuste y ha-
bilita solamente una maniobra proporcional a la vez, cuando está
insertada.
En el caso que se quiera volver a los valores iniciales de fabrica (los indicados en la
especificación técnica), es necesario mantener presionado el pulsador de restableci-
miento P hasta que el led verde L deje de parpadear para encenderse de manera con-
tinua. Este maniobra debe hacerse con la llave K1 insertada. La llave de memoria
datos K2 se fija al modulo RI97-08 a través de un tornillo. Para mantener los mismos
valores de ajuste en el caso de sustitución del modulo, hay que cambiar la llave de
memoria K2 al modulo nuevo.
Preparación
de la regula- 1. Cerciorarse de que la unidad transmisora esté apagada
ción 2. Desconectar la alimentación de la unidad receptora
3. Abrir la unidad receptora e introducir la llave de regulación K1 en el conector C4.
4. Conectar la alimentación a la unidad receptora. ATENCIÓN: desde este momento
al final de la regulación no hay que tocar la unidad receptora ( se arriesga perder las
regulaciones establecidas).
5. En la unidad transmisora girar la llave de encendido en la posición "I" y presionar
el pulsador START.
6. Girar la llave de encendido en la posición " " (REMOTE SET UP).
Regulación
7. Seleccionar los parámetros que deben ser regulados por medio del selector rotatorio S que
tiene el módulo RI97-08 y empleando el selector RPM+/- que se encuentra en la unidad tran-
smisora (donde + sirve para aumentar el valor que se esté regulando y - para disminuirlo).
En los módulos con salidas bajo tensión se pueden efectuar las re-
gulaciones en las posiciones 1, 2, 3, 4 y 5. En los módulos con salidas
con corriente (PWM) se pueden efectuar regulaciones en las posi-
ciones 0, 1, 3 y 4.
Durante la regulación moviendo el joystick fuera de la posición de

reposo un sonido de claxon o alarma de unos 0, 5 segundos señali-
zará que se encuentra en la zona de regulación del mínimo.
Las regulaciones se deben efectuar por cada posición del selector de

