Repair 860L

REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
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GENERAL INSTRUCTIONS AND SAFETY NOTICE
INDEX 1-1
GROUP 0 CHARACTERISTICS A 1-2
GROUP 0 CHARACTERISTIC B 1-3
ENGINE
GROUP 10 ENGINE A 2-1
GROUP 10 ENGINE B 2-2
TRANSMISSION
GROUP 20 Transmission PUMP MOTOR 3-1
GROUP 20 Transmission GEARBOX 3-2
AXLE ASSEMBLY - AXLE

GROUP 30 Axle 4-1
HYDRAULIC
GROUP 70 Hydraulic 5-1
ELECTRICITY
GROUP 80 Electricity 6-1
COSTRUZIONI INDUSTRIALI
Via Cristoforo Colombo, 2
Loc. CAVAZZONA
41013 Castelfranco Emilia (MO)
( Tel.059/959811 - Fax 059/959850)
YOUR DEALER
647145 EN (17/03/2012)
MHT 780 T-E3

MHT 860 LT-E3
MHT 950 LT-E3
MHT-X 780 T-E3
MHT-X 860 LT-E3
MHT-X 950 LT-E3
REPAIR MANUAL
THIS OPERATOR’S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS.
1st DATE OF ISSUE 03/12
DATE PUBLICATION OBSERVATION
30/03/2012 1ST DATE OF ISSU
THE TEXTS AND ILLUSTRATIONS IN THIS DOCUMENT MUST NOT BE REPRODUCED EITHER WHOLLY OR IN PART.
TABLE OF CONTENTS
CHAPTER UNITS
C H A R A C T E R IS T IC S 1
E N G IN E 1104D - 44T A 2
H Y D R O S T AT IC 3
D R IV E A X L E S T Y P E MO 212 4
G E A R BO X 5
Drop Box MO357
H Y D R A U L IC 6
H y draulic s y s te m
P re s s ure c o ntro l
Pump A10VO 28-85 DFR Series 52
E L E C T R IC A L 7
E le c tric s y s te m
Te s ting the s afe ty s y s te m
3
CHARACTERISTICS
MHT 780 T-E3 / MHT-X 780 T-E3
I.C. ENGINE
Type PERKINS 1104D-44TA NJ 38996
Fuel Diesel
Number of cylinders 4 in line
Suction Supercharged
Injection system Direct
Ignition sequence 1,3,4,2
Capacity cm3 4400
Bore and stroke mm 105 x 127
Compression ratio 18,2:1
Nominal rating loaded rpm 2200
Rating slow unladen rpm 930
Max. rating unladen rpm 2200
Power ISO/TR 14396 cv- kW 144 - 106
Power SAE J 1995 cv- kW 144 - 106
Maximum torque ISO/TR 14396 Nm 556 to 1400 rpm
Air cleaner m 3
Type of cooling By water
Fan Puller (1760 min-1)
TRANSMISSION
Hydrostatic pump REXROTH
A4VG71DA Hydrostatic with continuous speed
Type
adjustment and engine with inching
Forward/reverse selector Electromagnetic
Number of forward speeds 2
Number of reverse speeds 2
Main pump
displacement min./max. cm3/giri 0 a 71
Capacity max. L/min. 170
Pressure bar 450
Supply pump
displacement cm3 19,6
Pressure bar 32 ±2
Hydrostatic motor REXROTH
Type A6VM107DA
Front axle DANA
Differential Limited slip
Reduction gear Planetary gear
Rear axle DANA
Drive wheels 4RM Permanent
Front tyres MICHELIN
Size 18R 22,5 XF 1E TL
Pressure bar 7,5
Rear tyres MICHELIN
Pressure bar 7,5
ELECTRIC CIRCUIT
Battery Standard 12 V - 105 Ah - 850 A EN
Alternator 12 V - 120 A
Starter 12 V - 3 kw
BRAKE CIRCUIT
Service brake Hydraulic power brake
Type of brake Multidisk brake immersed in oil
Type of control Foot-operated for the front and rear axles
Parking brake
Type of brake Negative action, acts on front axle service brakes
Type of control Electro-hydrailc
1-1
SOUND AND VIBRATION
Level of sound pressure in the driver’s cab LpA
dB 79,7
(according to standard NF EN 12053)
Level of sound power ensured in the LwA environment 103 (measured)
dB
(according to directive 2000/14/EC modified by directive 2005/88/EC) 105 (ensured)
Average weighted acceleration on driver’s body
m/s2
The average weighted acceleration transmitted to the driver’s hand/arm system
m/s2 < 2,5
(according to standard ISO 5349-2)
HYDRAULIC CIRCUIT
Hydraulic pump
Type Variable volume pistons
1st casing
Capacity cm3 63
Max. rating capacity unladen l/mn 140
Flow rate at 1600 rpm l/mn 100
Maximum service pressure bar 270
Telescoping circuit bar 220 / 270
Lifting circuit bar 270 / 270
Tilt circuit bar 190 / 280
Attachment circuit bar 270
Steering circuit bar 175
HYDRAULIC MOVEMENTS
Longitudinal stability limiter and warning device Electronic
Lifting motions (boom retracted)
Unladen lifting s - m/mn -
Unladen lowering s - m/mn -
Telescoping motions (boom raised)
Unladen extending s - m/mn -
Unladen retracting s - m/mn -
Tilting movements
Unladen digging s - °/s -
Forward tilting unladen s - °/s -
SPECIFICATIONS AND WEIGHTS

Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen km/h 28
laden km/h 10
Rear unladen km/h 28
laden km/h 10
Rated capacity with standard attachment kg 8000
Standard lifting height kg 6800
Fork dimensions (length x width x thickness) mm 1200 x 200 x 60
Distance from the centre of gravity from the load to the lug of the forks mm 600
Lift truck weight with standard attachment
Unladen kg 12775
At rated load kg 20775
Weight per axle with standard attachment (transport position)
Front unladen kg 4085
Rear unladen kg 8690
Front rated load kg 18175
Rear rated load kg 2600
Drag strain on the coupling hook
Unladen (sliding) daN 9200
At rated load (transmission setting) daN 10500
Pull strain with open carrier (according to standard ISO 8313) daN -
1-2
DIMENSIONS AND LOAD CHART
MHT 780 T-E3 / MHT-X 780 T-E3
U
M
N
Y
G2
23°
G1
22°
23°
G
L
C B I
Z
A D
MHT 780 E
A 1200 J
B 2670
C 1075
D 5225
E 6425
F 1990
G 380
G1 445
G2 445 F
I 1480 W1 W
J 865
K 1750
L 60
1
V
M 1865 R
T
N 1805 V2
O 200
R 2990
V3 V
S 8040
K
T 4070
O
U 2520
V 4420
V1 495
V2 3265
V3 3675
W 2440 S
W1 2440
Y 12°
Z 124°
mm
1-9
CHARACTERISTICS
MHT 860 LT-E3 / MHT-X 860 LT-E3
I.C. ENGINE
Fuel Diesel
Capacity cm3 4400
Power SAE J 1995 cv- kW 144 - 106
Air cleaner m 3
TRANSMISSION
Type
Main pump
Pressure bar 450
Supply pump
Pressure bar 32 ±2
Type A6VM107DA
Front axle DANA
Rear axle DANA
Pressure bar 7,5
Rear tyres MICHELIN
Pressure bar 7,5
ELECTRIC CIRCUIT
Starter 12 V - 3 kw
BRAKE CIRCUIT
Parking brake
1-3
SOUND AND VIBRATION
dB 79,7
dB
m/s2
m/s2 < 2,5
HYDRAULIC CIRCUIT
Hydraulic pump
1st casing
Capacity cm3 63
HYDRAULIC MOVEMENTS
Unladen lifting s - m/mn 9,8 - 30,6
Unladen lowering s - m/mn 7,8 - 38,5-
Unladen extending s - m/mn 11,3 - 17
Unladen retracting s - m/mn 6,7 - 28,6
Tilting movements
Unladen digging s - °/s 4,1 - 33
Forward tilting unladen s - °/s 3,5 - 38,5

laden km/h 10
laden km/h 10
Unladen kg 11580
Front rated load kg -
Rear rated load kg -
1-4
U
N
M
Y
24°
24°
34°
G1
L
G2
G
Z
C B I
A D
MHT 860 J
A 1200
B 2730
C 1540
D 5365
E 6565
F 1930
G 410
G1 450 F
W1 W
G2 410
I 1095
J 865
K 1750
L 60
M 1700
1
N 1845
V
R
O 200
T
R 3560 V2
S 7883
T 4406 V
U 2460
K
V 5205
O
V1 1130
V2 3780
W 2400
Y 11°
Z 123°
S
mm
1-10
CHARACTERISTICS
I.C. ENGINE
Fuel Diesel
Capacity cm3 4400
Power SAE J 1995 cv- kW 144 - 106
Air cleaner m 3
TRANSMISSION
Type
Main pump
Pressure bar 450
Supply pump
Pressure bar 32 ±2
Type A6VM107DA
Front axle DANA
Rear axle DANA
Pressure bar 7,5
Rear tyres MICHELIN
Pressure bar 7,5
ELECTRIC CIRCUIT
Starter 12 V - 3 kw
BRAKE CIRCUIT
Parking brake
1-5
SOUND AND VIBRATION
dB 79,7
dB
m/s2
m/s2 < 2,5
HYDRAULIC CIRCUIT
Hydraulic pump
1st casing
Capacity cm3 63
HYDRAULIC MOVEMENTS
Unladen lifting s - m/mn 10,8 - 30,6
Unladen lowering s - m/mn 8,6 - 38,5-
Unladen extending s - m/mn 12,7 - 17
Unladen retracting s - m/mn 7,5 - 28,6
Tilting movements
Unladen digging s - °/s 4,1 - 33
Forward tilting unladen s - °/s 3,5 - 38,5

laden km/h 10
laden km/h 10
Unladen kg 10650
Front rated load kg -
Rear rated load kg -
1-6
U
N
M
Y
24°
24°
34°
G1
L
G2
G
Z
C B I
A D
MHT 950 J
A 1200
B 2730
C 1940
D 5765
E 6965
F 1930
G 410
G1 450 F
W1 W
G2 410
I 1095
J 865
K 1320
L 50
M 1700
1
N 1845
V
R
O 150
T
R 3800 V2
S 8535
T 4545 V
U 2460
K
V 5520
O
V1 1375
V2 4035
W 2400
Y 11°
Z 125°
mm S
1-11
CARACTÉRISTIQUES
MHT 1076 LT-E3
MOTEUR THERMIQUE
Carburant Diesel
Nombre de cylindres 4 en ligne
Aspiration Suralimentée
Système d’injection Directe
Séquence d’allumage 1,3,4,2
Cylindrée cm3 4400
Alésage et course mm 105 x 127
Taux de compression 18,2:1
Régime nominal en charge tr/mn 2200
Régime au ralenti à vide tr/mn 930
Régime maximum à vide tr/mn 2200
Puissance ISO/TR 14396 cv - kW 144 - 106
Puissance SAE J 1995 cv - kW 144 - 106
Couple maxi ISO/TR 14396 Nm 556 a 1400 giri/min.
Filtration air m 3
Type de refroidissement Par eau
Ventilateur Aspirant (1760 min-1)
TRANSMISSION
Pompe hydrostatique REXROTH
A4VG71DA Avec le réglement continu des
Type
vitesses et la commande inching
Sélecteur de marche Électrohydraulique
Nombre de vitesses avant 2
Nombre de vitesses arrière 2
Pompe principale
Cylindrée MINI/MAXI cm3/giri 0 a 71
Débit MAXI L/min. 170
Pression de service bar 450
Pompe alimentation
Cylindrée cm3 19,6
Débit MAXI L/min. 47
Pression de service bar 32 ±2
Moteur hydrostatique REXROTH
Type A6VM115DA
Cylindrée MINI/MAXI cm3/giri 29 a 115
Essieu avant DANA
Différentiel Glissement limité
Essieu arrière DANA
Différentiel Sans blocage
Roues motrices 4 RM Permanent
Pneumatiques avant MICHELIN
Dimension 18R 22,5 XF 1E TL
Pression bar 7,5
Pneumatiques arrière MICHELIN
Dimension 18R 22,5 XF 1E TL
Pression bar 7,5
CIRCUIT ÉLECTRIQUE
Batterie Standard 12 V - 105 Ah - 850 A EN
Alternateur 12 V - 120 A
Démarreur 12 V - 3 kw
CIRCUIT FREINAGE
Frein de service Frein hydraulique assisté
Type de frein Multidisque à bain d'huile
Type de commande À pied sur les essieux avant et arrière
Frein de stationnement
Type de frein Sur les essieux avant et arrière
Type de commande Manuel, Électrohydraulique
2-14
BRUIT ET VIBRATION
Niveau de pression acoustique au poste de conduite LpA
dB 79,7
(suivant norme NF EN 12053)
Niveau de puissance acoustique garanti à l'environnement LwA 103 mesuré
dB
(suivant directive 2000/14/CE modifiée par la directive 2005/88/CE) 105 garanti
Accélération pondérée moyenne sur le corps du conducteur
m/s2
(suivant norme NF EN 13059)
L'accélération pondérée moyenne transmise au système mains/bras du conducteur
m/s2 < 2,5
(suivant norme ISO 5349-2)
CIRCUIT HYDRAULIQUE
Pompe hydraulique
Type Pistons cylindrée variable
1er corps
Cylindrée cm3 63
Débit au régime maximum à vide l/mn 140
Débit à 1600 tr/mn l/mn 100
Pression de service maximum bar 270
Circuit télescopage bar 220 / 270
Circuit levage bar 270 / 270
Circuit inclinaison bar 190 / 280
Circuit accessoire bar 270
Circuit direction bar 175
MOUVEMENTS HYDRAULIQUES
Dispositif avertisseur et limiteur de stabilité longitudinale Electronique
Mouvements de levage (flèche rentrée)
Levée à vide s - m/mn -
Descente à vide s - m/mn -
Mouvements de télescopage (flèche levée)
Sortie à vide s - m/mn -
Rentrée à vide s - m/mn -
Mouvements d’inclinaison
Cavage à vide s - °/s -
Déversement à vide s - °/s -
SPÉCIFICATIONS ET MASSES
Vitesse de déplacement du chariot élévateur en configuration standard 25 km/h maxi EN FRANCE LES AUTRES PAYS, METTRE VALEUR RÉELLES AVEC L’ANNOTATION
sur sol horizontal

Avant en charge: km/h 8,5
Avant à vide km/h 25,0 35
Arrière en charge: km/h 8,5
Arrière à vide km/h 25 35
Accessoire standard fourches PFB
Dimensions des fourches (long. x larg. x épais.) mm 1200 x 200 x 60
Distance du centre de gravité de la charge au talon des fourches mm 600
Capacité nominale avec accessoire standard kg 7600
Hauteur de levée standard mm 9600
Masse du chariot élévateur avec accessoire standard
À vide kg 13250
En charge nominale kg 20450
Masse par essieu avec accessoire standard
À vide avant kg 4990
À vide arrière kg 8260
En charge avant kg -
En charge arrière kg -
Effort de traction au crochet d’attelage
À vide (patinage) daN 9200
En charge nominale (calage transmission) daN 10500
Effort d’arrachement avec benne (suivant norme ISO 8313) daN -
2-15
DIMENSIONS ET ABAQUES DE CHARGE
D1
on
Evoluti
U1
U
M
N
Y
G2
L
18°
18°
21°
Z
C B I
A D
MHT 1072LL
MHT 1076
A 1200 E
B 2950
C 1480 J
D 5870
D1 5790
E 7075
F 1970
G 380
G1 400
G2 425
I 1445 F W
J 865 W1
K 1750
L 60
M 1990
N 1805
O 200
R 3280
T
S 8050 V3
T 4445 V1
R
V2
U 2520
U1 2570
V 4985
V1 770
K
V2 3555
O
V
V3 3990
W 2435
W1 2435
Y 12°
Z 124°
mm
2-22
RENR8913
September 2006
Specifications
1104D Industrial Engine
NH (Engine)
NJ (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.
RENR8913 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
Fuel Filter Base .................................................... 7
Fuel Priming Pump .............................................. 7
Lifter Group ........................................................... 7
Rocker Shaft ........................................................ 8
Valve Mechanism Cover ...................................... 9
Cylinder Head Valves ........................................... 10
Cylinder Head ...................................................... 11
Turbocharger ....................................................... 12
Exhaust Manifold ................................................. 12
Camshaft ............................................................. 13
Camshaft Bearings .............................................. 13
Engine Oil Filter Base .......................................... 14
Engine Oil Cooler ................................................. 15
Engine Oil Pump .................................................. 15
Engine Oil Pressure ............................................. 17
Engine Oil Pan ..................................................... 17
Engine Oil Bypass Valve ...................................... 19
Crankcase Breather ............................................. 20
Water Temperature Regulator and Housing ......... 21
Water Pump ......................................................... 21
Cylinder Block ...................................................... 22
Crankshaft ........................................................... 23
Crankshaft Seals ................................................. 25
Crankshaft Pulley ................................................. 26
Connecting Rod Bearing Journal ......................... 27
Main Bearing Journal ............................................ 27
Connecting Rod ................................................... 27
Piston and Rings .................................................. 29
Piston Cooling Jet ................................................. 30
Front Housing and Covers ................................... 30
Gear Group (Front) ............................................... 31
Flywheel ............................................................... 33
Flywheel Housing ................................................ 33
Belt Tension Chart ............................................... 34
Engine Lifting Bracket ........................................... 34
Alternator ............................................................. 34
Starter Motor ........................................................ 36
Coolant Temperature Sensor ............................... 37
Fuel Pressure Sensor .......................................... 37
Engine Oil Pressure Sensor ................................. 37
Boost Pressure Sensor ......................................... 38
Inlet Manifold Temperature Sensor ....................... 38
Crankshaft Position Sensor .................................. 39
Electronic Control Module ..................................... 39
Glow Plugs ........................................................... 40
Index Section
Index ..................................................................... 41
4 RENR8913
Specifications Section When the crankshaft is viewed from the front of

the engine, the crankshaft rotates in the following
direction: ................................................... Clockwise
i02503001
When the camshaft is viewed from the front of
Engine Design the engine, the camshaft rotates in the following
direction: ................................................... Clockwise
The front of the engine is opposite the flywheel end.

The left side and the right side of the engine are
viewed from the flywheel end. The No. 1 cylinder is
the front cylinder.
i02519279
Fuel Injection Lines
Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
g01187485
Refer to Operation and Maintenance Manual,
Illustration 1 “General Hazard Information and High Pressure Fuel
Cylinder and valve location Lines” before adjustments and repairs are performed.
(A) Exhaust valve
(B) Inlet valve Note: Refer to Systems Operation, Testing
and Adjusting, “Cleanliness of Fuel System
Bore ......................................... 105 mm (4.133 inch) Components” for detailed information on the
standards of cleanliness that must be observed
Stroke ...................................... 127 mm (5.000 inch) during ALL work on the fuel system.
Displacement ...................................... 4.4 L (269 in3) Ensure that all adjustments and repairs are performed
by authorized personnel that have had the correct
Cylinder arrangement ..................................... In-line training.
Type of combustion ............................ Direct injection
Compression ratio
Turbocharged engines and turbocharged
aftercooled engines ................................. 16.2:1
Number of cylinders ................................................ 4
Valves per cylinder .................................................. 4
Valve lash
Inlet valve ....................... 0.35 mm (0.0138 inch)
Exhaust valve ................. 0.35 mm (0.0138 inch)
Firing order ................................................. 1, 3, 4, 2

RENR8913 5
Manifold to Injector i02519422
Fuel Injection Pump
Note: Before the 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. In order to time the fuel injection pump,
refer to Disassembly and Assembly, “Fuel Injection
Pump - Install”.
Note: Refer to Systems Operation, Testing

Components” for detailed information on the
Illustration 2
g01260742 standards of cleanliness that must be observed
Typical example during ALL work on the fuel system.
(1) Tighten the union nuts for the high pressure fuel
lines (1) to the following torque. ............... 30 N·m
(22 lb ft)
Pump to Manifold
g01260784
Illustration 4
Typical example
(1) Locking screw
(2) Washer
g01260743
Illustration 3 (3) Setscrews
Typical example
(4) Support bracket
(1) Tighten the union nuts for the high pressure fuel
line (2) to the following torque. .. 30 N·m (22 lb ft) (5) Setscrew
Locking the shaft

6 RENR8913
Loosen locking screw (1) and move the washer (1) Tighten the nuts to the following torque 2.4 N·m
(2) to the locked position. Tighten the locking (21 lb in).
screw to the following torque. .... 9 N·m (79 lb in)
(2) Tighten the bolt in the clamp for the fuel injection
Unlocking the shaft nozzle to the following torque. .. 27 N·m (19 lb ft)
Loosen locking screw (1) and move the washer (3) Clamp
(2) to the unlocked position. Tighten the locking
screw to the following torque. ..... 9 N·m (79 lb in) (4) O ring seal
(3) Tighten the mounting setscrews to the following (5) Trim code
torque. ...................................... 22 N·m (16 lb ft)
Note: Refer to the Troubleshooting, “Injector Trim
(5) Tighten the mounting setscrew to the following File” for more information.
torque. ...................................... 44 N·m (32 lb ft)
Note: The support bracket must be installed after i02519286

the coolant pump is installed. In order to stop the
distortion of the timing case, finger tighten the Fuel Transfer Pump
setscrew (5) and then tighten the setscrews (3).
Tighten the bolts that hold the fuel pump to the front
housing to the following torque. ...... 25 N·m (18 lb ft)
i02519280 and Adjusting, “Cleanliness of Fuel System
Fuel Injectors standards of cleanliness that must be observed
during ALL work on the fuel system.

g01260765
Illustration 6
(1) Fuel outlet
(2) Fuel return from cylinder head
(3) Fuel supply
(4) Retaining setscrew
(4) Retaining setscrew ................... 30 N·m (22 lb ft)
The outlet pressure for the fuel ......... 400 to 500 kPa
g01179017 (58.0160 to 72.5200 psi)
Illustration 5
RENR8913 7
i02519336 Hand Fuel Priming Pump

Fuel Filter Base

g01265616
Illustration 8
Typical example
(1) The plunger that is hand operated.
Electric fuel Priming Pump

The electric fuel priming pump operates on 12 volts
or 24 volts.
g01260768 i02392326
Illustration 7
Typical example
Lifter Group
(1) Retaining setscrews ................. 44 N·m (32 lb ft)
(2) The canister for the fuel filter
i02519432
Fuel Priming Pump

g00629433
Illustration 9
(1) Diameter of the lifter body .. 18.987 to 19.012 mm

(0.7475 to 0.7485 inch)
Bore diameter in the cylinder block

............. 19.05 to 19.082 mm (0.7500 to 0.7513 inch)
8 RENR8913
Clearance The service limit for both rocker arm

bores ............................... 0.17 mm (0.0067 inch)
Clearance of the lifter .......... 0.038 to 0.095 mm
(0.0015 to 0.0037 inch) (5) Rocker shaft
Diameter of the rocker
i02504776
shaft .................................. 24.962 to 24.987 mm
Rocker Shaft (0.9828 to 0.9837 inch)
(6) Spring
(7) Snap ring
(8) Spring
(9) Adjuster
(10) Locknut
Torque for the locknut ............... 27 N·m (20 lb ft)
g01253910
Illustration 10
g01254105
Typical example Illustration 11
Tightening sequence
(1) Pedestal
Tighten the fasteners in the sequence that is in
(2) Locator illustration 11. Tighten the fasteners to the following
torque. ............................................. 35 N·m (25 lb ft)
(3) Inlet rocker arm
Diameter of the rocker arm bore
.... 25.031 to 25.051 mm (0.9855 to 0.9863 inch)
(4) Exhaust rocker arm

Diameter of the rocker arm
bore .................................. 25.031 to 25.051 mm
(0.9855 to 0.9863 inch)
Clearance
Maximum clearance of both the rocker arm
bores ............................. 0.089 mm (0.0035 inch)
RENR8913 9
i02503083
Valve Mechanism Cover
g01252367
Illustration 12
Typical example
Tighten the bolts for the valve mechanism cover in

the sequence that is shown in illustration 12 to the
following torque. ................................ 6 N·m (53 lb in)
10 RENR8913
i02503124
Cylinder Head Valves
g01193821
Illustration 14
(2) Valve face angle

Inlet ................................................... 30 degrees
Exhaust ............................................. 45 degrees
(3) Valve stem diameter

Inlet .. 5.942 to 5.957 mm (0.2339 to 0.2345 inch)
Exhaust ................................. 5.927 to 5.942 mm
(0.2333 to 0.2339 inch)
Clearance
Maximum clearance of the inlet valve
stem ................................ 0.05 mm (0.0020 inch)
g01164859
The service limit for the inlet valve
Illustration 13 stem ................................ 0.08 mm (0.0031 inch)
Typical example
Clearance
The valve spring (1) may be used on the inlet valve
or the exhaust valve. When the valve springs are Maximum clearance of the exhaust valve
replaced the valve springs must be replaced in pairs. stem .............................. 0.065 mm (0.0026 inch)
The service limit for the inlet valve
Table 1 stem ................................ 0.09 mm (0.0035 inch)
The load for the valve The length of the valve
spring spring (4) Length of valve
161.5 to 178.5 N 31.5 mm (1.2402 inch) Inlet valve ..................... 107.925 to 108.375 mm
(36.3 to 40.1 lb) (4.2490 to 4.2667 inch)
Exhaust valve ............... 107.703 to 108.153 mm
337.9 ± 373.5 N (76 ± 84 lb) 21.5 mm (0.8465 inch) (4.2403 to 4.2580 inch)
(5) Valve head

Diameter of inlet valve head .................... 35 mm
(1.3780 inch)
Diameter of exhaust valve head .............. 33 mm
(1.2992 inch)
RENR8913 11
i02505671 Note: The maximum distortion of the bottom face of

the cylinder head is given in table 2.
Cylinder Head
Table 2
Maximum Permissible
Dimension
Distortion
Width (A) 0.03 mm (0.0018 inch)
Length (B) 0.05 mm (0.0019 inch)
Diagonal Line (C) 0.05 mm (0.0019 inch)
g01250785
Illustration 15
Typical example
Lubricate the threads and the underside of the head

bolts with clean engine oil.
Tighten the bolts in the sequence that is shown in
illustration 15 to the following torque. ...... 50 N·m
(37 lb ft)
Tighten the bolts again to the following
torque. .................................... 100 N·m (74 lb ft)
Tighten the head bolts to the additional
amount. ........................................... 225 degrees
Minimum thickness of cylinder head ....... 100.95 mm

(3.9744 inch)
g01185843
Illustration 17
Typical example
(1) Valve guide bores

Inlet and exhaust .................. 5.979 to 5.992 mm
(0.2354 to 0.2359 inch)
(2) Valve depths

Inlet .. 0.905 to 1.163 mm (0.0356 to 0.0458 inch)
The service limit for the depth of the inlet valve
........................................ 1.41 mm (0.0555 inch)
Exhaust ................................. 0.876 to 1.131 mm
(0.0345 to 0.0445 inch)
The service limit for the exhaust valve
depth ............................... 1.38 mm (0.0543 inch)
g01254471
Illustration 16
Typical example
12 RENR8913
i02527109 Table 3
Turbocharger The part number for

the turbocharger
The pressure for the
wastegate
2674A804 112 kPa (16.2445 psi)
2674A805 112 kPa (16.2445 psi)
2674A806 112 kPa (16.2445 psi)
2674A607 112 kPa (16.2445 psi)
2674A608 112 kPa (16.2445 psi)
2674A609 100 kPa (14.5040 psi)
2674A611 100 kPa (14.5040 psi)
2674A612 100 kPa (14.5040 psi)
i02504751
Exhaust Manifold
g01265255
Illustration 18
Typical example
(1) Turbocharger
g01253896
Illustration 19
(2) Actuator Typical example
(3) Actuator rod Tighten the exhaust manifold bolts in the sequence
that is shown in illustration 19 to the following
The maximum test pressure for the torque. ............................................. 40 N·m (30 lb ft)
wastegate .............................. 112 kPa (16.2445 psi)
The movement for the rod actuator ................. 1 mm

(0.0394 inch)
RENR8913 13
i02526614 Table 4
Camshaft Camshaft Journals Standard Diameter

50.711 to 50.737 mm
1
(1.9965 to 1.9975 inch)
50.457 to 50.483 mm
2
(1.9865 to 1.9875 inch)
49.949 to 49.975 mm
3
(1.9665 to 1.9675 inch)
Maximum wear on the camshaft journals ... 0.05 mm

(0.0021 inch)
Check the camshaft lobes for visible damage. If a

new camshaft is installed you must install new lifters.
i02505262
Camshaft Bearings
g00987750
Illustration 20
Checking the end play of the camshaft
(1) End play of a camshaft ......... 0.126 to 0.558 mm

(0.0050 to 0.0220 inch)
Maximum permissible end play of a worn

camshaft ............................... 0.62 mm (0.0244 inch)
g01195129
Illustration 21
Typical example
(2) Bolt
Tighten the bolt to the following torque. ... 95 N·m
(70 lb ft)
g01254209
(3) The diameters of the camshaft journals are given Illustration 22
in the following tables. Typical example
(1) The diameter of the installed camshaft

bearing .............................. 50.787 to 50.848 mm
(1.9995 to 2.0019 inch)
14 RENR8913
i02505073
Engine Oil Filter Base
g01254115
Illustration 24
Typical example
(3) Setscrew
Tighten the setscrews to the following
g01254114 torque. .......................................... 22 N·m (16 ft)
Illustration 23
Typical example (4) Engine oil filter
(1) Setscrew Tighten the engine oil filter to the following
torque. ........................................ 12 N·m (8 lb ft)
Tighten the setscrews to the following
torque. .......................................... 22 N·m (16 ft) (5) Plug
(2) Engine oil filter Tighten the plug to the following torque. .. 12 N·m
(8 lb ft)
Tighten the engine oil filter to the following
torque. ........................................ 12 N·m (8 lb ft)
RENR8913 15
i02505212 i02505677
Engine Oil Cooler Engine Oil Pump
Engines with Balancer Group

Type ............................. Gear-driven differential rotor
Number of lobes
Inner rotor ......................................................... 6
Outer rotor ........................................................ 7
g00952614
Illustration 25
Typical example
(1) Joint
(2) Oil cooler
(3) Housing
(4) Setscrew
(5) Seal
(6) Setscrew
(7) Setscrew
g00989248
Illustration 27
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)
g01254185
Illustration 26
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 26 to the following torque.
.................................................. 22 N·m (16 lb ft)
16 RENR8913
g00938724
Illustration 30
The end cover
(4) Torque for cover bolts for oil pump .......... 26 N·m
(19 lb ft)
g00989236
Illustration 28
Inner rotor
(2) Clearance of inner rotor to outer

rotor ...................................... 0.050 to 0.200 mm
(0.0020 to 0.0079 inch)
g00989519
Illustration 31
Idler gear and pump gear
Note: Replace the idler gear bolt (5) and the nut for
the oil pump gear (6).
(5) Tighten the idler gear bolt to the following

torque. ...................................... 26 N·m (19 lb ft)
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
g00989217
Illustration 29 and tighten the nut (6).
The end play for the rotor
(6) Tighten the nut to the following torque. .... 95 N·m
(3) End play of rotor assembly (70 lb ft)
Inner rotor .................................. 0.04 to 0.11 mm Tighten the bolts that hold the balancer to the cylinder
(0.0016 to 0.0043 inch) block to the following torque. .......... 54 N·m (40 lb ft)
Outer rotor ................................ 0.04 to 0.00 mm
(0.0016 to 0.0043 inch)
Engines without Balancer Group
Type ............................. Gear-driven differential rotor
RENR8913 17
Number of lobes (3) End play of rotor assembly

Inner rotor ......................................................... 5 Inner rotor ............................. 0.038 to 0.089 mm
Outer rotor ........................................................ 6 (0.0014 to 0.0035 inch)
Outer rotor ............................ 0.025 to 0.076 mm
(0.0010 to 0.0029 inch)
Tighten the bolts that hold the front cover of the oil
pump assembly to the following torque. ........ 26 N·m
(19 lb ft)
i01958104
Engine Oil Pressure
g00938064
Illustration 32
The minimum oil pressure at the maximum engine
The oil pump speed and at normal operating temperature is the
following value. ............................... 300 kPa (43 psi)
(1) Clearance of the outer rotor to the
body ...................................... 0.152 to 0.330 mm
(0.0059 to 0.0129 inch) i02506230
Engine Oil Pan
Table 5
Required Tools
Tool Part Number Part Description Qty
POWERPART
A 21826038 1
Retainer
g00938061
Illustration 33
Checking the clearance
(2) Clearance of inner rotor to outer

rotor ...................................... 0.040 to 0.127 mm
(0.0015 to 0.0050 inch)
g00938799
Illustration 34
Checking the end play
18 RENR8913
Front sealant ApplyTooling (A) to the bridge. The sealant must not
protrude more than 5 mm (0.1969 inch) above the
bridge.
g01254690
Illustration 35
Applying sealant
Apply Tooling (A) to the cylinder block and to the

timing case.
Note: Apply a sealant bead of 3.5 mm (0.1378 inch)

that is shown in illustration 35.
g01255016
Illustration 37
Rear sealant Typical example
Note: Install the rear oil seal before sealant is applied (1) Tighten the four front bolts in position (X) to the
to the bridge. following torque. ....................... 22 N·m (16 lb ft)
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)
g01254887
Illustration 36
Applying sealant
RENR8913 19
i02505676 Installed in the Balancer

Engine Oil Bypass Valve
Installed in the Oil Pump
g00919890
Illustration 40
Plug
g00919893
Illustration 38
Typical engine oil pump
g00921379
Illustration 41
The relief valve for the balancer
(1) Tighten the plug for the relief valve to the

following torque. ....................... 35 N·m (26 lb ft)
(2) Plunger
Illustration 39
g00921377 Diameter of the plunger ........ 14.46 to 14.48 mm
Relief valve and spring
(0.5692 to 0.5700 inch)
Clearance of the plunger in the
(1) Tighten the plug for the relief valve to the bore .... 0.04 to 0.08 mm (0.0015 to 0.0031 inch)
(3) Spring
(2) Plunger
Length of the spring ........... 67 mm (2.6378 inch)
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)
20 RENR8913
i02527053 Breather Canister

Crankcase Breather
Open crankcase breather
g01277901
Illustration 42
Typical example
(1) Connection
(2) Clamp
(3) Hose
(4) Clip g01277902
Illustration 43
Typical example
(2) Tighten the clamp to the following torque. .. 5 N·m
(1) Connection
(44 lb in) (2) Clamp
(3) Hose
(4) Filter base
(5) Bolts
(6) Clamp
(7) Hose
(8) Canister
(5) Tighten the bolts to the following torque. .. 22 N·m

(16 lb ft)
(2) Tighten the clamps to the following

torque. ........................................ 3 N·m (26 lb in)
(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)
RENR8913 21
i02504533 i02363605
Water Temperature Regulator Water Pump

and Housing
Table 6
Required Tools
POWERPART Red
A 21820221 1
Rubber Grease
g01183807
Illustration 45
Tightening sequence
Tighten the setscrews in the numerical sequence

that is shown in illustration 45 to the following
torque. ............................................. 22 N·m (16 lb ft)
g01253716
Illustration 44
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

(2) Water temperature regulator housing
(3) Water temperature regulator

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)
22 RENR8913
i02505673 Diameter of the bore in the cylinder

block for the number 2 camshaft
Cylinder Block journal ............................... 50.546 to 50.597 mm
(1.9900 to 1.9920 inch)
Diameter of the bore in the cylinder
journal ............................... 50.038 to 50.089 mm
(1.9700 to 1.9720 inch)
(4) Main bearings

Bore in the cylinder block for the main
bearings ............................ 88.246 to 88.272 mm
(3.4742 to 3.4753 inch)
Install the main bearing cap bolts (5). Refer to

Disassembly and Assembly, “Crankshaft Main
Bearings - Remove and Install” or Disassembly
and Assembly, “Crankshaft - Install” for the correct
procedure.
(5) Main bearing cap bolts

Evenly tighten the main bearing cap bolts. Torque
for the main bearing cap bolts. .. 80 N·m (59 lb ft)
Note: Tighten the bolts for the main bearing cap for
an additional 90 degrees.
Note: Ensure that the crankshaft can rotate freely.
g01254475
Illustration 46
Cylinder block
(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
(4.1535 to 4.1545 inch)
The second oversize bore

diameter .............................. 106.000 to 106.025 mm
(4.1732 to 4.1742 inch)
The maximum permissible wear for the cylinder

bore ....................................... 0.15 mm (0.0059 inch)
(3) Camshaft bearings

Diameter of the bushing in the cylinder
bearing .............................. 55.563 to 55.593 mm
(2.1875 to 2.1887 inch)
RENR8913 23
i02506995
Crankshaft
g01255050
Illustration 47
Typical example
(1) Crankshaft gear
(2) Crankshaft
(3) Crankshaft thrust washers
Maximum permissible temperature of the gear for

installation on the crankshaft ........... 180 °C (356 °F)
The end play of a new crankshaft ... 0.16 to 0.38 mm

(0.0063 to 0.0150 inch)
Standard thickness of thrust

washer ...... 2.26 to 2.31 mm (0.0890 to 0.0909 inch)
Oversize thickness of thrust

washer ...... 2.45 to 2.50 mm (0.0965 to 0.0984 inch)
24 RENR8913
g01261588
Illustration 48
Typical example
Table 7
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)
75.926 to 75.905 mm 75.672 to 75.651 mm 75.418 to 75.397 mm
1
(2.9892 to 2.9884 inch) (2.9792 to 2.9784 inch) (2.9692 to 2.9684 inch)
63.236 to 63.216 mm 62.982 to 62.962 mm 62.728 to 62.708 mm
2
(2.4896 to 2.4888 inch) (2.4796 to 2.4788 inch) (2.4696 to 2.4688 inch)
40.551 mm (1.5965 inch)
3 N/A N/A
maximum
39.47 mm (1.5539 inch)
4 N/A N/A
maximum
39.47 mm (1.5539 inch)
5 N/A N/A
maximum
44.68 mm (1.7591 inch)
6 N/A N/A
maximum
7 Do not machine this diameter. Do not machine this diameter. Do not machine this diameter.
Item (6) in table 7 can be repaired with a crankshaft Table 8

wear sleeve. Refer to Disassembly and Assembly, Minimum Width of machined Area of Crankshaft Web
“Crankshaft Wear Sleeve (Rear) - Remove and
Install” for more information. Web 1, 2, 3, 6 4 and 5 8
and 7
18.31 mm 19.11 mm 26.61 mm
(0.7209 (0.7524 (1.0476
inch) inch) inch)
RENR8913 25
If necessary, machine the thrust face in order to Refer to Specifications, “Connecting Rod Bearing
remove damage. Refer to table 8 for information. Journal” for more information on the connecting rod
bearing journals and connecting rod bearings.
Refer to table 9 for the run out of the crankshaft
journals. Refer to Specifications, “Main Bearing Journal” for
information on the main bearing journals and for
Table 9 information on the main bearings.
Journal Run out of the Journals
(1) Mounting i02504536
(2) 0.08 mm (0.0031 inch) Crankshaft Seals

(3) 0.15 mm (0.0059 inch)
(4) 0.08 mm (0.0031 inch)
(5) Mounting
The radii of all the crankshaft journals must be

machined. This machining must return the crankshaft
to the original standard. The radii must give a smooth
transition from the journal to the side machined face.
g01253721
Illustration 50
Typical example
(1) Crankshaft
(2) Crankshaft seal

g01261590
Illustration 49
Typical example (3) Plastic sleeve
The edge of the oil holes (4) must be machined to the (4) Alignment tool
original standard after machining of the crankshaft.
Oil hole
The maximum radius of the edge of the oil
hole ................................... 0.5 mm (0.0197 inch)
Surface finish of all journals .............. Ra 0.2 microns
Surface finish of all radii .................... Ra 0.4 microns
Inspect the crankshaft for structural cracking after

machining.
26 RENR8913
(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
(3) Crankshaft pulley
Crankshaft Pulley for the Poly

V-Belt
g00915076
Illustration 51
(5) Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in the

sequence that is shown in Illustration 51 to the
Remove the alignment tool.
Tighten bolts 8 and 9 in the sequence that is shown

in Illustration 51 to the following torque. ........ 22 N·m
(16 lb ft)
g01254970
Illustration 53
i02506934
Typical example
Crankshaft Pulley (1) Bolt
(2) Thrust block
(3) Crankshaft adapter
(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.
(5) Tighten the three bolts for the crankshaft pulley

to the following torque. ............. 78 N·m (58 lb ft)
g00915497
Illustration 52
A standard pulley
Note: Lubricate the threads of the bolts with clean

engine oil before installation.
RENR8913 27
i02504771 Surface finish of radii .............................. 1.3 microns

Connecting Rod Bearing Width of new main bearing
Journal journal ... 39.34 to 39.24 mm (1.5488 to 1.5449 inch)
Width of new center main bearing

journal ... 44.22 to 44.15 mm (1.7409 to 1.7382 inch)
The shell for the main bearings

The shells for the main bearings are available
for remachined journals which have the following
Refer to Specifications, “Crankshaft” for information undersize dimensions.
on the undersize crankshaft journals.
Undersize bearing shell .... 0.25 mm (0.010 inch)
Undersize bearing shell .... 0.51 mm (0.020 inch)
The original size of the connecting rod bearing Undersize bearing shell .. 0.76 mm (0.0299 inch)
journal ... 63.47 to 63.49 mm (2.4988 to 2.4996 inch)
Thickness at center of the shells .. 2.083 to 2.089 mm
Maximum permissible wear of a bearing journal on a (0.0820 to 0.0823 inch)
new connecting rod .............. 0.04 mm (0.0016 inch)
Width of the main bearing shells .. 31.62 to 31.88 mm
Width of the connecting rod bearing (1.244 to 1.255 inch)
journals ................................... 40.348 to 40.424 mm
(1.5885 to 1.5915 inch)
Clearance between the bearing shell and the main
bearing journals ........................... 0.117 to 0.058 mm
Radius of the fillet of the connecting rod bearing
(0.0046 to 0.0023 inch)
journals ......... 3.68 to 3.96 mm (0.145 to 0.156 inch)
Surface finish of connecting rod bearing i02505708

journals ............................................ Ra 0.4 microns
Connecting Rod
Surface finish of radii ....................... Ra 1.3 microns
i02506007
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 ..................................... 76.180 to 76.159 mm
(2.9992 to 2.9984 inch)
Maximum permissible wear of the main bearing Illustration 54

g01254512
journals ............................... 0.040 mm (0.0016 inch)
Typical example
Radius of the fillet of the main bearing

journals ..... 3.68 to 3.69 mm (0.1448 to 0.1452 inch) (1) The bearing shell for the connecting rod
Surface finish of bearing journals and crank pins

................................................................ 0.4 microns
28 RENR8913
Table 10
Thickness of Connecting
1.8352 to 1.8415 mm
Rod Bearing at the
(0.0723 to 0.0725 inch)
Center
Thickness of Connecting
1.8352 to 1.8415 mm
Rod Bearing for the Cap
(0.0723 to 0.0725 inch)
at the Center
0.034 ± 0.081 mm
Bearing Clearance
(0.0013 ± 0.0032 inch)
Table 11
Undersized Connecting Rod Bearing
0.25 mm (0.010 inch)

0.51 mm (0.020 inch)
0.76 mm (0.030 inch)
The mating surfaces of the connecting rod are

produced by hydraulically fracturing the forged
connecting rod.
(2) Tighten the setscrews for the connecting rod to

the following torque. ................. 18 N·m (13 lb ft)
Tighten the setscrews for the connecting rod again to g01254518

the following torque. ........................ 70 N·m (52 lb ft) Illustration 55
Typical example
Tighten the setscrews for the connecting rod for
an additional 120 degrees. The setscrews for the (3) Diameter of the finished bore for the piston
connecting rod (2) must be replaced after this pin ..................................... 39.738 to 39.723 mm
procedure. (1.5645 to 1.5639 inch)
Note: Always tighten the connecting rod cap to the (4) Distance between the parent bores
connecting rod, when the assembly is out of the ...... 219.05 to 219.1 mm (8.6240 to 8.6260 inch)
engine. Tighten the assembly to the following torque
20 N·m (14 lb ft). (5) Diameter for the finished bore for the connecting
rod bearing ....................... 67.208 to 67.221 mm
(2.6460 to 2.6465 inch)
g00915056
Illustration 56
RENR8913 29
Connecting rods are color coded. The color code Note: When you install a new top compression ring,
is a reference for the length (Y) of the connecting make sure that the word “TOP” is facing the top
rod. Refer to table 12 for the different lengths of of the piston. New top piston rings have a yellow
connecting rods. identification mark which must be on the left of the
ring end gap when the top piston ring is installed on
Table 12 an upright piston.
Length Grades for Connecting Rods
(2) Intermediate compression ring
Grade Letter Color Code Length (Y)
The shape of the intermediate compression
165.761 to 165.728 mm
F Red
(6.5260 to 6.5247 inch)
ring ....................................... Internal bevel in the
bottom edge with a tapered face
165.715 to 165.682 mm
G Orange Width of intermediate compression
(6.5242 to 6.5229 inch)
ring .... 2.47 to 2.495 mm (0.0972 to 0.0982 inch)
165.670 to 165.637 mm
H White
(6.5224 to 6.5211 inch) The clearance between a new intermediate
165.624 to 165.591 mm compression ring and the piston groove in a new
J Green piston ..................................... 0.065 to 0.011 mm
(6.5206 to 6.5193 inch)
(0.0026 to 0.0004 inch)
165.578 to 165.545 mm
K Purple
(6.5188 to 6.5175 inch) Ring gap ................................... 0.65 to 0.85 mm
165.532 to 165.499 mm
(0.0256 to 0.0335 inch)
L Blue
(6.5170 to 6.5157 inch)
Note: When you install a new intermediate
compression ring, make sure that the word “TOP” is
i02363087
facing the top of the piston. New intermediate rings
have a blue identification mark which must be on the
Piston and Rings left of the ring end gap when the top piston ring is
installed on an upright piston.
(3) The oil control ring

Width of oil control ring ............. 2.97 to 2.99 mm
(0.1169 to 0.1177 inch)
The clearance between a new oil control ring and
the groove in a new piston ........ 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: The oil control ring is a two-piece ring that is

spring loaded. 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.
Illustration 57
g01155119 Piston
Typical example Note: An arrow which is marked on the piston crown
must be toward the front of the engine.
(1) Top compression ring
Piston height above cylinder block .. 0.21 to 0.35 mm
The shape of the top compression ring .. tapered
(0.008 to 0.014 inch)
Ring gap ................................... 0.30 to 0.45 mm
(0.0118 to 0.0177 inch) Width of top groove in the piston ................. Tapered
Width of second groove in new

piston ........ 2.56 to 2.58 mm (0.1008 to 0.1016 inch)
30 RENR8913
Width of third groove in new piston .. 3.02 to 3.04 mm Piston Cooling Jet Alignment
(0.1189 to 0.1197 inch)
Piston pin
Diameter of a new piston
pin ..................................... 39.694 to 39.700 mm
(1.5628 to 1.5630 inch)
Oversize Piston
Table 13
Standard piston
1 Oversize +0.5 mm (0.0197 inch) piston
2 Oversize +1.0 mm (0.0394 inch) piston g01006929
Illustration 59
(2) Piston cooling jet
(3) Rod
i02367100 (4) Cylinder block
Piston Cooling Jet Use the following procedure in order to check the
alignment of the piston cooling jet.
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 14 mm
(0.5512 inch).
Note: Ensure that the rod (3) can not damage the
piston cooling jet when the alignment is checked. The
g00942652
Illustration 58 piston cooling jets can not be adjusted. If a piston
(1) Installed piston cooling jets cooling jet is not in alignment the piston cooling jet
must be replaced.
The valve must move freely. Tighten the bolt to the
following torque. .................................. 9 N·m (7 lb ft)
i02369751
Front Housing and Covers
The front housing must be aligned to the cylinder

block face. ......................... + 0.05 to minus 0.05 mm
(+ 0.0020 to minus 0.0020 inch )
RENR8913 31
g00995663 g00918672
Illustration 60 Illustration 62
Alignment Typical example
(2) Tighten the bolts that fasten the water pump to the
front housing to the following torque. ....... 22 N·m
(16 lb ft)
Note: Refer to Specifications, “Water Pump” for the

correct bolt tightening sequence for the water pump.
i02504717
Gear Group (Front)
g01203927
Illustration 61
Typical example
Tighten the setscrew to the sequence that is shown

in illustration 61 to the following torque. ......... 28 N·m
(20 lb ft)
(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 63
Gear train
32 RENR8913
(1) Fuel injection pump drive gear

Tighten the nut to the following torque. ... 25 N·m
(18 lb ft)
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 g00996214
Illustration 64
The gear train for the oil pump
Number of teeth .............................................. 68
(4) Crankshaft gear
(3) Idler gear and hub
Bore diameter of crankshaft gear
Tighten the bolts for the idler gear to the following ........ 51.00 to 51.03 mm (2.0079 to 2.0091 inch)
torque. ...................................... 44 N·m (33 lb ft)
Outside diameter of crankshaft
Width of idler gear and split bearing hub .................................... 51.021 to 51.002 mm
assembly .......................... 30.165 to 30.135 mm (2.0087 to 2.0079 inch)
(1.1876 to 1.1864 inch)
Clearance of gear on
Inside diameter of idler gear bearings with crankshaft ......................... −0.021 to +0.028 mm
flanges .............................. 50.797 to 50.818 mm (−0.0008 to 0.0011 inch)
(1.9999 to 2.0007 inch)
Number of teeth .............................................. 34
Outside diameter of idler gear
hub .................................... 50.716 to 50.737 mm (5) Oil pump idler gear
(1.9967 to 1.9975 inch)
Inside diameter of oil pump idler gear
Clearance of idler gear bearing on bearing .............................. 16.012 to 16.038 mm
hub .... 0.06 to 0.102 mm (0.0024 to 0.0040 inch) (0.6304 to 0.6314 inch)
Idler gear end play .................. 0.13 to 0.205 mm Outside diameter of oil pump idler gear
(0.0051 to 0.0081 inch) shaft .................................. 15.966 to 15.984 mm
(0.6286 to 0.6293 inch)
Maximum permissible end play ............ 0.38 mm
(0.015 inch) Clearance of oil pump idler gear bearing on
shaft ...................................... 0.028 to 0.072 mm
Idler gear end play with roller (0.0011 to 0.0028 inch)
bearings .................................. 0.24 to 0.954 mm
(0.0094 to 0.0376 inch) End play of the oil pump idler
gear ...................................... 0.050 to 0.275 mm
Number of teeth .............................................. 73 (0.0019 to 0.0108 inch)
(6) Oil pump gear

The number of teeth on the oil pump gear ..... 17
Backlash values
Backlash between the idler gear (5) and the oil
pump drive gear (6) .................. 0.05 to 0.14 mm
(0.0020 to 0.0055 inch)
Backlash between the oil pump idler gear (5) and
the crankshaft gear (4) ............... 0.8 to 0.23 mm
(0.0315 to 0.0091 inch)
RENR8913 33
Backlash between the idler gear (3) and the (3) Bolt
crankshaft gear (4) ................. 0.05 to 0.015 mm
(0.0020 to 0.0006 inch) Tighten the flywheel bolts to the following
torque. ..................................... 115 N·m (85 lb ft)
Backlash between the camshaft gear (2) and the
idler gear (3) ............................. 0.05 to 0.15 mm
i02505674
(0.0020 to 0.0059 inch)
Backlash between the fuel injection pump gear Flywheel Housing
(1) and the idler gear (3) ........... 0.05 to 0.15 mm
(0.0020 to 0.0059 inch)
Backlash between the water pump gear (not
shown) and the fuel injection pump gear
Table 14
(1) ....... 0.05 to 0.15 mm (0.0020 to 0.0059 inch)
Backlash between the power take-off Required Tools
drive (if equipped) and the idler gear Tool Part Number Part Description Qty
(3) ..... 0.05 to 0.250 mm (0.0020 to 0.0098 inch)
POWERPART
A 21820117 Threadlock and 1
i02503254 Nutlock
Flywheel
g01254486
Illustration 66
Typical example
g00584712
Illustration 65
Typical example Setscrew
(1) Tighten the setscrew to the following
(1) Flywheel ring gear
torque. ................................ 75 N·m (55 lb ft)
Heat the flywheel ring gear to the following
temperature. .............................. 250 °C (480 °F) Setscrew
(2) Tighten the setscrew to the following
Note: Do not use an oxyacetylene torch to heat the
torque. ................................ 63 N·m (46 lb ft)
flywheel ring gear.
(2) Flywheel
34 RENR8913
Note: If 12.9 setscrews are installed, apply Tooling

(A) to the setscrews. Tighten the 12.9 setscrews to a
torque of 70 N·m (52 lb ft).
i02519438
Belt Tension Chart
Table 15
Required Tools
A - Belt Tension Gauge 1
Table 16
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 belt that is farthest from the engine.
(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 i02504537

length of belt and check the tension on both belts.
Check and adjust the tension on the tightest belt. Alternator
To adjust the belt tension, refer to Disassembly and
Assembly, “Alternator - Install”.
Note: A poly v-belt has an automatic belt tensioner.

No manual adjustment of the poly v-belt is required.
The 12 Volt Denso Alternator
To replace the poly v-belt, refer to Disassembly and
Assembly, “Alternator Belt - Remove and Install”. Six types of alternator are available.
Output
i01721280
Four 12 volt alternators are available. ... 75 Amp,
Engine Lifting Bracket 85 Amp, 100 Amp and 120 Amp
Two 24 volt alternators are
available. ........................... 55 Amp and 75 Amp
All engines are equipped with two engine lifting

brackets.
Tighten the two bolts on each engine lifting
bracket to the following torque. .. 44 N·m (32 lb ft)
RENR8913 35
The 24 Volt Iskra Alternator
g01194950
Illustration 67
g01194953
Typical example Illustration 68
Typical example
(1) Terminal “W”
(1) Terminal “B+”
Tighten the terminal nut to the following
torque. ..................................... 1.5 N·m (13 lb in) Tighten the terminal nut to the following
torque. ...................................... 11 N·m (97 lb in)
(2) Terminal “D+”
(2) Terminal “D+”
torque. ..................................... 1.5 N·m (13 lb in) Tighten the terminal nut to the following
torque. ........................................ 3 N·m (26 lb in)
(3) Terminal “B+”
(3) The terminal “W” is spade-type.
torque. ..................................... 3.3 N·m (29 lb in) 24 volt output
The 24 volt alternator ............................ 100 Amp
36 RENR8913
i02504538 12 Volt Starting Motor 3 Kw

Starter Motor
24 Volt Starting Motor 4.5 Kw
g01200844
Illustration 70
Typical example
(1) Tighten the nut for the positive terminal (terminal

30) to the following torque. ....... 6 N·m (53 lb in )
(2) Tighten the solenoid terminal (terminal 50) to the

g01200801
following torque. ........................ 8 N·m ( 70 lb in)
Illustration 69
Typical example (3) Tighten the nut for the terminal for the earth to
the following torque. ................ 8 N·m ( 70 lb in)
(1) Tighten the negative terminal nut to the following
torque. ....................................... 15 N·m (11 lb ft) Rated voltage ................................................ 12 volts
(2) Tighten the positive terminal nut to the following Pull in voltage ................................................. 8 volts
torque. ...................................... 21 N·m (15 lb ft)
(3) Tighten the solenoid terminal to the following

torque. ..................................... 3.5 N·m (31 lb in)
Rated voltage ................................................ 24 volts

RENR8913 37
i02371978 Ensure that all adjustments and repairs are performed

by personnel that have had the correct training.
Coolant Temperature Sensor
g01192226
Illustration 72
(1) Fuel pressure sensor
(2) Washer
Illustration 71
g01183334 Fuel pressure sensor
Typical example Tighten the fuel pressure sensor to the following
torque. ...................................... 34 N·m (25 lb ft)
(1) Sensor
Tighten the sensor to the following i02371981
torque. ....................................... 15 N·m (11 lb ft)
Engine Oil Pressure Sensor
i02388157
Fuel Pressure Sensor

Refer to the Operation and Maintenance manual,

“General Hazard Information and High Pressure Fuel
Lines” before adjustments and repairs are performed.
Note: Refer to Testing and Adjusting Manual

, “Cleanliness of Fuel System Components”
for detailed information on the standards of
cleanliness that must be observed during ALL
g01183333
work on the fuel system. Illustration 73
Typical example
38 RENR8913
(1) Sensor i02493822
Tighten the sensor to the following torque. Inlet Manifold Temperature

.................................................... 10 N·m (7 lb ft)
Sensor
i02371977
Boost Pressure Sensor
g01183334
Illustration 75
Typical example
g01183333
(1) Sensor
Illustration 74
Typical example Tighten the sensor to the following
torque. ...................................... 20 N·m (15 lb ft)
(1) Sensor
Tighten the sensor to the following
torque. ........................................ 10 N·m (7 lb ft)
RENR8913 39
i02404840 i02506817
Crankshaft Position Sensor Electronic Control Module
g01201229 g01254910
Typical example (1) Electronic control module (ECM)
(2) Connectors
(3) Setscrew
(1) Tighten the bolt for the sensor to the following
(4) Setscrew
torque. ...................................... 22 N·m (16 lb ft)
(2) Connectors
Tighten the connectors to the following
torque. ................................... 18.5 N·m (14 lb ft)
(3) Setscrew
Tighten the setscrew to the following
torque. ........................................ 5 N·m (44 lb in)
(4) Setscrew
Tighten the setscrew to the following
torque. ...................................... 22 N·m (16 lb ft)
40 RENR8913
i02505941
Glow Plugs
g01254601
Illustration 78
Typical example
Tighten the glow plugs (2) in the cylinder head to the

following torque. ............................... 15 N·m (11 lb ft)
Tighten the nuts (1) for the bus bar (3) that is
installed on top of the glow plugs to the following
torque. ............................................... 2 N·m (18 lb in)
Voltage ................................................. 12 or 24 volts

RENR8913 41
Index Section
Index
A Fuel Injection Lines................................................ 4
Manifold to Injector............................................. 5
Alternator ............................................................... 34 Pump to Manifold ............................................... 5
The 12 Volt Denso Alternator............................. 34 Fuel Injection Pump............................................... 5
The 24 Volt Iskra Alternator ............................... 35 Fuel Injectors ......................................................... 6
Fuel Pressure Sensor............................................ 37
Fuel Priming Pump ................................................ 7
B Electric fuel Priming Pump................................. 7
Hand Fuel Priming Pump................................... 7
Belt Tension Chart ................................................. 34 Fuel Transfer Pump............................................... 6
Boost Pressure Sensor.......................................... 38
G
C
Gear Group (Front)................................................ 31
Camshaft ............................................................... 13 Glow Plugs ............................................................ 40
Camshaft Bearings ................................................ 13
Connecting Rod..................................................... 27
Connecting Rod Bearing Journal........................... 27 I
Coolant Temperature Sensor................................. 37
Crankcase Breather............................................... 20 Important Safety Information ................................. 2
Breather Canister............................................... 20 Inlet Manifold Temperature Sensor........................ 38
Open crankcase breather .................................. 20
Crankshaft ............................................................ 23
Crankshaft Position Sensor ................................... 39 L
Crankshaft Pulley .................................................. 26
Crankshaft Pulley for the Poly V-Belt................. 26 Lifter Group............................................................ 7
Crankshaft Seals ................................................... 25
Cylinder Block........................................................ 22
Cylinder Head........................................................ 11 M
Cylinder Head Valves ............................................ 10
Main Bearing Journal............................................. 27
The shell for the main bearings.......................... 27
E
Electronic Control Module ..................................... 39 P

Engine Design ....................................................... 4
Engine Lifting Bracket............................................ 34 Piston and Rings ................................................... 29
Engine Oil Bypass Valve ....................................... 19 Oversize Piston.................................................. 30
Installed in the Balancer..................................... 19 Piston ................................................................. 29
Installed in the Oil Pump .................................... 19 Piston Cooling Jet.................................................. 30
Engine Oil Cooler .................................................. 15 Piston Cooling Jet Alignment ............................. 30
Engine Oil Filter Base............................................ 14
Engine Oil Pan....................................................... 17
Front sealant ...................................................... 18 R
Rear sealant....................................................... 18
Engine Oil Pressure............................................... 17 Rocker Shaft.......................................................... 8
Engine Oil Pressure Sensor .................................. 37
Engine Oil Pump.................................................... 15
Engines with Balancer Group ............................ 15 S
Engines without Balancer Group ....................... 16
Exhaust Manifold ................................................... 12 Specifications Section ........................................... 4
Starter Motor.......................................................... 36
12 Volt Starting Motor 3 Kw ............................... 36
F 24 Volt Starting Motor 4.5 Kw ............................ 36
Flywheel ................................................................ 33
Flywheel Housing .................................................. 33 T
Front Housing and Covers..................................... 30
Fuel Filter Base ..................................................... 7 Table of Contents................................................... 3
42 RENR8913
Index Section
Turbocharger ......................................................... 12
Valve Mechanism Cover........................................ 9
Water Pump........................................................... 21
Water Temperature Regulator and Housing .......... 21
RENR8913 43
Index Section
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.
RENR7967
September 2006
Systems Operation
Testing and Adjusting
NH (Engine)
NJ (Engine)

this publication.

replacement parts.
death.
RENR7967 3
Table of Contents
Table of Contents Gear Group - Inspect ............................................ 75

Crankshaft Pulley - Check .................................... 76
Electrical System
Systems Operation Section Alternator - Test .................................................... 78
Battery - Test ......................................................... 79
General Information
V-Belt - Test .......................................................... 79
Introduction ............................................................ 4
Charging System - Test ........................................ 80
Electric Starting System - Test .............................. 81
Engine Operation
Glow Plugs - Test .................................................. 83
Basic Engine ........................................................... 6
Air Inlet and Exhaust System ................................ 11
Cooling System .................................................... 14 Index Section
Lubrication System .............................................. 16
Electrical System ................................................. 17 Index ..................................................................... 84
Cleanliness of Fuel System Components ............. 18
Fuel Injection ....................................................... 20
Electronic Control System ................................... 27
Power Sources ..................................................... 36
Glossary of Electronic Control Terms ................... 39
Testing and Adjusting Section

Fuel System
Fuel System - Inspect ........................................... 45
Air in Fuel - Test .................................................... 45
Finding Top Center Position for No. 1 Piston ........ 46
Fuel Injection Timing - Check ............................... 47
Fuel Quality - Test ................................................. 48
Fuel System - Prime ............................................. 49
Gear Group (Front) - Time .................................... 50
Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ................. 51
Turbocharger - Inspect .......................................... 52
Compression - Test ............................................... 55
Engine Valve Lash - Inspect/Adjust ...................... 56
Valve Depth - Inspect ............................................ 58
Valve Guide - Inspect ............................................ 59
Lubrication System
Engine Oil Pressure - Test .................................... 61
Engine Oil Pump - Inspect .................................... 61
Excessive Bearing Wear - Inspect ........................ 62
Excessive Engine Oil Consumption - Inspect ....... 62
Increased Engine Oil Temperature - Inspect ........ 63
Cooling System
Cooling System - Check ....................................... 64
Cooling System - Inspect ...................................... 64
Cooling System - Test ........................................... 65
Engine Oil Cooler - Inspect ................................... 66
Water Temperature Regulator - Test ..................... 67
Water Pump - Inspect ........................................... 68
Basic Engine
Piston Ring Groove - Inspect ................................ 69
Connecting Rod - Inspect ..................................... 69
Cylinder Block - Inspect ........................................ 72
Cylinder Head - Inspect ........................................ 72
Piston Height - Inspect .......................................... 72
Flywheel - Inspect ................................................. 73
Flywheel Housing - Inspect ................................... 74
4 RENR7967
Systems Operation Section
General Information
i02517251
Introduction
The following model views show a typical 1104D

engine. Due to individual applications, your engine
may appear different from the illustrations.
g01245941
Illustration 1
Front left engine view
(1) Front lifting eye (6) Oil gauge (11) Crankshaft pulley
(2) Water outlet (7) Secondary fuel filter (12) Water pump
(3) Rear lifting eye (8) Oil filler (13) Belt tensioner
(4) Fuel manifold (rail) (9) Oil sampling valve
(5) Electronic control module (10) Oil filter
RENR7967 5
g01245940
Illustration 2
Rear right engine view
(14) Turbocharger (18) Starting motor (22) Hand fuel priming pump
(15) Alternator (19) Oil pan (23) Flywheel housing
(16) Exhaust manifold (20) Drain plug (24) Heat shield
(17) Wastegate solenoid (21) Primary fuel filter
Note: The primary fuel filter is mounted off the Each cylinder has a piston cooling jet that is installed
engine. in the cylinder block. The piston cooling jet sprays
engine oil onto the inner surface of the piston in order
The 1104D models NH1 and NJ1 diesel engines are to cool the piston. The pistons have a Quiescent
electronically controlled. The 1104D engine uses combustion chamber in the top of the piston in order
an Electronic Control Module (ECM) that receives to achieve clean exhaust emissions. The piston pin is
signals from the fuel injection pump and other off-center in order to reduce the noise level.
sensors in order to control the fuel injectors. The
pump supplies fuel to the fuel injectors. The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard
The four cylinders are arranged in-line. The cylinder metal insert in order to reduce wear of the groove.
head assembly has two inlet valves and two exhaust The skirt has a coating of graphite in order to reduce
valves for each cylinder. The ports for the exhaust wear when the engine is new. The correct piston
valves are on the right side of the cylinder head. The height is important in order to ensure that the piston
ports for the inlet valves are on the left side of the does not contact the cylinder head. The correct
cylinder head. Each cylinder valve has a single valve piston height also ensures the efficient combustion
spring. of fuel which is necessary in order to conform to
requirements for emissions.
6 RENR7967
A piston and a connecting rod are matched to The fuel injection pump (1) that is installed on the
each cylinder. The piston height is controlled by the left side of the engine is gear-driven from the timing
distance between the center of the big end bearing case. The fuel transfer pump (25) is attached to the
and the center of the small end bearing of the fuel injection pump (1). The fuel transfer pump draws
connecting rod. Three different lengths of connecting low pressure fuel from the primary fuel filter. The
rods are available in order to attain the correct piston fuel transfer pump delivers the fuel to the secondary
height. The three different lengths of connecting rods filter at a pressure of 400 kPa (58 psi) to 500 kPa
are made by machining the blank small end bearing (72.5200 psi). The fuel injection pump draws fuel
of each rod at three fixed distances vertically above from the secondary filter. The fuel injection pump
the centerline of the big end bearing. . increases the fuel to a maximum pressure of 130 MPa
(18855 psi). The fuel injection pump delivers the fuel
The crankshaft has five main bearing journals. End to the fuel manifold. The fuel injection pump is not
play is controlled by thrust washers which are located serviceable. Adjustments to the pump timing should
on both sides of the number three main bearing. only be made by personnel that have had the correct
training. The fuel injection pump uses the engine
The timing case is made of aluminum. The timing ECM to control the engine RPM.
gears are stamped with timing marks in order to
ensure the correct assembly of the gears. When the The specifications for the 1104D refer to the
number 1 piston is at the top center position on the Specifications, “Engine Design”.
compression stroke, the marked teeth on the idler
gear will match with the marks that are on the fuel
injection pump, the camshaft, and the gear on the
crankshaft. There is no timing mark on the rear face Engine Operation
of the timing case.
i02525716
The crankshaft gear turns the idler gear which then
turns the following gears: Basic Engine
• the camshaft gear
Introduction (Basic Engine)
• the fuel injection pump
The eight major mechanical components of the basic
The camshaft and the fuel injection pump run at half engine are the following parts:
the rpm of the crankshaft. The cylinder bores are
machined into the cylinder block. • Cylinder block
• Cylinder head
• Pistons
• Connecting rods
• Crankshaft
• Timing gear case and gears
• Camshaft
• Rocker shaft assembly
g01259333
Illustration 3
RENR7967 7
Cylinder Block and Cylinder Head Cylinder head
g01263698 g01263700
Typical Cylinder Block Typical cylinder head
The cast iron cylinder block for the 1104D engine The engine has a cast iron cylinder head. The inlet
has four cylinders which are arranged in-line. The manifold is integral within the cylinder head. There
cylinder block is made of cast iron in order to provide are two inlet valves and two exhaust valve for each
support for the full length of the cylinder bores. Worn cylinder. Each pair of valves are connected by a valve
cylinders may be rebored in order to accommodate bridge that is controlled by a pushrod valve system.
oversize pistons and rings. The ports for the inlet valves are on the left side of
the cylinder head. The ports for the exhaust valves
The cylinder block has five main bearings which are on the right side of the cylinder head. The valve
support the crankshaft. Thrust washers are installed stems move in valve guides that are machined into
on both sides of number three main bearing in order the cylinder head. There is a renewable valve stem
to control the end play of the crankshaft. seal that fits over the top of the valve guide.
Passages supply the lubrication for the crankshaft

bearings. These passages are cast into the cylinder
block.
The cylinders are honed to a specially controlled

finish in order to ensure long life and low oil
consumption.
The cylinder block has a bush that is installed for the

front camshaft journal. The other camshaft journals
run directly in the cylinder block.
The engine has a cooling jet that is installed in the

cylinder block for each cylinder. The piston cooling
jet sprays lubricating oil onto the inner surface of the
piston in order to cool the piston.
A multi-layered steel (MLS) cylinder head gasket is

used between the engine block and the cylinder head
in order to seal combustion gases, water, and oil.
8 RENR7967
Pistons, Rings and Connecting The connecting rods are machined from forged
molybdenum steel. The connecting rods have
Rods bearing caps that are fracture split. The bearing caps
on fracture split connecting rods are retained with
Torx screws. Connecting rods with bearing caps that
are fracture split have the following characteristics:
• The splitting produces an accurately matched

surface on each side of the fracture for improved
strength.
Crankshaft
g01263701
Illustration 6
Typical example
The pistons have a Quiescent combustion chamber Illustration 7

g01263702
in the top of the piston in order to provide an efficient
mix of fuel and air. The piston pin is off-center in The crankshaft is a chromium molybdenum forging.
order to reduce the noise level. The crankshaft has five main journals. Thrust
washers are installed on both sides of number three
The pistons have two compression rings and an oil main bearing in order to control the end play of the
control ring. The groove for the top ring has a hard crankshaft.
metal insert in order to reduce wear of the groove.
The piston skirt has a coating of graphite in order to The crankshaft changes the linear energy of the
reduce the risk of seizure when the engine is new. pistons and connecting rods into rotary torque in
order to power external equipment.
The correct piston height is important in order to
ensure that the piston does not contact the cylinder A gear at the front of the crankshaft drives the timing
head. The correct piston height also ensures the gears. The crankshaft gear turns the idler gear which
efficient combustion of fuel which is necessary in then turns the following gears:
order to conform to requirements for emissions.
• Camshaft gear
• Fuel injection pump and fuel transfer pump
RENR7967 9
• Lower idler gear which turns the gear of the The camshaft and the fuel injection pump rotate at
lubricating oil pump. half the engine speed.
Lip type seals are used on both the front of the

crankshaft and the rear of the crankshaft.
Camshaft
A timing ring is installed to the crankshaft. The timing

ring is used by the ECM in order to measure the
engine speed and the engine position.
g01263706
Illustration 10
The engine has a single camshaft. The camshaft

is made of cast iron. The camshaft lobes are chill
g01263703
hardened.
Illustration 8
The camshaft is driven at the front end. As the
Gears and Timing Gear Case camshaft turns, the camshaft lobes move the valve
system components. The valve system components
move the cylinder valves.
The camshaft gear must be timed to the crankshaft

gear. The relationship between the lobes and the
camshaft gear causes the valves in each cylinder to
open at the correct time. The relationship between
the lobes and the camshaft gear also causes the
valves in each cylinder to close at the correct time.
g01263705
Illustration 9
The crankshaft oil seal is mounted in the aluminum

timing case. The timing case cover is made from
pressed steel.
The timing gears are made of steel.
The crankshaft gear drives an upper idler gear and

a lower idler gear. The upper idler gear drives the
camshaft and the fuel injection pump. The lower idler
gear drives the oil pump. The water pump drive gear
is driven by the fuel injection pump gear.
10 RENR7967
Rocker Shaft Assembly
g01263708
Illustration 11
The camshaft has two camshaft lobes for each

cylinder. The lobes operate either a pair of inlet
valves or a pair of exhaust valves. As the camshaft
turns, lobes on the camshaft cause the lifter to move
the pushrod up and down. Upward movement of the
pushrod against rocker arm results in a downward
movement that acts on the valve bridge. This action
opens a pair of valves which compresses the valve
springs. When the camshaft has rotated to the
peak of the lobe, the valves are fully open. When
the camshaft rotates further, the two valve springs
under compression start to expand. The valve stems
are under tension of the springs. The stems are
pushed upward in order to maintain contact with the
valve bridge. The continued rotation of the camshaft
causes the rocker arm, the pushrods and the lifters
to move downward until the lifter reaches the bottom
of the lobe. The valves are now closed. The cycle is
repeated for all the valves on each cylinder.
RENR7967 11
i02526613
g01205681
Illustration 12
Air inlet and exhaust system
(1) Exhaust manifold (5) Aftercooler core (if equipped) (9) Air inlet from the air cleaner
(2) Electronic unit injector (6) Exhaust outlet (10) Inlet valve
(3) Glow plug (7) Turbine side of turbocharger (11) Exhaust valve
(4) Inlet manifold (8) Compressor side of turbocharger
The components of the air inlet and exhaust system Air is drawn in through the air cleaner into the air
control the quality of air and the amount of air that is inlet of the turbocharger (9) by the turbocharger
available for combustion. The air inlet and exhaust compressor wheel (8). The air is compressed and
system consists of the following components: heated to about 150 °C (300 °F) before the air is
forced to the aftercooler (5). As the air flows through
• Air cleaner the aftercooler the temperature of the compressed
air lowers to about 50 °C (120 °F). Cooling of the
• Turbocharger inlet air increases combustion efficiency. Increased
combustion efficiency helps achieve the following
• Aftercooler benefits:
• Inlet manifold • Lower fuel consumption

• Cylinder head, injectors and glow plugs • Increased horsepower output
• Valves and valve system components • Reduced particulate emission
• Piston and cylinder From the aftercooler, air is forced into the inlet
manifold (4). Air flow from the inlet manifold to the
• Exhaust manifold cylinders is controlled by inlet valves (10). There are
two inlet valves and two exhaust valves for each
cylinder. The inlet valves open when the piston
moves down on the intake stroke. When the inlet
valves open, cooled compressed air from the inlet
port is forced into the cylinder. The complete cycle
consists of four strokes:
• Inlet
• Compression
12 RENR7967
• Power Turbocharger
• Exhaust
On the compression stroke, the piston moves back
up the cylinder and the inlet valves (10) close. The
cool compressed air is compressed further. This
additional compression generates more heat.
Note: If the cold starting system is operating, the

glow plugs (3) will also heat the air in the cylinder.
Just before the piston reaches the TC position, the

ECM operates the electronic unit injector. Fuel is
injected into the cylinder. The air/fuel mixture ignites.
The ignition of the gases initiates the power stroke.
Both the inlet and the exhaust valves are closed
and the expanding gases force the piston downward
toward the bottom center (BC) position .
From the BC position, the piston moves upward.