velocidad que tiene la unidad transmisora.
Regulaciones
en los módu- Posición 1: mínimos y máximos Z2-Z7
los con sali- Con el selector rotativo S en posición 1 se regula el valor máximo y mínimo de tensión
das bajo de los distintos semiejes de un manipulador. Proceder como se indica:
tensión 1. Para definir el valor máximo, llevar el manipulador a la posición tope en el semieje
que queremos ajustar. Manteniendo dicha posición accionar el selector de palanca
RPM +/- presente en la unidad transmisora para modificar el valor deseado.
2. Para definir el valor mínimo, llevar el manipulador afuera de la posición de reposo
(que no este en la posición de reposo no más de la mitad de su recorrido) del semieje
que queremos ajustar. Manteniendo este posición, accionar el selector de palanca
RPM +/- de la unidad transmisora para modificar el valor deseado.
Posición 2: tensión de la posición de reposo del joystick
Con el selector rotativo S en posición 2 se regula el valor de la tensión que correspon-
de a la posición mecánica de reposo del manipulador.
Este valor no debería ser modificado. En el caso sea necesario, ajustar como se indica:
- accionar un manipulador (que no este en la posición de reposo)
- manteniendo esta posición, accionar el selector de palanca L presente en la unidad
transmisora para modificar el valor preajustado
Posiciónes 3 y 4: mínimos y máximos Z8 y Z9
Con el selector rotativo S en posición 3 y 4 se regulan los valores máximo y mínimo
de la tensión de la salida auxiliar Z8 y Z9. Proceder como se indica:
1. Para definir el valor máximo, girar el selector rotativo (en la unidad transmisora)
relativo a las maniobras Z8 (o Z9) completamente en sentido de las agujas del reloj.
Manteniendo esta posición, accionar el selector de palanca RPM +/- presente en la
unidad transmisora para modificar el valor preajustado.
2. Para definir el valor mínimo, girar el selector rotativo (en la unidad transmisora)
relativo a las maniobras Z8 (o Z9) completamente en sentido contrario al de las
agujas del reloj. Manteniendo esta posición accionar el selector de palanca RPM +/-
presente en la unidad transmisora para modificar el valor preajustado
LIPROMU2
- 69 - Español
Posición 5: inversión de los semi ejes
Con el selector rotativo S en posición 5 se invierte la dirección de los semiejes.
Proceder como ahora se indica:
- accionar un manipulador (que no este en la posición de reposo)
- manteniendo esta posición accionar el selector de palanca RPM +/- presente en la
unidad transmisora moviéndola en la posición + para invertir la dirección de los se-
miejes o en la posición - para restablecer la dirección original de los semiejes.
Regulaciones
en los módu- Posición 0: frecuencia de la señal PWM
los con cor- Con el selector rotativo S en posición 0 se regula la frecuencia de la señal PWM (corriente).
riente (PWM) Este valor no debería ser modificado. En el caso sea necesario, ajustar como se indica:
- accionar un manipulador (que no este en la posición de reposo).
- manteniendo esta posición accionar el selector de palanca PRM +/- presente en la
Posición 1: mínimos y máximos Z2-Z7
Con el selector rotativo S en posición 1 se regula el valor máximo y mínimo de tensión
de los distintos semiejes de un manipulador. Proceder como se indica:
1. Para definir el valor máximo, llevar el manipulador a la posición tope en el semieje
que queremos ajustar. Manteniendo dicha posición accionar el selector de palanca
RPM +/- presente en la unidad transmisora para modificar el valor deseado.
2. Para definir el valor mínimo, llevar el manipulador afuera de la posición de reposo
(que no este en la posición de reposo no más de la mitad de su recorrido) del semieje
que queremos ajustar. Manteniendo este posición, accionar el selector de palanca
RPM +/- de la unidad transmisora para modificar el valor deseado.
Posiciónes 3 y 4: mínimos y máximos Z8 y Z9
Con el selector rotativo S en posición 3 y 4 se regulan los valores máximo y mínimo
de la tensión de la salida auxiliar Z8 y Z9. Proceder como se indica:
1. Para definir el valor máximo, girar el selector rotativo (en la unidad transmisora)
relativo a las maniobras Z8 (o Z9) completamente en sentido de las agujas del reloj.
Manteniendo esta posición, accionar el selector de palanca RPM +/- presente en la
2. Para definir el valor mínimo, girar el selector rotativo (en la unidad transmisora)
relativo a las maniobras Z8 (o Z9) completamente en sentido contrario al de las
agujas del reloj. Manteniendo esta posición accionar el selector de palanca RPM +/-
presente en la unidad transmisora para modificar el valor preajustado
Memoriza-
ción de la re- 8. Apagar la unidad transmisora para memorizar las regulaciones.
gulación 9. Desconectar la alimentación de la unidad receptora.
10. Extraer la llave de regulación K1.
11. Cerrar la unidad receptora y conectarla a la alimentación
12 FRECUENCIAS RADIO
La frecuencias radio progrmadas en el radiomando pertenecen al conjunto de fre-
cuencias admitidas por las normativas europeas en vigor al momento de su introduc-
ción en el mercado.
Comprobar en el anexo “Limitaciones y Autorizaciones” de este ma-

nual, posible limitaciones en el estado empleado.
Un radiomando se puede programar con la modalidad de ANÁLISIS EN AUTOMÁTICO

o de SELECCIÓN MANUAL.
Análisis en
automático Normalmente, el radiomando viene programado por el constructor en esta modali-
dad: puede funcionar por lo tanto en cualquier frecuencia disponible. En caso de in-
terferencia o conflicto con otros equipos, dicha modalidad consiente cambiar la
frecuencia de trabajo (ver "Cambio frecuenciax") sin tener que intervenir al interior
de la unidad transmisora ni al interior de la unidad receptora.
Selección
manual Para regular esta modalidad de funcionamiento de la frecuencia radio
de trabajo contactar exclusivamente personal autorizado Autec.
Un radiomando que opere en la modalidad de selección manual consiente trabajar en