This initiates the exhaust stroke. The exhaust valves
open. The exhaust gases are forced through the g01263770
Illustration 13
open exhaust valves into the exhaust manifold.
Turbocharger
Exhaust gases from exhaust manifold (1) enter the (1) Air intake
turbine side of the turbocharger in order to turn (2) Compressor housing
(3) Compressor wheel
turbocharger turbine wheel (7). The turbine wheel is (4) Bearing
connected to the shaft that drives the compressor (5) Oil inlet port
wheel. Exhaust gases from the turbocharger pass (6) Bearing
through exhaust outlet (6), a silencer and an exhaust (7) Turbine housing
pipe. (8) Turbine wheel
(9) Exhaust outlet
(10) Oil outlet port
(11) Exhaust inlet
The turbocharger is mounted on the outlet of the

exhaust manifold in one of two positions on the right
side of the engine, toward the top of the engine or
to the side of the engine. The exhaust gas from
the exhaust manifold enters the exhaust inlet (11)
and passes through the turbine housing (7) of the
turbocharger. Energy from the exhaust gas causes
the turbine wheel (8) to rotate. The turbine wheel is
connected by a shaft to the compressor wheel (3).
As the turbine wheel rotates, the compressor

wheel is rotated. This causes the intake air to be
pressurized through the compressor housing (2) of
the turbocharger.
RENR7967 13
If a wastegate solenoid (15) is installed, then the

wastegate is controlled by the engine Electronic
Control Module (ECM). The ECM uses inputs from a
number of engine sensors to determine the optimum
boost pressure. This will achieve the best exhaust
emissions and fuel consumption at any given engine
operating condition. The ECM controls the solenoid
valve, which regulates the boost pressure to the
wastegate actuator.
When high boost pressure is needed for the engine

performance, a signal is sent from the ECM to the
wastegate solenoid . This causes low pressure in
the air inlet pipe (14) to act on the diaphragm within
the wastegate actuator (13). The actuating rod (12)
acts upon the actuating lever to close the valve in
the wastegate. When the valve in the wastegate
is closed, more exhaust gas is able to pass over
the turbine wheel. This results in an increase in the
speed of the turbocharger.
When low boost pressure is needed for the engine

performance, a signal is sent from the ECM to the
wastegate solenoid. This causes high pressure in
the air inlet pipe (14) to act on the diaphragm within
the wastegate actuator (13). The actuating rod (12)
acts upon the actuating lever to open the valve in
the wastegate. When the valve in the wastegate is
g01287919
Illustration 14 opened, more exhaust gas from the engine is able to
Typical turbocharger with the wastegate bypass the turbine wheel, resulting in an decrease in
(12) Actuating lever the speed of the turbocharger.
(13) Wastegate actuator
(14) Line (boost pressure) The shaft that connects the turbine to the compressor
(15) Wastegate solenoid wheel rotates in bearings (4 and 6). The bearings
require oil under pressure for lubrication and cooling.
When the load on the engine increases, more fuel The oil that flows to the lubricating oil inlet port (5)
is injected into the cylinders. The combustion of passes through the center of the turbocharger which
this additional fuel produces more exhaust gases. retains the bearings. The oil exits the turbocharger
The additional exhaust gases cause the turbine and from the lubricating oil outlet port (10) and returns
the compressor wheels of the turbocharger to turn to the oil pan.
faster. As the compressor wheel turns faster, air is
compressed to a higher pressure and more air is
forced into the cylinders. The increased flow of air
into the cylinders allows the fuel to be burnt with
greater efficiency. This produces more power.
A wastegate is installed on the turbine housing of

the turbocharger. The wastegate is a valve that
allows exhaust gas to bypass the turbine wheel of
the turbocharger. The operation of the wastegate is
dependent on the pressurized air (boost pressure)
from the turbocharger compressor. The boost
pressure acts on a diaphragm that is spring loaded
in the wastegate actuator which varies the amount of
exhaust gas that flows into the turbine.
14 RENR7967
Valve System Components The camshaft has two camshaft lobes for each
cylinder. The lobes operate either a pair of inlet
valves or a pair of exhaust valves. As the camshaft
turns, lobes on the camshaft cause the lifter (4)
to move the pushrod (3) up and down. Upward
movement of the pushrod against rocker arm (2)
results in a downward movement that acts on the
valve bridge (1). This action opens a pair of valves
(6) which compresses the valve springs (5). When
the camshaft has rotated to the peak of the lobe, the
valves are fully open. When the camshaft rotates
further, the two valve springs (5) under compression
start to expand. The valve stems are under tension of
the springs. The stems are pushed upward in order
to maintain contact with the valve bridge (1). The
continued rotation of the camshaft causes the rocker
arm (2), the pushrods (3)and the lifters (4) to move
downward until the lifter reaches the bottom of the
lobe. The valves (6) are now closed. The cycle is
repeated for all the valves on each cylinder.
i02527637
g01191272
Illustration 15
Valve system components
Cooling System
(1) Bridge
(2)
(3)
Rocker arm
Pushrod
Introduction (Cooling System)
(4) Lifter
(5) Spring The cooling system has the following components:
(6) Valve
• Radiator
The valve system components control the flow of
inlet air into the cylinders during engine operation. • Water pump
The valve system components also control the flow
of exhaust gases out of the cylinders during engine • Cylinder block
operation.
• Oil cooler
The crankshaft gear drives the camshaft gear through
an idler gear. The camshaft must be timed to the • Cylinder head
crankshaft in order to get the correct relation between
the piston movement and the valve movement. • Water temperature regulator (thermostat)
RENR7967 15
Coolant Flow
g01264578
Illustration 16
Coolant flow
(1) Radiator (6) Water temperature regulator (thermostat)
(2) Water pump and housing
(3) Cylinder block (7) Bypass for the water temperature
(4) Engine oil cooler regulator (thermostat)
(5) Cylinder head
The coolant flows from the bottom of the radiator (1)

to the centrifugal water pump (2). The water pump
(2) is installed on the front of the timing case. The
water pump is driven by a gear. The gear of the fuel
injection pump drives the water pump gear. The
water pump forces the coolant through a passage in
the timing case to the front of the cylinder block (3).
The coolant enters a passage in the left side of the

cylinder block (3). Some coolant enters the cylinder
block. Some coolant passes over the element of the
oil cooler (4). The coolant then enters the block (3).
Coolant flows around the outside of the cylinders
then flows from the cylinder block into the cylinder
head (5).
The coolant flows forward through the cylinder

head (5). The coolant then flows into the housing
of the water temperature regulator (6). If the water
temperature regulator (6) is closed, the coolant goes
directly through a bypass (7) to the inlet side of the
water pump. If the water temperature regulator is
open, and the bypass is closed then the coolant flows
to the top of the radiator (1).
16 RENR7967
i02527751
Lubrication System
g01264620
Illustration 17
Flow diagram of the lubrication system
Lubricating oil from the oil pan flows through a The inner rotor has five lobes which mesh with the six
strainer and a pipe (9) to the suction side of the lobes of the outer rotor. When the pump rotates, the
engine oil pump (10). Pressure for the lubrication distance increases between the lobes of the outer
system is supplied by the oil pump. The crankshaft rotor and the lobes of the inner rotor in order to create
gear (13) drives a lower idler gear (12). The lower suction. When the distance decreases between the
idler gear drives the oil pump gear (11). The pump lobes, pressure is created.
has an inner rotor and an outer rotor. The axis of
rotation of the rotors are off-center relative to each The lubricating oil flows from the outlet side of the oil
other. There is an interference fit between the inner pump (10) through a passage to the oil filter head
rotor and the drive shaft. (7). The oil then flows from the oil filter head through
a passage to a plate type oil cooler. The oil cooler is
located on the left side of the cylinder block.
RENR7967 17
From the oil cooler, the oil returns through a passage Starting Motor
to the oil filter head. The oil then flows through a
bypass valve that permits the lubrication system
to function if the oil filter becomes blocked. Under
normal conditions, the oil then flows to the oil filter (8).
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

g01216877
passages in the cylinder block to the journals of the Illustration 18
camshaft. Then, the oil flows from the front journal Typical example
of the camshaft (2) at a reduced pressure to the 12 Volt Starting Motor
cylinder head. The oil then flows through the center (1) Terminal for connection of the ground cable
of the rocker shaft (1) to the rocker arm levers. The (2) Terminal 30 for connection of the battery cable
valve stems, the valve springs and the valve lifters (3) Terminal 50 for connection of the ignition switch
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 supplies oil to the high pressure fuel

pump. The oil then flows through a return line into the
timing case and back 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.
i02403276
Electrical System
g01200801
The electrical system is a negative ground system. Illustration 19
Typical example
The charging circuit operates when the engine 24 Volt Starting Motor
is running. The alternator in the charging circuit (1) Terminal for connection of the ground
produces direct current for the electrical system. (2) Terminal 30 for connection of the battery cable
(3) Terminal 50 for connection of ignition switch
The starting motor turns the engine via a gear on the

engine flywheel. The starting motor speed must be
high enough in order to initiate a sustained operation
of the fuel ignition in the cylinders.
18 RENR7967
The starting motor has a solenoid. When the ignition The alternator is connected to the battery through
switch is activated, voltage from the electrical system the ignition switch. Therefore, alternator excitation
will cause the solenoid to move the pinion toward occurs when the switch is in the ON position.
the flywheel ring gear of the engine. The electrical
contacts in the solenoid close the circuit between the
i02406189
battery and the starting motor just before the pinion
engages the ring gear. This causes the starting motor
to rotate. This type of activation is called a positive
Cleanliness of Fuel System
shift. Components
When the engine begins to run, the overrunning
clutch of the pinion drive prevents damage to the
armature. Damage to the armature is caused by Cleanliness of the Engine
excessive speeds. The clutch prevents damage by
stopping the mechanical connection. However, the
pinion will stay meshed with the ring gear until the NOTICE
ignition switch is released. A spring in the overrunning It is important to maintain extreme cleanliness when
clutch returns the clutch to the rest position. working on the fuel system, since even tiny particles
can cause engine or fuel system problems.
Alternator
The entire engine should be washed with a high
The electrical outputs of the alternator have the pressure water system in order to remove dirt and
following characteristics: loose debris before starting a repair on the fuel
system.
• Three-phase
Environment
• Full-wave
When possible, the service area should be positively
• Rectified pressurized in order to ensure that the components
are not exposed to contamination from airborne dirt
The alternator is an electro-mechanical component.
and debris. When a component is removed from
The alternator is driven by a belt from the crankshaft
the system, the exposed fuel connections must be
pulley. The alternator charges the storage battery
closed off immediately with suitable sealing plugs.
during the engine operation.
The sealing plugs should only be removed when
the component is reconnected. The sealing plugs
The alternator is cooled by an external fan which is
must not be reused. Dispose of the sealing plugs
mounted behind the pulley. The fan may be mounted
immediately after use. Contact your nearest Perkins
internally. The fan forces air through the holes in the
dealer or your nearest approved Perkins distributor in
front of the alternator. The air exits through the holes
order to obtain the correct sealing plugs.
in the back of the alternator.
The alternator converts the mechanical energy and New Components

the magnetic field into alternating current and voltage.
This conversion is done by rotating a direct current High pressure lines are not reusable. New high
electromagnetic field on the inside of a three-phase pressure lines are manufactured for installation in
stator. The electromagnetic field is generated by one position only. When a high pressure line is
electrical current flowing through a rotor. The stator replaced, do not bend or distort the new line. Internal
generates alternating current and voltage. damage to the pipe may cause metallic particles to
be introduced to the fuel.
The alternating current is changed to direct current
by a three-phase, full-wave rectifier. Direct current All new fuel filters, high pressure lines, tube
flows to the output terminal of the alternator. The assemblies and components are supplied with
direct current is used for the charging process. sealing plugs. These sealing plugs should only
be removed in order to install the new part. If
A regulator is installed on the rear end of the the new component is not supplied with sealing
alternator. Two brushes conduct current through two plugs then the component should not be used.
slip rings. The current then flows to the rotor field. A The technician must wear suitable rubber gloves.
capacitor protects the rectifier from high voltages. The rubber gloves should be disposed of immediately
after completion of the repair in order to prevent
contamination of the system.
RENR7967 19
Refueling
In order to refuel the diesel fuel tank, the refueling
pump and the fuel tank cap assembly must be clean
and free from dirt and debris. Refueling should take
place only when the ambient conditions are free
from dust, wind and rain. Only use fuel, free from
contamination, that conforms to the specifications
in the Operation and Maintenance Manual, “Fluid
Recommendations” Fuel Specifications.
20 RENR7967
i02528870
Fuel Injection
Introduction (Fuel Injection)
g01236714
Illustration 20
Diagram of the basic fuel system (typical example)
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the fuel injection pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector
(3) Wastegate Valve (if equipped) (8) Fuel Manifold Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Injection Pump (10) Intake Manifold Temperature Sensor
RENR7967 21
Low Pressure Fuel System
g01265309
Illustration 21
Low pressure fuel system (typical example)
(1) Primary fuel filter (7) Fuel Injection Pump (D) Return from the Electronic Unit Injectors
(2) Water separator (A) Outlet for high pressure fuel to the high (E) Fuel in from the fuel tank
(3) Fuel transfer pump pressure fuel manifold (F) Alternative route for the fuel (air cooled
(4) Fuel cooler (optional) (B) Return from the Pressure Relief Valve ECM)
(5) ECM that is fuel cooled. (PRV) on the high pressure fuel manifold
(6) Secondary fuel filter (C) Return to fuel tank
22 RENR7967
Fuel is drawn from the fuel tank (E) through a 20

micron Primary fuel filter (1) and the Water separator
(2) to the Transfer pump (3). The transfer pump
increases the fuel pressure to 25 kPa (3.6260 psi).
The fuel is pumped through the fuel cooler (optional)
(4) to the ECM (5). The fuel cools the ECM. The fuel
passes from the ECM to a 2 micron fuel filter (6). The
fuel filter removes particulates from 20 microns to 2
microns in size in order to prevent contamination of
the high pressure components in the fuel system.
Fuel passes from the fuel filter to the fuel injection
pump (7). The fuel is pumped at an increased
pressure to the high pressure fuel manifold.
Excess fuel from the high pressure fuel pump returns

to the tank through a non-return valve. There is a
small orifice in the fuel filter base in order to bleed
any air back to the tank.
The leak off fuel from the electronic unit injectors

returns from a connection in the cylinder head to the
pressure side of the transfer pump.
RENR7967 23
High Pressure Fuel System
g01288650
Illustration 22
High pressure fuel system (typical example)
(1) Electronic Unit Injector (4) Fuel Pressure Relief Valve (7) Fuel Injection Pump
(2) High Pressure Fuel Manifold (5) Fuel Transfer Pump
(3) Fuel Pressure Sensor (6) Solenoid for the Fuel Injection Pump
24 RENR7967
The fuel injection pump (7) feeds fuel to the high Fuel Priming Pump
pressure fuel manifold (2). The fuel is at a pressure
of 70 MPa (10152.7 psi) to 130 MPa (18855 psi). A
pressure sensor (3) in the high pressure fuel manifold
(2) monitors the fuel pressure in the high pressure
fuel manifold (2). The ECM controls a solenoid (6) in
the fuel injection pump (7) in order to maintain the
actual pressure in the high pressure fuel manifold
(2) at the desired level. The high pressure fuel is
continuously available at each injector. The ECM
determines the correct time for activation of the
correct electronic unit injector (1) which allows fuel
to be injected into the cylinder. The leakoff fuel from
each injector passes into a drilling which runs along
the inside of the cylinder head. A pipe is connected
to the rear of the cylinder head in order to return the
leakoff fuel to the pressure side of the fuel transfer
pump.
Components of the Fuel Injection System

The fuel injection system has the following
mechanical components: Illustration 23
g01265623
Hand Fuel Priming Pump

• Primary filter/water separator
The pump has a plunger (1) which is manually
• Fuel priming pump operated in order to prime the fuel system. Air is
removed from the fuel system to the fuel return line
• Secondary fuel filter to the tank. The fuel transfer pump is located in the
fuel injection pump. A water drain(2)is installed at the
• Fuel injection pump bottom of the filter in order to remove any water that
has contaminated the fuel.
• Fuel injectors
The electric fuel priming pump can be installed on
• Fuel manifold some engines.
• Pressure relief valve
• Fuel pressure sensor
The following list contains examples of both
service and repairs when you must prime the
system:
• A fuel filter is changed.

• A fuel line is replaced.
• The fuel injection pump is replaced.
Primary Filter/water Separator

The primary filter/water separator is located between
the fuel tank and the priming pump.
RENR7967 25
Secondary Fuel Filter Fuel Injection Pump
g01249050 g01266023
Typical example Typical example
The secondary fuel filter (1) is located after the The fuel injection pump has the following
priming pump. The filter is always before the fuel operations:
injection pump.
• Generation of high pressure fuel
Fuel Pump Assembly The fuel output of the fuel injection pump is controlled
by the ECM in response to changes in fuel pressure.
The fuel pump assembly consists of a low pressure
transfer pump (2) and a high pressure fuel injection
pump (1). The pump assembly is driven from a gear Fuel Transfer Pump
in the front timing case at half engine speed. The fuel
injection pump has two pistons that are driven by a
camshaft. There is a cam for each piston and each
cam has three lobes. The fuel injection pump delivers
a volume of fuel four times for each revolution. The
stroke of the pistons is fixed. The injector will use
only part of the fuel that is delivered by each stroke
of the pistons in the pump. The solenoid for the fuel
injection pump is controlled by the ECM in order to
maintain the fuel manifold pressure at the correct
level. The solenoid allows excess fuel to be diverted
away from the fuel manifold and back to the tank. A
feature of the fuel injection pump allows fuel to return
to the tank continuously.
g01265683
Illustration 26
The fuel transfer pump is a serviceable component.

26 RENR7967
The fuel transfer pump provides a relatively low fuel

pressure to the fuel injection pump. The fuel transfer
pump has a regulating valve in order to control the
low pressure. The fuel transfer pump circulates fuel
through the primary fuel filter and the secondary fuel
filter. The fuel transfer pump has a fuel bypass valve
in order to allow the low pressure fuel system to be
primed.
Shutoff
The engine shuts off by interrupting the fuel supply.
The engine electronic control module (ECM) specifies
the amount of fuel. The quantity of the fuel that is
required by the ECM is set to zero.
Control
g01216984
Illustration 27
Electronic control for the fuel system (typical example)
The ECM determines the quantity, timing and The amount of fuel is proportional to the duration of
pressure of the fuel in order to be injected into the the signal to the injector solenoid.
fuel injector.
The ECM uses input from the sensors on the engine.

These sensors include the speed/timing sensors and
the pressure sensors.
The ECM controls the fuel pressure by increasing

or decreasing the flow of fuel from the fuel injection
pump. The ECM controls the timing and the flow of
fuel by actuating the injector solenoid.
RENR7967 27
Fuel Injectors Fuel Manifold
g01201611
Illustration 28
The fuel injectors are not serviceable.
When the ECM sends a signal to the injector

solenoid, a valve inside the injector opens. The valve
allows the high pressure fuel from the fuel manifold Illustration 29
g01266024
to enter the injector. The pressure of the fuel pushes
Typical example
the needle valve and a spring. When the force of the
fuel pressure is greater than the force of the spring,
The fuel manifold (1) stores high pressure fuel from
the needle valve will lift up.
the fuel injection pump. The high pressure fuel will
flow to the injectors.
The timing and duration of injection is controlled by
a solenoid valve in the injector. The valve has two
The fuel pressure sensor (2) measures the fuel
positions. In the closed position, the valve closes the
pressure in the fuel manifold (1).
inlet to the injector. In this position, fuel above the
injector needle is allowed to vent through the leakoff
The relief valve (3) will prevent the fuel pressure from
port.
getting too high.
In the open position, the valve opens the inlet to the
injector. Simultaneously, the valve closes the leakoff i02531522
port in order to allow high pressure fuel to flow to the
needle. When the solenoid valve is closed, some fuel Electronic Control System
escapes past the valve in order to vent through the
leakoff port. A certain volume of fuel always flows
from the leakoff port. If the volume of fuel increases
Introduction (Electronic Control
beyond a critical level, the high pressure fuel pump System)
will not be able to maintain pressure in the fuel
manifold. The faulty electronic unit injector must be The ECM and the sensors are located on the left side
identified and replaced. of the engine. Refer to illustration 30.
When the signal to the injector ends, the valve closes.

The fuel in the injector changes to a low pressure.
When the pressure drops the needle valve will close
and the injection cycle stops. When the needle valve
opens, fuel under high pressure will flow through
nozzle orifices into the cylinder. The fuel is injected
into the cylinder through the orifices in the nozzle as
a very fine spray.
The needle valve has a close fit with the inside of the
nozzle. This makes a positive seal for the valve.
28 RENR7967
g01248060
Illustration 30
A typical example of a 1104D electronic control system
(1) Fuel Pressure Sensor (5) Oil Pressure Sensor (9) Intake Manifold Pressure Sensor
(2) Intake Manifold Air Temperature Sensor (6) Oil Pressure Sensor (alternative location) (10) Intake Manifold Pressure Sensor
(3) Electronic Control Module (ECM) (7) Secondary Speed/Timing Sensor (alternative location)
(4) Primary Speed/Timing Sensor (8) Solenoid for the Fuel Injection Pump (11) Coolant Temperature Sensor
Note: If equipped, the wastegate solenoid is installed

on the right side of the engine.
RENR7967 29
g01248066
Illustration 31
30 RENR7967
Table 1
Connector Function
P1 Machine Harness to ECM Connector (64 Pin Connector)
P2 Engine Harness to ECM Connector (64 Pin Connector)
P532 Fuel Injection Pump Solenoid Connector (2 Pin Connector)
P402 Secondary Speed/Timing Sensor (2 Pin Connector)
P401 Primary Speed/Timing Sensor (2 Pin Connector)
P201 Engine Oil Pressure Sensor (3 Pin Connector)
P228 Fuel Pressure Sensor (3 Pin Connector)
P200 Intake Manifold Pressure Sensor (3 Pin Connector)
P103 Intake Manifold Temperature Sensor (2 Pin Connector)
P100 Coolant Temperature Sensor (2 Pin Connector)
J23 Diagnostic Connector (if equipped)
P691/J691 Electronic Unit Injectors for No. 1 and No. 2 Cylinders (4 Pin
Connector)
P692/J692 Electronic Unit Injectors for No. 3 and No. 4 Cylinders (4 Pin
Connector)
P601 Wastegate Valve (if equipped) (2 Pin Connector)
The 1104D engine was designed for electronic

control. The engine has an Electronic Control
Module (ECM), a fuel injection pump and electronic
unit injectors. All of these items are electronically
controlled. There are also a number of engine
sensors. Turbocharged engines can be equipped
with an electronically controlled wastegate for
the turbocharger. The ECM controls the engine
operating parameters through the software within
the ECM and the inputs from the various sensors.
The software contains parameters that control the
engine operation. The parameters include all of the
operating maps and customer selected parameters.
RENR7967 31
g01236714
Illustration 32
The electronic control system has the following

components:
• ECM
• Pressure Sensors
• Temperature Sensors
• Crankshaft Position Sensor
• Secondary Position Sensor
• Solenoid for the Fuel Injection Pump
• Wastegate Solenoid
• Electronic Unit Injectors
32 RENR7967
ECM The personality module contains the software with

all the fuel setting information. The information
determines the engine performance.
Flash programming is the method of programming

or updating the personality module. Refer to the
following Troubleshooting, RENR2417, “Flashing
Programming ” for the instructions on the flash
programming of the personality module.
The ECM is sealed and the ECM needs no routine

adjustment or maintenance.
Engine Speed Governor

The electronic controls determine the injection timing,
the amount of fuel that is delivered to the cylinders
and the intake manifold pressure if an electronically
controlled wastegate is installed on the turbocharger.
These decisions are based on the actual conditions
and the desired conditions at any given time.
g01199973 The governor has software that compares the desired
Illustration 33
Typical example engine speed to the actual engine speed. The actual
engine speed is determined through the primary
The Electronic Control Module (ECM) (1) functions speed/timing sensor and the secondary speed/timing
as a governor and a computer for the fuel system. sensor. If the desired engine speed is greater than
The ECM receives signals from the sensors in order the actual engine speed, the governor injects more
to control the timing and the engine speed. fuel in order to increase engine speed.
The electronic system consists of the ECM, the Timing Considerations

engine sensors and inputs from the parent machine.
The ECM is the computer. The personality module Once the governor has determined the amount of
is the software for the computer. The personality fuel that is required, the software must determine the
module contains the operating maps. The operating timing of the fuel injection. Fuel injection timing is
maps define the following characteristics of the determined by the ECM after considering input from
engine: the following components:
• Engine power • Engine coolant temperature sensor

• Torque curves • The sensor for the intake manifold air temperature
• Engine speed (rpm) • The sensor for the intake manifold pressure
• Engine Noise
• Smoke and Emissions
The factory passwords restrict changes to authorized
personnel. Factory passwords are required to
clear any event code. Refer to the following
Troubleshooting, “Factory Passwords” For more
information on the passwords.
The ECM has an excellent record of reliability. Any

problems in the system are most likely to be the
connectors and the wiring harness. The ECM should
be the last item in troubleshooting the engine.
RENR7967 33
At start-up, the ECM determines the top center If the operator indicates that a performance problem
position of the number 1 cylinder from the secondary has occurred, the diagnostic code may indicate the
speed/timing sensor in the fuel injection pump. cause of the problem. Use a laptop computer to
The ECM decides when fuel injection should occur access the diagnostic codes. The problem should
relative to the top center position. The ECM optimizes then be corrected.
engine performance by control of each of the
electronic unit injectors so that the required amount Event Codes
of fuel is injected at the precise point of the engine’s
cycle. The electronic unit injectors are supplied high Event Codes are used to indicate that the ECM has
pressure fuel from the fuel injection pump. The ECM detected an abnormal engine operating condition.
also provides the signal to the solenoid in the fuel The ECM will log the occurrence of the event code.
injection pump. The solenoid in the fuel injection This does not indicate an electrical malfunction or
pump controls a valve in the fuel injection pump. This an electronic malfunction. If the temperature of the
valve controls the pressure in the fuel injection pump. coolant in the engine is higher than the permitted
Fuel that is not required for the engine is diverted limit, then the ECM will detect the condition. The
away from the fuel injection pump back to the fuel ECM will then log an event code for the condition.
tank.
The ECM adjusts injection timing and fuel pressure Passwords

for the best engine performance, the best fuel
economy and the best control of exhaust emissions. System Configuration Parameters are protected by
The actual timing can be viewed with an electronic factory passwords. This will prevent unauthorized
service tool. Also, the desired timing can be viewed reprogramming of the system and the unauthorized
with an electronic service tool. removal of logged events. Factory passwords are
calculated on a computer system that is available
only to Perkins distributors. Since factory passwords
Fuel Injection contain alphabetic characters, only an electronic
service tool may change System Configuration
The personality module software inside the ECM
Parameters. System Configuration Parameters affect
sets certain limits on the amount of fuel that can be the power rating or the emissions. Passwords also
injected.
allow the customer to control certain programmable
engine parameters.
The FRC Limit is a limit that is based on intake
manifold air pressure and engine rpm. The FRC
Refer to Troubleshooting, “Programming Parameters”
Limit is used to control the air/fuel ratio in order to
and Troubleshooting, “Factory Passwords”.
control the engine’s exhaust emissions. When the
ECM senses a higher intake manifold air pressure,
the ECM increases the FRC Limit. A higher intake Speed/Timing Sensor
manifold air pressure indicates that there is more air
in the cylinder. When the ECM increases the FRC
Limit, the ECM allows more fuel into the cylinder.
The Rated Fuel Limit is a limit that is based on the

power rating of the engine and on the engine rpm.
The Rated Fuel Limit enables the engine power and
torque outputs to conform to the power and torque
curves of a specific engine model.
These limits are in the personality module and these

limits cannot be changed.
Diagnostic Codes
When the ECM detects an electronic system problem,
the ECM generates a diagnostic code. Also, the ECM
logs the diagnostic code in order to indicate the time
of the problem’s occurrence. The ECM also logs the
number of occurrences of the problem. Diagnostic
codes are provided in order to indicate that the ECM
g01266457
has detected an electrical problem or an electronic Illustration 34
problem with the engine control system. In some Timing wheel on the crankshaft
cases, the engine performance can be affected when
the condition that is causing the code exists.
34 RENR7967
The primary engine position is a passive sensor. The

timing wheel (1) is located on the crankshaft. The
speed/timing sensor receives a signal from the teeth
on timing wheel. The extra space on the timing wheel
gives one revolution per space. The space is oriented
so that the space is 40 degrees after top center.
g01266905
Illustration 35
Schematic for speed/timing sensor
g01266620
Illustration 36
RENR7967 35
When the engine is cranking, the ECM uses the

signal from the speed/timing sensor in the fuel
injection pump. When the engine is running the ECM
uses the signal from the speed/timing sensor on the
crankshaft. This speed/timing sensor is the primary
source of the engine position.
Pressure Sensors
g01266903
Illustration 37
Schematic for pressure sensors
The boost pressure sensor and the engine oil The operating range for the engine oil pressure
pressure sensor are active sensors. sensor ................ 55 kPa to 339 kPa (8 psi to 50 psi)
The boost pressure sensor provides the ECM with a

measurement of inlet manifold pressure in order to
control the air/fuel ratio. This will reduce the engine
smoke during transient conditions.
The operating range of the boost pressure sensors
For standard power engines,

the range is up to the following. .................. 339 kPa
(49.169 psi)
For all high power engine,

the range is up to the following. .................. 440 kPa
(63.818 psi)
The engine oil pressure sensor provides the ECM

with a measurement of engine oil pressure. The ECM
can warn the operator of possible conditions that can
damage the engine. This includes the detection of
an oil filter that is blocked.
36 RENR7967
Temperature Sensors
g01249915
Illustration 38
Schematic for the temperature sensors
The air inlet temperature sensor and the coolant

temperature sensor are passive sensors. Each
sensor provides a temperature input to the ECM. The
ECM controls following operations:
• Fuel delivery
• Injection timing
The operating range for the
sensors ............ −40 °C to 150 °C (−40 °F to 302 °F)
The sensors are also used for engine monitoring.
i02532754
Power Sources
Introduction (Power Supplies)
The 1104D Engine supplies power to the ECM.
The ECM powers the following components:
• All sensors on the engine

• The solenoid for the fuel Injection Pump
• The solenoid for the Wastegate (optional)
• Diagnostic connector
• Electronic unit injectors
The glow plugs are powered directly from the battery.
RENR7967 37
ECM Power Supply
g01245123
Illustration 39
Schematic for ECM
The power supply to the ECM and the system

is drawn from the 24 volt or the 12 volt battery.
The power supply for the ECM has the following
components:
• Battery
• disconnect switch
• Key start switch
• Fuses
• Ground bolt
• ECM connector
• Machine interface connector
The Schematic for the ECM shows the main
components for a typical power supply circuit. Battery
voltage is normally connected to the ECM. The input
from the key start switch turns on the ECM.
The wiring harness can be bypassed for

troubleshooting purposes.
The display screen on the electronic service tool can

be used in order to check the voltage supply.
38 RENR7967
Power Supply for the Pressure

Sensors
g01266903
Illustration 40
Schematic for pressure sensors
The ECM supplies 5.0 ± 0.2 DC volts through the

ECM connector to each sensor. The power supply is
protected against short circuits. A short in a sensor or
a wiring harness will not cause damage to the ECM.
RENR7967 39
Power supply for the Glow plugs
g01245657
Illustration 41
Schematic for the glow plugs
Adaptive Trim – This is a software process that
is performed in the ECM that optimizes engine
i02533811 performance by automatically compensating for
degradation of injector components.
Glossary of Electronic Control
Terms Alternating Current (AC) – Alternating current is an
electric current that reverses direction at a regular
Air-To-Air Aftercooler – An air-to-air aftercooler is a interval that is reoccurring.
device that is used on turbocharged engines in order
to cool inlet air that has undergone compression. The Before Top Center (BTC) – BTC is the 180 degrees
inlet air is cooled after the inlet air passes through of crankshaft rotation before the piston reaches the
the turbocharger. The inlet air is passed through an top center position in the normal direction of rotation.
aftercooler (heat exchanger) that uses ambient air for
cooling. The inlet air that has been cooled advances Breakout Harness – The breakout harness is a
to the inlet manifold. test harness that is designed to connect into the
engine harness. This connection allows a normal
Active Diagnostic Code – An active diagnostic circuit operation and the connection simultaneously
code alerts the operator or the service technician that provides a Breakout T in order to measure the
an electronic system malfunction is currently present. signals.
Refer to the term “Diagnostic Code” in this glossary.
Bypass Circuit – A bypass circuit is a circuit that is
used as a substitute circuit for an existing circuit. A
bypass circuit is typically used as a test circuit.
40 RENR7967
CAN Data Link (see also J1939 CAN Data Link) – Diagnostic Lamp – A diagnostic lamp is sometimes
The CAN Data Link is a serial communications called the check engine light. The diagnostic lamp
port that is used for communication with other is used to warn the operator of the presence of an
microprocessor based devices. active diagnostic code. The diagnostic lamps are
red and orange. The lamp may not be included in
Code – Refer to “Diagnostic Code” or “Event Code”. all applications.
Cold Mode – Cold mode is a mode for cold starting Digital Sensor Return – The common line (ground)
and for cold engine operation. This mode is used for from the ECM is used as ground for the digital
engine protection, reduced smoke emissions and sensors.
faster warm up time.
Digital Sensors – Digital sensors produce a pulse
Communication Adapter Tool – The width modulated signal. Digital sensors are supplied
communication adapter provides a communication with power from the ECM.
link between the ECM and the Electronic Service
Tool. Digital Sensor Supply – The power supply for the
digital sensors is provided by the ECM.
Component Identifier (CID) – The CID is a number
that identifies the specific component of the electronic Direct Current (DC) – Direct current is the type of
control system that has experienced a diagnostic current that flows consistently in only one direction.
code.
Duty Cycle – See Pulse Width Modulation.
Coolant Temperature Sensor – The coolant
temperature sensor detects the engine coolant DT, DT Connector, or Deutsch DT – This is a type
temperature for all normal operating conditions and of connector that is used on Perkins engines. The
for engine monitoring. connectors are manufactured by Deutsch.
Code – See the Diagnostic Code. Electronic Service Tool – The electronic service
tool is used for diagnosing a variety of electronic
Customer Specified Parameters – A customer controls and the electronic service tool is also used
specified parameter is a parameter that can be for programming a variety of electronic controls.
changed in the ECM with the Electronic Service Tool.
A customer specified parameter’s value is set by Electronic Engine Control – The electronic
the customer. These parameters are protected by engine control is a complete electronic system.
customer passwords. The electronic engine control monitors the engine
operation under all conditions. The electronic engine
Data Link – The Data Link is a serial communication control also controls the engine operation under all
port that is used for communication with other conditions.
microprocessor based devices.
Engine Control Module (ECM) – The ECM is the
Derate – Certain engine conditions will generate control computer of the engine. The ECM provides
event codes. Also, engine derates may be applied. power to the electronics. The ECM monitors data that
The map for the engine derate is programmed into is input from the sensors of the engine. The ECM
the ECM software. The derate can be one or more of acts as a governor in order to control the speed and
3 types: reduction of rated power, reduction of rated the power of the engine.
engine speed, and reduction of rated machine speed
for OEM products. Electronic Service Tool – The electronic service
tool allows a computer (PC) to communicate with the
Desired Engine Speed – The desired engine speed ECM.
is input to the electronic governor within the ECM.
The electronic governor uses the signal from the Engine Monitoring – Engine Monitoring is the part
throttle position sensor, the engine speed/timing of the electronic engine control that monitors the
sensor, and other sensors in order to determine the sensors. This also warns the operator of detected
desired engine speed. problems.
Diagnostic Code – A diagnostic code is sometimes Engine Oil Pressure Sensor – The engine oil
referred to as a fault code. These codes indicate an pressure sensor measures engine oil pressure. The
electronic system malfunction. sensor sends an electronic signal to the ECM that is
dependent on the engine oil pressure.
RENR7967 41
Engine Speed/Timing Sensor – An engine 14 and 15 – These locations are reserved for a
speed/timing sensor is a Hall effect sensor. The future assignment.
ECM interprets this signal as the crankshaft position
and the engine speed. Two sensors are used to Flash Programming – Flash programming is the
provide the speed and timing signals to the ECM. method of programming or updating an ECM with an
The primary sensor is associated with the crankshaft electronic service tool over the data link.
and the secondary sensor is associated with the fuel
injection pump camshaft. Fuel Injector E-Trim – Fuel injector E-trim is a
software process that allows precise control of fuel
Estimated Dynamic Timing – Estimated dynamic injectors by parameters that are programmed into
timing is the estimate of the actual injection timing the ECM for each fuel injector. With the use of the
that is calculated by the ECM. electronic service tool, the service technician can
read status information for the E-Trim. Data for
Ether Relay – The ether relay is used to actuate the E-Trim can also be programmed.
ether injection system. The ECM controls the relay.
Flash Memory – See the Programmable software.
Event Code – An event code may be activated
in order to indicate an abnormal engine operating Fuel Ratio Control (FRC) – The FRC is a limit that
condition. These codes usually indicate a mechanical is based on the control of the fuel to the air ratio. The
problem instead of an electrical system problem. FRC is used for emission control. When the ECM
senses a higher turbocharger outlet pressure, the
Failure Mode Identifier (FMI) – This identifier ECM increases the limit for the FRC in order to allow
indicates the type of failure that is associated with more fuel into the cylinders.
the component. The FMI has been adopted from the
SAE practice of J1587 diagnostics. The FMI follows Fuel Pump – See “Fuel Injection Pump”.
the parameter identifier (PID) in the descriptions of
the fault code. The descriptions of the FMIs are in Fuel Rail – This item is sometimes referred to as
the following list. the High Pressure Fuel Rail or high pressure fuel
manifold. The fuel rail supplies fuel to the electronic
0 – The data is valid but the data is above the normal unit injectors. The fuel injection pump and the fuel
operational range. rail pressure sensor work with the ECM in order to
maintain the desired fuel pressure in the fuel rail. This
1 – The data is valid but the data is below the normal pressure is determined by calibration of the engine
operational range. in order to enable the engine to meet emissions and
performance requirements.
2 – The data is erratic, intermittent, or incorrect.
Fuel Rail Pressure Sensor – The fuel rail pressure
3 – The voltage is above normal or the voltage is sensor sends an electronic signal to the ECM that is
shorted high. dependent on the pressure of the fuel in the fuel rail.
4 – The voltage is below normal or the voltage is Fuel Injection Pump – This item is sometimes
shorted low. referred to as the High Pressure Fuel Rail Pump.
This is a device that supplies fuel under pressure to
5 – The current is below normal or the circuit is open. the fuel rail (high pressure fuel rail).
6 – The current is above normal or the circuit is The Solenoid Valve for the Fuel Injection Pump –
grounded. This is sometimes referred to as the High Pressure
Fuel Rail Pump Solenoid Valve. This is a control
7 – The mechanical system is not responding device in the fuel injection pump. The ECM controls
properly. the pressure in the fuel rail by using this valve to
divert excess fuel from the pump to the fuel tank.
8 – There is an abnormal frequency, an abnormal
pulse width, or an abnormal time period. Full Load Setting (FLS) – The FLS is the number
that represents the fuel system adjustment. This
9 – There has been an abnormal update. adjustment is made at the factory in order to fine tune
the fuel system. The correct value for this parameter
10 – There is an abnormal rate of change. is stamped on the engine information ratings plate.
This parameter must be programmed.
11 – The failure mode is not identifiable.
12 – The device or the component is damaged.
13 – The device or the component is not calibrated.

42 RENR7967
Glow Plug – The glow plug is an optional starting aid Integrated Electronic Controls – The engine is
for cold conditions. One glow plug is installed in each designed with the electronic controls as a necessary
combustion chamber in order to improve the ability of part of the system. The engine will not operate
the engine to start. The ECM uses information from without the electronic controls.
the engine sensors such as the engine temperature
to determine when the glow plug relay must provide Intake Manifold Pressure Sensor – The Intake
power to each glow plug. Each of the glow plugs Manifold Pressure Sensor measures the pressure
then provides a very hot surface in the combustion in the intake manifold. The pressure in the intake
chamber in order to vaporize the mixture of air and manifold may be different to the pressure outside
fuel. This improves ignition during the compression the engine (atmospheric pressure). The difference
stroke of the cylinder. in pressure may be caused by an increase in air
pressure by a turbocharger (if equipped).
Glow Plug Relay – The glow plug relay is controlled
by the ECM in order to provide high current to the J1939 CAN Data Link – Logged diagnostic codes
glow plugs that are used in the starting aid system. are codes which are stored in the memory. These
codes are meant to be an indicator of possible
Harness – The harness is the bundle of wiring causes for intermittent problems. Refer to the
(loom) that connects all components of the electronic term “Diagnostic Code” in this glossary for more
system. information.
Hertz (Hz) – Hertz is the measure of frequency in Logged Diagnostic Codes – Logged diagnostic
cycles per second. codes are codes which are stored in the memory.
These codes are meant to be an indicator of possible
High Pressure Fuel Rail Pump – See “Fuel Rail causes for intermittent problems. Refer to the
Pump”. term “Diagnostic Code” in this glossary for more
information.
High Pressure Fuel Rail Pump Solenoid Valve –
See “Fuel Rail Pump Solenoid Valve”. Open Circuit – An open circuit is a condition that is
caused by an open switch, or by an electrical wire
High Pressure Fuel Rail – See “Fuel Rail”. or a connection that is broken. When this condition
exists, the signal or the supply voltage can no longer
Injector Codes – The injector codes or injector trim reach the intended destination.
codes are numeric codes or alphanumeric codes
that are etched or stamped on individual electronic OEM – OEM is an abbreviation for the Original
unit injectors. These codes are used to fine tune the Equipment Manufacturer. This is the manufacturer of
fuel delivery. the machine or the vehicle that uses the engine.
Injector Trim Files – Injector trim files are Parameter – A parameter is a value or a limit that
downloaded from a disk to the ECM. The injector trim is programmable. This helps determine specific
files compensate for variances in manufacturing of characteristics or behaviors of the engine.
the electronic unit injector. The serial number for the
electronic unit injector must be obtained in order to Parameter Identifier (PID) – A PID is a numerical
retrieve the correct injector trim file. code that contains two digits or three digits. A
numerical code is assigned to each component. The
Inlet Manifold Air Temperature Sensor – The numerical code identifies data via the data link to the
intake manifold air temperature sensor detects the ECM.
air temperature in the intake manifold. The ECM
monitors the air temperature and other data in the Password – A password is a group of numeric
intake manifold in order to adjust injection timing and characters or a group of alphanumeric characters
other performance functions. that is designed to restrict access to parameters. The
electronic system requires correct passwords in order
Inlet Manifold Pressure (Engines that are to change some parameters (Factory Passwords).
turbocharged) – The difference between the Refer to Troubleshooting, “Factory Passwords” for
turbocharger outlet pressure and atmospheric more information.
pressure is commonly referred to as inlet manifold
pressure. The sensor for the inlet manifold air Personality Module – This module is software
pressure measures the amount of boost. that is inside the ECM. The module contains all the
instructions (software) for the ECM and the module
contains the performance maps for a specific engine.
The personality module may be reprogrammed
through flash programming.
RENR7967 43
Programmable Software – The software is Relay – A relay is an electromechanical switch. A

programmed into the ECM. The software contains flow of electricity in one circuit is used to control the
all the instructions (software) for the ECM and the flow of electricity in another circuit. A small current or
software contains the performance maps for a voltage is applied to a relay in order to switch a much
specific engine. The software may be reprogrammed larger current or voltage.
through flash programming.
Sensor – A sensor is used to detect a change in
Position Sensor – This sensor determines the the pressure, in the temperature, or in mechanical
position of the fuel injection pump camshaft during movement. When any of these changes are detected,
start-up. If the speed/timing sensor fails during engine a sensor converts the change into an electrical signal.
operation, the position sensor is used to provide the
signal. The sensor determines the position of the fuel Short Circuit – A short circuit is a condition that has
injection pump camshaft for injection timing and for an electrical circuit that is inadvertently connected to
engine speed. If the position sensor fails, the engine an undesirable point. An example of a short circuit
will continue to operate but the engine will not start. is a wire which rubs against a vehicle frame and
this rubbing eventually wears off the wire insulation.
Power Cycled – Power cycled happens when power Electrical contact with the frame is made and a short
to the ECM is cycled: ON, OFF, and ON. Power circuit results.
cycled refers to the action of cycling the keyswitch
from any position to the OFF position, and to the Signal – The signal is a voltage or a waveform that
START/RUN position. is used in order to transmit information typically from
a sensor to the ECM.
Primary Speed/Timing Sensor – This sensor
determines the position of the crankshaft during Secondary Speed/Timing Sensor – This sensor
engine operation. If the primary speed/timing determines the position of the camshaft during engine
sensor fails during engine operation, the secondary operation. If the primary speed/timing sensor fails
speed/timing sensor is used to provide the signal. during engine operation, the secondary speed/timing
sensor is used to provide the signal.
Pulse Width Modulation (PWM) – The PWM is a
signal that consists of pulses that are of variable Supply Voltage – The supply voltage is a continuous
width. These pulses occur at fixed intervals. The ratio voltage that is supplied to a component in order to
of “TIME ON” versus total “TIME OFF” can be varied. provide the electrical power that is required for the
This ratio is also referred to as a duty cycle. component to operate. The power may be generated
by the ECM or the power may be battery voltage that
is supplied by the engine wiring.
System Configuration Parameters – System

configuration parameters are parameters that affect
emissions and/or operating characteristics of the
engine.
Tattletale – Certain parameters that affect the

operation of the engine are stored in the ECM.
These parameters can be changed by use of the
electronic service tool. The tattletale logs the number
of changes that have been made to the parameter.
The tattletale is stored in the ECM.
g00284479
Illustration 42 Theft Deterrent – This feature uses a four digit code
in order to prevent the engine from starting. The
Rated Fuel Limit – This is a limit that is based on feature requires a password to be entered.
the power rating of the engine and on the engine rpm.
The Rated Fuel Limit enables the engine power and “T” Harness – This harness is a test harness that
torque outputs to conform to the power and torque is designed to permit normal circuit operation and
curves of a specific engine model. These limits are the measurement of the voltage simultaneously.
in the personality module and these limits cannot be Typically, the harness is inserted between the two
changed. ends of a connector.
Reference Voltage – Reference voltage is a Throttle Position – The throttle position is the
regulated voltage and a steady voltage that is interpretation by the ECM of the signal from the
supplied by the ECM to a sensor. The reference throttle position sensor or the throttle switch.
voltage is used by the sensor to generate a signal
voltage.
44 RENR7967
Throttle Position Sensor – The throttle position

sensor is an electronic sensor that is usually
connected to an accelerator pedal or a hand lever.
This sensor sends a signal to the ECM that is used
to calculate desired engine speed.
Throttle Switch – The throttle switch sends a signal

to the ECM that is used to calculate desired engine
speed.
Timing Calibration – The timing calibration is the

adjustment of an electrical signal. This adjustment is
made in order to correct the timing error between the
camshaft and the engine speed/timing sensors or
between the crankshaft and the engine speed/timing
sensors.
Top Center Position – The top center position refers

to the crankshaft position when the engine piston
position is at the highest point of travel. The engine
must be turned in the normal direction of rotation in
order to reach this point.
Total Tattletale – The total tattletale is the total

number of changes to all the parameters that are
stored in the ECM.
Wait To Start Lamp – This is a lamp that is included

in the cold starting aid circuit in order to indicate when
the wait to start period has expired. The glow plugs
have not deactivated at this point in time.
Wastegate – This is a device in a turbocharged

engine that controls the maximum boost pressure
that is provided to the inlet manifold.
Wastegate Valve – The wastegate valve regulates

the pressure in the inlet manifold to a value that
is determined by the ECM. The wastegate valve
provides the interface between the ECM and the
mechanical system that regulates inlet manifold
pressure to the desired value that is determined by
the software.
RENR7967 45
Testing and Adjusting i02405571
Section Air in Fuel - Test
Fuel System NOTICE

Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
i02563346 authorised personnel that have the correct train-
Fuel System - Inspect ing.
Before begining ANY work on the fuel system, re-

fer to Operation and Maintenance Manual, “Gen-
eral Hazard Information and High Pressure Fuel
NOTICE Lines” for safety information.
carried out to the fuel system are performed by Refer to Testing and Adjusting Manual, “Clean-
authorised personnel that have the correct train- liness of Fuel System Components” for detailed
ing. information on the standards of cleanliness that
must be observed during ALL work on the fuel
Before begining ANY work on the fuel system, re- system.
Lines” for safety information. This procedure checks for air in the fuel system. This
procedure also assists in finding the source of the air.
Refer to Systems Operation, “Cleanliness of Fu-
el System Components” for detailed information 1. Examine the fuel system for leaks. Check the fuel
on the standards of cleanliness that must be ob- level in the fuel tank. Air can enter the fuel system
served during ALL work on the fuel system. on the suction side between the fuel transfer pump
and the fuel tank.
A problem with the components that transport fuel
to the engine can cause low fuel pressure. This can
decrease engine performance.
Work carefully around an engine that is running.
1. Check the fuel level in the fuel tank. Ensure that Engine parts that are hot, or parts that are moving,
the vent in the fuel cap is not filled with dirt. can cause personal injury.
2. Check all fuel lines for fuel leakage. The fuel lines 2. Install a suitable fuel flow tube with a visual
must be free from restrictions and faulty bends. sight gauge in the fuel return to tank line. When
Verify that the fuel return line is not collapsed. possible, install the fuel flow tube in a straight
section of the fuel line that is at least 304.8 mm
3. Install new fuel filters. (12 inches) long. Do not install the fuel flow tube
near the following devices that create turbulence:
4. Cut the old filter open with a suitable filter cutter.
Inspect the filter for excess contamination. • Elbows
Determine the source of the contamination. Make
the necessary repairs. • Relief valves
5. Operate the hand priming pump (if equipped). If • Check valves
excessive resistance is felt, check that there is
fuel in the fuel return line to the tank. Observe the fuel flow during engine cranking.
Look for air bubbles in the fuel. If there is no fuel
that is present in the fuel flow tube, prime the
fuel system. Refer to Testing and Adjusting, “Fuel
System - Prime” for more information. If the engine
starts, check for air in the fuel at varying engine
speeds. When possible, operate the engine under
the conditions which have been suspect.
46 RENR7967
4. Pressurize the fuel tank to 35 kPa (5 psi). Do not

use more than 55 kPa (8 psi) in order to avoid
damage to the fuel tank. Check for leaks in the fuel
lines between the fuel tank and the fuel transfer
pump. Repair any leaks that are found.
5. If the source of the air is not found, disconnect

the supply line from the fuel tank and connect an
external fuel supply to the inlet of the fuel transfer
pump. If this corrects the problem, repair the fuel
tank or the stand pipe in the fuel tank.
i02535648
Finding Top Center Position

for No. 1 Piston
Table 2
g00578151 Required Tools
Illustration 43
(1) A steady stream of small bubbles with a diameter of Part
approximately 1.60 mm (0.063 inch) is an acceptable amount Tool Part Description Qty
Number
of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) A 21825576 Crankshaft turning tool 1
are also acceptable if there is two seconds to three seconds
intervals between bubbles. B 27610211 Crankshaft timing pin 1
(3) Excessive air bubbles in the fuel are not acceptable.
C 27610212 Camshaft timing pin 1
3. If excessive air is seen in the fuel flow tube in the D 27610289 Crankshaft turning tool 1
fuel return line, install a second fuel flow tube at
the inlet to the fuel transfer pump. If a second fuel E 27610291 Crankshaft turning tool 1
flow tube is not available, move the fuel flow tube
from the fuel return line and install the fuel flow
tube 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 not seen at the inlet to the fuel

transfer pump, the air is entering the system after
the fuel transfer pump. Refer to the Testing and
Adjusting, “Fuel System - Prime”.
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.
g01268087
Illustration 44
NOTICE (1) Hole for camshaft pin
To avoid damage, do not use more than 55 kPa (8 psi) (2) Hole for crankshaft pin
to pressurize the fuel tank.
RENR7967 47
1. Remove the valve mechanism cover, the glow

plugs, and the cover for the front housing. Refer to NOTICE
Disassembly and Assembly Manual, “Front Cover Ensure that all adjustments and repairs that are
- Remove and Install”. carried out to the fuel system are performed by
authorised personnel that have the correct train-
Note: The crankshaft timing pin can be inserted with ing.
the crankshaft pulley still on the engine.
2. Use tooling (A) to rotate the crankshaft in the fer to Operation and Maintenance Manual, “Gen-
normal direction of the engine until the inlet eral Hazard Information and High Pressure Fuel
valve of the No. 4 cylinder has just opened and Lines” for safety information.
the exhaust valve of the No. 4 cylinder has not
completely closed. Refer to Testing and Adjusting Manual, “Clean-
liness of Fuel System Components” for detailed
Note: Use the alternative Tooling (D) and Tooling (E) information on the standards of cleanliness that
if the access to the front of the engine is restricted. must be observed during ALL work on the fuel
system.
3. Carefully rotate the crankshaft in the normal
direction of the engine in order to align the hole in
the crankshaft with the hole in the cylinder block This procedure must be done before any of the
(2) and the timing case. Insert Tooling (B) fully into following reasons:
the hole in the crankshaft web.
• Removal of the fuel injection pump
4. Insert Tooling (C) through the hole in the camshaft
gear (1) at the top center position for No. 1 piston. • The bolts that hold the fuel injection pump to the
front housing are loosened.
Note: The camshaft gear can rotate a small amount
when the pin is installed. 1. Set the number one piston at the top center piston
on the compression stroke. Refer to Testing and
5. Remove the timing pins from the camshaft gear Adjusting, “Finding Top Center Position for the No.
and the crankshaft web. 1 Pistion” for the procedure.
2. Carefully remove the fuel injection pump from the

i02536614 front housing. Refer to Disassembly and Assembly
Manual, “Fuel Injection Pump - Remove” for the
Fuel Injection Timing - Check correct procedure.
Table 3
Required Tools
Part
Tool Number Part Description Qty
Fuel Injection Pump
A 27610302 1
Timing Tool
g01200897
Illustration 45
3. To check the fuel injection pump timing, follow

Steps 3.a and 3.b.
48 RENR7967
a. Position Tooling (A) onto the shaft (8) of the i02563386

fuel injection pump. Align the lever of Tooling
(A) with the key slot (7). Engage the lever into Fuel Quality - Test
the key slot.
Note: Refer to Systems Operation, “Cleanliness
b. Insert the locking pin of Tooling (A) into the of Fuel System Components” for detailed
hole (6) in fuel injection pump. information on the standards of cleanliness that
must be observed during ALL work on the fuel
If the locking pin can be inserted into the hole, system.
the fuel injection pump timing is correct.
Ensure that all adjustments and repairs are performed
If the locking pin cannot be inserted into the by authorized personnel that have had the correct
hole, the fuel injection pump timing is not training.
correct.
Use the following procedure to test for problems
Note: There should be no resistance when the regarding fuel quality:
locking pin is inserted.
1. Determine if water and/or contaminants are
4. If the fuel injection pump timing has been lost present in the fuel. Check the water separator (if
follow Steps 5 through 9 in order to reset the fuel equipped). If a water separator is not present,
injection pump timing. proceed to Step 2. Drain the water separator, if
necessary. A full fuel tank minimizes the potential
5. If necessary, loosen the locking screw (4) on for overnight condensation.
the fuel injection pump. Slide the spacer (5) into
position (X). Tighten the locking screw (4) to a Note: A water separator can appear to be full of fuel
torque of 9 N·m (80 lb in). This will prevent the when the water separator is actually full of water.
locking screw from tightening against the shaft (8).
2. Determine if contaminants are present in the
The fuel injection pump is now unlocked. fuel. Remove a sample of fuel from the bottom
of the fuel tank. Visually inspect the fuel sample
6. Position Tooling (A) onto the shaft (8) of the fuel for contaminants. The color of the fuel is not
injection pump. Align the lever of Tooling (A) with necessarily an indication of fuel quality. However,
the key slot (7) in the fuel injection pump. Engage fuel that is black, brown, and/or similar to sludge
the lever into the key slot. can be an indication of the growth of bacteria or
oil contamination. In cold temperatures, cloudy
7. Use the lever of Tooling (A) to rotate the shaft (8) fuel indicates that the fuel may not be suitable for
until the pin of Tooling (A) can be engaged into operating conditions.
the hole (6). Engage the pin of Tooling (A) into
the hole. Refer to Operation and Maintenance Manual,
“Fuel Recommendations” for more information.
8. Loosen the locking screw (4) in the fuel injection
pump. Slide the spacer (5) into position (Y). 3. If fuel quality is still suspected as a possible
Tighten the locking screw (4) against the shaft cause to problems regarding engine performance,
of the fuel injection pump to a torque of 9 N·m disconnect the fuel inlet line, and temporarily
(80 lb in). operate the engine from a separate source of
fuel that is known to be good. This will determine
The fuel injection pump is now locked. if the problem is caused by fuel quality. If fuel
quality is determined to be the problem, drain the
9. Remove Tooling (A). fuel system and replace the fuel filters. Engine
performance can be affected by the following
10. Reinstall the fuel injection pump to the front characteristics:
housing. Refer to Disassembly and Assembly
Manual, “Fuel Injection Pump - Install” for the • Cetane number of the fuel
correct procedure.
• Air in the fuel
There are functional tests in order to ensure that
electronic unit injectors operate correctly. Refer to • Other fuel characteristics
Troubleshooting for further information.
RENR7967 49
i02543918
Fuel System - Prime

Refer to the Operation and Maintenance Manual ,

“General Hazard Information and High Pressure Fuel
Lines” before adjustments and repairs are performed.
Note: Refer to Systems Operation,Testing

Components” for detailed information on the g01191752
Illustration 46
during ALL work on the fuel system. Typical example
Ensure that all adjustments and repairs are performed 2. Operate the fuel priming pump (1). Count the
by authorized personnel that have had the correct number of operations of the fuel priming pump.
training. After 100 depressions of the fuel priming pump
stop.
NOTICE 3. The engine fuel system should now be primed and
Do not crank the engine continuously for more than the engine should now be able to start.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. Note: Do not loosen the high pressure fuel line
in order to purge air from the fuel system. This
If air enters the fuel system, the air must be purged procedure is not required.
from the fuel system before the engine can be
started. Air can enter the fuel system when the 4. Operate the engine starter and crank the engine.
following events occur: After the engine has started, operate the engine at
low idle for a minimum of five minutes, immediately
• The fuel tank is empty or the fuel tank has been after air has been removed from the fuel system.
partially drained.
Note: Operating the engine for this period of time will
• The low pressure fuel lines are disconnected. help ensure that the fuel system is free of air.
• A leak exists in the low pressure fuel system. After the engine has stopped, you must wait for
60 seconds in order to allow the fuel pressure to
• The fuel filter has been replaced. be purged from the high pressure fuel lines before
any service or repair is performed on the engine
fuel lines. If necessary, perform minor adjustments.
Hand Fuel Priming Pump Repair any leaks from the low pressure fuel system
and from the cooling, lubrication or air systems.
Use the following procedures in order to remove air Replace any high pressure fuel line that has leaked.
from the fuel system: Refer to Disassembly and Assembly, “Fuel Injection
Lines - Install”.
1. Ensure that the fuel system is in working order.
Restore the fuel supply. If you inspect the engine in operation, always use
the proper inspection procedure in order to avoid
a fluid penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
50 RENR7967
Electric Fuel Priming Pump i02403273
1. Ensure that the fuel system is in working order. Gear Group (Front) - Time
Restore the fuel supply.
NOTICE
The electric fuel priming pump will operate for 90 sec-
onds. If necessary the electric fuel priming pump can
be stopped during the 90 seconds of operation, by op-
eration of the switch.
2. Turn the keyswitch to the “RUN” position. Operate

the switch for the electric priming pump. After
100 seconds of the electric fuel priming pump
operation the fuel system will be primed and the
electric fuel priming pump will turn off.
3. The engine should now be able to start.

g01194949
Illustration 47
Note: Do not loosen the high pressure fuel line
in order to purge air from the fuel system. This (1) Camshaft gear
(2) Idler gear
procedure is not required. (3) Fuel Injection Pump gear
4. Operate the engine starter and crank the engine. 1. Install the camshaft gear (1) onto the camshaft.
After the engine has started, operate the engine at Refer to Disassembly and Assembly Manual,
low idle for a minimum of five minutes, immediately “Camshaft Gear - Remove and Install” for the
after air has been removed from the fuel system. correct procedure.
Note: Operating the engine for this period of time will 2. Ensure that the crankshaft and the camshaft
help ensure that the fuel system is free of air. are locked in the correct position. Refer to
Disassembly and Assembly Manual, “Gear
After the engine has stopped, you must wait for Group (Front) - Remove and Install” for the
60 seconds in order to allow the fuel pressure to correct procedure. Ensure that the fuel injection
be purged from the high pressure fuel lines before pump is locked in the correct position. Refer
any service or repair is performed on the engine to Disassembly and Assembly Manual, “Fuel
fuel lines. If necessary, perform minor adjustments. Injection Pump - Remove” for the correct
Repair any leaks from the low pressure fuel system procedure.
and from the cooling, lubrication or air systems.
Replace any high pressure fuel line that has leaked. 3. Install the idler gear (2). Refer to Disassembly
Refer to Disassembly and Assembly Manual, “Fuel and Assembly Manual, “Idler Gear - Remove and
Injection Lines - Install”. Install” for the correct procedure.
If you inspect the engine in operation, always use 4. Install the fuel injection pump gear (3). Refer
the proper inspection procedure in order to avoid to Disassembly and Assembly Manual, “Fuel
a fluid penetration hazard. Refer to Operation and Injection Pump Gear - Install” for the correct
Maintenance Manual, “General hazard Information”. procedure.
5. Make sure that the timing marks on the gears

(1), (2) and (3) are in alignment. If the timing
marks are not aligned, refer to Disassembly and
Assembly Manual, “Gear Group (Front) - Remove
and Install”.
RENR7967 51
Air Inlet and Exhaust

System
i02553540

- Inspect
A general visual inspection should be made to the air
inlet and exhaust system. Make sure that there are
no signs of leaks in the system.
There will be a reduction in the performance of the

engine if there is a restriction in the air inlet system or
the exhaust system.
Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
g01274757
Illustration 48
Typical unfiltered breather (open circuit)
Making contact with a running engine can cause

burns from hot parts and can cause injury from
rotating parts.
When working on an engine that is running, avoid

contact with hot parts and rotating parts.
1. Inspect the engine air cleaner inlet and ducting

in order to ensure that the passageway is not
blocked or collapsed.
2. Inspect the engine air cleaner element. Replace

a dirty engine air cleaner element with a clean
engine air cleaner element.
3. Check for dirt tracks on the clean side of the

engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the
engine air cleaner element and/or the seal for the
engine air cleaner element.
Note: There are two types of open circuit crankcase

breather that may be installed on the engine, a
filtered breather and an unfiltered breather.
52 RENR7967
5. Remove the breather tube (3) from the breather

(1) and check for obstructions. If the breather
tube is obstructed, use low pressure air to remove
the obstruction. If a filtered breather assembly is
installed, check that the filter element is free from
oil. Ensure that the filter has been renewed at the
correct service interval. Refer to the Operation
and Maintenance Manual, “Maintenance Interval
Schedule - 500 hours Service” for the correct
procedure. If a blockage is inside the cover (2),
remove the cover. Refer to Disassembly and
Assembly Manual, “Crankcase Breather - Remove
and Install” for the correct procedure. Check the
breather for cracks or external damage. If the
breather is faulty, renew the breather.
Note: The new filter must not be filled with oil when
the canister is renewed.
i02554967
Turbocharger - Inspect
Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
NOTICE
g01277997
Illustration 49 Keep all parts clean from contaminants.
Typical filtered breather (Open circuit)
Contaminants may cause rapid wear and shortened
4. If there is excessive crankcase pressure, check component life.
the breather for blockages, and debris. Refer
to Disassembly and Assembly Manual, “Valve
Mechanism Cover - Remove and Install (Filtered NOTICE
Breather) or Remove and Install (Unfiltered Care must be taken to ensure that fluids are contained
Breather)” for the correct procedure. Inspect the during performance of inspection, maintenance, test-
inside of the valve mechanism cover for debris. ing, adjusting and repair of the product. Be prepared to
Ensure that all of the debris is removed. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Note: The breather (1) that is within the valve nent containing fluids.
mechanism cover (2) is not a serviceable item. The
breather should only be renewed if the breather is Dispose of all fluids according to local regulations and
damaged. mandates.
Before you begin inspection of the turbocharger,

be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the
exhaust system restriction is within the specifications
for your engine. Refer to Testing and Adjusting, “Air
Inlet and Exhaust System - Inspect”.
RENR7967 53
The condition of the turbocharger will have definite a. Check the oil level in the crankcase. If the oil
effects on engine performance. Use the following level is too high, adjust the oil level.
inspections and procedures to determine the
condition of the turbocharger. b. Inspect the engine crankcase breather. Clean
the engine crankcase breather or replace
• Inspection of the compressor and the compressor the engine crankcase breather if the engine
housing crankcase breather is plugged.
• Inspection of the turbine wheel and the turbine c. Remove the pipe for the oil drain. Inspect the
housing drain opening. Inspect the oil drain line. Inspect
the area between the bearings of the rotating
• Inspection of the wastegate assembly shaft. Look for oil sludge. Inspect the
oil drain hole for oil sludge. Inspect the oil drain
line for oil sludge in the drain line. If necessary,
Inspection of the Compressor and clean the oil drain line.
the Compressor Housing
d. If Steps 3.a through 3.c did not reveal the
source of the oil leakage, the turbocharger has
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.
g01278821 3. Turn the rotating assembly by hand. While you

Illustration 50
turn the assembly, push the assembly sideways.
Typical example of a turbocharger The assembly should turn freely. The turbine
(1) Turbine housing wheel should not rub turbine wheel housing (1).
(2) Compressor housing Replace turbocharger (2) if turbine wheel rubs
turbine housing (1). If there is no rubbing or
1. Inspect the compressor wheel for damage from scraping, go to Step 4.
a foreign object. If there is damage, determine
the source of the foreign object. Replace the 4. Inspect the turbine and turbine housing (1) for oil
turbocharger. If there is no damage, go to Step 2. leakage. Inspect the turbine and turbine housing
(1) for oil coking. Some oil coking may be cleaned.
2. Turn the rotating assembly by hand. While you Heavy oil coking may require replacement of
turn the assembly, push the assembly sideways. the turbocharger. If the oil is coming from the
The assembly should turn freely. The compressor turbocharger center housing go to Step 4.a.
wheel should not rub the compressor housing. The Otherwise go to “Inspection of the Wastegate”.
turbocharger must be replaced if the compressor
wheel rubs the compressor wheel housing. If there a. Remove the pipe for the oil drain. Inspect the
is no rubbing or scraping, go to Step 3. drain opening. Inspect the area between the
bearings of the rotating assembly shaft. Look
3. Inspect the compressor and the compressor for oil sludge. Inspect the oil drain hole for oil
wheel housing for oil leakage. An oil leak from the sludge. Inspect the oil drain line for oil sludge.
compressor may deposit oil in the aftercooler. If oil If necessary, clean the drain line.
is found in the aftercooler, then drain and clean
the aftercooler.
54 RENR7967
b. If crankcase pressure is high, or if the oil drain Check the Wastegate for Proper
is restricted, pressure in the center housing Operation
may be greater than the pressure of turbine
housing (1). Oil flow may be forced in the wrong Table 4
direction and the oil may not drain. Check the
Required Tools
crankcase pressure and correct any problems.
Part
c. If the oil drain line is damaged, replace the oil Tool Number Part Description Qty
drain line. A 21825617 Dial Gauge 1
d. Check the routing of the oil drain line. Eliminate
any sharp restrictive bends. Make sure that
the oil drain line is not too close to the engine
exhaust manifold.
e. If Steps 4.a through 4.d did not reveal the

source of the oil leakage, turbocharger (3) has
internal damage. Replace turbocharger (3).
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. Illustration 51
g01289484
Typical example
The following levels of boost pressure indicate a
problem with the wastegate:
Note: The turbocharger is a nonserviceable item.
The pressure for the wastegate can be checked, but
• Too high at full load conditions not adjusted.
• Too low at all lug conditions 1. Disconnect the pipe for the boost sensor (6) at
the wastegate actuator (5). Connect an air supply
The boost pressure controls the maximum rpm of the
to the wastegate actuator that can be adjusted
turbocharger, because the boost pressure controls
accurately.
the position of the wastegate. The following factors
also affect the maximum rpm of the turbocharger:
2. Install Tooling (A) to the turbocharger so that
the end of the actuator rod (1) is in contact with
• The engine rating Tooling (A). This will measure axial movement of
the actuator rod (4).
• The horsepower demand on the engine
• The high idle rpm
• Inlet air restriction
• Exhaust system restriction
RENR7967 55
3. Slowly apply air pressure to the wastegate so that • All glow plugs are removed.
the actuator rod (4) moves 1.0 mm (0.039 inch).
The air pressure should be within 107 to 117 kPa • The fuel supply is disconnected.
(15.5 to 17.0 psi). Ensure that the dial indicator
returns to zero when the air pressure is released.
Repeat the test several times. This will ensure that
an accurate reading is obtained.
4. If the operation of the wastegate is not correct, the

actuator rod (4) can be adjusted.
5. Remove Tooling (A) from the turbocharger.
6. When the air pressure is applied, loosen the nut

on the actuator. Remove the circlip (1). Remove
the pin (2) from the actuator rod (4).
7. When the air pressure is too low, adjust the end of

the actuator rod (4) in order to reduce the length
of the actuator rod (4). If the air pressure is too
high, adjust the end of the actuator rod (4) in order
to increase the length of the actuator rod (4).
8. Install the pin (2) to the actuator rod (4). Install the
circlip (1) to the actuator rod (4). Tighten the nut to g01282556
a torque of 5 N·m (44 lb in). Illustration 52
Typical example
9. Repeat steps 2 to 3 in order to repeat the pressure
test. 1. Remove the glow plug (1) from the hole in the
cylinder head (2). Refer to Disassembly and
10. If the air pressure is correct, remove the air Assembly Manual, “Glowplugs - Remove and
supply. Remove Tooling (A). Install the pipe for the Install” for the correct procedure for the removal of
boost sensor (7). the glow plug (1).
2. Install a suitable gauge for measuring the cylinder

i02562219 compression in the hole for a glow plug.
Compression - Test 3. Operate the starting motor in order to turn the
engine. Record the maximum pressure which is
indicated on the compression gauge.
The cylinder compression test should only be used in 4. Repeat steps 1 to 3 for all cylinders.
order to compare the cylinders of an engine. If one or
more cylinders vary by more than 350 kPa (51 psi),
the cylinder and related components may need to
be repaired.
A compression test should not be the only method

which is used to determine the condition of an engine.
Other tests should also be conducted in order to
determine if the adjustment or the replacement of
components is required.
Before the performance of the compression test,

make sure that the following conditions exist:
• The battery is in good condition.

• The battery is fully charged.
• The starting motor operates correctly.
• The valve lash is set correctly.
56 RENR7967
i02556539 Too much valve lash can cause broken valve stems,
springs, and spring retainers. This will produce
Engine Valve Lash - emissions in excess of the correct specification.
Inspect/Adjust Too much valve lash can be an indication of the
following problems:
Table 5 • Worn camshaft and valve lifters

Required Tools
• Worn rocker arms
Part
Tool Number Part Description Qty • Bent pushrods
A 27610298 Angled feeler gauge 1
• Broken socket on the upper end of a pushrod
• Loose adjustment screw for the valve lash
If the camshaft and valve lifters show rapid wear,
look for fuel in the lubrication oil or dirty lubrication
oil as a possible cause.
Valve Lash Check

An adjustment is NOT NECESSARY if the
measurement of the valve lash is in the acceptable
range. Check the valve lash while the engine is
stopped. The temperature of the engine does not
change the valve lash setting.
If the measurement is not within the acceptable

clearance, adjustment is necessary. Refer to “Valve
Lash Adjustment”.
Valve Lash Adjustment

g01187485
Illustration 53
Table 6
Cylinder and valve location
Inlet Valves Exhaust Valves
(A) Exhaust valve
(B) Inlet valve 0.35 ± 0.05 mm 0.35 ± 0.05 mm
Valve Lash (0.0138 ± 0.0020 (0.0138 ± 0.0020
If the valve lash requires adjustment several times inch) inch)
in a short period of time, excessive wear exists in
a different part of the engine. Find the problem and Firing Order 1-3-4-2(2)
make necessary repairs in order to prevent more (2) The No. 1 Cylinder is at the front of the engine.
damage to the engine.
Note: When the engine is new, the valve lash should
Not enough valve lash can be the cause of rapid be checked and reset after a service interval of 1000
wear of the camshaft and valve lifters. Not enough hours.
valve lash can indicate that the seats for the valves
are worn. Note: For example, if the pushrods in a
remanufactured engine have been replaced with new
Valves become worn due to the following causes: parts then Adjust the valve lash to 0.25 ± 0.05 mm
(0.0098 ± 0.0020 inch) for the initial rebuild.
• Fuel injection nozzles that operate incorrectly The tappets should be reset to 0.35 ± 0.05 mm
(0.0138 ± 0.0020 inch) at the normal service intervals
• Excessive dirt and oil are present on the filters for thereafter.
the inlet air.
• The load capacity of the engine is frequently

exceeded.
RENR7967 57
g01193809
Illustration 54
Setting the valve lash
(A) Angled feeler gauge
(1) Adjustment screw
(2) Locking screw
Accidental engine starting can cause injury or

death to personnel.
To prevent accidental engine starting, turn the ig-

nition switch to the OFF position and place a do
not operate tag at the ignition switch location.
g01278980
Illustration 55
58 RENR7967
1. Remove the valve mechanism cover. Refer to 3. Rotate the crankshaft by 180 degrees in the
Disassembly and Assembly , “Valve Mechanism direction of engine rotation, until the piston of
Cover - Remove and Install” for the removal No. 3 cylinder is at the top center position on the
procedure. compression stroke. The exhaust valves and the
inlet valves of No. 2 cylinder are in valve overlap.
Note: When the valve mechanism cover is removed Adjust the valve lash for both the inlet valves
or installed, the electrical harness must be checked. (5) and the exhaust valves (6) of No. 3 cylinder.
Do not trap the injector harness when the valve Complete the sequence of checks according to
mechanism cover is installed. Do not allow the Table7 until all the cylinders have been checked
harness to be in contact with the valve mechanism or adjusted. Reinstall the valve mechanism cover.
cover. Renew the harness, if the harness is damaged. Refer to Disassembly and Assembly, “Valve
Mechanism Cover - Remove and Install” for the
Table 7 installation procedure.
Piston in Set valve lash for the following :
top center
i02556543
position
and inlet
and exhaust
Exhaust valves Inlet valves
Valve Depth - Inspect
valves in (Cylinder number) (Cylinder number)
valve overlap
1 2 Table 8
4
(1) (1) Required Tools
5 6 Tool Part Number Part Description Qty

2
(3) (3) A 21825617 Dial gauge 1
7 8 B 21825496 Dial gauge holder 1

1
(4) (4)
3 4
3
(2) (2)
2. See illustration 55. Rotate the crankshaft

clockwise until the piston of No. 1 cylinder is at
the top center position on the compression stroke.
The exhaust valves and the inlet valves of No. 4
cylinder are in valve overlap. Measure the valve
lash on the pair of exhaust valves (1) and the pair
of inlet valves (2) of No. 1 cylinder. If necessary,
adjust the valve lash to the settings in Table 6.
a. See illustration 55. Loosen the valve adjustment

locknut that is on the adjustment screw (1).
b. Place Tooling (A) between the rocker arm

and the valve. Turn the adjustment screw (1)
while the valve adjustment screw locknut (2) is
prevented from turning. Adjust the valve lash Illustration 56
g01201916
until the correct specification is achieved. Typical example
c. After each adjustment, tighten the valve 1. Ensure that the face of the valves are clean.
adjustment screw locknut to 21.5 to 32.5 N·m Ensure that the bottom face of the cylinder head
(15.9 to 24 lb ft) while the valve adjustment is clean. Ensure that the cylinder head is not
screw (1) is held in position. distorted. Refer to Testing and Adjusting, “Cylinder
Head - Inspect” for the procedure to measure
flatness of the cylinder head.
RENR7967 59
2. Use the Tooling (A) to check the depths of the inlet

valves and the exhaust valves below the face of
the cylinder head. Use Tooling (B) to zero Tooling
(A).
3. Measure the depth of the inlet valve and the

exhaust valve below the cylinder head face. The
minimum and maximum limits for a new engine
follow:
Inlet valves
Minimum .................. 0.905 mm (0.0356 inch)
Maximum ................. 1.163 mm (0.0458 inch)
g00314806
Exhaust valves Illustration 57
Measure the radial movement of the valve in the valve guide.
Minimum .................. 0.876 mm (0.0345 inch)
(1) Valve guide
Maximum ................. 1.131 mm (0.0445 inch) (2) Radial movement of the valve in the valve guide
(3) Valve stem
4. Service wear occurs on an engine which has (4) Dial indicator
been in operation. If the valve depth below the (5) Valve head
cylinder head face on a used engine exceeds
the specification for service wear, the following 1. Place a new valve in the valve guide.
components must be replaced.
2. Place a dial indicator with a magnetic base on the
• Valves face of the cylinder head.
• Valve inserts 3. Lift the edge of the valve head to a distance of

15.0 mm (0.60 inch).
Wear limit for inlet valves .. 1.41 mm (0.0555 inch)
4. Move the valve in a radial direction away from the
Wear limit for exhaust valves ................. 1.38 mm dial indicator. Make sure that the valve moves
(0.0543 inch) away from the dial indicator as far as possible.
Position the contact point of the dial indicator on
5. Check each valve for cracks. Check the stems of the edge of the valve head. Set the position of the
the valves for wear. Ensure that the valves are needle of the dial indicator to zero.
the correct fit in the valve guides. Refer to Testing
and Adjusting, “Valve Guide - Inspect” for the 5. Move the valve in a radial direction toward the dial
procedure to inspect the valve guides. indicator as far as possible. Note the distance of
movement which is indicated on the dial indicator.
6. Check the load on the valve springs. Refer to If the distance is greater than the maximum
Specifications, “Cylinder Head Valves” for the clearance of the valve in the valve guide, replace
correct lengths and specifications for the valve the valve guide.
springs.
The maximum clearance for the inlet valve stem
in the valve guide with a valve lift of 15.0 mm
i02400035 (0.60 inch) is the following value. ........... 0.08 mm
(0.0031 inch)
Valve Guide - Inspect
The maximum clearance for the exhaust valve
Perform this test in order to determine if a valve guide stem in the valve guide with a valve lift of 15.0 mm
should be replaced. (0.60 inch) is the following value. ........... 0.09 mm
(0.0035 inch)
60 RENR7967
The original valve guides are bored into the cylinder

head. When new valve guides(1) are installed, new
valves and new valve seat inserts must be installed.
The cylinder head must be rebored in order to install
the new valve guide. Valve guides and valve seat
inserts are supplied as an unfinished part. The
unfinished valve guides and unfinished valve seat
inserts are installed in the cylinder head. Then, the
valve guides and valve inserts are cut and reamed in
one operation with special tooling.
Refer to Disassembly and Assembly, “Inlet and

Exhaust Valve Guides - Remove and install” for the
replacement of the valve guides.
RENR7967 61
Lubrication System Perform the following procedures in order to inspect

the oil pump for clearances and torques.
i02557748
Refer to the Specifications Module, “Engine Oil
Engine Oil Pressure - Test Pump”.
1. Remove the oil pump from the engine. Refer to

the Disassembly and Assembly, “Engine Oil Pump
- Remove”. Remove the cover of the oil pump.
Low Oil Pressure
2. Remove the outer rotor. Clean all of the parts.
The following conditions will cause low oil pressure. Look for cracks in the metal or other damage.
• 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 g00985779
Illustration 58
normal at low idle.
Clearance for the outer rotor body
A suitable pressure gauge can be used in order to (1) Measure the clearance of the outer rotor to the body.
test the pressure of the lubrication system.
3. Install the outer rotor. Measure the clearance of
the outer rotor to the body (1).
High Oil Pressure
High oil pressure can be caused by the following
conditions.
• The spring for the oil pressure relief valve is

installed incorrectly.
• 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.
i01893791
Engine Oil Pump - Inspect
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.
62 RENR7967
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.
i02414692
Excessive Engine Oil

Illustration 59
g00985780
Consumption - Inspect
Clearance for the inner rotor
(2) Measure the clearance of the inner rotor to the outer rotor.
Engine Oil Leaks on the Outside of
4. Measure the clearance of the inner rotor to the the Engine
outer rotor (2).
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
the combustion area of the cylinders:
• Failed valve stem seals
g00989217 • Leaks between worn valve guides and valve stems

Illustration 60
• Worn components or damaged components
5. Measure the end play of the rotor with a straight (pistons, piston rings, or dirty return holes for the
edge and a feeler gauge (3). engine oil)
6. Clean the top face of the oil pump and the bottom • Incorrect installation of the compression ring and/or
face of the cover. Install the cover on the oil the intermediate ring
pump. Install the oil pump on the engine. Refer to
Disassembly and Assembly, “Engine Oil Pump -
Install”.
RENR7967 63
• Leaks past the seal rings in the turbocharger shaft

• Overfilling of the crankcase
• 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.
64 RENR7967
b. Clean the radiator and other components with
hot water or steam at low pressure. Detergent
Cooling System in the water may also be used. Compressed
air may be used to remove materials from
the cooling system. Identify the cause of the
i02419296 restriction before you choose the method for
cleaning.
Cooling System - Check
c. Straighten any fins of the radiator if the fins
Engine And Cooling System Heat are bent.
Problems 5. Check the high idle of the engine. The engine may
overheat if the high idle rpm is set too high.
1. The following conditions indicate that a heat
problem exists.
i01889427
a. Hot coolant is released through the pressure
cap during the normal operation of the engine. Cooling System - Inspect
Hot coolant can also be released when the
engine is stopped. This engine has a pressure type cooling system. A
pressure type cooling system gives two advantages:
b. Hot coolant is released from the coolant system
but not through the pressure cap during normal • The pressure type cooling system can operate
operation of the engine. Hot coolant can also safely at a higher temperature than the boiling
be released when the engine is stopped. point of water at a range of atmospheric pressures.
c. Coolant must be added frequently to the • The pressure type cooling system prevents
cooling system. The coolant is not released cavitation in the water pump.
through the pressure cap or through an outside
leak. Cavitation is the sudden generation of low pressure
bubbles in liquids by mechanical forces. The
2. If any of the conditions in Step 1 exist, perform generation of an air or steam pocket is much more
the following procedures: difficult in a pressure type cooling system.
a. Run the engine at medium idle, which is Regular inspections of the cooling system should be
approximately 1200 rpm, for three minutes made in order to identify problems before damage
after the high idle shuts off. Running the engine can occur. Visually inspect the cooling system before
at medium idle will allow the engine to cool tests are made with the test equipment.
before the engine is stopped.
Visual Inspection Of The Cooling
b. Inspect the poly v-belt for wear or for damage.
If necessary, replace the poly v-belt. Refer to System
Disassembly and Assembly Manual, “Alternator
Belt - Remove and Install” for the correct 1. Check the coolant level in the cooling system.
procedure.
2. Look for leaks in the system.
3. Refer to “Visual Inspection Of The Cooling
System” in order to determine if a leak exists in 3. Inspect the radiator for bent fins and other
the cooling system. restriction to the flow of air through the radiator.
a. Refer to “Testing The Radiator And Cooling 4. Inspect the drive belt for the fan.
System For Leaks” procedures.
5. Inspect the blades of the fan for damage.
4. If the coolant does not flow through the radiator
and through other components of the cooling 6. Look for air or combustion gas in the cooling
system, perform the following procedures. system.
a. Perform the “Testing The Water Temperature 7. Inspect the radiator cap for damage. The sealing
Regulator ” procedures. surface must be clean.
RENR7967 65
8. Look for large amounts of dirt in the radiator core. The level of the coolant should not be more than
Look for large amounts of dirt on the engine. 13 mm (0.5 inch) from the bottom of the filler pipe. If
the cooling system is equipped with a sight glass,
9. Shrouds that are loose or missing cause poor air the coolant should be to the correct level in the sight
flow for cooling. glass.
i01964006 Checking the Filler Cap

Cooling System - Test One cause for a pressure loss in the cooling system
can be a faulty seal on the radiator pressure cap.
Remember that temperature and pressure work

together. When a diagnosis is made of a cooling
system problem, temperature and pressure must
be checked. The cooling system pressure will have
an effect on the cooling system temperature. For
an example, refer to Illustration 61. This will show
the effect of pressure on the boiling point (steam) of
water. This will also show the effect of height above
sea level.
g00296067
Illustration 62
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.
g00286266
At operating temperature, engine coolant is hot
Illustration 61 and under pressure. The radiator and all lines
Cooling system pressure at specific altitudes and boiling points to heaters or the engine contain hot coolant or
of water steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool
Personal injury can result from hot coolant, steam enough to touch with your bare hand.
and alkali.
To check for the amount of pressure that opens the
At operating temperature, engine coolant is hot filler cap, use the following procedure:
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or 1. After the engine cools, carefully loosen the filler
steam. Any contact can cause severe burns. cap. Slowly release the pressure from the cooling
system. Then, remove the filler cap.
when engine is stopped and radiator cap is cool 2. Inspect the pressure cap carefully. Look for
enough to touch with your bare hand. damage to the seal. Look for damage to the
surface that seals. Remove any debris on the cap,
The coolant level must be to the correct level in order the seal, or the sealing surface.
to check the coolant system. The engine must be
cold and the engine must not be running. Carefully inspect the filler cap. Look for any
damage to the seals and to the sealing surface.
After the engine is cool, loosen the pressure cap Inspect the following components for any foreign
in order to relieve the pressure out of the cooling substances:
system. Then remove the pressure cap.
• Filler cap
66 RENR7967
• Seal • You do NOT observe any leakage after five

minutes.
• Surface for seal
• The dial indicator remains constant beyond five
Remove any deposits that are found on these minutes.
items, and remove any material that is found on
these items. The inside of the cooling system has leakage only
if the following conditions exist:
3. Install the pressure cap onto a suitable
pressurizing Pump. • The reading on the gauge goes down.
4. Observe the exact pressure that opens the filler • You do NOT observe any outside leakage.
cap.
Make any repairs, as required.
5. Compare the pressure to the pressure rating that
is found on the top of the filler cap.
i02558841
6. If the filler cap is damaged, replace the filler cap. Engine Oil Cooler - Inspect
Testing The Radiator And Cooling
System For Leaks
Use the following procedure to test the radiator and
the cooling system for leaks. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Personal injury can result from hot coolant, steam There is only one type of engine oil cooler that can
and alkali. be installed on this engine.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.

when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
1. When the engine has cooled, loosen the filler cap

to the first stop. Allow the pressure to release from
the cooling system. Then remove the filler cap.
2. Make sure that the coolant covers the top of the

radiator core.
3. Put a suitable pressurizing Pump onto the radiator.
4. Use the pressurizing pump to increase the

pressure to an amount of 20 kPa (3 psi) more than
the operating pressure of the filler cap.
5. Check the radiator for leakage on the outside.
6. Check all connections and hoses of the cooling

system for leaks.
The radiator and the cooling system do not have

leakage if all of the following conditions exist:
RENR7967 67
Mounted Filter Dry the oil cooler (1) with low pressure air. Flush
the inside of the oil cooler (1) with clean lubricating
oil.
5. Refer to Disassembly and Assembly , “Engine

Oil Cooler - Install” for installation of the engine
oil cooler.
6. Ensure that the cooling system of the engine is

filled to the correct level. Operate the engine.
Note: Refer to the Operation And Maintenance

Manual, “Refill Capacities” for additional information.
Check for oil or coolant leakage.
i02414647
Water Temperature Regulator

- Test
g01254472
Illustration 63
Typical example
(1) Oil cooler
(2) Joint
(3) Cooler matrix Personal injury can result from escaping fluid un-
(4) Joints der pressure.
(5) Housing
(6) Four setscrews
(7) Setscrews (different lengths) If a pressure indication is shown on the indicator,
push the release valve in order to relieve pressure
Perform the following procedure in order to inspect before removing any hose from the radiator.
the engine oil cooler:
1. Remove the water temperature regulator from
1. Place a container under the oil cooler in order to the engine. Refer to Disassembly and Assembly
collect any engine oil or coolant that drains from Manual, “Water Temperature Regulator - Remove
the oil cooler. and Install”.
2. Refer to Disassembly and Assembly , “Engine 2. Heat water in a pan until the temperature of
Oil Cooler - Remove” for removal of the engine the water is equal to the fully open temperature
oil cooler. of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator”
3. Thoroughly clean the oil cooler (1) and the cylinder for the fully open temperature of the water
block. temperature regulator. Stir the water in the pan.
This will distribute the temperature throughout the
pan.
Personal injury can result from air pressure. 3. Hang the water temperature regulator in the pan
of water. The water temperature regulator must
Personal injury can result without following prop- be below the surface of the water. The water
er procedure. When using pressure air, wear a pro- temperature regulator must be away from the
tective face shield and protective clothing. sides and the bottom of the pan.
Maximum air pressure at the nozzle must be less 4. Keep the water at the correct temperature for ten
than 205 kPa (30 psi) for cleaning purposes. minutes.
4. Inspect the oil cooler (1) for cracks and dents.

Replace the oil cooler (1) if cracks or dents
exist. Ensure that no restrictions for the flow of
lubricating oil exist in the oil cooler (1).
68 RENR7967
5. After ten minutes, remove the water temperature

regulator. Immediately measure the opening
of the water temperature regulator. Refer to
Specifications, “Water Temperature Regulator”
for the minimum opening distance of the
water temperature regulator at the fully open
temperature.
If the distance is less than the amount listed in the

manual, replace the water temperature regulator.
i01628133
Water Pump - Inspect

1. Inspect the water pump for leaks at vent hole. The
water pump seal is lubricated by coolant in the
cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and
the parts contract.
2. Refer to Disassembly and Assembly, “Water Pump

- Remove ” and Disassembly and Assembly,
“Water Pump - Install”.
3. Inspect the water pump shaft for unusual noise,

excessive looseness and/or vibration of the
bearings.
RENR7967 69
Basic Engine Inspect the Piston Ring End Gap
i01889476
Piston Ring Groove - Inspect
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
g00983549
and the piston rings. Illustration 65
(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.
i02560333
Connecting Rod - Inspect

Illustration 64
g00905732 These procedures determine the following
(1) Feeler gauge characteristics of the connecting rod:
(2) Piston ring
(3) Piston grooves • The length of the connecting rod
2. Fit new piston rings (2) in the piston grooves (3). • The distortion of the connecting rod
3. Check the clearance for the piston ring by placing • The parallel alignment of the bores of the
a suitable feeler gauge (1) between the piston connecting rod
groove (3) and the top of piston ring (2). Refer
to Specifications, “Piston and Rings” for the Note: If the crankshaft or the cylinder block are
dimensions. replaced, the piston height for all cylinders must be
measured. The grade of length of the connecting
Note: Some pistons have a tapered top groove and rods may need to be changed in order to obtain the
the piston ring is wedged. The clearance for the top correct piston height.
piston ring cannot be checked by the above method
when this occurs.
70 RENR7967
If the grade of length must be changed, one of the If the piston pin bearing requires replacement but the
following actions must be taken: original connecting rod is not replaced, the following
procedures must be performed:
• New connecting rod assemblies that are the
correct grade of length must be installed. Refer to 1. Determine the grade of length of the connecting
“Length Of The Connecting Rod”. rod. Use one of the following characteristics:
• New piston pin bearings must be bored after • The mark

installation in the original connecting rods. Refer
to “Piston Pin Bearings”. • The color
Note: When the piston pin is installed, always install • Measuring the length
new retaining rings on each end of the piston pin. If
the piston pin cannot be removed by hand, heat the 2. Ensure that the connecting rod is aligned parallel
piston to a temperature of 45° ± 5 °C (113° ± 9 °F) in and that the connecting rod is not distorted. Refer
order to aid the removal of the piston pin. Heating to “Distortion Of A Connecting Rod” in this service
the piston to this temperature may also aid the module.
installation of the piston pin.
3. Remove the piston pin bearing from the connecting
Length of The Connecting Rod rod. Install a new bearing in the connecting rod.
The new bearing is partially finished. The new
bearing must be bored off-center to the correct
The connecting rod length (CRL) is the length of the
connecting rod. Refer to Table 9 for each grade of diameter. This off-center position is determined by
the grade of length of the connecting rod. Refer to
length of connecting rod.
Table 9. The correct diameter of the bore in the
In order to ensure that the piston height above the piston pin bearing is given in the Specifications
Module, “Connecting Rod”.
cylinder block is correct, three grades of connecting
rods “F” to “L” are used during manufacture at the
factory. Replacement connecting rods are available Surface finish of the bored hole in the piston pin
bearing .................................. Ra 0.8 micrometers
in six grades. These grades of connecting rod are
“F” to “L”. The grade of length is identified by a
letter or a color which is marked on the side of the 4. Machine the ends of the piston pin bearing to the
correct length. Remove any sharp edges. Refer to
connecting rod. The longest grade is marked with the
the Specifications Module, “Connecting Rod”.
letter “F”. The shortest grade is marked with the letter
“L”. The difference in length between each grade of
5. If the grade of length of the connecting rod
connecting rods is the following value: 0.046 mm
is changed, the letter that is stamped on the
(0.0018 inch)
connecting rod must be removed. Etch a letter
that is for the new grade of length on the side of
The grade of length of a connecting rod is determined
the connecting rod.
in the factory by machining an eccentric hole in a
semi-finished piston pin bushing. Therefore, the
Note: Do not stamp a new letter on the connecting
grade of length is determined by the position of the
rod. The force of stamping may damage the
center of the hole in the piston pin bearing.
connecting rod.
If the connecting rod must be replaced, a new
Table 9 references the following information: Grade
connecting rod assembly must be purchased and
installed. Refer to Table 9 for more information. of letter of the connecting rod, the color code of the
connecting rods, and the lengths of the connecting
rods.
A new piston pin bearing is installed in the new
connecting rod at the factory. The bore of the piston
pin bearing is reamed to the correct eccentricity.
Piston Pin Bearings

Note: This procedure requires personnel with the
correct training and the use of specialized equipment
for machining.
RENR7967 71
Table 9 Measure “CRL”. Compare the “CRL” that is given

Length Grades for Connecting Rods
in Table 9. The grade of length of the connecting
rod is determined by the “CRL”. Refer to Table 9
Grade Letter Color Code
Length Of The for the correct grade of length.
Connecting Rod (CRL)
F Red
165.728 to 165.761 mm Distortion of The Connecting Rod
(6.5247 to 6.5260 inch)
165.682 to 165.715 mm 1. Use the following tools in order to measure the
G Orange distances for the connecting rod (2) which are
(6.5229 to 6.5242 inch)
specified in Illustration 66:
165.637 to 165.670 mm
H White
(6.5211 to 6.5224 inch)
• Appropriate gauges for measuring distance
165.591 to 165.624 mm
J Green
(6.5193 to 6.5206 inch) • Measuring pins (1)
165.545 to 165.578 mm
K Purple
(6.5175 to 6.5188 inch)
165.499 to 165.532 mm
L Blue
(6.5157 to 6.5170 inch)
Measure The Length Of The Connecting

Rod
If the mark or the color of the grade of length cannot
be observed on the connecting rod, perform the
following procedure:
g00326423
Illustration 67
Measure the connecting rod for distortion.
(1) Measuring pins
(2) Connecting rod
(L) The length between the centers of the piston pin bearing and
the crankshaft journal bearing is shown in Illustration 67.
2. Refer to illustration 67. Measure the connecting

rod for distortion and parallel alignment between
the bores.
The bores for the crankshaft bearing and the

bearing for the piston pin must be square and
g00326546 parallel with each other within the required limits.
Illustration 66
Measure the length of the connecting rod. If the piston pin bearing is removed, the limit “L” is
(1) Measuring pins
the following value: ± 0.25 mm (± 0.010 inch)
(2) Connecting rod
(CRL) Connecting Rod Length The limits are measured at a distance of 127 mm
(5.0 inch) from each side of the connecting rod.
1. Refer to Illustration 66. Use the following tools in
order to measure the length of the connecting rod: If the piston pin bearing is not removed, the limit “L”
is the following value: ± 0.06 mm (± 0.0024 inch)
• Appropriate gauges for measuring distance
L is equal to 219.08 ± 0.03 mm (8.625 ± 0.001 inch).
• Measuring pins (1)
3. Inspect the piston pin bearing and the piston pin
2. Ensure that the measuring pins (1) are parallel. for wear.
“CRL” is measured when the bearing for the
crankshaft journal is removed and the original 4. Measure the clearance of the piston pin in the
piston pin bearing is installed. piston pin bearing. Refer to the Specifications
Module, “Connecting Rod” for dimensions.
72 RENR7967
i02399735
Cylinder Block - Inspect

1. Clean all of the coolant passages and the oil
passages.
2. Check the cylinder block for cracks and damage.
3. The top deck of the cylinder block must not be

machined. This will affect the depth of the cylinder
liner flange and the piston height above the
cylinder block.
4. Check the front camshaft bearing for wear. Refer

to Specifications, “Camshaft Bearings” for the
correct specification of the camshaft bearing. If a
new bearing is needed, use a suitable adapter to
press the bearing out of the bore. Ensure that the
oil hole in the new bearing faces the front of the
block. The oil hole in the bearing must be aligned
with the oil hole in the cylinder block. The bearing Illustration 68
g01254471
must be aligned with the face of the recess.
Flatness of the cylinder head (typical example)
(A) Side to side
i02560426 (B) End to end
(C) Diagonal
Cylinder Head - Inspect
8. Measure the cylinder head for flatness. Use a
1. Remove the cylinder head from the engine. straight edge and a feeler gauge to check the
cylinder head for flatness.
2. Remove the water temperature regulator housing.
• Measure the cylinder head from one side to the
3. Inspect the cylinder head for signs of gas or opposite side (A).
coolant leakage.
• Measure the cylinder head from one end to the
4. Remove the valve springs and valves. opposite end (B).
5. Clean the bottom face of the cylinder head • Measure the cylinder head from one corner to
thoroughly. Clean the coolant passages and the opposite corner (C).
the lubricating oil passages. Make sure that the
contact surfaces of the cylinder head and the Refer to Specifications, “Cylinder Head” for the
cylinder block are clean, smooth and flat. requirements of flatness.
6. Inspect the bottom face of the cylinder head for i01889496

pitting, corrosion, and cracks. Inspect the area
around the valve seat inserts and the holes for the Piston Height - Inspect
fuel injection nozzles carefully.
Table 10
7. Test the cylinder head for leaks at a pressure of
200 kPa (29 psi).
Required Tools
Part Part Description Qty

Number
21825617 Dial gauge 1
21825496 Dial gauge holder 1
RENR7967 73
If the height of the piston above the cylinder block 2. Rotate the crankshaft until the piston is at the
is not within the tolerance that is given in the approximate top center.
Specifications Module, “Piston and Rings”, the
bearing for the piston pin must be checked. Refer to 3. Position the dial gauge holder (2) and the dial
Testing and Adjusting, “Connecting Rod - Inspect”. gauge (1) in order to measure the piston height
If any of the following components are replaced or above the cylinder block. Slowly rotate the
remachined, the piston height above the cylinder crankshaft in order to determine when the piston
block must be measured: is at the highest position. Record this dimension.
Compare this dimension with the dimensions that
• Crankshaft are given in Specifications, “Piston and Rings”.
• Cylinder head
i02543991
• Connecting rod Flywheel - Inspect

• Bearing for the piston pin
The correct piston height must be maintained in order Table 11
to ensure that the engine conforms to the standards
for emissions. Required Tools
Part
Note: The top of the piston should not be machined. Tool Number Part Description Qty
If the original piston is installed, be sure that the
A 21825617 Dial Indicator Group 1
original piston is assembled to the correct connecting
rod and installed in the original cylinder.
Six grades of length of connecting rods determine

Alignment of the Flywheel Face
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.
g01273119
Illustration 70
Typical example
1. Install Tooling (A) in illustration 70, as shown.
2. Set the pointer of the dial indicator to 0 mm

Illustration 69
g00983585 (0 inch).
(1) Dial gauge
(2) Dial gauge holder 3. Turn the flywheel. Read the dial indicator for every
45 degrees.
1. Use the dial gauge (1) and the dial gauge holder
(2) in order to measure the piston height above Note: During the check, keep the crankshaft pressed
the cylinder block. Use the cylinder block face to toward the front of the engine in order to remove any
zero the dial gauge (1). end clearance.
74 RENR7967
4. Calculate the difference between the lowest Concentricity of the Flywheel

measurement and the highest measurement of the
four locations. This difference must not be greater
Housing
than 0.03 mm (0.001 inch) for every 25 mm
Note: This check must be made with the flywheel
(1.0 inch) of the radius of the flywheel. The radius
and the starter removed and the bolts for the flywheel
of the flywheel is measured from the axis of the
housing tightened lightly.
crankshaft to the contact point of the dial indicator.
Flywheel Runout
g01199468
Illustration 72
Typical example
g01273120
Illustration 71 1. Install Tooling (A). See illustration 72.
Typical example
2. Set the pointer of the dial indicator to 0 mm
1. Install Tooling (A) in illustration 71, as shown. (0 inch).
2. Set the pointer of the dial indicator to 0 mm 3. Check the concentricity at intervals of 45 degrees
(0 inch). around the flywheel housing.
3. Turn the flywheel. Read the dial indicator for every 4. Calculate the difference between the lowest
45 degrees. measurement and the highest measurement. This
difference must not be greater than the limit that is
4. Calculate the difference between the lowest given in Table 13.
measurement and the highest measurement of
the four locations. This difference must not be Note: Any necessary adjustment must be made on
greater than 0.30 mm (0.012 inch). the flywheel housing. Then, recheck the concentricity.
i02544044 Alignment of the Flywheel Housing

Flywheel Housing - Inspect Note: This check must be made with the flywheel
and the starter removed and the bolts for the flywheel
housing tightened to the correct torque.
Table 12
Required Tools
Part
A 21825617 Dial Gauge 1
RENR7967 75
i02543954
Gear Group - Inspect
g01273087
Illustration 74
g01199467 (1) Camshaft gear

Illustration 73 (2) Idler gear
Typical example (3) Fuel injection pump gear
1. Install Tooling (A). See illustration 73. Note: If one or more of the gears need to be removed
for repair, refer to Disassembly and Assembly, “Gear
2. Set the pointer of the dial indicator to 0 mm Group (Front) - Remove and Install” in order to
(0 inch). properly remove the gears. Refer to Disassembly and
Assembly, “Gear Group (Front) - Remove and Install”
3. Check the alignment at intervals of 45 degrees in order to properly install the gears.
around the flywheel housing.
1. Inspect the gears for wear or for damage. If the
4. Calculate the difference between the lowest gears are worn or damaged, use new parts for
measurement and the highest measurement. This replacement.
difference must not be greater than the limit that is
given in Table 13. 2. Measure the backlash between the camshaft
gear (1) and the idler gear (2). Refer to
Note: Any necessary adjustment must be made on Specifications, “Gear Group (Front)” for the
the flywheel housing. backlash measurement.
Table 13 3. Measure the backlash between the idler

Limits for Flywheel Housing Runout and Alignment gear (2) and the crankshaft gear. Refer to
(Total Indicator Reading) Specifications, “Gear Group (Front)” for the
backlash measurement.
Bore of the Housing Maximum Limit (Total
Flange Indicator Reading) 4. Measure the backlash between the fuel injection
410 mm (16.14 inch) 0.25 mm (0.010 inch) pump gear (3) and the idler gear (2). Refer to
Specifications, “Gear Group (Front)” for the
448 mm (17.63 inch) 0.28 mm (0.011 inch) backlash measurement.
76 RENR7967
g01273091
Illustration 75
5. Measure the end play on idler gear (2). Refer

to Disassembly and Assembly, “Idler Gear
- Install” for the correct procedure. Refer to
Specifications, “Gear Group (Front)” for the end
play measurement. g01273828
Illustration 77
Typical example of a crankshaft pulley with poly v-belt
i02545551 (1) Bolt
Crankshaft Pulley - Check (2)

(3)
Thrust block
Crankshaft adapter
(5) Bolt
The crankshaft pulley is installed on the front of the
crankshaft. There are two types of crankshaft pulley
that can be installed to the engine. Replace the crankshaft pulley if any of the following
conditions exist:
• There is any impact damage to the outer casing.

• There is leakage of the viscous fluid from the cover
plate.
• There is movement of the pulley.

• There is a large amount of gear train wear that is
not caused by lack of oil.
• Analysis of the engine oil has revealed that the

front main bearing is badly worn.
• The engine has had a failure because of a broken

crankshaft.
g01273827
Illustration 76
A standard pulley Check the areas around the holes for the bolts in
(1) Bolt
the crankshaft pulley for cracks or for wear and for
(2) Thrust block damage.
Use the following steps in order to check the
alignment and the runout of the crankshaft pulley:
1. Remove any debris from the front face of the

crankshaft pulley. Remove any debris from the
circumference of the crankshaft pulley.
RENR7967 77
2. Mount the dial indicator on the front cover. Use

the dial indicator to measure the outer face of the
crankshaft pulley. Set the dial indicator to read
0.00 mm (0.00 inch).
3. Rotate the crankshaft at intervals of 45 degrees

and read the dial indicator.
4. The difference between the lower measurements

and the higher measurements that are read on the
dial indicator at all four points must not be more
than 0.18 mm (0.007 inch).
If the reading on the dial indicator is more than

0.18 mm (0.007 inch), inspect the pulley for
damage. If the pulley is damaged, use new parts
for replacement.
5. Move the dial indicator so that the dial indicator

will measure the circumference of the crankshaft
pulley. Set the dial indicator to read 0.00 mm
(0.00 inch).
6. Slowly rotate the crankshaft in order to measure

the runout of the circumference of the crankshaft
pulley. Use the highest reading and the lowest
reading on the dial indicator. The maximum and
the minimum readings on the dial indicator should
not vary more than 0.12 mm (0.005 inch).
If the reading on the dial indicator is more than

0.12 mm (0.005 inch), inspect the pulley for
damage. If the pulley is damaged, use new parts
for replacement.
78 RENR7967
Electrical System
i02544065
Alternator - Test
1. Put the positive lead “+” of a suitable multimeter
on the “B+” terminal of the alternator. Put the
negative “-” lead on the ground terminal or on the
frame of the alternator. Put a suitable ammeter
around the positive output wire of the alternator.
2. Turn off all electrical accessories. Turn off the fuel

to the engine. Crank the engine for 30 seconds.
Wait for two minutes in order to cool the starting
motor. If the electrical system appears to operate
correctly, crank the engine again for 30 seconds.
Note: Cranking the engine for 30 seconds partially

discharges the batteries in order to do a charging
test. If the battery has a low charge, do not perform
this step. Jump start the engine or charge the battery
before the engine is started.
3. Start the engine and run the engine at full throttle.
4. Check the output current of the alternator. The

initial charging current should be equal to the
minimum full load current or greater than the
minimum full load current. Refer to Specifications,
“Alternator and Regulator” for the correct minimum
full load current.
Table 14
Fault Conditions And Possible Causes
Current At Start-up The Voltage Is Below The Voltage Is Within The Voltage Is Above
Specifications After 10 Specifications After 10 Specifications After 10
Minutes. Minutes. Minutes.
Less than the Replace the alternator. Turn on all accessories. If the -
specifications Check the circuit of the voltage decreases below the
ignition switch. specifications, replace the
alternator.
Decreases after matching Replace the alternator. The alternator and the battery Replace the alternator.
specifications match the specifications.
Turn on all accessories in
order to verify that the voltage
stays within specifications.
The voltage consistently Test the battery. Test the The alternator operates Replace the alternator.
exceeds specifications. alternator again. within the specifications. Test Inspect the battery for
the battery. damage.
RENR7967 79
5. After approximately ten minutes of operating the i02545695

engine at full throttle, the output voltage of the
alternator should be 14.0 ± 0.5 volts for a 12 volt V-Belt - Test
system and 28.0 ± 1 volts for a 24 volt system.
Refer to the Fault Conditions And Possible Table 15
Causes in Table 14. Required Tools
6. After ten minutes of engine operation, the charging Tool Part Number Part Description Qty
current should decrease to approximately 10 A - Belt Tension Gauge 1
amperes. The actual length of time for the
decrease to 10 amperes depends on the following
conditions:
• The battery charge

• The ambient temperature
• The speed of the engine
Refer to the Fault Conditions And Possible
Causes in Table 14.
i01126605
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.
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electrical components.
See Special Instruction, SEHS7633, “Battery Test

Procedure” for the correct procedures to use to
test the battery. This publication also contains the
specifications to use when you test the battery.
80 RENR7967
Table 16
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 belt that is farthest from the engine.
(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
i02418527
Poly V-Belt Charging System - Test

NOTICE The condition of charge in the battery at each
Ensure that the engine is stopped before any servicing regular inspection will show if the charging system is
or repair is performed. operating correctly. An adjustment is necessary when
the battery is constantly in a low condition of charge
or a large amount of water is needed. A large amount
To maximize the engine performance, inspect the of water would be more than one ounce of water
poly v-belt (1) for wear and for cracking. Replace the 28 ml per cell per week or per every 100 service
poly v-belt if the belt is worn or damaged. hours. There are no adjustments on maintenance
free batteries.
• If the poly v-belt (1) has more than four cracks per
25.4000 mm (1 inch) the belt must be replaced. When it is possible, make a test of the charging
unit and voltage regulator on the engine, and use
• Check the poly v-belt of cracks, splits, glazing, wiring and components that are a permanent part of
grease, and splitting. the system. Off-engine testing or bench testing will
give a test of the charging unit and voltage regulator
operation. This testing will give an indication of
needed repair. After repairs are made, perform a test
in order to prove that the units have been repaired to
the original condition of operation.
Alternator Regulator
The charging rate of the alternator should be checked
when an alternator is charging the battery too much
or not charging the battery enough.
Alternator output should be 28 ± 1 volt on a 24 volt

system and 14 ± 0.5 volt on a 12 volt system. No
adjustment can be made in order to change the rate
of charge on the alternator regulators. If the rate of
charge is not correct, a replacement of the regulator
is necessary. For individual alternator output, refer to
Specification, “Alternator and Regulator”.
g01216014
Illustration 78
Typical example
To replace the poly v-belt, refer to Disassembly and

Assembly, “Alternator Belt - Remove and Install”.
RENR7967 81
See Special Instruction, REHS0354, “Charging Table 17

System Troubleshooting” for the correct procedures
to use to test the charging system. This publication Typical Voltage Of Electrical System During Cranking
also contains the specifications to use when you test At Various Ambient Temperatures
the charging system. Temperature 12 Volt 24 Volt
System System
i02399802 −23 to −7°C 6 to 8 volts 12 to 16 volts
(−10 to 20°F)
Electric Starting System - Test −7 to 10°C 7 to 9 volts 14 to 18 volts
(20 to 50°F)
10 to 27°C 8 to 10 volts 16 to 24 volts
(50 to 80°F)
General Information
All electrical starting systems have four elements: Table 18 shows the maximum acceptable loss of
voltage in the battery circuit. The battery circuit
supplies high current to the starting motor. The values
• Keyswitch in the table are for engines which have service of
2000 hours or more.
• Start relay
Table 18
• Starting motor solenoid
Maximum Acceptable Voltage Drop In The Starting
• Starting motor Motor Circuit During Cranking
Circuit 12 Volt 24 Volt
Keyswitches have a capacity of 5 to 20 amperes. The System System
coil of a start relay draws about 1 ampere between
test points. The switch contacts of the start relay for Battery post “-” to 0.7 volts 1.4 volts
the starting motor are rated between 100 and 300 the starting motor
terminal “-”
amperes. The start relay can easily switch the load of
5 to 50 amperes for the starting motor solenoid. Drop across the 0.5 volts 1.0 volts
disconnect switch
The starting motor solenoid is a switch with a capacity
Battery post “+” 0.5 volts 1.0 volts
of about 1000 amperes. The starting motor solenoid to the terminal of
supplies power to the starter drive. The starting motor the starting motor
solenoid also engages the pinion to the flywheel. solenoid “+”
The starting motor solenoid has two coils. The Solenoid terminal 0.4 volts 0.8 volts
pull-in coil draws about 40 amperes. The hold-in coil “Bat” to the solenoid
terminal “Mtr”
requires about 5 amperes.
When the magnetic force increases in both coils, Voltage drops that are greater than the amounts
the pinion gear moves toward the ring gear of the in Table 18 are caused most often by the following
flywheel. Then, the solenoid contacts close in order conditions:
to provide power to the starting motor. When the
solenoid contacts close, the ground is temporarily • Loose connections
removed from the pull-in coil. Battery voltage is
supplied on both ends of the pull-in coil while the • Corroded connections
starting motor cranks. During this period, the pull-in
coil is out of the circuit. • Faulty switch contacts
Cranking of the engine continues until current to the
solenoid is stopped by releasing the keyswitch.
Diagnosis Procedure
The procedures for diagnosing the starting motor
Power which is available during cranking varies
are intended to help the technician determine if a
according to the temperature and condition of the
starting motor needs to be replaced or repaired. The
batteries. Table 17 shows the voltages which are
procedures are not intended to cover all possible
expected from a battery at the various temperature
problems and conditions. The procedures serve only
ranges.
as a guide.
82 RENR7967
The current and the voltages that are specified

NOTICE in the Specifications Module are measured
If equipped with electric start, do not crank the engine at a temperature of 27°C (80°F). When the
for more than 30 seconds. Allow the starter to cool for temperature is below 27°C (80°F), the voltage will
two minutes before cranking again. be lower through the starting motor. When the
temperature is below 27°C (80°F), the current
Never turn the disconnect switch off while the engine through the starting motor will be higher. If the
is running. Serious damage to the electrical system current is too great, a problem exists in the starting
can result. motor. Repair the problem or replace the starting
motor.
If the starting motor does not crank or cranks slow, If the current is within the specification, proceed
perform the following procedure: to Step 3.
1. Measure the voltage of the battery. 3. Measure the voltage of the starting motor.
Measure the voltage across the battery posts with a. Use the multimeter in order to measure the
the multimeter when you are cranking the engine voltage of the starting motor, when you are
or attempting to crank the engine. Do not measure cranking or attempting to crank the engine.
the voltage across the cable post clamps.
b. If the voltage is equal to or greater than the
a. If the voltage is equal to or greater than the voltage that is given in Table 17, then the
voltage in Table 17, then go to Step 2. battery and the starting motor cable that goes
to the starting motor are within specifications.
b. The battery voltage is less than the voltage in Go to Step 5.
Table 17.
c. The starting motor voltage is less than the
A low charge in a battery can be caused by voltage specified in Table 17. The voltage drop
several conditions. between the battery and the starting motor is
too great. Go to Step 4.
• Deterioration of the battery
4. Measure the voltage.
• A shorted starting motor
a. Measure the voltage drops in the cranking
• A faulty alternator circuits with the multimeter. Compare the
results with the voltage drops which are
• Loose drive belts allowed in Table 18.
• Current leakage in another part of the b. Voltage drops are equal to the voltage drops
electrical system that are given in Table 18 or the voltage drops
are less than the voltage drops that are given
2. Measure the current that is sent to the starting in Table 18. Go to Step 5 in order to check the
motor solenoid from the positive post of the engine.
battery.
c. The voltage drops are greater than the voltage
Note: If the following conditions exist, do not perform drops that are given in Table 18. The faulty
the test in Step 2 because the starting motor has a component should be repaired or replaced.
problem.
5. Rotate the crankshaft by hand in order to ensure
• The voltage at the battery post is within 2 volts that the crankshaft is not stuck. Check the oil
of the lowest value in the applicable temperature viscosity and any external loads that could affect
range of Table 17. the engine rotation.
• The large starting motor cables get hot. a. If the crankshaft is stuck or difficult to turn,
repair the engine.
Use a suitable ammeter in order to measure the
current. Place the jaws of the ammeter around the b. If the engine is not difficult to turn, go to Step 6.
cable that is connected to the “bat” terminal. Refer
to the Specifications Module, “Starting Motor” for 6. Attempt to crank the starting motor.
the maximum current that is allowed for no load
conditions. a. The starting motor cranks slowly.
RENR7967 83
Remove the starting motor for repair or Table 19

replacement. 12 Volt System
b. The starting motor does not crank. Amp Time (sec)
16.6 Initial
Check for the blocked engagement of the
pinion gear and flywheel ring gear. 12 5.7
9 11.1
Note: Blocked engagement and open solenoid
contacts will give the same electrical symptoms. 7 20
6 60
i02404326
Glow Plugs - Test Table 20

24 Volt System
Amp Time (sec)
9 Initial
Continuity Check of the Glow Plugs
7 3.3
The following test will check the continuity of the glow 6 5.3
plugs.
3 60
1. Disconnect the power supply and the bus bar.
6. Check the reading on each glow plugs.
2. Use a suitable digital multimeter to check
continuity (resistance). Turn the audible signal on 7. If there is no reading on the ammeter check the
the digital multimeter ON. electrical connections. If the readings on the
ammeter are low replace the faulty glow plug. If
3. Place one probe on the connection for the glow there is still no reading replace the faulty glow
plug and the other probe to a suitable ground. The plug.
digital multimeter should make an audible sound.
Replace the glow plug if there is no continuity.
4. Check the continuity on each the glow plugs.
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.
RENR7967 81
See Special Instruction, REHS0354, “Charging Table 17

System Troubleshooting” for the correct procedures
to use to test the charging system. This publication Typical Voltage Of Electrical System During Cranking
also contains the specifications to use when you test At Various Ambient Temperatures
the charging system. Temperature 12 Volt 24 Volt
System System
i02399802 −23 to −7°C 6 to 8 volts 12 to 16 volts
(−10 to 20°F)
Electric Starting System - Test −7 to 10°C 7 to 9 volts 14 to 18 volts
(20 to 50°F)
10 to 27°C 8 to 10 volts 16 to 24 volts
(50 to 80°F)
General Information
All electrical starting systems have four elements: Table 18 shows the maximum acceptable loss of
voltage in the battery circuit. The battery circuit
supplies high current to the starting motor. The values
• Keyswitch in the table are for engines which have service of
2000 hours or more.
• Start relay
Table 18
• Starting motor solenoid
Maximum Acceptable Voltage Drop In The Starting
• Starting motor Motor Circuit During Cranking
Circuit 12 Volt 24 Volt
Keyswitches have a capacity of 5 to 20 amperes. The System System
coil of a start relay draws about 1 ampere between
test points. The switch contacts of the start relay for Battery post “-” to 0.7 volts 1.4 volts
the starting motor are rated between 100 and 300 the starting motor
terminal “-”
amperes. The start relay can easily switch the load of
5 to 50 amperes for the starting motor solenoid. Drop across the 0.5 volts 1.0 volts
disconnect switch
The starting motor solenoid is a switch with a capacity
Battery post “+” 0.5 volts 1.0 volts
of about 1000 amperes. The starting motor solenoid to the terminal of
supplies power to the starter drive. The starting motor the starting motor
solenoid also engages the pinion to the flywheel. solenoid “+”
The starting motor solenoid has two coils. The Solenoid terminal 0.4 volts 0.8 volts
pull-in coil draws about 40 amperes. The hold-in coil “Bat” to the solenoid
terminal “Mtr”
requires about 5 amperes.
When the magnetic force increases in both coils, Voltage drops that are greater than the amounts
the pinion gear moves toward the ring gear of the in Table 18 are caused most often by the following
flywheel. Then, the solenoid contacts close in order conditions:
to provide power to the starting motor. When the
solenoid contacts close, the ground is temporarily • Loose connections
removed from the pull-in coil. Battery voltage is
supplied on both ends of the pull-in coil while the • Corroded connections
starting motor cranks. During this period, the pull-in
coil is out of the circuit. • Faulty switch contacts
Cranking of the engine continues until current to the
solenoid is stopped by releasing the keyswitch.
Diagnosis Procedure
The procedures for diagnosing the starting motor
Power which is available during cranking varies
are intended to help the technician determine if a
according to the temperature and condition of the
starting motor needs to be replaced or repaired. The
batteries. Table 17 shows the voltages which are
procedures are not intended to cover all possible
expected from a battery at the various temperature
problems and conditions. The procedures serve only
ranges.
as a guide.
RENR7967 85
Index Section
Gear Group (Front) - Time..................................... 50

General Information................................................. 4
Glossary of Electronic Control Terms .................... 39
Glow Plugs - Test................................................... 83
Checking The Operation of The Glow Plug ....... 83
Continuity Check of the Glow Plugs................... 83
Important Safety Information ................................... 2

Increased Engine Oil Temperature - Inspect ......... 63
Introduction.............................................................. 4
Lubrication System .......................................... 16, 61
Piston Height - Inspect .......................................... 72

Piston Ring Groove - Inspect................................. 69
Inspect the Clearance of the Piston Ring........... 69
Inspect the Piston and the Piston Rings ............ 69
Inspect the Piston Ring End Gap....................... 69
Power Sources ...................................................... 36
ECM Power Supply............................................ 37
Introduction (Power Supplies)............................ 36
Power supply for the Glow plugs ....................... 39
Power Supply for the Pressure Sensors ............ 38
Systems Operation Section ..................................... 4
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 45
Turbocharger - Inspect .......................................... 52
Inspection of the Compressor and the Compressor
Housing ............................................................ 53
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 53
Inspection of the Wastegate .............................. 54
V-Belt - Test ........................................................... 79

Poly V-Belt ......................................................... 80
Valve Depth - Inspect ............................................ 58
Valve Guide - Inspect ............................................ 59
Water Pump - Inspect............................................ 68

Water Temperature Regulator - Test ..................... 67
86 RENR7967
Index Section
RENR7967 87
Index Section
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved Printed in U.K.
RENR9525
July 2006
Disassembly and
Assembly
NH1 (Engine)
NJ1 (Engine)

this publication.

replacement parts.
death.
RENR9525 3
Table of Contents
Table of Contents Housing (Front) - Install ........................................ 83

Accessory Drive - Remove and Install ................. 85
Crankcase Breather - Remove and Install (Filtered
Breather) ............................................................. 87
Disassembly and Assembly Section Crankcase Breather - Remove and Install (Unfiltered
Breather) ............................................................. 88
Fuel Priming Pump - Remove and Install (Electric
Valve Mechanism Cover - Remove and Install ..... 88
Fuel Priming Pump) .............................................. 5
Valve Mechanism Cover Base - Remove and
Fuel Priming Pump - Remove and Install (Manual
Install ................................................................... 90
Priming Pump) ...................................................... 6
Rocker Shaft and Pushrod - Remove ................... 92
Fuel Filter Base - Remove and Install (Secondary
Rocker Shaft - Disassemble ................................ 93
Fuel Filter) ............................................................. 8
Rocker Shaft - Assemble ..................................... 94
Fuel Transfer Pump - Remove ................................ 9
Rocker Shaft and Pushrod - Install ....................... 95
Fuel Transfer Pump - Install ................................... 11
Cylinder Head - Remove ...................................... 97
Fuel Injection Lines - Remove ............................. 13
Cylinder Head - Install ........................................ 100
Fuel Injection Lines - Install ................................. 14
Lifter Group - Remove and Install ....................... 104
Fuel Manifold (Rail) - Remove and Install ............. 16
Camshaft - Remove and Install ......................... 105
Fuel Injection Pump - Remove ............................ 18
Camshaft Gear - Remove and Install ................ 106
Fuel Injection Pump - Install ................................ 21
Camshaft Bearings - Remove and Install .......... 109
Fuel Injection Pump Gear - Remove .................... 24
Engine Oil Pan - Remove and Install (Aluminum and
Fuel Injection Pump Gear - Install ........................ 26
Pressed Steel Oil Pans) ..................................... 110
Electronic Unit Injector - Remove ......................... 27
Engine Oil Pan - Remove and Install (Cast Iron Oil
Electronic Unit Injector - Install ............................. 31
Pan) ................................................................... 113
Turbocharger - Remove ........................................ 36
Balancer - Remove .............................................. 116
Turbocharger - Install ............................................ 37
Balancer - Install .................................................. 118
Wastegate Solenoid - Remove and Install ............ 38
Piston Cooling Jets - Remove and Install ........... 120
Exhaust Manifold - Remove and Install ............... 39
Pistons and Connecting Rods - Remove ............ 121
Exhaust Elbow - Remove and Install ................... 41
Pistons and Connecting Rods - Disassemble ..... 122
Inlet and Exhaust Valve Springs - Remove and
Pistons and Connecting Rods - Assemble ......... 124
Install ................................................................... 42
Pistons and Connecting Rods - Install ................ 126
Inlet and Exhaust Valves - Remove and Install .... 45
Connecting Rod Bearings - Remove (Connecting
Engine Oil Filter Base - Remove and Install ........ 48
rods in position) ................................................. 128
Engine Oil Cooler - Remove ................................. 49
Connecting Rod Bearings - Install (Connecting rods
Engine Oil Cooler - Install ..................................... 50
in position) ......................................................... 129
Engine Oil Relief Valve - Remove and Install (Engines
Crankshaft Main Bearings - Remove and Install
with a Balancer Unit) ........................................... 51
(Crankshaft in position) ..................................... 130
Engine Oil Relief Valve - Remove and Install (Engines
Crankshaft - Remove .......................................... 135
Without a Balancer Unit) ..................................... 53
Crankshaft - Install .............................................. 137
Engine Oil Pump - Remove and Install (Engines
Crankshaft Timing Ring - Remove and Install .... 140
Without a Balancer Unit) ..................................... 54
Crankshaft Gear - Remove and Install .............. 141
Water Pump - Remove ......................................... 56
Bearing Clearance - Check ................................. 142
Water Pump - Install ............................................. 57
Crankshaft Position Sensor - Remove and
Water Temperature Regulator - Remove and Install
Install ................................................................. 143
............................................................................. 58
Coolant Temperature Sensor - Remove and
Flywheel - Remove ............................................... 60
Install ................................................................. 144
Flywheel - Install ................................................... 61
Engine Oil Pressure Sensor - Remove and Install
Crankshaft Pulley - Remove and Install (Engines
........................................................................... 145
With an Automatic Belt Tensioner) ...................... 62
Position Sensor (Fuel Injection Pump) - Remove and
Crankshaft Pulley - Remove and Install (Engines
Install ................................................................. 147
Without an Automatic Belt Tensioner) ................. 63
Fuel Pressure Sensor - Remove and Install ....... 148
Crankshaft Rear Seal - Remove ........................... 64
Boost Pressure Sensor - Remove and Install ..... 149
Crankshaft Rear Seal - Install ............................... 65
Inlet Air Temperature Sensor - Remove and
Crankshaft Wear Sleeve (Rear) - Remove and
Install ................................................................. 150
Install ................................................................... 66
Glow Plugs - Remove and Install ....................... 151
Flywheel Housing - Remove and Install .............. 67
V-Belts - Remove and Install (Engines Without an
Crankshaft Front Seal - Remove and Install ......... 69
Automatic Belt Tensioner ) ................................ 152
Crankshaft Wear Sleeve (Front) - Remove and
Alternator Belt - Remove and Install (Engines With
Install ................................................................... 70
an Automatic Belt Tensioner) ............................ 153
Front Cover - Remove and Install ......................... 72
Fan - Remove and Install ................................... 154
Gear Group (Front) - Remove and Install ............. 73
Fan Drive - Remove and Install ......................... 155
Idler Gear - Remove ............................................. 76
Electronic Control Module - Remove and Install .. 156
Idler Gear - Install ................................................. 79
ECM Mounting Bracket - Remove and Install ..... 158
Housing (Front) - Remove .................................... 81
4 RENR9525
Table of Contents
Alternator - Remove (Engines Without an Automatic

Belt Tensioner) .................................................. 159
Alternator - Remove (Engines With an Automatic Belt
Tensioner) ......................................................... 160
Alternator - Install (Engines Without an Automatic
Belt Tensioner) .................................................. 161
Alternator - Install (Engines With an Automatic Belt
Tensioner) ......................................................... 161
Electric Starting Motor - Remove and Install ..... 162
Air Compressor - Remove and Install ................ 163
Vacuum Pump - Remove and Install .................. 167
Index Section
Index ................................................................... 169
RENR9525 5
Disassembly and Assembly Section
Disassembly and Assembly

Section
i02583374
Fuel Priming Pump - Remove

and Install
(Electric Fuel Priming Pump)
Removal Procedure
NOTICE
ing.
g01269003
Illustration 1
Before begining ANY work on the fuel system, re- Typical example
eral Hazard Information and High Pressure Fuel 3. Disconnect harness assembly (3) from electric
Lines” for safety information. priming pump (4).
Refer to Systems Operation, Testing and Adjust- 4. Disconnect plastic tube assemblies (1) and (2).
ing Manual, “Cleanliness of Fuel System Compo-
nents” for detailed information on the standards Note: If the tube assemblies have quick fit
of cleanliness that must be observed during ALL connections, ensure that the connections are clean
work on the fuel system. before the tube assemblies are plugged.
5. Remove bolts (5) from electric priming pump (4).

NOTICE
Care must be taken to ensure that fluids are contained 6. Remove electric priming pump (4) from the
during performance of inspection, maintenance, test- mounting bracket.
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- Installation Procedure
nent containing fluids.
NOTICE
Dispose of all fluids according to local regulations and Ensure that all adjustments and repairs that are
mandates. carried out to the fuel system are performed by
Note: Put identification marks on all hoses, on all ing.
hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies Before begining ANY work on the fuel system, re-
and tube assemblies. This helps to prevent fluid loss fer to Operation and Maintenance Manual, “Gen-
and this helps to keep contaminants from entering eral Hazard Information and High Pressure Fuel
the system. Lines” for safety information.
1. Isolate the fuel supply. Refer to Systems Operation, Testing and Adjust-
2. Isolate the electrical supply. nents” for detailed information on the standards
of cleanliness that must be observed during ALL
work on the fuel system.
1. Ensure that the electric priming pump is clean and

free from wear or damage. If necessary, replace
the electric priming pump.
6 RENR9525
i02583376
Fuel Priming Pump - Remove

and Install
(Manual Priming Pump)
Removal Procedure
NOTICE
ing.

g01269003
Lines” for safety information.
Illustration 2
Typical example Refer to Systems Operation, Testing and Adjust-
2. Position electric priming pump (4) on the mounting nents” for detailed information on the standards
bracket. Install bolts (5) to the electric priming of cleanliness that must be observed during ALL
pump. work on the fuel system.
3. Tighten bolts (5) to a torque of 9 N·m (79 lb in).

NOTICE
4. Connect plastic tube assemblies (1) and (2) to Care must be taken to ensure that fluids are contained
electric priming pump (4). during performance of inspection, maintenance, test-
Note: If the tube assemblies have quick fit collect the fluid with suitable containers before open-
connections, ensure that the connections are clean ing any compartment or disassembling any compo-
before the tube assemblies are connected. nent containing fluids.
5. Connect harness assembly (3) to electric priming Dispose of all fluids according to local regulations and
pump (4). mandates.
6. Restore the electrical supply. Note: Put identification marks on all hoses, on all
7. Restore the fuel supply. for installation purposes. Plug all hose assemblies
and tube assemblies. This helps to prevent fluid loss
8. Remove the air from the fuel system. Refer to and this helps to keep contaminants from entering
Operation and Maintenance Manual, “Fuel System the system.
- Prime”.
1. Isolate the fuel supply.
2. Drain primary filter (7). Refer to Operation and

Maintenance Manual, “Fuel System Primary Filter
(Water Seperator) Element - Replace”.
RENR9525 7
Installation Procedure
NOTICE
ing.

Refer to Systems Operation, Testing and Adjust-

nents” for detailed information on the standards
1. Ensure that the fuel priming pump is clean and

Illustration 3
g01269012 free from wear or damage. If necessary, replace
the fuel priming pump.
Typical example
3. Disconnect plastic tube assemblies (1).
Note: If the tube assemblies have quick fit

connections, ensure that the connections are clean
before the tube assemblies are plugged.
4. Remove primary filter (7) from fuel priming pump

(4). Refer to Operation and Maintenance Manual,
“Fuel System Primary Filter (Water Seperator)
Element - Replace”.
5. Remove bolts (6) from fuel priming pump (4).

Remove fuel priming pump (4) from the mounting
bracket.
6. If necessary, follow Steps 6.a through 6.c in order

to disassemble the fuel priming pump.
a. Remove connectors (2) from fuel priming pump

(4).
g01269012
Illustration 4
b. Remove plugs (5) from fuel priming pump (4). Typical example
c. Remove O-ring seals (3) from connectors (2) 2. If necessary, follow Steps 2.a through 2.d in order
and plugs (5). to assemble the fuel priming pump (4).
a. Install new O-ring seals (3) to connectors (2)

and plugs (5).
b. Install connectors (2) to the fuel priming pump

(4).
c. Install plugs (5) to fuel priming pump (4).
d. Tighten the plugs and the connectors to a

8 RENR9525
3. Position fuel priming pump (4) on the mounting

bracket. Install bolts (6) to the fuel priming pump . NOTICE
Tighten the bolts to a torque of 44 N·m (32 lb ft). Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
4. Connect plastic tube assemblies (1) to connectors ing, adjusting and repair of the product. Be prepared to
(2). collect the fluid with suitable containers before open-
Note: If the tube assemblies have quick fit nent containing fluids.
before the tube assemblies are connected. Dispose of all fluids according to local regulations and
mandates.
5. Install a new primary filter (7) to fuel priming pump
(4). Refer to Operation and Maintenance Manual,
“Fuel System Primary Filter (Water Seperator) Note: Put identification marks on all hoses, on all
Element - Replace”. hose assemblies, on wires and on all tube assemblies
for installation purposes. Plug all hose assemblies
6. Restore the fuel supply. and tube assemblies. This helps to prevent fluid loss
and this helps to keep contaminants from entering
7. Remove the air from the fuel system. Refer to the system.
Operation and Maintenance Manual, “Fuel System
- Prime”. 1. Isolate the fuel supply.
2. If necessary, remove the boost pressure sensor.

i02583399 Refer to Disassembly and Assembly, “Boost
Pressure Sensor - Remove and Install”.
Fuel Filter Base - Remove and
Install
(Secondary Fuel Filter)
Removal Procedure
Table 1
Required Tools
A - Strap Wrench 1
NOTICE
ing.
g01247416
Illustration 5
Before begining ANY work on the fuel system, re- Typical example
eral Hazard Information and High Pressure Fuel 3. Disconnect plastic tube assemblies (3), (5) and (6)
Lines” for safety information. from fuel filter base (1).
Refer to Systems Operation, Testing and Adjust- Note: If the tube assemblies have quick fit
ing Manual, “Cleanliness of Fuel System Compo- connections, ensure that the connections are clean
nents” for detailed information on the standards before the tube assemblies are plugged.
work on the fuel system. 4. Remove tube assembly (4), if equipped.
5. Use Tooling (A) in order to remove fuel filter (7).

“Fuel System Secondary Filter - Replace”.
RENR9525 9
6. Remove bolts (2) from fuel filter base (1). Remove 4. If necessary, install the boost pressure sensor.
the fuel filter base from the cylinder head. Refer to Disassembly and Assembly, “Boost
Pressure Sensor - Remove and Install”.
Note: Do not attempt to disassemble the fuel filter
base. 5. Install tube assembly (4), if equipped. Tighten the
nuts to a torque of 9 N·m (80 lb in).
NOTICE
NOTICE Ensure that the plastic tube assemblies are installed
Ensure that all adjustments and repairs that are in the original positions. Failure to connect the plastic
carried out to the fuel system are performed by tube assemblies to the correct ports will allow contam-
authorised personnel that have the correct train- ination to enter the fuel system. Contaminated fuel will
ing. cause serious damage to the engine.
Before begining ANY work on the fuel system, re- 6. Connect plastic tube assemblies (3), (5) and (6) to
fer to Operation and Maintenance Manual, “Gen- fuel filter base (1).
Lines” for safety information. Note: If the tube assemblies have quick fit
Refer to Systems Operation, Testing and Adjust- before the tube assemblies are connected.
nents” for detailed information on the standards 7. Restore the fuel supply.
work on the fuel system. 8. Remove the air from the fuel system. Refer to
1. Ensure that the fuel filter base is clean and free - Prime”.
from damage. If necessary, replace the complete
fuel filter base assembly. i02583377
Fuel Transfer Pump - Remove
Removal Procedure
Start By:
a. Remove the mounting bracket for the electronic

control module. Refer to Disassembly and
Assembly, “ECM Mounting Bracket - Remove and
Install”.
NOTICE
ing.
g01247416
Illustration 6 fer to Operation and Maintenance Manual, “Gen-
Typical example eral Hazard Information and High Pressure Fuel
2. Position fuel filter base (1) onto the cylinder head.
Install bolts (2). Tighten the bolts to a torque of Refer to Systems Operation, Testing and Adjust-
22 N·m (16 lb ft). ing Manual, “Cleanliness of Fuel System Compo-
3. Install a new fuel filter (7) to fuel filter base (1). of cleanliness that must be observed during ALL
Refer to Operation and Maintenance Manual, work on the fuel system.
“Fuel System Secondary Filter - Replace” for the
correct procedure.
10 RENR9525
4. Disconnect the plastic tube assembly from inlet

NOTICE connection (7) on the fuel transfer pump.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Note: If the tube assembly has quick fit connections,
ing, adjusting and repair of the product. Be prepared to ensure that the connections are clean before the tube
collect the fluid with suitable containers before open- assembly is plugged.
nent containing fluids. 5. Remove the plastic tube assembly from outlet
connection (2).
Dispose of all fluids according to local regulations and
mandates. 6. Remove outlet connection (2) from fuel transfer
pump (4). Plug the open port in the fuel transfer
pump immediately with a new plug. Remove the
Note: Put identification marks on all hoses, on all O-ring seal from the connection.
for installation purposes. Plug all hose assemblies If necessary, remove the inlet connection (7) from
and tube assemblies. This helps to prevent fluid loss fuel transfer pump (4). Plug the open port in the
and this helps to keep contaminants from entering fuel transfer pump immediately with a new plug.
the system. Remove the O-ring seal from the connection.
2. If necessary, disconnect the hose for the

crankcase breather from the clip that secures the
hose to the engine oil pan. Position the hose away
from the fuel transfer pump.
g01256540
Illustration 8
7. Loosen banjo bolts (3) and (8). Remove tube

assembly (9) for the fuel return from the cylinder
head to the fuel transfer pump.
g01247425 Note: Disconnect the tube assembly at the fuel

Illustration 7
transfer pump first in order to drain the fuel from the
Typical example cylinder head.
3. If necessary, disconnect the harness assembly 8. Remove banjo bolt (3) and sealing washers (10)
from position sensor (1). Refer to Disassembly from tube assembly (9). Remove banjo bolt (8)
and Assembly, “Position Sensor (Fuel Injection and sealing washers (10) from tube assembly (9).
Pump) - Remove and Install”. Position the harness
assembly away from the fuel transfer pump. 9. Use an allen wrench with a ball end in order to
remove allen head screws (6) that secure fuel
Note: If the tube assembly has quick fit connections, transfer pump (4) to fuel injection pump (5).
ensure that the connections are clean before the tube
assembly is plugged.
RENR9525 11
i02583378
Fuel Transfer Pump - Install
NOTICE
ing.
Illustration 9
g01254881 Before begining ANY work on the fuel system, re-
10. Remove the fuel transfer pump from fuel injection eral Hazard Information and High Pressure Fuel
pump (5). Lines” for safety information.
Note: Do not remove dowels (11) from the fuel Refer to Systems Operation, Testing and Adjust-
injection pump. ing Manual, “Cleanliness of Fuel System Compo-
1. Ensure that the mating surfaces of the fuel

injection pump and the fuel transfer pump are
clean and free from damage. Replace any
components that are damaged.
g01254883
Illustration 10
11. Remove O-ring seal (12) from fuel transfer pump

(4).
g01254883
Illustration 11
2. Install a new O-ring seal (12) to fuel transfer pump

(4).
12 RENR9525
g01254881
Illustration 12
3. Align fuel transfer pump (4) with dowels (11) in

fuel injection pump (5). Install the fuel transfer
pump to the fuel injection pump.
g01256540
Illustration 14
6. Install banjo bolt (8) and new sealing washers (10)

to tube assembly (9). Install banjo bolt (3) and new
sealing washers (10) to tube assembly (9).
7. Install tube assembly (9) for the fuel return to

fuel transfer pump (4) and to the cylinder head.
Tighten banjo bolts (3) and (8) to a torque of
22 N·m (16 lb ft).
8. If necessary, install a new O-ring seal to inlet

connection (7). Install inlet connection (7) to fuel
transfer pump (4). Tighten the connection to
Note: If the tube assembly has quick fit connections,

ensure that the connections are clean before the tube
assembly is connected.
g01247425
Illustration 13 9. Install the plastic tube assembly to outlet
connection (2) on the fuel transfer pump.
4. Use an allen wrench with a ball end to install allen
head screws (6). Tighten the allen head screws to 10. Install the plastic tube assembly to inlet
a torque of 30 N·m (22 lb ft). connection (7) on the fuel transfer pump.
5. Install a new O-ring seal to outlet connection (2). 11. If necessary, connect the harness assembly to
Install outlet connection (2) to fuel transfer pump position sensor (1). Refer to Disassembly and
(4). Tighten the connection to torque of 15 N·m Assembly, “Position Sensor (Fuel Injection Pump)
(11 lb ft). - Remove and Install”.
12. If necessary, connect the hose for the crankcase

breather to the clip that secures the hose to the
engine oil pan.
13. Install the mounting bracket for the electronic

control module. Refer to Disassembly and
Assembly, “ECM Mounting Bracket - Remove and
Install”.
RENR9525 13
14. Install the electronic control module. Refer to

Disassembly and Assembly, “Electronic Control NOTICE
Module - Remove and Install”. Care must be taken to ensure that fluids are contained
15. Restore the fuel supply. ing, adjusting and repair of the product. Be prepared to
16. Remove the air from the fuel system. Refer to ing any compartment or disassembling any compo-
Operation and Maintenance Manual, “Fuel System nent containing fluids.
- Prime”.
mandates.
i02583423
Fuel Injection Lines - Remove Note: Put identification marks on all hoses, on all
Removal Procedure and this helps to keep contaminants from entering
the system.
Table 2
Required Tools
Tool
Part
Part Name Qty 2. Isolate the electrical supply.
Number
A U5MK1124 Cap Kit 1

NOTICE
ing.

eral Hazard Information and High Pressure Fuel g01245087
Illustration 15
Typical example
ing Manual, “Cleanliness of Fuel System Compo- 3. Disconnect fuel injection line (3) from electronic
nents” for detailed information on the standards unit injector (2).
work on the fuel system. 4. Disconnect fuel injection line (3) from fuel manifold
(4).
5. Remove fuel injection line (3). Discard the fuel

injection line.
6. Plug the open port in fuel manifold (4) immediately.

Use Tooling (A) in order to plug the open port.
7. Remove seal (1) from electronic unit injector (2)

and from the base of the valve mechanism cover.
14 RENR9525
8. Plug the open port in electronic unit injector (2) i02583440

immediately. Use Tooling (A) in order to plug the
open port. Fuel Injection Lines - Install
9. Repeat Steps 3 through 8 in order to remove the
remaining fuel injection lines from the electronic
unit injectors. Installation Procedure
10. If necessary, remove the crankcase breather. Table 3
Refer to Disassembly and Assembly, “Crankcase Required Tools
Breather - Remove”.
Part
Tool Part Name Qty
11. Remove the electronic control module. Refer to Number
disassembly and Assembly, “Electronic Control A 27610294 Injector Pipe Nut Tool 1
Module - Remove and Install”.
NOTICE
ing.


Note: The following procedure should be adopted

in order to install the fuel injection lines when the
g01254886
electronic unit injectors or the fuel manifold have
Illustration 16 not been removed. If the electronic unit injectors
Typical example or the fuel manifold have been removed, refer to
Disassembly and Assembly, “Electronic Unit Injector
12. Remove bolt (7) from clip (8). - Install” and Disassembly and Assembly, “Fuel
Manifold - Install” for more information.
13. Disconnect fuel injection line (6) from fuel injection
pump (5).
14. Disconnect fuel injection line (6) from fuel

manifold (4).
15. Remove fuel injection line (6). Discard the fuel

injection line. Plug all open ports immediately. Use
Tooling (A) in order to plug the open ports in the
fuel manifold and in the fuel injection pump.
RENR9525 15
g01254886 g01245087
1. Remove the caps from the port in fuel injection

pump (5) and from the appropriate port in fuel
manifold (4). Remove the caps from the new fuel
injection line (6).
2. Loosely connect the nuts at both ends of fuel

injection line (6), to fuel manifold (4) and to fuel
injection pump (5). Ensure that the ends of the
fuel injection line are correctly seated in the fuel
injection pump and in the fuel manifold.
3. Use Tooling (A) to tighten the nuts on fuel injection

line (6) to a torque of 30 N·m (22 lb ft).
g01271377
4. Install bolt (7) to clip (8). Tighten bolt (7) to a Illustration 19
torque of 22 N·m (16 lb ft). Typical example
Ensure that fuel injection line does not contact 7. Install a new seal (1) to electronic unit injector (2)
any other engine component. and to valve mechanism cover base (13).
5. Install the electronic control module. Refer to Note: Ensure that the flange on the seal is flush with
Disassembly and Assembly, “Electronic Control the valve mechanism cover base.
8. Remove the caps from the new fuel injection line
6. If necessary, install the crankcase breather. (3).
Refer to Disassembly and Assembly, “Crankcase
Breather - Install”. Note: Ensure that a dust seal is installed to the fuel
injection line. Install the fuel injection line for number
one cylinder first. Install the fuel injection lines in
numerical order.
9. Remove the caps from electronic unit injector (2)

and from the appropriate port in fuel manifold (4).
16 RENR9525
10. Loosely connect the nuts at both ends of fuel

injection line (3), to electronic unit injector (2) and NOTICE
to the appropriate port in fuel manifold (4). Ensure Ensure that all adjustments and repairs that are
that the ends of the fuel injection line are correctly carried out to the fuel system are performed by
seated in the electronic unit injector and in the authorised personnel that have the correct train-
fuel manifold. ing.
11. Use Tooling (A) to tighten the nuts on fuel injection Before begining ANY work on the fuel system, re-
line (3) to a torque of 30 N·m (22 lb ft). Ensure that fer to Operation and Maintenance Manual, “Gen-
the dust seal is seated correctly against seal (1). eral Hazard Information and High Pressure Fuel
12. Follow Steps 7 through 11 in order to install the
remaining fuel injection lines. Refer to Systems Operation, Testing and Adjust-
Note: Ensure that fuel injection lines do not contact nents” for detailed information on the standards
any other engine component. of cleanliness that must be observed during ALL
13. Restore the fuel supply.
14. Restore the electrical supply. NOTICE

15. Remove the air from the fuel system. Refer to during performance of inspection, maintenance, test-
the Operations and Maintenance Manual, “Fuel ing, adjusting and repair of the product. Be prepared to
System - Prime”. collect the fluid with suitable containers before open-
i02583756
Fuel Manifold (Rail) - Remove Dispose of all fluids according to local regulations and
mandates.
and Install
Note: Put identification marks on all hoses, on all
Removal Procedure and tube assemblies. This helps to prevent fluid loss
Start By: the system.
a. Remove the fuel injection lines. Refer to

Disassembly and Assembly, “Fuel Injection Lines
- Remove”.

g01243702
Illustration 20
The fuel manifold is shown with fuel injection lines in position.
RENR9525 17
1. If necessary, remove fuel pressure sensor (4). Note: Do not install a fuel manifold that has not
Refer to Disassembly and Assembly, “Fuel been capped. All caps must be left in place until the
Pressure Sensor - Remove and Install”. fuel injection lines or the fuel pressure sensor are
installed.
2. If fuel pressure sensor (4) does not require
removal, slide locking tab (3) into the unlocked
position. Disconnect the plug on harness assembly
(7) from fuel pressure sensor (4).
3. Disconnect tube assembly (6) from the fuel

pressure relief valve (5). Immediately cap the
open port in the pressure relief valve with a new
cap. Immediately plug the open end of the tube
assembly with a new plug.
Note: Do not remove the fuel pressure relief valve

from the fuel manifold.
4. Remove bolts (2) from fuel manifold (1). Note the

position of any brackets that are secured by the
bolts.
5. Remove fuel manifold (1) from mounting bracket

(8).
6. If necessary, remove the bolts and remove Illustration 21

g01243702
mounting bracket (8).
The fuel manifold is shown with fuel injection lines in position.
Installation Procedure 2. If necessary, install mounting bracket (8) and

install the bolts. Tighten the bolts to a torque of
Table 4 22 N·m (16 lb ft).
Required Tools
3. Position fuel manifold (1) onto mounting bracket
Part (8). Install bolts (2) to the fuel manifold finger tight.
Tool Part Name Qty
Number Ensure that any brackets that are secured by bolts
A 27610294 Injector Pipe Nut Tool 1 (2) are installed in the correct position.
4. Loosely install a new set of fuel injection lines.

NOTICE Refer to Disassembly and Assembly, “Fuel
Ensure that all adjustments and repairs that are Injection Lines - Install” for more information.
authorised personnel that have the correct train- 5. Tighten bolts (2) to a torque of 22 N·m (16 lb ft).
ing.
6. Use Tooling (A) to tighten the nuts on the fuel
Before begining ANY work on the fuel system, re- injection lines to a torque of 30 N·m (22 lb ft). Refer
fer to Operation and Maintenance Manual, “Gen- to Disassembly and Assembly, “Fuel Injection
eral Hazard Information and High Pressure Fuel Lines - Install” for more information.
7. Remove the plug from tube assembly (6). Remove
Refer to Systems Operation, Testing and Adjust- the cap from the appropriate port in fuel manifold
ing Manual, “Cleanliness of Fuel System Compo- (1). Connect tube assembly (6) to the fuel
nents” for detailed information on the standards pressure relief valve (5).
work on the fuel system. 8. If fuel pressure sensor (4) was removed from
fuel manifold (1), install a new sealing washer
1. Ensure that all ports on the fuel manifold are and install the fuel pressure sensor. Refer to
capped. Ensure that the fuel manifold is externally Disassembly and Assembly, “Fuel Pressure
clean and free from damage. Sensor - Remove and Install” for more information.
18 RENR9525
If fuel pressure sensor (4) was not removed from

fuel manifold (1), connect the plug on harness NOTICE
assembly (7) to fuel pressure sensor (4). Slide Ensure that all adjustments and repairs that are
locking tab (3) into the locked position. carried out to the fuel system are performed by
9. Remove the air from the fuel system. Refer to ing.
- Prime” for more information. Before begining ANY work on the fuel system, re-
i02590384
Fuel Injection Pump - Remove
Removal Procedure work on the fuel system.
Table 5
Required Tools NOTICE
Part
Tool
Number
Part Name Qty during performance of inspection, maintenance, test-
A1 21825576 Crankshaft Turning Tool 1 collect the fluid with suitable containers before open-
27610291 Barring Device Housing 1
A2 nent containing fluids.
27610289 Gear 1
B 27610212 Camshaft Timing Pin 1
mandates.
C 27610211 Crankshaft Timing Pin 1
D U5MK1124 Cap Kit 1 Note: Put identification marks on all hoses, on all
Start By: and tube assemblies. This helps to prevent fluid loss
a. Remove the electronic control module. Refer to the system.
Disassembly and Assembly, “Electronic Control
Module - Remove and Install”. 1. Isolate the fuel supply.
b. Remove the front cover. Refer to Disassembly 2. Isolate the electrical supply.
and Assembly, “Front Cover - Remove and Install”.
3. If necessary, remove the fuel filter base. Refer to
Note: Either Tooling (A) can be used. Use the Tooling Disassembly and Assembly, “Fuel Filter Base -
that is most suitable. Remove and Install”.
4. If necessary, remove the fuel priming pump. Refer

to Disassembly and Assembly, “Fuel Priming
Contact with high pressure fuel may cause fluid Pump - Remove”.
el spray may cause a fire hazard. Failure to fol- 5. If necessary, remove the crankcase breather.
low these inspection, maintenance and service in- Refer to Disassembly and Assembly, “Crankcase
structions may cause personal injury or death. Breather - Remove”.
6. 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”.
RENR9525 19
7. 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.
8. Remove the backlash from the fuel pump gear.

Lock the fuel injection pump in the correct
position and remove the fuel pump gear. Refer to
Disassembly and Assembly, “Fuel Pump Gear -
Remove and Install” for the correct procedure.
g01256934
Illustration 23
Typical example
11. Remove the plastic tube assembly from inlet

connection (13) on fuel transfer pump (8).
12. Remove the plastic tube assembly from outlet

connection (10) on fuel transfer pump (8).
13. Remove the plastic tube assembly from

connection (5) on fuel injection pump (1).
g01263061
Illustration 22
Typical example
9. Disconnect plastic tube assembly (2) from fuel

injection pump (1).
10. Disconnect harness assembly (7) from solenoid

(3). Slide the locking tab into the unlocked position
and disconnect harness assembly (7) from
position sensor (4). If necessary, cut the cable ties
that secure the harness assembly.
Note: The harness assembly should be positioned

in order to avoid an obstruction to the fuel injection
pump. g01256937
Illustration 24
14. Remove tube assembly (12) for the fuel return

from the cylinder head to the fuel transfer pump.
Note: Disconnect the tube assembly at the fuel

transfer pump first in order to drain the fuel from the
cylinder head.
20 RENR9525
15. Remove banjo bolt (11) and sealing washers (15)

from tube assembly (12). Remove banjo bolt (14)
and sealing washers (15) from tube assembly
(12).
16. Plug or cap all open ports and tube assemblies

immediately with new plugs or caps.

17. Remove fuel injection line (6). Refer to

- Remove”. Plug all open ports in the fuel injection
pump and in the fuel manifold with new plugs
immediately. Discard the fuel injection line.
18. Remove tube assembly (9) for the engine oil

supply to the fuel injection pump (1). Remove
the banjo bolt and the sealing washers from tube
assembly (9). Illustration 26
g01254901
Typical example
20. Remove bolts (19) and sealing washers (20).
Note: The fuel injection pump should be supported

by hand as the bolts are removed.
21. Carefully remove fuel injection pump (1) from

front housing (21). Ensure that bore (22) in the
front housing is not damaged as the fuel injection
pump is removed.
22. Remove O-ring seal (23) from fuel injection pump

(1).
23. If necessary, remove position sensor (4) from

fuel injection pump (1). Refer to Disassembly and
Assembly, “Position Sensor (Fuel Injection Pump)
- Remove and Install”.
24. If necessary, remove fuel transfer pump (8) from

g01247430
Illustration 25 fuel injection pump (1). Refer to Disassembly and
Typical example Assembly, “Fuel Transfer Pump - Remove”.
19. Remove bolt (18). Remove bolts (16) and remove

support bracket (17) from fuel injection pump (1).
RENR9525 21
i02590409
Fuel Injection Pump - Install
Table 6
Required Tools
Part
A 1
21825576 Crankshaft Turning Tool 1
A2
27610289 Gear 1
Fuel Injection Pump g01254907
E 27610302 1 Illustration 27
Timing Tool
POWERPART -
1. If the fuel injection pump was previously
F 21820221
Rubber Grease disassembled, follow Steps 1.a and 1.b in order to
assemble the fuel injection pump.
Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable. a. Install fuel transfer pump (8) to fuel injection
pump (1). Refer to Disassembly and Assembly,
“Fuel Transfer Pump - Install”.
NOTICE
Ensure that all adjustments and repairs that are b. Install position sensor (4) to fuel injection pump
carried out to the fuel system are performed by (1). Refer to Disassembly and Assembly,
authorised personnel that have the correct train- “Position Sensor (Fuel Injection Pump) -
ing. Remove and Install”.
Before begining ANY work on the fuel system, re- Note: A new fuel injection pump assembly includes
fer to Operation and Maintenance Manual, “Gen- the fuel transfer pump and the position sensor.
Lines” for safety information. 2. To check the fuel injection pump timing, follow
Steps 2.a and 2.b.
ing Manual, “Cleanliness of Fuel System Compo- a. Position Tooling (E) onto shaft (24) of the fuel
nents” for detailed information on the standards injection pump. Align the lever of Tooling (E)
of cleanliness that must be observed during ALL with key slot (25). Engage the lever into the
work on the fuel system. key slot.
b. Insert the locking pin of Tooling (E) into hole

(26) in fuel injection pump.
If the locking pin can be inserted into the hole,

the fuel injection pump timing is correct.
If the locking pin cannot be inserted into the

hole, the fuel injection pump timing is not
correct.
Note: There should be no resistance when the

locking pin is inserted.
3. If the fuel injection pump timing has been lost

follow Steps 3.a through 3.e in order to reset the
fuel injection pump timing.
22 RENR9525
a. If necessary, loosen locking screw (27) on 6. Align the holes in fuel injection pump (1) with the
the fuel injection pump. Slide spacer (28) into holes in front housing (21). Carefully install the
position (Z1). Tighten locking screw (27) to a fuel injection pump to the front housing.
torque of 9 N·m (80 lb in). This will prevent
the locking screw from tightening against shaft Note: The fuel injection pump should be supported
(24). by hand until the bolts are installed.
The fuel injection pump is now unlocked. 7. Install bolts (19) and new sealing washers (20).
Tighten the bolts to a torque of 25 N·m (18 lb ft).
b. Position Tooling (E) onto shaft (24) of the fuel
injection pump. Align the lever of Tooling (E) 8. If necessary, use Tooling (A) in order to rotate the
with key slot (25) in the fuel injection pump. crankshaft so that number one piston is at top
Engage the lever into the key slot. dead center on the compression stroke. Refer
to Systems Operation, Testing and Adjusting,
c. Use the lever of Tooling (E) to rotate shaft (24) “Finding Top Centre Position for No.1 Piston”.
until the pin of Tooling (E) can be engaged into
hole (26). Engage the pin of Tooling (E) into 9. Use Tooling (B) in order to lock the camshaft in
the hole. the correct position. Use Tooling (C) in order to
lock the crankshaft in the correct position. Refer to
d. Loosen locking screw (27) in the fuel injection Disassembly and Assembly, “Gear Group (Front)
pump. Slide spacer (28) into position (Z2). - Remove” for the correct procedure.
Tighten locking screw (27) against the shaft of
the fuel injection pump to a torque of 9 N·m 10. Install the fuel injection pump gear to the fuel
(80 lb in). injection pump. Refer to Disassembly and
Assembly, “Fuel Injection Pump Gear - Install”
The fuel injection pump is now correctly timed and refer to Disassembly and Assembly, “Gear
and locked. Group (Front) - Install”.
e. Remove tooling (E). Note: Ensure that spacer (28) on the fuel injection
pump is in the unlocked position (Z1) after the
installation of fuel injection pump gear is completed.
Refer to Illustration 27.
11. Install the front cover. Refer to Disassembly and

Assembly, “Front Cover - Remove and Install”.
g01254901
Illustration 28
4. Inspect bore (22) in front housing (21) for

damage. If the bore is damaged, replace the front
housing. Refer to Disassembly and Assembly,
“Housing (Front) - Remove” and Disassembly and
g01247430
Assembly, “Housing (Front) - Install”. Illustration 29
Typical example
5. Use Tooling (F) to lubricate a new O-ring seal (23).
Install the O-ring seal onto fuel injection pump (1).
RENR9525 23
12. Position support bracket (17) against fuel injection

pump (1). Install bolts (16) finger tight.
13. Install bolt (18) finger tight.
14. Tighten bolt (18) to a torque of 44 N·m (32.5 lb ft).

Tighten bolts (16) to a torque of 22 N·m (16 lb ft).
Note: Ensure that the fuel injection pump is not

stressed as the bolts for the bracket are tightened.
g01256937
Illustration 31
16. Install banjo bolt (11) and new sealing washers

(15) to tube assembly (12). Install banjo bolt (14)
and new sealing washers (15) to tube assembly
(12).
17. Install tube assembly (12) for the fuel return

from the cylinder head to the fuel transfer pump.
Tighten both banjo bolts (11) finger tight.
g01256934
Illustration 30
Typical example
18. Tighten banjo bolts (11) and (14) to a torque of
22 N·m (16 lb ft).
15. Remove the appropriate plugs and caps in order
to install tube assembly (9) for the engine oil
supply to the fuel injection pump. Install the banjo
bolt and new sealing washers to tube assembly
(9). Install tube assembly (9) to the fuel injection
pump and to the cylinder head. Tighten the banjo
bolt to a torque of 15 N·m (11 lb ft). Tighten the nut
to a torque of 15 N·m (11 lb ft).
24 RENR9525
25. Install plastic tube assembly (2) to the fuel

injection pump.
26. Install the electronic control module. Refer to

27. If necessary, install the fuel filter base. Refer to

Disassembly and Assembly, “Fuel Filter Base -
Remove and Install”.
28. If necessary, install the fuel priming pump. Refer

to Disassembly and Assembly, “Fuel Priming
Pump - Remove and Install”.
29. Turn the fuel supply to the ON position.
30. Turn the battery disconnect switch to the ON

position.
31. Remove the air from the fuel system. Refer to

- Prime” for more information.
i02590469
Fuel Injection Pump Gear -

Illustration 32
g01263061
Remove
Typical example
19. Remove the appropriate caps in order to install

the fuel injection line (6). Install a new fuel injection Removal Procedure
line (6) to the fuel injection pump and to the fuel
manifold. Refer to Disassembly and Assembly, Table 7
“Fuel Injection Lines - Install”.
Required Tools
20. Remove the plugs and caps from the remaining Part
Tool Part Name Qty
ports and tube assemblies. Number
A1 21825576 Crankshaft Turning Tool 1
connections, ensure that the connections are clean 27610291 Barring Device Housing 1
before the tube assemblies are installed. A2
27610289 Gear 1
21. Install the plastic tube assembly to connection (5) B 27610212 Camshaft Timing Pin 1
on the fuel injection pump.
22. Install the plastic tube assembly to outlet D - Puller (Two Leg) 1
connection (10) on the fuel transfer pump. Refer
to Illustration 30.
Start By:
23. Install the plastic tube assembly to inlet
connection (13) on the fuel transfer pump. Refer a. Remove the front cover. Refer to Disassembly and
to Illustration 30.
24. Connect harness assembly (7) to solenoid (3) Note: Either Tooling (A) can be used. Use the Tooling
that is most suitable.
on the fuel injection pump. Connect harness
assembly (7) to position sensor (4) on the fuel
injection pump. Slide the locking tab into the
locked position. Secure the harness assembly
with new cable ties.
RENR9525 25
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 fuel pump gear. Carefully follow the
procedure in order to remove the fuel pump gear.
1. Use Tooling (A) in order to rotate the crankshaft so g01247434

Illustration 34
that number one piston is at the top center position Typical example
Operation, Testing and Adjusting, “Finding Top 4. Apply sufficient pressure to fuel injection pump
Centre Position for No.1 Piston”. gear (3) in a counterclockwise direction in order
to remove the backlash. Lock fuel injection pump
(5) in this position.
In order to lock the fuel injection pump (5), loosen

locking screw (6) in the fuel injection pump. Slide
spacer (7) into position (Z2). Tighten locking screw
(6) against the shaft of the fuel injection pump to a
torque of 9 N·m (80 lb in).
g01247433
Illustration 33
Typical example g01247435
Illustration 35
2. Install Tooling (B) through hole (X) in camshaft Alignment of timing marks
gear (1) into the front housing. Use Tooling (B) in
order to lock the camshaft in the correct position. 5. Mark gears (1), (2) and (3) in order to show
alignment. Refer to Illustration 35.
3. Install Tooling (C) into hole (Y) in the front housing.
Use Tooling (C) in order to lock the crankshaft in Note: Identification will ensure that the gears can be
the correct position. installed in the original alignment.
26 RENR9525
1. Ensure that number one piston is at the top center

position on the compression stroke. Refer to
the Systems Operation, Testing and Adjusting,
“Finding Top Center Position for No. 1 Piston”.
g01247436
Illustration 36
6. Loosen nut (8) on fuel pump gear (3).
7. Install Tooling (D) through two opposite holes in Illustration 37

g01247475
fuel pump gear (3). Tighten Tooling (D) until the Typical example
fuel pump gear is released.
2. Ensure that Tooling (C) is installed in hole (Y) in
8. Remove Tooling (D) from fuel pump gear (3). the front housing. Use Tooling (C) in order to lock
the crankshaft in the correct position.
9. Remove nut (8) and the washer from fuel pump
gear (3). Remove the fuel pump gear. 3. Ensure that Tooling (B) is installed into hole (X) in
camshaft gear (1).
i02585395
4. Ensure that shaft (9) on the fuel injection pump is
Fuel Injection Pump Gear - clean, dry and free from damage.
Install 5. Ensure that the fuel injection pump is locked in
the correct position. Refer to Disassembly and
Assembly, “Fuel Injection Pump - Install”.
Installation Procedure 6. Ensure that the fuel pump gear is clean, dry and
free from wear or damage. If necessary, replace
Table 8 the fuel pump gear.
Required Tools
Part
Tool Part Name Qty
Number
21825617 Dial Indicator Group 1
E
- Finger Clock 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened g01247435

Illustration 38
component life.
Alignment of timing marks
Note: The fuel injection pump must remain locked 7. Install fuel pump gear (3) to shaft (9) of the fuel
until the procedure instructs you to unlock the fuel injection pump. Ensure that the timing marks on
injection pump. gears (2) and (3) are in alignment and that the
mesh of the gears is correct.
RENR9525 27
11. Use Tooling (E) 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:
a. Install the front cover. Refer to Disassembly and

i02590481
g01247478
Illustration 39
Typical example
Electronic Unit Injector -
Remove
Removal Procedure
Table 9
Required Tools
A 1
A2
27610289 Gear 1
B 27610307 T40 Torx Socket 1
C 27610288 Pry Bar 1
Start By:
Illustration 40
g01247434 a. Remove the valve mechanism cover. Refer to
Typical Disassembly and Assembly, “Valve Mechanism
Cover - Remove and Install”.
8. Install a new spring washer (10) and install nut
(8) to shaft (9) of the fuel injection pump. Apply Note: Either Tooling (A) can be used. Use the Tooling
sufficient pressure to the fuel injection pump gear that is most suitable.
(3) in a counterclockwise direction in order to
remove the backlash. Tighten nut (8) to a torque
of 25 N·m (18 lb ft). Unlock the fuel injection pump
(5). Contact with high pressure fuel may cause fluid
In order to unlock the fuel injection pump, loosen el spray may cause a fire hazard. Failure to fol-
locking screw (6) on the fuel injection pump. Slide low these inspection, maintenance and service in-
spacer (7) into position (Z1). Tighten the locking structions may cause personal injury or death.
screw against the spacer to a torque of 9 N·m
(80 lb in). This will prevent the locking screw from
tightening against the shaft of the fuel injection
pump.
9. Remove Tooling (B) and (C).
10. Tighten nut (8) to a torque of 90 N·m (66.4 lb ft).