una frecuencia específica. Para poder regular esta frecuencia hay que regular los dip
switch que se encuentran en el módulo transmisor y receptor.
- 70 -
LIPROMU2
13 DIAGNÓSTICA
En el caso en que el "radiomando + máquina" no se activen conviene controlar si el
problema concierne el radiomando o la máquina. Por lo tanto, antes de efectuar cual-
quier comprobación, conectar el puesto mando con cable: si la máquina no se activa,
el problema concierne la máquina.
Si por el contrario la máquina se activa sólo regularmente, sólo desde el puesto de
mando con cable el problema concierne el radiomando. En tal caso, efectuar los si-
guientes controles:
Diagnóstica
de la unidad ¿El led de señaliza- ¿El led de señaliza-
trasmisora ción verde está en- ¿El led de señaliza-
ción verde está en-
cendido con ción rojo está encen-
cendido con
intermitente rápida)? dido con luz fija?
intermitente lenta?
Desactivar los actua-

Efectuar la Introducir
dores y el pulsador
diagnóstica de la una batería segura-
STOP que pudieran
unidad receptora. mente recargada
estar insertados
Si la unidad transmisora
no se enciende cor-
rectamente: INTERPE-
LAR LA ASISTENCIA
Diagnóstica
de la unidad ¿El enchufe de conexión Poner correctamente
receptora ¿ El indicado lumino- el enchufe de co-
de la unidad receptora y
so POWER está en- nexión y activar el ra-
la máquina está co-
cendido? diomando.
nectado correctamente?
Desconectar la tensión Sustituir el fusible.

de la unidad receptora Controlar las co-
y abrirla. ¿El fusible F1 nexiones
está integro? de alimentación.
INTERPELAR Conectar
la tensión y activar
LA ASISTENCIA
el radiomando.
¿ El indicado lumino- Efectuar el proceso

so ENABLE está ende cambio de fre-
cendido? cuencia. ¿Se ha acti-
vado la máquina?
Desconectar la tensión Sustituir el fusible.

de la unidad receptora Conectar
y abrirla. ¿El fusibles la tensión y activar
F2-F3 están integros? el radiomando.
INTERPELAR
LA ASISTENCIA
LIPROMU2
- 71 - Español
14 DATOS TËCNICOS
Generales
Frecuencia de trabajo .................................................. 433.050 - 434.790 MHz
............................................................................................ 869.7 - 870 MHz
Canales de radio disponibles (433 MHz) ....................................................... 64
Canales de radio disponibles (870 MHz) ........................................................ 12
Canal utilizado ............................................................... 25 kHz (opt 12.5 kHz)
Distancia de Hamming ............................................................................... 8
Probabilidad de fall en la detección de error ............................................ <10-11
Radio de acción tipico ........................................................................... 150 m
Tiempo de emergencia pasiva ......................................................... 0.5/1.5 sec
Tiempo de respuesta de los mandos ............................................... 70 - 120 ms
Tiempo de respuesta de STOP ........................................................ 70 - 120 ms
Categoria funciones de securidad segun EN 954 - 1

Protección de STOP .............................................................................. Cat. 4
Protección de los movimientos involuntarios de la posición de reposo ......................
de los actuadores ..................................................................................... Cat.3
Unidad
transmissora Número de mandos disponibles .............. 6+2 analogicós+12 on/off + start + stop
Antena .............................................................................................. interna
Tipo de modulación ................................................................................ GFSK
Potencia ........................................................................... <10 mW (433 MHz)
........................................................................................ < 5 mW (870 MHz)
Alimentación: paquete de baterías ........................................ NiMH 7.2V - 1.3 Ah
Tensión de apagado ............................................................................... 6.0 V
Autonomía con batería cargada (a 20 °C) ................................... 10 horas aprox.
Tiempo de preaviso de la batería casi descargadaa ....................... 15 min. aprox.
Tiempo de preaviso de la batería descargada ................................. 3 min. aprox.
Temperatura de trabajo ....................................................... (-20°C) - (+55°C)
Fundas ....................................................................................... PA6 fg 20%
Grado di protección ................................................................................. IP65
Medidas ........................................................................... (263x160x173) mm
Pesos (con batería) ................................................................................. 2 kg
Unidad
receptora Tensión de alimentación ...................................................... 8 - 30 Vdc (< 40W)
Antena .............................................................................................. externa
Capacidad de los contactos de relay de STOP y SAFETY ................... 10 A (30 Vdc)
Capacidad de los contactos de relay de mandos de movimiento .......... 4 A (30 Vdc)
Capacidad de los contactos de relay de mandos de selección ............. 6 A (30 Vdc)
Sensibilidad del receptor ............................................... 0,5µV per 20 dB SINAD
Temperatura de trabajo ....................................................... (-20°C) - (+70°C)
Fundas ....................................................................................... PA6 fg 20%
Grado di protección ................................................................................. IP65
Medidas ............................................................................. (180x230x95) mm
Pesos ................................................................................................. 2.8 kg
Dima di foratura .......................................................................... A = 148 mm
B = 116 mm
C = 253 mm
D = 253 mm
Baterías y
cargador de
la bateria Los datos técnicos están indicados en el correspondiente manual
- 72 -
LIPROMU2
SPURGO DEL FRENO
BLEEDING THE BRAKE
ENTLÜFTEN DER BREMSE
MRT 1440-1640-1840 EASY