28 RENR9525
NOTICE
ing.


nents” for detailed information on the standards g01269378
Illustration 41
work on the fuel system. Typical example
3. Use Tooling (A) in order to rotate the crankshaft

NOTICE until rocker arms (1) for the appropriate cylinder
Care must be taken to ensure that fluids are contained are in the correct position in order to adjust
during performance of inspection, maintenance, test- the valve lash. Refer to Systems Operation,
ing, adjusting and repair of the product. Be prepared to Testing and Adjusting, “Engine Valve Lash -
collect the fluid with suitable containers before open- Inspect/Adjust”.
nent containing fluids. 4. Follow Steps 4.a through 4.c in order to gain
access to the electronic unit injector.
mandates. a. Loosen nuts (3) for the appropriate cylinder.
Unscrew adjusters (2) for the appropriate
cylinder until pushrods (4) can be withdrawn
NOTICE from the balls of the adjusters.
Use a deep socket in order to remove the electrical
connections from the electronic unit injectors. Use of b. Withdraw the cups of pushrods (4) from the
incorrect tooling will result in damage to the electronic balls of adjusters (2).
unit injectors.
c. Make a temporary mark on valve bridges (5)
Note: Put identification marks on all hoses, on all in order to show the location and orientation.
hose assemblies, on wires and on all tube assemblies Remove the valve bridges from the cylinder
for installation purposes. Plug all hose assemblies head.
and this helps to keep contaminants from entering Note: Identification will ensure that the valve bridges
the system. can be reinstalled in the original location and the
original orientation. Do not interchange the location
1. Isolate the fuel supply to the engine. or the orientation of used valve bridges.
2. Isolate the electrical supply to the engine.

RENR9525 29
9. Place a temporary identification mark on the

electronic unit injector. The electronic unit injector
must be reinstalled in the original location in the
cylinder head.
g01247489
Illustration 42
Typical example
5. Loosen banjo bolt (7) sufficiently in order to allow

the fuel to drain from tube assembly (6).
g01255700
Illustration 44
The rocker shaft is not shown for clarity.
10. Use Tooling (C) to pry beneath clamp (13) and

free electronic unit injector (11) from the cylinder
head.
11. Remove electronic unit injector (11) and clamp

(13) from the cylinder head.
Note: Always handle electronic unit injectors with

care.
g01255699
Illustration 43
6. Remove the fuel injection line and remove seal

(8) from the appropriate electronic unit injector
(11). Refer to Disassembly and Assembly, “Fuel
Injecton Lines - Remove”.
Note: Cap all open ports immediately with new caps.
7. Use a deep socket to remove connections (10)

g01255701
from electronic unit injector (11). Illustration 45
Typical example
8. Slide rocker arms (1) to one side in order to gain
access to torx screw (12). Use Tooling (B) in order 12. Remove sealing washer (14). Remove O-ring
to remove the torx screw from clamp (13). Discard seal (15) from the electronic unit injector.
the torx screw.
30 RENR9525
Alternative Removal Procedure

NOTICE
Table 10
Required Tools during performance of inspection, maintenance, test-
B 27610307 T40 Torx Socket 1 ing any compartment or disassembling any compo-
C 27610288 Pry Bar 1
Start By: mandates.
a. Remove the rocker shaft assembly. Refer to

Disassembly and Assembly, “Rocker Shaft - NOTICE
Remove”. Use a deep socket in order to remove the electrical
connections from the electronic unit injectors. Use of
b. Remove the fuel injection lines. Refer to incorrect tooling will result in damage to the electronic
Disassembly and Assembly, “Fuel Injecton Lines - unit injectors.
Remove”.
Note: This is an optional procedure to remove the hose assemblies, on wires and on all tube assemblies
electronic unit injectors. The method should ONLY be for installation purposes. Plug all hose assemblies
used when all electronic unit injectors are removed and tube assemblies. This helps to prevent fluid loss
and when the engine is removed from the application. and this helps to keep contaminants from entering
the system.
1. Isolate the fuel supply to the engine.

penetration and burn hazards. High pressure fu- 2. Isolate the electrical supply to the engine.
NOTICE
ing.

Lines” for safety information. g01247489
Illustration 46
Refer to Systems Operation, Testing and Adjust- Typical example
nents” for detailed information on the standards 3. Loosen banjo bolt (7) sufficiently in order to allow
of cleanliness that must be observed during ALL the fuel to drain from tube assembly (6).
RENR9525 31
9. Remove electronic unit injector (11) and clamp

(13) from the cylinder head.
Note: Always handle electronic unit injectors with

care.
g01255701
Illustration 49
Illustration 47
g01255699 Typical example
4. Place a temporary identification mark on 10. Remove sealing washer (14). Remove O-ring
connections (10) for harness assembly (9). seal (15) from the electronic unit injector.
5. Use a deep socket to remove connections (10) 11. Repeat Steps 4 through 11 in order to remove the
from electronic unit injector (11). remaining electronic unit injectors.
6. Use Tooling (B) in order to remove torx screw (12) i02585456

from clamp (13). Discard the torx screw.
Electronic Unit Injector - Install
electronic unit injector. The electronic unit injector
must be reinstalled in the original location in the
cylinder head.
Table 11
Required Tools
Tool Part Part Description Qty
Number
GE50028 Vacuum Pump 1
D Tube
GE50030 1
7.9 mm (0.31 inch) OD
E 27610294 Injector Pipe Nut Tool 1
F 27610296 Torque Wrench 1
g01255700
Illustration 48
8. Use Tooling (C) to pry beneath clamp (13) and free

electronic unit injector (11) from the cylinder head.
32 RENR9525
1. If a replacement electronic unit injector is installed,

NOTICE the correct injector trim file must be programmed
Ensure that all adjustments and repairs that are into the electronic control module. Refer to
carried out to the fuel system are performed by Troubleshooting, “Injector Trim File” for more
authorised personnel that have the correct train- information. The code that is required to obtain
ing. the injector trim file is located at position (X).
Before begining ANY work on the fuel system, re- Note: Record code (X) before the electronic unit
fer to Operation and Maintenance Manual, “Gen- injector is installed.
Lines” for safety information. 2. Use Tooling (D) in order to remove any fuel from
the cylinder.
ing Manual, “Cleanliness of Fuel System Compo- Note: Evacuate as much fuel as possible from the
nents” for detailed information on the standards cylinder before installing the electronic unit injector.
work on the fuel system. 3. Ensure that the fuel inlet port of the electronic unit
injector is capped. Ensure that the electronic unit
injector is clean.
NOTICE

mandates.
NOTICE
incorrect tooling will result in damage to the electronic Illustration 51
g01255701
unit injectors.
4. Install a new O-ring seal (15) to electronic unit
injector (11).
Note: Do not lubricate the O-ring seal.
5. Ensure that the seat for the electronic unit injector

in the cylinder head is clean and free from
damage. Position a new sealing washer (14)
onto the seat for the electronic unit injector in the
cylinder head.
g01255702
Illustration 50
Typical calibration code
RENR9525 33
g01263415
Illustration 53
Typical example
12. Install valve bridges (5) to the cylinder head.
Note: Ensure that used valve bridges are reinstalled

Illustration 52
g01255699 in the original location and the original orientation.
Do not interchange the location or the orientation of
used valve bridges.
6. Position clamp (13) between the rocker arm and 13. Ensure that the bottoms of the pushrods are
the valve springs. Align electronic unit injector (11) seated in the cups of the valve lifters. Locate the
to the bore for the electronic unit injector in the balls of adjusters (2) into the cups of pushrods
cylinder head. Install the clamp to the electronic (4). Adjust the valve lash. Refer to Systems
unit injector. Ensure that the electronic unit injector Operation, Testing and Adjusting, “Engine Valve
is pushed firmly against the seat in the cylinder Lash - Inspect/Adjust”.
head.
14. Use a deep socket to install harness assembly
7. Install a new torx screw (12) to clamp (13). Tighten (9) to electronic unit injector (11). Use Tooling (F)
the torx screw finger tight. to tighten connections (10) to a torque of 2.4 N·m
(21 lb in).
8. Remove the cap from electronic unit injector (11).
Install a new seal (8) to electronic unit injector (11)
and to the valve mechanism cover base. Ensure
that the flange on the seal is flush with the valve
mechanism cover base.
9. Remove the plugs from the new fuel injection

line. Loosely install the fuel injection line. Refer to
Disassembly and Assembly, “Fuel Injecton Lines -
Install”.
Note: Ensure that the ends of the fuel injection line

are seated in the electronic unit injector and the fuel
manifold. Tighten the nuts finger tight.
10. Use Tooling (B) to tighten torx screw (12) to a Illustration 54

g01247489
Typical example
11. Use Tooling (E) to tighten the fuel injection line to

15. Tighten banjo bolt (7) for tube assembly (6).
a torque of 30 N·m (22 lb ft). Refer to Disassembly
Tighten the banjo bolt to a torque of 22 N·m
and Assembly, “Fuel Injecton Lines - Install”.
(16 lb ft).
16. Install the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism
17. Restore the fuel supply to the engine.

34 RENR9525
18. Restore the electrical supply to the engine.

NOTICE
19. Remove the air from the fuel system. Refer to Use a deep socket in order to remove the electrical
Operation and Maintenance Manual, “Fuel System connections from the electronic unit injectors. Use of
- Prime” for more information. incorrect tooling will result in damage to the electronic
unit injectors.
Alternative Installation Procedure
Table 12
Required Tools
Number
GE50028 Vacuum Pump 1
D Tube
GE50030 1
7.9 mm (0.31 inch) OD
E 27610294 Injector Pipe Nut Tool 1
F 27610296 Torque Wrench 1
Note: This is an optional procedure to install the

electronic unit injectors. The method should ONLY be
used when all electronic unit injectors are installed
and when the engine is removed from the application.
g01255702
NOTICE Illustration 55
Ensure that all adjustments and repairs that are Typical calibration code
authorised personnel that have the correct train- 1. If a replacement electronic unit injector is installed,
ing. the correct injector trim file must be programmed
into the electronic control module. Refer to
Before begining ANY work on the fuel system, re- Troubleshooting, “Injector Trim File” for more
fer to Operation and Maintenance Manual, “Gen- information. The code that is required to obtain
eral Hazard Information and High Pressure Fuel the injector trim file is located at position (X).
Note: Record code (X) before the electronic unit
Refer to Systems Operation, Testing and Adjust- injector is installed.
nents” for detailed information on the standards 2. Use Tooling (D) to remove any fuel from the
of cleanliness that must be observed during ALL cylinder.
Note: Evacuate as much fuel as possible from the
cylinder before installing the electronic unit injector.
NOTICE
Care must be taken to ensure that fluids are contained 3. Ensure that the fuel inlet port of the electronic unit
during performance of inspection, maintenance, test- injector is capped. Ensure that the electronic unit
ing, adjusting and repair of the product. Be prepared to injector is clean.

mandates.
RENR9525 35
8. Remove the cap from electronic unit injector (11).

Install a new seal (8) to electronic unit injector (11)
and to the valve mechanism cover base. Ensure
that the flange on the seal is flush with the valve
9. Remove the plugs from the new fuel injection

line. Loosely install the fuel injection line. Refer to
Disassembly and Assembly, “Fuel Injecton Lines -
Install”.
Note: Ensure that the ends of the fuel injection line

are seated in the electronic unit injector and the fuel
manifold. Tighten the nuts finger tight.
g01255701
Illustration 56 10. Use Tooling (B) to tighten torx screw (12) to a
4. Install a new O-ring seal (15) to electronic unit
injector (11). 11. Use Tooling (E) to tighten the fuel injection line to
a torque of 30 N·m (22 lb ft). Refer to Disassembly
Note: Do not lubricate the O-ring seal. and Assembly, “Fuel Injecton Lines - Install”.
5. Ensure that the seat for the electronic unit injector 12. Repeat Steps 2 through 11 in order to install the
in the cylinder head is clean and free from remaining electronic unit injectors.
damage. Position a new sealing washer (14)
on the seat for the electronic unit injector in the 13. Use a deep socket to install harness assemblies
cylinder head. (9) to electronic unit injectors (11). Use Tooling (F)
to tighten connections (10) to a torque of 2.4 N·m
(21 lb in).
14. Install the rocker shaft assembly. Refer to

Disassembly and Assembly, “Rocker Shaft -
Install”.
g01247489
g01255699 Illustration 58
Illustration 57
Typical example
6. Install clamp (13) to electronic unit injector (11).
Install the electronic unit injector assembly into the 15. Tighten banjo bolt (7) for tube assembly (6).
original location in the cylinder head. Tighten the banjo bolt to a torque of 22 N·m
(16 lb ft).
Note: Ensure that the electronic unit injector is
pushed firmly against the seat in the cylinder head. 16. Restore the fuel supply to the engine.
Install the electronic unit injector for number one
cylinder first. Install the electronic unit injectors in 17. Restore the electrical supply to the engine.
numerical order.
18. Remove the air from the fuel system. Refer to
7. Install a new torx screw (12) to clamp (13). Tighten Operation and Maintenance Manual, “Fuel System
the torx screw finger tight. - Prime” for more information.
36 RENR9525
i02585942
Turbocharger - Remove
Removal Procedure
NOTICE

component life.
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 -
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. Illustration 59
g01264131
Typical example
4. If the valve mechanism cover is equipped with a
heat shield, remove the heat shield.
5. If the turbocharger is equipped with an adapter
(9), Remove nuts (10) and remove adapter (9)
from turbocharger (5).
6. Remove banjo bolt (1) and disconnect tube

assembly (3) from turbocharger (5). Remove
sealing washers (2) from tube assembly (3).
If necessary, remove tube assembly (3) from the

tube assembly for actuator (6). Tube assembly (3)
is secured to the tube assembly for the actuator
by clips.
7. Disconnect the hose from the actuator (6).

RENR9525 37
8. Remove banjo bolt (4) and remove tube assembly

(3) from the cylinder block. Remove sealing
washers (2) from tube assembly (3).
9. Remove bolts (12). Disconnect tube assembly

(13) from turbocharger (5). Remove joint (11).
If necessary, remove bolts (14) and remove tube

assembly (13) from the cylinder block. Remove
joint (15).
If tube assembly (13) 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”.
10. Remove nuts (8) and remove turbocharger (5).
Note: Do not use the actuator rod to lift the

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

manifold.
i02590550
Turbocharger - Install
Table 13
Required Tools
Tool Part Number Part Description Qty g01264131
Illustration 60
POWERPART Typical example
A 21820117 1
Threadlock and Nutlock
2. Test the actuator (6) for correct operation. Refer
NOTICE
“Turbacharger - Inspect”. If the actuator is
damaged or the actuator does not operate within
the specified limits, the complete turbocharger
must be replaced.
component life.
3. Clean the mating surfaces of the exhaust manifold.
1. Ensure that the turbocharger is clean and free If necessary, install the studs to the exhaust
from damage. Inspect the turbocharger for manifold. Tighten the studs to a torque of 18 N·m
wear. Refer to Systems Operation, Testing and (13 lb ft).
Adjusting, “Turbacharger - Inspect” for more
information. If the turbocharger is worn, the 4. Install a new gasket (7) to the exhaust manifold.
complete turbocharger must be replaced.
5. Position turbocharger (5) onto the exhaust
manifold and install nuts (8). Tighten the nuts to a
38 RENR9525
Note: Do not use the actuator rod to lift the If the engine has an air pipe, install the air pipe
turbocharger. and install the joint to the cylinder head. Apply
Tooling (A) to the fasteners for the air pipe. Tighten
6. Position a new joint (11) and tube assembly (13) the fasteners to a torque of 22 N·m (16 lb ft).
onto turbocharger (5). Install bolts (12) finger tight.
Tighten the hose clamps to a torque of 5 N·m
7. Position a new joint (15) onto the cylinder block. (44 lb in).
Install bolts (14) finger tight.
Note: If the air outlet hose has a reflective heat
8. Tighten bolts (12) to a torque of 22 N·m (16 lb ft). shield, ensure that the reflective heat shield is
Tighten bolts (14) to a torque of 22 N·m (16 lb ft). installed toward the engine.
If tube assembly (13) is secured with tube clips, 18. Connect the air inlet hose to turbocharger (5).
tighten the fasteners for the tube clips to a torque
of 44 N·m (32 lb ft). 19. If the valve mechanism cover has a heat shield,
install the heat shield. Tighten the fasteners for
9. Lubricate the bearings of turbocharger (5) with the heat shield to a torque of 9 N·m (80 lb in).
clean engine oil through the oil inlet port. Rotate
the shaft of the turbocharger in order to distribute
i02585944
the lubricant.
10. Position tube assembly (3) onto turbocharger (5).

Wastegate Solenoid - Remove
Install new washers (2) and banjo bolt (1) to tube and Install
assembly (3). Tighten the banjo bolt finger tight.
11. Install new washers (2) and banjo bolt (4) onto
tube assembly (3). Connect the tube assembly to Removal Procedure
the cylinder block. Tighten the banjo bolt finger
tight. Note: Put identification marks on all hoses, on
all hose assemblies, on wires and on all tube
12. Tighten banjo bolts (1) and (4) to a torque of assemblies for installation purposes. Plug all hose
18 N·m (13 lb ft). assemblies and tube assemblies. This helps to keep
contaminants from entering the system.
Note: Ensure that the tube assembly does not come
into contact with any other engine components.
13. Connect the hose to actuator (6). If necessary,

secure tube assembly (3) to the tube assembly for
actuator (6). Tube assembly (3) is secured to the
tube assembly for the actuator by clips.
14. If the turbocharger has an adapter (9), position

the adapter onto the turbocharger. Install nuts (10)
finger tight.
15. If the turbocharger has an exhaust elbow, install

the exhaust elbow. Refer to Disassembly and
Assembly, “Exhaust Elbow - Remove and Install”.
g01247498
Illustration 61
16. If the turbocharger has an adapter (9), tighten the
Typical example
three nuts (10) progressively. Tighten the nuts to a
1. Follow Steps 1.a through 1.d in order to disconnect
the harness assembly for the wastegate solenoid.
Note: Ensure that the adapter is square with the
mating face of the turbocharger.
a. Slide locking tab (1) into the unlocked position.
17. Connect the air outlet hose to turbocharger (5).
b. Disconnect plug (2) from the engine wiring
harness.
c. Cut cable tie (3).

RENR9525 39
d. Remove harness assembly (4) from tube 2. Loosely install tube assembly (8) to wastegate
assembly (5). The harness assembly is secured solenoid (7).
to the tube assembly by plastic clips (6).
3. Install bolts (9). Tighten bolts (9) to a torque of
22 N·m (16 lb ft).
4. Tighten tube assemblies (5) and (8) to a torque of

18 N·m (13 lb ft).
5. Secure tube assembly (8) to the tube assembly for

the oil feed for the turbocharger. Tube assembly
(8) is secured by spring clips.
Note: Ensure that the tube assemblies do not contact

any other engine component.
g01247569
Illustration 62
Typical example
2. Disconnect tube assembly (5) from wastegate

solenoid (7).
3. Disconnect tube assembly (8) from wastegate

solenoid (7). Remove tube assembly (8) from the
tube assembly for the oil feed for the turbocharger.
Tube assembly (8) is secured to the tube assembly
for the oil feed for the turbocharger by spring clips.
g01247498
Note: Tube assembly (8) must be loose in order Illustration 64
to release the tube assembly from the wastegate Typical example
solenoid.
6. Follow Steps 6 through 6.d in order to connect the
4. Remove the two bolts (9) and remove wastegate wire lead for the wastegate solenoid.
solenoid (7) from the cylinder block.
a. Install harness assembly (4) to tube assembly
5. Remove bolts (9) and remove wastegate solenoid (5). The harness assembly is secured to the
(7) from the cylinder block. tube assembly by plastic clips (6).
b. Connect plug (2) to the engine harness

Installation Procedure assembly.
c. Slide locking tab (1) into the locked position.
d. Install a new cable tie (3).
i02585962
Exhaust Manifold - Remove

and Install
g01247569
Removal Procedure
Illustration 63
Typical example Start By:
1. Loosely install wastegate solenoid (7) to tube a. Remove the turbocharger. Refer to Disassembly
assembly (5). and Assembly, “Turbocharger - Remove”.
40 RENR9525
Table 14
Required Tools
Part
Tool Part Description Qty
Number
- Guide Stud
A 2
(M10 by 100 mm)
g01245092
Illustration 65
Typical example
g01245092
Illustration 67
Typical example
1. Ensure that the exhaust manifold is clean and free

from damage. If necessary, replace the exhaust
manifold. Clean the joint face of the cylinder head.
Illustration 66
g01264513 2. If necessary, install studs (2) to exhaust manifold
(3). Tighten the studs to a torque of 18 N·m
Tightening sequence for the exhaust manifold
(13 lb ft).
1. Loosen bolts (4) in reverse numerical order to the
sequence that is shown in Illustration 66.
Note: This will help prevent distortion of the exhaust

manifold.
2. Remove bolts (4) from exhaust manifold (3).
Note: Support the manifold as the bolts are removed.
3. Remove exhaust manifold (3).
4. Remove exhaust manifold gasket (1).
5. If necessary, remove studs (2) from exhaust Illustration 68

g01245093
manifold (3).
Tightening sequence for the exhaust manifold
3. Install Tooling (A) to the cylinder head in positions

(X). Refer to Illustration 68.
RENR9525 41
4. Position a new exhaust manifold gasket (1) onto 1. Remove bolts (5) and remove exhaust elbow (2)
Tooling (A). from turbocharger (1). Note the orientation of the
exhaust elbow.
Note: Ensure that the exhaust manifold gasket is
correctly oriented. 2. Remove coupling (4) that connects exhaust elbow
(2) to turbocharger (1).
5. Align exhaust manifold (3) with Tooling (A). Install
the exhaust manifold to the cylinder head. 3. If necessary, remove bolts (6) and remove support
bracket (3) from the cylinder block.
Note: If the engine has a top mounted turbocharger,
the tube assembly for the oil drain from the Installation Procedure
turbocharger must be connected to the cylinder block
before the exhaust manifold is installed.
6. Install new bolts (4) finger tight.
7. Remove Tooling (A). Install the remaining bolts

(4) finger tight.
8. Tighten bolts (4) to a torque of 33 N·m (24 lb ft) in

the sequence that is shown in Illustration 68.
End By:
a. Install the turbocharger. Refer to Disassembly and

Assembly, “Turbocharger - Install”.
i02585967
Exhaust Elbow - Remove and

Install
g01261613
Illustration 70
Typical example
Removal Procedure 1. Ensure that the exhaust elbow, the coupling

and the outlet of the turbocharger are free from
damage. Replace any components that are
damaged.
2. Install coupling (4) to exhaust elbow (2).
3. Align coupling (4) to the outlet of turbocharger (1)

and install the assembly of the exhaust elbow.
4. If necessary, install support bracket (3) to the

cylinder block and install bolts (6). Tighten the
bolts to a torque of 44 N·m (33 lb ft).
5. Install bolts (5) finger tight.
6. Ensure that coupling (4) is fully engaged into the

outlet of the turbocharger (1). Ensure that the gap
between the turbocharger and the exhaust elbow
is evenly spaced.
g01261613
7. Tighten bolts (5) to a torque of 44 N·m (33 lb ft).
Illustration 69
Typical example
42 RENR9525
i02590671
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 15 recommended tooling to release the spring force.
Required Tools
Part NOTICE
Tool Part Description Qty Plug the apertures for the push rods in the cylinder
Number
head in order to prevent the entry of loose parts into
A - Circlip Pliers 1 the engine.
21825739 Valve Spring Compressor 1
B 27610235 Adapter 1 NOTICE
27610295 Head 1 Use a deep socket in order to remove the electrical
C 1
21825576 Crankshaft Turning Tool 1 incorrect tooling will result in damage to the electronic
27610291 Barring Device Housing 1 unit injectors.
C2
27610289 Gear 1
Start By:

Disassembly and Assembly, “Rocker Shaft and
Pushrod - Remove”.
Note: Either Tooling (C) can be used. Use the Tooling

NOTICE

component life.
Note: The following procedure should be adopted in

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
and Install” for the procedure to remove the valve
g01269383
springs from a cylinder head that has been removed Illustration 71
from the engine. Typical example
Note: Ensure that the appropriate piston is at the top 2. Follow Steps 2.a through 2.h in order to remove
center position before the valve spring is removed. the harness assemblies for the electronic unit
Failure to ensure that the piston is at the top center injectors.
position may allow the valve to drop into the cylinder
bore. a. Place a temporary identification mark on
connections (1).
b. Use a deep socket to remove connections (1)

from electronic unit injectors (2).
RENR9525 43
c. Cut cable tie (3). Note: Do not use excessive force to turn the
crankshaft. The use of force can result in bent valve
d. Disconnect plug (6) from harness assembly (4). stems.
e. Use Tooling (A) to remove circlip (5). d. Continue to rotate the crankshaft and gradually
release the pressure on Tooling (B) until the
f. From the outside of the valve mechanism cover piston is at the top center position. The valve
base (7), push harness assembly (4) inward. is now held in a position that allows the valve
Withdraw the harness assembly from the valve spring to be safely removed.
Note: Valve springs must be replaced in pairs for the
g. Remove O-ring seal (8) from harness assembly inlet valve or the exhaust valve of each cylinder. If all
(4). valve springs require replacement the procedure can
be carried out on two cylinders at the same time. The
h. Repeat Steps 2.a through 2.g in order to procedure can be carried out on the following pairs of
remove the remaining harness assembly. cylinders. 1 with 4 and 2 with 3. Ensure that all of the
valve springs are installed before changing from one
pair of cylinders to another pair of cylinders.
NOTICE
Do not turn the crankshaft while the valve springs are
removed.
4. Apply sufficient pressure to Tooling (B) in order to

allow removal of the valve keepers (9).
Note: Do not compress the spring so that the valve

spring retainer (10) touches the valve stem seal .
Remove valve keepers (9).
5. Slowly release the pressure on Tooling (B).
6. Remove valve spring retainer (10) and remove

valve spring (11).
g01243732 7. If necessary, remove the valve stem seals.

Illustration 72
Typical example 8. Repeat Steps 4 through 7 in order to remove
the remaining valve springs from the appropriate
NOTICE cylinder.
Ensure that the valve spring is compressed squarely
or damage to the valve stem may occur. 9. Remove Tooling (B).
3. Follow Steps 3.a through 3.d in order to position

the appropriate piston at top dead center.
a. Install Tooling (B) in position on the cylinder

head in order to compress a valve spring for
the appropriate piston.
b. Use Tooling (B) in order to compress valve

spring (11) and open the valve slightly.
Note: Do not compress the spring so that the valve

spring retainer (10) touches the valve stem seal (not
shown).
c. Use Tooling (C) in order to rotate the crankshaft

carefully, until the piston touches the valve.
44 RENR9525
Table 16
Required Tools
Part
Number
A - Circlip Pliers 1
B 27610235 Adapter 1
27610295 Head 1
C1 21825576 Crankshaft Turning Tool 1
C2
27610289 Gear 1
POWERPART
D 21820221 1
Rubber Grease
E 27610296 Torque Wrench 1
g01243732
Illustration 73
Note: Either Tooling (C) can be used. Use the Tooling Typical example
3. Install valve spring (11) onto the cylinder head.
NOTICE Position valve spring retainer (10) onto valve
Keep all parts clean from contaminants. spring (11).

component life.
Improper assembly of parts that are spring loaded
can cause bodily injury.
NOTICE
Do not turn the crankshaft while the valve springs are To prevent possible injury, follow the established
removed. assembly procedure and wear protective equip-
ment.
NOTICE
Plug the apertures for the push rods in the cylinder
NOTICE
head in order to prevent the entry of loose parts into
the engine.
or damage to the valve stem may occur.
NOTICE 4. Install Tooling (B) in the appropriate position on

Use a deep socket in order to remove the electrical the cylinder head in order to compress the valve
connections from the electronic unit injectors. Use of spring.
incorrect tooling will result in damage to the electronic
unit injectors. 5. Apply sufficient pressure to Tooling (B) in order to
install valve keepers (9).
1. Inspect the valve springs for the correct length.
Refer to Specifications, “Cylinder Head Valves ”. Note: Do not compress the spring so that the valve
spring retainer (10) touches the valve stem seal .
2. If necessary, install a new valve stem seal onto
the valve guide. Install the valve spring keepers.
Note: The outer face of the valve guide must be 6. Carefully release the pressure on Tooling (B).
clean and dry before installing the valve stem seal.
Note: Ensure that the valve keepers are correctly
seated.
RENR9525 45
7. Repeat steps 2 to 6 for the remaining valves. d. Use Tooling (A) to install the circlip (5).
e. Connect plug (6) to harness assembly (4).
f. Use a deep socket to install connections (1)

The valve spring keepers can be thrown from to the electronic unit injectors (2). Use Tooling
the valve when the valve spring compressor is (E) to tighten the connections to a torque of
released. Ensure that the valve spring keepers 2.5 N·m (22 lb in).
are properly installed on the valve stem. To help
prevent personal injury, keep away from the front g. Install a new cable tie (3).
of the valve spring keepers and valve springs
during the installation of the valves. Note: Ensure that the cable ties conform to the
Perkins specification.
8. Remove the Tooling (B).
h. Repeat Steps 9.a through 9.g for the remaining
Note: Valve springs must be replaced in pairs for the harness assemblies.
inlet valve or the exhaust valve of each cylinder. If all
valve springs require replacement the procedure can 10. Restore the electrical supply to the engine.
be carried out on two cylinders at the same time. The
procedure can be carried out on the following pairs of End By:
cylinders. 1 with 4 and 2 with 3. Ensure that all of the
valve springs are installed before changing from one a. Install the rocker shaft assembly. Refer to
pair of cylinders to another pair of cylinders. Disassembly and Assembly, “Rocker Shaft and
Pushrod - Install”.
i02585973
Inlet and Exhaust Valves -

Remove and Install
Removal Procedure
Table 17
Required Tools
Part
Number
A 27610235 Adapter 1
27610295 Head 1
g01269383
Illustration 74
9. Follow Steps 9.a through 9.g in order to install a. Remove the cylinder head. Refer to Disassembly
the harness assemblies for the electronic unit and Assembly, “Cylinder Head - Remove”.
injectors.
a. Ensure that harness assembly (4) and the bore NOTICE

in the valve mechanism cover base (7) are Keep all parts clean from contaminants.
clean and free from damage.
b. Use Tooling (D) to lubricate a new O-ring seal. component life.
Install the new O-ring seal (8) onto harness
assembly (4). 1. Clean the bottom face of the cylinder head.
Check the depth of the valves below the face of
c. From the inside of the valve mechanism cover the cylinder head before the valve springs are
base (7), push harness assembly (4) into the removed. Refer to Specifications, “Cylinder Head
valve mechanism cover base. Valves” for the correct dimensions.
46 RENR9525

heads of the valves in order to identify the correct
position. Inlet valves have a recess in the center
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.
3. Use a suitable lifting device to position the cylinder

head with the valve springs upward. The weight of
the cylinder head is approximately 56 kg (125 lb).
Note: Ensure that the cylinder head is kept on a

clean, soft surface in order to prevent damage to the
machined face.

parts propelled by a released spring force.
g01245105
Illustration 76
ment. 5. Apply sufficient pressure to Tooling (A) in order to
remove valve keepers (1).
recommended tooling to release the spring force. Note: Do not compress the spring so that valve
spring retainer (2) touches valve stem seal (4).
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 18
Illustration 75
Typical example Part
Number
4. Install Tooling (A) in position on the cylinder head 21825666 Valve Spring Compressor 1
in order to compress the appropriate valve spring.
A 27610235 Adapter 1
NOTICE 27610295 Head 1
RENR9525 47
2. Lubricate the stems of valves (5) with clean engine

NOTICE oil. Install valves (5) in the appropriate positions in
Keep all parts clean from contaminants. the cylinder head. Check the depth of the valves
below the face of the cylinder head. Refer to
Contaminants may cause rapid wear and shortened Systems Operation, Testing and Adjusting, “Valve
component life. Depth - Inspect” for more information.
3. Use a suitable lifting device to carefully turn over

1. Clean all components of the cylinder head the cylinder head. The weight of the cylinder head
assembly. Ensure that all ports, all coolant is approximately 56 kg (125 lb).
passages and all lubrication passages in the
cylinder head are free from debris. Follow Steps Note: Ensure that all of the valves remain in place.
1.a through 1.e in order to inspect the components
of the cylinder head assembly. Replace any 4. Install new valve stem seals (4) onto each of the
components that are worn or damaged. valve guides.
a. Inspect the cylinder head for wear and for Note: The outer face of the valve guides must be
damage. Refer to Systems Operation, Testing clean and dry before installing the valve stem seals.
and Adjusting, “Cylinder Head Inspect”.
5. Install valve spring (3) onto the cylinder head.
b. Inspect the valve seats for wear and for Position valve spring retainer (2) onto valve spring
damage. Refer to Specifications, “Cylinder (3).
Head Valves” for further information.
c. Inspect the valve guides for wear and for

damage. Refer to Specifications, “Cylinder
Head Valves” and Systems Operation, Testing Personal injury can result from being struck by
and Adjusting, “Valve Guide - Inspect” for parts propelled by a released spring force.
further information.
d. Inspect the valves for wear and for damage. ment.
Refer to Specifications, “Cylinder Head Valves”.
e. Inspect the valve springs for damage and for recommended tooling to release the spring force.
the correct length. Refer to Specifications,
“Cylinder Head Valves”.
g01257370
Illustration 78

Illustration 77
6. Install Tooling (A) in the appropriate position on
the cylinder head in order to compress the valve
spring (3).
48 RENR9525
NOTICE NOTICE
Ensure that the valve spring is compressed squarely Keep all parts clean from contaminants.
component life.
7. Apply sufficient pressure to Tooling (A) in order to
install valve keepers (1).
NOTICE
Note: Do not compress the spring so that valve Care must be taken to ensure that fluids are contained
spring retainer (2) touches valve stem seal (4). during performance of inspection, maintenance, test-
ing, adjusting, and repair of the product. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
The valve spring keepers can be thrown from ponent containing fluids.
the valve when the valve spring compressor is
released. Ensure that the valve spring keepers Dispose of all fluids according to local regulations and
are properly installed on the valve stem. To help mandates.
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).
9. Repeat Steps 5 to 8 for the remaining valves.
10. Remove Tooling (A) from the cylinder head.
11. Use a suitable lifting device to position the cylinder

head on a support. Ensure that the heads of the
valves are not obstructed. Gently strike the top of
the valves with a soft hammer in order to ensure
that valve keepers (1) are properly installed. Illustration 79
g01254186
Typical example
End By:
1. Use Tooling (A) to remove engine oil filter (3).
a. Install the cylinder head. Refer to Disassembly Refer to Disassembly and Assembly, “Engine Oil
and Assembly, “Cylinder Head - Install”. and Filter - Change”.
i02585988 2. If the engine oil pressure sensor is located in

the engine oil filter base, remove the engine
Engine Oil Filter Base - oil pressure sensor. Refer to Operation and
Maintenance Manual, “Engine Oil Pressure
Remove and Install Sensor - Remove and Install”.
3. Remove bolts (4) and remove engine oil filter base

(2).
Removal Procedure
4. Remove joint (1).
Table 19
Required Tools 5. If the engine oil filter base has a spacer plate,
remove the spacer plate and remove the joint.
A - Strap Wrench 1 6. If necessary, remove plug (6) from engine oil filter
base (2). Remove O-ring seal (5) from the plug.
Note: The oil filter may be installed vertically or the
oil filter may be installed horizontally.
RENR9525 49
Installation Procedure i02585998
Table 20 Engine Oil Cooler - Remove

Required Tools
A 21820117
POWERPART
1
Removal Procedure
Start By:
NOTICE a. Remove the bracket for the Electronic Control
Keep all parts clean from contaminants. Module. Refer to Disassembly and Assembly,
“ECM Mounting Bracket - Remove and Install”.
component life.
NOTICE
ing.


g01254186 work on the fuel system.
Illustration 80
Typical example
NOTICE
1. Ensure that the engine oil filter base is clean. Keep all parts clean from contaminants.
Clean the mating surfaces of the cylinder block.
2. If necessary, install a new O-ring seal (5) to plug component life.
(6). Install plug (6) to engine oil filter base (2).
Tighten the plug to a torque of 12 N·m (106 lb in).
NOTICE
3. Install bolts (4) to engine oil filter base (2). Care must be taken to ensure that fluids are contained
4. Install a new joint (1) onto bolts (4). If the engine ing, adjusting and repair of the product. Be prepared to
oil filter base has a spacer plate, install the spacer collect the fluid with suitable containers before open-
plate and a new joint onto the bolts. ing any compartment or disassembling any compo-
5. Apply Tooling (A) to the threads of the bolts. Install
the assembly of the engine oil filter base to the Dispose of all fluids according to local regulations and
cylinder block. mandates.
6. Tighten bolts (4) to a torque of 22 N·m (16 lb ft). 1. Drain the coolant from the cooling system into
a suitable container. Refer to Operation and
7. If the engine oil pressure sensor is located in the Maintenance Manual, “Cooling System Coolant -
engine oil filter base, Install the engine oil pressure Drain” for the correct procedure.
sensor. Refer to Operation and Maintenance
Manual, “Engine Oil Pressure Sensor - Remove 2. Drain the engine lubricating oil into a suitable
and Install”. container. Refer to Operation and Maintenance
Manual, “Engine Oil and Filter - Change” for the
8. Install a new engine oil filter (3). If necessary, correct procedure.
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”.
50 RENR9525
3. If necessary, remove the electric starting motor. Note: Bolts of different lengths are installed. Note
Refer to Disassembly and Assembly, “Electric the correct position of the bolts. Note the position of
Starting Motor - Remove and Install”. any brackets that are secured by the bolts. Do not
remove bolts (6) at this time.
4. Position the engine wiring harness away from the
assembly of oil cooler (1). If necessary, cut the 6. Remove the assembly of oil cooler (1) from the
cable tie. cylinder block.
8. Follow Steps 8.a through 8.c in order to

disassemble the engine oil cooler.
a. Remove bolts (6).
b. Remove cooler matrix (3) from housing (5).
c. Remove joints (4).
i02586025
Engine Oil Cooler - Install
Illustration 81
g01254472 NOTICE
Typical example

component life.
g01254473
Illustration 82
Tightening sequence for the engine oil cooler
g01254472
5. Loosen bolts (7) in reverse numerical order to the Illustration 83
sequence that is shown in Illustration 82. Remove Typical example
bolts (7). Support the assembly of engine oil
cooler (1) as the bolts are removed. 1. Follow Steps 1.a through 1.c in order to assemble
the engine oil cooler.
RENR9525 51
a. Ensure that cooler matrix (3) is clean and free 8. Fill the cooling system to the correct level. Refer
from damage. Ensure that housing (5) is clean to Operation and Maintenance Manual, “Cooling
and free from damage. Replace any damaged System Coolant - Fill” for the correct procedure.
components.
9. Fill the engine oil pan to the correct level. Refer to
b. Position new joints (4) onto housing (5). Install Operation and Maintenance Manual, “Engine Oil
cooler matrix (3). Filter - Change” for the correct procedure.
c. Install bolts (6) finger tight. End By:
2. Clean the joint surface of the cylinder block. a. Install the bracket for the Electronic Control
Module. Refer to Disassembly and Assembly,
3. Install bolts (7). “ECM Bracket - Remove”.
Note: The bolts are different lengths. Ensure that the

i02586067
different bolts are installed in the correct location.
Ensure that any brackets that are secured by the
bolts are installed in the correct location.
Engine Oil Relief Valve -
Remove and Install
4. Install a new joint (2) to the assembly of oil cooler
(1). Push bolts (7) through the holes in the joint.
(Engines with a Balancer Unit)
Note: The holes in the joint have serrations that hold
the bolts captive.
Removal Procedure
Table 21
Required Tools
Number
A - Telescopic Magnet 1
Start By:
a. Remove the engine oil pan. Refer to Disassembly

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

component life.
g01254473
Illustration 84
Tightening sequence for the engine oil cooler
5. Install the assembly of oil cooler (1) to the cylinder Personal injury can result from being struck by
block. Tighten bolts (7) to a torque of 22 N·m parts propelled by a released spring force.
(16 lb ft). Tighten the bolts in the sequence that is
shown in Illustration 84. Make sure to wear all necessary protective equip-
ment.
Tighten bolts (6) to a torque of 22 N·m (16 lb ft).
Refer to Illustration 83. Follow the recommended procedure and use all
recommended tooling to release the spring force.
6. Place the engine wiring harness in the correct
position. If necessary, install a new cable tie.
7. If necessary, Install the electric starting motor.

Refer to Disassembly and Assembly, “Electric
Starting Motor - Remove and Install”.
52 RENR9525
g01265618 g01265618
1. Loosen cap (2). Carefully remove the cap from 1. Ensure that all components are clean and free
balancer (1). from wear or damage. If necessary, replace any
components that are worn or damaged. If the
Note: The spring force will be released when the cap bore for the relief valve in balancer (1) is worn or
is removed. damaged, the complete assembly of the balancer
must be replaced.
2. Remove spring (3) from 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). Improper assembly of parts that are spring loaded
Installation Procedure To prevent possible injury, follow the established

assembly procedure and wear protective equip-
Table 22 ment.
Required Tools
Part 2. Lubricate plunger (4) with clean engine oil. Install
Number plunger (4) and spring (3) into the bore for the
- relief valve in balancer (1).
B Loctite 577 1
Note: The plunger must slide freely in the bore for
NOTICE the relief valve.
3. Apply Tooling (B) to the threads of cap (2). Install
Contaminants may cause rapid wear and shortened cap (2) to balancer (1). Tighten the cap to a torque
component life. of 21 N·m (15.5 lb ft).
Note: Ensure that the spring is properly located

inside the plunger and the cap. Ensure that Tooling
(B) does not contaminate the bore for the relief valve
in balancer (1).
RENR9525 53
End By: Note: The spring force will be released when the cap
is removed.
a. Install the engine oil pan. Refer to Disassembly
and Assembly, “Engine Oil Pan - Remove and 2. Remove spring (3) from the bore for the relief
Install”. valve in the housing of engine oil pump (1).
3. Use long nose pliers to remove plunger (4) from

i02586039
the bore for the relief valve in the housing of
Engine Oil Relief Valve - engine oil pump (1).
Remove and Install Installation Procedure

(Engines Without a Balancer
Table 23
Unit) Required Tools
Part
Number
Removal Procedure A - Loctite 640 1
Start By:
NOTICE
a. Remove the engine oil pan. Refer to Disassembly Keep all parts clean from contaminants.
and Assembly, “Engine Oil Pan - Remove and
Install”. Contaminants may cause rapid wear and shortened
component life.
NOTICE

component life.

parts propelled by a released spring force.

ment.
g00959674
Follow the recommended procedure and use all Illustration 88
recommended tooling to release the spring force. Typical example
1. Ensure that all components are clean and free

from wear or damage. If necessary, replace any
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
assembly of the engine oil pump must be replaced.

To prevent possible injury, follow the established

g00959674 assembly procedure and wear protective equip-
Illustration 87
ment.
Typical example
1. Loosen cap (2). Carefully remove cap (2) from the

housing of engine oil pump (1).
54 RENR9525
2. Lubricate plunger (4) with clean engine oil. Use

long nose pliers to install plunger (4) and spring NOTICE
(3) into the bore for the relief valve in the housing Care must be taken to ensure that fluids are contained
of engine oil pump (1). during performance of inspection, maintenance, test-
Note: The plunger must slide freely in the bore for collect the fluid with suitable containers before open-
the relief valve. ing any compartment or disassembling any compo-
3. Apply Tooling (A) to the threads of cap (2). Install
cap (2) to engine oil pump (1). Tighten the cap to Dispose of all fluids according to local regulations and
a torque of 35 N·m (26 lb ft). mandates.
Note: Ensure that the spring is properly located

inside the plunger and the cap. Ensure that Tooling
(A) does not contaminate the bore for the relief valve
in the housing of the engine oil pump.
End By:

Install”.
i02590322
Engine Oil Pump - Remove and

Install
(Engines Without a Balancer
Unit)
g01255703
Illustration 89
Removal Procedure Typical example
Start By: 1. Remove bolts (1) and suction pipe (2).
a. Remove the engine oil pan. Refer to Disassembly 2. Remove the joint from the suction pipe.
Install”. 3. Remove bolts (5). Remove the assembly of the
engine oil pump (3) from the cylinder block.
Note: This procedure is for the removal of the engine
oil pump on engines that are not equipped with 4. If necessary, remove pressure relief valve (4)
a balancer. Refer to Disassembly and Assembly, from the housing of engine oil pump (3). Refer to
“Balancer Group - Remove” for information on the Disassembly and Assembly, “Engine Oil Relief
removal of the engine oil pump for engines that are Vave - Remove and Install”.
equipped with a balancer.
NOTICE

component life.
RENR9525 55
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.
g01255705
Illustration 90
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 24
Required Tools
Part
Tool Part Name Qty
Number
A
- Finger Clock 1
Note: This procedure is for the installation of the g01255705

Illustration 91
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).
56 RENR9525
i02586341
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.
g01255703
Illustration 92 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 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 a
engine oil pump are aligned with the holes in the suitable container for storage or disposal. Refer
cylinder block. to Operation and Maintenance Manual, “Cooling
System Coolant - Drain” for the correct procedure.
5. Install bolts (5). Tighten the bolts to a torque of
44 N·m (32 lb ft). 2. Loosen the hose clamps and remove the hose
from the water pump inlet.
6. Install suction pipe (2) and a new joint to the
assembly of the engine oil pump.
7. Install bolts (1). Tighten the bolts to a torque to

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”.
RENR9525 57
i02586360
Water Pump - Install
Table 25
Required Tools
Part
- Guide Stud
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 93
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.
6. If necessary, remove 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 94
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).

58 RENR9525
b. Position a new joint (5) onto water pump (3).
c. Install cover (6) to water pump (3).
d. Install bolts (7) to the cover (6). Tighten the

bolts finger tight.
3. Clean the mating surface of front cover (1).
g01269393
Illustration 96
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 94. Tighten the bolts
in the sequence that is shown in Illustration 96.
10. Install the hose to the water pump inlet. Tighten

g01269392 the hose clamps.
Illustration 95
4. Install Tooling (A) in position (X). 11. Fill the cooling system with coolant. Refer to the
Operation and Maintenance Manual, “Cooling
5. Use Tooling (A) in order to align a new joint (2) to System Coolant - Fill” for the correct procedure.
front cover (1). Install the joint to the front cover.
End By:
6. Align water pump (3) with Tooling (A). Install the
water pump to front cover (1). a. Install the fan and the fan pulley. Refer to
Disassembly and Assembly, “Fan - Remove and
Note: Ensure that the gear of the water pump and Install”.
the gear of the fuel injection pump mesh.
i02586781
7. Install bolts (4). Refer to Illustration 94. Tighten
the bolts finger tight. Water Temperature Regulator -
Note: Ensure that bolts of different lengths are Remove and Install
installed in the correct positions.
8. Remove Tooling (A) and install remaining bolts

(4) finger tight. Removal Procedure
NOTICE

component life.
RENR9525 59
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. g01269481
Illustration 98
Refer to Operation and Maintenance Manual, Typical example
“Cooling System Coolant - Drain” for the correct
draining procedure. 5. Remove O-ring seal (3) from water temperature
regulator housing (2).
2. Loosen the hose clamps from the upper radiator
hose and disconnect the upper radiator hose from
water temperature regulator housing (2). Installation Procedure
NOTICE

component life.
1. Ensure that all components of the water

temperature regulator housing (2) are clean
and free of wear or damage. Check the water
temperature regulator for correct operation. Refer
“Water Temperature Regulator - Test” for the
procedure to test the water temperature regulator.
Illustration 97
g01269478 If any components of the water temperature
regulator housing are worn or damaged, the
Typical example
complete assembly must be replaced.
3. Remove bolts (1) from water temperature
regulator housing (2).
4. Remove water temperature regulator housing (2)

from the cylinder head.
Note: Note the orientation of the water temperature

regulator housing.
g01263044
Illustration 99
Typical example
2. If the original water temperature regulator housing

is installed, position a new O-ring seal (3) into the
groove in the water temperature regulator housing
(2). Ensure that locating tab (4) is correctly seated
in water temperature regulator housing (2).
60 RENR9525
A new water temperature regulator housing is

supplied with a new O-ring seal. NOTICE
3. Install water temperature regulator housing (2) to
the cylinder head. Contaminants may cause rapid wear and shortened
component life.
Note: Ensure the correct orientation of the water
temperature regulator housing.
g01269478
Illustration 100
Typical example

44 N·m (32.5 lb ft).
g01245126
Illustration 101
5. Connect the upper radiator hose and tighten the Typical example
hose clamps.
1. Remove two bolts from positions (X) on flywheel
6. Fill the cooling system to the correct level. Refer (1).
to Operation and Maintenance Manual, “Cooling
System Coolant - Check” and Operation and 2. Install Tooling (A) to positions (X) on flywheel (1).
Maintenance Manual, “Cooling System Coolant -
Fill” for the correct filling procedure. 3. Attach a suitable lifting device to flywheel (1).
Support the weight of the flywheel. The weight of
the flywheel is approximately 71 kg (155 lb).
i02586782
Flywheel - Remove 4. Remove remaining bolts (2).
5. Use the lifting device in order to remove the

flywheel from the engine.
Removal Procedure
Table 26
Required Tools
Part
- Guide Stud
A 2
(1/2 inch - UNF by 4 inch)
Start By:
a. Remove the electric starting motor. Refer to

Disassembly and Assembly, “Electric Starting g01245152
Motor - Remove and Install”. Illustration 102
Typical example
RENR9525 61
6. Inspect flywheel (1) and ring gear (3) for wear or 1. If the flywheel ring gear was removed, follow
damage. Replace any components that are worn Steps 1.a through 1.c in order to install a new ring
or damaged. gear to the flywheel.
7. To remove the flywheel ring gear, follow Steps 7.a a. Identify the orientation of teeth (4) on the new
and 7.b. ring gear (4).
a. Place the flywheel assembly on a suitable Note: The chamfered side of the ring gear teeth must
support. face toward the starting motor when the flywheel is
installed. This will ensure the correct engagement of
Note: Identify the orientation of the teeth on the the starting motor.
flywheel ring gear.
b. Heat flywheel ring gear (3) in an oven to a
b. Use a hammer and a punch in order to remove maximum temperature of 250 °C (482 °F) prior
ring gear (3) from flywheel (1). to installation.
Note: Do not use a torch to heat the ring gear.

i02586783
Flywheel - Install c. Ensure that the orientation of ring gear (3) is

correct and quickly install the ring gear onto
flywheel (1).
2. Inspect the crankshaft rear seal for leaks. If there

Installation Procedure are any oil leaks, replace the crankshaft rear seal.
Refer to Disassembly and Assembly, “Crankshaft
Table 27
Rear Seal - Remove”.
Required Tools
Part
Guide Stud
A - (1/2 inch - 20 UNF by 4 2
inch)
NOTICE

component life.
g01245126
Illustration 104
Typical example
3. Install a suitable lifting device to flywheel (1). The

weight of the flywheel is approximately 71 kg
(155 lb).
Illustration 103
g01245153 4. Install Tooling (A) to positions (X) on the
crankshaft.
Typical example
5. Use the lifting device in order to position flywheel

(1) onto Tooling (A).
Always wear protective gloves when handling 6. Install bolts (2) to flywheel (1) finger tight.
parts that have been heated.
62 RENR9525
7. Remove Tooling (A) and install remaining bolts

(2) to the flywheel (1).
8. Remove the lifting device from flywheel (1).
9. Use a suitable tool to prevent the flywheel from

rotating. Tighten bolts (2) to a torque of 120 N·m
(88 lb ft).
10. Check the run out of the flywheel. Refer to

Specifications, “Flywheel” for further information.
End By:
a. Install the electric starting motor. Refer to

Disassembly and Assembly, “Electric Starting
Motor - Remove and Install”.
i02586784
Crankshaft Pulley - Remove g01249049

and Install Illustration 105
(Engines With an Automatic 1. Use a suitable tool in order to prevent the

crankshaft from rotating. Remove bolts (1).
Belt Tensioner)
2. Remove thrust block (2).
3. Carefully remove the assembly of the crankshaft

Removal Procedure pulley from the crankshaft.
Start By: 4. Follow Steps 4.a through 4.b in order to

disassemble the crankshaft pulley.
a. Remove the Alternator belt. Refer to Disassembly
and Assembly, “Alternator Belt - Remove and a. Remove bolts (5).
Install”.
b. Remove crankshaft pulley (4) from crankshaft
NOTICE adapter (3).
component life. NOTICE

component life.
1. Ensure that the crankshaft adapter, the pulley and

the thrust block are clean and free from damage.
Replace any components that are damaged. It
is possible to reclaim a crankshaft adapter with
a worn seal surface by installing a wear sleeve.
Wear Sleeve (Front) - Remove and Install”.
RENR9525 63
i02586787
Crankshaft Pulley - Remove

and Install
(Engines Without an Automatic
Belt Tensioner)
Removal Procedure
Start By:
a. Remove the V-Belts. Refer to Disassembly and

Assembly, “V-Belts - Remove and Install”.
NOTICE
g01249049
Illustration 106 Contaminants may cause rapid wear and shortened
component life.
2. If necessary, follow Steps 2.a through 2.b in order
to assemble the crankshaft pulley.
a. Install crankshaft pulley (4) to crankshaft

adapter (3).
b. Install bolts (5) to the assembly of the

crankshaft pulley, and the crankshaft adapter.
The bolts should be evenly spaced.
c. Tighten the bolts to a torque of 78 N·m (58 lb ft).
3. Ensure that the front of the crankshaft is clean

and free from damage. Install the assembly of the
crankshaft pulley to the crankshaft.
g01255707
Illustration 107
4. Align the holes in the thrust block with the holes
in the crankshaft. Install thrust block (2) to the 1. Use a suitable tool in order to prevent the
assembly of the crankshaft pulley. crankshaft from rotating. Remove bolts (1).
5. Install bolts (1) to thrust block (2). 2. Remove thrust block (2).
6. Use a suitable tool in order to prevent the 3. Carefully remove crankshaft pulley (3) from the
crankshaft from rotating. Tighten the bolts to a crankshaft.
7. Repeat Step 6 two more times in order to ensure

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

and Assembly, “Alternator Belt - Remove and
Install”.
64 RENR9525
Crankshaft Rear Seal - Remove
Removal Procedure
Table 28
Required Tools
Part
Number
A - E12 Torx Socket 1
g01255707
Illustration 108 Start By:
1. Ensure that the crankshaft pulley and the thrust a. Remove the flywheel. Refer to Disassembly and
block are clean and free from damage. Replace Assembly, “Flywheel - Remove”.
any components that are damaged. It is possible
to reclaim a crankshaft pulley with a worn seal
NOTICE
surface by installing a wear sleeve. Refer to
Disassembly and Assembly, “Crankshaft Wear
Sleeve (Front) - Remove and Install”.
component life.
2. Ensure that the front of the crankshaft is clean and
free from damage. Install crankshaft pulley (3) to
the crankshaft. NOTICE
3. Align the holes in the thrust block with the holes during performance of inspection, maintenance, test-
in the crankshaft. Install thrust block (2) to the ing, adjusting and repair of the product. Be prepared to
crankshaft pulley. collect the fluid with suitable containers before open-
4. Install bolts (1) to thrust block (2). nent containing fluids.
5. Use a suitable tool in order to prevent the Dispose of all fluids according to local regulations and
crankshaft from rotating. Tighten bolts (1) to a mandates.
6. Repeat Step 5 two more times in order to ensure Note: The crankshaft rear seal and the housing
correct torque. are manufactured as a one-piece assembly. The
assembly is not serviceable. If the crankshaft rear
End By: seal is removed, the assembly must be replaced.
a. Install the V-Belts. Refer to Disassembly and

Assembly, “V-Belts - Remove and Install”.
g01269512
Illustration 109
Typical example
RENR9525 65
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.
i02586792
Crankshaft Rear Seal - Install
g01255709
Table 29 Illustration 111
Required Tools Typical example
Part 1. Ensure that crankshaft flange (1) is clean, dry

Number and free from damage. It is possible to reclaim a
A - E12 Torx Socket 1 crankshaft flange that has a worn seal surface,
or a damaged seal surface by installing a wear
B 27610306 Alignment Tool 1 sleeve. Refer to Disassembly and Assembly,
“Crankshaft Wear Sleeve (Rear) - Remove and
Note: The crankshaft rear seal and the housing are Install” for more information.
manufactured as a one-piece assembly.
2. Ensure that the mating surface of the cylinder
block and the bridge piece are clean and dry.
NOTICE
3. A new crankshaft rear seal is supplied with a
plastic sleeve (3). Ensure that the plastic sleeve is
squarely installed within crankshaft rear seal (2).
component life.
Note: The plastic sleeve is included in order to
protect the lip of the seal as the seal is pushed over
the crankshaft flange.
Note: Do not lubricate the crankshaft rear seal or

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.
During this process, the plastic sleeve will be

forced out of the crankshaft rear seal. Discard the
g01258105
Illustration 110 plastic sleeve.
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.
66 RENR9525
i02586793
Crankshaft Wear Sleeve (Rear)

- Remove and Install
Removal Procedure
Start By:
a. Remove the crankshaft rear seal. Refer to

Disassembly and Assembly, “Crankshaft Rear
Seal - Remove”.
NOTICE

component life.
g01258357
Illustration 112
Tightening sequence for the crankshaft rear seal Note: Wear sleeves are used to reclaim worn seal
surfaces or damaged seal surfaces. Wear sleeves
6. Install torx screws (4) finger tight. are not original equipment.
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
112.
9. Remove the Tooling (B).
10. Install the remaining torx screws (4) to positions

g01266598
(X). Use Tooling (A) in order to tighten the torx Illustration 113
screws to a torque of 22 N·m (16 lb ft). Refer to Sectional view of the crankshaft and of the wear sleeve
Illustration 112.
1. Use a sharp tool to score a deep line across
End By: crankshaft wear sleeve (1).
a. Install the flywheel. Refer to Disassembly and Note: Take care to avoid damaging the crankshaft.
Assembly, “Flywheel - Install”.
2. Insert a thin blade between crankshaft wear
sleeve (1) and crankshaft (2) below the scored
line. The crankshaft wear sleeve will separate
along the line.
3. Remove crankshaft wear sleeve (1) from

crankshaft (2). Discard the crankshaft wear
sleeve.
RENR9525 67
Installation Procedure 3. Align crankshaft wear sleeve (1) with crankshaft

(2). Position installation tool (3) that is provided
Table 30 with the crankshaft wear sleeve over the
Required Tools crankshaft. Use a hammer to drive the crankshaft
wear sleeve onto the crankshaft. Ensure that
Tool Part Number Part Description the flange of the crankshaft wear sleeve is
POWERPART 0.40 to 0.60 mm (0.017 to 0.024 inch) from the
A 21820518 cylinder block.
Liquid Gasket
Note: Measure distance (Y) between the flange of

NOTICE crankshaft wear sleeve (1) and the cylinder block in
Keep all parts clean from contaminants. two places that are 180 degrees from each other.
Contaminants may cause rapid wear and shortened 4. Remove installation tool (3).
component life.
5. Ensure that the crankshaft wear sleeve has no
1. Ensure that the crankshaft is thoroughly clean and rough edges.
dry. Remove any areas of raised damage.
End By:
a. Install a new crankshaft rear seal. Refer to

Seal - Install”.
i02586796
Flywheel Housing - Remove

and Install
Removal Procedure
g01269521
Illustration 114
Sectional view of the wear sleeve Start By:
2. Apply a small continuous bead of Tooling (A) to a. Remove the flywheel. Refer to Disassembly and
the inner surface of crankshaft wear sleeve (1) at Assembly, “Flywheel - Remove”.
position X. Apply the bead of Tooling (A) 5.00 mm
(0.2 inch) from the flange end of the crankshaft NOTICE
wear sleeve. Keep all parts clean from contaminants.

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

housing in order to support the flywheel
housing. The weight of the flywheel housing is
approximately 30 kg (66 lb).
g01266582
Illustration 115
Sectional view of the crankshaft, the wear sleeve and the
installation tool
68 RENR9525
Table 31
Required Tools
Part
Number
- Guide Stud
A 2
(M10 by 100 mm)
B 21825617 Dial Indicator Group 1
NOTICE

component life.
1. Ensure that the flywheel housing is clean and free

from damage. If necessary, replace the flywheel
Illustration 116
g01244050 housing.
Typical example
2. Remove bolts (2) and (3) from flywheel housing

(1).
3. Use the lifting device in order to remove flywheel

housing (1) from the cylinder block.
g01244056
Illustration 118
Typical example
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
Illustration 117
g01244051 and Assembly, “Crankshaft Rear Seal - Install”.
Typical example
3. Clean the rear face of the cylinder block. If
necessary, install dowels (4) to the cylinder block.
4. If the engine has an aluminum oil pan, remove
dust seal (5). 4. Install Tooling (A) to the cylinder block.
5. If necessary, remove dowels (4) from the cylinder 5. Install dust seal (5).
block.
RENR9525 69
i02586797
Crankshaft Front Seal -

Remove and Install
Removal Procedure
Table 32
Required Tools
Part
Number
A 27610230 Puller 1
Start By:
a. Remove the crankshaft pulley. Refer to

Disassembly and Assembly, “Crankshaft Pulley
g01244050
Illustration 119 - Remove and Install”.
Typical example
NOTICE
6. Install a suitable lifting device to the flywheel Keep all parts clean from contaminants.
housing. The weight of the flywheel housing is
approximately 30 kg (66 lb). Contaminants may cause rapid wear and shortened
component life.
7. Use the lifting device to align flywheel housing (1)
with Tooling (A). Install the flywheel housing to
the cylinder block.
8. Install the bolts (2) and (3) finger tight.
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
“Flywheel Housing - Inspect”. g01266942
Illustration 120
End By:
1. Install the legs of Tooling (A) behind crankshaft
front seal (1). Install a suitable spacer (2) between
a. Install the flywheel. Refer to Disassembly and
Tooling (A) and crankshaft (3). Use Tooling (A) in
Assembly, “Flywheel - Install”.
order to pull the crankshaft front seal out of the
front housing.
Note: Do not damage the bore for the crankshaft

front seal in the front housing.
70 RENR9525
Table 33 Crankshaft Wear Sleeve (Front)

Required Tools - Remove and Install
Part
Number
21825577 Threaded Bar 1
Removal Procedure
21825580 Anchor Plate 1
B 21825579 Sleeve 1
Start By:
21825578 Pressure Plate 1 a. Remove the crankshaft pulley. Refer to

21825581 Adapter 1
NOTICE b. Remove the crankshaft front seal . Refer to

Keep all parts clean from contaminants. Disassembly and Assembly, “Crankshaft Front
Seal - Remove and Install”.
1. Ensure that the bore for the crankshaft front seal in
the front housing is clean and free from damage.
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 121
Typical example
2. Assemble Tooling (B).
3. Align a new crankshaft front seal (1) to the front g01269535

housing. Illustration 122
Sectional view of the crankshaft pulley and the wear sleeve
4. Use Tooling (B) to install crankshaft front seal (1).
Ensure that the front face of the seal is installed 1. Use a sharp tool to score a deep line across wear
to a depth of 9 ± 0.2 mm (0.354 ± 0.008 inch) into sleeve (1).
the front housing.
Note: Take care to avoid damaging to the crankshaft
5. Remove Tooling (B) from the crankshaft. pulley.
End By: 2. Insert a thin blade between wear sleeve (1) and
crankshaft pulley (2) below the scored line. The
a. Install the crankshaft pulley. Refer to Disassembly wear sleeve will separate along the line.
and Assembly, “Crankshaft Pulley - Remove and
Install”. 3. Remove wear sleeve (1) from crankshaft pulley
(2).
RENR9525 71
Table 34
Required Tools
Tool Part Number Part Description
POWERPART
A 21820518
Liquid Gasket
NOTICE

component life.
1. Ensure that the crankshaft pulley is thoroughly

clean and dry. Remove any areas of raised
damage.
g01258423
Illustration 124
Typical example
g01269521
Illustration 123
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.
g01258430
Illustration 125
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.

72 RENR9525
End By:
a. Install a new crankshaft front seal. Refer to

Disassembly and Assembly, “Crankshaft Front
Seal - Remove and Install”.
b. Install the crankshaft pulley. Refer to Disassembly

Install”.
i02586802
Front Cover - Remove and

Install
Removal Procedure
Start By:
g01258462
Illustration 126
a. If the engine is equipped with a fan, remove the Typical example
fan. Refer to Disassembly and Assembly, “Fan
- Remove and Install”. 1. Remove bolts (3), (4) and (5). Identify the positions
of the different bolts.
b. Remove the water pump. Refer to Disassembly
and Assembly, “Water Pump - Remove”. 2. Remove front cover (1) from the front housing.
NOTICE 3. Remove joint (2) from front cover (1).

during performance of inspection, maintenance, test- Installation Procedure
collect the fluid with suitable containers before open- Table 35
ing any compartment or disassembling any compo- Required Tools
Part
Tool Part Name Qty
Dispose of all fluids according to local regulations and Number
mandates. Guide Stud
A - 2
(M8 by 80 mm)
NOTICE
Keep all parts clean from contaminants. NOTICE
component life. Contaminants may cause rapid wear and shortened
component life.
Note: In order to remove the front cover, it is not
necessary to remove the crankshaft pulley or the
alternator.
RENR9525 73
End By:
a. If the engine is equipped with a fan, install the

fan. Refer to Disassembly and Assembly, “Fan
i02591045
Gear Group (Front) - Remove

and Install
Removal Procedure
Table 36
Required Tools
Tool Part Number Part Name Qty
A 1
A2
27610289 Gear 1
g01269923
Illustration 127
1. Thoroughly clean the mating surface of the front a. If the engine is equipped with an air compressor,
housing. remove the air compressor. Refer to Disassembly
and Assembly, “Air Compressor - Remove and
2. If the original front cover is installed, follow Steps Install”.
2.a and 2.b in order to install the joint.
b. If the engine is equipped with a vacuum pump,
a. Thoroughly clean the front cover. remove the vacuum pump. Refer to Disassembly
and Assembly, “Vacuum Pump - Remove and
b. Install a new joint (2) to front cover (1). Engage Install”.
locators (Y) into the holes in the front cover.
c. If the engine is equipped with an accessory drive,
3. Install Tooling (A) into holes (X) in the front remove the accessory drive. Refer to Disassembly
housing. and Assembly, “Accessory Drive - Remove and
Install”.
4. Use Tooling (A) in order to position the front cover
assembly onto the front housing. d. Remove the front cover. Refer to Disassembly and
5. Install bolts (3), (4) and (5) finger tight. Ensure
that the different bolts are installed in the correct e. Remove the valve mechanism cover. Refer to
positions. Disassembly and Assembly, “Valve Mechanism
6. Loosely install the water pump assembly and
remove Tooling (A). Refer to Disassembly and Note: Either Tooling (A) can be used. Use the Tooling
Assembly, “Water Pump - Install” for the correct that is most suitable.
procedure.
NOTICE
7. Tighten bolts (3), (4) and (5) to a torque of 22 N·m Keep all parts clean from contaminants.
(16 lb ft).
8. Tighten the bolts for the water pump to a torque of component life.
22 N·m (16 lb ft).
74 RENR9525
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 g01269925
Illustration 129
follow the procedure in order to remove the gear
group. 3. Loosen nuts (6) on all rocker arms (7). Unscrew
adjusters (5) on all rocker arms (7) until all valves
1. Use Tooling (A) in order to rotate the crankshaft so are fully closed.
on the compression stroke. Refer to Systems Note: Failure to ensure that ALL adjusters are fully
Operation, Testing and Adjusting, “Finding Top unscrewed can result in contact between the valves
Centre Position for No.1 Piston”. 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 128 g01247435
Illustration 130
Typical example
Typical example
2. Install Tooling (B) through hole (X) in camshaft
gear (1) into the front housing. Use Tooling (B) in 5. Mark gears (1), (2) and (3) in order to show
order to lock the camshaft in the correct position. alignment. Refer to Illustration 130.
Install Tooling (C) into hole (Y) in the front housing.
Use Tooling (C) in order to lock the crankshaft in Note: Identification will ensure that the gears can be
the correct position. Refer to Systems Operation, installed in the original alignment.
Testing and Adjusting, “Finding Top Centre
Position for No.1 Piston”. 6. Remove fuel pump gear (3). Refer to Disassembly
and Assembly, “Fuel Pump Gear - Remove” for
Note: Do not use excessive force to install Tooling the correct procedure.
(C). Do not use Tooling (C) to hold the crankshaft
during repairs.
RENR9525 75
7. Remove camshaft gear (1). Refer to Disassembly 2. If necessary, install Tooling (C) into hole (Y) in
and Assembly, “Camshaft Gear - Remove and the front housing. Use Tooling (C) in order to
Install”. lock the crankshaft in the correct position. Refer
8. Remove idler gear (2). Refer to Disassembly and “Finding Top Centre Position for No.1 Piston”.
Assembly, “Idler Gear - Remove and Install”.
Note: Do not use excessive force to install Tooling
Installation Procedure (C). Do not use Tooling (C) to hold the crankshaft
during repairs.
Table 37
3. Ensure that all of the components of the front gear
Required Tools group are clean and free from wear of damage. If
Part necessary, replace any components that are worn
Tool Part Name Qty or damaged.
Number
D
- Finger Clock 1
NOTICE

component life.
Note: The fuel injection pump must remain locked g01269928

Illustration 132
until the procedure instructs you to unlock the
fuel injection pump. Typical example
1. Ensure that number one piston is at the top center 4. Install camshaft gear (1). Loosely install bolt
position on the compression stroke. Refer to (6) and washer (5). Refer to Disassembly and
the Systems Operation, Testing and Adjusting, Assembly, “Camshaft Gear - Remove and Install”
“Finding Top Center Position for No. 1 Piston”. for more information.

gear (1) into the front housing.
g01269927
Illustration 133
Typical example
g01247433
Illustration 131
Typical example
76 RENR9525
End By:

b. Install the valve mechanism cover. Refer to

c. If the engine is equipped with an air compressor,

install the air compressor. Refer to Disassembly
Install”.
g01247435
d. If the engine is equipped with a vacuum pump,
Illustration 134 install the vacuum pump. Refer to Disassembly
Alignment of timing marks and Assembly, “Vacuum Pump - Remove and
Install”.
6. Install idler gear (2). Ensure that the timing marks
on gears (1) and (2) are in alignment and that the e. If the engine is equipped with an accessory drive,
mesh of the gears is correct. Refer to Disassembly install the accessory drive. Refer to Disassembly
and Assembly, “Idler Gear - Remove and Install”. and Assembly, “Accessory Drive - Remove and
Check the end play of the idler gear. Refer to Install”.
Specifications, “Gear Group (Front)” and refer to
Disassembly and Assembly, “Idler Gear - Remove
and Install” for further information. i02586822
7. Remove Tooling (B) and (C). Tighten the bolt

Idler Gear - Remove
(6) for the camshaft gear to a torque of 95 N·m
(70 lb ft). Check the end play of the camshaft
gear. Refer to Specifications, “Camshaft” for more
information. Removal Procedure (Standard Idler
Install Tooling (B) through hole (X) in camshaft
Gear)
gear (1) into the front housing and install Tooling Table 38
(C) into hole (Y) in the front housing.
Required Tools
8. Ensure that the fuel injection pump is locked in Part
the correct position. Refer to Disassembly and Tool Part Name Qty
Number
Assembly, “Fuel Injection Pump - Install”.
A 27610212 Camshaft Timing Pin 1
9. Install fuel injection pump gear (3). Refer to B 27610211 Crankshaft Timing Pin 1
Disassembly and Assembly, “Fuel Injection Pump
Gear - Install” for the correct procedure. Ensure
Start By:
that timing marks on gears (2) and (3) are in
alignment. See Illustration 134. Ensure that the
a. If the engine is equipped with an air compressor,
mesh of the gears is correct.
remove the air compressor. Refer to Disassembly
Install”.
11. Use Tooling (D) in order to measure the backlash
for the gears (1), (2) and (3). Ensure that the
remove the vacuum pump. Refer to Disassembly
backlash for the gears is within specified values.
Refer to Specifications, “Gear Group (Front)” for
Install”.
further information.
12. Lubricate each gear with clean engine oil.
remove the accessory drive. Refer to Disassembly
and Assembly, “Accessory Drive - Remove and
13. Adjust the engine valve lash. Refer to Systems
Install”.
Operation, Testing and Adjusting, “Engine Valve
Lash - Inspect/Adjust”.
RENR9525 77
d. Remove the fuel injection pump gear. Refer to 3. Loosen nuts (5) on all rocker arms (6). Unscrew
Disassembly and Assembly, “Fuel Pump Gear - adjusters (4) on all rocker arms (6) until all valves
Remove”. are fully closed.
e. Remove the valve mechanism cover. Refer to Note: Failure to ensure that ALL adjusters are fully
Disassembly and Assembly, “Valve Mechanism unscrewed can result in contact between the valves
Cover - Remove and Install”. and pistons.
Note: Care must be taken in order to ensure that 4. Mark plate (3) in order to show orientation. Refer
the fuel injection pump timing is not lost during the to Illustration 135.
procedure in order to remove the fuel pump gear. Note: Identification will ensure that the plate can be
installed in the original orientation.
NOTICE
Keep all parts clean from contaminants. 5. Remove bolts (1). Refer to Illustration 135.
Contaminants may cause rapid wear and shortened 6. Remove plate (3).
component life.
g01269930
Illustration 137

Illustration 135
Alignment of timing marks 7. Remove the assembly of idler gear (2) and hub (7)
from the recess in the front housing.
1. Ensure that Tooling (A) is installed into hole (X) in
the camshaft gear. Use Tooling (A) in order to lock Note: The idler gear must be tilted during removal.
the camshaft in the correct position.
8. Remove hub (7) from idler gear (2).
Note: Ensure that the gears are marked in order to
show alignment. Refer to Illustration 135.
Removal Procedure (Heavy-Duty
2. Ensure that Tooling (B) is installed in hole (Y) in Idler Gear)
the front housing. Use Tooling (B) in order to lock
the crankshaft in the correct position. Table 39
Required Tools
Part
Tool Part Name Qty
Number
B 27610211 Crankshaft Timing Pin 1
Start By:
a. If the engine is equipped with an air compressor,

remove the air compressor. Refer to Disassembly
Install”.
g01269929
Illustration 136
78 RENR9525

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

Remove”.
e. Remove the valve mechanism cover. Refer to g01269932

Disassembly and Assembly, “Valve Mechanism Illustration 139
3. Loosen nuts (4) on all rocker arms (5). Unscrew
Note: Care must be taken in order to ensure that adjusters (3) on all rocker arms (5) until all valves
the fuel injection pump timing is not lost during the are fully closed.
procedure in order to remove the fuel pump gear. Note: Failure to ensure that ALL adjusters are fully
unscrewed can result in contact between the valves
and pistons.
NOTICE
Keep all parts clean from contaminants. 4. Remove bolts (1) from the assembly of idler gear
(2). Refer to Illustration 138.
component life.
Note: The assembly of heavy-duty idler gear is not

serviceable. Do not disassemble the heavy-duty idler
gear.
g01269933
Illustration 140
Typical example
5. Remove the assembly of idler gear (2) from the

recess in the front housing.
Illustration 138
g01269931 Note: The idler gear must be tilted during removal.
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 138.
2. Ensure that Tooling (B) is installed in hole (Y) in

RENR9525 79
i02586870
Idler Gear - Install
Installation Procedure (Standard

Idler Gear)
Table 40
Required Tools
Part
Tool Part Name Qty
Number
g01269934
A 27610212 Camshaft Timing Pin 1 Illustration 142
B 27610211 Crankshaft Timing Pin 1 4. Clean idler gear (2) and inspect the idler gear for
21825617 Dial Indicator Group 1 wear or damage. Refer to Specifications, “Gear
C Group (Front)” for more information. If necessary,
- Finger Clock 1 replace the idler gear.
NOTICE 5. Clean hub (7) and inspect the hub for wear or
Keep all parts clean from contaminants. damage. Refer to Specifications, “Gear Group
(Front)” for more information. If necessary, replace
Contaminants may cause rapid wear and shortened the hub.
component life.
6. Lubricate hub (7) with clean engine oil. Slide the
hub into idler gear (2). Ensure that the timing
1. Ensure that number one piston is at the top center marks are toward the front of the idler gear.
“Finding Top Center Postion for No. 1 Piston”.
g01269935
Illustration 143
Typical example
g01249059
Illustration 141 7. Align the timing mark on idler gear (2) with the
Alignment of timing marks timing mark on the camshaft gear. Refer to the
Illustration 141. Install the assembly of idler gear
2. Ensure that Tooling (A) is installed into hole (X) in (2) and hub (7) into the recess in the timing case.
camshaft gear (1). Ensure that oil hole (Z) is to the top of the hub.
3. Ensure that Tooling (B) is installed in hole (Y) Note: The idler gear must be tilted during installation.
in the front housing. Use Tooling (B) in order to Ensure that the holes in the hub are aligned with the
lock the crankshaft in the correct position. Refer holes in the cylinder block.
“Finding Top Centre Position for No.1 Piston”. 8. Clean plate (3) and inspect the plate for wear or
damage. If necessary, replace the plate.
80 RENR9525
9. Lubricate plate (3) with clean engine oil. A used d. If the engine is equipped with an accessory drive,
plate should be installed in the original orientation. install the accessory drive. Refer to Disassembly
If a new plate is installed, ensure that the holes and Assembly, “Accessory Drive - Remove and
in plate (3) are aligned with the holes in hub (7). Install”.
Install plate (3) to hub (7).

Installation Procedure (Heavy-Duty
44 N·m (32 lb ft). Idler Gear)
Table 41
Required Tools
Part
Tool Part Name Qty
Number
C
- Finger Clock 1
NOTICE
g01269936 Keep all parts clean from contaminants.
Illustration 144
Checking end play by using a set of feeler gauge’s Contaminants may cause rapid wear and shortened
component life.
11. Use a set of feeler gauge’s in order to check the
end play of the idler gear. Refer to Specifications,
“Gear Group (Front)” for more information. 1. Ensure that number one piston is at the top
center position on the compression stroke. Refer
12. Use Tooling (C) in order to check the backlash to Systems Operation, Testing and Adjusting,
between the idler gear and the camshaft gear. “Finding Top Center Postion for No. 1 Piston”.
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:
a. Install the fuel injection pump gear. Refer to

Disassembly and Assembly, “Fuel Pump Gear - g01269931
Install”. Illustration 145
b. If the engine is equipped with an air compressor,
install the air compressor. Refer to Disassembly 2. Ensure that Tooling (A) is installed into hole (X) in
and Assembly, “Air Compressor - Remove and the camshaft gear.
Install”.
3. Ensure that Tooling (B) is installed in hole (Y) in
c. If the engine is equipped with a vacuum pump, the cylinder block. Use Tooling (B) in order to
install the vacuum pump. Refer to Disassembly lock the crankshaft in the correct position. Refer
and Assembly, “Vacuum Pump - Remove and to Systems Operation, Testing and Adjusting,
Install”. “Finding Top Centre Position for No.1 Piston”.
RENR9525 81
4. Clean the assembly of idler gear (2) and inspect 10. Use Tooling (C) in order to check the backlash
the assembly of the idler gear for wear or damage. between the idler gear and the crankshaft gear.
Refer to Specifications, “Gear Group (Front)” Refer to Specifications, “Gear Group (Front)” for
for more information. If necessary, replace the more information.
assembly of the idler gear.
11. Lightly lubricate all of the gears with clean engine
5. Lubricate the bearings in the assembly of idler oil.
gear (2) with clean engine oil.
End By:
a. Install the fuel injection pump gear. Refer to

Install”.
b. If the engine is equipped with an air compressor,

install the air compressor. Refer to Disassembly
Install”.
c. If the engine is equipped with a vacuum pump,

install the vacuum pump. Refer to Disassembly
Install”.
g01269933
Illustration 146
d. If the engine is equipped with an accessory drive,
6. Align the timing mark on idler gear (2) with the install the accessory drive. Refer to Disassembly
timing mark on the camshaft gear. Refer to and Assembly, “Accessory Drive - Remove and
Illustration 145. Install the assembly of idler gear Install”.
(2) into the recess in the timing case. Ensure that
the identification mark TOP is upward.
i02586916
Note: The idler gear must be tilted during installation.