IT-EN-DE
40-4-M96 MRT 1440-1640-1840 EASY
IT EN DE
PROCEDURA SPURGO DEI FRENI BRAKE BLEEDING PROCEDURE ENTLÜFTEN DER BREMSEN
- Scollegare il tubo di scarico (FIG.1 Rif. T) Disconnect drainage pipe (FIG. 1 Ref. T) of - Die Ablaufleitung (Abb.1 Bez. T) des
della vaschetta liquido freni e mettervi brake liquid tray and fit a hydraulic seal Behälters der Bremsflüssigkeit abtren-
un tappo a tenuta idraulica. cap. nen und einen hydraulisch gut abdich-
tenden Stopfen daraufsetzen.
- Riempire completamente la vaschetta - First fill the brake oil tray.
olio freni. - Den Behälter ganz mit Bremsflüssigkeit
- Connect the brake bleeder (FIG.2) on füllen.
- Collegare lo spurgatore del freno (FIG.2) tank S (FIG.4 pag. 3-7), located on the
sul serbatoio S (FIG.4 pag. 3-7), situato instrument panel; (connector size = 1/4 - Den Bremsentlüfter (Abb. 2) auf dem
sul cruscotto; (dimensione del raccordo gas). Behälter S (Abb. 4 Seite 3-7), der sich
= 1/4 gas). auf dem Armaturenbrett befindet, ansch-
- Slacken the two bleed screws situated on ließen (Abmessungen des Anschlusses
- Allentare le 2 viti di spurgo situate sul the rear axle and fit the transparent = 1/4 Gas).
ponte posteriore e mettervi i tubi traspa- tubes (FIG.2 Ref. A).
renti (FIG.2 Rif.A). - Die 2 Entlüftungsschrauben, die sich auf
- Pressurise the brake bleeder, and wait der Hinterachse befinden, lockern und
- Mettere in pressione lo spurgatore del for all the air to come out of the transpa- die Klarsichtschläuche daraufstecken
freno, e attendere l'uscita completa del- rent tubes. (Abb.2 Bez. A).
l'aria dai tubi trasparenti. Relock the two bleed screws of the rear
Ribloccare le 2 viti di spurgo del ponte axle. - Den Bremsentlüfter unter Druck setzen
posteriore. und abwarten, dass die Luft ganz durch
- Repeat the same procedure with the front die Klarsichtschläuche austritt.
- Ripetere la stessa procedura con il ponte axle. Die beiden Entlüftungsschrauben der
anteriore. Hinterachse wieder anziehen.
- Also make sure that the brake pump
- Assicurarsi inoltre che la corsa della stroke is normal. - Das gleiche Verfahren auf der
pompa freno sia normale. If this is not the case, adjust the brakes Vorderachse wiederholen.
In caso contrario procedere alla regola- for both axles (see procedure: DISAS-
zione dei freni per entrambi i ponti SEMBLING AXLE Chapter). - Außerdem sicherstellen, dass der Hub
(vedere la procedura: capitolo SMON- der Bremspumpe normal ist.
TAGGIO PONTE). - When the procedure of brakes drainage Andernfalls die Einstellung der Bremsen
is finished, connect again the hydraulic auf beiden Achsen vornehmen (siehe
- Terminata la procedura di spurgo freni hose (FIG.1 Ref. T page1) to the exhau- das Verfahren: Kapitel AUSBAU DER
ricollegare il tubo idraulico (FIG.1 Rif. T st manifold. ACHSE).
pag.1) al collettore di scarico.
- Nach Abschluss der Entlüftung der
Bremsen die hydraulische Leitung
(Abb.1 Bez. T Seite 1) wieder an den
Auspuffkrümmer anschließen.
2
MRT M Series 40
FIG. 1
FIG. 2 FIG. 3
3
40 MRT 1440-1640-1840 EASY (400°)
IT EN DE
FIG. 4
SPURGATORE FRENO
BRAKE BLEEDER
BREMS-ENTLÜFTER
W W
W SPURGARE FRENI SUI PONTI HURTH