Ensure that the holes in assembly of the idler gear
Housing (Front) - Remove
are aligned with the holes in the cylinder block.

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 147 Install”.
Checking end play by using a dial indicator group
e. Remove the timing gears. Refer to Disassembly
8. Use Tooling (C) in order to check the end play and Assembly, “Gear Group (Front) - Remove
of the idler gear. Refer to Specifications, “Gear and Install”.
Group (Front)” for more information.
f. Remove the fuel injection pump. Refer to
9. Use Tooling (C) in order to check the backlash Disassembly and Assembly, “Fuel Injection Pump
between the idler gear and the camshaft gear. - Remove”.
more information.
82 RENR9525
NOTICE

component life.
NOTICE

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

container for storage or disposal. Refer to
g01265270
Operation and Maintenance Manual, “Cooling Illustration 149
System Coolant - Drain” for the correct procedure. Typical example
3. Remove bolts (7), (8) and (9) from front housing

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

positions of the different bolts.
4. Remove front housing (3) from the cylinder block.
g01265269
Illustration 148
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).
g01265293
Illustration 150
Typical example
6. Remove thrust washer (10) from the cylinder

block.
RENR9525 83
i02588314
Housing (Front) - Install
Table 42
Required Tools
Part
Number
POWERPART
A 21820117 Threadlock and 1 g01265293
Illustration 151
Nutlock
Typical example
- Guide Stud
B 2
(M8 by 80 mm) 4. Install thrust washer (10) into the recess
27610216 Alignment Tool 1 in the cylinder block. Refer to Disassembly
C
and Assembly, “Camshaft - Install” for more
- Bolts information.
3
(M10 by 50 mm)
D - Straight Edge 1
POWERPART
E 21820221 1
Rubber Grease
NOTICE

component life.
1. Ensure that the front housing is clean and free

from damage. If necessary, replace the front
housing.
If necessary, install blanking plugs to a new front

housing. Use Tooling (A) to seal all D-plugs.
2. Check the condition of the crankshaft front seal. If

the front seal is damaged, remove the front seal Illustration 152
g01269946
from the front housing.
Typical example
3. Clean all the mating surfaces of the cylinder block.
5. Install Tooling (B) to the cylinder block. Refer to
Illustration 152.
6. Install Tooling (C) to the cylinder block.
7. Align a new joint (6) with Tooling (B). Install the

joint to the cylinder block.
Note: Ensure that tabs (X) on the joint are engaged

in holes (Y) in the cylinder block.
84 RENR9525
g01269947
Illustration 153
Typical example
8. Install the front housing over Tooling (B) and over

Tooling (C) onto the cylinder block.
g01269949
Illustration 155
Tightening sequence for the front housing
13. Tighten bolts (6), (7) and (8) to a torque of 28 N·m

(20 lb ft). Tighten the bolts in the sequence that is
shown in Illustration 155.
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”.
g01269948
Illustration 154
(7) M8 by 20 mm
(8) M8 by 35 mm
(9) M8 by 25 mm
9. Install bolts (9) to front housing (3) finger tight.
10. Remove Tooling (B).
11. Loosely install bolts (7) and (8). Refer to

g01265269
Illustration 154 for the correct position of the bolts. Illustration 156
Typical example
12. Align the bottom face of front housing (3) to the
lower machined face of the cylinder block. Use a 16. Install new O-ring seals (4) and (5) to bypass tube
Tooling (D) and a feeler gauge in order to check (1). Use Tooling (E) in order to lubricate O-ring
the alignment between the front housing and the seal (5). Install bypass tube (2) to the cylinder
cylinder block. Refer to Illustration 153. Refer to head. Install bolts (1). Ensure that any brackets
Specifications, “Front Housing and Covers” for that are secured by the bolts are installed in the
further information. correct location. Tighten the bolts to a torque of
22 N·m (16 lb ft).
RENR9525 85
17. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling NOTICE
System Coolant - Fill” for the correct procedure. Care must be taken to ensure that fluids are contained
End By: ing, adjusting and repair of the product. Be prepared to
a. Install the fuel injection pump. Refer to ing any compartment or disassembling any compo-
Disassembly and Assembly, “Fuel Injection Pump nent containing fluids.
- Install”.
b. Install the timing gears. Refer to Disassembly and mandates.
Assembly, “Gear Group (Front) - Install”.
c. Install the engine oil pan. Refer to Disassembly

Install”.
d. Install the crankshaft pulley. Refer to Disassembly

Install”.
e. Install the alternator. Refer to Disassembly and

f. Install the fan. Refer to Disassembly and

i02588315
Accessory Drive - Remove and

Install
g01269954
Illustration 157
Typical example
Removal Procedure
1. Remove allen head screw (1) from accessory
Table 43 drive housing (8). Remove allen head screws (6)
from accessory drive housing (8).
Required Tools
Part 2. Remove accessory drive housing (8) from the
Number front housing.
- Bearing Puller 1
3. If necessary, follow Steps 3.a through 3.c in order
- Puller 1 to disassemble the accessory drive.
A
- Crossblock 1
a. Remove circlip (2) from accessory drive
- Puller Leg 2 housing (8).
b. Place accessory drive housing (8) onto a

NOTICE suitable support. Press the assembly of gear
Keep all parts clean from contaminants. (4) and bearings (3) and (5) out of accessory
drive housing (8). Use a Tooling (A) in order to
Contaminants may cause rapid wear and shortened remove bearings (3) and (5) from gear (4).
component life.
c. Remove O-ring seal (7) from accessory drive
housing (8).
86 RENR9525
Installation Procedure c. Apply a small continuous bead of Tooling (B) to

inner surface (Z) of bearing (3). Place the inner
Table 44 race of bearing (3) onto a suitable support.
Required Tools Press the shaft of gear (4) into bearing (3) until
the shoulder of the gear is against the bearing.
Part Remove any excess sealant.
Number
POWERPART d. Apply a small continuous bead of Tooling
B 21820603 -
Retainer (B) to outer surface (Y) of bearings (3) and
(5). Place accessory drive housing (8) on a
POWERPART
C 21820221 1 suitable support. Press the assembly of the
Rubber Grease
gear into the accessory drive housing. Ensure
POWERPART that bearing (5) is against the front face of the
D 21820117 1
Threadlock and Nutlock recess in accessory drive housing (8). Remove
any excess sealant.
NOTICE e. Install circlip (2) into the groove in accessory
Keep all parts clean from contaminants. drive housing (8). Ensure that circlip (2) is
correctly positioned in the groove.
component life. 2. Lightly lubricate a new O-ring seal (7) with Tooling
(C). Install the O-ring seal into the groove in
accessory drive housing (8).
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 the
accessory drive housing (8). Tighten the allen
head screws to a torque of 22 N·m (16 lb ft).
6. Ensure that there is tactile backlash between the

g01264852 idler gear and the accessory drive gear.
Illustration 158
Typical example
1. If necessary, follow Steps 1.a through 1.e in order

to assemble the accessory drive.
a. Inspect the condition of the teeth and the

splines of gear (4) for wear or damage. Inspect
bearings (3) and (5), circlip (2), and the front
housing for wear or damage. Replace any
components that are worn or damaged.
b. Apply a small continuous bead of Tooling (B)

to inner surface (X) of bearing (5). Place the
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
excess sealant.
RENR9525 87
i02588318 2. Loosen clamp (6) and remove hose (7).

Crankcase Breather - Remove 3. Release spring clamps (2) in order to remove hose
and Install (3). Remove the hose from connection (1) on the
valve mechanism cover and from filter base (4).
(Filtered Breather)
4. Remove bolts (5) and remove filter base (4).
Note: If a spacer is installed between the filter base

Removal Procedure and the engine, remove the spacer.
NOTICE Installation Procedure

during performance of inspection, maintenance, test- NOTICE
ing, adjusting, and repair of the product. Be prepared Keep all parts clean from contaminants.
opening any compartment or disassembling any com- Contaminants may cause rapid wear and shortened
ponent containing fluids. component life.

mandates. 1. Ensure that all components of the crankcase
breather are clean and free from damage. Replace
any components that are damaged.
NOTICE

component life.
g01293387
Illustration 160
Typical example
2. Install bolts (5) to filter base (4).

g01293387 Note: If spacers are installed, position the spacers
Illustration 159
Typical example over the bolts.
1. Remove canister (8). Refer to Operation and 3. Install the assembly of the filter base to the engine.
Maintenance Manual, “Crankcase Breather
(Canister) - Replace”. 4. Tighten bolts (5) to a torque of 22 N·m (16 lb ft).
88 RENR9525
5. Install spring clamps (2) to hose (3). Install hose Installation Procedure
(3) to connection (1) and to filter base (4).
NOTICE
Note: Ensure that the spring clamps are correctly Keep all parts clean from contaminants.
positioned in order to secure the hose.
6. Install clamp (6) to hose (7). Install hose (7) to component life.
filter base (4). Tighten the clamp.
7. Install a new canister (8) to filter base (4). Refer to 1. Ensure that all components of the crankcase
Operation and Maintenance Manual, “Crankcase breather are clean and free from damage. Replace
Breather (Canister) - Replace”. any components that are damaged.
i02588317
Crankcase Breather - Remove

and Install
(Unfiltered Breather)
Removal Procedure
NOTICE
Keep all parts clean from contaminants. g01249095
Illustration 162
Contaminants may cause rapid wear and shortened Typical example
component life.
2. Connect hose (3) to connection (1) on the valve
mechanism cover. Tighten clamp (2). Install hose
(3) into clip (4).
i02588319
Valve Mechanism Cover -

Remove and Install
Removal Procedure
Start By:
g01249095
Illustration 161
Typical example a. Disconnect the crankcase breather or remove the
crankcase breather. Refer to Disassembly and
1. Loosen clamp (2) and remove hose (3) from Assembly, “Crankcase Breather - Remove”.
connection (1) on the valve mechanism cover.
Withdraw hose (3) from clip (4) and remove the NOTICE
hose. Keep all parts clean from contaminants.

component life.

heat shield, remove the heat shield.
RENR9525 89
g01245161 g01245161
2. Remove bolts (1) and (2) from valve mechanism 2. Install a new joint (4) to valve mechanism cover
cover (3). (3).
3. Remove valve mechanism cover (3) from the Note: Ensure that the joint is fully seated into the
valve mechanism cover base. groove of the valve mechanism cover.
4. Remove joint (4) from valve mechanism cover (3).
NOTICE

component life.
1. Thoroughly clean the valve mechanism cover.

Clean the mating surfaces of the valve mechanism
cover base. g01269961
Illustration 165
Typical example
3. Ensure that harness assemblies (6) are not in

contact with the rocker arms or in contact with
the valve mechanism cover base. Position valve
mechanism cover (3) onto valve mechanism cover
base (5). Ensure that harness assemblies (6) are
not trapped during the assembly procedure. Install
bolts (1) and (2).
90 RENR9525
NOTICE

component life.
NOTICE
incorrect tooling will result in damage to the electronic
unit injectors.
g01245162
Illustration 166
Tightening sequence for the valve mechanism cover
4. Tighten bolts (1) and (2) in the numerical sequence

that is shown in Illustration 166. Tighten the bolts
to a torque of 6 N·m (53 lb in).

heat shield, install the heat shield. Tighten the
bolts to a torque of 9 N·m (79 lb in).
End By:
a. Connect the crankcase breather or install the

crankcase breather. Refer to Disassembly and
Assembly, “Crankcase Breather - Install”.
i02588321
Valve Mechanism Cover Base - Illustration 167

g01269979
Remove and Install Typical example
1. Make a temporary identification mark on

connections (1).
Removal Procedure
2. Use a deep socket to remove connections (1)
Table 45 from electronic unit injectors (2).
Required Tools
3. Disconnect plugs (7) from harness assemblies (4).
Part
Number 4. If necessary, follow Steps 4.a through 4.e in order
A - Circlip Pliers 1 to remove harness assemblies (4) from valve
mechanism cover base (6).
Start By: a. Cut cable ties (3).
a. Remove the valve mechanism cover. Refer to b. Use Tooling (A) to remove circlip (5).
Cover - Remove and Install”. c. From the outside of valve mechanism cover
base (6), push harness assembly (4) inward.
b. Remove the fuel injection lines. Refer to Withdraw the harness assembly from valve
Disassembly and Assembly, “Fuel Injection Lines mechanism cover base (6).
- Remove”.
d. Remove O-ring seal (8) from harness assembly
(4).
RENR9525 91
e. Repeat Steps 4.a through 4.d in order to Installation Procedure

remove the remaining harness assembly.
Table 46
Required Tools
Part
Number
POWERPART
B 21820221 1
Rubber Grease
C 27610296 Torque wrench 1
NOTICE

component life.
NOTICE
g01245186
Illustration 168 incorrect tooling will result in damage to the electronic
Typical example unit injectors.
1. Clean the valve mechanism cover base. Ensure

that the mating surfaces are free from damage.
g01245190
Illustration 169
Tightening sequence for the valve mechanism cover base
5. Gradually loosen the captive bolts that secure the

valve mechanism cover base in reverse numerical
order. Refer to Illustration 169. This will help
prevent distortion of the valve mechanism cover
base.
Note: The captive bolts cannot be removed from the

g01245186
valve mechanism cover base. Illustration 170
Typical example
6. Remove valve mechanism cover base (6) from
the cylinder head. 2. Install seal (9) to valve mechanism cover base
(6). Ensure that the seal is seated correctly in the
7. Remove seal (9) from valve mechanism cover groove in the valve mechanism cover base.
base (6).
92 RENR9525
a. Ensure that harness assembly (4) and the bore

in valve mechanism cover base (6) are clean
and free from damage. Replace any damaged
components.
b. Use Tooling (B) to lubricate a new O-ring

seal (8). Install O-ring seal (8) onto harness
assembly (4).
c. From the inside of valve mechanism cover

base (6), push harness assembly (4) into the
valve mechanism cover base.
d. Use Tooling (A) to install circlip (5).

g01272185
Illustration 171 e. Repeat Steps 6.a through 8 for the remaining
Tightening sequence for the valve mechanism cover base harness assembly.
3. Position valve mechanism cover base (6) on the 7. Use a deep socket to connect harness (4) to
cylinder head. Temporarily install two long bolts electronic unit injectors (2). Use Tooling (C) to
from the valve mechanism cover in positions (X). tighten connectors (1) to a torque of 2.4 N·m
(21 lb in).
Note: The long bolts must be installed in order to
align the valve mechanism cover base. 8. If necessary, install new cable ties (3) to harness
assemblies (4).
4. Gradually tighten the captive bolts that secure
the valve mechanism cover base to a torque of Note: Ensure that the cable ties conform to the
9 N·m (79 lb in) in the sequence that is shown in Perkins specification.
Illustration 171.
9. Connect plugs (7) to harness assemblies (4).
5. Remove the bolts from positions (X).
End By:
a. Install new fuel injection lines. Refer to

- Install”.

i02588323
Rocker Shaft and Pushrod -

Remove
Removal Procedure
Table 47
g01269979
Illustration 172 Required Tools
Typical example
Part
Number
6. If necessary, install the harness assemblies for the
electronic unit injectors. Follow Steps 6.a through A - E12 Torx Socket 1
6.e in order to install the harness assemblies to
the electronic unit injectors.
RENR9525 93
Start By: 4. Make a temporary mark on pushrods (3) in order

to show the location. Remove the pushrods from
a. Remove the valve mechanism cover. Refer to the cylinder head.
Cover - Remove and Install”. Note: Identification will ensure that the pushrods
can be reinstalled in the original positions. Do not
NOTICE interchange the positions of used pushrods.
5. Make a temporary mark on valve bridges (4) in
Contaminants may cause rapid wear and shortened order to show the location and the orientation.
component life. Remove the valve bridges from the cylinder head.
Note: Identification will ensure that the valve bridges

can be reinstalled in the original location and the
original orientation. Do not interchange the location
or the orientation of used valve bridges.
i02590313
Illustration 173
g01244058 Rocker Shaft - Disassemble
Disassembly Procedure
Start By:

Pushrod - Remove”.
NOTICE

component life.

Illustration 174
g01270001 parts propelled by a released spring force.
Typical example
1. Use Tooling (A) to progressively loosen torx ment.
screws (1). Begin at the ends of the rocker shaft
assembly and work toward the center. Follow the recommended procedure and use all
recommended tooling to release the spring force.
Note: To avoid distortion of the rocker shaft assembly,
each torx screw should be loosened by a quarter of a 1. Make an identification mark on each rocker arm
turn at one time. Repeat the procedure until all torx assembly in order to show the location.
screws are loosened.
Note: The components must be reinstalled in the
2. Remove torx screws (1) from rocker shaft original location. Do not interchange components.
assembly (2).
3. Remove rocker shaft assembly (2) from the

cylinder head.
94 RENR9525
g01270008
Illustration 176
6. If necessary, remove retaining clip (7) and remove

spring (8) from the front end of rocker shaft (5).
7. If necessary, remove nuts (9) and adjusters

(10) 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.
g01244059
Illustration 175
i02588326
Typical example
Rocker Shaft - Assemble
2. Remove pedestals (1) from rocker shaft (5). Do
not remove dowels (2) from the pedestals.
3. Remove rocker arm assembly (4) for the exhaust

valve from rocker shaft (5). Remove rocker arm
Assembly Procedure
assembly (3) for the inlet valve from rocker shaft
(5). Begin at the rear of the rocker shaft assembly. NOTICE
Note: The rocker arm assembly for the inlet valve is
longer than the rocker arm assembly for the exhaust Contaminants may cause rapid wear and shortened
valve. component life.
4. Remove spring (6) from rocker shaft (5).

1. Ensure that all components are clean and free
5. Repeat Steps 3 and 4 in order to remove the from wear or damage. Refer to Specifications,
remaining rocker arms from rocker shaft (5). “Rocker Shaft” for more information. If necessary,
replace any components that are worn or
damaged.
RENR9525 95
5. Place the rocker shaft in the inverted position with

the counterbores for the holes downward. 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 (5).
Note: The rocker arms for the inlet valves are

longer than the rocker arms for the exhaust valves.
Install rocker arms in the inverted position. Used
components should be installed in the original
location.
6. Ensure that dowel (2) is correctly seated in

pedestal (1). Align the dowel with the appropriate
hole in rocker shaft (5). Install the pedestal to the
rocker shaft.

To prevent possible injury, follow the established

assembly procedure and wear protective equip-
ment.
g01244059
Illustration 177 7. Install spring (6) to rocker shaft (5).
Typical example
8. Repeat Steps 5 to 7 in order to assemble the
2. If necessary, install nuts (9) and adjusters (10) to remaining components to rocker shaft (5).
rocker arm assemblies (3) and (4). If the original
adjusters are reused, ensure that the adjusters End By:
are installed in the original positions.
a. Install the rocker shaft assembly. Refer to
i02588327
Rocker Shaft and Pushrod -

Install
Table 48
g01270008
Illustration 178
Required Tools
3. Install retaining clip (7) and spring (8) to the front Part
end of rocker shaft (5). Number
A - E12 Torx Socket 1
4. Lubricate the bores of rocker arm assemblies (3)
and (4) and rocker shaft (5) with clean engine oil. B 27610298 Angled Feeler Gauges 1
96 RENR9525
NOTICE

component life.
1. Clean the valve bridges. Inspect the valve bridges

for wear or damage. Replace any valve bridges
that are worn or damaged.
g01270057
Illustration 180
6. Position rocker shaft assembly (2) onto the

cylinder head. The retaining clip (6) should face
the front of the engine.
Note: Ensure that adjustment screws (5) are properly

seated in the ends of pushrods (3).
7. Install torx screws (1) to the rocker shaft assembly.
8. Install torx screws (1) finger tight. 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,

g01270054 each torx screw should be tightened by a quarter of a
Illustration 179
turn at one time. Repeat the procedure until all torx
Typical example screws are tightened.
2. Lubricate valve bridges (4) with clean engine oil. Tighten torx screws (1) to a torque of 35 N·m
Install the valve bridges to the cylinder head. (26 lb ft).
Note: Install used valve bridges in the original
location and in the original orientation. Ensure that the
valve bridges are correctly seated on the valves. New
valve bridges may be installed in either orientation.
3. Clean the pushrods. Inspect the pushrods for

wear or damage. Replace any pushrods that are
worn or damaged.
4. Apply clean engine lubricating oil to both ends of

pushrods (3). Install the pushrods to the engine
with the cup upward.
Note: Ensure that the pushrods are installed in the

original location and that the ball end of each pushrod Illustration 181
g01259267
is correctly seated in the valve lifters. Typical example
5. Ensure that the rocker shaft assembly is clean

and free from wear or damage.
RENR9525 97
9. Use Tooling (B) in order to check the valve

lash. Refer to Systems Operation, Testing and NOTICE
Adjusting, “Engine Valve Lash - Inspect/Adjust”. If Care must be taken to ensure that fluids are contained
necessary, adjust the valve lash. Refer to Systems during performance of inspection, maintenance, test-
Operation, Testing and Adjusting, “Engine Valve ing, adjusting and repair of the product. Be prepared to
Lash - Inspect/Adjust” for the correct procedure. collect the fluid with suitable containers before open-
End By: nent containing fluids.
a. Install the valve mechanism cover. Refer to Dispose of all fluids according to local regulations and
Disassembly and Assembly, “Valve Mechanism mandates.
i02588329 hose assemblies, on wires and on all tube assemblies
Cylinder Head - Remove and tube assemblies. This helps to prevent fluid loss
the system.
Removal Procedure 1. If the alternator bracket is mounted on the cylinder

head, remove the alternator. Refer to Disassembly
Start By: and Assembly, “ Alternator - Remove”.
a. Remove the exhaust manifold. Refer to 2. If the fuel priming pump and the primary fuel filter
Disassembly and Assembly, “Exhaust Manifold are mounted on the cylinder head, remove the fuel
- Remove and Install”. priming pump and the primary fuel filter. Refer to
Disassembly and Assembly, “Fuel Priming Pump
b. Remove the fuel manifold. Refer to Disassembly - Remove and Install”.
and Assembly, “Fuel Manifold (Rail) - Remove
and Install”. 3. Drain the coolant from the cooling system into
a suitable container for storage or for disposal.
c. Remove the mounting bracket for the electronic Refer to Operation and Maintenance Manual,
control module. Refer to Disassembly and “Cooling System Coolant - Change” for the correct
Assembly, “ECM Mounting Bracket- Remove and draining procedure.
Install”.
d. Remove the electronic unit injectors. Refer to

Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
e. Remove the valve mechanism cover base. Refer

to Disassembly and Assembly, “Valve Mechanism
Cover Base - Remove”.
f. Remove the glow plugs. Refer to Disassembly

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

component life.
g01245537
Illustration 182
Typical example
4. Disconnect the upper radiator hose from water

temperature regulator housing (1).
98 RENR9525
5. If necessary, remove the air hose from the inlet

connection.
6. Follow Steps 6.a and 6.b in order to disconnect

harness assembly (4) from coolant temperature
sensor (2).
a. Slide the locking tab into the unlocked position.
b. Disconnect harness assembly (4) from coolant

temperature sensor (2).
7. If necessary, follow Steps 7.a and 7.b in order

to disconnect harness assembly (4) from boost
pressure sensor (3).
b. Disconnect harness assembly (4) from boost

g01249474
Illustration 184
Typical example
10. Remove tube assembly (6) from the cylinder head

and from transfer pump (7).
g01249835
Illustration 183
Typical example
8. Follow Steps 8.a and 8.b in order to disconnect

harness assembly (4) from inlet air temperature
sensor (5).
b. Disconnect harness assembly (4) from inlet air

9. Remove all cable ties that secure harness

g01249479
assembly (4) to the cylinder head. The harness Illustration 185
assembly should be positioned in order to avoid Typical example
causing an obstruction during the removal of the
cylinder head. 11. If the engine is equipped with a wastegate
solenoid, remove harness assembly (9) from tube
assembly (8). Remove the fasteners for tube clips
(10) and (11). Remove tube assembly (8) from the
wastegate solenoid and from the cylinder head.
RENR9525 99
14. Remove bolts (16) from cylinder head (17).
g01249836
Illustration 186
Typical example
12. Remove bolts (12). Note the position of any

brackets that are secured by the bolts. Remove
bypass tube (13) from the cylinder head. Remove
O-ring seals (14) and (15) from the bypass tube.
g01245540
Illustration 189
Typical example
15. Attach a suitable lifting device (18) to cylinder

head (17). Support the weight of the cylinder head.
The weight of the cylinder head is approximately
56 kg (124 lb).
Note: It is advisable to use a spreader bar during the

lifting operation in order to distribute the weight of
the cylinder head .
16. Use lifting device (18) to carefully lift cylinder

head (17) off the cylinder block.
g01245538
Illustration 187
Note: Do not use a lever to separate the cylinder
head from the cylinder block. Take care not to
damage the machined surfaces of the cylinder head
during the removal procedure.
NOTICE
Place the cylinder head on a surface that will not
scratch the face of the cylinder head.
g01250785
Illustration 188
Sequence for tightening the bolts for the cylinder head
13. Gradually loosen bolts (16) in the reverse

numerical order to the sequence that is shown
in Illustration 188.
Note: Follow the correct sequence in order to help

prevent distortion of the cylinder head.
100 RENR9525
i02588330
Cylinder Head - Install
Table 49
Required Tools
Part
Number
- Guide Stud
A 2
g01244060 (M16 by 115mm)
Illustration 190
Typical example B - Straight Edge 1
C 21825607 Angle gauge 1
17. Remove cylinder head gasket (20).
POWERPART
D 21820221 1
18. Note the position of dowels (19) in the cylinder Rubber Grease
block. Do not remove the dowels unless the
dowels are damaged.
NOTICE

component life.
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

g01266027
for distortion. Refer to Specifications, “Cylinder
Illustration 191 Head” for more information. If the mating surface
Typical example of the cylinder head is distorted beyond maximum
permitted limits, replace the cylinder head.
19. If necessary, remove screws (21) and remove
mounting bracket (22) from the cylinder head.
20. If necessary, remove the water temperature

regulator from the cylinder head. Refer to
Disassembly and Assembly, “Water Temperature
Regulator - Remove and Install”.
21. If necessary, remove the electronic sensors

from the cylinder head. Refer to Disassembly
and Assembly, “Coolant Temperature Sensor -
Remove and Install”. Refer to Disassembly and
Assembly, “Air Temperature Sensor - Remove
and Install”. Refer to Disassembly and Assembly,
“Boost Pressure Sensor - Remove and Install”.
g01244064
Illustration 192
3. Inspect dowels (19) for damage. If necessary,

replace the dowels in the cylinder block.
RENR9525 101
4. Install Tooling (A) to the cylinder block. Refer to 8. Clean bolts (16). Follow Steps 8.a and 8.b for the
Illustration 192. procedure to inspect the bolts.
5. Align cylinder head gasket (20) with Tooling (A) a. Check the length of the bolts.
and with dowels (19). Install the cylinder head
gasket onto the cylinder block. b. Use Tooling (B) in order to check the threads of
the bolts. Refer to Illustration 194. 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

(16) with clean engine oil.
10. Remove Tooling (A).
g01245540
Illustration 193
Typical example g01245538
Illustration 195
6. Use a suitable lifting device (18) 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.
7. Use Tooling (A) to align cylinder head (17) with

the cylinder block. Install the cylinder head to the
cylinder block.
Note: Ensure that the cylinder head is correctly

positioned onto dowels (19).
g01245620
Illustration 196
Sequence for tightening the bolts for the cylinder head
11. Install bolts (16) to cylinder head (17).
12. Tighten bolts (16) to a torque of 50 N·m (37 lb ft)

Illustration 194
g01250784 13. Tighten bolts (16) to a torque of 100 N·m (74 lb ft)
102 RENR9525
14. Use Tooling (C) to turn bolts (16) through an

additional 225 degrees. Turn bolts (16) in the
sequence that is shown in Illustration 196.
g01249836
Illustration 197
Typical example
15. Install new O-ring seals (14) and (15) to bypass Illustration 199
g01249474
tube (13). Use Tooling (D) in order to lubricate Typical example
O-ring seal (14). Install the bypass tube to the
cylinder head. Install bolts (12). Ensure that any 17. Follow Steps 17.a through 17.c in order to install
brackets that are secured by the bolts are installed tube assembly (6) for the fuel return.
in the correct position. Tighten the bolts to a
torque of 22 N·m (16 lb ft). a. Install the banjo bolts and new sealing washers
to tube assembly (6).
b. Install tube assembly (6) to the cylinder head

and to transfer pump (7).
c. Tighten the banjo bolts to a torque of 22 N·m

(16 lb ft).
18. If necessary, install the electronic sensors to

the cylinder head. Refer to Disassembly and
Assembly, “Coolant Temperature Sensor -
Remove and Install”. Refer to Disassembly and
Assembly, “Air Temperature Sensor - Remove
and Install”. Refer to Disassembly and Assembly,
“Boost Pressure Sensor - Remove and Install”.
g01249479
Illustration 198
Typical example
16. If the engine is equipped with a wastegate

solenoid, install tube assembly (9) to the
wastegate solenoid and to the cylinder head.
Install the fasteners for tube clips (10) and (11).
Tighten M8 fasteners to a torque of 22 N·m
(16 lb ft). tighten M10 fasteners to a torque of Illustration 200
g01266027
44 N·m (32 lb ft). Secure harness assembly (9) to
Typical example
tube assembly (8).
RENR9525 103
19. If necessary, install mounting bracket (22) and 22. Follow Steps 22.a and 22.b in order to connect
install screws (21) to the cylinder head. Tighten harness assembly (4) to coolant temperature
the screws to a torque of 22 N·m (16 lb ft). sensor (2).
a. Connect harness assembly (4) to coolant

b. Slide the locking tab into the locked position.
23. Use new cable ties in order to secure the harness

assembly to the cylinder head. Ensure that the
harness assembly is not strained.
Note: Ensure that the harness assembly is clear of

other engine components.
24. If necessary, install water temperature regulator

housing (1) to the cylinder head. Refer to
g01249835
Illustration 201 Disassembly and Assembly, “Water Temperature
Typical example Regulator Housing - Remove and Install”.
20. Follow Steps 20.a and 20.b in order to connect 25. Install the mounting bracket for the electronic
harness assembly (4) to inlet air temperature control module. Refer to Disassembly and
sensor (5). Assembly, “ECM Mounting Bracket - Remove and
Install”.
a. Connect harness assembly (4) to inlet air
temperature sensor (5). 26. Install the glow plugs. Refer to Disassembly and
Assembly, “Glow Plugs - Remove and Install”.
b. Slide the locking tab into the locked position.
27. Install the valve mechanism cover base. Refer to
Cover Base - Install”.
28. Install the electronic unit injectors. Refer to

Disassembly and Assembly, “Electronic Unit
Injector - Remove”.
29. Install the fuel manifold. Refer to Disassembly and

Assembly, “Fuel Manifold - Remove and Install”.
30. Install the exhaust manifold. Refer to Disassembly

and Assembly, “Exhaust Manifold - Remove and
Install”.
31. If necessary, install the fuel filter base and the

secondary fuel filter. Refer to Disassembly and
Assembly, “Fuel Filter Base - Remove and Install”.
32. If necessary, install the fuel priming pump and

the primary fuel filter. Refer to Disassembly and
g01245537 Assembly, “Fuel Priming Pump - Remove and
Illustration 202
Install”.
Typical example
33. If the alternator bracket is mounted on the cylinder
21. Follow Steps 21.a and 21.b in order to connect head, install the alternator. Refer to Disassembly
harness assembly (4) to boost pressure sensor and Assembly, “ Alternator - Install”.
(3).
34. If necessary, install the air hose to the inlet
a. Connect harness assembly (4) to boost connection.
35. Connect the upper radiator hose to water
b. Slide the locking tab into the locked position. temperature regulator housing (1).
104 RENR9525
36. Fill the cooling system with coolant. Refer to

Operation and Maintenance Manual, “Cooling
System Coolant - Change” for the correct filling
procedure.
37. If necessary, fill the engine oil pan to the correct

level that is indicated on the engine oil level
gauge. Refer to Operation and Maintenance
Manual, “Engine Oil Level - Check”.
i02588331
Lifter Group - Remove and

Install g01266042
Illustration 203
Typical example
2. Use Tooling (B) in order to remove lifters (1).

Removal Procedure
Table 50 Note: Place a temporary identification mark on each
lifter in order to identify the correct location.
Required Tools
Tool Part Part Description Qty 3. Repeat Steps 1 and 2 in order to remove the
Number remaining lifters.
A 21825576 Crankshaft Turning Tool 1
-
B Telescopic Magnet 1
Table 51
Start By: Required Tools
a. If the engine is equipped with a balancer, remove
Number
“Balancer - Remove”. If the engine is not equipped A 21825576 Crankshaft Turning Tool 1
with a balancer, remove the engine oil pump. -
B Telescopic Magnet 1
Refer to Disassembly and Assembly, “Engine Oil
Pump - Remove”.
NOTICE
b. Remove the camshaft. Refer to Disassembly and Keep all parts clean from contaminants.
Assembly, “Camshaft - Remove and Install”.
NOTICE component life.
Contaminants may cause rapid wear and shortened NOTICE

component life. It is strongly recommended that all lifters should be
replaced when a new camshaft is installed.
1. If the crankshaft is installed, use Tooling (A) to

rotate the crankshaft in order to gain access to 1. Clean the lifters. Follow Steps 1.a through 1.c in
lifters (1). order to inspect the lifters. Replace lifters that are
worn or damaged.
a. Inspect the seat of the pushrod in the lifter for

visual wear or damage.
b. Inspect the shank of the lifter for wear or

damage. Refer to Specifications, “Lifter Group”
for more information.
RENR9525 105
c. Inspect the face of the lifter that runs on the b. Remove the front housing. Refer to Disassembly
camshaft for visual wear or damage. and Assembly, “Housing (Front) - Remove”.
2. If the crankshaft is installed, use Tooling (A) to NOTICE

rotate the crankshaft. Rotate the crankshaft to Keep all parts clean from contaminants.
access to the cylinder block in order to install
lifters (1). Contaminants may cause rapid wear and shortened
component life.
3. Lubricate lifters (1) with clean engine oil.
1. The engine should be mounted on a suitable

stand and placed in the inverted position.
g01266042
Illustration 204
Typical example
g01266056
4. Use Tooling (B) to install lifters (1) to the cylinder Illustration 205
block. Ensure that used lifters are installed in the Typical example
correct location.
2. Remove thrust washer (1) from the cylinder block.
Note: The lifters should be free to rotate. Do not remove dowel (2) from the cylinder block
unless the dowel is damaged.
5. Repeat Steps 1 and 4 in order to install the
remaining lifters. Note: The thrust washer can have one or two slots
(X).
End By:
a. Install the camshaft. Refer to Disassembly and

b. If the engine is equipped with a balancer, install

“Balancer - Install”. If the engine is not equipped
with a balancer, install the engine oil pump. Refer
to Disassembly and Assembly, “Engine Oil Pump
- Install”.
i02588358
Camshaft - Remove and Install Illustration 206

g01266057
NOTICE
Do not damage the lobes or the bearings when the
Removal Procedure camshaft is removed or installed.
Start By:
3. Carefully remove camshaft (3) from the cylinder
a. Remove the rockershaft and pushrods. Refer to block.
Disassembly and Assembly, “Rocker shaft and
Pushrod - Remove”. 4. Do not remove key (4) from camshaft (3) unless
the key is damaged.
106 RENR9525
Installation Procedure 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.
2. Clean the camshaft bearing in the cylinder

block. Inspect the camshaft bearing for wear
g01266056
and for damage. Refer to Specifications, Illustration 208
“Camshaft Bearings” for more information. If Typical example
necessary, replace the camshaft bearing. Refer to
Disassembly and Assembly, “Camshaft Bearing 7. Lubricate the thrust washer with clean engine oil.
- Remove and Install”. Align slot (X) in thrust washer (1) with dowel (2)
in the cylinder block. Install thrust washer (1) into
NOTICE the recess in the cylinder block.
It is strongly recommended that all lifters should be
replaced when a new camshaft is installed. Note: The thrust washer can have one or two slots.
End By:
3. Inspect the lifters for wear and for damage.
Refer to Specifications, “Lifter Group” for more a. Install the front housing. Refer to Disassembly and
information. Replace any worn lifters or any Assembly, “Housing (Front) - Install”.
damaged lifters. Refer to Disassembly and
Assembly, “Lifter Group - Remove and install”. b. Install the rockershaft and pushrods. Refer to
Disassembly and Assembly, “Rocker shaft and
i02590360
Camshaft Gear - Remove and

Install
Removal Procedure
Table 52
Illustration 207
Part
4. If necessary, install a new key (4) to camshaft (3). Tool Part Name Qty
Number
5. Lubricate the bearing surfaces of camshaft (3) A1 21825576 Crankshaft Turning Tool 1
and lubricate the lobes of the camshaft with clean 27610291 Barring Device Housing 1
engine oil. A2
27610289 Gear 1
NOTICE B 27610212 Camshaft Timing Pin 1
Do not damage the lobes or the bearings when the
camshaft is removed or installed.
RENR9525 107
Start By: Note: Do not use excessive force to install Tooling

(C). Do not use Tooling (C) to hold the crankshaft
a. Remove the valve mechanism cover. Refer to during repairs.
b. Remove the front cover. Refer to Disassembly and


NOTICE

component life.
g01270430
Illustration 210
NOTICE Typical example
during performance of inspection, maintenance, test- 4. Loosen nuts (6) on ALL rocker arms (7). Unscrew
ing, adjusting and repair of the product. Be prepared to adjusters (5) on all rocker arms (7) until all valves
collect the fluid with suitable containers before open- are fully closed.
nent containing fluids. Note: Failure to ensure that all adjusters are fully
unscrewed can result in contact between the valves
Dispose of all fluids according to local regulations and and pistons.
mandates.

Operation, Testing and Adjusting, “Finding Top
g01255715
Illustration 211
5. Mark gears (1) and (4) in order to show alignment.

Note: Identification will ensure that the gears can be

g01255712
Illustration 209 installed in the original alignment.
Typical example

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.

Use Tooling (C) in order to lock the crankshaft in
the correct position.
108 RENR9525
g01270432 g01255712
6. Remove Tooling (B) and Tooling (C). Remove bolt 2. Install Tooling (C) into hole (Y) in the cylinder
(3) and washer (2) from camshaft gear (1). block. Use Tooling (C) in order to lock the
crankshaft in the correct position. Refer to
7. Remove camshaft gear (1) from the camshaft. Systems Operation, Testing and Adjusting,
“Finding Top Centre Position for No.1 Piston”.
Note: If the camshaft gear is a tight fit on the nose
of the camshaft, use a prybar in order to remove the 3. Ensure that the camshaft gear and the key are
camshaft gear. clean and free from wear or damage.
8. If necessary, remove the key from the nose of the 4. If necessary, install the key into the nose of the
camshaft. camshaft.
Installation Procedure Note: Ensure that the key is squarely seated.
Table 53
Required Tools
Part
Tool Part Name Qty
Number
D
- Finger Clock 1
NOTICE
Keep all parts clean from contaminants. g01255715
Illustration 214
component life. 5. Align the keyway in camshaft gear (1) with the key
in the camshaft. Install the camshaft gear onto the
1. Ensure that number one piston is at the top center camshaft. Ensure that the timing marks on gears
position on the compression stroke. Refer to (1) and (8) are in alignment and that the mesh of
the Systems Operation, Testing and Adjusting, the gears is correct. Refer to Illustration 214.
RENR9525 109
i02588511
Camshaft Bearings - Remove

and Install
Removal Procedure
Table 54
Required Tools
Part
g01270432
Illustration 215 A 27610271 Bearing Puller Group 1
Typical example
Start By:
6. Install Tooling (B) through hole (X) in the camshaft
gear into the front housing. Install washer (2) and
bolt (3) to camshaft gear (1).
“Balancer - Remove”. If the engine is not equipped
with a balancer, remove the engine oil pump.
8. Tighten bolt (3) to a torque of 95 N·m (70 lb ft).
Pump - Remove”.
9. Use Tooling (D) to check the backlash for gears (1)
b. Remove the camshaft. Refer to Disassembly and
and (8). Ensure that the backlash for the gears is
within specified values. Refer to the Specifications,
“Gear Group (Front)” for further information.
NOTICE
10. Use Tooling (D) to check the end play for Keep all parts clean from contaminants.
camshaft gear (1). Ensure that the end play is
within specified values. Refer to the Specifications, Contaminants may cause rapid wear and shortened
“Camshaft” for further information. component life.
11. Lubricate the teeth of the gears with clean engine

oil.
12. Adjust the valve lash. Refer to Systems

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


Cover - Remove and Install”. Illustration 216
g01270437
1. Inspect camshaft bearing (1). Refer to

Specifications, “Camshaft Bearings” for more
information.
2. If camshaft bearing (1) is worn or damaged use

Tooling (A) in order to remove the camshaft
bearing from the cylinder block.
Note: Remove the camshaft bearing from the front of

the cylinder block.
110 RENR9525
Installation Procedure b. If the engine is equipped with a balancer, install

Table 55 “Balancer - Install”. If the engine is not equipped
Required Tools with a balancer, install the engine oil pump. Refer
Part - Install”.
A 27610271 Bearing Puller Group 1
i02588515
NOTICE
Engine Oil Pan - Remove and
Keep all parts clean from contaminants. Install
Contaminants may cause rapid wear and shortened (Aluminum and Pressed Steel
component life. Oil Pans)
1. Clean the bearing housing in the cylinder block.
Ensure that the oil holes in the bearing housing
are free from debris. Removal Procedure
NOTICE

component life.
NOTICE
g01266512 nent containing fluids.
Illustration 217
2. Lubricate the bearing housing in the cylinder block mandates.
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
block.
Note: Ensure that all oil holes are correctly aligned.

If the oils are not correctly aligned, the camshaft
bearing should be removed.
End By:
a. Install the camshaft. Refer to Disassembly and

RENR9525 111
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 bolts (9) and (10).
Remove the clip.
6. Remove engine oil pan (8) and remove joint (7)

from the cylinder block.
g01251772
Illustration 218
Typical example Table 56
Required Tools
1. Place a suitable container below the engine
oil pan. Remove drain plug (5) and drain the Part
engine lubricating oil. Refer to Operation and Tool Number Part Description Qty
Maintenance Manual, “Engine Oil and Filter - Guide Stud
A - 4
Change” for the correct procedure. (M8 by 100 mm)
Note: Clean up any spillage of oil immediately. 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 219
Typical example
112 RENR9525
g01251766
Illustration 222
Typical example
4. Apply a bead of Tooling (B) to positions (Y) on the

cylinder block.
Illustration 220
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 221
Typical example
g01251767
Illustration 223
Typical example
5. Position a new joint (7) onto engine oil pan (8).

RENR9525 113
i02588533
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
g01251772 Contaminants may cause rapid wear and shortened

Illustration 224
component life.
Typical example
6. Align the assembly of the engine oil pan with NOTICE

Tooling (A). Install the assembly of the engine Care must be taken to ensure that fluids are contained
oil pan to the cylinder block. Install the clip (6), during performance of inspection, maintenance, test-
that secures the breather hose (1) in the correct ing, adjusting and repair of the product. Be prepared to
position. collect the fluid with suitable containers before open-
7. Install bolts (9). Tighten the bolts finger tight. nent containing fluids.
8. Remove Tooling (A). Dispose of all fluids according to local regulations and
mandates.
9. Apply Tooling (C) to bolts (10). Install bolts (10)
and the remaining bolts (9).
1. The engine should be mounted in a suitable stand
and placed in the inverted position.
10. Tighten bolts (10) and (10) to a torque of 22 N·m
(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
g01251772
to Operation and Maintenance Manual, “Oil Filter Illustration 225
Change” for the procedure. Typical example
114 RENR9525
2. Disconnect breather hose (1) from clip (6). 9. If necessary, remove drain plug (5). Remove
Position the breather hose away from the engine O-ring seal (11) from oil drain plug (5).
oil pan.
Note: Identify the position and orientation of the tube

assembly before removal. Table 57
3. Remove the assembly of dipstick tube. Loosen Required Tools

nut (3) and remove tube assembly (2). Remove Part
seal (4) from the tube assembly. Tool Number Part Description Qty
POWERPART -
A 21826038
Silicon Rubber Sealant
POWERPART -
B 21820117
C - Straight Edge 1
Note: In order to install a cast iron oil pan, the engine

must be removed from the machine.
NOTICE

component life.
1. Ensure that the joint face 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.
g01251978
Illustration 226
Typical example
4. Mark the position of clip (6) that secures the

breather hose. Refer to Illustration 225. Loosen
the bolt that secures the clip and remove the clip.
5. Remove nuts (10) and bolts (9).
Note: The bolts are different lengths. Note the

position of the different bolts.
g01251763
Illustration 227
6. Attach a suitable lifting device to engine oil pan
Typical example
(8). Support the weight of the engine oil pan. The
weight of the engine oil pan is approximately41 kg
(90 lb).
7. Use the lifting device to remove engine oil pan (8)

from the cylinder block.
8. Remove joint (7) from the cylinder block.

RENR9525 115
6. Use the lifting device to align engine oil pan (8)

with the studs in the cylinder block. Install the
engine oil pan to the cylinder block. Remove the
lifting device from the engine oil pan.
7. Install bolts (9) and nuts (10) finger tight. Install

the clip (6), that secures the breather hose in the
correct position.
g01251766
Illustration 228
Typical example
3. Apply a bead of Tooling (A) to positions (Y) on the

cylinder block.
Note: If the bridge piece for the cylinder block has

just been installed, the engine oil pan must be
g01251982
installed before Tooling (A) has cured. Illustration 230
Typical example
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.
9. Tighten bolts (9) and nuts (10) to a torque of

22 N·m (16 lb ft).
10. If necessary, install a new O-ring seal (11) to drain

plug (5). Install drain plug (5) to engine oil pan
(8). Tighten the drain plug to a torque of 34 N·m
(25 lb ft).
g01251978
Illustration 229
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 weight of the engine oil pan is approximately g01251772
Illustration 231
41 kg (90 lb).
Typical example
116 RENR9525
11. Follow Steps 11.a through 11.c in order to install

the assembly of the dipstick tube. NOTICE
a. Install a new seal (4) to tube assembly (2).
b. Apply Tooling (B) to nut (3). Install the tube component life.
assembly to the engine oil pan.
Note: Ensure that the orientation of the tube NOTICE

assembly is correct. Care must be taken to ensure that fluids are contained
c. Tighten the nut to a torque of 18 N·m (13 lb ft). ing, adjusting and repair of the product. Be prepared to
Install the dipstick. collect the fluid with suitable containers before open-
12. Install breather hose (1) to clip (6) that secures nent containing fluids.
the hose to the engine oil pan.
Note: After the engine has been installed, ensure that mandates.
the engine oil pan is filled with lubricating oil to the
correct level. Refer to Operation and Maintenance 1. Use Tooling (A) in order to rotate the crankshaft
Manual, “Oil Filter Change” for the correct procedure. so that number one piston is at the top center
position.
i02589157
Balancer - Remove
Removal Procedure
Table 58
Required Tools
Part
Tool Part Name Qty
Number
A 21825576 Crankshaft Turning Tool 1
g01259627
B 27610211 Crankshaft Timing Pin 1 Illustration 232
Typical example
C 27610225 Timing Pin (Balancer) 1
D - Puller (Two Leg) 1 2. Install Tooling (B) through hole (X) in the front
housing. Use Tooling (B) in order to lock the
crankshaft in the correct position.
Start By:
a. Remove the engine oil pan. Refer to Disassembly

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.
RENR9525 117
g01259636
Illustration 235
8. Do not remove dowels (6) and (7) unless the

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

g01259635 The engine oil pump and the engine oil relief valve
Illustration 233
are the only serviceable parts of the balancer.
Typical example
3. Remove bolts (3) and suction pipe (2). Disassembly Procedure

4. Remove the joint from the suction pipe. 1. Remove the engine oil relief valve. Refer to
Disassembly and Assembly, “Engine Oil Relief
Valve - Remove and Install”.
g01252310
Illustration 234
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

the balancer.
g01252311
Illustration 236
2. Remove bolt (8) and hub (9). Remove idler gear

(10) and thrust washer (11).
118 RENR9525
g01259631
Illustration 237
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

order to loosen nut (12).
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. Illustration 238

g01252311
Typical example
i02589159
2. Install inner rotor (16) and install outer rotor (17).
Balancer - Install 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 Procedure assembly. Refer to Specifications, “Engine Oil
Table 59 Pump” for more information.
Required Tools 3. Lubricate the assembly of the oil pump with clean
Tool Part Number Part Description Qty engine oil. Install front cover (15). Install bolts (14).
Tighten the bolts to a torque of 26 N·m (19 lb ft).
POWERPART
E 21820117 1
Threadlock and Nutlock 4. Ensure that the shaft of the oil pump is clean
and dry. Position gear (13) onto the shaft. Install
NOTICE nut (12). Tighten the nut to a torque of 95 N·m
Keep all parts clean from contaminants. (70 lb ft).
Contaminants may cause rapid wear and shortened Note: Do not use a timing pin to lock the balancer in
component life. order to tighten nut (12).
5. Lubricate hub (9), thrust washer (11) and the bush

1. Ensure that all components of the engine oil pump of idler gear (10) with clean engine oil. Install hub
are clean and free from wear or damage. (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).
RENR9525 119
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”.
9. Install the engine oil relief valve . Refer to

Disassembly and Assembly, “Engine Oil Relief
Valve - Remove and Install” for further information.
Table 60 g01252312
Illustration 240
Required Tools
3. Install Tooling (G) to the cylinder block.
C 27610225 Timing Pin (Balancer) 1
F
- Finger Clock 1
- Guide Studs
G 1
(M10 by 75 mm)
g01260306
Illustration 241
4. Ensure that dowels (6) and (7) are seated in the

housing of balancer (1).
g01259627
Illustration 239
1. Ensure that No. 1 piston is at the top center

position and that Tooling (B) is installed to position
(X) in the front housing.
2. Clean the mating surfaces of the cylinder block.
g01252310
Illustration 242
5. Install Tooling (C) to balancer (1). Ensure that

Tooling (C) is engaged into shaft (5).
6. Attach a suitable lifting device to the balancer. The

balancer weighs approximately 23 kg (51 lb).
120 RENR9525
7. Use the lifting device to align balancer (1) with i02591050

Tooling (G). Install the balancer to the cylinder
block. Ensure that dowels (6) and (7) are aligned Piston Cooling Jets - Remove
with the holes in the cylinder block. Ensure that and Install
gear (10) and the crankshaft gear mesh. Remove
the lifting device.
Removal Procedure
Table 61
Required Tools
Number
A2
27610289 Gear 1
Start By:

Illustration 243
g01259635 Pump - Remove”.
8. Install bolts (4) to balancer (1) finger tight. Note: Either Tooling (A) can be used. Use the Tooling
9. Remove the Tooling (G) and install remaining
bolts (4). Tighten the bolts to a torque of 54 N·m NOTICE
(40 lb ft). Keep all parts clean from contaminants.
10. Remove the Tooling (B) and (C). Contaminants may cause rapid wear and shortened
component life.
11. Install suction pipe (2) and a new joint to balancer
(1).
1. If the crankshaft is installed, use Tooling (A) to
12. Install bolts (3). Tighten the bolts to a torque to rotate the crankshaft in order to gain access to the
22 N·m (16 lb ft). appropriate piston cooling jet.
13. Use Tooling (F) in order to check the backlash

between gears (10) and (13). Refer to Illustration
241. 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:

and Assembly , “Engine Oil Pan - Remove and
Install”. g01265615
Illustration 244
b. Install the front cover. Refer to Disassembly and Typical example
RENR9525 121
2. Remove bolt (1) and piston cooling jet (2) from 5. If the cylinder head has been removed, It is
the cylinder block. possible to check the alignment of the piston
cooling jets. Refer to Specifications, “Piston
3. Repeat Steps 1 and 2 for the remaining piston Cooling Jet Alignment” for more information.
cooling jets.
Note: It is not possible to check the alignment of the
piston cooling jets with the cylinder head in position.
Table 62 End By:
Required Tools a. If the engine is equipped with a balancer, install
Tool Part Part Description Qty the balancer. Refer to Disassembly and Assembly,
Number “Balancer - Install”. If the engine is not equipped
A1 21825576 Crankshaft Turning Tool 1 to Disassembly and Assembly, “Engine Oil Pump
27610291 Barring Device Housing 1 - Install”.
A2
27610289 Gear 1
i02591051
Note: Either Tooling (A) can be used. Use the Tooling Pistons and Connecting Rods
- Remove
NOTICE
Contaminants may cause rapid wear and shortened Removal Procedure

component life.
Table 63
Required Tools
A 1
A2
27610289 Gear 1
B 27610274 Ridge Reamer 1
Start By:
a. Remove the cylinder head. Refer to Disassembly

and Assembly , “Cylinder Head - Remove”.
g01265615
Illustration 245
b. If the engine is equipped with a balancer, remove
1. Clean the piston cooling jets and inspect the the balancer. Refer to Disassembly and Assembly,
piston cooling jets for damage. Ensure that the “Balancer - Remove”. If the engine is not equipped
valve is free to move within each piston cooling with a balancer, remove the engine oil pump.
jet. Replace any damaged piston cooling jets. Refer to Disassembly and Assembly, “Engine Oil
Pump - Remove”.
2. If the crankshaft is installed, use Tooling (A)
to rotate the crankshaft in order to access the c. Remove the piston cooling jets. Refer to
mounting flange for the piston cooling jet. Disassembly and Assembly , “Piston Cooling Jets
3. Position piston cooling jet (2) in the cylinder block.
Install bolt (1). Tighten the bolt to a torque of Note: Either Tooling (A) can be used. Use the Tooling
9 N·m (80 lb in). that is most suitable.
4. Repeat Steps 2 through 3 for the remaining piston NOTICE

cooling jets. Keep all parts clean from contaminants.

component life.
122 RENR9525
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 247
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.
6. Temporarily install connecting rod cap (2) and

g01252442 bolts (1) to the connecting rod when the assembly
Illustration 246
is out of the engine. Tighten bolts (1) to a torque
of 20 N·m (14 lb ft).
3. The connecting rod and the connecting rod
cap should have an etched number (X) on the Note: Fracture split connecting rods should not be left
side. The number on the connecting rod and the without the connecting rod caps installed. Ensure that
connecting rod cap must match. Ensure that the the etched number on connecting rod cap matches
connecting rod and connecting rod cap (2) are the etched number on connecting rod. Ensure the
marked for the correct location. If necessary, correct orientation of the connecting rod cap.
make a temporary mark on the connecting rod
and the connecting rod cap in order to identify the 7. Repeat Steps 1 through 5 for the remaining
cylinder number. pistons and connecting rods.
Note: Do not stamp the connecting rod assembly.
Stamping or punching the connecting rod assembly i02591124
could cause the connecting rod to fracture.
Pistons and Connecting Rods
4. Remove bolts (1) and remove connecting rod cap
(2) from the connecting rod.
- Disassemble
Disassembly Procedure
Table 64
Required Tools
Part
B - Piston Ring Expander 1
RENR9525 123
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 249
Typical example
2. Place the piston and connecting rod assembly on

a suitable surface with the connecting rod upward.
Use Tooling (A) in order to remove circlips (5).
Note: The forged marks (X) identify the front of the

connecting rod assembly. The forged marks should
be used for the purposes of orientation.
3. Remove piston pin (8) and connecting rod (6) from

piston (4).
Note: If the piston pin cannot be removed by hand,

heat the piston to a temperature of 45 ± 5 °C
(113 ± 9 °F). Do not use a torch to heat the piston.
Note the orientation of the connecting rod and the
piston.
g01244067
Illustration 248 4. Place the piston on a suitable surface with the
crown upward. Use Tooling (B) in order to remove
compression rings (1) and (2), and oil control ring
(3) from piston (4).
Note: Identify the position and orientation of

compression rings (1) and (2), and oil control ring (3).
124 RENR9525
i02589163

- Assemble
Assembly Procedure
Table 65
Required Tools
Part
Number
g01244068
Illustration 250 A - Circlip Pliers 1
5. Remove bolts (12) and connecting rod cap (11) B - Piston Ring Expander 1
from connecting rod (6). Discard the bolts.
NOTICE
Note: Fracture split connecting rods should not be left Keep all parts clean from contaminants.
without the connecting rod caps installed. After the
disassembly procedure for the piston and connecting Contaminants may cause rapid wear and shortened
rod is completed, carry out the assembly procedure component life.
and the installation procedure as soon as possible.
Refer to Disassembly and Assembly, “Piston and
Connecting Rods - Assemble” and Disassembly and 1. Ensure that all components are clean and free
Assembly, “Piston and Connecting Rods - Install”. from wear or damage. If necessary, replace any
components that are worn or damaged.
6. Remove the lower half of connecting rod bearing
(10) from connecting rod cap (11). Remove the 2. If the original piston is assembled, follow Steps
upper half of connecting rod bearing (9) from 2.a through 2.e in order to install the piston rings.
connecting rod (6). Keep the connecting rod
bearings together. a. Position the spring for oil control ring (3) into
the oil ring groove in piston (4). The central wire
NOTICE must be located inside the end of the spring.
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.
7. Inspect the connecting rod for wear or damage. If

necessary, replace connecting rod (6) or replace
bush (7) for the piston pin.
Note: If the connecting rod or the bush for the piston

pin are replaced, first identify the height grade of the
connecting rod. Refer to Specifications, “Connecting
Rods”.
g01155119
Illustration 251
8. Repeat Steps 5 through 7 in order to disassemble
the remaining pistons and connecting rods. 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.
RENR9525 125
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.
d. Use Tooling (B) to install top compression ring

(1) into the top groove in piston (4). The word
“TOP” must be upward.
e. Position the piston ring gaps at 120 degrees

away from each other.
Note: A new piston assembly is supplied with new

piston rings. g01244172
Illustration 253
NOTICE 5. Place the piston on a suitable surface with the

Removal of the piston pin bushing in the connecting crown downward. Install connecting rod (6) and
rod must be carried out by personnel with the correct piston pin (8) to piston (4). Ensure that square
training. Also special machinery is required. For more boss (13) on the piston, and forged mark (X) on
information refer to your authorized Perkins distribu- the connecting rod are in the correct position. See
tor. illustration 253.
3. If the connecting rod assembly or the bush for Note: If the piston pin cannot be installed by hand,
the piston pin have been replaced, ensure that heat the piston to a temperature of 45° ± 5°C
the height grade of the connecting rod is correct. (113° ± 9°F).
Refer to Specifications, “Connecting Rods” for
further information. 6. Use Tooling (A) in order to install circlips (5) to the
piston pin bore in piston (4).
Note: Ensure that the circlips are seated in the

grooves in the piston.
g01244068
Illustration 254
g01244067
Illustration 252
4. Lubricate bush (7) and lubricate the bore for the

piston pin in piston (4) with clean engine oil.
126 RENR9525
i02591052

- Install
Table 66
Required Tools
Number
g01001160
Illustration 255 A1 21825576 Crankshaft Turning Tool 1
Aligning the connecting rod bearing in the center of the connecting
rod 27610291 Barring Device Housing 1
A2
27610289 Gear 1
7. Install the upper half of connecting rod bearing (9)
to connecting rod (6). Ensure that the connecting B 21825491 Piston Ring Compressor 1
rod bearing is centralized in the connecting rod. C 21825607 Angle gauge 1
Note: New connecting rod bearings are supplied with Note: Either Tooling (A) can be used. Use the Tooling
an alignment tool. If new connecting rod bearings that is most suitable.
are installed, use the tool to align the connecting rod
bearing in the connecting rod. NOTICE
8. Install the lower half of connecting rod bearing
(10) to connecting rod cap (11). Ensure that Contaminants may cause rapid wear and shortened
the connecting rod bearing is centralized in the component life.
connecting rod cap. Refer to Illustration 255.
Note: New connecting rod bearings are supplied with NOTICE

an alignment tool. If new connecting rod bearings Discard all used connecting rod bolts.
are installed, use the tool to align the connecting rod
bearing in the connecting rod cap. 1. If the connecting rod caps were temporarily
installed, remove the connecting rod caps. If
9. Repeat Steps 2 through 8 for the remaining piston necessary, thoroughly clean all of the components.
and connecting rod assemblies.
2. Apply clean engine oil to the cylinder bore, to the
Note: Fracture split connecting rods should not be piston rings, to the outer surface of the piston and
left without the connecting rod caps installed. After to the connecting rod bearings.
the assembly procedure for the piston and connecting
rod is completed, carry out the installation procedure Note: Install the connecting rod bearings dry
as soon as possible. Refer to Disassembly and when clearance checks are performed. Refer to
Assembly, “Piston and Connecting Rods - Install”. Disassembly and Assembly, “Bearing Clearance -
Check”. Apply clean engine oil to the connecting rod
End By: bearings during final assembly.
a. Install the pistons and the connecting rods. 3. Use Tooling (A) to rotate the crankshaft until the
Refer to Disassembly and Assembly, “Piston and crankshaft pin is at the bottom center position.
Connecting Rods - Install”. Lubricate the crankshaft pin with clean engine oil.
RENR9525 127
Note: Ensure that etched number (X) on the

connecting rod cap matches the etched number on
the connecting rod. Ensure the correct orientation of
connecting rod cap (2).
7. Install new bolts (1) to the connecting rod. Tighten

the bolts evenly to a torque of 18 N·m (13 lb ft).
8. Tighten the bolts evenly to a torque of 70 N·m

(52 lb ft).
9. Use Tooling (B) to turn the bolts through an

additional 120 degrees.
g01253096
10. Ensure that the installed connecting rod assembly
Illustration 256 has tactile side play. Carefully rotate the crankshaft
Typical example in order to ensure that there is no binding.
4. Ensure that the gaps for the piston rings are at 11. Repeat Steps 2 through 10 in order to install the
120 degrees away from each other. Install Tooling remaining pistons and connecting rods.
(B) onto piston (3).
Note: If all pistons and connecting rods require
Note: Ensure that Tooling (B) is installed correctly replacement the procedure can be carried out on
and that the piston can easily slide from the tool. two cylinders at the same time. The procedure can
Ensure that the piston and the connecting rod be carried out on the following pairs of cylinders. 1
assembly are installed in the correct cylinder. The with 4 and 2 with 3. Ensure that both pairs of the
arrow on the top of the piston must be toward the pistons and connecting rods are installed before
front of the engine. changing from one pair of cylinders to another
pair of cylinders..
5. Carefully push the piston and the connecting rod
assembly into the cylinder bore and onto the 12. Check the height of the pistons above the top face
crankshaft pin. of the cylinder block. Refer to Systems Operation,
Testing and Adjusting, “Piston Height - Inspect” for
Note: Do not damage the finished surface of the the correct procedure.
crankshaft pin.
End By:
a. Install the piston cooling jets. Refer to Disassembly

and Assembly, “Piston Cooling Jets - Remove
and Install”.
b. If the engine is equipped with a balancer, install

- Install”.
c. Install the cylinder head. Refer to Disassembly

and Assembly, “Cylinder Head - Install”.
g01253095
Illustration 257
Typical example
6. Install connecting rod cap (2) onto the connecting

rod.
128 RENR9525
i02591096 Note: Removal of the glow plugs aids removal of the

connecting rod bearings. It is not essential.
Connecting Rod Bearings -
Remove
(Connecting rods in position)
Removal Procedure
Table 67
Required Tools
A 1
A2
27610289 Gear 1
Start By:
a. If the engine is equipped with a balancer, remove g01252442

Illustration 258
Pump - Remove”.

NOTICE

component life.
g01253101
Illustration 259
NOTICE
Discard all used connecting rod bolts. 2. The connecting rod and the connecting rod
cap should have an etched number (X) on the
Note: If all connecting rod bearings require side. The number on the connecting rod and the
replacement the procedure can be carried out on connecting rod cap must match. If necessary,
two cylinders at the same time. The procedure can make a temporary mark on connecting rod (5)
be carried out on the following pairs of cylinders. and connecting rod cap (2) in order to identify the
1 with 4 and 2 with 3. Ensure that both pairs cylinder number.
of the connecting rod bearings are installed
before changing from one pair of cylinders to Note: Do not punch identification marks onto fracture
another pair of cylinders.. Refer to Disassembly split connecting rods. Do not stamp identification
and Assembly, “Connecting Rod Bearings - Install”. marks onto fracture split connecting rods.
1. Use Tooling (A) to rotate the crankshaft until the 3. Remove bolts (1) and connecting rod cap (2) from
crank pin is at the bottom center position. connecting rod (5). Discard the bolts.
If necessary, remove the glow plugs. Refer 4. Remove the lower half of connecting rod bearing
to Disassembly and Assembly, “Glow Plugs - (3) from connecting rod cap (2). Keep the
Remove and Install”. connecting rod bearing and the connecting rod
cap together.
RENR9525 129
5. Carefully push the piston and connecting rod

assembly into the cylinder bore until connecting
rod (5) is clear of the crankshaft. Remove the
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 g01260354
Assembly, “Connecting Rod Bearings - Install”. Illustration 260
i02591123
Connecting Rod Bearings -

Install
(Connecting rods in position)
Table 68
Required Tools Illustration 261
g01001160
Tool Part Number Part Description Qty Aligning the bearing in the center of the connecting rod

Note: New connecting rod bearings are supplied with
27610291 Barring Device Housing 1 an alignment tool. If new bearings are installed, use
A2 the tool to align the bearing in the connecting rod.
27610289 Gear 1
B 21825607 Angle Gauge 1 2. Install the upper half of connecting rod bearing
(4) to connecting rod (5). Ensure that the bearing
is centralized in the connecting rod. Refer to
Note: Either Tooling (A) can be used. Use the Tooling Illustration 261.
The ends of the bearing must be centered in the
NOTICE connecting rod. The ends of the bearing must be
Keep all parts clean from contaminants. equally positioned in relation to the mating faces
of the connecting rod.
component life. 3. Clean the connecting rod cap. Install lower
connecting rod bearing (3) to connecting rod cap
(2). Ensure that the connecting rod bearing is
NOTICE centralized in the connecting rod cap. Refer to
Discard all used connecting rod bolts. Illustration 261.
1. Inspect the pins of the crankshaft for damage. The ends of the lower connecting rod bearing
If the crankshaft is damaged, replace the must be centered in the connecting rod cap. The
crankshaft or recondition the crankshaft. Refer ends of the lower connecting rod bearing must be
to Disassembly and Assembly, “Crankshaft equally positioned in relation to the mating faces
- Remove” and Disassembly and Assembly, of the connecting rod cap.
“Crankshaft - Install”. Ensure that the connecting
rod bearings are clean and free from wear or 4. Lubricate upper connecting rod bearing (4) with
damage. If necessary, replace the connecting rod clean engine oil.
bearings.
130 RENR9525
5. If necessary, use Tooling (A) in order to rotate the 13. Repeat Steps 2 through 12 for the remaining
crankshaft until the crankshaft pin is at the bottom connecting rod bearings.
dead center position.
Note: If all connecting rod bearings require
6. Carefully pull connecting rod (5) against the replacement the procedure can be carried out on
crankshaft pin. two cylinders at the same time. The procedure can
be carried out on the following pairs of cylinders.
Note: Do not allow the connecting rod to contact the 1 with 4 and 2 with 3. Ensure that both pairs of
piston cooling jet. the connecting rod bearings are installed before
changing from one pair of cylinders to another
7. Lubricate the pin of the crankshaft and lubricate pair of cylinders..
lower connecting rod bearing (3) with clean engine
oil. 14. If the glow plugs were removed, install the glow
plugs. Refer to Disassembly and Assembly, “Glow
Plugs - Install”.
End By:
a. If the engine is equipped with a balancer, install

- Install”.
i02591100
Crankshaft Main Bearings -

Remove and Install
(Crankshaft in position)
g01260355
Illustration 262
Removal Procedure
8. Install connecting rod cap (2) to connecting rod Table 69
(5).
Required Tools
Note: Ensure that etched number (X) on connecting Tool Part Number Part Description Qty
rod cap (2) matches etched number (X) on
connecting rod (5). Ensure the correct orientation of A1
the connecting rod cap. The forged marks (Y) on the 27610291 Barring Device Housing 1
connecting rod and the connecting rod cap should be A2
on the same side. Refer to Illustration 260. 27610289 Gear 1
9. Install new bolts (1). Tighten the bolts evenly to a Start By:
Note: Do not reuse the old bolts in order to secure the balancer. Refer to Disassembly and Assembly,
the connecting rod cap. “Balancer - Remove”. If the engine is not equipped
10. Tighten the bolts evenly to a torque of 70 N·m Refer to Disassembly and Assembly, “Engine Oil
(52 lb ft). Pump - Remove”.
11. Use Tooling (B) to turn the bolts through an b. Remove the crankshaft rear seal. Refer to
additional 120 degrees. Disassembly and Assembly, “Crankshaft Rear
Seal - Remove”.
12. Ensure that the installed connecting rod assembly
has tactile side play. Carefully rotate the crankshaft
in order to ensure that there is no binding.
RENR9525 131

NOTICE
This procedure must only be used to remove and in-
stall the main bearing shells with the crankshaft in po-
sition.
The removal procedure and the installation procedure

must be completed for each pair of main bearing shells
before the next pair of main bearing shells are re-
moved.
NOTICE g01253146
Keep all parts clean from contaminants. Illustration 265
Typical example
component life. 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.
g01253717
Illustration 263
Typical example
1. Remove allen head screws (1). Remove bridge

piece (2).
2. Ensure that the main bearing cap is marked for Illustration 266
g01253137
the correct location and orientation.
Typical example
5. For number three main bearing cap, remove thrust

washers (7).
g01253719
Illustration 264
Typical example
3. Remove bolts (3). Remove main bearing cap (4) g01253142

from the cylinder block. Illustration 267
Typical example
132 RENR9525
6. For number three main bearing, remove thrust

washers (8) from the cylinder block. In order to NOTICE
remove the thrust washers, push the crankshaft This procedure must only be used to remove and in-
toward the front of the engine or push the stall the main bearing shells with the crankshaft in po-
crankshaft toward the rear of the engine. Use sition.
Tooling (A) in order to rotate the crankshaft. If
necessary, use a suitable tool to free the thrust The removal procedure and the installation procedure
washers. must be completed for each pair of main bearing shells
before the next pair of main bearing shells are re-
Note: Do not damage the machined surfaces of the moved.
crankshaft during removal of the thrust washers.
NOTICE

component life.
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
g01253145 the crankshaft.
Illustration 268
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.
Note: Do not damage the machined surfaces of the

crankshaft during removal of the upper main bearing.
The upper main bearing has a groove and two oil
holes.
g01253145
Table 70 Illustration 269
Required Tools Typical example
Part 3. Lubricate the crankshaft journal and the upper

Number main bearing (9) with clean engine oil. Slide the
B 21825617 Dial Indicator Group 1 upper main bearing (9) into position between the
crankshaft journal and the cylinder block. Ensure
C - Straight Edge 1 that the locating tab for the upper main bearing is
D - 5 mm Allen Socket 1 correctly seated in the slot in the cylinder block.
POWERPART Note: The upper main bearing has a groove and two
E 21826038 Silicon Rubber -
oil holes.
Sealant
RENR9525 133
g01261200 g01253137
4. For number three main bearing, ensure that thrust 6. For number three main bearing cap, ensure that
washers (8) are clean and free from wear or thrust washers (7) are clean and free from wear or
damage. If necessary, replace the thrust washers. damage. If necessary, replace the thrust washers.
Lubricate thrust washers (8) with clean engine oil. Lubricate thrust washers (7) with clean engine
Slide the thrust washers into position between the oil. Place the thrust washers into position on the
crankshaft and the cylinder block. The grooves in main bearing cap. Ensure that the locating tab is
the thrust washers must be located against the correctly seated in the main bearing cap.
crankshaft.
g01253719
Illustration 273
g01253146
Illustration 271
Typical example
Typical example
7. Lubricate the crankshaft journal and the lower
5. Install lower main bearing (5) into main bearing main bearing with clean engine oil. Install main
cap (4). Ensure that the locating tab for the lower bearing cap (4) to the cylinder block.
main bearing is correctly seated into the slot in
the bearing cap. Note: Ensure the correct orientation of the main
bearing cap. The locating tab for the upper and the
Note: The lower main bearing is a plain bearing that lower bearing should be on the same side of the
has no oil holes. engine.
8. Lubricate the threads of bolts (3) with clean engine

oil. Lubricate the underside of the heads of the
bolts with clean engine oil.
9. Install bolts (3) to main bearing cap (4). Evenly

tighten the bolts in order to pull cap (5) into
position. Ensure that the cap is correctly seated.
Note: Do not tap the main bearing cap into position

as the bearing may be dislodged.
134 RENR9525
10. Tighten bolts (3) to a torque of 245 N·m (180 lb ft). c. Use Tooling (C) in order to align the rear face
of the bridge piece with the rear face of the
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

Seal - Install”.
g01253186
Illustration 274
Typical example
g01261208
Illustration 276
11. Check the crankshaft end play. Push the Typical example
crankshaft toward the front of the engine. Install
Tooling (B) to the cylinder block and the rear face 14. Apply Tooling (E) to cavities (Y) in bridge piece
of the crankshaft. Push the crankshaft toward the (2). Continue to apply Tooling (E) until sealant
rear of the engine. Use Tooling (B) to measure the extrudes from cavities (X).
crankshaft end play. The permissible crankshaft
end play is 0.17 mm (0.007 inch) to 0.41 mm Note: If the oil pan will not be installed immediately,
(0.016 inch). ensure that the joint face of the bridge piece. and the
cylinder block are left free of sealant.
End By:
a. If the engine is equipped with a balancer, install

- Install”.
g01253836
Illustration 275
Typical example
12. Follow Steps 12.a through 12.d in order to install

the bridge piece.
a. Ensure that the recess in the cylinder block and

the bridge piece are clean, dry and free from
old sealant.
b. Install bridge piece (2) and allen head screws

(1). Tighten the allen head screws finger tight.
RENR9525 135
i02589166 If the cylinder head, the pistons and the

connecting rods have not been removed, remove
Crankshaft - Remove the connecting rod caps. Refer to Disassembly
and Assembly, “Connecting Rod Bearings -
Remove”.
Removal Procedure
Table 71
Required Tools
Part
Number
A - Lifting Strap 1
Start By:
a. Remove the rocker shaft and pushrods. Refer to

g01253717
Pushrod - Remove”. Illustration 277
Typical example
b. Remove the front housing. Refer to Disassembly
and Assembly, “Housing (Front) - Remove”. 3. Remove allen head screws (1). Remove bridge
piece (2).
c. Remove the crankshaft rear seal. Refer to
Disassembly and Assembly, “Crankshaft Rear 4. Ensure that the main bearing caps are marked for
Seal - Remove”. the location and orientation.
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.
g01253719
Illustration 278
NOTICE Typical example
5. Remove bolts (3) and main bearing caps (4) from
Contaminants may cause rapid wear and shortened the cylinder block.
component life.
1. The engine should be mounted on a suitable

stand and placed in the inverted position.
2. If necessary, remove the cylinder head. Refer

to Disassembly and Assembly, “Cylinder Head
- Remove”. Remove the pistons and connecting
rods. Refer to Disassembly and Assembly,
“Pistons and Connecting Rods - Remove”.
136 RENR9525
g01253146 g01254099
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, the crankshaft must be supported
on a suitable stand in order to prevent damage to
the crankshaft timing ring.
g01253137
Illustration 280
Typical example
6. Remove lower main bearings (5) from main

bearing caps (4). Take care not to displace dowels
(6). For number three main bearing cap, remove
thrust washers (7). Keep the lower main bearings
and the thrust washers with the respective main
bearing caps.
Note: The lower main bearings are plain bearings

g01254104
that have no oil holes. The dowels may remain in the Illustration 282
main bearing cap or in the cylinder block. Typical example
8. Remove upper main bearings (9) from the cylinder

block. Keep the upper main bearings with the
respective main bearing caps.
Note: The upper main bearings have a groove and

two oil holes.
9. Remove thrust washers (10) from number three

main bearing in the cylinder block.
10. If necessary, remove the crankshaft timing ring.

Timing Ring - Remove and Install”.
RENR9525 137
11. If necessary, remove the crankshaft gear. Refer 5. Clean the crankshaft bearings and the thrust
to Disassembly and Assembly, “Crankshaft Gear washers. Inspect the bearings and the thrust
- Remove and Install”. washers for wear or damage. If necessary, replace
the bearings and the thrust washers.
i02589167
Note: If the crankshaft bearings are replaced, check
Crankshaft - Install whether oversize bearings were previously installed.
If the thrust washers are replaced, check whether
oversize thrust washers were previously installed.
Table 72
Required Tools
Part
Number
A - Lifting Strap 1
B 21825617 Dial Indicator Group 1
C - Straight Edge 1
D - 5 mm Allen Socket 1
g01253240
POWERPART Illustration 283
E 21826038 -
Silicon Rubber Sealant Typical example
6. Install upper bearings(9) to the cylinder block.

NOTICE
Ensure that the locating tabs for the upper
bearings are seated in the slots in the cylinder
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 7. 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 284
3. If necessary, install a new crankshaft timing ring. Typical example
Timing Ring - Remove and Install”. 8. Attach Tooling (A) and a suitable lifting device to
crankshaft (8). Carefully lift the crankshaft into the
Note: The engine should be mounted on a suitable cylinder block. The weight of the crankshaft is
stand and placed in the inverted position. approximately 30 kg (66 lb). Remove Tooling (A).
4. Ensure that the parent bores for the crankshaft Note: Do not damage any of the finished surfaces on
bearings in the cylinder block are clean. Ensure the crankshaft. Do not damage the bearing.
that the threads for the bearing bolts in the cylinder
block are clean and free from damage.
138 RENR9525
10. 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
11. Lubricate lower bearings (5) and lubricate the
Illustration 285 journals of crankshaft (8) with clean engine oil.
Typical example Install bearing caps (4) to the cylinder block.
9. 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 288
12. 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 286
13. 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.
15. Rotate the crankshaft in order to ensure that there

is no binding.
g01253137
Illustration 287
RENR9525 139
18. Follow Steps 18.a through 18.d in order to install

the bridge piece.
a. Ensure that the cylinder block and the bridge

piece are clean, dry and free from old sealant.
b. Install bridge piece. (2) and allen head screws

(1). Tighten the allen head screws finger tight.
c. Use Tooling (C) in order to align the rear face

of the bridge piece with the rear face of the
cylinder block.
d. Use Tooling (D) in order to tighten the allen

head screws to a torque of 16 N·m (12 lb ft).
19. Install the crankshaft rear seal. Refer to

Seal - Install”.
g01253186
Illustration 289
Typical example
16. 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).
17. If the crankshaft has been replaced or the Illustration 291

g01261164
crankshaft has been reconditioned, inspect the
Typical example
height of the piston above the cylinder block. Refer
20. Apply Tooling (E) to cavities (Y) in the bridge
“Piston Height - Inspect” for more information.
piece (2). Continue to apply Tooling (E) until
sealant extrudes from cavities (X).
If the crankshaft has not been replaced or the
crankshaft has not been reconditioned, install the
Note: If the oil pan will not be installed immediately,
connecting rod caps. Refer to Disassembly and
ensure that the joint face of the bridge piece and the
Assembly, “Connecting Rod Bearings - Install”.
cylinder block are left free of sealant.
End By:
a. If necessary, install the pistons and connecting

rods. Refer to Disassembly and Assembly,
“Pistons and Connecting Rods - Install”.
b. If the engine has a balancer, install the balancer.

Refer to Disassembly and Assembly, “Balancer -
Install”. If the engine does not have a balancer,
install the engine oil pump. Refer to Disassembly
and Assembly, “Engine Oil Pump - Install”.
c. Install the front housing. Refer to Disassembly and

Illustration 290
g01254102 Assembly, “Housing (Front) - Install”.
Typical example
d. If necessary, install the cylinder head. Refer to
Disassembly and Assembly, “Cylinder Head -
Install”.
140 RENR9525
e. Install the rockershaft and pushrods. Refer to Note: Do not remove dowel (5) from crankshaft (1)
Disassembly and Assembly, “Rockershaft and unless the dowel is damaged.
Push Rods - Install”.
i02589168
Table 73
Crankshaft Timing Ring - Required Tools
Remove and Install Tool Part Part Description Qty
Number
A - 4 mm Allen Socket 1
Removal Procedure
NOTICE
Start By: Keep all parts clean from contaminants.
a. Remove the crankshaft. Refer to Disassembly and Contaminants may cause rapid wear and shortened
Assembly, “Crankshaft - Remove ”. component life.
NOTICE 1. Support crankshaft (1) on a suitable stand.

2. Ensure that the flange for the crankshaft timing
Contaminants may cause rapid wear and shortened ring on the crankshaft is clean and free from
component life. damage.
g01254108
Illustration 292
g01254108 Illustration 293
1. Support crankshaft (1) on a suitable stand. 3. If dowel (5) was removed, install a new dowel to
crankshaft (1).
2. Remove allen head screws (2) from crankshaft
timing ring (3). Do not reuse the allen head screws. 4. Position crankshaft timing ring (3) onto the
crankshaft with the teeth toward rear seal surface
3. Carefully remove crankshaft timing ring (3) from (4). Align the hole in crankshaft timing ring (3) with
crankshaft (1). Do not reuse the crankshaft timing dowel (5). Carefully install crankshaft timing ring
ring. (3) to crankshaft (1).
Note: Ensure that seal surface (4) of the crankshaft Note: Ensure that seal surface (4) on the crankshaft
is not damaged when the crankshaft timing ring is is not damaged when the crankshaft timing ring is
removed. installed.
RENR9525 141
5. Use Tooling (A) to install new allen head screws

(2). Tighten the allen head screws to a torque of
9 N·m (80 lb in).
End By:
a. Install the crankshaft. Refer to Disassembly and

Assembly, “Crankshaft - Install ”.
i02589170
Crankshaft Gear - Remove and

Install
g01270547
Illustration 294
Typical example
Removal Procedure
Table 74
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

and Assembly, “Housing (Front) - Remove”.
b. If the engine is equipped with a balancer, remove

the balancer. Refer to Disassembly and Assembly, g01270549
“Balancer - Remove”. If the engine is not equipped Illustration 295
with a balancer, remove the engine oil pump. Typical example
Pump - Remove”. 1. If the crankshaft gear is a sliding fit on the
crankshaft, remove crankshaft gear (1) from
NOTICE crankshaft (2).
If the crankshaft gear is an interference fit on the
Contaminants may cause rapid wear and shortened crankshaft, use Tooling (A) in order to remove
component life. crankshaft gear (1) from crankshaft (2).
2. If necessary, remove key (3) from crankshaft (2).

Note: The crankshaft gear may be a sliding fit on the
crankshaft or an interference fit on the crankshaft. Note: Do not remove the key from the crankshaft
unless the key is damaged.
NOTICE

component life.
142 RENR9525
1. Ensure that all components are clean and free i02347769

from wear or damage. If necessary, replace any
components that are worn or damaged. Bearing Clearance - Check
Measurement Procedure
Table 75
Required Tools
Description Qty
Plastigauge (Green) 1
0.025 to 0.076 mm
(0.001 to 0.003 inch)
Plastigauge (Red) 1
0.051 to 0.152 mm
Illustration 296
g01270552 (0.002 to 0.006 inch)
Typical example Plastigauge (Blue) 1
0.102 to 0.229 mm
2. If necessary, install a new key (3) to crankshaft (2). (0.004 to 0.009 inch)
Plastic Gauge (Yellow) 1
Note: The crankshaft gear may be a sliding fit on the 0.230 to 0.510 mm
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. However, if the technician still wants to
crankshaft, heat crankshaft gear (1) in an oven to
measure the clearance of the bearing shell , the use
150° ± 50°C (302° ± 90°F). Align the keyway in
of Plastigauge is an acceptable method. Plastigauge
crankshaft gear (1) with key (3) in the crankshaft.
is less accurate on journals with small diameters if
Install crankshaft gear (1) to crankshaft (2).
clearances are less than 0.10 mm (0.004 inch).
Ensure that shoulder (4) on crankshaft gear (1) is
Note: The bearing clearance for the crankshaft
toward the front of the engine.
should be within specifications if the crankshaft
journals and the crankshaft pins were checked before
End By:
installing the crankshaft and the correct bearing shells
are installed. No further checks should be necessary.
a. Install the front housing. Refer to Disassembly and
Assembly Manual, “Housing (Front) - Install”.
NOTICE
b. If the engine is equipped with a balancer, install Lead wire, shim stock or a dial bore gauge can dam-
the balancer. Refer to Disassembly and Assembly, age the bearing surfaces.
The technician must be very careful to use
Plastigauge correctly. The following points must be
- Install”.
observed:
RENR9525 143
• Ensure that the backs of the bearing shells and the Note: When Plastigauge is used, the readings can
bores of the bearing shells are clean and dry. sometimes be unclear. For example, all parts of the
Plastigauge are not the same width. Measure the
• If the bearing shells have locating tabs ensure that major width in order to ensure that the parts are within
the locating tabs are properly seated in the tab the specification range. Refer to the Specifications
grooves. Manual, “Connecting Rod Bearing Journal” and refer
to the Specifications Manual, “Main Bearing Journal”
• The crankshaft must be clean and free of oil at the for the correct clearances.
contact points of the Plastigauge.
i02589173
Crankshaft Position Sensor -

Remove and Install
Removal Procedure
NOTICE

component life.
g01010832
Illustration 297
Typical example
1. Place a piece of the Plastigauge (1) onto the

crown of the bearing shell that is in the cap.
Note: Do not allow the Plastigauge (1) to extend over

the edge of the bearing shell.
2. Use the correct torque-turn specifications in order Illustration 298

g01270854
to install the bearing cap. Do not use an impact Typical example
wrench. Be careful not to dislodge the bearing
shell when the cap is installed. 1. Slide locking tab (1) into the unlocked position.
Note: Do not turn the crankshaft when the 2. Disconnect harness assembly (2) from position
Plastigauge (1) is installed. sensor (3).
3. Carefully remove the bearing cap, but do not 3. Remove bolt (4).
remove the Plastigauge (1). Measure the width of
the Plastigauge (1) while the Plastigauge is in the 4. Carefully remove position sensor (3) from the
bearing cap or on the crankshaft journal. Refer cylinder block.
to the Illustration 297.
Note: Do not use a lever to remove the position
4. Remove all of the Plastigauge (1) before you sensor from the cylinder block.
install the bearing cap.
5. Remove O-ring seal (5) from position sensor (3).
144 RENR9525
Table 76 Coolant Temperature Sensor -

Required Tools Remove and Install
Part
Number
POWERPART
A 21820221
Rubber Grease
1 Removal Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
component life.
NOTICE
ponent containing fluids.

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

level below the coolant temperature sensor, into
g01270854
Illustration 299 Refer to Operation and Maintenance Manual,
Typical example “Cooling System Coolant - Change” for the correct
draining procedure.
1. Install a new O-ring seal (5) to the groove in
position sensor (3). Lubricate the new O-ring seal
with Tooling (A).
2. Align the hole in position sensor (3) with the hole

in the cylinder block. Install the position sensor to
the cylinder block.
Note: Do not use bolt (4) to pull the position sensor

into position against the cylinder block.
3. Install bolt (4). Tighten the bolt to a torque of

22 N·m (16 lb ft).
4. Connect harness assembly (2) to position sensor

(3).
5. Slide locking tab (1) into the locked position.
g01254109
Illustration 300
Typical example
2. Slide locking tab (2) into the unlocked position.

RENR9525 145
3. Disconnect harness assembly (3) from coolant 2. Use a deep socket in order to install coolant
temperature sensor (1). temperature sensor (1) to the cylinder head.
Tighten the coolant temperature sensor to a
Note: The coolant temperature sensor has a two-wire torque of 15 N·m (11 lb ft).
plug.
3. Connect harness assembly (3) to coolant
4. Use a deep socket to remove coolant temperature temperature sensor (1).
sensor (1) from the cylinder head.
Note: If necessary, install the bracket for the harness
Note: If necessary, remove the bracket for the assembly to the bypass tube.
harness assembly from the bypass tube.
5. Remove O-ring seal (4) from coolant temperature
sensor (1). 5. Fill the cooling system to the correct level. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant Level - Check” and refer to
Installation Procedure Operation and Maintenance Manual, “Cooling
Table 77 System Coolant - Fill” for the correct filling
procedure.
Required Tools
Part
Tool Part Description Qty i02589174
Number
A 21820221
POWERPART
1
Engine Oil Pressure Sensor -
Rubber Grease Remove and Install
NOTICE
Removal Procedure

component life.
NOTICE
ponent containing fluids.

mandates.
Note: The engine oil pressure sensor may be located

in the cylinder block, on a plate or in the engine oil
filter base. Ensure that the engine oil pressure sensor
is installed in the correct position.
g01254109
Illustration 301
Typical example

coolant temperature sensor (1). Lubricate the new
O-ring seal with Tooling (A).
146 RENR9525
NOTICE

component life.
Note: The engine oil pressure sensor may be located

in the cylinder block, on a blanking plate or in the
engine oil filter base. Ensure that the engine oil
pressure sensor is installed in the correct position.
g01245956
Illustration 302
Typical example
2. Disconnect harness assembly (3) from engine oil

3. If necessary, remove the engine oil filter in order

to gain access to engine oil pressure sensor (1).
“Engine Oil and Filter - Change”.
g01245956
Illustration 303
4. If necessary, remove the dipstick tube in order to Typical example
gain access to engine oil pressure sensor (1).
Refer to Disassembly and Assembly, “Engine Oil 1. Install a new O-ring seal (4) to the groove in
Pan - Remove and Install”. engine oil pressure sensor (1). Lubricate the new
5. Use a deep socket to remove engine oil pressure
sensor (1). 2. Use a deep socket to install engine oil pressure
sensor (1). Tighten the engine oil pressure sensor
6. Remove O-ring seal (4) from engine oil pressure to a torque of 10 N·m (89 lb in).
sensor (1).
3. If necessary, install the engine oil filter. Refer to
Operation and Maintenance Manual, “Engine Oil
Installation Procedure and Filter Change”.
Table 78
4. If necessary, install the dipstick tube. Refer to
Required Tools Disassembly and Assembly, “Engine Oil Pan -
Part Remove and Install”.
Number
5. Connect harness assembly (3) to engine oil
POWERPART pressure sensor (1).
A 21820221 1
Rubber Grease
RENR9525 147
7. If necessary, fill the engine oil pan to the correct Installation Procedure
level that is indicated on the engine oil level
gauge. Refer to Operation and Maintenance Table 79
Manual, “Engine Oil Level - Check”. Required Tools
Part
i02589176 Number
Position Sensor (Fuel Injection A 21820221

POWERPART
Rubber Grease
1
Pump) - Remove and Install
NOTICE
Removal Procedure Contaminants may cause rapid wear and shortened
component life.
NOTICE

component life.
g01262753
Illustration 305
Typical example

g01262753 position sensor (3). Lubricate the new O-ring seal
Illustration 304 with Tooling (A).
Typical example
2. Remove the plug from the hole in the fuel injection
1. Slide locking tab (1) into the unlocked position. pump for the position sensor.
2. Disconnect harness assembly (2) from position 3. Align the hole in position sensor (3) with the hole
sensor (3). in the fuel injection pump. Install the position
sensor to the fuel injection pump.
3. Remove bolt (4).
Note: Do not use bolt (4) to pull the position sensor
4. Carefully remove position sensor (3) from the fuel into position against the fuel injection pump.
injection pump.
4. Install bolt (4). Tighten the bolt to a torque of
Note: Do not use a lever to remove the position 22 N·m (16 lb ft).
sensor from the fuel injection pump.
5. Connect harness assembly (2) to position sensor
5. Plug the hole for the position sensor in the fuel (3).
injection pump with a new plug.
6. Remove O-ring seal (5) from position sensor (3).
148 RENR9525
i02589178
Fuel Pressure Sensor -

Remove and Install
Removal Procedure
Table 80
Required Tools
Part
Tool Part Name Qty
Number
A - Seal Pick 1

penetration and burn hazards. High pressure fu- g01296350
Illustration 306
low these inspection, maintenance and service in- Typical example
NOTICE 2. Disconnect harness assembly (3) from fuel

Ensure that all adjustments and repairs that are pressure sensor (1).
authorised personnel that have the correct train- 3. Use a deep socket to remove fuel pressure sensor
ing. (1) from the fuel manifold.
Before begining ANY work on the fuel system, re- 4. If necessary, use Tooling (A) in order to remove
fer to Operation and Maintenance Manual, “Gen- sealing washer (4) from the fuel manifold.
Lines” for safety information. Note: Do not damage the seat for the washer in the
fuel manifold. Ensure that no debris enters the fuel
Refer to Systems Operation, Testing and Adjust- manifold during the removal of the sealing washer.
nents” for detailed information on the standards 5. Plug the open port in the fuel manifold immediately
of cleanliness that must be observed during ALL with a new plug.
NOTICE
Care must be taken to ensure that fluids are contained NOTICE
during performance of inspection, maintenance, test- Keep all parts clean from contaminants.
collect the fluid with suitable containers before open- Contaminants may cause rapid wear and shortened
ing any compartment or disassembling any compo- component life.

mandates.
RENR9525 149
g01296350 g01254121
1. Position a new sealing washer (4) onto fuel 1. Slide locking tab (2) into the unlocked position.
2. Disconnect harness assembly (3) from boost
2. Remove the plug from the fuel manifold. pressure sensor (1).
3. Install fuel pressure sensor (1) to the fuel manifold. Note: The boost pressure sensor has a three-wire
Use a deep socket to tighten the fuel pressure plug.
sensor to a torque of 34 N·m (25 lb ft).
3. Use a deep socket to remove boost pressure
4. Connect harness assembly (3) to fuel pressure sensor (1).
sensor (1).
Note: If necessary, remove the bracket for the
5. Slide locking tab (2) into the locked position. harness assembly from the bypass tube.
6. Remove the air from the fuel system. Refer to 4. Remove O-ring seal (4) from boost pressure
Operation and Maintenance Manual, “Fuel System sensor (1).
- Prime”.
i02589180
Table 81
Boost Pressure Sensor - Required Tools
Remove and Install Part
Number
POWERPART
A 21820221 1
Rubber Grease
Removal Procedure
NOTICE NOTICE
Keep all parts clean from contaminants. Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened Contaminants may cause rapid wear and shortened
component life. component life.
Note: The boost pressure sensor may be located on Note: The boost pressure sensor may be located on
the secondary fuel filter base or in the cylinder head. the secondary fuel filter base or in the cylinder head.
150 RENR9525
g01254121 g01245945
1. Install a new O-ring seal (4) to the groove in boost 1. Slide locking tab (2) into the unlocked position.
pressure sensor (1). Lubricate the new O-ring seal
with Tooling (A). 2. Disconnect harness assembly (3) from inlet air
2. Use a deep socket to install boost pressure sensor
(1). Tighten the boost pressure sensor to a torque Note: The inlet air temperature sensor has a two
of 10 N·m (89 lb in). wire plug.
Note: If necessary, install the bracket for the harness 3. Use a deep socket in order to remove inlet air
assembly to the bypass tube. temperature sensor (1) from the cylinder head.
3. Connect harness assembly (3) to boost pressure 4. Remove O-ring seal (4) from inlet air temperature
sensor (1). sensor (1).

Table 82
i02589252
Required Tools
Inlet Air Temperature Sensor -
Part
Remove and Install Tool
Number
Part Description Qty
POWERPART
A 21820221 1
Rubber Grease
Removal Procedure
NOTICE
NOTICE Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
component life.
RENR9525 151
g01245945
Illustration 311
Typical example
1. Install a new O-ring seal (4) to the groove in inlet

air temperature sensor (1). Lubricate the new
g01245944
Illustration 312
2. Install inlet air temperature sensor (1) to the
Typical example
cylinder head. Use a deep socket in order to
tighten the inlet air temperature sensor to a torque
of 20 N·m (15 lb ft). 2. Remove nut (3) and disconnect wire (5) from bus
bar (1).
3. Connect harness assembly (3) to inlet air
temperature sensor (1). Note: The wire may be connected to either end of
the bus bar. Note the position of the wire.
3. Remove nuts (2) that secure bus bar (1) to glow
plugs (4).
i02589259
4. Remove bus bar (1) from glow plugs (4).
Glow Plugs - Remove and
Install 5. Remove glow plugs (4) from the cylinder head.
Table 83
Removal Procedure
Required Tools
NOTICE Part
Keep all parts clean from contaminants. Tool Part Name Qty
Number
A 27610296 Torque Wrench 1
component life.
NOTICE
1. Isolate the electrical supply. Keep all parts clean from contaminants.

component life.
152 RENR9525
1. Ensure that the threads of the glow plugs are clean i02589274
and free from damage. Replace any damaged
glow plugs. V-Belts - Remove and Install
Belt Tensioner )
Removal Procedure
g01245944
Illustration 313 g01254466
Illustration 314
Typical example
Typical example
2. Install glow plugs (4) into the cylinder head.

1. If the engine has fan guards, remove the fan
Tighten the glow plugs to a torque of 15 N·m
guards.
(132 lb in).
2. Loosen nut (1), bolt (2) and bolt (4). Slide the
3. Position bus bar (1) onto glow plugs (4). Install
alternator toward the engine.
nuts (2) onto the glow plugs. Use Tooling (A) in
order to tighten the nuts to a torque of 2 N·m
3. Remove V-belts (3).
(17 lb in).
Note: Mark the position and direction of rotation if the
4. Connect wire (5) to the stud on bus bar (1).
V-belts will be reused. Never replace single V-belts.
Always replace V-belts as a pair.
Note: The wire may be connected to either end of
the bus bar. Ensure that the wire is installed in the
correct position. Installation Procedure
5. Install nut (3) to the stud on bus bar (1). Tighten Table 84
the nut to a torque of 6 N·m (53 lb in). Required Tools
6. Restore the electrical supply to the engine. Tool Part Part Description Qty
Number
A - Belt Tension Gauge 1
RENR9525 153
1. If the engine has fan guards, remove the fan

guards.
g01254466
Illustration 315
Typical example
g01260739
Illustration 316
1. Install V-belts (3) onto the correct pulleys. Typical example
Note: Used V-belts should be installed in the original 2. Install a suitable square drive tool into hole (X) in
position and direction of rotation. tensioner (3). From the front of the engine, turn
the tool in a clockwise direction.
2. Adjust the tension on the V-belts by moving the
alternator away from the engine. Use Tooling (A) 3. Insert Tooling (A) into hole (Y). Release the
in order to achieve the correct belt tension. Refer pressure on the square drive tool.
to Specifications, “Belt Tension Chart” for more
information. Tighten bolt (4) to a torque of 22 N·m 4. Remove alternator belt (1).
(16 lb ft).
Note: Mark the direction of rotation if the belt will
3. Tighten bolt (2) to a torque of 44 N·m (32 lb ft). be reused.
4. Tighten nut (1) to a torque of 22 N·m (16 lb ft). 5. From the front of the engine, turn the square drive
tool in a clockwise direction. Release the pressure
5. If the engine has fan guards, install the fan guards. on Tooling (A). Remove Tooling (A) from hole (Y).
i02589352
6. Release the pressure on the square drive tool and
remove the tool from hole (X).
Alternator Belt - Remove and
7. If necessary, follow Steps 7.a and 7.b in order to
Install remove tensioner (3) from mounting bracket (2).
(Engines With an Automatic
a. Remove bolt (4) that secures tensioner (3) to
Belt Tensioner) mounting bracket (2).
b. Remove tensioner (3) from mounting bracket

(2).
Removal Procedure
Table 85
Required Tools
Number
- Locking Pin
A 1
(Ø 8mm by 85 mm)
154 RENR9525
Installation Procedure 5. From the front of the engine, turn the square drive
tool in a clockwise direction. Release the pressure
Table 86 on Tooling (A). Remove Tooling (A) from hole (Y).
Required Tools
6. Release the pressure on the square drive tool
Tool Part Part Description Qty until the alternator belt is tensioned. Remove the
Number tool from hole (X).
- Locking Pin
A 1 Note: The tensioner should be at the nominal
(Ø 8mm by 85 mm)
position.
7. If the engine has fan guards, install the fan guards.
i02589437
Fan - Remove and Install
Removal Procedure
Start By:
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”.
g01270907
Illustration 317
Typical example
1. If the tensioner was previously removed, follow

Steps 1.a through 1.c in order to install the
tensioner.
a. Align the dowel in the back of tensioner (3) with

the hole in mounting bracket (2).
b. Install tensioner (3) to mounting bracket (2).
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.
g01270917
Illustration 318
4. Install alternator belt (1). Ensure that the alternator Typical example
belt is centered on pulley (5). A used alternator
belt should be installed in the original direction 1. Remove locking nuts (1).
of rotation.
2. Remove fan (2).
Note: The ribs on the alternator belt must be located
into the ribs of all pulleys. Note: Note the orientation of the fan.
RENR9525 155
3. Remove fan adapter (3). i02589445
4. Remove fan pulley (4). Fan Drive - Remove and Install

5. If necessary, remove studs (5) from fan drive (6).
Installation Procedure 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. Remove the fan. Refer to Disassembly and
g00944500
Illustration 320
Typical example
1. Remove bolts (1) from fan drive (2).
g01270917 Note: Identify the orientation and the position of the

Illustration 319 fan drive.
Typical example
2. Remove fan drive (2).
2. If necessary, install studs (5) to fan drive (6).
3. Install fan pulley (4). Installation Procedure

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

tensioner, install the Alternator Belt. Refer to Illustration 321
g00944500
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).

156 RENR9525
Note: Ensure the correct orientation of the fan drive. 2. If the electronic control module is equipped with a
fuel supply, isolate the fuel supply to the engine.
44 N·m (32 lb ft).
End By:
a. Install the fan. Refer to Disassembly and

i02589457
Electronic Control Module -

Remove and Install
Removal Procedure
NOTICE
ing.

Lines” for safety information. Illustration 322
g01271315
Typical example
nents” for detailed information on the standards 3. Cut cable tie (3). Unscrew bolt (6) that secures
of cleanliness that must be observed during ALL machine wiring harness (2) to electronic control
work on the fuel system. module (5). Disconnect the machine wiring
harness from the electronic control module.
NOTICE 4. Cut cable ties (1), (9) and (10). Unscrew bolt
Care must be taken to ensure that fluids are contained (8) that secures engine harness (7) to electronic
during performance of inspection, maintenance, test- control module (5). Disconnect the engine harness
ing, adjusting and repair of the product. Be prepared to from the electronic control module.
ing any compartment or disassembling any compo- 5. If the electronic control module is equipped with
nent containing fluids. a fuel supply, disconnect plastic tube assemblies
(4) and (11).
mandates. Note: If the tube assemblies have quick fit
the system.
Note: Some engines do not have a fuel supply to the

electronic control module.

RENR9525 157
Table 87
Required Tools
Part
Tool Part Name Qty
Number
A 27610296 Torque Wrench 1
1. If a replacement electronic control module is

installed, the module must be programmed with
the correct information. Refer to Troubleshooting,
“Replacing the ECM” and refer to Troubleshooting,
“Flash Programming” for the correct procedure.
2. Ensure that the electronic control module is clean

and free from damage. If necessary, replace the
electronic control module.
g01271316
Illustration 323
Typical example
6. Remove bolts (19) and remove the assembly of

the electronic control module. Note the position of
any brackets that are secured by bolts (19). Note
the orientation of the electronic control module.
7. Remove bolts (19) and remove washers (18) from

electronic control module (5). Note the position of
the ground strap for the electronic control module.
8. If necessary, follow Steps 8.a through 8.e in order

to disassemble the electronic control module.
a. Remove isolation mounts (20) and spacers

(21).
b. Remove connectors (13). Remove O-ring seals g01271316

Illustration 324
(12) from the connectors.
Typical example
c. Remove bolt (15) and remove bracket (14) for
the engine wiring harness. Note the orientation 3. If necessary, follow Steps 3.a through 3.e in order
of the bracket. to assemble the electronic control module.
d. Loosen bolt (17) and remove bracket (16) from a. Install new O-ring seals (12) to connectors (13).
the engine wiring harness. Note the orientation Install connectors (13) to electronic control
of the bracket. module (5). Tighten the connectors to a torque
of 18.5 N·m (13.6 lb ft).
e. Remove the bolt and remove the support
bracket for the machine wiring harness. Note b. Position bracket (14) on electronic control
the orientation of the bracket. module (5). Ensure that the bracket is correctly
oriented. Install torx screw (15). Tighten the
torx screw to a torque of 14 N·m (10 lb ft).
c. Position bracket (16) on electronic control

module (5). Ensure that the bracket is correctly
oriented. Install bolt (17). Tighten the bolt to a
158 RENR9525
d. Position the bracket for the machine wiring Note: If the tube assemblies have quick fit
harness on electronic control module (5). connections, ensure that the connections are clean
Ensure that the bracket is correctly oriented before the tube assemblies are connected.
and install the bolt. Tighten the bolt to a torque
of 20 N·m (14 lb ft). 7. Connect engine wiring harness (7) to electronic
control module (5). Use Tooling (A) to tighten bolt
e. Install isolation mounts (20) and spacers (21) (8) to a torque of 5 N·m (44 lb in). If the engine is
to electronic control module (5). equipped with a diagnostic connection, install the
diagnostic connection to the support clip.
4. Install washers (18) and bolts (19) to electronic
control module (5). Note: Care must be taken in order to avoid damage to
the connector pins during installation of the harness.
Note: Ensure that the ground strap for the electronic
control module is clamped between the washer and 8. Position the assembly of the engine wiring
the appropriate bolt. harness onto brackets (14) and (16). Use new
cable ties (1), (9) and (10) in order to secure the
5. Install the assembly of the electronic control harness assembly to the brackets.
module to the mounting bracket . Ensure that
any brackets that are secured by bolts (19) are 9. Connect machine wiring harness (2) to electronic
installed in the correct position. Tighten bolts (19) control module (5). Use Tooling (A) to tighten bolt
to a torque of 22 N·m (16 lb ft). (6) to a torque of 5 N·m (44 lb in).
Note: Ensure that the electronic control module is Note: Care must be taken in order to avoid damage to
correctly oriented. Ensure that the ground strap is not the connector pins during installation of the harness.
strained as the bolt is tightened.
10. Use a new cable tie (3) in order to secure the
machine wiring harness (2).
11. If the electronic control module is equipped with a

fuel supply, restore the fuel supply.
12. Restore the electrical supply to the engine.
13. If the electronic control module is equipped with a

fuel supply, remove the air from the fuel system.
“Fuel System - Prime”.
i02589500
ECM Mounting Bracket -

Remove and Install
Removal Procedure
Start By:
a. Remove the electronic control module. Refer to

g01271315
Illustration 325
Typical example
6. If the electronic control module is equipped with

a fuel supply, connect plastic tube assemblies (4)
and (11) to electronic control module (5).
RENR9525 159
g01254468 g01254468
1. Remove plastic tube assemblies (3) and (4) from 2. If necessary, install clips (5) to mounting bracket
clips (5). (2).
2. Cut the cable tie and position the engine wiring 3. Position mounting bracket (2) against the cylinder
harness away from mounting bracket (2). head. Install bolts (1). Tighten the bolts to a torque
of 22 N·m (16 lb ft).
3. Remove bolts (1) and remove mounting bracket
(2) from the cylinder head. 4. Position the engine wiring harness against
mounting bracket (2). Secure the engine wiring
4. If necessary, remove clips (5) from mounting harness with a new cable tie.
bracket (2).
5. Install plastic tube assemblies (3) and (4) to clips
(5).
End By:
1. Ensure that the mounting bracket for the electronic
control module is clean and free from damage. If
necessary, replace the mounting bracket. a. Install the electronic control module. Refer to
i02589511
Alternator - Remove
Belt Tensioner)
Removal Procedure
Start By:
a. Remove the V-belts. Refer to Disassembly and

Assembly, “V-belts - Remove and Install”.
160 RENR9525
i02589521
NOTICE
Alternator - Remove
component life. Belt Tensioner)
2. Make temporary identification marks on the

Removal Procedure
connections of the harness assembly.
Start By:
a. Remove the alternator belt. Refer to Disassembly

Install”.
NOTICE

component life.

connections of the harness assembly.
g01255718
Illustration 328
Typical Example
3. Disconnect the harness assembly from alternator

(1).
4. Remove bolt (6) from alternator (4).
5. Remove nut (1) and washer (2). Remove bolt (5)

from alternator (4). Remove alternator (4) from g01271317
Illustration 329
alternator bracket (3).
Typical example
6. If necessary, remove pulley (8) from alternator (4).
Follow Steps 6.a and 6.b for the method in order 3. Disconnect the harness assembly from alternator
to remove the pulley from the alternator. (3).
Note: This method may not be suitable for some 4. Remove bolt (5) from alternator (3).
configurations of pulley.
5. Remove nut (1) and washer (2). Remove bolt (6)
a. Hold the shaft of alternator (4) with an allen from alternator (3). Remove the alternator from
wrench. Use a cranked ring spanner (box alternator bracket (4).
wrench) in order to loosen nut (7).
6. If necessary, follow Steps 6.a and 6 in order to
b. Remove nut (7) and pulley (8) from alternator remove pulley (8) from alternator (1).
(4).
a. Hold the shaft of alternator (3) with an allen
wrench. Use a cranked ring spanner (box
wrench) in order to loosen nut (7).
RENR9525 161
b. Remove nut (7) and pulley (8) from alternator 5. Install the V-belts. Refer to the Disassembly and
(1). assembly, “V-belts - Remove and Install” for the
correct procedure.
i02590297
6. Tighten nut (1) and bolt (6) to a torque of 22 N·m
Alternator - Install (16 lb ft).
(Engines Without an Automatic 7. Connect the wiring harness assembly to alternator

Belt Tensioner) (4).
8. Restore the electrical supply.
Alternator - Install
Belt Tensioner)
NOTICE

component life.
g01263045
Illustration 330
Typical example
1. If necessary, install the pulley to the alternator.

Follow Steps 1.a and 1.b for the method in order
to install the pulley to the alternator.
Note: This method may not be suitable for some

configurations of pulley.
g01271317
Illustration 331
a. Install pulley (8) and nut (7) to the shaft of Typical example
alternator (4).
1. If necessary, install pulley (8) and nut (7) to
b. Hold the shaft of the alternator with an allen alternator (3). Hold the shaft of the alternator with
wrench. Use a cranked ring spanner (box an allen wrench. Use a cranked ring spanner (box
wrench) in order to tighten nut (7). Tighten the wrench) in order to tighten nut (7).
nut to a torque of 80 N·m (59 lb ft).
Note: Different types of alternator have different
2. Install alternator (4) to bracket (3) and install bolt sizes of nut. Ensure that the correct torque value is
(5) to alternator (4). used for the nut.
3. Install washer (2) and nut (1) to bolt (5) finger tight. Tighten M16 and M17 nuts to a torque of 80 N·m
(59 lb ft). Tighten 5/8 inch - 18 UNF nuts to a
4. Install bolt (6) through adjusting link (9) to torque of 102 N·m (75 lb ft).
alternator (4) finger tight.
2. Position alternator (3) on alternator mounting
bracket (4).
162 RENR9525
3. Install bolt (6) to alternator (3). Install washer (2)

and nut (1) to bolt (6).
4. Install bolt (5) to alternator (3).
5. Tighten nut (1) and bolt (5) to a torque of 22 N·m

(16 lb ft).
6. Connect the wiring harness assembly to alternator

(3).
7. Install the alternator belt. Refer to Disassembly

Install”.
g01261155
8. Restore the electrical supply. Illustration 332
Typical example
i02590299 4. Disconnect the harness assemblies from the

electric starting motor and from the solenoid.
Electric Starting Motor -
Remove and Install 5. Remove nuts (3) from electric starting motor (1).
Note: Support the weight of the electric starting

motor as the nuts are removed.
Removal Procedure 6. Remove electric starting motor (1).
7. If necessary, remove studs (2).
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

location to inform personnel that the equipment is
being worked on.
1. Disconnect the battery.

g01261155
2. If necessary, remove the hose for the crankcase Illustration 333
breather. Refer to Disassembly and Assembly, Typical example
“Crankcase Breather - Remove”.
1. If necessary, install studs (2).
harness assemblies that are connected to the 2. Align electric starting motor (1) to studs (2). Install
electric starting motor and to the solenoid. the electric starting motor.
3. Install nuts (3).
Tighten M10 nuts to a torque of 44 ± 11 N·m

(32 ± 8 lb ft).
Tighten M12 nuts to a torque of 78 ± 19.5 N·m

(57 ± 14 lb ft).
RENR9525 163
4. Connect the harness assemblies to the electric

starting motor and the solenoid.
Do not disconnect the air lines until the air pres-
5. Connect the battery.
sure in the system is at zero. If hose is disconnect-
ed under pressure it can cause personal injury.
End By:
a. If necessary, install the hose for the crankcase 1. Release the pressure from the air system.
breather. Refer to Disassembly and Assembly,
“Crankcase Breather - Install”. 2. Drain the coolant from the cooling system into
i02590351
“Cooling System Coolant - Change” for the correct
Air Compressor - Remove and draining procedure.
Install 3. Remove the front cover. Refer to Disassembly and

4. If the engine is equipped with a hydraulic pump

Removal Procedure on the rear of the air compressor, remove the
hydraulic pump.
Table 88
Required Tools
Part on the compression stroke. Refer to Systems
Tool Part Name Qty
Number Operation, Testing and Adjusting, “Finding Top
27610291 Barring Device Housing 1 Note: The air compressor must be timed with the
A2 engine in order to minimize engine vibration.
27610289 Gear 1
C - Puller (Three Leg) 1

NOTICE
nent containing fluids. g01272266
Illustration 334
Dispose of all fluids according to local regulations and Typical example
mandates.
6. Install Tooling (B) through hole (X) in the front
housing. Use Tooling (B) in order to lock the
NOTICE crankshaft.

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.
164 RENR9525
g01250794 g01250816
7. Disconnect coolant hoses (1) and (2) from air 11. Support air compressor (4). Remove nuts (13)
compressor (4). and remove the air compressor from front housing
(6).
8. Disconnect the air lines from ports (3) and (5).
9. Remove tube assembly (7) from air compressor

(4) and from the cylinder block.
10. Remove bolts (8) and (10) from support bracket

(9) and remove the support bracket.
RENR9525 165
NOTICE

mandates.
g01250889
Illustration 337
Typical example
12. Remove O-ring seal (18) from air compressor (4).
13. If necessary, remove bolts (15) and remove plate

(14). Remove O-ring seal (11) from plate (14).
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 g01250889
Illustration 338
compressor.
Typical example
Installation Procedure 1. If necessary, follow Steps 1.a through 1.b in order

to install the gear to the air compressor.
Table 89
Required Tools a. Ensure that the shaft of air compressor (4) is
clean and dry. Ensure that gear (16) is clean
Part
Tool
Number
Part Name Qty and free from damage.
B 27610211 Crankshaft Timing Pin 1 b. Install gear (16) and a new spring washer to
the shaft of the air compressor.
POWERPART -
D 21826051
High Strength Retainer
c. Apply Tooling (D) to the threads of the shaft.
POWERPART - Install nut (17) to the shaft of air compressor
E 21820221
Rubber Grease (4). Tighten the nut to a torque of 120 N·m
(89 lb ft).
NOTICE
2. Install the O-ring seal to air compressor (4). Use
Tooling (E) in order to lubricate the O-ring seal.
component life.
166 RENR9525
3. Ensure that number one piston is at the top center

Note: The air compressor must be timed with the

engine in order to minimize engine vibration.
g01251223
Illustration 341
Typical air compressor with a DIN drive
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 340 for air compressors with a SAE
g01272266 drive. Refer to Illustration 341 for air compressors
Illustration 339
Typical example with a DIN drive.
4. Ensure that Tooling (B) is installed in hole (X) in

g01250968
Illustration 340
Typical air compressor with a SAE drive
g01250816
Illustration 342
Typical example
6. Align the air compressor (4) with studs (12).

Install the air compressor to the front housing.
If necessary, rotate the crankshaft of the air
compressor in a clockwise direction in order to
align the gears.
RENR9525 167
Note: Ensure that timing mark (X) is aligned with 12. Install tube assembly (7) to air compressor (4)
the timing mark A4. Refer to Illustration 340 for air and to the cylinder block. Tighten the nuts to a
compressors with a SAE drive. Refer to Illustration torque of 9 N·m (80 lb in).
341 for air compressors with a DIN drive.
13. Remove Tooling (B) from hole (X) in the front
7. Install nuts (13). Tighten the nuts to a torque of housing.
78 N·m (58 lb ft).
14. Install the front cover. Refer to Disassembly and
8. If necessary, follow Steps 8.a through 8.c in order Assembly, “Front Cover - Remove and Install”.
to install cover (14).
15. If the engine is equipped with a hydraulic pump
a. Install a new O-ring seal (11) to cover (14). Use on the rear of the air compressor, install the
Tooling (E) in order to lubricate the O-ring seal. hydraulic pump.
b. Install cover (14) to air compressor (4). 16. Connect the air lines to ports (3) and (5) in the
air compressor.
c. Install bolts (15). Tighten the bolts to a torque
of 13 N·m (9.5 lb ft). 17. Connect coolant hoses (1) and (2) to air
compressor (4).
18. Fill the cooling system with coolant to the correct

level. Refer to the Operation and Maintenance
Manual.
i02590301
Vacuum Pump - Remove and

Install
Removal Procedure
NOTICE

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
g01250794
Illustration 343 system.
Typical example
9. Position support bracket (9) onto air compressor

(4). Install bolts (8) finger tight.
10. Install bolts (10) finger tight.
11. Tighten the bolts (8) to a torque of 22 N·m

(16 lb ft). Tighten the bolts (10) to a torque 22 N·m
(16 lb ft).
Note: Ensure that the air compressor is not stressed

as the bolts are tightened.
UNIT 3
HYDROSTATIC
TRANSMISSION REGULATIONS
3-3
S
TRANSMISSION REGULATION AND CONTROL
SPECIFIC ADVANTAGES OF HYDROMATIK TRANSMISSION UNITS
Before making any kind of adjustment on DA engines, it is absolutely necessary to abide by

the following operating conditions:
The adjustment, start-up and checking the operating data of the
primary part A4VG71DA 1D2 must be done before re-calibration, if necessary, of the
secondary part A6VM107DA 1.
The operating temperature must be approx. 50-60 °C (circuit temperature).
Throttling or cutting of the pressure must be in operation. On vehicles not provided with
throttling, it is necessary to ensure that the relief valves are not activated.
Do not make adjustments or calibrations on the variable engine without a pressure gauge.
All the adjustments and calibrations must be done at the maximum operating pressure and
at maximum engine rpm (with load).
For all adjustment operations on the variable engine, suitable precautions must be taken to
prevent involuntary shifting of the vehicle.
The best precaution is to raise the vehicle and block the wheels with the brake.
In addition to the traditional features of hydrostatic transmission systems (freedom of trans-
mission installation, minimum space requirements, instant drive reversal, no clutches,
dynamic braking), HYDROMATIK transmission units have the following advantages:
1) Specific output of A4VG71DA 1D2 pumps is the highest on the market.

2) High speed A4VG71DA 1D2 pumps and A6VM107DA 1 motors.
3) Bent axis design of A6VM107DA 1 motors, the pistons have no shoes, this allows 90% of
rated load torque to be transmitted on start-up and produces a wide control range.
4) Continuos automatic variation of transmission ratio, controlled by the operator (accelerator
pedal) or according to the load, and consequently a better use of the installed capacity.
5) Conventional drive with accelerator pedal and brake and inching pedal.
6) The DA control acts as a “maximum load power control”. Pumps with DA control are used
universally on diesel engines and do not require any power calibration,thus making the cor-
responding settings easier.
Tha DA control allows peak pressure and maximum displacement to be reached well befor
the maximum diesel engine speed (1600-2000 rpm), and therefore maximum machine
power or 75% of the travel speed are achieved within a favourable fuel consumption range
and a restricted noise level range.
7) When used on loaders, a high average travel speed and maximum propulsive force for a
favourable diesel engine is possible. The efficiency of the machine (hourly capacity:hourly
consumption) is also very high.
3-4
S
8) The inching valve coupled up to the brake pedal clearance stroke allows the driver to
reduce the machine speed whilst increasing the IC engine speed, and, consequently, the
delivery of the pump supplying the various hydraulic movements. It is therefore possible to
achieve maximum lifting speed at low travel speed, hence more efficient handling.
Thanks to the inching valve, when the driver brakes,firstly hydrostatic braking of the
machine occurs, then the brakes are activated, giving economy and long life to the braking
system.
9) Limited negative impact on diesel engine speed at full load.
10) No diesel engine overload.
11) When immobilized, diesel power is not transformed into heat; the HP relief valves are not
activated due to the combined restoring force-DR valve system.
12) Displacement of the A 6 VM variable motor controlled by the same pilot pressure as the
pump (still the only system of this type on the market).
13) The installation of the DA controlled variable motor allows the pump module to be better
adapted to the power of the IC engine (and not to the apparent power of the machine)
Thus, the constant power delivery range of the pump is maximized and is still satisfacto-
ry with the transfer of power to the working hydraulics.
14) HP locking system on the A 6 VM motor permitting detection of the torque direction in rela-
tion to the direction of travel, thus avoiding untimely braking in stoppage.
BASIC DIAGRAM OF HYDROSTATIC TRANSMISSION SYSTEMS
1 2 3
4
5 6 6
Regulation
and
reversal
1) PERKINS engine type 1104C-44TA
2) Variable displacement hydrostatic pump type A4VG71DA 1D2
3) Variable displacement hydrostatic engine type A6VM107DA 1
4) Booster pump gear
5) Booster relief valve
6) High pressure valves
3-5
S
DESCRIPTION OF HYDROMATIK A 4 VG..DA/A 6 VM..DA

TRANSMISSION UNIT OPERATION
GENERAL
By its principle, hydrostatic transmission adapts the torque provided by the IC engine to the
wheels according to the resistance by the vehicle and the speed at which the driver wishes
to travel.
The transmission ratio varies continuosly and automatically.
The agent enabling the power to be transmitted is mineral oil which is pratically incompress-
ible and which is able to withstand substantial loads.
The HYDROMATIK A4VG71DA 1D2/A6VM107DA 1 transmission system consists of two

separate organs.
1° An A4VG71DA 1D2 axial piston pump of a plate design, flange-mounted on to the

diesel engine and driven directly by the flywheel by means of a flexible coupling.
2° An A6VM107DA 1 hydraulic axial piston motor of a bent axis design, flange-mount-

ed on to a coupling case and a transfer case and driving the two axle shafts via a
differential.
The pump and the hydraulic motor are linked together by a series of hoses, as are various
accessories required for operation of the system: reservoir, filter, drain and return to the
cooler, etc.
The pump absorbs the maximum power supplied by the IC engine and converts it into
hydraulic power (product of the pressure generated and the delivery rate).
The hydraulic motor receives the hydraulic power and absorbs it completely. The output
shaft is then given a torque and speed which is transferred to the axle and distributed to the
wheels.
The variation in the transmission ratio is obtained by the variation in the displacement of the
pump and the hydraulic motor.
The pilot pressure acts against the high pressure on the servo positioner in a set ratio (1/3).
The preponderance of one in relation to the other determines whether the motor is con-
trolled or not .
The minimum motor displacement is limited by a butt screw.
A control system sets the motor switching time.
3-6
S
HP HOSE
TANK BRAKE
F
FILTER OIL COOLER I
BOOSTER N
PUMP A
L
T
R
3-7
IC ENGINE TRANSFER A
CASE N
S
M
I
S
S
I
VARIABLE CAPACITY VARIABLE O
PUMP DISPLACEMENT N
MOTOR
KINEMATIC CHAIN OF THE TRANSMISSION UNIT
BRAKE
HIGH PRESSURE HOUSE

3-8
MHT 780 T-E3
MHT-X 780 T-E3
3-9
P.F.
3 bar
T2
U
T1 G
b a
R T1 T2 PS MB
B
HYDROSTATIC TRANSMISSION SYSTEM LAYOUT
480 bar
480 bar
32 bar
Vg min
Vg max
450 bar
M. A a
b
3-10
X1 X2 G S MA
P.I. M.I.
MHT 780 T-E3
A B X1 X3
MHT-X 780 T-E3
S.C.
F.A. F.R.
10 MICRONS 25 MICRONS
R
LEGEND – HYDROSTATIC TRANSMISSION SYSTEM LAYOUT MHT 780 T-E3
MHT-X 780 T-E3
EEM = Manipulator exclusion solenoid valve

EFS = Parking brake solenoid valve
F.A. = Intake filter
F.R. = Exhaust filter
M. = I.C. engine
M.I. = Hydrostatic motor
P.F. = Brake pump
P.I. = Hydrostatic pump
PI (G) = G connection of hydrostatic pump
S.C. = Radiator
R. = Oil tank
VSLR = Slow-fast speed selector valve
3-11
MONTAGGIO MOTORE E TRASMISSIONE IDROSTATICA
CIRCUIT TRANSMISSION HYDROSTATIQUE MHT 780 T-E3
4AADI HYDROSTATIC TRANSMISSION CIRCUIT
MHT 780
MHT-X 780 T-E3
HYDROSTATIK GETRIEBEKREIS
010 MOTOR Y TRANSMISION HIDROSTATICA E3
BCDI022 BCDI001
APDI125
30
25
13
37
35 28 14
24 12
32 17
34 21
10 15 23
27
33 13 20
25
APDI152 1 11
4 18
3-12
22
10 16 19
7
13
5 3 14 36
6
12
9
17
8
26 15
2
23
31
11 20
ACCOPPIAMENTO COMPLETO 25 8
ACCOUPLEMENT COMPLET
29 COMPLETE COUPLING
KOMPLETTER ANSCHLUSS FLANSCH 18 9
ACOPLAMIENTO COMPLETO
19
CIRCUITO TRASMISSIONE IDROSTATICA MHT 780 T-E3
4ABDI CIRCUIT TRANSMISSION HYDROSTATIQUE MHT 780
HYDROSTATIC TRANSMISSION CIRCUIT MHT-X 780 T-E3
003 CIRCUITO TRANSMISION HIDROSTATICA E3
17 12
11
18
8
7
5
7
5 4
3-13
15 11 4ABDI005
3
8
4 3
13 PS 15
X1 1 1
12 2
T1
BCDI001
T2
16 10
MB 9
2
14
1 12
17 13
3 1
BCDI010 12 T2
19 3
4
4
5 6
5
6
648585
TRASMISSIONE IDROSTATICA (Radiatore olio) MHT 780 T-E3
4ABDI CIRCUIT TRANSMISSION HYDROSTATIQUE (Radiateur d'huile) MHT 780
HYDROSTATIC TRANSMISSION (Oil cooler) MHT-X 780 T-E3
HYDROSTATIK GETRIEBEKREIS (Oelkuehler)
005 TRANSMISION HIDROSTATICA (Radiador de aceite) E3
55
20 19 41
42 45
54 20 5
43
33 58 19 30
34 10DDDI001 20 44
18 46
21
39
58
47 61
60
20 30 12
55 57
20 9
57 38 14
56 20 30 39 15
24
16
53 25 15
39 14
37
26
3-14
36
20
35
13
49 48 14
31 30 29 2
3 22 14
37 62 49 15
39
1 16
48
15
14
38 28 4 17
40
23 32
32 39 27 6
53 56 47
14 7
31 30 15 11
50 51 16
10
10 15
10AADI005 14 9
52 9 9 8
30 59
46 12
648585
CIRCUITO TRASMISSIONE IDROSTATICA (Circuito cambio di velocità)
CIRCUIT TRANSMISSION HYDROSTATIQUE (Circuit changement vitesse) MHT 780 T-E3
4ABDI HYDROSTATIC TRANSMISSION CIRCUIT (Speed changer circuit)
MHT 780
MHT-X 780 T-E3
HYDROSTATICK GETRIEBEKREIS (Geschw-wechselkreis)
020 CIRCUITO TRANSMISION HIDROSTATICA (Circuito cambio de velocidad) E3
1 8
3 12 6
2
5 9
12
3 4 P
A
8 A B
P B T
3 12
12 T
10
3
12
6BADI016
3-15
9
8
12
7
8
12
7
6BADI016
10
11
PONTE ANTERIORE
ESSIEU AVANT
FRONT AXLE
VORNACHSE
EJE DELANTERO
648585
IMPIANTO IDRAULICO (Servocomandi)
HYDRAULIQUE (Servocommande) MHT 780 T-E3
10EADI HYDRAULIC (Hydraulic controls)
MHT 780
MHT-X 780 T-E3
HYDRAULIK (Hydraulik kommande)
010 HIDRAULICO (Servomando) E3
10EADI005
19
3
14 3
17 10EADI006
T P 1 2 3 4
13 13 13 13 13 13
4
10AADI005 4 4 4 4 4
19 20 21 22 23 18
3-16
22
5 4
23 10DADI001
4 4 11
21
13
4
16 12
8
6BADI016
Pr
13 15
8 16 4
Tp
r
17 3 1 1
6 3
Tdd 9
7 4
14 2 10 15
3
9 4 4
4 11
5
18 20
MHT 860 LT-E3
MHT-X 860 LT-E3
P.F.
3 bar
T2
U
T1 G
b a
R T1 T2 PS MB
B
480 bar
480 bar
32 bar
Vg min
Vg max
450 bar
M. A a
b
3-18
X1 X2 G S MA
P.I. M.I.
A B X1 X3
MHT 860 LT-E3
MHT-X 860 LT-E3
S.C.
F.A. F.R.
R
LEGEND – HYDROSTATIC TRANSMISSION SYSTEM LAYOUT MHT 860 LT-E3
MHT-X 860 LT-E3

M. = I.C. engine
P.F. = Brake pump
S.C. = Radiator
R. = Oil tank
3-19
MONTAGGIO MOTORE E TRASMISSIONE IDROSTATICA MHT 860 LT-E3
4AADI CIRCUIT TRANSMISSION HYDROSTATIQUE MHT 860L
HYDROSTATIC TRANSMISSION CIRCUIT MHT-X 860 LT-E3
BCDI022 BCDI001
APDI125
30
25
13
37
28 14
35 12
24 38
32 17
34 21
10 15 23
27
33 13 20
25
APDI152 1 11
4 18
22
3-20
20
10 16
7 19
13
14 38
5 3 6 36
12
9
17
Cinghia motore (senza aria condizionata)
Engine belt (sans air conditionee) 8
Courroie moteur (without air conditioned) 15
Keilriemen (ohne klimatisierte luft)
26 Correa motor (sin aire acondicionado) 2
23
31
11 20
ACOPLAMIENTO COMPLETO 20
19
CIRCUITO TRASMISSIONE IDROSTATICA
CIRCUIT TRANSMISSION HYDROSTATIQUE MHT 860 LT-E3
4ABDI HYDROSTATIC TRANSMISSION CIRCUIT
MHT 860L
MHT-X 860 LT-E3
7
5
11 4
7 11
8 5 8 3
PS 15
10 15
16 1
4 3
1 9
X1 MB
3-21
14
12
BCDI010 13
2 1
T2
1 12 BCDI001
3
13 4
3 6
5
4 6
5
648587
TRASMISSIONE IDROSTATICA (Radiatore olio)
CIRCUIT TRANSMISSION HYDROSTATIQUE (Radiateur d'huile) MHT 860 LT-E3
4ABDI HYDROSTATIC TRANSMISSION (Oil cooler)
MHT 860L
MHT-X 860 LT-E3
19
20 42 45 41
31 30 5
30 43
50 51 19 30
BCDI010 20 44
10 18 46
21
52
9
30 13
46
53 49 22
14
59 15
48
30 16
62 60 15
49
57 14
58 17
36
3-22
10AADI005 20
35
17
53
14
55 15
49 31 30 29
9 2 3
56 34 33 16
39 1 15
26 4 14
54 37
28 37
39 13
40
38 24
27 12
32 39
47 39
38 7
25 11
22 6 10
61 23 9
10CFDI001 47 49 8
T 39 48
CIRCUITO TRASMISSIONE IDROSTATICA (Circuito cambio di velocità)
CIRCUIT TRANSMISSION HYDROSTATIQUE (Circuit changement vitesse) MHT 860 LT-E3
4ABDI HYDROSTATIC TRANSMISSION CIRCUIT (Speed changer circuit)
MHT 860L
MHT-X 860 LT-E3
1 8
3 12 6
2 9
5
12
3 4
A T
8
P B
3 12
T
10 12
3
12
9
3-23
6BADI016
8
12
7
8
12
7
6BADI016
10
11
PONTE ANTERIORE
ESSIEU AVANT
FRONT AXLE
VORNACHSE
EJE DELANTERO
3-24
MHT 950 LT-E3
MHT-X 950 LT-E3
3-25
P.F.
3 bar
T2
U
T1 G
b a
R T1 T2 PS MB
B
480 bar
480 bar
32 bar
Vg min
Vg max
450 bar
M. A a
b
3-26
X1 X2 G S MA
P.I. M.I.
A B X1 X3
MHT 950 LT-E3
MHT-X 950 LT-E3
S.C.
F.A. F.R.
R
LEGEND – HYDROSTATIC TRANSMISSION SYSTEM LAYOUT MHT 950 LT-E3
MHT-X 950 LT-E3

M. = I.C. engine
P.F. = Brake pump
S.C. = Radiator
R. = Oil tank
3-27
MONTAGGIO MOTORE E TRASMISSIONE IDROSTATICA MHT 950 LT-E3
4AADI CIRCUIT TRANSMISSION HYDROSTATIQUE MHT 950L
BCDI022 BCDI001
APDI125
30
25
13
37
28 14
35 12
24 38
32 17
34 21
10 15 23
27
33 13 20
25
APDI152 1 11
4 18
22
3-28
20
10 16
7 19
13
14 38
5 3 6 36
12
9
17
Cinghia motore (senza aria condizionata)
Engine belt (sans air conditionee) 8
Courroie moteur (without air conditioned) 15
Keilriemen (ohne klimatisierte luft)
26 Correa motor (sin aire acondicionado) 2
23
31
11 20
ACOPLAMIENTO COMPLETO 20
19
648594
CIRCUITO TRASMISSIONE IDROSTATICA MHT 950 LT-E3
4ABDI CIRCUIT TRANSMISSION HYDROSTATIQUE MHT 950L
7
5
11 4
7 11
8 5 8 3
PS 15
10 15
16 1
4 3
1 9
X1 MB
3-29
14
12
BCDI010 13
2 1
T2
1 12 BCDI001
3
13 4
3 6
5
4 6
5
648594
TRASMISSIONE IDROSTATICA (Radiatore olio) MHT 950 LT-E3
4ABDI CIRCUIT TRANSMISSION HYDROSTATIQUE (Radiateur d'huile) MHT 950L
HYDROSTATIC TRANSMISSION (Oil cooler) MHT-X 950 LT-E3
19
20 42 45 41
31 30 5
30 43
50 51 19 30
BCDI010 20 44
10 18 46
21
52
9
30 13
46
53 49 22
14
59 15
48
30 16
62 60 15
49
57 14
58 17
3-30
10AADI005 36
20
35
17
53
14
55 15
49 31 30 29
9 2 3
56 34 33 16
39 1 15
26 4 14
54 37
28 37
39 13
40
38 24
27 12
32 39
47 39
38 7
25 11
22 6 10
61 23 9
10CFDI001 47 49 8
T 39 48
648 94
CIRCUITO TRASMISSIONE IDROSTATICA (Circuito cambio di velocità) MHT 950 LT-E3
4ABDI CIRCUIT TRANSMISSION HYDROSTATIQUE (Circuit changement vitesse) MHT 950L
HYDROSTATIC TRANSMISSION CIRCUIT (Speed changer circuit) MHT-X 950 LT-E3
1 8
3 12 6
2
5 9
12
3 4
A T
8
P B
3 12
T
10 12
3
12
3-31
9 6BADI016
8
12
7
8
12
7
6BADI016
10
11
PONTE ANTERIORE
ESSIEU AVANT
FRONT AXLE
VORNACHSE
EJE DELANTERO
648594
3-32
VARIABLE PUMP A4VG 71-180
Series 32
3-33
Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Verstellpumpe A4VG 71–180 RDE 92 003-21-R/01.06
Variable Pump A4VG 71–180

Baureihe/Series 32 R1
Reparaturanleitung / Repair Manual
Baugruppen / Assembly Groups
2/40 Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Vermeidung von Gefahren Avoiding Dangers

Für einen sicheren Betrieb und um Schäden bei der Reparatur To ensure safe operations and avoid damages during repairs,
zu vermeiden, lesen Sie diese Reparaturanleitung sorgfältig read this complete repair manual carefully and attentively.
und aufmerksam durch!
Für Personen- oder Maschinenschäden, die durch Nichtbe- Bosch Rexroth AG accepts no responsibility for personal
achtung dieser Reparaturanleitung entstehen, verfällt jegliche injuries or damages to the machine that arise from disregarding
Gewährleistung von Bosch Rexroth AG. this repair manual.
1 Zu dieser Anleitung 1 About this Manual

Diese Anleitung unterstützt Sie bei der Reparatur, den Über- This manual supports you in the repair, adjustment and recom-
prüfungen und der Wiederinbetriebnahme von Rexroth A4VG missioning of Rexroth A4VG variable pumps, sizes 71–180.
Verstellpumpen, NG 71–180. Diese Anleitung umfasst die The manual is structured as follows:
folgenden Kapitel:
• „Sicherheit“ auf Seite 7 • “Safety” on page 7
Hier erhalten Sie grundsätzliche Hinweise zum sicheren This chapter provides you with basic hints and tips regarding
Umgang mit Verstellpumpen und zu deren Betrieb. working with and operating variable pumps.
Lesen Sie dieses Kapitel bevor Sie anfangen zu arbeiten. Read this chapter before you start working.
• „Produktbeschreibung“ auf Seite 11 • “Product Description” on page 11
Hier erfahren Sie, wie Sie den Typ einer Verstellpumpe This chapter explains how you identify the variable pump.
feststellen. Ferner finden Sie hier eine Übersicht über die Addtionally, it provides you an overview of the how the vari-
Funktionsweise und Informationen zur bestimmungsgemäßen able pump and information regarding the correct usage.
Verwendung der Verstellpumpe. Read this chapter to refresh your knowledge of the variable
Lesen Sie dieses Kapitel, um Ihr Grundwissen über die pumps.
Verstellpumpe aufzufrischen.
• „Austausch externer Baugruppen“ auf Seite 15 • “Exchanging Extermnal Assembly Groups” on page 15
Dieses Kapitel erklärt Ihnen, wie Sie Baugruppen einer Ver- Rexroth provides various replacement parts for repairs. This
stellpumpe austauschen. section provides you an overview of the available spare parts
subassemblies.
• „Überprüfungen“ auf Seite 33 • “Checking” on page 33
Dieses Kapitel erklärt Ihnen, wie Sie die Einstellarbeiten an Read this chapter to be able to restore the settings on an
einer Verstellpumpe vornehmen. variable pump after a repair.
RDE 92 003-21-R/01.06 Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG 3/40
1.1 Inhaltsverzeichnis 1.1 Contents
1. Zu dieser Anleitung 2 1. About this Manual 2

1.1 Inhaltsverzeichnis 3 1.1 Contents 3
1.2 Gültigkeitsbereich dieser Anleitung 4 1.2 Validity of this Manual 4
1.3 Wichtige Unterlagen 5 1.3 Important Documents 5
1.4 Gefahrenkennzeichnungen und Pictogramme 6 1.4 Danger Labels and Pictograms 6
2. Sicherheit 7 2. Safety 7
2.1 Grundlegende Sicherheitshinweise 7 2.1 Basic Safety Information 7
2.2 Anforderungen an das Personal 10 2.2 Requirements on the Personnel 10
3. Produktbeschreibung 11 3. Product Description 11
3.1 Typschild 11 3.1 Name Plate 11
3.2 Funktionsbeschreibung 11 3.2 Functional Description 11
3.3 Technische Daten 14 3.3 Technical Data 14
4. Austausch externer Baugruppen 15 4. Exchanging External Assembly Groups 15
4.1 Wellendichtring austauschen 16 4.1 Exchanging the Shaft Seal 16
4.2 Dichtungen austauschen 18 4.2 Exchanging Seals 18
4.3 Hilfspumpe austauschen 24 4.3 Exchanging the Backing Pump 24
4.4 Steuergerät austauschen 26 4.4 Exchanging the Control Unit 26
5. Überprüfungen 33 5. Checking 33
5.1 Niederdruck (Speisedruck) überprüfen 34 5.1 Checking Low Pressure (Charge Pressure) 34
5.2 Hochdruck überprüfen 34 5.2 Checking High Pressure 34
5.3 Mechanische Nulllage überprüfen 35 5.3 Checking the Mechanical Zero Stroke 35
5.4 Hydraulische Nulllage überprüfen 36 5.4 Checking the Hydraulic Zero Stroke 36
1.2 Gültigkeitsbereich dieser 1.2 Validity of this Manual

Anleitung
Diese Reparaturanleitung gilt für die Axialkolben-Verstellpumpe This manual is valid for the Bosch Rexroth axial piston variable
A4VG NG 71–180 der Bosch Rexroth AG. Informationen zu pump A4VG NG 71–180. Refer to the system manufacturer for
zugelassenen Druckflüssigkeiten entnehmen Sie den Angaben information about the allowed hydraulic fluids.
des Anlagenherstellers.
Diese Reparaturanleitung richtet sich an: This repair manual is directed at:
• Anlagenbetreiber, • the system operator
• den autorisierten Fachbetrieb bzw. Händler, • authorized dealers
• den Anlagenhersteller. • the system manufacturer
Für den Anlagenhersteller sind zusätzlich auch die jeweilige For the system manufacturer, the installation drawing, the
Einbauzeichnung, das technische Datenblatt, die Betriebsan- catalog sheet, the manual, and the confirmation of order from
leitung und die Auftragsbestätigung der Bosch Rexroth AG the Bosch Rexroth AG are also obligatory.
verbindlich.
1.3 Wichtige Unterlagen 1.3 Important Documents

Bevor Sie mit den in dieser Anleitung beschriebenen Arbeiten Before you start any of the procedures described in this manu-
anfangen, stellen Sie sicher, dass Sie folgende Unterlagen al, make sure you have the following documents:
griffbereit haben:
• Auftragsbestätigung • Confirmation of order
Die Auftragsbestätigung enthält die voreingestellten techni- The confirmation of order contains the values set during the
schen Daten. Die Axialkolbenmaschine darf nur unter den in commissioning by Rexroth. Before you can recommission the
der Auftragsbestätigung angegebenen Werten und Bedin- axial piston unit after a repair, you have to restore the values
gungen betrieben werden. originally set by Rexroth.
• Einbauzeichnung • Installation drawing
Die Einbauzeichnung der Axialkolbenmaschine enthält die The installation drawing of the axial piston unit contains the
Außenabmessungen, sämtliche Anschlüsse und den Schalt- sizes of all connections.
plan.
• Technisches Datenblatt • Technical data sheet
Das technische Datenblatt RD 92 003 enthält u.a. die zuläs- The technical data sheet RE 92 003 contains the maximum
sigen technischen Daten für die Axialkolbenmaschine. allowed performance data.
• Gesamtschaltplan der Maschine bzw. Anlage • Hydraulic diagram / Wiring diagram
Der Hydraulikschaltplan und der elektrische Schaltplan der The hydraulic diagram and the wiring diagram of the unit
Maschine bzw. Anlage enthalten die Informationen zu den or system contain the information related to the respective
hydraulischen bzw. elektrischen Anschlüssen. Diese Daten machine.You need this data to work with the axial piston as
brauchen Sie, um mit der Axialkolbenmaschine als Teil der part of the machine or system. You can get this information
Maschine bzw. Anlage zu arbeiten. Die Unterlagen erhalten from the unit or system manufacturer.
Sie vom Maschinen- bzw. Anlagenhersteller.
• RD 90 300-B: Allgemeine Betriebsanleitung für Axialkol- • RE 90 300-B: General Manual for Axial Piston Units
benmaschinen The general manual supports you during the installation,
Die allgemeine Betriebsanleitung unterstützt Sie bei Installa- initiation, and operation of Rexroth axial piston units.
tion, Inbetriebnahme und Betrieb von Rexroth-Axialkolbenma-
schinen.
• Produktspezifische Betriebsanleitung • Product Specific Manual
Die produktspezifische Betriebsanleitung enthält spezielle, The product-specific manual contains information specially
für die Axialkolbenmaschine gültige Informationen. Informie- designed for the axial piston unit. Get in touch with Rexroth
ren Sie sich bei Rexroth, ob es zu Ihrer Axialkolbenmaschine to find out if there is any product-specific information on your
eine produktspezifische Betriebsanleitung gibt. specific axial piston unit.
Folgende Rexroth-Druckschriften geben Ihnen weitere Informa- The following Rexroth publications provide additional informati-
tionen zu Installation und Betrieb der Axialkolbenmaschine: on to the installation and operation of axial piston units:
• RD 90 220: Druckflüssigkeiten auf Mineralölbasis • RE 90 220: Mineral-oil Based Pressure Fluids
Beschreibt die Anforderungen an eine Druckflüssigkeit auf This publication describes the requirements on a hydraulic
Mineralölbasis für den Betrieb mit Rexroth-Axialkolbenma- fluid for operation in an axial piston unit and supports you in
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- the selection of a hydraulic fluid for your installation.
keit für Ihre Anlage.
• RD 90 221: Umweltfreundliche Druckflüssigkeiten HEES, • RE 90 221: Environmentally Acceptable Hydraulic Fluids
HEPG, HETG für Axialkolbenmaschinen HEES, HEPG, HETG for Axial Piston Units
Beschreibt die Anforderungen an eine umweltfreundliche Describes the demands on environmentally compatible, rea-
Druckflüssigkeit für den Betrieb mit Rexroth-Axialkolbenma- dily biodegradeable hydraulic fluids HEPG, HEES that can
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- be used in Rexroth axial piston units and supports you by the
keit für Ihre Anlage. choice of a hydraulic fluid for your system.
• RD 90 223: Axialkolbenmaschinen für den Betrieb mit • RE 90 223: Axial Piston Units for Use with HF Fluids
HF-Druckflüssigkeiten Provides additional information for the use of Rexroth axial
Enthält zusätzliche Informationen zum Einsatz von Rexroth- piston units with HF hydraulic fluids.
Axialkolbenmaschinen mit HF-Druckflüssigkeiten.
• RD 90 300-03-B: Hinweise zum Einsatz von hydrauli- • RE 90 300-03-B: Instructions on the Use of Hydrostatic
schen Antrieben bei tiefen Temperaturen Drives at Low Temperatures
Enthält zusätzliche Informationen zum Einsatz von Rexroth- Provides additional information for the use of Rexroth axial
Axialkolbenmaschinen bei tiefen Temperaturen. piston units for low temperatures.
1.4 Gefahrenkennzeichnungen 1.4 Danger Labels and Pictograms

und Piktogramme
Diese Anleitung unterscheidet zwischen Kategorien von Gefah- This manual differentiates between the following categories of
ren gemäß ISO Guide 37: danger according to ISO Guide 37:
! GEFAHR ! DANGER
Weist auf hohes Risiko und die Gefahr von Tod oder schwe- Indicates high risk, mortal danger and serious injuries.
ren Verletzungen hin.
! WARNUNG ! WARNING
Weist auf mittleres Risiko und die Gefahr von Verletzungen Indicates middle risk, injuries or serious material damage.
und schweren Sachschäden hin.
! VORSICHT ! CAUTION
Weist auf geringes Risiko und Sachschäden hin. Indicates low risk or material damage.
Hinweis Note
Kennzeichnet Informationen, die zum besseren Verständnis Indicates information that contributes to a better understan-
der Maschinenabläufe beitragen oder weist auf einen beson- ding of the machine processes or indicates important informa-
deren bzw. wichtigen Sachverhalt hin. tion.
Tipp Tip
Kennzeichnet Informationen, die zum effizienteren Arbeiten Indicates information that contributes to more efficient work.
beitragen.
2 Sicherheit 2 Safety
Lesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbei- Read through this chapter carefully before you start any work
ten an der Verstellpumpe beginnen. on the variable pump.
Die Rexroth-Verstellpumpen sind im Sinne der Maschinenricht- The Rexroth variable pump are in the sense of the machine gui-
linie 98/37/EG Komponenten, die zum Einbau in eine Anlage deline 98/37/EG components of a larger machine or system.
bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung be- The safety guidelines in this manual only cover the variable
ziehen sich nur auf die Verstellpumpe. Beachten Sie zusätzlich pump. You must additionally follow the system manufacturer’s
die Sicherheitsrichtlinien des Anlagenherstellers. safety guidelines.
Informieren Sie sich an Hand der allgemeinen Betriebsanlei- Read the general manual for axial piston units to get more infor-
tung für Axialkolbenmaschinen über die bestimmungsgemäße mation on the designated use and the operator‘s obligation to
Verwendung und die Sorgfaltspflicht des Betreibers und exercise dilligence.
Bedieners.
2.1 Grundlegende 2.1 Basic Safety Information

Sicherheitshinweise
Befolgen Sie die folgenden Sicherheitshinweise und die des Pay exact attention to the following safety information and that
Anlagenherstellers genau, um Verletzungen und Gesundheits- of the system manufacturer to eliminate injuries and health
schäden sowie Sach- und Umweltschäden auszuschließen. damages as well as damages to material or the environment.
! GEFAHR ! DANGER
Lebensgefahr Danger to Life

Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen Working on systems that have not been shut down is life-thre-
stellt eine Gefahr für Leib und Leben dar. atening.
Die in diesem Dokument beschriebenen Arbeiten dürfen nur The work described in this document can only be carried out
an stillgelegten Maschinen bzw. Anlagen vorgenommen on a shut down system. Before you start any of the tasks:
werden. Bevor Sie mit den Arbeiten beginnen:
• Stellen Sie sicher, dass der Antriebsmotor nicht eingeschal- • Make sure that the engine / motor cannot be switched on.
tet werden kann.
• Stellen Sie sicher, dass sämtliche kraftübertragenden Kom- • Make sure that all components and connections that carry
ponenten und Anschlüsse (elektrisch, pneumatisch, hydrau- energy (electrical, pneumatic, hydraulic) have been shut
lisch) gemäß den Herstellerangaben ausgeschaltet sind und down according to the manufacturer’s instructions and
nicht eingeschaltet werden können. Falls möglich, entfernen cannot be switched on. If possible, disable the main fuse.
Sie die Hauptsicherung der Maschine bzw. Anlage.
• Stellen Sie sicher, dass die Maschine bzw. Anlage komplett • Make sure that the system is completely unloaded. Follow
hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den the instructions of the the system manufacturer.
Angaben des Maschinen- bzw. Anlagenherstellers.
! WARNUNG ! WARNING
Verletzungsgefahr Danger of injuries

Um Verletzungen zu vermeiden, beachten Sie bitte folgende To avoid injuries, pay attention to the following regarding
Empfehlungen betreffend Sicherheitskleidung: safety clothing.
• Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicher- • When working on the system, wear steel-toed safety shoes.
heitsschuhe mit Stahlkappen.
• Tragen Sie bei Arbeiten mit gefährlichen Stoffen (beispiels- • When working with dangerous substances (for example,
weise Druckflüssigkeiten) Schutzhandschuhe und Schutz- certain hydraulic fluids), wear protective gloves and protec-
brille. tive glasses.
! GEFAHR ! DANGER
Vergiftungs- und Verletzungsgefahr Danger of poisoing or injuries

Der Kontakt mit Drückflüssigkeiten ruft Gesundheitsschäden Contact with hydraulic fluids can cause health damage (eye
hervor (z.B. Augenverletzungen, Haut- und Gewebeschädi- injuries, skin damage, poisoning due to inhalation).
gungen, Vergiftungen beim Einatmen).
• Überprüfen Sie vor jeder Inbetriebnahme die Leitungen auf • Always check the hydraulic lines for wear and damage prior
Verschleiß bzw. Beschädigungen. to putting the unit into operation.
• Tragen Sie dabei Schutzhandschuhe und Schutzbrille. • Always wear protective gloves and safety glasses.
• Wenn dennoch Druckflüssigkeit in die Augen gelangt oder • Should pressure fluid come into contact with your eyes or
in die Haut eindringt, konsultieren Sie unmittelbar einen skin: Get medical help immediately!
Arzt.
• Beachten Sie beim Umgang mit Druckflüssigkeiten unbe- • When handling hydraulic fluids, pay exact attention to the
dingt die Sicherheitsangaben des Druckflüssigkeitsherstel- manaufacturer’s safety instructions.
lers.
! WARNUNG ! WARNING
Verbrennungsgefahr Danger of burns

Die Axialkolbenmaschine erwärmt sich während des Betriebs. The variable pump heats up during operation. The unit’s sole-
Auch die Magnete an der Axialkolbenmaschine werden im noids get hot during operation. Touching the variable pump or
laufenden Betrieb heiß. Bei Berührung der Axialkolbenma- solenoids can lead to severe injuries.
schine oder der Magnete können schwere Brandverletzungen
entstehen.
• Lassen Sie die Axialkolbenmaschine vor jedem Kontakt • Let the variable pump cool down prior to any contact.
abkühlen.
• Schützen Sie sich mit hitzebeständigen Handschuhen und • Protect yourself from burns by wearing safety gloves and
Schutzkleidung. protective clothing.
! GEFAHR ! DANGER
Vergiftungs- und Verletzungsgefahr Danger of poisoning

Beim Suchen nach Leckstellen kann entweichende Druckflüs- When looking for leaks, escaping hydraulic fluid can break
sigkeit in die Haut eindringen und schwerste Vergiftungen und into the skin and cause serious poisoning.
Verletzungen hervorrufen.
• Suchen Sie nur bei abgestellter und druckloser Maschine • Always use a piece of cardboard or paper to look for leaks.
nach Leckstellen.
! WARNUNG ! WARNING
Verletzungs- und Beschädigungsgefahr Danger of injuries or damage

Durch falsch angeschlossene Komponenten können erhebli- Incorrectly connected components can considerably impair
che Fehlfunktionen entstehen. the functionality of a hydraulic system.
• Achten Sie auf korrekte Verrohrung gemäß Schaltplan. • Make sure that the hydraulic lines are connected properly.
• Führen Sie komponentenorientierte Funktionstests durch. • Check the correct functioning of all components.
! GEFAHR ! DANGER
Feuergefahr Danger of fire

Hydraulische Druckflüssigkeit ist brennbar. Hydraulic fluid is inflammable.
• Halten Sie offenes Feuer von der Verstellpumpe fern. • Keep open fires away from the variable pump.
! WARNUNG ! WARNING
Gehörschäden Danger of hearing loss

Die Geräuschemission von Axialkolbenmaschinen ist u.a. von The noise emission produced by axial piston units depends
Drehzahl, Betriebsdruck und Einbauverhältnissen abhängig. on speed, operating pressure, and installation. During normal
Es ist damit zu rechnen, dass der Schalldruckpegel bei nor- application conditions, over 70 dBA can be anticipated. This
malen Einsatzbedingungen über 70 dBA steigt. Dies kann zu can lead to hearing damage.
Gehörschäden führen.
• Schützen Sie sich stets mit Gehörschutz bei Arbeiten in • Always wear hearing protection when working in the vicinity
der Nähe der Axialkolbenmaschine während des laufenden of the variable pump during operation.
Betriebs.
! WARNUNG ! WARNING
Umweltschäden Risk of damage to the environment

Druckflüssigkeiten sind wassergefährdende Flüssigkeiten. Hydraulic fluid leakage leads to contamination of the ground
Das Austreten von Druckflüssigkeiten kann zu Grundwasser- and ground water.
vergiftung und Bodenverseuchung führen.
• Bringen Sie unter der Axialkolbenmaschine eine Auffang- • A basin for catching any hydraulic fluid must be placed
wanne an. under the variable pump.
• Beseitigen Sie Leckstellen unverzüglich. • Leaks must be cleaned up immediately.
• Es sind stets die nationalen Gesetze und Vorschriften zu • In Europe, hydraulic systems are considered “Systems
beachten. In Deutschland sind hydraulische Maschinen bzw. using water-threatening substances” in the sense of the
Anlagen „Anlagen zum Umgang mit wassergefährdenden Water Management Law (WHG).Therefore, pay special
Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG)“. attention to §1 and §19 WHG( §19g, 19i, 19l). Additionally
Beachten Sie in diesem Zusammenhang besonders §1 und pay attention to any national regulations and norms.
§19 WHG (§19g, 19i, 19l).
• Weitere Informationen zum richtigen Umgang mit Rexroth- • For further information regarding the correct use of Bosch
Hydraulikprodukten finden Sie in unseren Druckschriften Rexroth hydraulic products, see the publications RE 90 220
„Allgemeine Produktinformationen für Hydraulikprodukte“, “Mineral-oil Based Pressure Fluids” and RE 90 221 “En-
RD 90 220 und „Umweltschonende, biologisch schnell vironmentally Acceptable Hydraulic Fluids HEES, HEPG,
abbaubare Druckflüssigkeiten HEPG, HEES für Axialkol- HETG for Axial Piston Units“, RD 90 221.
benmaschinen“, RD 90 221.
2.2 Anforderungen an das Personal 2.2 Requirements on the Personnel

Diese Reparaturanleitung richtet sich an Fachkräfte mit This repair manual is directed at qualified personnel with
Hydraulik-Fachwissen, die an einer Service-Schulung bei specialized hydraulics know-how who have taken part at a
Rexroth teilgenommen haben. service training at Rexroth.
Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung Qualified personnel is defined as persons who have sufficient
und Erfahrung ausreichende Kenntnisse hat, sowie mit den knowledge on the basis of specialized training and experience,
einschlägigen Bestimmungen so weit vertraut ist, dass er and are familiar with the relevant regulations, so that they are
able to
• die ihm übertragenene Arbeiten beurteilen kann, • judge the delegated tasks,
• mögliche Gefahren erkennen kann, • recognize possible dangers,
• die notwendigen Maßnahmen zur Beseitigung von Gefahren • take the necessary measures for the elimination of dangers,
ergreifen kann,
• Kenntnisse über die möglichen Gesundheitsgefahren von • judge the possible health risks from hydraulic fluids,
Druckflüssigkeiten hat
• und die erforderlichen Reparatur- und Montagekenntnisse • and have the required repair and installation know-how.
hat.
Hydraulik-Fachwissen bedeutet, das Personal muss, Specialized hydraulics know-how means that these persons
must:
• in der Lage sein, die Hydraulikpläne zu lesen und vollständig • be able to read and completely understand hydraulic plans,
zu verstehen,
• insbesondere die Zusammenhänge bezüglich der eingebau- • especially understand the connections regarding the in-
ten Sicherheitseinrichtungen vollständig verstehen stalled safety equipment,
• und Kenntnisse über Funktion und Aufbau von hydraulischen • and are familiar with the function and structure of hydraulic
Bauteilen haben. components.
3 Produktbeschreibung 3 Product Description

Dieses Kapitel gibt Ihnen einen allgemeinen Überblick über die This chapter provides a general overview of the functionality of
Funktionalität der Rexroth A4VG Verstellpumpe. the A4VG variable pump.
Machen Sie sich mit den Inhalten dieses Kapitels vertraut, You should be familiar with the contents of this chapter before
bevor Sie mit Arbeiten an einer Verstellpumpe beginnen. starting any work on the variable pump.
3.1 Typschild 3.1 Name Plate

Die Verstellpumpe ist am Typschild zu identifizieren: The variable pump can be identified on its name plate:
1 3FYSPUI
D-89275 Elchingen
2 TYP: A4VG90DA2D2/32R-NZF02F001SP 7
3 MNR: R90XXXXXXX
8
4 SN: 12345678 7202
5 FD: 05W28 Rotation:

9
6 n = XXXX min -1
P = XXX kW
Made in Germany 10
Folgende Informationen finden Sie auf dem Typschild: The following information can be found on the name plate:
1 Hersteller 1 Manufacturer
2 Typschlüssel 2 Ordering code
3 Materialnummer der Axialkolbenmaschine 3 Material number of the axial piston unit
4 Seriennummer 4 Serial number
5 Fertigungsdatum 5 Date of manufacturing
6 Drehzahl 6 Speed
7 interne Werksbezeichnung 7 Internal manufacturing code
8 Drehrichtung (bei Blick auf die Welle; hier: rechts) 8 Direction of rotation (when facing the shaft; here: clockwi-
se)
9 vorgesehener Platz für Prüfstempel 9 Designated space for certification stamp
10 Leistung 10 Power
Stellen Sie sicher, dass Typ und Nenngröße der zu reparieren- Ensure that the variable pump to be repaired is of the type and
den Verstellpumpe mit dieser Anleitung übereinstimmen. size covered by this manual.
3.2 Funktionsbeschreibung 3.2 Functional Description