BLEED BRAKES ON HURTH AXLES
BREMSEN AUF HURTH-ACHSEN ENTLÜFTEN
4
MRT 1440-1640-1840 EASY (360°) 40
FIG. 4
SPURGATORE FRENO
BRAKE BLEEDER
BREMS-ENTLÜFTER
W W
W SPURGARE FRENI SUI PONTI HURTH

BLEED BRAKES ON HURTH AXLES
BREMSEN AUF HURTH-ACHSEN ENTLÜFTEN

Manuel de Réparation MRT-X - 1840

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REPAIR MANUAL

This document has been printed from my e doc

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Specifications Section When the camshaft is viewed from the front of

Fuel Injection Lines

Bore ......................................... 105 mm (4.133 inch)

Stroke ...................................... 127 mm (5.000 inch)

Displacement ...................................... 4.4 L (269 in3)

Cylinder arrangement ..................................... In-line

Firing order ................................................. 1, 3, 4, 2

When the crankshaft is viewed from the front of

i02663071 Unlocking the shaft

Note: Before the fuel injection pump is removed from

(4) Tighten the mounting bolt to the following

(5) Tighten the mounting bolt and the nut to the

Note: The support bracket must be installed after

Note: The solenoid on the fuel injection pump is

(2) Locking screw

Locking the shaft

Fuel Injectors Fuel Transfer Pump

The fuel injector should be tested at the pressure in

Leakage in 10 seconds ................................. 0 drops

Service setting for the Fuel Injector g00986823

(4) Fuel transfer pump

(5) Fuel filter element

(7) Fuel filter bowl

Note: Tighten the fuel filter bowl by hand. Rotate the

Rocker Shaft (3) Rocker arm

(4) Rocker arm bore

Note: Install the longest screw at the front of the

(6) Tighten the screws evenly. Begin in the center

(7) Rocker shaft

(8) In order to install the rocker shaft assembly, i02662486

Valve Mechanism Cover

Tighten the bolts for the valve mechanism cover

(1) Valve spring

Turbocharged aftercooled engines Service limit ........................... 2.06 mm (0.0811 inch)

Turbocharged engines .................... 1.55 to 1.81 mm

The head bolts require an additional torque turn

(5) Tighten the bolt to the following torque. ..... 9 N·m

(6) Tighten the bolt to the following torque. ... 22 N·m

The maximum test pressure for the

The movement for the rod actuator ................. 1 mm

The part number for

(1) End play of a new camshaft ..... 0.10 to 0.55 mm

Maximum permissible end play of a worn

1. Mount the camshaft between centers.

2. By using a dial indicator in contact with the surface

Note: There may be two lobes on the camshaft. i02663064

3. Subtract the smallest dimension from the largest

Maximum permissible deviation between the

(2) Engine oil filter

(1) The diameter of the installed camshaft

Engine Oil Cooler

(4) Engine oil filter

Engine Oil Pump

Engines with Balancer Group

(2) Clearance of inner rotor to outer

(1) Clearance of the outer rotor to the

(3) End play of rotor assembly

(6) Tighten the nut to the following torque. .... 95 N·m

Tighten the bolts that hold the balancer to the cylinder