Damit Sie in der Lage sind, Probleme an der Verstellpumpe To make sure that you are able to identify problems with a vari-
zu identifizieren und gezielt Reparaturen durchzuführen, sind able pump and to carry out specific repairs, familiarity with how
Kenntnisse der Funktionsweise und des Aufbaus erforderlich. the unit functions and its assembly are required. This section
Dieser Abschnitt gibt Ihnen eine grobe Übersicht. provides you with a rough overview.
Die A4VG Verstellpumpe ist eine Axialkolben-Verstellpum- The variable displacement axial piston pump type A4VG in
pe in Schrägscheibenbauart für hydrostatische Antriebe im swashplate design is designed for closed circuit hydrostatic
geschlossenen Kreislauf. Der Volumenstrom ist proportional zu drives. The flow is proportional to the input drive speed and
der Antriebsdrehzahl und dem Verdrängungsvolumen. Durch displacement. By adjusting the swashplate, it is possible to
die Verstellung der Schrägscheibe ist eine stufenlose Volumen- infinitely vary the flow.
stromänderung möglich.
3.2.1 Schnittzeichnung 3.2.1 Sectional Drawing

Die folgenden Schnittzeichnungen zeigen das Zusammenspiel The following drawings show the interrelation of the compon-
der Komponenten der A4VG Verstellpumpe. ents of the A4VG variable pump.
Seitenansicht / Side View Steuergerät (siehe unten) /

Control unit (see below)
Schwenkwiege /
Cradle
Antriebswelle /
Drive Shaft
Anschlussplatte
mit Hilfspumpe /
Port Plate with
Auxiliary Pump
Wellendichtring /
Shaft Seal Ring
Triebwerk /
Rotary Group
Draufsicht Verstellungen/
Top View with Controllers
Steuergerät
HWD Control unit DAD
Antriebswelle
Antriebswelle Drive Shaft
Drive Shaft
Verstellkolben
Control Piston
EPD HDD
Antriebswelle
Drive Shaft
Antriebswelle
Drive Shaft
Steuergerät
Control unit
Ansicht Anschlussplatte /
View Port Plate
HWD / EPD / HDD
DAD
3.3 Technische Daten 3.3 Technical Data

Die technischen Daten der Verstellpumpe finden Sie in der Auf- You can find the technical data for the variable pump in the
tragbestätigung. Ergänzend dazu ist das jeweilige technische Confirmation of Order. This is supplemented by the unit‘s data
Datenblatt. Für die A4VG Verstellpumpe gilt das technische sheet. For the A4VG variable pump, the valid data sheet is
Datenblatt RD 92 003. RE 92 003.
4 Austausch externer 4 Exchanging External

Baugruppen Assembly Groups
Dieses Kapitel beschreibt den Austausch von extern zugängli- This chapter describes the replacement of the externally acces-
chen Baugruppen der Verstellpumpe A4VG. sible assembly groups of the variable pump A4VG.
Der Austausch folgender Baugruppen wird beschrieben: The exchange of the following assembly groups is described:
• Wellendichtring • Shaft seal
• Dichtungen • Seals
• Hilfspumpe • Auxiliary pump
• Steuergerät • Control unit
Hinweis Note
Alle in nachfolgenden Zeichnungen dargestellten Steuergerä- All the following illustrations are only examples and do not
te sind nur stellvertretend und müssen nicht der Konfiguration have to completely correspond with the configrations of your
Ihrer Axialkolbenmaschine entsprechen. axial piston unit.
! WARNUNG ! WARNING
Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der The durability of the hydraulic unit depends to a great extent
Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept. Dirt in the hydraulic fluid can
Verschmutzung der Druckflüssigkeit führt zu Verschleiß und lead to malfunctions. Especially hard foreign matter in the
Funktionsstörungen. Insbesondere harte Fremdkörper in den hydraulic conduits, for example, welding beads and cuttings,
Hydraulikleitungen, wie z.B. Schweißperlen und Metallspäne, can damage the axial piston unit.
können die Axialkolbenmaschine beschädigen.
Beachten Sie daher unbedingt folgende Hinweise: Therefore you should observe the following instructions:
• Achten Sie auf äußerste Sauberkeit. Die Axialkolbenmaschi- • Make sure everything is kept extremely clean. The axial pis-
ne muss schmutzfrei eingebaut werden. Verunreinigungen ton unit must be installed in a dirt-free environment. Conta-
in der Druckflüssigkeit können die Funktion und Lebensdau- mination of the hydraulic fluid can lead to considerable wear
er der Axialkolbenmaschine erheblich beeinträchtigen. and malfunctions of the axial piston unit.
• Achten Sie besonders bei der Installation darauf, dass • Espacially during the istallation, you should make sure that
Anschlüsse, Hydraulikleitungen und Anbauteile (z.B. Mess- ports, hydraulic conduits, and mounting components (for
geräte) sauber sind. Reinigen Sie diese gründlich, bevor example, gauges) are clean. Clean these thoroughly before
Sie Anschlüsse öffnen. Stellen Sie sicher, dass auch beim you open connections. After that, when sealing the ports,
nachfolgenden Verschließen der Anschlüsse keine Verunrei- make sure that contaminating elements cannot enter the
nigungen eindringen. system.
• Verwenden Sie für die Beseitigung von Schmiermitteln und • When removing grease and other dirt you should use ap-
anderen starken Verschmutzungen geeignete flüssige Reini- propriate liquid cleaning agents. Cleaning agents must not
gungsmittel. Es darf kein Reinigungsmittel in das Hydraulik- enter the hydraulic system.
system eindringen.
• Verwenden Sie zur Reinigung keine Putzwolle oder fasern- • Do not use cotton waste or rags which lose threads.
de Putzlappen.
• Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder • Never use hemp or putty as a sealant.
Kitt.
4.1 Wellendichtring austauschen 4.1 Exchanging the Shaft Seal

Dieser Abschnitt erklärt, wie Sie den Wellendichtring austau- This section explains how you can replace the shaft seal.
schen.
Benötigtes Sonderwerkzeug: Required Special Tools:
• Montagehülse • Mounting sleeve
Die Materialnummern sind je nach Pumpenmodell verschie- The material number depends on the pump model.
den:
– A4VG71: Mat.-nr. R909877509 – A4VG71: Mat. no. R909877509
NG 71, 90, 125
NG 180
b
a
a: Sicherungsring Circlip
b: Wellendichtring Shaft Seal
c: Triebwelle Drive Shaft
Um den Wellendichtring auszutauschen: To exchange the shaft seal:

1 Kleben Sie die Triebwelle (c) ab, um Beschädigungen am 1 Mask the drive shaft (c) for protection against damage of the
Wellendichtring (b) zu vermeiden. shaft seal (b).
2 Entfernen Sie den Sicherungsring (a). 2 Remove the safety ring (a).
a
3 Drehen Sie Blechschrauben in die mit Gummi gefüllten 3 Screw the tapping screw into the rubber lined holes of the
Löcher des Wellendichtrings (b) und ziehen Sie den Wellen- shaft seal (b), and use pliers to pull the shaft seal out.
dichtring mit einer Zange heraus.
4 Fetten Sie den Wellendichtring zwischen Dicht- und Staub- 4 Grease the shaft seal between the seal and dust lip to avoid
lippe leicht ein, um Trockenlauf zu vermeiden. a dry run.
5 Pressen Sie den Wellendichtring mit Hilfe der Montagehülse 5 Using the mounting sleeve (special tool), press the shaft seal
(Sonderwerkzeug) auf Anschlag ein. until it is in stop position.
6 Führen Sie den Sicherungsring so ein, dass er in die dafür 6 Place the safety ring so that it locks into place in the respec-
vorgesehene Nut einrastet. tive slot.
7 Entfernen Sie die Abklebung an der Triebwelle. 7 Remove the mask on the drive shaft.
4.2 Dichtungen austauschen 4.2 Exchanging Seals

Die Baugruppe „Dichtungssatz komplett“ enthält Dichtungen The assembly group "complete seal set" contains seals for the
für folgende Komponenten: following components:
• Stellkolbendeckel • Positioning piston covers
• Ventile • Valves
• Druckabschneidung • Pressure cut-off
• Hilfspumpe (siehe „Hilfspumpe austauschen“) • Auxiliary pump (refer to "Exchanging the Auxiliary Pump")
• Steuerung (siehe „Steuergerät austauschen“) • Control unit (refer to "Exchanging the Control Unit")
Benötigtes Sonderwerkzeug: Keines Required Special Tools: none
Dichtung an den Stellkolbendeckeln austauschen Exchanging the valve positioning piston covers
Die beiden Seiten des Stellkolbens sind mit zwei unterschiedli- Both sides of the positioning piston have their own different
chen Deckeln abgedeckt. Die nötigen Schritte zum Austausch covers. The required steps to exchange the covers are threre-
der Deckeldichtungen unterscheiden sich daher. fore different.
a
c
d
c c
b
e
f
a: Linker Deckel Left cover
b: Rechter Deckel Right cover
c: O-Ring O-ring
d: Stellschraube Adjustment screw
e: Kontermutter Counter nut
f: Befestigungsschrauben Fastening screw
Um die Dichtung an den Stellkolbendeckeln auszutauschen: To exchange the valves of the positioning pistons:
1 Kennzeichnen Sie die Lage des linken Deckels (a) und ent- 1 Mark the position of the left cover (a) and remove the faste-
fernen Sie die Befestigungsschrauben (f). ning screws (f).
2 Verdrehen Sie den Deckel (a) und lösen Sie ihn vorsichtig 2 Twist the cover (a) and carefully loosen it by tapping it with a
mit leichten Hammerschlägen (Gummihammer). (rubber) hammer.
a
3 Entfernen Sie den alten O-Ring (c). Kontrollieren Sie die 3 Remove the old o-ring (c). Check the slot (h) and the
Nut (h) und das Gehäuse (g) auf Verschleiß und Verunreini- housing (g) for wear and dirt.
gungen.
c
h g
4 Setzen Sie einen neuen O-Ring ein und schrauben Sie den 4 Install a new o-ring and screw the cover shut.
linken Deckel fest.
5 Markieren Sie die Lage des rechten Deckels (b), damit Sie 5 Mark the position of the right cover (b) so that you can set it
ihn nach dem Abdichten wieder lagerichtig aufsetzen kön- back to its original position after sealing.
nen.
Messen und notieren Sie das Maß X der Kontermutter (e) für Measure and write down the dimension X of the counter
die spätere Montage. nut (e). You need this for the subsequent assembly.
Entfernen Sie die Kontermutter (e). Halten Sie dazu die Remove the counter nut (e). To do so, grip the positioning
Stellschraube (d) fest. screw (d).
b
e
X
d
X
6 Schrauben Sie den Deckel von der Stellschraube durch 6 Unscrew the cover from the positioning screw.
Drehen ab.
7 Entfernen Sie die beiden O-Ringe (c). Kontrollieren Sie die 7 Remove the two o-rings (c). Check the slots (h) and housing
Nuten (h) und das Gehäuse (g) auf Verschleiß und Verunrei- (g) for wear and dirt.
nigungen.
c
g h
h
8 Kleben Sie das Gewinde ab, um Beschädigungen des O- 8 Mask the screw thread to avoid damaging the o-ring, and
Rings zu vermeiden, und schieben Sie den kleinen O-Ring push the smaller o-ring up to the designated slot.
bis zur vorgesehenen Nut auf.
9 Setzen Sie den großen O-Ring ein, entfernen Sie die Abkle- 9 Insert the larger o-ring, remove the masking and screw the
bung und schrauben Sie den Deckel fest. cover back on.
10 Schrauben Sie die Kontermutter (e) per Hand ein. Blockie- 10 Screw in the counter nut (e) manually. Block the adjusting
ren Sie die Stellschraube (d) während Sie die Kontermutter- screw (d) while you tighten the counter nut.
festziehen.
Kontrollieren Sie das Maß X nach der Montage. Check the dimension X after assembly.
b
e
X
d
X
Hinweis Note
Nach dem Einbau im Gerät bzw. Prüfstand muss die korrekte After the installation of the unit or the test rig, the correct
mechanische Nulllagen-Einstellung erfolgen, siehe „Überprü- mechnical zero stroke must be adjusted, refer to "Checking",
fungen“ auf Seite 29. page 29.
Ventildichtungen austauschen Exchanging the valve seals
Hinweis Note
Möglicherweise sind nicht alle in den Zeichnungen gezeigten It is possible that the valves displayed in these illustrations are
Ventile an Ihrer Einheit vorhanden. not all present in your unit.
Hochdruckventil /
High-pressure valve
Niederdruckventil
Low-pressure valve
Um die Ventildichtungen auszutauschen: To exchange the valve seals:

1 Schrauben Sie das Niederdruckventil heraus. 1 Unscrew the low pressure valve.
2 Kleben Sie die Gewinde der Niederdruckventile ab, um 2 Mask the screw thread to avoid damage to the o-rings.
Beschädigungen der O-Ringe zu vermeiden.
3 Setzen Sie die neuen O-Ringe ein, entfernen Sie die Abkle- 3 Insert the new o-rings, remove the masking from the screw
bungen an den Gewinden und schrauben Sie das Nieder- thread, and screw the low pressure valve back in.
druckventil wieder ein.
Ziehen Sie es mit einem Drehmoment von 70 Nm fest. Tighten it with a torque of 70 Nm.
4 Schrauben Sie die Hochdruckventile heraus. 4 Unscrew the high-pressure valves.
Beachten Sie: Bei NG 71–90 gibt es zwei O-Ringe und Note: NG 71–90 have two o-rings and one There are two
einen Stützring, bei NG 125 und 180 nur einen O-Ring. types of this valve: with or without bypass function.
Sicherungskappe / Tamper prof cap
O-Ring
O-Ring
Stützring /
Support ring
O-Ring
NG 71–90 NG 125, 180

5 Entfernen Sie die O-Ringe und den Stützring (NG 71–90) 5 Remove the o-rings and the supprot ring (NG 71–90) and
und kontrollieren Sie das Gehäuse auf Verschleiß und Verun- check the housing for wear and dirt.
reinigungen.
6 Bauen Sie das Hochdruck-Ventil ein und ziehen Sie es mit 6 Install the high-pressure valve and tighten it with a torque of
einem Drehmoment von 150 Nm (NG 71–90) bzw. 200 Nm 150 Nm (NG 71–90) or 200 Nm (NG 125, 180).
(NG 125, 180) fest.
Hinweis Hinweis
Nach dem Einbau muss eine Überprüfung des Hochdrucks Nach dem Einbau muss eine Überprüfung des Hochdrucks
erfolgen, siehe „Überprüfungen“ auf Seite 29. erfolgen, siehe „Überprüfungen“ auf Seite 29.
Dichtung der Druckabschneidung austauschen Exchanging the seals of the pressure cut-off
Um die Dichtung der Druckabschneidung auszutauschen: To exchange the seal of the pressure cut-off:
1 Notieren Sie das Einstellmaß X der Dichtmutter für die späte- 1 Write down the sealing nut's setting dimension X for the
re Montage. subsequent assembly.
2 Bauen Sie die Dichtmutter (a) und die Verschlussschraube 2 Extract the sealing nut (a) and the locking screw (b).
(b) aus.
Entfernen Sie den O-Ring (c). Remove the o-ring (c).
a
b X
3 Setzen Sie einen neuen O-RIng (c) ein. 3 Install a new o-ring (c).
4 Setzen Sie die Verschlussschraube (b) ein und ziehen Sie 4 Install the locking screw (b) and tighten it with a torque of 35
sie mit einem Drehmoment von 35 Nm fest. Nm.
5 Bauen Sie eine neue Dichtmutter (a) ein und stellen Sie das 5 Install the new sealing nut (a) and adjust to the setting
notierte Einstellmaß X ein. measure X that you wrote down previously.
Ziehen Sie die Dichtmutter mit 25 Nm fest. Tighten it with a torque of 25 Nm.
Dichtung des Regelventils austauschen Exchanging the control valve
b
a
a: Regelventil Control valve

b: O-Ring O-ring
Um die Dichtung am Regelventil auszutauschen: To exchange the control valve:

1 Schrauben Sie das Regelventil (a) aus. 1 Unscrew the control valve (a).
2 Kleben Sie das Gewinde zur Vermeidung von Beschädigun- 2 Mask the screw thread to avoid damaging the o-ring.
gen des O-Rings ab.
3 Schieben Sie den neuen O-Ring auf. 3 Slide the new o-ring on.
4 Entfernen Sie die Abklebung und schrauben Sie das Regel- 4 Remove the masking and screw the control valve back on.
ventil ein.
Ziehen Sie sie mit einem Drehmoment von 50 Nm fest. Tighten them with a torque of 50 Nm.
4.3 Hilfspumpe austauschen 4.3 Exchanging the Auxiliary Pump

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of an auxiliary pump
einer Hilfspumpe als auch für den Austausch eines O-Rings. as well as to the exchange of an o-ring.
Um die Hilfspumpe auszutauschen: To exchange the auxiliary pump:
1 Markieren Sie die Lage des Deckels (a), damit Sie ihn nach 1 Mark the position of the cover (a), so that you can replace it
dem Abdichten wieder lagerichtig aufsetzen können. in its original position after the sealing.
2 Entfernen Sie die vier Befestigungsschrauben (b). 2 Remove the four fastening screws (b).
3 Drücken Sie den Deckel wie gezeigt ab. 3 Press the cover off as illustrated.
4 Entfernen Sie die Hilfspumpe und untersuchen Sie die Teile 4 Remove the auxiliary punp and check the part for wear and
der Hilfspumpe auf Verschleiß und Verunreinigungen. dirt.
Markieren Sie vorher die Lage der Hilfspumpe, damit Sie sie Mark the position of the auxiliary pump beforehand, so that
später wieder lagerichtig einbauen können (sofern Sie die you can return it to its original position afterwards (if you
alte Hilfspumpe weiter verwenden). keep the old auxiliary pump in use).
Hinweis Note
Die Hilfspumpe kann nur komplett ausgetauscht werden. The auxiliary pump can only be exchanged as a whole.
5 Setzen Sie zwei neue O-Ringe (c) ein. 5 Install two new o-rings (c).
6 Setzen Sie die (neue) Hilfspumpe ein. 6 Install the (new) auxiliary pump.
Achten Sie darauf, dass die angefaste „Seite“ (d) zum De- Pay attention that the chamfered "side" (d) is assembled
ckel (a) montiert wird. facing the cover (a).
d a
d
Hinweis Note
Die Hilfspumpe wird mit Haltestopfen (e) geliefert. Diese wer- The auxiliary pump is delivered with fixing plugs (e). These are
den bei der Montage auf die Anschlussplatte in die entspre- pressed into the bore of the port plate during assembly.
chenden Bohrungen eingepresst.
7 Schrauben Sie den Deckel (a) fest. Beachten Sie dabei die 7 Screw the cover (a) back on. Pay attention to the marking
vorher angebrachte Markierung. made previously.
4.4 Steuergerät austauschen 4.4 Exchanging the Control Unit

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of the whole control
des ganzen Steuergeräts als auch für den Austausch eines O- unit as well as to the exchange of an o-ring.
Rings am Steuergerät.
• NG 71: Keines • NG 71: none
• NG 90–180: 2 Hilfsschrauben (Mat.-nr. R02774871) • NG 90–180: 2 auxiliary screws (Mat. no. R02774871)
Hinweis Note
Es gibt eine Vielzahl von Steuergeräten (siehe Abbildung). There exists a multitude of control units (as illustrated).
Bitte beachten Sie, dass hier exemplarisch nur der Austausch Please pay attention to the fact that only the example of an
eines HW Steuergeräts gezeigt wird. HW controller is described here.
alt / old
DA
neu / new alt / old
HD
neu / new
EP
HW alt / old
neu / new
Polrohr
Anziehmoment 19 Nm /
Pole tube
Tightening torque 19 Nm
Anziehmoment 5+1 Nm
Steckschlüssel SW 26 /
Tightening torque 5+1 Nm
26 A/F socket spanner
Austausch des Steuergeräts bei NG 71 Exchanging the Control Unit with NG 71

Um das Steuergerät bei NG 71 auszutauschen: To exchange the control unit:
1 Entfernen Sie die fünf Befestigungsschrauben (a). 1 Remove all five fastening screws (a).
2 Drücken Sie das Steuergerät (b) wie gezeigt ab. 2 Press the control unit (b) off as illustrated.
3 Entfernen Sie den O-Ring (c) und die Flachdichtung (e). 3 Remove the o-ring (c) and the gasket (e). Check the sealing
Kontrollieren Sie die Dichtflächen (d) auf Beschädigungen surfaces (d) for wear and dirt.
und Verunreinigungen.
Tauschen Sie das Steuergerät bei Bedarf aus. Exchange the control unit if required.
Hinweis Note
Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.
d
e
e
d
4 Setzen Sie einen neuen O-Ring (c) und eine neue Flachdich- 4 Insert the new o-ring (c) and the new gasket (e).
tung (e) ein.
5 Setzen Sie das (neue) Steuergerät ein. 5 Insert the new control unit.
6 Zentrieren Sie die Dichtung (e) mit zwei Befestigungsschrau- 6 Center the seal (e) with two fastening screws (a) and install
ben (a) und bauen Sie das Steuergerät ein. the control unit.
Ziehen Sie alle vier Befestigungsschrauben mit halbem Screw all four fastening screws tight with half the torque.
Drehmoment an.
a
a: Befestigungsschraube Fixing screw

b: Steuergerät Control unit
e: Dichtung Seal
7 Setzen Sie die fünfte Schraube (f) ein und ziehen Sie sie mit 7 Insert the fifth screw (f) and tighten it with a torque of
einem Drehmoment von 10,4 Nm fest. 10.4 Nm.
Ziehen Sie die anderen vier Schrauben (a) nach Drehmo- Tighten the other four screws (a) crosswise and according
ment über Kreuz fest. to torque.
Hinweis Note
Nach der Montage des Steuergeräts muss die hydraulische After installing the control unit, the hydraulic zero stroke must
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), be re-established. This does not apply to DA-control. Please
siehe „Überprüfungen“ auf Seite 33. refer to "Checking", page 33.
Austausch des Steuergeräts bei NG 90–180 Exchanging the Control Unit with NG 90–180
Hinweis Note
Die folgende Handlungsanweisung behandelt exemplarisch The following instructions show how to exchange an HD
den Austausch eines HD-Steuergeräts. control unit, exemplarily.
Um das HD-Steuergerät bei NG 90–180 auszutauschen: To exchange the HD control unit with NG 90–180:
1 Entfernen Sie die vier Befestigungsschrauben (a). 1 Remove all four fastening screws (a).
Entfernen Sie den Deckel (g) und die Flachdichtung (d). Remove the cover (g) and the gasket (d).
g
d
a
2 Entfernen Sie die zwei Zylinderschrauben (f). 2 Remove the two assembly screws (f).
f
3 Drücken Sie das Steuergerät (b) wie gezeigt ab. 3 Press the control unit (b) off as illustrated.
b
4 Entfernen Sie die O-Ringe (c). Kontrollieren Sie die Dichtflä- 4 Remove the o-rings (c). Check the sealing surfaces for wear
chen auf Beschädigungen und Verunreinigungen. and dirt.
Tauschen Sie Steuergerät bei Bedarf aus. Exchange the control unit if required.
Hinweis Note
Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.
c
d
5 Setzen Sie neue O-Ringe (c) und eine neue Flachdichtung 5 Insert the new o-rings (c) and the new gasket (d).
(d) ein.
6 Setzen Sie das (neue) Steuergerät (b) ohne Deckel auf. 6 Insert the (new) control unit (b) without cover.
Schrauben Sie das Steuergerät diagonal mit zwei Hilfs- Tighten the control unit with two auxiliary screws (e) (special
schrauben (e) (Sonderwerkzeug) an (mit 7 Nm). tools) diagonally (with a torque of 7 Nm).
Schrauben Sie es mit zwei Zylinderschrauben (f) an (mit Fix it with two assembly screws (f) (with a torque of
10,4 Nm). 10,4 Nm).
f e
7 Entfernen Sie die Hilfsschrauben (e) wieder. 7 Remove the auxiliary screws (e).
8 Kontrollieren Sie, ob die Zugfedern richtig in den Kerben des 8 Make sure that both spring catches are hooked to the pair of
Hebelpaares eingehängt sind. leavers.
9 Setzen Sie den Deckel (g) mit der Dichtung (d) auf und 9 Put on the cover (g) with the gasket (d) and fix it with the
schrauben Sie ihn mit den vier Befestigungsschrauben fest. four fastening screws.
Ziehen Sie die schrauben mit 10,4 Nm fest. Tighten the screws with a torque of 10,4 Nm.
a
g
d
Hinweis Note
Nach der Montage des Steuergeräts muss die hydraulische After installing the control unit, the hydraulic zero stroke must
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), be re-established. This does not apply to DA-control. Please
siehe „Überprüfungen“ auf Seite 33. refer to "Checking", page 33.
5 Überprüfungen 5 Checking
Bei der ersten Inbetriebnahme nach einer Reparatur müssen When starting up for the first time after a repair, you must
Sie die ursprünglichen Einstellungen der Verstellpumpe kontrol- check the original settings of the variable pump. This chapter
lieren. Dieses Kapitel erklärt folgende Überprüfungen: describes the following checkings:
• Niederdruck • Low pressure
• Hochdruck • High pressure
• Mechanische Nulllage • Mechanical zero stroke
• Hydraulische Nulllage • Hydraulic zero stroke
Hinweis Note
Führen Sie alle Überprüfungen bei Betriebstemperatur durch. Carry out checkings at operating temperature.
Hinweis Note
Wenn die überprüften Werte von den ursprünglichen Einstel- If the checked values differ from the original settings, please
lungen abweichen, setzen Sie sich bezüglich der Einstellung contact Rexroth in terms of adjusting the settings.
bitte mit dem Rexroth-Service in Verbindung.
! WARNUNG ! WARNING

Arbeiten an der Verstellpumpe bei Betriebstemperatur sind Working on the variable pump at operating temperature is
gefährlich. dangerous.
• Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ • Pay exact attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).
! WARNUNG ! WARNING

Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept.
• Achten Sie bei Überprüfungen darauf, dass Messanschlüs- • When checking settings, you should make sure that gauge
se, Schläuche und Messgeräte sauber sind. Reinigen Sie ports, hydraulic conduits, and und gauges are clean. Clean
diese gründlich bevor Sie die Messpunkte öffnen und mit these thoroughly before you open gauge ports and begin
den Einstellarbeiten beginnen. adjusting settings.
• Stellen Sie sicher, dass auch beim nachfolgenden Verschlie- • After that, when sealing the ports, make sure that contami-
ßen der Messpunkte keine Verunreinigungen eindringen. nating elements cannot enter the system.
5.1 Niederdruck (Speisedruck) überprüfen 5.1 Checking Low Pressure (Charge Pressure)
Dieser Abschnitt erklärt, wie Sie ND-Ventile überprüfen. This section describes how to check the low pressure valves.
Um den Niederdruck zu überprüfen: To check the low pressure:
1 Schließen Sie wie gezeigt ein Manometer an Anschluss G 1 Connect a manometer to connection G as displayed.
an.
bei DA-
Ausführung /
with DA
version
2 Überprüfen Sie den Niederdruck (G). 2 Check the low pressure (G):
Hinweis Note
Die genauen Einstelldaten entnehmen Sie dem Technischen Refer to the catalog sheet RE 92 003 and your specification
Datenblatt RD 92 003 und Ihrer Spezifikation. for the detailed setting data.
5.2 Hochdruck überprüfen 5.2 Checking the High Pressure

Die Begrenzung des Hochdrucks erfolgt über die Druckab- The limitation of the operating pressure is performed by a high
schneidung. Zusätzlich ist ein Hochdruckbegrenzungsventil pressure relief valve. Additionally, a high pressure relief valve
(Sicherheitsventil) überlagert. Der Druckwert der Druckab- (safety valve) is in superposition. The pressure value of the
schneidung liegt ca. 10 % unter dem Wert des Hochdruckbe- pressure cut-off is 10 % below that of the high pressure relief
grenzungsventils. valve.
Es kann also nur der Druckwert der Druckabschneidung über- Therefore, only the pressure value of the pressure cut-off can
prüft werden. be measured.
Hinweis Note
Die genauen Einstelldaten entnehmen Sie Ihrer Spezifikation. Refer to your specification for the detailed setting data.
5.3 Mechanische Nulllage überprüfen 5.3 Checking the Mechanical Zero Stroke
Dieser Abschnitt erklärt, wie Sie die mechanische Nulllage bei This section describes how to check the mechanical zero stro-
HW-, HD-, EP- und DA-Steuergeräten überprüfen. ke for HW, HD, EP, and DA controllers.
HW HD EP DA
! WARNUNG ! WARNING

Die im Folgenden beschriebenen Arbeiten an der Verstellpum- The following procedures carried out on the variable pump are
pe sind gefährlich. dangerous.
• Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ • Please pay attention to the safety advice (refer to "Safety",
• Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage • Block the machinery or unit before you carry out the installa-
bevor Sie die Einstellarbeiten durchführen. tion.
mind. / at least
Nennweite 6 / Nominal Width 6
MA
Messbereich/
Metering range
0 ... 600 bar
MB
Um die mechanische Nulllage zu überprüfen: To check the mechanical zero stroke:

1 Verbinden Sie beide Stellkammern über einen Schlauch mit 1 Connect the two position chambers with a hose (with at
mindestens Nennweite NW6. least nominal width NW6).
Dadurch stellen Sie sicher, dass ein Restsignal aus dem Thus, you ensure that a residual signal from the controller
Steuergerät keine Auswirkung auf die Einstellung der me- has no influence on the setting of the hydraulic zero stroke.
chanischen Nullage hat.
2 Schließen Sie an die Messanschlüsse MA und M B Manome- 2 Connect manometers to the measuring ports MA and M B.
ter an.
3 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 3 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked.
5.4 Hydraulische Nulllage überprüfen 5.4 Checking the Hydraulic Zero Stroke
Dieser Abschnitt erklärt, wie Sie die hydraulische Nulllage bei This section describes how to check the hydraulic zero stroke
HW-, HD- und EP-Steuergeräten überprüfen. for HW, HD, and EP controllers.
! WARNUNG ! WARNING

Die folgenden Arbeiten an der Verstellpumpe sind gefährlich. The following procedures carried out on the variable pump are
dangerous.
• Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“
auf Seite 7). • Pay attention to the safety advice (refer to "Safety",
page 7).
• Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage • Block the machinery or unload the unit before you procede
bevor Sie die Einstellarbeiten durchführen. with the installation.
HW HD EP
Messbereich/
Metering range
0 ... 60 bar
X1
X2
Um die hydraulische Nulllage zu überprüfen: To check the hydraulic zero stroke:

1 Schließen Sie an die Anschlüsse X1 und X2 Manometer an. 1 Connect manometers to the ports X1 und X2.
2 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 2 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked
Hinweis Note
Verdrehen Sie die Exzenterjustierung (a) am Steuergerät nicht Never turn the eccentric calibration (a) of the controller over
über ±90°. ±90 degrees.
Bosch Rexroth AG
Hydraulics
Produktsegment
Axialkolbenmaschinen
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72-74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
© This document, as well as the data, © Alle Rechte bei Bosch Rexroth AG,
specifications and other information auch für den Fall von Schutzrechtsan-
set forth in it, are the exclusive proper- meldungen. Jede Verfügungsbefugnis,
ty of Bosch Rexroth AG. It may not be wie Kopier- und Weitergaberecht,
reproduced or given to third parties bei uns.
without its consent.
Die angegebenen Daten dienen
The data specified above only serve to allein der Produktbeschreibung.
describe the product. No statements Eine Aussage über eine bestimmte
concerning a certain condition or Beschaffenheit oder eine Eignung für
suitability for a certain application can einen bestimmten Einsatzzweck kann
be derived from our information. The aus unseren Angaben nicht abgeleitet
information given does not release werden. Die Angaben entbinden
the user from the obligation of own den Verwender nicht von eigenen
judgment and verification. It must be Beurteilungen und Prüfungen. Es ist
remembered that our products are
zu beachten, dass unsere Produkte
subject to a natural process of wear
einem natürlichen Verschleiß- und
and aging.
Alterungsprozess unterliegen.
Subject to change. Änderungen vorbehalten.
Printed in Germany
RDE 92 003-21-R/01.06
VARIABLE DISPLACEMENT MOTOR A6VM NG 28–200
Series 63
Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service
Verstellmotor A6VM NG 28–200 RDE 91 604-11-R/03.06
Variable Displ. Motor A6VM NG 28–200

Baureihe/Series 63 R1
Reparaturanleitung / Repair Manual
Baugruppen / Assembly Groups
2/32 Bosch Rexroth AG Reparaturanleitung/Repair Manual A6VM RDE 91 604-11-R/03.06
Vermeidung von Gefahren Avoiding Dangers

Für einen sicheren Betrieb und um Schäden bei der Reparatur To ensure safe operations and avoid damages during repairs,
zu vermeiden, lesen Sie diese Reparaturanleitung sorgfältig read this complete repair manual carefully and attentively.
und aufmerksam durch!
Für Personen- oder Maschinenschäden, die durch Nichtbe- Bosch Rexroth AG accepts no responsibility for personal
achtung dieser Reparaturanleitung entstehen, verfällt jegliche injuries or damages to the machine that arise from disregarding
Gewährleistung von Bosch Rexroth AG. this repair manual.
1 Zu dieser Anleitung 1 About this Manual

Diese Anleitung unterstützt Sie bei der Reparatur, den Einstel- This manual supports you in the repair, adjustment and recom-
lungen und der Wiederinbetriebnahme von Rexroth A6VM Ver- missioning of Rexroth A6VM variable displacement motors. The
stellmotoren. Diese Anleitung umfasst die folgenden Kapitel: manual is structured as follows:
• „Sicherheit“ auf Seite 7 • “Safety” on page 7
Hier erhalten Sie grundsätzliche Hinweise zum sicheren This chapter provides you with basic hints and tips regarding
Umgang mit Verstellpumpen und zu deren Betrieb. working with and operating variable pumps.
Lesen Sie dieses Kapitel bevor Sie anfangen zu arbeiten. Read this chapter before you start working.
• „Produktbeschreibung“ auf Seite 11 • “Product Description” on page 11
Hier erfahren Sie, wie Sie den Typ einer Verstellmotor This chapter explains how you identify the variable displace-
feststellen. Ferner finden Sie hier eine Übersicht über die ment motor. Addtionally, it provides you an overview of the
Funktionsweise und Informationen zur bestimmungsgemäßen how the variable displacement motor and information regar-
Verwendung der Verstellmotor. ding the correct usage.
Lesen Sie dieses Kapitel, um Ihr Grundwissen über die Read this chapter to refresh your knowledge of the variable
Verstellmotor aufzufrischen. pumps.
• „Austausch externer Baugruppen“ auf Seite 15 • “Exchanging External Subassemblies” on page 15
Dieses Kapitel erklärt Ihnen, wie Sie Baugruppen einer Ver- Rexroth provides various replacement parts for repairs. This
stellmotor austauschen. section provides you an overview of the available spare parts
subassemblies.
• „Überprüfungen“ auf Seite 25 • “Checking” on page 25
Dieses Kapitel erklärt Ihnen, wie Sie die Einstellarbeiten an Read this chapter to be able to restore the settings on an
einer Verstellmotor vornehmen. variable displacement motor after a repair.
RDE 91 604-11-R/03.06 Reparaturanleitung/Repair Manual A6VM Bosch Rexroth AG 3/32
1.1 Inhaltsverzeichnis 1.1 Contents
1. Zu dieser Anleitung 2 1. About this Manual 2

1.1 Inhaltsverzeichnis 3 1.1 Contents 3
1.2 Gültigkeitsbereich dieser Anleitung 4 1.2 Validity of this Manual 4
1.3 Wichtige Unterlagen 5 1.3 Important Documents 5
1.4 Gefahrenkennzeichnungen und Pictogramme 6 1.4 Danger Labels and Pictograms 6
2. Sicherheit 7 2. Safety 7
2.1 Grundlegende Sicherheitshinweise 7 2.1 Basic Safety Information 7
2.2 Anforderungen an das Personal 10 2.2 Requirements on the Personnel 10
3. Produktbeschreibung 11 3. Product Description 11
3.1 Typschild 11 3.1 Type Plate 11
3.2 Funktionsbeschreibung 11 3.2 Functional Description 11
3.3 Technische Daten 14 3.3 Technical Data 14
4. Austausch externer Baugruppen 15 4. Exchanging External Subassemblies 15
4.1 Wellendichtring austauschen 16 4.1 Exchanging the Shaft Seal 16
4.2 Dichtungen austauschen 18 4.2 Exchanging Seals 18
4.3 Steuerteil austauschen 19 4.3 Exchanging the Controller 19
4.4 Deckel abdichten 22 4.4 Sealing the Cover 22
5 Überprüfung 25 5. Checking 25
5.1 Regelbeginn überprüfen Motorverstellung EP 26 5.1 Checking Beginn of Regulation Control EP 26
5.2 Regelbeginn überprüfen Motorverstellung HD 27 5.2 Checking Beginn of Regulation Control HP 27
5.3 Regelbeginn überprüfen Motorverstellung HA 28 5.3 Checking Beginn of Regulation Control HA 28
5.4 Regelbeginn überprüfen Motorverstellung 29 5.4 Checking Beginn of Regulation Control DA1/4, 29
DA1/4, DA2, 3, 4, 5, 6 DA2, 3, 4, 5, 6
1.2 Gültigkeitsbereich dieser 1.2 Validity of this Manual

Anleitung
Diese Reparaturanleitung gilt für die Axialkolben-Verstellmotor This manual is valid for the Bosch Rexroth axial piston variable
A6VM der Bosch Rexroth AG. Informationen zu zugelassenen displacement motor A6VM. Refer to the system manufacturer
Druckflüssigkeiten entnehmen Sie den Angaben des Anlagen- for information about the allowed hydraulic fluids.
herstellers.
Diese Reparaturanleitung richtet sich an: This repair manual is directed at:
• Anlagenbetreiber, • the system operator
• den autorisierten Fachbetrieb bzw. Händler, • authorized dealers
• den Anlagenhersteller. • the system manufacturer
Für den Anlagenhersteller sind zusätzlich auch die jeweilige For the system manufacturer, the installation drawing, the
Einbauzeichnung, das technische Datenblatt, die Betriebsan- catalog sheet, the manual, and the confirmation of order from
leitung und die Auftragsbestätigung der Bosch Rexroth AG the Bosch Rexroth AG are also obligatory.
verbindlich.
1.3 Wichtige Unterlagen 1.3 Important Documents

Bevor Sie mit den in dieser Anleitung beschriebenen Arbeiten Before you start any of the procedures described in this manu-
anfangen, stellen Sie sicher, dass Sie folgende Unterlagen al, make sure you have the following documents:
griffbereit haben:
• Auftragsbestätigung • Confirmation of order
Die Auftragsbestätigung enthält die voreingestellten techni- The confirmation of order contains the values set during the
schen Daten. Die Axialkolbenmaschine darf nur unter den in commissioning by Rexroth. Before you can recommission the
der Auftragsbestätigung angegebenen Werten und Bedin- axial piston unit after a repair, you have to restore the values
gungen betrieben werden. originally set by Rexroth.
• Einbauzeichnung • Installation drawing
Die Einbauzeichnung der Axialkolbenmaschine enthält die The installation drawing of the axial piston unit contains the
Außenabmessungen, sämtliche Anschlüsse und den Schalt- sizes of all connections.
plan.
• Technisches Datenblatt • Technical data sheet
Das technische Datenblatt RD 92 003 enthält u.a. die zuläs- The technical data sheet RE 92 003 contains the maximum
sigen technischen Daten für die Axialkolbenmaschine. allowed performance data.
• Gesamtschaltplan der Maschine bzw. Anlage • Hydraulic diagram / Wiring diagram
Der Hydraulikschaltplan und der elektrische Schaltplan der The hydraulic diagram and the wiring diagram of the unit
Maschine bzw. Anlage enthalten die Informationen zu den or system contain the information related to the respective
hydraulischen bzw. elektrischen Anschlüssen. Diese Daten machine.You need this data to work with the axial piston as
brauchen Sie, um mit der Axialkolbenmaschine als Teil der part of the machine or system. You can get this information
Maschine bzw. Anlage zu arbeiten. Die Unterlagen erhalten from the unit or system manufacturer.
Sie vom Maschinen- bzw. Anlagenhersteller.
• RD 90 300-B: Allgemeine Betriebsanleitung für Axialkol- • RE 90 300-B: General Manual for Axial Piston Units
benmaschinen The general manual supports you during the installation,
Die allgemeine Betriebsanleitung unterstützt Sie bei Installa- initiation, and operation of Rexroth axial piston units.
tion, Inbetriebnahme und Betrieb von Rexroth-Axialkolbenma-
schinen.
• Produktspezifische Betriebsanleitung • Product Specific Manual
Die produktspezifische Betriebsanleitung enthält spezielle, The product-specific manual contains information specially
für die Axialkolbenmaschine gültige Informationen. Informie- designed for the axial piston unit. Get in touch with Rexroth
ren Sie sich bei Rexroth, ob es zu Ihrer Axialkolbenmaschine to find out if there is any product-specific information on your
eine produktspezifische Betriebsanleitung gibt. specific axial piston unit.
Folgende Rexroth-Druckschriften geben Ihnen weitere Informa- The following Rexroth publications provide additional informati-
tionen zu Installation und Betrieb der Axialkolbenmaschine: on to the installation and operation of axial piston units:
• RD 90 220: Druckflüssigkeiten auf Mineralölbasis • RE 90 220: Mineral-oil Based Pressure Fluids
Beschreibt die Anforderungen an eine Druckflüssigkeit auf This publication describes the requirements on a hydraulic
Mineralölbasis für den Betrieb mit Rexroth-Axialkolbenma- fluid for operation in an axial piston unit and supports you in
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- the selection of a hydraulic fluid for your installation.
keit für Ihre Anlage.
• RD 90 221: Umweltfreundliche Druckflüssigkeiten HEES, • RE 90 221: Environmentally Acceptable Hydraulic Fluids
HEPG, HETG für Axialkolbenmaschinen HEES, HEPG, HETG for Axial Piston Units
Beschreibt die Anforderungen an eine umweltfreundliche Describes the demands on environmentally compatible, rea-
Druckflüssigkeit für den Betrieb mit Rexroth-Axialkolbenma- dily biodegradeable hydraulic fluids HEPG, HEES that can
schinen und unterstützt Sie bei der Wahl einer Druckflüssig- be used in Rexroth axial piston units and supports you by the
keit für Ihre Anlage. choice of a hydraulic fluid for your system.
• RD 90 223: Axialkolbenmaschinen für den Betrieb mit • RE 90 223: Axial Piston Units for Use with HF Fluids
HF-Druckflüssigkeiten Provides additional information for the use of Rexroth axial
Enthält zusätzliche Informationen zum Einsatz von Rexroth- piston units with HF hydraulic fluids.
Axialkolbenmaschinen mit HF-Druckflüssigkeiten.
• RD 90 300-03-B: Hinweise zum Einsatz von hydrauli- • RE 90 300-03-B: Instructions on the Use of Hydrostatic
schen Antrieben bei tiefen Temperaturen Drives at Low Temperatures
Enthält zusätzliche Informationen zum Einsatz von Rexroth- Provides additional information for the use of Rexroth axial
Axialkolbenmaschinen bei tiefen Temperaturen. piston units for low temperatures.
1.4 Gefahrenkennzeichnungen 1.4 Danger Labels and Pictograms

und Piktogramme
Diese Anleitung unterscheidet zwischen Kategorien von Gefah- This manual differentiates between the following categories of
ren gemäß ISO Guide 37: danger according to ISO Guide 37:
! GEFAHR ! DANGER
Weist auf hohes Risiko und die Gefahr von Tod oder schwe- Indicates high risk, mortal danger and serious injuries.
ren Verletzungen hin.
! WARNUNG ! WARNING
Weist auf mittleres Risiko und die Gefahr von Verletzungen Indicates middle risk, injuries or serious material damage.
und schweren Sachschäden hin.
! VORSICHT ! CAUTION
Weist auf geringes Risiko und Sachschäden hin. Indicates low risk or material damage.
Hinweis Note
Kennzeichnet Informationen, die zum besseren Verständnis Indicates information that contributes to a better understan-
der Maschinenabläufe beitragen oder weist auf einen beson- ding of the machine processes or indicates important informa-
deren bzw. wichtigen Sachverhalt hin. tion.
Tipp Tip
Kennzeichnet Informationen, die zum effizienteren Arbeiten Indicates information that contributes to more efficient work.
beitragen.
2 Sicherheit 2 Safety
Lesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbei- Read through this chapter carefully before you start any work
ten an der Verstellmotor beginnen. on the variable displacement motor.
Die Rexroth-Verstellpumpen sind im Sinne der Maschinenricht- The Rexroth variable displacement motor are in the sense of
linie 98/37/EG Komponenten, die zum Einbau in eine Anlage the machine guideline 98/37/EG components of a larger ma-
bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung chine or system. The safety guidelines in this manual only cover
beziehen sich nur auf die Verstellmotor. Beachten Sie zusätz- the variable displacement motor. You must additionally follow
lich die Sicherheitsrichtlinien des Anlagenherstellers. the system manufacturer’s safety guidelines.
Informieren Sie sich an Hand der allgemeinen Betriebsanlei- Read the general manual for axial piston units to get more infor-
tung für Axialkolbenmaschinen über die bestimmungsgemäße mation on the designated use and the operator‘s obligation to
Verwendung und die Sorgfaltspflicht des Betreibers und exercise dilligence.
Bedieners.
2.1 Grundlegende 2.1 Basic Safety Information

Sicherheitshinweise
Befolgen Sie die folgenden Sicherheitshinweise und die des Pay exact attention to the following safety information and that
Anlagenherstellers genau, um Verletzungen und Gesundheits- of the system manufacturer to eliminate injuries and health
schäden sowie Sach- und Umweltschäden auszuschließen. damages as well as damages to material or the environment.
! GEFAHR ! DANGER
Lebensgefahr Danger to Life

Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen Working on systems that have not been shut down is life-thre-
stellt eine Gefahr für Leib und Leben dar. atening.
Die in diesem Dokument beschriebenen Arbeiten dürfen nur The work described in this document can only be carried out
an stillgelegten Maschinen bzw. Anlagen vorgenommen on a shut down system. Before you start any of the tasks:
werden. Bevor Sie mit den Arbeiten beginnen:
• Stellen Sie sicher, dass der Antriebsmotor nicht eingeschal- • Make sure that the engine / motor cannot be switched on.
tet werden kann.
• Stellen Sie sicher, dass sämtliche kraftübertragenden Kom- • Make sure that all components and connections that carry
ponenten und Anschlüsse (elektrisch, pneumatisch, hydrau- energy (electrical, pneumatic, hydraulic) have been shut
lisch) gemäß den Herstellerangaben ausgeschaltet sind und down according to the manufacturer’s instructions and
nicht eingeschaltet werden können. Falls möglich, entfernen cannot be switched on. If possible, disable the main fuse.
Sie die Hauptsicherung der Maschine bzw. Anlage.
• Stellen Sie sicher, dass die Maschine bzw. Anlage komplett • Make sure that the system is completely unloaded. Follow
hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den the instructions of the the system manufacturer.
Angaben des Maschinen- bzw. Anlagenherstellers.
! WARNUNG ! WARNING

Um Verletzungen zu vermeiden, beachten Sie bitte folgende To avoid injuries, pay attention to the following regarding
Empfehlungen betreffend Sicherheitskleidung: safety clothing.
• Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicher- • When working on the system, wear steel-toed safety shoes.
heitsschuhe mit Stahlkappen.
• Tragen Sie bei Arbeiten mit gefährlichen Stoffen (beispiels- • When working with dangerous substances (for example,
weise Druckflüssigkeiten) Schutzhandschuhe und Schutz- certain hydraulic fluids), wear protective gloves and protec-
brille. tive glasses.
! GEFAHR ! DANGER
Vergiftungs- und Verletzungsgefahr Danger of poisoing or injuries

Der Kontakt mit Drückflüssigkeiten ruft Gesundheitsschäden Contact with hydraulic fluids can cause health damage (eye
hervor (z.B. Augenverletzungen, Haut- und Gewebeschädi- injuries, skin damage, poisoning due to inhalation).
gungen, Vergiftungen beim Einatmen).
• Überprüfen Sie vor jeder Inbetriebnahme die Leitungen auf • Always check the hydraulic lines for wear and damage prior
Verschleiß bzw. Beschädigungen. to putting the unit into operation.
• Tragen Sie dabei Schutzhandschuhe und Schutzbrille. • Always wear protective gloves and safety glasses.
• Wenn dennoch Druckflüssigkeit in die Augen gelangt oder • Should pressure fluid come into contact with your eyes or
in die Haut eindringt, konsultieren Sie unmittelbar einen skin: Get medical help immediately!
Arzt.
• Beachten Sie beim Umgang mit Druckflüssigkeiten unbe- • When handling hydraulic fluids, pay exact attention to the
dingt die Sicherheitsangaben des Druckflüssigkeitsherstel- manaufacturer’s safety instructions.
lers.
! WARNUNG ! WARNING
Verbrennungsgefahr Danger of burns

Die Axialkolbenmaschine erwärmt sich während des Betriebs. The variable displacement motor heats up during operation.
Auch die Magnete an der Axialkolbenmaschine werden im lau- The unit’s solenoids get hot during operation. Fingers and
fenden Betrieb heiß. Finger und Hände können bei Berührung hands can be badly burned when touching the variable dis-
der Axialkolbenmaschine oder der Magnete schwere Brand- placement motor or solenoids.
verletzungen erleiden.
• Lassen Sie die Axialkolbenmaschine vor jedem Kontakt
abkühlen. • Let the variable displacement motor cool down prior to any
• Schützen Sie sich mit hitzebeständigen Handschuhen und contact.
Schutzkleidung.
• Protect yourself from burns by wearing safety gloves and
protective clothing.
! GEFAHR
Vergiftungs- und Verletzungsgefahr ! DANGER

Beim Suchen nach Leckstellen kann entweichende Druckflüs-
Danger of poisoning
sigkeit in die Haut eindringen und schwerste Vergiftungen und
Verletzungen hervorrufen. When looking for leaks, escaping hydraulic fluid can break
into the skin and cause serious poisoning.
• Suchen Sie nur bei abgestellter und druckloser Maschine
nach Leckstellen.
• Always use a piece of cardboard or paper to look for leaks.
! WARNUNG ! WARNING
Verletzungs- und Beschädigungsgefahr Danger of injuries or damage

Durch falsch angeschlossene Komponenten können erhebli- Incorrectly connected components can considerably impair
che Fehlfunktionen entstehen. the functionality of a hydraulic system.
• Achten Sie auf korrekte Verrohrung gemäß Schaltplan. • Make sure that the hydraulic lines are connected properly.
• Führen Sie komponentenorientierte Funktionstests durch. • Check the correct functioning of all components.
! GEFAHR ! DANGER
Feuergefahr Danger of fire

Hydraulische Druckflüssigkeit ist brennbar. Hydraulic fluid is inflammable.
• Halten Sie offenes Feuer von der Verstellmotor fern. • Keep open fires away from the variable displacement motor.
! WARNUNG ! WARNING
Gehörschäden Danger of hearing loss

Die Geräuschemission von Axialkolbenmaschinen ist u.a. von The noise emission produced by axial piston units depends
Drehzahl, Betriebsdruck und Einbauverhältnissen abhängig. on speed, operating pressure, and installation. During normal
Es ist damit zu rechnen, dass der Schalldruckpegel bei nor- application conditions, over 70 dBA can be anticipated. This
malen Einsatzbedingungen über 70 dBA steigt. Dies kann zu can lead to hearing damage.
Gehörschäden führen.
• Schützen Sie sich stets mit Gehörschutz bei Arbeiten in • Always wear hearing protection when working in the vicinity
der Nähe der Axialkolbenmaschine während des laufenden of the variable displacement motor during operation.
Betriebs.
! WARNUNG ! WARNING
Umweltschäden Risk of damage to the environment

Druckflüssigkeiten sind wassergefährdende Flüssigkeiten. Hydraulic fluid leakage leads to contamination of the ground
Das Austreten von Druckflüssigkeiten kann zu Grundwasser- and ground water.
vergiftung und Bodenverseuchung führen.
• Bringen Sie unter der Axialkolbenmaschine eine Auffang- • A basin for catching any hydraulic fluid must be placed
wanne an. under the variable displacement motor.
• Beseitigen Sie Leckstellen unverzüglich. • Leaks must be cleaned up immediately.
• Es sind stets die nationalen Gesetze und Vorschriften zu • In Europe, hydraulic systems are considered “Systems
beachten. In Deutschland sind hydraulische Maschinen bzw. using water-threatening substances” in the sense of the
Anlagen „Anlagen zum Umgang mit wassergefährdenden Water Management Law (WHG).Therefore, pay special
Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG)“. attention to §1 and §19 WHG( §19g, 19i, 19l). Additionally
Beachten Sie in diesem Zusammenhang besonders §1 und pay attention to any national regulations and norms.
§19 WHG (§19g, 19i, 19l).
• Weitere Informationen finden Sie in den Rexroth- • Further information is available in the Rexroth publications
Druckschriften „Druckflüssigkeiten auf Mineralölbasis“, „Mineral-oil based hydraulic fluids“, RE 90 220. „Environ-
RD 90 220, „Umweltschonende, biologisch schnell abbau- mentally acceptable, rapid biologically degradable hydraulic
bare Druckflüssigkeiten HEPG, HEES für Axialkolbenma- fluids HEPG, HEES for axial piston units“, RE 90 221 and
schinen“, RD 90 221 und „Axialkolbenmaschinen für den „Axial piston units for operation with HF hydraulic fluids, RE
Betrieb mit HF-Druckflüssigkeiten, RD 90 223. 90 223.
2.2 Anforderungen an das Personal 2.2 Requirements on the Personnel

Diese Reparaturanleitung richtet sich an Fachkräfte mit This repair manual is directed at qualified personnel with
Hydraulik-Fachwissen, die an einer Service-Schulung bei specialized hydraulics know-how who have taken part at a
Rexroth teilgenommen haben. service training at Rexroth.
Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung Qualified personnel is defined as persons who have sufficient
und Erfahrung ausreichende Kenntnisse hat, sowie mit den knowledge on the basis of specialized training and experience,
einschlägigen Bestimmungen so weit vertraut ist, dass er and are familiar with the relevant regulations, so that they are
able to
• die ihm übertragenene Arbeiten beurteilen kann, • judge the delegated tasks,
• mögliche Gefahren erkennen kann, • recognize possible dangers,
• die notwendigen Maßnahmen zur Beseitigung von Gefahren • take the necessary measures for the elimination of dangers,
ergreifen kann,
• Kenntnisse über die möglichen Gesundheitsgefahren von • judge the possible health risks from hydraulic fluids,
Druckflüssigkeiten hat
• und die erforderlichen Reparatur- und Montagekenntnisse • and have the required repair and installation know-how.
hat.
Hydraulik-Fachwissen bedeutet, das Personal muss Specialized hydraulics know-how means that these persons
must:
• in der Lage sein, die Hydraulikpläne zu lesen und vollständig • be able to read and completely understand hydraulic plans,
zu verstehen,
• insbesondere die Zusammenhänge bezüglich der eingebau- • especially understand the connections regarding the in-
ten Sicherheitseinrichtungen vollständig verstehen stalled safety equipment,
• und Kenntnisse über Funktion und Aufbau von hydraulischen • and are familiar with the function and structure of hydraulic
Bauteilen haben. components.
3 Produktbeschreibung 3 Product Description

Dieses Kapitel gibt Ihnen einen allgemeinen Überblick über die This chapter provides a general overview of the functionality of
Funktionalität der Rexroth A6VM Verstellmotor. the A6VM variable displacement motor.
Machen Sie sich mit den Inhalten dieses Kapitels vertraut, You should be familiar with the contents of this chapter before
bevor Sie mit Arbeiten an einer Verstellmotor beginnen. starting any work on the variable displacement motor.
3.1 Typschild 3.1 Name Plate

Die Verstellmotor ist am Typschild zu identifizieren: The variable displacement motor can be identified on its type
plate:
1 3FYSPUI
D-89275 Elchingen
2 TYP: A6VM160HA1T/63W-VAB027A 7
3 MNR: R90XXXXXXX
8
4 SN: 12345678 7202
5 FD: 05W28 Rotation:

Vg min = 123,4 cm³ 9
6
Made in Germany 10
Folgende Informationen finden Sie auf dem Typschild: The following information can be found on the type plate:
1 Hersteller 1 Manufacturer
2 Typschlüssel 2 Ordering code
3 Materialnummer der Axialkolbenmaschine 3 Material number of the axial piston unit
4 Seriennummer 4 Serial number
5 Fertigungsdatum 5 Date of manufacturing
6 Drehzahl 6 Speed
7 interne Werksbezeichnung 7 Internal manufacturing code
8 Drehrichtung (bei Blick auf die Welle; hier: wechselnd) 8 Direction of rotation (when facing the shaft; here: alterna-
ting)
9 vorgesehener Platz für Prüfstempel 9 Designated space for certification stamp
10 Leistung 10 Power
Stellen Sie sicher, dass Typ und Nenngröße der zu reparieren- Ensure that the variable displacement motor to be repaired is
den Verstellmotor mit dieser Anleitung übereinstimmen. of the type and size covered by this manual.
3.2 Funktionsbeschreibung 3.2 Functional Description

Damit Sie in der Lage sind, Probleme an der Verstellmotor To make sure that you are able to identify problems with a
zu identifizieren und gezielt Reparaturen durchzuführen, sind variable displacement motor and to carry out specific repairs,
Kenntnisse der Funktionsweise und des Aufbaus erforderlich. familiarity with how the unit functions and its assembly are
Dieser Abschnitt gibt Ihnen eine grobe Übersicht. required. This section provides you with a rough overview.
Die A6VM Verstellmotor ist eine Axialkolben-Verstellmotor in The variable displacement axial piston pump type A6VM in
Schrägscheibenbauart für hydrostatische Antriebe im ge- swashplate design is designed for closed circuit hydrostatic
schlossenen Kreislauf. Der Volumenstrom ist proportional zu drives. The flow is proportional to the input drive speed and
der Antriebsdrehzahl und dem Verdrängungsvolumen. Durch displacement. By adjusting the swashplate, it is possible to
die Verstellung der Schrägscheibe ist eine stufenlose Volumen- infinitely vary the flow.
stromänderung möglich.
Schnittzeichnung Sectional Drawing

Die folgenden Schnittzeichnungen zeigen das Zusammenspiel The following drawings show the interrelation of the compon-
der Komponenten des A6VM Verstellmotors. ents of the A6VM variable displacement motor.
Seitenansicht / Side View
Steuerteil (siehe unten) /
Qmin -Anschlag/
Controller (see below)
Qmin Stop Position
Abtriebswelle /
Drive Shaft
Anschlussplatte /
Wellendichtring / Port Plate
Shaft Seal
Triebwerk /
Rotary Unit
Deckel, Spülschieber /
Cover, Flushing Valve
Ansicht Anschlussplatte mit Verstellungen/ View Port Plate with Controllers
DA 3 DA 1
Steuerteil / Steuerteil /
Controller Controller
Deckel / Deckel /
Cover Anschlussplatte / Cover HD
EP
Port Plate
Deckel / Spülschieber /
Cover Flushing Valve
Seitenansicht / Side View
Qmin -Anschlag/
Deckel, Spülschieber /
Qmin Stop Position
Cover, Flushing Valve
Abtriebswelle /
Drive Shaft
Anschlussplatte /
Wellendichtring / Port Plate
Shaft Seal
Triebwerk /
Rotary Unit
Steuerteil /
Controller
Ansicht Anschlussplatte mit Verstellungen/ View Port Plate with Controllers
HA 1 R HA 1 T
Spülschieber / Deckel /
Flushing Valve Cover
Steuerteil /
Controller Steuerteil /
Controller
Anschlussplatte /
Port Plate
EP HA 2 U
Deckel / Deckel /
Cover Cover
3.3 Technische Daten 3.3 Technical Data

Die technischen Daten der Verstellmotor finden Sie in der Auf- You can find the technical data for the variable displacement
tragbestätigung. Ergänzend dazu ist das jeweilige technische motor in the Confirmation of Order. This is supplemented by
Datenblatt. Für den A6VM Verstellmotor gilt das technische the unit‘s data sheet. For the A6VM variable displacement
Datenblatt RD 92 003. motor, the valid data sheet is RE 92 003.
4 Austausch externer 4 Exchanging External

Baugruppen Assembly Groups
Dieses Kapitel beschreibt den Austausch von extern zugängli- This chapter describes the replacement of the externally ac-
chen Baugruppen des Verstellmotors A6VM. cessible assembly groups of the variable displacement motor
A6VM.
Der Austausch folgender Baugruppen wird beschrieben: The exchange of the following assembly groups is described:
• Wellendichtring • Shaft seal
• Dichtungen • Seals
• Steuerteil • Controller
• Deckel, Spülschieber • Cover, Flushing Valve
Hinweis Note
Alle in nachfolgenden Zeichnungen dargestellten Steuergerä- All the following illustrations pictured controllers are only
te sind nur stellvertretend und müssen nicht der Konfiguration examples and do not have to completely correspond with the
Ihrer Axialkolbenmaschine entsprechen. configrations of your axial piston unit.
! WARNUNG ! WARNING

Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept. Dirt in the hydraulic fluid can
Verschmutzung der Druckflüssigkeit führt zu Verschleiß und lead to malfunctions. Especially hard foreign matter in the
Funktionsstörungen. Insbesondere harte Fremdkörper in den hydraulic conduits, for example, welding beads and cuttings,
Hydraulikleitungen, wie z. B. Schweißperlen und Metallspäne, can damage the axial piston unit.
können die Axialkolbenmaschine beschädigen.
Beachten Sie daher unbedingt folgende Hinweise: Therefore you should observe the following instructions:
• Achten Sie auf äußerste Sauberkeit. Die Axialkolbenmaschi- • Make sure everything is kept extremely clean. The axial pis-
ne muss schmutzfrei eingebaut werden. Verunreinigungen ton unit must be installed in a dirt-free environment. Conta-
in der Druckflüssigkeit können die Funktion und Lebensdau- mination of the hydraulic fluid can lead to considerable wear
er der Axialkolbenmaschine erheblich beeinträchtigen. and malfunctions of the axial piston unit.
• Achten Sie besonders bei der Installation darauf, dass • Espacially during the installation, you should make sure that
Anschlüsse, Hydraulikleitungen und Anbauteile ( z. B. Mess- ports, hydraulic conduits, and mounting components (for
geräte) sauber sind. Reinigen Sie diese gründlich, bevor example, gauges) are clean. Clean these thoroughly before
Sie Anschlüsse öffnen. Stellen Sie sicher, dass auch beim you open connections. After that, when sealing the ports,
nachfolgenden Verschließen der Anschlüsse keine Verunrei- make sure that contaminating elements cannot enter the
nigungen eindringen. system.
• Verwenden Sie für die Beseitigung von Schmiermitteln und • When removing grease and other dirt you should use ap-
anderen starken Verschmutzungen geeignete flüssige Reini- propriate liquid cleaning agents. Cleaning agents must not
gungsmittel. Es darf kein Reinigungsmittel in das Hydraulik- enter the hydraulic system.
system eindringen.
• Verwenden Sie zur Reinigung keine Putzwolle oder fasern- • Do not use cotton waste or rags which lose threads.
de Putzlappen.
• Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder • Never use hemp or putty as a sealant.
Kitt.
4.1 Wellendichtring austauschen 4.1 Exchanging the Shaft Seal

Dieser Abschnitt erklärt, wie Sie den Wellendichtring austau- This section explains how you can replace the shaft seal.
schen.
• Montagehülse • Mounting sleeve
Die Materialnummern sind je nach Motormodell verschieden: The material number depends on the motor model:
– A6VM28: Mat. nr. R909877507 – A6VM28: Mat. no. R909877507
d
b
a c
a: Sicherungsring Circlip
b: Wellendichtring Shaft Seal
c: Scheibe Shim
d: Triebwelle Drive Shaft
Um den Wellendichtring auszutauschen: To exchange the shaft seal:

1 Kleben Sie die Triebwelle (d) ab, um Beschädigungen am 1 Mask the drive shaft (d) for protection against damage of the
Wellendichtring (b) zu vermeiden. shaft seal (b).
2 Entfernen Sie den Sicherungsring (a) und die Scheibe (c). 2 Remove the safety ring (a) and the shim (c).
a
3 Drehen Sie Blechschrauben in die mit Gummi gefüllten 3 Screw the tapping screw into the rubber lined holes of the
Löcher des Wellendichtrings (b) und ziehen Sie den Wellen- shaft seal (b), and use pliers to pull the shaft seal out.
dichtring mit einer Zange heraus.
4 Fetten Sie den neuen Wellendichtring zwischen Dicht- und 4 Grease the new shaft seal between the seal and dust lip to
Staublippe leicht ein, um Trockenlauf zu vermeiden. avoid a dry run.
5 Pressen Sie den Wellendichtring (b) mit Hilfe der Montage- 5 Using the mounting sleeve (e) (special tool), press in the
hülse (e) (Sonderwerkzeug) auf Anschlag ein. shaft seal (b) until it is in stop position.
Anschlag / e
Stop position b
6 Legen Sie die Scheibe (c) ein. 6 Place the shim (c).
7 Führen Sie den Sicherungsring (a) so ein, dass er in die 7 Place the safety ring (a) that it locks into place in the respec-
dafür vorgesehene Nut einrastet. tive slot.
8 Entfernen Sie die Abklebung an der Triebwelle (d). 8 Remove the mask on the drive shaft (d).
c
d
Ergebnis/Result
c
4.2 Dichtungen austauschen 4.2 Exchanging Seals

Dichtmutter austauschen Exchanging the seal nut

Um die Dichtmutter auszutauschen: To exchange the seal nut:
1 Messen und notieren Sie das Maß X der Dichtmutter (a) für 1 Measure and write down the dimension X of the seal nut (a).
die spätere Montage. You need this for the subsequent assembly.
Entfernen Sie die Dichtmutter. Remove the seal nut.
a
X
2 Schrauben Sie die Dichtmutter (a) ein. Blockieren Sie die 2 Screw in the seal nut (a) manually. Block the adjusting
Stellschraube (b) während Sie die Dichtmutter festziehen. screw (b) while you tighten the seal nut.
Kontrollieren Sie das Maß X nach der Montage. Check the dimension X after assembly.
a
4.3 Steuerteil austauschen 4.3 Exchanging the Controller

Einstellschraube entspannen Release the set screw

Um die Einstellschraube zu entspannen: To release the tension of the set screw:
1 Messen und notieren Sie das Maß X der Einstellschraube (a) 1 Measure and write down the dimension X of the adjustment
für die spätere Montage. screw (a). You need this for the subsequent assembly.
2 Drehen Sie die Einstellschraube heraus bis die Einstellhülse 2 Unscrew the adjustment screw until the adjustment sleeve
(b) am Gehäuse des Steuerteils (c) anliegt. touches the housing of the contoller (c).
a b
c
x
a b
c
Steuerteil entfernen Removing the Controller

Um das Steuerteil zu entfernen: To remove the controller:
1 Lösen Sie die Befestigungsschrauben des Steuerteils (c) 1 Remove the fastening screw of the controller (c). Pay attenti-
und entfernen Sie dieses. Beachten Sie, dass die Federn (d) on that the springs (d) und (e) are under initial tension!
und (e) unter Vorspannung stehen!
Nur bei HD und EP /

HD and EP only
2 Kontrollieren Sie den Zylinderstift (f). Er sitzt nun lose im 2 Inspect the cylinder pin. It is not fixed in the housing of the
Gehäuse des Steuerteils. Die Einstellschraube wird nicht controller. Do not remove the adjustment screw.
entfernt.
f
3 Kontrollieren Sie O-RIng, O-Ring-Nut und das Gehäuse. 3 Inspect the O-ring, O-ring groove, housing.
4 Tauschen Sie die Dichtungen aus. 4 Exchange the seals.
Steuerteil austauschen Exchange the Controller

Um das neue Steuerteil zu montieren: To exchange the controller:
1 Schrauben Sie das neue Steuerteil fest. Achten Sie dabei 1 Screw in the new controller. Pay attention to the cylinder pin,
auf den Zylinderstift, der lose in der Führung der Einstell- which is not fixed in the track of the set screw.
schraube sitzt.
a e b e d
e
f f
c c
e
a: Hochdruck - kleine Stellkolbenseite High pressure - small control piston side
b: Stelldruck Control pressure
c: Hochdruck - A/B High pressure - A/B
d: Stützring Back up ring
e: O-Ring O-ring
f: Rückschlagventil Check valve
2 Drehen Sie die Einstellschraube bis zum Maß X ein. 2 Screw in the adjustment screw until dimension X is reached.
3 Kontrollieren Sie Maß X nach der Montage. 3 Check dimension X after assembly.
Hinweis Note
Nach der Montage des Steuerteils muss der Regelbeginn After installing the control unit, the begin of regulation must be
überprüft werden, siehe „Überprüfungen“ auf Seite 25. checked. Please refer to „Checking“, page 25.
4.4 Deckel abdichten 4.4 Sealing the Cover

Um den Deckel abzudichten: To seal the cover:
1 Schrauben Sie den Deckel ab. 1 Unscrew the cover.
Beispiel: Motor mit HD-Verstellung Example: Motor with HD-displacement
HA c
DA
HZ
a
EZ d
HD
EP
b
HA
DA
HZ d
EZ
HD
EP
a: Deckel Cover
b: Spülventil Flushing valve
c: O-Ring O-ring
d: Einbauvariante Installation type
Drosselstift nach Werksauftrag Throttle pin as to production order
O-Ringe austauschen Exchanging the o-rings
2 Prüfen und ersetzen Sie die O-Ringe (c). 2 Inspect and replace the o-rings (c).
O-Ringe O-Rings
e h
c
f c
c g
c: O-Ring O-ring
e: Stellölzulauf Input flow of oil control
f: Hochdruck bzw. Niederdruck High pressure/Low pressure
g: Lecköl Leckage oil
h: Stellkolben Control piston
Deckel Cover
c
e
a
i
a: Deckel Cover
c: O-Ring O-ring
e: Stellölzulauf Input flow of oil control
i: Drosselstift Throttle pin
Beachten Sie, dass die Einbaulage des Drosselstifts (i) je nach Pay attention that the throttle pin (i) can be in different post
Steuerteil verschieden sein kann assembly positions.
5 Überprüfungen 5 Checking
Bei der ersten Inbetriebnahme nach einer Reparatur müssen When starting up for the first time after a repair, you must
Sie die ursprünglichen Einstellungen der Verstellmotor kontrol- check the original settings of the variable displacement motor.
lieren. Dieses Kapitel erklärt folgende Überprüfungen: This chapter describes the following checkings:
• Regelbeginn Motorverstellung EP • Begin of regulation variable displacement motor control EP
• Regelbeginn Motorverstellung HD • Begin of regulation variable displacement motor control HD
• Regelbeginn Motorverstellung HA • Begin of regulation variable displacement motor control HA
• Regelbeginn Motorverstellung DA1/4, DA2, 3, 4, 5, 6 • Begin of regulation variable displacement motor control
DA1/4, DA2,3,4,5,6
Hinweis Note
Führen Sie alle Überprüfungen bei Betriebstemperatur durch. Carry out checkings at operating temperature.
Hinweis Note
Wenn die überprüften Werte von den ursprünglichen Einstel- If the checked values differ from the original settings, please
lungen abweichen, setzen Sie sich bezüglich der Einstellung contact Rexroth in terms of adjusting the settings.
bitte mit dem Rexroth-Service in Verbindung.
! WARNUNG ! WARNING

Arbeiten an der Verstellmotor bei Betriebstemperatur sind Working on the variable displacement motor at operating
gefährlich. temperature is dangerous.
• Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ • Pay exact attention to the safety advice (refer to "Safety",
! WARNUNG ! WARNING

Hydraulikanlage stehen in unmittelbarem Zusammenhang. on how clean the unit is kept.
• Achten Sie bei Überprüfungen darauf, dass Messanschlüs- • When checking settings, you should make sure that gauge
se, Schläuche und Messgeräte sauber sind. Reinigen Sie ports, hydraulic conduits, and und gauges are clean. Clean
diese gründlich bevor Sie die Messpunkte öffnen und mit these thoroughly before you open gauge ports and begin
den Einstellarbeiten beginnen. adjusting settings.
• Stellen Sie sicher, dass auch beim nachfolgenden Verschlie- • After that, when sealing the ports, make sure that contami-
ßen der Messpunkte keine Verunreinigungen eindringen. nating elements cannot enter the system.
5.1 Regelbeginn überprüfen Motorverstellung 5.1 Checking Begin of Regulation Control EP

EP
This section describes how to check the beginn of regulation
Dieser Abschnitt erklärt, wie Sie den Regelbeginn der Verstel- the control EP.
lung EP überprüfen können.
Setting test
Einstellüberprüfung
(Begin of regulation of Vg max - Vg min )
(Regelbeginn von Vg max - Vg min )
P
a
b G
~P/2
M1:2
M1
c
a: Einstellschraube- Regelbeginn Set screw - Begin of control
b: Vg min Vg min
G: Betriebsdruck Operating pressure
M1: Stelldruck Control pressure
c: Drossel Throttle
Observe safety regulations!
Sicherheitsbestimmungen beachten! Setting data as to production order
Einstelldaten nach Werksauftrag! Blocked condition (travel mode and manual brake).
Blockzustand (Straßengang und festgebremst).
A6VM - EP Vg max - Vg min
A6VM - EP Vg max - Vg min
• Pressure gauge „G“ = 600 bar
• Manometer „G“ = 600 bar • Pressure gauge „M1“ = 600 bar
• Manometer „M1“ = 600 bar • Solenoid = multi measuring device
• Magnet = Multimessgerät
Begin of regulation
Regelbeginn
Example: 200/400 mA
Beispiel: 200/400 mA
1 Observe pressure gauge at M1!
1 Manometer an M1 beachten! 2 Increase current till at M1 half the pressure is generated from
2 Strom erhöhen bis an M1 die Hälfte des Druckes von G G → Begin of regulation
ansteht → Regelbeginn − Setscrew turned clockwise→ Begin of regulation
− Einstellschraube im Uhrzeigersinn → Regelbeginn earlier
früher − Setscrew turned anti-clockwise → Begin of regulation
− Einstellschraube gegen Uhrzeigersinn → Regelbeginn later
später
5.2 Regelbeginn überprüfen Motorverstellung 5.2 Checking Begin of Regulation Control

HD HD
Dieser Abschnitt erklärt, wie Sie den Regelbeginn der Verstel- This section describes how to check beginn of regulation the
lung HD überprüfen. control HD.
Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
X - 10 bar
a
b
G
X
M1:2
M1
c
b: Vg min Vg min
c: Drossel Throttle
X: Steuerdruck Pilpt pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!

Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).
A6VM - HD Vg max - Vg min A6VM - HD Vg max - Vg min

• Manometer „G“ = 600 bar • Pressure gauge „G“ = 600 bar
• Manometer „M1“ = 600 bar • Pressure gauge „M1“ = 600 bar
• Manometer „X“ = 60 bar • Pressure gauge „X“ = 60 bar
Regelbeginn Begin of regulation

Beispiel: 10 bar Steuerdruck an X Example: 10 bar pilot pressure at X
1 Manometer an M1 beachten! 1 Observe pressure gauge at M1!
2 Druckwert an X erhöhen bis an M1 die Hälfte des Druckes 2 Increase pressure value at X till at M1 half the pressure is
von G ansteht → Regelbeginn generated from G → Begin of regulation
− Einstellschraube im Uhrzeigersinn → Regelbeginn − Setscrew turned clockwise → Begin of regulation
früher earlier
− Einstellschraube gegen Uhrzeigersinn → Regelbeginn − Setscrew turned anti-clockwise → Begin of regulation
später later
5.3 Regelbeginn überprüfen Motorverstellung 5.3 Checking Begin of Regulation Control HA

HA
This section describes how to check the begin of regulation
Dieser Abschnitt erklärt, wie Sie den Regelbeginn der the control HA.
Verstellung HA überprüfen können.
Setting test
Einstellüberprüfung
(Begin of regulation of Vg max - Vg min )
(Regelbeginn von Vg max - Vg min )
b c
M1:2
M1
X G
a

b: Vg min Vg min
c: Drossel Throttle
X: Anschluß für Übersteuerung Connection for overriding
Observe safety regulations!

Sicherheitsbestimmungen beachten! Setting data as to production order
Einstelldaten nach Werksauftrag! Blocked condition (travel mode and manual brake)
Blockzustand (Straßengang und festgebremst). Connect pressure gauge 600 bar at G and M1
Manometer 600 bar an G und M1 anschließen. Example 1: Begin of regulation 200 bar
Beispiel 1: Regelbeginn 200 bar
Increase service pressure slowly till pressure
Betriebsdruck langsam erhöhen bis Manometer an gauge at G = 200 bar
G 200 bar Positioning pressure gauge M1
Stelldruck Manometer M1 1/2 of the sevice pressure = approx. 100 bar
1/2 des Betriebsdruckes = ca. 100 bar → Begin of control
→ Regelbeginn Readjust positioning pressure at set screw - start of control
Nachjustierung des Stelldruckes an Einstellschraube - Regel-
beginn
Note
Hinweis
Clockwise turning - begin of regulation earlier
Drehen im Uhrzeigersinn - Regelbeginn früher. Anti-clockwise turning - begin of regulation later
Drehen gegen Uhrzeigersinn - Regelbeginn später.
5.4 Regelbeginn überprüfen 5.4 Checking Begin of Regulation

Motorverstellung DA1,4 Control DA1,4
(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
G1
X3
a
b 5/8
100
M1:2
M1
c
b: Vg min Vg min
M1 : Stelldruck Control pressure
c: Drossel Throttle
Um den Regelbeginn zu überprüfen: To check the begin of regulation:

1 Starten Sie die Brennkraftmaschine. 1 Start the internal combustion engine.
2 Achten Sie darauf, dass Manometer an den Messstellen G 2 Ensure that the manometer is connected at measuring points
und M1 des Motors angeschlossen sind bzw. schließen Sie G and M1 of the motor, if not then connect it.
diese an.
3 Schalten Sie den Fahrtrichtungsschalter auf „Vorwärts“. 3 Set the travel direction switch to „Forwards“.
Schalten Sie den Antrieb dabei in den Gang, in dem der Mo- Set the drive to the gear in which the motor has independent
tor frei regeln darf, und bremsen Sie den Antrieb fest, indem control and brake it using the service brake or chocks or
Sie die Feststellbremse betätigen, Unterlegkeile benutzen come to a stop against an obstacle. Ensure that the wheels
oder gegen ein Hindernis fahren. Achten Sie dabei darauf, do not spin.
dass die Räder nicht durchdehen.
4 Erhöhen Sie den Betriebsdruck, bis Sie am Messan- 4 Increase the operating pressure until the pressure for the
schluss G den Druck für den eingestellen Regelbeginn set start of control is detected at measuring connection G.
messen. Den Wert entnehmen Sie der Auftragsbestätigung. Obtain the value from the order confirmation.
5 Beobachten Sie den Druck am Messanschluss M1: 5 Note the pressure at measuring connection M1:
Bei einem DA-Motor baut sich Druck an M1 ab. With a DA motor, the pressure at M1 drops.
Motorverstellungen DA2, 3, 5, 6 Control DA2, 3, 5, 6

a
G
b
M1

b: Vg min Vg min
c: Drossel Throttle
Um den Regelbeginn zu überprüfen: To check the begin of regulation:

1 Starten Sie die Brennkraftmaschine. 1 Start the internal combustion engine.
2 Achten Sie darauf, dass Manometer an den Messstellen G 2 Ensure that the manometer is connected at measuring points
und M1 des Motors angeschlossen sind bzw. schließen Sie G and M1 of the motor, if not then connect it.
diese an.
3 Schalten Sie den Fahrtrichtungsschalter auf „Vorwärts“. 3 Set the travel direction switch to „Forwards“.
Schalten Sie den Antrieb dabei in den Gang, in dem der Mo- Set the drive to the gear in which the motor has independent
tor frei regeln darf, und bremsen Sie den Antrieb fest, indem control and brake it using the service brake or chocks or
Sie die Feststellbremse betätigen, Unterlegkeile benutzen come to a stop against an obstacle. Ensure that the wheels
oder gegen ein Hindernis fahren. Achten Sie dabei darauf, do not spin.
dass die Räder nicht durchdehen.
4 Erhöhen Sie den Betriebsdruck, bis Sie am Messan- 4 Increase the operating pressure until the pressure for the
schluss G den Druck für den eingestellen Regelbeginn set start of control is detected at measuring connection G.
messen. Den Wert entnehmen Sie der Auftragsbestätigung. Obtain the value from the order confirmation.
5 Beobachten Sie den Druck am Messanschluss M1: 5 Note the pressure at measuring connection M1:
Bei einem DA-Motor baut sich Druck an M1 ab. With a DA motor, the pressure at M1 drops.
© Alle Rechte bei Bosch Rexroth AG, auch für den Fall von Schutzrechtsanmeldungen.
Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Die angegebenen Daten dienen allein der Produktbeschreibung. Eine Aussage über eine
bestimmte Beschaffenheit oder eine Eignung für einen bestimmten Einsatzzweck kann
aus unseren Angaben nicht abgeleitet werden. Die Angaben entbinden den Verwender
nicht von eigenen Beurteilungen und Prüfungen. Es ist zu beachten, dass unsere Produk-
te einem natürlichen Verschleiß- und Alterungsprozess unterliegen.
Änderungen vorbehalten.
Bosch Rexroth AG © This document, as well as the data, specifications and other information set forth in
Hydraulics it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to
Produktsegment Axialkolbenmaschinen third parties without its consent.
Werk Elchingen
The data specified above only serve to describe the product. No statements concerning
Glockeraustraße 2
a certain condition or suitability for a certain application can be derived from our informa-
89275 Elchingen, Germany
tion. The information given does not release the user from the obligation of own judgment
Telefon +49 (0) 73 08 82-0
and verification. It must be remembered that our products are subject to a natural process
Telefax +49 (0) 73 08 72-74 of wear and aging.
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm Subject to change.
PRESSURE PUMP/MOTOR
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
3-38
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.
3-39
MHT 780 T-E3 MHT-X 780 T-E3
MHT 860 LT-E3 MHT-X 860 LT-E3
MHT 950 LT-E3 MHT-X 950 LT-E3
3-40
COSTRUZIONI INDUSTRIALI
Via Cristoforo Colombo, 2
Loc. CAVAZZONA
41013 Castelfranco Emilia (MO)
( Tel.059/959811 - Fax 059/959850)
YOUR DEALER
648000000 EN (17/03/2012)
MHT 780 T-E3

MHT 860 LT-E3
MHT 950 LT-E3
MHT-X 780 T-E3
MHT-X 860 LT-E3
MHT-X 950 LT-E3
REPAIR MANUAL
3° PART
THIS OPERATOR’S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS.
UNIT 5
GEAR BOX
MAINTENANCE AND REPAIR
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
UNIT 4
AXLES
MAINTENANCE AND REPAIR INSTRUTIONS
-AINTENANCEAND2EPAIR-ANUAL

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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 ! Indicación 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
Prüfen - Einstellen z.B. Momente, Maße, 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=Página
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la dirección de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale
Kontrollieren -Prüfen
Examinar mediante inspección 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 nécessaire)
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 (flüssige 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 lı́quido) 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 verhüten
Evitar dañar 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 (für 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)
Einfüllen - Auffüllen - Nachfüllen (Öl-Schmiermittel)
Cargar - llenar (aceite lubricante)
7
Charger - remplir (huile - lubrifiant)
Drain off oil, lubricant
Scaricare olio, lubrificante
Öl, 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 presión en el circuito hidráulico
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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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
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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,)#/
'" 2EMOVALANDDISASSEMBLY )4! 2IMOZIONEESMONTAGGIO
!SSEMBLYANDINSTALLATION !SSEMBLAGGIOEDINSTALLAZIONE
(9$2!5,)3#(%.%'!4)6"2%-3% &2%./.%'!4)6/(9$2!5,)#/
$ %NTFERNENUNDABMONTIEREN %30 2EMOCIONYDESMONTAJE
:USAMMENBAUUND)NSTALLATION !SEMBLAJEYINSTALACION
&2%)..%'!4)&(9$2!5,)15%
& %NLEVERETD£MONTER
!SSEMBLAGEETINSTALLATION
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
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28
5 19
26
10
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27
1 3 14
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241
UNIT 6
HYDRAULIC
MOVEMENTS HYDRAULIC SYSTEM LAYOUT
5
LEGEND OF MOVEMENTS HYDRAULIC SYSTEM LAYOUT
A = Accumulator
CPD = Relief and balancing valve
CSD = Double relief valve
CSD = Piloted relief valve
D = Distributor
EVS = Anti-tilting solenoid valve
MCM = Manipulator
P. = Gear pump
P.A. = Optional socket
P.F. = Brake pump
R = Oil tank
VL = Lift cylinder
VI = Inclination cylinder
VC = Compensation cylinder
VSLR = Slow-fast selector valve
VT = Extension cylinder
STEERING AND BRAKES HYDRAULIC SYSTEM LAYOUT
LEGEND - STEERING AND BRAKES HYDRAULIC SYSTEM LAYOUT
C.F.S. = Parking brake cylinder

C.S. = Steering cylinder
D = Distributor
D.3. = Steering distributor
FDAR = Rear axle brake disks
FDAV = Front axle brake disks
P. = Gear pump
P.D. = Hydraulic powered steering
P.F. = Brake pump
PI = Connection to hydrostatic pump
R. = Oil tank
S. = Brake oil tank
VCLR = Slow-fast control cylinder
VSLR = Slow-fast selector valve
M.V.R.O. M.V.R.A.
FANS HYDRAULIC SYSTEM LAYOUT
B B
175bar 175bar
A A
M
16 cc 16 cc
205 bar
PVD
S S
16 cc 14 cc
8
B L B L
FR 2b
FA
250
MICRONS 10
MICRONS
R
LEGEND - FANS HYDRAULIC SYSTEM LAYOUT

M. = I.C. engine
M.V.R.A. = Water radiator fan motor
M.V.R.O. = Oil radiator fan motor
P.V.D. = Double fan pump
R. = Oil tank
9
MHT 860 LT
MHT-X 860 LT
21
MOVEMENTS HYDRAULIC SYSTEM LAY-OUT
22
LEGEND OF MOVEMENTS HYDRAULIC SYSTEM LAY-OUT
A= Accumulator
CPD= Relief and balancing valve
CSD= Double relief valve
CSD= Piloted relief valve
D= Distributor
EEM= Manipulator exclusion solenoid valve
EFS= Parking brake solenoid valve
EVS= Anti-tilting solenoid valve
F.A.= Intake filter
F.R.= Exhaust filter
MCM= Manipulator
P.= Gear pump
P.A.= Optional socket
P.F.= Brake pump
PI (G)= G connection of hydrostatic pump
R= Oil tank
VL= Lift cylinder
VI= Inclination cylinder
VC= Compensation cylinder
VSLR= Slow-fast selector valve
VT= Extension cylinder
23
STEERING AND BRAKES HYDRAULIC SYS-TEM LAYOUT
24
LEGEND - STEERING AND BRAKES HYDRAULIC SYS-TEM LAYOUT
C.F.S.= Parking brake cylinder

D= Distributor
F.A.= Intake filter
FDAR= Rear axle brake disks
FDAV= Front axle brake disks
P.= Gear pump
P.D.= Hydraulic powered steering
P.F.= Brake pump
PI= Connection to hydrostatic pump
R.= Oil tank
S.= Brake oil tank
VCLR= Slow-fast control cylinder
25
V.L.
M.V.R.O. M.V.R.A.
B B
175bar 175bar
A A
M
16 cc 16 cc Ø 1.2 Ø 1.2
205 bar
PVD
LEVELLING AND FANS HYDRAULIC SYS-TEM LAYOUT
S S
16 cc 14 cc
2 0 1
E.C.L. B L B L
26
FR 2b
FA
250
MICRONS 10
MICRONS
R
LEGEND - LEVELLING AND FANS HYDRAULIC SYS-TEM LAYOUT
E.C.L.= Levelling control solenoid valve

F.A.= Intake filter
M.= I.C. engine
M.V.R.A.=Water radiator fan motor
M.V.R.O.=Oil radiator fan motor
P.V.D.= Double fan pump
R.= Oil tank
V.L.= Levelling cylinder
27
IMPIANTO IDRAULICO FRENANTE
6BADI CIRCUIT FREINAGE MHT
MHT 860 LT-E3
860L
BRAKES CIRCUIT MHT-X 860 LT-E3
BREMSEKREIS
015 CIRCUIDO FRENADO E3
24
28
PRESSOSTATO LENTA-VELOCE
22 PONTE POSTERIORE
PRESSOSTAT LENTE-RAPIDE
29 SLOW-FAST PRESSURE SWITCH PONT ARRIERE
LANGSAMMER-EIL DRUCKWÄCHTER REAR AXLE
23 PRESÓSTATO LENTA-VELOZ
35 HINTERACHSE
30 PUENTE TRASERO
35 33
32
25 8 17 66 62
6BADI016 9 16
18 65
26
32 31 65
38 27 8
9 6 14 19
4 20
6 15
32 7
3 8 5 6
1
Z 2 7 6 12
FA BULBO LUCE STOP
BOULE STOP
STOP BULB 34
28
THERMOMETERKUGEL STOP 10
BULBO STOP 32
16 33 11
13
34 36 33
33 31
43 20
57 21
33 52
53
37 55 42
45
54
41
BCDI001 56 39
33
38 50
51
61 49 40
63 65 48
48
65 64 6BADI016 46 44
36 45
56 33 47
PONTE ANTERIORE
64 10AADI005
PONT AVANT 65
FRONT AXLE
VORNACHSE
PUENTE DELANTERO 33 37
648587
IMPIANTO IDRAULICO FRENANTE
6BADI CIRCUIT FREINAGE MHT
MHT 860 LT-E3
860L
BRAKES CIRCUIT MHT-X 860 LT-E3
BREMSEKREIS
016 CIRCUIDO FRENADO E3
4ABDI020
28
29
28 30
26
29
29
24
25
27 5 6 6
11
P 10
A 33
11
B
T 12 31
10AADI005
29 8
29
7 9
32
2
FA
4 6
3 6BADI015
1
6BADI015 13
BCDI001
15 4ABDI020
34 35
14 23
31
16 33
PONTE ANTERIORE
PONT AVANT 30
FRONT AXLE 31
VORNACHSE 29 32 17
PUENTE DELANTERO
18 19
19 22
20 19
21
648587
IMPIANTO IDRAULICO (Circuito principale)
10AADI HYDRAULIQUE (Circuit principal) MHT
MHT 860 LT-E3
860L
HYDRAULIC (Principal circuit)
HYDRAULIK (Haupkreis) MHT-X 860 LT-E3
001 HIDRAULICO (Circuito principal) E3
4
12 11
5
8
44
40
6
7
10DADI001 47
D 48
3 49
M
40
39 LS 33
2
31 42 41
T 1 P
43 40
41 41 45 21 20 37
8 46
33 36
32 22 35
BCDI022 40
30
30
49
24
26
29 25 27
28 10AADI005
18 9
12 40
14 23
* 32 34
17 10
* 15 * 38
31
* 14 16 39
* 34
SUPPORTO COMPLETO
SUPPORT COMPLET
13 COMPLETE CARRIER 19
* KOMPLETTER GEHAEUSE
SOPORTE COMPLETO 20
21 10AADI005
648587
IMPIANTO IDRAULICO (Circuito aspirazione)
HYDRAULIQUE (Circuit d'admission) MHT 860 LT-E3
10AADI HYDRAULIC (Intake circuit)
MHT 860L
MHT-X 860 LT-E3
HYDRAULIK (Ansaugkreis)
005 HIDRAULICO (Circuito aspiracion) E3
32
34
T1
33
BCDI001
52 45
53 18 31
6 19 46 44
54 8 17 57
55 58
7
30 44
53 8 20
31
5
54 16 42
43
36
28
33 35
28 41
34
51
41
1 47 20
49 5 29
2 21
4
48 25
20
37 23
11 38
14 14 24 50
39 27
13 5 56 26 10
11 41
12 22 9
40
3
20
648587
IMPIANTO IDRAULICO (Circuito ventola)
10AADI HYDRAULIQUE (Circuit ventilateur) MHT
MHT 860 LT-E3
860L
HYDRAULIC (Fan circuit)
HYDRAULIK (Lufter) MHT-X 860 LT-E3
010 HIDRAULICO (Circuito ventilador) E3
41
RADIATORE COMPLETO 40 10DDDI001
RADIATEUR COMPLET
COMPLET RADIATOR 3 42
KOMPLETTER KUHLER
RADIADOR COMPLETO 44
45
26 42
23 49
27 43
46 1
16 14 15
39 13 15
16 41 2
16
15 46
22 7
49
18 19
19
49
4 20 48
6
24 8
32
49
47
10AADI005
54
28 12
32 13
29
31 10
5
30
51 11
31
29 52 20
33 49
53 25 21
50
13 55 36
16 1
38 35 47
26 49 22
34 2
27 36 10AADI005
16
13
648587
IMPIANTO IDRAULICO (Circuito alimentazione braccio)
10AEDI HYDRAULIQUE (Circuit alimentation fleche) MHT
MHT 860 LT-E3
860L
HYDRAULIC (Jib feed circuit) MHT-X 860 LT-E3
HYDRAULIK (Ausleger zuschiebung kreis)
001 HIDRAULICO (Circuito alimentacion aguilon) E3
10DADI001
10 11
13
17 16
10 15
12
31 7 29 10
11 11
14
10 12
11 13 17
16
30 34
28 9
8
7
20
11
33
10CBDI005
18 4
5
24 19 14
11 11 4
22 28 5 4
34
3 21
11
11
11
6
22 1
5 2
20 32
24 3 11
24 33 11
21 7 31
11
15
11 3
24
23
11
23
26
10CBDI006 25
27
648587
IMPIANTO IDRAULICO (Circuito braccio telescopico)
HYDRAULIQUE (Circuit fleche) MHT 860 LT-E3
10AEDI HYDRAULIC (Jib circuit)
MHT 860L
HYDRAULIK (Ausleger kreis)
MHT-X 860 LT-E3
005 HIDRAULICO (Circuito aguilon) E3
C
15 14
8 7
23 16 3
38 B 26 4
A
15
24 16 6
9 5 5
B 6
6 27
2
1
A B 25
6 2
3 16 A 11
1 9 C
A
1
B
1 4 5
34
1 C 5 10
6 8 6
6 A
5
B A
12 A
11 14
13 24
15 15
16 10
2 22 22
35
2 21 21 36 33
15 6 38
16 6 15
30 37
7 29 32
15 28
14
10AEDI001 19
17 15 30 31
20 29
28
10AEDI001 26 26
18
34 34
648587
IMPIANTO IDRAULICO (Circuito sollevamento)
10AEDI HYDRAULIQUE (Circuit levage) MHT LT-E3
MHT860860L
HYDRAULIC (Lifting compensation circuit)
HYDRAULIK (Aufwind compensation) MHT-X 860 LT-E3
010 HIDRAULICO (Circuito levantamiento) E3
8
8
9 6 9 9
4
6
21 2 5
4
35
9
1
9
10DADI001 2 7
3
17
9
7
10
20
16 11 19
18
14
12
15
10CADI001
13
648587
IMPIANTO IDRAULICO (Circuito sterzo)
10BADI HYDRAULIQUE (Circuit direction) MHT
MHT 860 LT-E3
860L
HYDRAULIC (Steering circuit) MHT-X 860 LT-E3
HYDRAULIK (Lenkungkreis)
001 HIDRAULICO (Circuito direccion) E3
10AADI001 10AADI005 PONTE ANTERIORE

PONT AVANT
FRONT AXLE
VORNACHSE
39 37 PUENTE DELANTERO
35
D 31
22 30
DL 24
S 39 38
23
45 35
43
44
10DADI001 34
1
5
12 10
13 42 35
14 33 9
2 3 8
14 41 4
36
20 10 3
40 A B 6
19 35 P
32 T
18 16 12 29
11
8
35 10 7
17 35 46
36 12 27 28 44
34 13
14 23
21
Ls 45
30
L 10 35
35 26 L 31
T R
33 30 T
P
35 25 39
32 10BADI010 37 35
PONTE POSTERIORE R
PONT ARRIERE
10 P
REAR AXLE 26
HINTERACHSE 18
PUENTE TRASERO 39
17 15 38 36
648587
IMPIANTO IDRAULICO (Circuito di livellamento)
10CFDI HYDRAULIQUE (Circuit nivellement) MHT
MHT 860 LT-E3
860L
HYDRAULIC (Leveling circuit) MHT-X 860 LT-E3
HYDRAULIK (Neigungkreis)
001 HIDRAULICO (Circuito nivelacion) E3
10DDDI001 39
40
38 41
37
10
8 34
13 9 42
29 10 43
28 12 33 44
27 13
4 10
10 39 45
13
31 10 3 45
32 11 3 36 13 10
22
31 P 5
26 32
24 A 35
B 2
37
25 1
T
23 31
22 32 6
30
31 10AADI005
21 7
32
19 6 34
10CFDI008 33
20
30
21
18
17
15 20
14
16
35 36
648587
IMPIANTO IDRAULICO (Servocomandi)
10EADI HYDRAULIQUE (Servocommande) MHT
MHT 860 LT-E3
860L
HYDRAULIC (Hydraulic controls) MHT-X 860 LT-E3
HYDRAULIK (Hydraulik kommande)
010 HIDRAULICO (Servomando) E3
10EADI005
24
4
18
6 3
22 10EADI006
T P 1 2 3 4
13 13 13 13 13 13
4
10AADI005 4 4 4 4
24 26 27 26 27
5
25
21 4
3 10 4 23
25
38
4 27
16 1 4
Tpr
9 4
20
Pr
2
21 14
Tdd 3 15
17 12
10DADI001 7 6BADI016
18 3 29
2 11 20
22 28 4
13 28
8 4
1 4 4
19 26 23
4 4
19
27 4
26
648587
MHT 950 LT
MHT-X 950 LT
39
MOVEMENTS HYDRAULIC SYSTEM LAY-OUT
40
LEGEND OF MOVEMENTS HYDRAULIC SYSTEM LAY-OUT
A= Accumulator
CPD= Relief and balancing valve
CSD= Double relief valve
CSD= Piloted relief valve
D= Distributor
EEM= Manipulator exclusion solenoid valve
EVS= Anti-tilting solenoid valve
F.A.= Intake filter
MCM= Manipulator
P.= Gear pump
P.A.= Optional socket
P.F.= Brake pump
R= Oil tank
VL= Lift cylinder
VI= Inclination cylinder
VC= Compensation cylinder
VT= Extension cylinder
41
STEERING AND BRAKES HYDRAULIC SYS-TEM LAYOUT
42
LEGEND - STEERING AND BRAKES HYDRAULIC SYS-TEM LAYOUT
C.F.S.= Parking brake cylinder

D= Distributor
F.A.= Intake filter
FDAR= Rear axle brake disks
FDAV= Front axle brake disks
P.= Gear pump
P.D.= Hydraulic powered steering
P.F.= Brake pump
PI= Connection to hydrostatic pump
R.= Oil tank
S.= Brake oil tank
VCLR= Slow-fast control cylinder
43
V.L.
M.V.R.O. M.V.R.A.
B B
175bar 175bar
A A
M
16 cc 16 cc Ø 1.2 Ø 1.2
205 bar
PVD
LEVELLING AND FANS HYDRAULIC SYS-TEM LAYOUT
S S
16 cc 14 cc
2 0 1
E.C.L. B L B L
44
FR 2b
FA
250
MICRONS 10
MICRONS
R
LEGEND - LEVELLING AND FANS HYDRAULIC SYS-TEM LAYOUT
E.C.L.= Levelling control solenoid valve

F.A.= Intake filter
M.= I.C. engine
M.V.R.A.=Water radiator fan motor
M.V.R.O.=Oil radiator fan motor
P.V.D.= Double fan pump
R.= Oil tank
V.L.= Levelling cylinder
45
PRESSURE CONTROL
MHT 780 T-E3 / MHT 860 LT-E3 / MHT 950 LT-E3
MHT -X 780 T-E3 / MHT -X 860 LT-E3 / MHT -X 950 LT-E3

59
MHT 780 T-E3
MHT -X 780 T-E3
MHT 860 LT-E3

MHT -X 860 LT-E3
MHT 950 LT-E3
MHT -X 950 LT-E3
Four pressure test connections are used for checking the pressure of the various circuits of
the hydraulic system : (Fig. 1 / 2 / 3).
FIG. 1 FIG. 1 FIG. 2

MHT 860 LT-E3 / MHT 950 LT-E3
MHT-X 860 LT-E3 / MHT-X 950 LT-E3
FIG. 1 FIG. 1
FIG. 3
MHT 780 T-E3 / MHT-X 780 T-E3
The valves are adjusted in the following manner :
- remove the valve cap

- loosen the lock nut using a 17 mm wrench.
- adjust the required value, using a 5 mm socket head wrench on the adjustment screws
turning the adjustment screw clockwise increases the operating pressure
turning the adjustment screw anticlockwise decreases the operating pressure
FIG. 4 C B
C B
MHT 860 LT-E3
MHT-X 860 LT-E3
MHT 950 LT-E3
MHT-X 950 LT-E3
B1 B2 B3 B4
B1 B2 B3 B4
A
P
P
LS
LS
A1 A3
A1 A2 A3 A4
T
T A2 A4
A4 A3 A2 A1 T
LS
P
A
A
B4 B3 B2 B1
MHT 780 T-E3
MHT-X 780 T-E3
B C
FIG. 4 FIG. 4
The machine’s hydraulic movements are adjusted in the following manner :
- The pressure of the anti-impact valve of the compensation cylinder, at the bottom, must be
280 bar (4060 PSI).
Connect the 0-600 bar pressure gauge (0-8700 PSI) to the quick coupling located to the
right of the frame at the bottom of the compensation cylinder (Fig. 2).
Swing the fork-holder completely backwards (forks upwards), slowly lower the arm to read
the calibration pressure.
Adjust the valve on the distributor if necessary (Ref. A - Fig. 4).
The pressure of the anti-impact valve of the compensation cylinder on the rod side must
be 200 bar (2900 PSI).
Connect the 0-600 bar pressure gauge (0-8700 PSI) to the quick coupling fitted on the dis-
tributor (Fig. 1).
Swing the fork-holder completely forward (fork downwards), accelerate the internal com-
bustion engine to the maximum speed and read the calibration pressure.
If necessary, adjust the pressure through the valve (Ref. B - Fig. 4).
- The pressure of the arm extension cylinder valve must be 220 bar (3190 PSI).
Connect the 0-600 bar pressure gauge (0-8700 PSI) to the
quick coupling fitted on the distributor (Fig. 1).
Extend the arm completely to end-of-travel, accelerate the
internal combustion engine to the maximum speed and read
the calibration pressure.
If necessary, adjust the pressure through the valve (Ref. C -
Fig. 4).
D
- The steering circuit valve pressure must be 175 bar (2538
PSI).
Connect the 0-600 bar pressure gauge (0-8700 PSI) to the
quick coupling fitted on the distributor (Fig. 1).
Bring the steering cylinder to the end-of-travel by steering the
wheels completely to the left or right.
Accelerate the internal combustion engine to the maximum
D
speed.
When the steering is at the end-of-travel, read the pressure on
the pressure gauge.
To adjust the pressure, act on the steering safety valve fitted
on the steering pump (Ref. D - Fig. 5). FIG. 5
Pressure control the cooling fan hydraulic circuit
- The cooling fan circuit valve pressure must be about 70÷90 bar (1015÷1305 PSI) for
obtaining 1760 min-1.
Connect the 0-600 bar pressure gauge (0-8700 PSI) to the quick coupling fitted on the
pump to the right of the engine (Fig. 3).
Accelerate the internal combustion engine to medium-high speed and read the calibration
pressure.
In case of pressure difference control the circuit’s components.
PUMP A10VO 28-85 DFR
Series 52
RDE 92703-01-R/09.00
Reparaturanleitung - A10VO 28-85 DFR Baureihe 52

Repair instructions - A10VO 28-85 DFR Series 52
RDE 92703-01-R/09.00
Hinweis / Inhalt Reparaturanleitung A10VO

Notice / Contents Repair Instructions A10VO
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen Specifications, descriptions and illustrative material shown
entsprechen dem Informationsstand zum Zeitpunkt der herein were as accurate as known at the time this
Drucklegung dieser Unterlage. publication was approved for printing.
Änderungen können den Service am Produkt beein- For repair, please use only original spare parts.
flussen, Verpflichtungen entstehen uns daraus nicht. Optional equipment and accessories may add cost to the
Methoden und Vorrichtungen sind Empfehlungen, für basic unit, and some options are available only in
deren Resultat wir keine Haftung übernehmen können. combination with certain models or other options.
Reparaturen nur mit Original-Ersatzteilen durchführen. For the available combinations refer to the relevant data
sheet for the basic unit and the desired option.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf
Adjustment and tests have to be carried out on the test
dem Teststand vorzunehmen.
bench under operating temperatures.
Schutz von Personen und Eigentum ist durch Vor- Protection of personnel and property has to be guar-
kehrungen sicherzustellen. anteed by appropriate measures.
Sachkenntnis, die Voraussetzung für jede Servicearbeit, Expert knowledge, the precondition of any service work,
vermitteln wir in unseren Schulungskursen. can be obtained in our training courses.
INHALT Seite/ CONTENTS

Page
A10VO A10VO
Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair guidelines
Triebwelle abdichten 5-6 Sealing the drive shaft
Steuerventil abdichten / reinigen 7 Sealing / cleaning the control valve
Pumpe demontieren 8-10 Disassemble the pump
Triebwerk ausbauen 11 Remove rotary group
Stellsystem ausbauen 12 Remove control device
Welle / Lager ausbauen 13 Remove shaft / beaerings
Überprüfungshinweise 14-15 Inspection hints
Pumpe montieren 16-17 Pump assembly
Abstimmung Lagerung 18 Adjustment of taper roller bearing
Pumpe montieren 19-24 Pump assembly
Steuerventil: Hinweise für DR, DFR, DFR 1 25 Control valve: Guidelines for the DR, DFR, DFR 1
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente 26 Tools, auxiliary tools, tightening torques
2 Brueninghaus Hydromatik
RDE 92703-01-R/09.00
Schnittbild Reparaturanleitung A10VO

Sectional view Repair Instructions A10VO
Brueninghaus Hydromatik 3
RDE 92703-01-R/09.00
Allgemeine Reparaturhinweise Reparaturanleitung A10VO

General repair guidelines Repair Instructions A10VO
Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!
Attention!
Observe the following guidelines when carrying out repairs
on hydraulic units!
Alle Öffnungen der Hydraulikaggregate verschließen.
Close off all openings of the hydraulic unit.
Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK
Ersatzteile verwenden.
Replace all of the seals.

Use only original BRUENINGHAUS HYDROMATIK
spare parts.
Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.
Check all sealing and sliding surfaces for wear.

Attention: Re-work of the sliding surfaces by using, for
example abrasive paper, can damage the surface.
Hydraulikaggregate vor Inbetriebnahme mit

Hydrauliköl befüllen.
Fill the hydraulic unit with hydraulic oil

before commissioning.
RDE 92703-01-R/09.00
Triebwelle abdichten Reparaturanleitung A10VO

Sealing the drive shaft Repair Instructions A10VO
2
1
1 2
1. Sicherungsring, 2. Wellendichtring, 3. Ring

4. Lager
1. Circlip, 2. Shaft seal, 3. Ring, 4. Bearing
3 4
(Paßfeder ausbauen bei Ausführung Paßfeder)

Triebwelle abkleben.
Sicherungsring ausbauen.
Wellendichtring nach vorne entnehmen.
(Remove key, version with keyway)

Protect the drive shaft.
Remove the circlip.
Remove shaft seal to front.
RDE 92703-01-R/09.00
Triebwelle abdichten Reparaturanleitung A10VO

Sealing the drive shaft Repair Instructions A10VO
Nach der Demontage des gelaufenen Wellendicht-

rings, einfetten des neuen WDR.
Sichtkontrolle Welle, Gehäuse.
Change the shaft seal and check its sliding surface

(drive shaft) and housing, grease the sealing ring.
Visual check shaft seal and housing.
Wellendichtring vorsichtig mit Montagewerkzeug bis

Anschlagring einpressen.
Assembling of the sealing ring carefully down to the

distance ring.
Sicherungsring einsetzen.
(Paßfeder einbauen bei Paßfederwelle).
Assemble the snap ring.

(Assemble key version with keyway).
Sitzkontrolle des Sicherungsrings in der Nut.
Visual check to ensure that the circlip is correctly

located in the groove.
RDE 92703-01-R/09.00
Steuerventil abdichten / reinigen Reparaturanleitung A10VO

Sealing / cleaning the control valve Repair Instructions A10VO
Steuerventil abbauen
* Maß * festhalten!
Dichtfläche (1) kontrollieren.
O-Ringe (2) kontrollieren.
Remove the control valve

Measure dimension * and note
* down!
Check sealing surface (1).
Check O-rings (2).
2
1
RDE 92703-01-R/09.00
Pumpe demontieren Reparaturanleitung A10VO

Disassemble the pump Repair Instructions A10VO
Übersicht
Overview
RDE 92703-01-R/09.00

Demontageposition
Lage der Anschlußplatte zum Gehäuse der
Pumpe kennzeichnen.
Disassembly position
Mark the location of the connection plate
on the housing of pump.
Steuerventil abbauen.
Remove the control valve.
RDE 92703-01-R/09.00

*
*
* 4 Befestigungsschrauben * ausbauen.
Remove the 4 socket screws *.
Anschlußplatte abheben und absetzen.

Verteilerplatte kann herunterfallen - festhalten
beim Abheben der Anschlußplatte.
Remove connection plate and store down.

Control plate can drop down - keep tight
while removing connection plate.
RDE 92703-01-R/09.00
Triebwerk ausbauen Reparaturanleitung A10VO

Remove rotary group Repair Instructions A10VO
Lager der Anschlußplatte mit Abzieher

ausbauen.
Dichtfläche nicht beschädigen.
Pull bearing of the connection plate out using

a bearing puller.
Do not damage the sealing surface.
Lager und Scheibe ausbauen.

Dichtfläche nicht beschädigen.
Remove bearing and shim.

Do not damage the sealing surface.
Triebwerk in horizontaler Lage herausziehen.
Remove the rotary group in a horizontal

position.
RDE 92703-01-R/09.00
Stellsystem ausbauen Reparaturanleitung A10VO

Remove control device Repair Instructions A10VO
1
2
3
Verschlußschraube (1) mit Dichtring (2)

ausbauen.
Verstellkolben (3) (-flache Seite*- ) mit
Werkzeug fassen und herausziehen.
Remove plug (1) with seal (2).

Pull out control piston (3)
(-flat surface*-) with tool.
Ausbau Kolbenstange und

Schwenkwiege
Innenliegende Schwenkwiege (5) mit
5
Werkzeug fassen und in Pumpe um
Z-Achse leicht drehen.
Z Kolbenstange (4) entnehmen.
Schwenkwiege (5) entnehmen.
Remove piston rod and swash plate.

Turn swash plate (5) inside of the
housing slightly along Z-axis with tool.
Remove piston rod (4).
Remove swash plate (5).
Lagerschalen und Feder entnehmen.

Auf Einbaulage achten!
Remove bearing shells and bearing.

Attention for position!
RDE 92703-01-R/09.00
Welle / Lager ausbauen Reparaturanleitung A10VO

Remove shaft / bearings Repair Instructions A10VO
Triebwelle mit Lager entnehmen.
Remove drive shaft with bearing.
Sicherungsring und Wellendichtring ausbauen.
Remove circlip and shaft seal.
Kegelrollenlager-Außenring mit Ab- und

Auszieher aus Gehäuse-Preßsitz herausziehen.
Pull out outer race of tapered bearing out of

housing press seat.
Use bearing puller.
Distanzscheibe entnehmen.
Alle Verschlußschrauben demontieren.
(NG 28 nur eine Verschlußschraube
vorhanden)
Remove shim.
Remove all plugs.
(Size 28 just one plug)
RDE 92703-01-R/09.00
Überprüfungshinweise Reparaturanleitung A10VO

Inspection hints Repair Instructions A10VO
Alle Lager und Dichtungen erneuern.
Renew all bearings and seals.
Kontrolle:
5
2 3 4 1. Verzahnung ausgeschlagen, Passungsrost
1
1.1 Paßfedersitz 2. Einlaufrille vom Wellendichtring
3. Lagersitz 4. Verzahnung - Mitnahme Zylinder
5. Lagersitz
Check:
1.1 1. Wear on slines, fretting
1.1 Key set 2. Drive shaft seal wear grooves
3. bearing seat 4. Splines for cylinder drive
5. Bearing seat
Kontrolle:
Gleitfläche riefenfrei.
* Beweglichkeit Kolbenstange prüfen
*
Check:
Sliding surface free of grooves.
* Check for freedom of piston rod movement
Kontrolle:
Lagerbahnen
Check:
Bearing surfaces
Kontrolle!
Rückzugeinrichtung riefenfrei, keine Einlaufspuren
im Gleitschuhbereich.
Check!
That the retaining plate is free of grooves and
that there is no wear in the slipper pad area.
RDE 92703-01-R/09.00
Überprüfungshinweise Reparaturanleitung A10VO

Inspection hints Repair Instructions A10VO
Kontrolle!
Lauffläche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).
Check!
Check to see that there are no scratches or metal deposits
on the sliding surface (1), and that there is no axial play (2),
(pistons must only be replaced as a set).
Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).
Check!
Cylinder bores (1), splines (2).
Riefenfrei, keine Einlaufspuren
Free of grooves, no signs of wear.
Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte nicht riefig (nur satzweise
austauschen).
Check!
Cylinder sliding surface free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on the control plate. (Only replace them as a set).
Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.
Check!
Mounting surface - control plate undamaged
RDE 92703-01-R/09.00
Pumpe montieren Reparaturanleitung A10VO

Pump assembly Repair Instructions A10VO
Distanzring und Lageraußenring mit Vorrichtung

einpressen.
Verschlußschraube* anziehen.
Press-in distance ring and outer racer with tool.

Pull plug* tight.
NG / Size a1 MA [Nm]
28 3/4 - 16 UNF-2B 72
45, 60 7/8 - 14 UNF-2B 127
* 85 1 1/16 - 12 UN 147
Welle in Lager einstecken.

Wellendichtring nicht beschädigen!
Assemble shaft in correct position.

Do not cut shaft seal!
RDE 92703-01-R/09.00

Lageraußenringe des hinteren Lagers mit Vorrich-

tung in Anschlußplatte einpressen.
Press-in outer racer of rear bearing into

connection plate
Anschlußplatte gemäß der Kennzeichnung

montieren.
4 Befestigungsschrauben anziehen.
Assemble connection plate to pump acc. sign.

Pull 4 socket screws tight.
Abstimmung der Triebwerkslagerung siehe

Seite 20.
Anschließend Anschlußplatte demontieren.
Adjustment of taper roller bearing set see

attachment page 20.
Disassemble connection plate.
RDE 92703-01-R/09.00
Abstimmung Lagerung Reparaturanleitung A10VO

Adjustment of taper roller bearing Repair Instructions A10VO
Montage Abstimmung (Kegelrollenlager)

Taper roller bearing initial tension
Pos. 12
0 - 0,05
Abstimmung der Triebwerkslagerung Adjustment of taper roller bearing set

Die Vorspannung der Triebwerkslagerung muß im Cast iron housing must have initial tension of the
Gußgehäuse von 0 bis 0,05 mm durch Abschleifen der bearings: 0 ..... 0,05 mm, grind Pos. 12 if necessary.
Abstimmscheibe Pos. 12 hergestellt werden.
RDE 92703-01-R/09.00

Montagehinweis Wellendichtring siehe Seite 6.
Assembly instruction shaft seal see page 6.
Lagerschalen und Feder einlegen

Mit Fett fixieren.
Fit in bearing shells and spring.

Fix with grease.
RDE 92703-01-R/09.00

Schwenkwiege (5) und Kolbenstange (4)

Z 5 einsetzen.
4 Anschlag Feder beachten.
Richtige Lage der Feder beachten.
Assemble swash plate (5) and piston rod (4)

into pump.
Spring guide pin in correct position.
Check correct position of the spring.
1 Kolbenstange (4), Verstellkolben (3), Dichtung (2),

und Verschlußschraube (1) montieren.
2
Verschlußschraube anziehen.
3 Nenngröße 28, 45, 60 MA =190 Nm + 20 Nm
Nenngröße 85 MA = 320 Nm + 20 Nm
Mit Loctite 242 sichern.
Assemble piston rod (4), control piston (3),

seal (2), and plug (1).
Pull plug tight.
Size 28, 45, 60 MA =190 Nm + 20 Nm
Size 85 MA = 320 Nm + 20 Nm
Secure with Loctite 242.
RDE 92703-01-R/09.00

Mit Vorrichtung Druckstifte montieren.
Fit pressure pins using an assembly aid.
Feder mit Vorrichtung vorspannen.
Pre-tension the spring using a suitable device.
Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.
Assemble piston with retaining plate.

Note:
Oil piston and slipper pad.
RDE 92703-01-R/09.00

Rotationsgruppe montieren!
Montagehilfe:
Mit O-Ring Kolben festhalten.
Fit rotary group!

Assembly aid:
Hold the pistons by using an O-ring.
Lager und Abstimmscheibe auf Welle

montieren.
Assemble bearing and adjustment shim to

shaft.
RDE 92703-01-R/09.00

O-Ring in Anschlußplatte einlegen.

Mit Fett fixieren.
Verteilerplatte auf Anschlußplatte legen.
Mit Fett fixieren.
Auf richtigen Sitz zum Fixierstift achten.
Anschlußplatte montieren.
Auf richtige Lage zum Gehäuse achten.
Markierung
Schrauben entsprechend Tabelle Seite 26
anziehen.
Assemble connection plate.

Check the correct position to housing.
Sign
Pull screws tight acc. list page 26.
RDE 92703-01-R/09.00

Ventil anbauen.
Assemble control valve.
Fertigmontage
Nochmals die Gehäusemarkierungen prüfen.
Final pump assembly
Double check of the housing signs.
RDE 92703-01-R/09.00
Steuerventil: Hinweise für DR, DFR, DFR 1 Reparaturanleitung A10VO

Control valve: Guidelines for the DR, DFR, DFR 1 Repair Instructions A10VO
Alle abgebildeten Ventile dieser Seite in Blendenlage offen (s. Skizzen-Einbaulage).

All of the valves shown on this page have the orifice shown in its open condition (see sketches - installation location)
Steuerventil DR / DR control valve

Beide X-Anschlüsse verschlossen / Both X-ports are plugged
Förderstromregler blockiert / Flow controller is blocked
Einbaulage der Blende Æ 0,6

Blende / Orifice 0,6 mm Position of the orifice Æ 0,6
Steuerventil DFR / DFR control valve

Ein X-Anschluß verschlossen / One X-port is plugged Bypassdüse /
X
X Decompression-orifice
P A T
Steuerventil DFR 1 / DFR 1 control valve

Ein X-Anschluß verschlossen / One X-port is plugged
Bypassdüse X-T mit Stopfen verschlossen / Bypass orifice X-T is closed using a plug
Stopfen / Plug X
P A T
Adapter am DFR-Steuerventil für metrische Verrohrung

des Steueranschlusses X (ohne Blende).
Adapter on the DFR control valve for metric piping

of the pilot connection X (without orifice).
RDE 92703-01-R/09.00
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente Reparaturanleitung A10VO

Tools / auxiliary tools / tightening torques Repair Instructions A10VO
Verwendete Loctite-Sorten
alle Abreißstopfen Nr. 601
sonst Nr. 242
Loctite types used:

For all break-off plugs No. 601
For all other parts No. 242
Anziehdrehmomente /
Tightening torques
Festigkeitsklassen 8,8; 10,9; 12,9

Bolt tensile strength grade:
M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30
8,8 2,3 5,0 8,5 21 41 72 115 176 240 350 600 1220
MA 10,9 3,2 7,2 12 29 58 100 165 250 350 490 840 1670
12,9 4,1 8,5 14,5 35 70 121 195 300 410 590 990 2000
MA (Nm) = max. Anziehdrehmoment (geölte Schrauben m = 0,125)

MA (Nm) = max. tightening torque (lubricated screws m = 0,125)
RDE 92703-01-R/09.00
Reparaturanleitung A10VO
Repair Instructions A10VO
Brueninghaus Hydromatik GmbH, Werk Elchingen, Glockeraustraße 2, D-89275 Elchingen, Tel. (07308) 820, Fax (07308) 7274, E-Mail: service.elchingen@bru-hyd.com
Brueninghaus Hydromatik GmbH, Werk Horb, An den Kelterwiesen 14, D-72160 Horb, Tel. (07451) 920, Fax (07451) 8221, E-Mail: service.horb@bru-hyd.com
UNIT 7
ELECTRIC
4-1
4-3
ELECTRIC SYSTEMS
MHT 780 T-E3

MHT-X 780 T-E3
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
MHT 780 HT
13
13
MHT 780 HT
13
ELETTRICITA' (Cablaggio cruscotto)
ELECTRICITE (Cablage tableau de bord) MHT 780 T-E3
11AADI ELECTRICITY (Instrum. Board cable)
MHT 780
MHT-X 780 T-E3
ELEKTRIZITAT (Verkabelung instrumentbrett)
012 ELECTRICIDAD (Cableado cuadro controllo) E3
18 CABLAGGIO CRUSCOTTO
Y
PH
UR
M
HY
APN
UCR
9 CABLAGE TABLEAU DE BORD
M
11AADI073 INSTRUMENTS BOARD WIRING 1
10 HANPTEURKABELUNG INSTRUMENTBRETT
21 CABLEADO CUADRO CONTROLO
11AADI001
11AADI001
13
p 17 2 3
86.
X1 14 15
10 16
11AADI013
11 X229
X228
X206.p
11AADI073
X1 11AADI014
85.
p
X168.1 X168.2 X169.1 X169.2
10
12 X216 X215 X214 X213
7
4
5 6 4 8 7 8 5
11AADI073 19
6
20
11AADI006 11AADI006 11AADI006 11AADI006

11AADI ELECTRICITE (Cablage tableau de bord) MHT
MHT T-E3
780780
ELECTRICITY (Instrum. Board cable) MHT-X 780 T-E3
11AADI006
OPTIONAL OPTIONAL OPTIONAL OPTIONAL
2 2
6 5 5 5 5 3
4 4 4 4 1
1 4
X227 X226 X225 X569 X224 X223 X222
4
11AADI012 OPTIONAL
X239
X217 X218 X219 X220 X221
1 4 4 1 1
2 5 2
3 5 3 2 3
RESET
11AADI006
11AADI ELECTRICITE (Cablage tableau de bord) MHT
MHT T-E3
780780
ELECTRICITY (Instrum. Board cable) MHT-X 780 T-E3
11AADI006
18
6 X232.2
1
15
20 19 STOP
12
16
3 7 8 9 3 2 X232.1
19
X484.s X235 X361.s 17
11AADI012 X231
11AADI006
X233
5
X234
5 3
5 4 12
9
3
6
4 X230.1
2
10
11
RP
15
Mx
100
9 20
0 25
2651 30
29
X230.2
10
11AADI006
11AADI006
648585
ELETTRICITA' (Scatola fusibili relè)
11AADI ELECTRICITE (Boite a fusible et relais) MHT
MHT T-E3
780780
ELECTRICITY (Fuse and relay box) MHT-X 780 T-E3
ELEKTRIZITAT (Sicherungsdose und relaise)
020 ELECTRICIDAD (Caya de fusibles y relevador) E3
19 20 18
17
X4
X5 23
21 X3
X2 X1 27 31
X6 16
8 29
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
X7
D3 D4
5
5
5
30
15
10
15
10
10
10
7.5
25 12
D1
2 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20
X10
6
5
25
15
10
15
7.5
7.5
7.5
7.5
5 7.5
F21 F22 F23 F24 F25 F26 F27 F28 F29 F30
24
5
15
10
15
15
15
10
7.5
7.5
7.5
X9
X11
13
X8 K17 K18 FLASHER
10
4 3 15
9 26 7 28 22
11
648585
ELETTRICITA' (Cablaggio principale carro)
ELECTRICITE (Cablage principal chariot) MHT 780 T-E3
11AADI ELECTRICITY (Truck main wiring)
MHT 780
MHT-X 780 T-E3
ELEKTRIZITAT (Hanpteurkabelung wagen)
060 ELECTRICIDAD (Cableado principal carro) E3
8 POMPA IDROSTATICA A CILINDRATA VARIABILE ELETTROVALVOLA STERZO MASSIMA CILINDRATA SENSORE CAMBIO
4 5 6 ELECTROVALVE DIRECTION MAX CILINDREE CAPTEUR BOITE DE VITESSE
POMPE A CYLINDREE VARIABLE
VARIABLE DISPLACEMENT PUMP STEERING ELECTROVALVE MAXIMUM DISPLACEMENT GEARBOX SENSOR
11AADI070 VERSTELLPUMPE LENKUNG ELEKTROVENTIL OBERE FÖRDERMENGE SENSOR SCHALTUNG
BOMBA HIDROSTATICA ELECTROVALVULA DIRECCION MAX CILINDRADA SENSORE CAMBIO
9
10
BCDI001 10BADI001 31
7
s
9
8.
2
X1
X1
X104
10
.2
04
6
.1
16
29
18 30
30 30 30
s
4
2 1.
X1
2 X237
17
11AADI061
4 X131 X132 X103 X104
p
3
2 0.
6
X6
11
CABLAGGIO COMPLETO
CABLAGE COMPLET
COMPLET WIRING 1
HANPTEURKABELUNG
36
CABLEADO COMPLETO
X2
13
12
X1 17
4ACDI001 08
X10 2 X194 .s
14 5.1 05. 23
X1 Gn .1 18
d1. d1 25
2 Gn 22 6
28 28 24
15 21
26
20
16
MASSA
6
MASSE
BODY 18
MASSE 11AADI003
MASA
FANALE ANTERIORE SINISTRO LUCE DI INGOMBRO ANTERIORE SINISTRA
FEU AVANT GAUCHE LUMIERE ENCOMBRE AVANT GAUCHE
19 FRONT LEFT LIGHT DIMENSIONS FRONT LEFT LIGHT
27 VORN LINKE SCHEINWERFER VORN LINKE VERSPERRT LICHT
11AADI001 FAZO DELANTERO IZQUIERDO LUZ ESTORBO DELANTERO IZQUIERDO
ELECTRICITE (Cablage principal chariot) MHT 780 T-E3
MHT 780
MHT-X 780 T-E3
ELETTROVALVOLA FRENO STAZIONAMENTO PRESSOSTATO FRENO STAZIONAMENTO ELETTROVALVOLA MARCIA LENTA ELETTROVALVOLA MARCIA VELOCE
ELECTOVALVE FREIN DE STATIONNEMENT PRESSOSTAT FREIN DE STATIONNEMENT ELECTROVALVE MARCHE LENTE ELECTROVALVE MARCHE RAPIDE
PARKING BRAKE ELECTROVALVE SENSOR BRAKE ELECTROVALVE SLOW GEAR ELECTROVALVE FAST GEAR ELECTROVALVE
ELEKTROVENTIL BREMSE ABSTELLUNG DRUCKWACHTER BREMSE ABSTELLUNG LANGSAMER GANG ELEKTROVENTIL EILGANG ELEKTROVENTIL
ELECTROVALVULA FRENO DE ESTACIONAMENTO MANOMETRO FRENO DE ESTACIONAMENTO ELECTROVALVULA ENGRANE LENTA ELECTROVALVULA ENGRANE VELOZ
PONTE ANTERIORE
PONT AVANT
6BADI016 6BADI016 6 8
FRONT AXLE
VORNACHSE 15
PUENTE DELANTERO 3
2 .2
4
8 6 X12
4.1
15
X12
X112 X133 X1
34
1 X111
7
11AADI060
11AADI063
7
11AADI062
X1
07
15 X1 5
.1
23
X101 .s
X107
.2 12 3 13
10 11
14
15
6 9
4
6BADI015
MICRO FRENO 11
MICRO FREIN
MICRO BRAKE
MICRO BREMSE
3 11AADI003
MICRO FRENO
FANALE ANTERIORE DESTRO LUCE DI INGOMBRO ANTERIORE DESTRA
FEU AVANT DROITE LUMIERE ENCOMBRE AVANT DROITE
FRONT RIGHT LIGHT DIMENSIONS FRONT RIGHT LIGHT
VORN RECHT SCHEINWERFER VORN RECHT VERSPERRT LICHT
FAZO DELANTERO DERECHO LUZ ESTORBO DELANTERO DERECHO
648585
11AADI ELECTRICITE (Cablage principal chariot) MHT
MHT T-E3
780780
ELECTRICITY (Truck main wiring)
ELEKTRIZITAT (Hanpteurkabelung wagen) MHT-X 780 T-E3
10ALDI010
TER
OME
ENS
EXT 177 0
EL
0-Z0
MOD -070
AY 0177
P/N
VISH
MASSA
MASSE
BODY
MASSE
MASA
PONTE POSTERIORE
ESSIEU ARRIERE
REAR AXLE 3 4
HINTERACHSE
EJE TRASERO
2.1
Gnd
2 2 LUCE DI INGOMBRO POSTERIORE SINISTRA
d2. LUMIERE ENCOMBRE ARRIERE GAUCHE
Gn 5 DIMENSIONS REAR LEFT LIGHT
1 VERSPERRT HINTER LINK LICHT
LUZ ESTORBO TRASERO IZQUIERDO
0 6 X605 X129
X1
6 3
12 7
11 8
11AADI061 13 9
FANALE POSTERIORE SINISTRO

18 . s FEU ARRIERE GAUCHE
14 REAR LEFT LIGHT
X1 X119 HINTER LINKE SCHEINWERFER
FAZO TRASERO IZQUIERDO
3
X1
27 10
X115.s
18
X604
16
6 14
17
X120
3 3 3
17 15
19 5 6
5
11AADI001 3 11AADI001
11AADI001
11AADI001
648585
11AADI ELECTRICITE (Cablage principal chariot) MHT
MHT 780 T-E3
780
ELECTRICITY (Truck main wiring) MHT-X 780 T-E3
OPTIONAL 2 OPTIONAL
3
6
1 5 10
11AADI061 9
3
4 LUCE DI INGOMBRO POSTERIORE DESTRA
LUMIERE ENCOMBRE ARRIERE DROITE
7 DIMENSIONS REAR RIGHT LIGHT
17
6 VERSPERRT HINTER RECHT LICHT
X1
7 11 LUZ ESTORBO TRASERO DERECHO
8 6
X130
X113
12 8 6
10EADI010 X118
19 13
8
18
25
17 3 14
X1
6
7 FANALE POSTERIORE DESTRO

8 FEU ARRIERE DROITE
REAR RIGHT LIGHT
15
X116 HINTER RECHT SCHEINWERFER
X6
6 FAZO TRASERO DERECHO
7 8
16
15
X6
6 16
7 8
71
X6
6
20 22
10DADI001
7 8 18
X126
X6
6 OPTIONAL
7 8
19
6
X6
6 21 3 23
7
648585
ELETTRICITA' (Cablaggio principale cabina)
ELECTRICITE (Cablage principal cabine) MHT T-E3
11AADI ELECTRICITY (Cab main wiring)
MHT 780780
MHT-X 780 T-E3
ELEKTRIZITAT (Hanpteurkabelung kabine)
070 ELECTRICIDAD (Cableado principal cabina) E3
9
3
30 4 CABLAGGIO COMPLETO PRINCIPALE CABINA
CABLAGE COMPLET PRINCIPALE CABINE
5 CAB MAIN COMPLET WIRING 1
2 OPTIONAL HANPTEURKABELUNG VOLLSTANDING KABINE
CABLEADO COMPLETO PRINCIPAL CABINA
15
X160.p
6BBDI005 16
12 11AADI073
11CDDI001 3 7
13
9 8
2 14 X199.s
29
X135.p
X201 Gnd4.5
6
Gnd4.4
MASSA
MASSE
X620.S BODY
11AADI060 MASSE
Gnd4.3 MASA
31 32
3 X163.s Gnd4.2
2
X256.p
Gnd4.1
2 X162.p
X121.p
26 8
3 2 25
10 23 11AADI071
27 28
11AADI060 17 2
18 19 22
21 20 24
2
OPTIONAL
X128.p
16
2 A/C
11 OPTIONAL
3 9
648585
ELECTRICITE (Cablage principal cabine) MHT 780 T-E3
MHT 780
MHT-X 780 T-E3
OPTIONAL
X211
20
23
28 26
12 25 27 26
18
24
11AADI007 X166 11AADI007
2 15
1
28 26
27
X170.1 X170.2 X171.s OPTIONAL
X608
X614 16
28
26
27
11AADI070
X208
11AADI007
X367 26
8 28
27
OPTIONAL
X237
X167 10
14 X178.1 X178.2 28
26
13 27
4 11
3 OPTIONAL
9 X212
7 16
16
5 21 22 28
27
10EADI005 11AADI007 11AADI072
11AADI002
648585
MHT 780
MHT-X 780 T-E3
RISCALDAMENTO 7
CIRCUIT CHAUFFAGE
HEATING CIRCUIT
ERHITZENKREIS
11AADI007 CIRCUITO CALDEO
X607
16 8
14 15 9
13 2 11 10 3
11AADI002
X606
X164.s X165.s 8
X174 19
9 2
1
MASSA
X204.3 MASSE
BODY
MASSE
11AADI071 MASA
18
1
X177
X173.2 X173.1 X172

2
1 RISCALDAMENTO
CIRCUIT CHAUFFAGE
X176 HEATING CIRCUIT
ERHITZENKREIS
2 CIRCUITO CALDEO
2 5
1
1 17 13
6 12
4
X175
OPTIONAL
MICRO SOTTO SEDILE PRESENZA OPERATORE

MICRO SOUS LESIEGE PRESENCE OPERATEUR
MICROSWITCH UNDER THE SEAT OPERATOR PRESENCE
MICRO UNTER DEMSITZ ANWESENHEIT WIRTSCHAFTS BETEILIGTER
MICRO BAJO LA SEDE PRESENCIA OPERADOR
648585
MHT 780
MHT-X 780 T-E3
0
0
1
2
TERGICRISTALLO ANTERIORE X193

ESSUIE-GLACE AVANT
FRONT WINDSHIELD WIPER
VORN SCHEIBENWISCHER
OPTIONAL LIMPIA-PARABRISSAS DELANTERO
23
8ABDI001 9
11AADI006 11AADI006
24
10
13 8 X192
1
9
14 11 12 3
3
21
11
0
22
2
X612.s X611 X188 X191
X187.1 X187.2
25
11AADI006
21
22
11AADI070 11AADI074
20
25 X613
3 X10.s
X206.s X186.s 5 X185.s 26 X238 X200
5 +30
20
11AADI020
5 8
19
4 16
6 7 18 16 +15
15 17
20
11AADI012
OPTIONAL
+15 Key
RISCALDAMENTO PREDISPOSIZIONE RADIO
CIRCUIT CHAUFFAGE PREDISPOSITION RADIO
HEATING CIRCUIT RADIO PREDISPOSITION
11AADI006 ERHITZENKREIS VOREINSTELLUNG RADIO 11AADI006
CIRCUITO CALDEO PREDISPOSICION RADIO
648585
MHT 780
MHT-X 780 T-E3
6
2
11AADI020
X7.s
1 3 4 5 15
2 2 2 2 2
X8.s
11AADI020
X1.s X2.s X3.s X4.s X5.s
2
7
X11.s
30
X300 X301
23 2 28 31
8
23 22 22
X610.s
26
11AADI073 27
25
24
24 19 29
X197.1
14
BULBO LUCE STOP
BOULE STOP
STOP BULB
X280.s X365 X196 X197.2 THERMOMETERKUGEL STOP
BULBO STOP
19
19 14
11 13
10 12 X198.1
9
X198.2
16
20 6BADI015
17 19
18 19 14
STRUMENTI DIAGNOSTICA POMPA TERGICRISTALLO

X281.1
INSTRUMENT DIAGNOSTIQUE POMPE ESSUIE-GLACE
DIAGNOSTIC INSTRUMENT WINDSCR. WIPER PUMP OPTIONAL
DIAGNOSTIKSTRUMENT SCHEIBENW. PUMPE X281.2
INSTRUMENTO DIAGNOSTICO BOMBA LIMPIAPARABREZA
21 19 14
ELETTRICITA’ (Cavi batteria)
ELECTRICITE (Cable batterie) MHT 780 T-E3
11AADI ELECTRICITY (Battery cable)
MHT 780
MHT-X 780 T-E3
ELEKTRIZITAT (Batterie kabel)
090 ELECTRICIDAD (Cable bateria) E3
APDI151
8
+
14 6
16 +
11 APDI152
17 13
12
15
18 10 19
21 20
9
_ +
19
21 20
9 12V 1
105A
h 85
0A
4
5
7 2
3
648585
ELETTRICITA' (Cablaggio motore)
ELECTRICITE (Cablage moteur) MHT 780 T-E3
11CDDI ELECTRICITY (Engine electric system)
MHT 780
MHT-X 780 T-E3
ELEKTRIZITAT (Elektric anlage motor)
001 ELECTRICIDAD (Instalacion electrica motor) E3
ELETTROVALVOLA MARCIA AVANTI ELETTROVALVOLA RETROMARCIA

12V
11AADI070 ELECTROVALVE MARCHE AVANT ELECTROVALVE MARCHE ARRIERE 105Ah
850A
FORWARD GEAR ELECTROVALVE BACKWARD GEAR ELECTROVALVE

VORW€RTSGANG ELEKTROVENTIL RUCKW€RTSGANG ELEKTROVENTIL
ELECTROVALVULA ENGRANE DE AVANCE ELECTROVALVULA ENGRANE DE REVERSA
24
MOTORINO AVVIAMENTO
11AADI090 DEMARREUR
STARTER MOTOR
23 ANALASSERMOTOR
9 _ + X156 MOTOR DE ARRANQUE
d +3
Gn 0
8 GENERATORE
5 GENERATEUR
X136 X137
13 GENERATOR
GENERATOR
GENERADOR
X158
3
11 4
10
X160.s
X138.p
X135.s
20 15 19 21 8
4 3 22
17
16
18 MASSA
8 MASSE
Gnd3.2 BODY
12 MASSE
7 6 5 MASA
25
14
2 11CDDI002
CABLAGGIO COMPLETO MOTORE
CABLAGE COMPLET MOTEUR
ENGINE COMPLET WIRING 1
HANPTEURKABELUNG KOMPLETTE MOTOR
CABLEADO COMPLETO MOTOR
11CDDI003
11AADI070
648 8
MHT 780
MHT-X 780 T-E3
APDI143
APDI151 APDI140 22
20
15 30A 30A
24
14 23
10
17 24
16
18 33 30A
35 32 25
19
40A PORTA-FUSIBILE
X142 X146 X144 PORTE-FUSIBLE
12 11 25 FUSE-HOLDER
SICHERUNGSSOCKEL
40A PORTA-FUSIBLE
11CDDI001
50A
5 X139
.1 X147.4 26
X147
X140 21
X1
47 11
.2 .3 X1 .1
47 8 48
X1 5
48.
3 X1 11
8
11
6 1
X148.2
31
2
BOSCH
27 12V 75A 4
30 13 3
7
28
29 9
TERMOAVVIATORE SERVIZI
THERMO DEMARREUR SERVICES
THERMOSTART UNIT
34 SERVICES
TERMOANLASSEUR DIENST
TERMOARRANQUE SERVICIOS
648585
MHT 780
MHT-X 780 T-E3
14
4AADI053
12
11
6 6
1 2
X1 3
17 5 4.2 54
X1 .1
13 7
16
15
X161
X141
11CDDI001
X153 APDI143
10
5 2
4
APDI153
ELECTRIC SYSTEMS
MHT 860-950 LT-E3

MHT-X 860-950 LT-E3
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
MHT 860 LT - 950 LT - 1076 LT
13
13
MHT 860 LT - 950 LT - 1076 LT
13
ELECTRICITE (Cablage tableau de bord) MHT 860 LT-E3 MHT 950 LT-E3
11AADI ELECTRICITY (Instrum. Board cable)
MHT 860L
MHT-X 860 LT-E3 MHT-X 950 LT-E3
18 CABLAGGIO CRUSCOTTO
Y
PH
UR
M
HY
APN
UCR
9 CABLAGE TABLEAU DE BORD
M
11AADI073 INSTRUMENTS BOARD WIRING 1
10 HANPTEURKABELUNG INSTRUMENTBRETT
CABLEADO CUADRO CONTROLO
11AADI001
11AADI001
13
p 17 2 3
86.
X1 14 15
10 16
11AADI013
11 X229
X228
X206.p
11AADI073
X1 11AADI014
85.
p
X168.1 X168.2 X169.1 X169.2
10
12 X216 X215 X214 X213
7
4
5 6 4 8 7 8 5
11AADI073 19
6
20
11AADI006 11AADI006 11AADI006 11AADI006
648587
ELETTRICITA' (Cablaggio cruscotto) MHT 860 LT-E3 MHT 950 LT-E3
11AADI ELECTRICITE (Cablage tableau de bord) MHT 860L
ELECTRICITY (Instrum. Board cable) MHT-X 860 LT-E3 MHT-X 950 LT-E3
11AADI006
OPTIONAL OPTIONAL OPTIONAL OPTIONAL
2 2
6 5 5 5 5 3
4 4 4 4 1
1 4
X227 X226 X225 X569 X224 X223 X222
4
11AADI012 OPTIONAL
X239
X217 X218 X219 X220 X221
1 4 4 1 1
2 5 2
3 5 3 2 3
RESET
11AADI006
648587
11AADI ELECTRICITE (Cablage tableau de bord) MHT 860 LT-E3 MHT LT-E3
MHT950860L
ELECTRICITY (Instrum. Board cable) MHT-X 860 LT-E3 MHT-X 950 LT-E3
11AADI006
18
6 X232.2
1
15
20 19 STOP
12
16
3 7 8 9 3 2 X232.1
19
X484.s X235 X361.s 17
11AADI012 X231
11AADI006
X233
5
X234
5 3
5 4 12
9
3
6
4 X230.1
2
10
11
RP
15
Mx
100
9 20
0 25
2651 30
29
X230.2
10
11AADI006
11AADI006
648587
ELETTRICITA' (Scatola fusibili relè) MHT 860 LT-E3 MHT 950 LT-E3
11AADI ELECTRICITE (Boite a fusible et relais) MHT 860L
ELECTRICITY (Fuse and relay box) MHT-X 860 LT-E3 MHT-X 950 LT-E3
ELEKTRIZITAT (Sicherungsdose und relaise)
020 ELECTRICIDAD (Caya de fusibles y relevador) E3
19 20 18
17
X4
X5 23
21 X3
X2 X1 27 31
X6 16
8 29
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
X7
D3 D4
5
5
5
30
15
10
15
10
10
10
7.5
25 12
D1
2 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20
X10
6
5
25
15
10
15
7.5
7.5
7.5
7.5
5 7.5
F21 F22 F23 F24 F25 F26 F27 F28 F29 F30
24
5
15
10
15
15
15
10
7.5
7.5
7.5
X9
X11
13
X8 K17 K18 FLASHER
10
4 3 15
9 26 7 28 22
11
648587
ELECTRICITE (Cablage principal chariot) MHT 860 LT-E3 MHT 950 LT-E3
MHT 860L
8 POMPA IDROSTATICA A CILINDRATA VARIABILE ELETTROVALVOLA STERZO MASSIMA CILINDRATA SENSORE CAMBIO
4 5 6 ELECTROVALVE DIRECTION MAX CILINDREE CAPTEUR BOITE DE VITESSE
POMPE A CYLINDREE VARIABLE
VARIABLE DISPLACEMENT PUMP STEERING ELECTROVALVE MAXIMUM DISPLACEMENT GEARBOX SENSOR
11AADI070 VERSTELLPUMPE LENKUNG ELEKTROVENTIL OBERE FÖRDERMENGE SENSOR SCHALTUNG
BOMBA HIDROSTATICA ELECTROVALVULA DIRECCION MAX CILINDRADA SENSORE CAMBIO
9
10
BCDI001 10BADI001 31
7
s
9
8.
2
X1
X1
X102
10
.2
02
6
.1
16
4 18 30
30 30 30
s
2 1.
X1
2 X237
17
11AADI061
4 X131 X132 X103 X104
p
3
2 0.
6
X6
CABLAGGIO COMPLETO
CABLAGE COMPLET
COMPLET WIRING 1
HANPTEURKABELUNG
36
CABLEADO COMPLETO
X2
13
12
X1 17
4ACDI001 0 8.
X10 2 X194 s
14 5.1 05. 23
X1 Gn .1 18
d1. d1 25
2 Gn 22 6
28 28 24
15 21
26
20
16
MASSA
6
MASSE
BODY 18
MASSE 11AADI003
MASA
FANALE ANTERIORE SINISTRO LUCE DI INGOMBRO ANTERIORE SINISTRA
FEU AVANT GAUCHE LUMIERE ENCOMBRE AVANT GAUCHE
19 FRONT LEFT LIGHT DIMENSIONS FRONT LEFT LIGHT
27 VORN LINKE SCHEINWERFER VORN LINKE VERSPERRT LICHT
11AADI001 FAZO DELANTERO IZQUIERDO LUZ ESTORBO DELANTERO IZQUIERDO
MHT 860L
ELETTROVALVOLA FRENO STAZIONAMENTO PRESSOSTATO FRENO STAZIONAMENTO ELETTROVALVOLA MARCIA LENTA ELETTROVALVOLA MARCIA VELOCE
ELECTOVALVE FREIN DE STATIONNEMENT PRESSOSTAT FREIN DE STATIONNEMENT ELECTROVALVE MARCHE LENTE ELECTROVALVE MARCHE RAPIDE
PONTE ANTERIORE
PARKING BRAKE ELECTROVALVE SENSOR BRAKE ELECTROVALVE SLOW GEAR ELECTROVALVE FAST GEAR ELECTROVALVE
PONT AVANT
ELEKTROVENTIL BREMSE ABSTELLUNG DRUCKWACHTER BREMSE ABSTELLUNG LANGSAMER GANG ELEKTROVENTIL EILGANG ELEKTROVENTIL
FRONT AXLE
ELECTROVALVULA FRENO DE ESTACIONAMENTO MANOMETRO FRENO DE ESTACIONAMENTO ELECTROVALVULA ENGRANE LENTA ELECTROVALVULA ENGRANE VELOZ
VORNACHSE
PUENTE DELANTERO 1
6BADI016 6BADI016 6 8
15
4.2
X112 8 6 X12
4.1
15
X12
X133 X1
34
X111
7
11AADI060
X1 11AADI063
09
8
X1
10 7 11AADI062
X1 5
23
X101 .s
X1
12 3 13
10
07
15 11
.1
14
8
X107 9
.2
15 4
6
10CFDI001
11
6BADI015 3 11AADI003
MICRO FRENO FANALE ANTERIORE DESTRO LUCE DI INGOMBRO ANTERIORE DESTRA
MICRO FREIN FEU AVANT DROITE LUMIERE ENCOMBRE AVANT DROITE
MICRO BRAKE FRONT RIGHT LIGHT DIMENSIONS FRONT RIGHT LIGHT
MICRO BREMSE VORN RECHT SCHEINWERFER VORN RECHT VERSPERRT LICHT
MICRO FRENO FAZO DELANTERO DERECHO LUZ ESTORBO DELANTERO DERECHO
648587
MHT 860L
10ALDI010
TER
OME
ENS
EXT 177 0
EL
0-Z0
MOD -070
AY 0177
P/N
VISH
MASSA
MASSE
BODY
PONTE POSTERIORE MASSE
ESSIEU ARRIERE MASA
REAR AXLE
HINTERACHSE 1
EJE TRASERO 4
2.1
Gnd
2 LUCE DI INGOMBRO POSTERIORE SINISTRA
d2. LUMIERE ENCOMBRE ARRIERE GAUCHE
Gn 5 DIMENSIONS REAR LEFT LIGHT
VERSPERRT HINTER LINK LICHT
LUZ ESTORBO TRASERO IZQUIERDO
06 X605 X129
X1
6 3
12 7
11 8
11AADI061 13 9
FANALE POSTERIORE SINISTRO

18 s FEU ARRIERE GAUCHE
2. REAR LEFT LIGHT
0 X119 HINTER LINKE SCHEINWERFER
X6 FAZO TRASERO IZQUIERDO
3
X1
27 10
9
X603.s
18
X604
16
6 14
17
9 X120
3 3 3
17 15
5 6
5
11AADI001 3 11AADI001
11AADI001
11AADI001
648587
MHT 860L
OPTIONAL 2 OPTIONAL
3
6
1 5 10
11AADI061 9
3
4 LUCE DI INGOMBRO POSTERIORE DESTRA
LUMIERE ENCOMBRE ARRIERE DROITE
7 DIMENSIONS REAR RIGHT LIGHT
17
6 VERSPERRT HINTER RECHT LICHT
X1
7 11 LUZ ESTORBO TRASERO DERECHO
8 6
X130
X113
12 8 6
10EADI010 X118
19 13
8
18
25
17 3 14
X1
6
7 FANALE POSTERIORE DESTRO

8 FEU ARRIERE DROITE
REAR RIGHT LIGHT
15
X116 HINTER RECHT SCHEINWERFER
X6
6 FAZO TRASERO DERECHO
7 8
16
15
X6
6 16
7 8
71
X6
6
20 22
10DADI001
7 8 18
X6 X126
6 OPTIONAL
7 8
19
6
X6
6 21 3 23
7
ELECTRICITE (Cablage principal cabine) MHT 860 LT-E3 MHT 950 LT-E3
MHT 860L
9
3
30 4 CABLAGGIO COMPLETO PRINCIPALE CABINA
CABLAGE COMPLET PRINCIPALE CABINE
5 CAB MAIN COMPLET WIRING 1
2 OPTIONAL HANPTEURKABELUNG VOLLSTANDING KABINE
CABLEADO COMPLETO PRINCIPAL CABINA
15
X160.p
6BBDI005 16
12 11AADI073
11CDDI001 3 7
13
9 8
2 14 X199.s
29
X135.p
X201 Gnd4.5
6
Gnd4.4
MASSA
MASSE
X620.S BODY
11AADI060 MASSE
Gnd4.3 MASA
31 32
3 X163.s Gnd4.2
2
X256.p
Gnd4.1
2 X162.p
X121.p
26 8
3 2 25
10 23 11AADI071
27 28
11AADI060 17 2
18 19 22
21 20 24
2
OPTIONAL
X128.p
16
2 A/C
11 OPTIONAL
3 9
ELETTRICITA' (Cablaggio principale cabina) MHT 860 LT-E3 MHT 950 LT-E3
11AADI ELECTRICITE (Cablage principal cabine) 860L
ELECTRICITY (Cab main wiring) MHT-X 860 LT-E3 MHT-X
MHT950 LT-E3
OPTIONAL
X211
20
23
28 26
12 25 27 26
18
24
11AADI007 X166 11AADI007
2 15
1
28 26
27
X170.1 X170.2 X171.s OPTIONAL
X608
X614 16
28
26
27
11AADI070
X208
11AADI007
X367 26
8 28
27
X237 11AADI007
X167 10
14 X178.1 X178.2 28
26
13 27
4 11
3 OPTIONAL
9 X212
7 16
16
5 21 22 28
27
10EADI005 11AADI007 11AADI072
11AADI002
648 8
11AADI ELECTRICITE (Cablage principal cabine) MHT 860L
ELECTRICITY (Cab main wiring) MHT-X 860 LT-E3 MHT-X 950 LT-E3
RISCALDAMENTO 7
CIRCUIT CHAUFFAGE
HEATING CIRCUIT
ERHITZENKREIS
11AADI007 CIRCUITO CALDEO
X607
16 8
14 15 9
13 2 11 10 3
11AADI002
X606
X164.s X165.s 8
X174 19
9 2
1
MASSA
X204.3 MASSE
BODY
MASSE
11AADI071 MASA
18
1
X177
X173.2 X173.1 X172

2
1 RISCALDAMENTO
CIRCUIT CHAUFFAGE
X176 HEATING CIRCUIT
ERHITZENKREIS
2 CIRCUITO CALDEO
2 5
1
1 17 13
6 12
4
X175
OPTIONAL
MICRO SOTTO SEDILE PRESENZA OPERATORE

MICRO SOUS LESIEGE PRESENCE OPERATEUR
MICROSWITCH UNDER THE SEAT OPERATOR PRESENCE
MICRO UNTER DEMSITZ ANWESENHEIT WIRTSCHAFTS BETEILIGTER
MICRO BAJO LA SEDE PRESENCIA OPERADOR
11AADI ELECTRICITE (Cablage principal cabine) 860L
ELECTRICITY (Cab main wiring) MHT-X 860 LT-E3 MHT-X
MHT950 LT-E3
0
0
1
2
TERGICRISTALLO ANTERIORE X193

ESSUIE-GLACE AVANT
FRONT WINDSHIELD WIPER
VORN SCHEIBENWISCHER
OPTIONAL LIMPIA-PARABRISSAS DELANTERO
23
8ABDI001 9
11AADI006 11AADI006
24
10
13 8 X192
1
9
14 11 12 3
3
21
11
0
22
2
X612.s X611 X188 X191
X187.1 X187.2
25
11AADI006
21
22
11AADI070 11AADI074
20
25 X613
3 X10.s
X206.s X186.s 5 X185.s 26 X238 X200
5 +30
20
11AADI020
5 8
19
4 16
6 7 18 16 +15
15 17
20
11AADI012
OPTIONAL
+15 Key
RISCALDAMENTO PREDISPOSIZIONE RADIO
CIRCUIT CHAUFFAGE PREDISPOSITION RADIO
HEATING CIRCUIT RADIO PREDISPOSITION
11AADI006 ERHITZENKREIS VOREINSTELLUNG RADIO 11AADI006
CIRCUITO CALDEO PREDISPOSICION RADIO
11AADI ELECTRICITE (Cablage principal cabine) MHT 860L
ELECTRICITY (Cab main wiring) MHT-X 860 LT-E3 MHT-X 950 LT-E3
6
2
11AADI020
X7.s
1 3 4 5 15
2 2 2 2 2
X8.s
11AADI020
X1.s X2.s X3.s X4.s X5.s
2
7
X11.s
30
X300 X301
23 2 28 31
8
23 22 22
X610.s
26
11AADI073 27
25
24
24 19 29
X197.1
14
BULBO LUCE STOP
BOULE STOP
STOP BULB
X280.s X365 X196 X197.2 THERMOMETERKUGEL STOP
BULBO STOP
19
19 14
11 13
10 12 X198.1
9
X198.2
16
20 6BADI015
17 19
18 19 14
STRUMENTI DIAGNOSTICA POMPA TERGICRISTALLO

X281.1
INSTRUMENT DIAGNOSTIQUE POMPE ESSUIE-GLACE
DIAGNOSTIC INSTRUMENT WINDSCR. WIPER PUMP OPTIONAL
DIAGNOSTIKSTRUMENT SCHEIBENW. PUMPE X281.2
INSTRUMENTO DIAGNOSTICO BOMBA LIMPIAPARABREZA
21 19 14
648587
ELETTRICITA’ (Cavi batteria) MHT 860 LT-E3 MHT 950 LT-E3
11AADI ELECTRICITE (Cable batterie) MHT 860L
ELECTRICITY (Battery cable) MHT-X 860 LT-E3 MHT-X 950 LT-E3
ELEKTRIZITAT (Batterie kabel)
090 ELECTRICIDAD (Cable bateria) E3
APDI151
8
+
14 6
16 +
11 APDI152
17 13
12
15
18 10 19
21 20
9
_ +
19
21 20
9 12V 1
105A
h 85
0A
4
5
7 2
3
ELECTRICITE (Cablage moteur) MHT 860 LT-E3 MHT 950 LT-E3
MHT 860L
ELETTROVALVOLA MARCIA AVANTI ELETTROVALVOLA RETROMARCIA

12V
11AADI070 ELECTROVALVE MARCHE AVANT ELECTROVALVE MARCHE ARRIERE 105Ah
850A
FORWARD GEAR ELECTROVALVE BACKWARD GEAR ELECTROVALVE

VORW€RTSGANG ELEKTROVENTIL RUCKW€RTSGANG ELEKTROVENTIL
ELECTROVALVULA ENGRANE DE AVANCE ELECTROVALVULA ENGRANE DE REVERSA
24
MOTORINO AVVIAMENTO
11AADI090 DEMARREUR
STARTER MOTOR
23 ANALASSERMOTOR
9 _ + X156 MOTOR DE ARRANQUE
d +3
Gn 0
8 GENERATORE
5 GENERATEUR
X136 X137
13 GENERATOR
GENERATOR
GENERADOR
X158
3
11 4
10
X160.s
X138.p
X135.s
20 15 19 21 8
4 3 22
17
16
18 MASSA
8 MASSE
Gnd3.2 BODY
12 MASSE
7 6 5 MASA
25
14
2 11CDDI002
CABLAGGIO COMPLETO MOTORE
CABLAGE COMPLET MOTEUR
ENGINE COMPLET WIRING 1
HANPTEURKABELUNG KOMPLETTE MOTOR
CABLEADO COMPLETO MOTOR
11CDDI003
11AADI070
648587
MHT 860L
APDI143
APDI151 APDI140 22
20
15 30A 30A
24
14 23
10
17 24
16
18 33 30A
35 32 25
19
40A PORTA-FUSIBILE
X142 X146 X144 PORTE-FUSIBLE
12 11 25 FUSE-HOLDER
SICHERUNGSSOCKEL
40A PORTA-FUSIBLE
11CDDI001
50A
5 X139
.1 X147.4 26
X147
X140 21
X1
47 11
.2 .3 X1 .1
47 8 48
X1 5
48.
3 X1 11
8
11
6 1
X148.2
31
2
BOSCH
27 12V 75A 4
30 13 3
7
28
29 9
TERMOAVVIATORE SERVIZI
THERMO DEMARREUR SERVICES
THERMOSTART UNIT
34 SERVICES
TERMOANLASSEUR DIENST
TERMOARRANQUE SERVICIOS
648587
MHT 860L
14
4AADI003
12
11
6 6
1 2
X1 3
17 5 4.2 54
X1 .1
13 7
16
15
X161
X141
11CDDI001
X153 APDI143
10
5 2
4
APDI153
SAFETY SYSTEM
LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
CHECK
- These tests are essential for checking the correct operation and adjustment of the different components of the device.
Use the test button only when requested to do so, performing short presses (less than 1 second) and long presses (2 seconds) as instructed. If in
doubt during the test procedure, exit cleanly by short pressing the “BUCKET” MODE or “SUSPENDED LOAD” MODE button .
Long press on the test button.
TEST OK
Short press - One audible beep and progresses to stage 2.
the test TEST NOT OK
STAGE 1 - Two audible beeps and lighting of the fault
button.
1
- Place the lift truck without any warning light .
- An audible beep. attachment, with the jib fully retracted - Exit test mode.
- First green led flashing. and raised. - Go to stage 4.
- Test button lit.
TEST OK
Short press - One audible beep and progresses to stage 3.
the test TEST NOT OK
STAGE 2
button. - Two audible beeps and lighting of the fault
2 1 - Lower the jib with the engine running at warning light .
full revs and the hydraulic control at the - Exit test mode.
- First green led continuously lit. maximum setting. Lowering slows until
- Second green led flashing. - Go to stage 4.
movement is cut-off.
- Test button lit.
TEST OK
- Conformity of aggravating movement cut-off.
- Lower the jib until the movement - Exit test mode. All the LEDs will light
3 Short press
is cut-off. for 2 seconds and an audible beep will
the test
STAGE 2 - Request the following, in order:a be sounded.
button.
3 1 reverse tilt, a forward tilt (dumping) and TEST NOT OK
a telescope extension. None of these 3
- First and second green leds - Fault warning light comes on .
movements should be possible.
continuously lit. - Exit test mode.
- Third green led flashing. - Go to stage 4.
- Test button lit.
- The fault indicator and a beep indicate a fault.
- Press the button briefly to view the error code.
- If there are several error codes, press the button briefly several times to loop through the error
codes.
NOTE: A defective fuse can generate several error codes. If this is the case, check the fuses
(see: 2 - DESCRIPTION: 11 - FUSES AND RELAYS IN THE CAB)
STAGE
4 A7
A6
- The fault warning light remains
permanently on until the error
A4
is repaired.
- If error code“ A3 is displayed”, the problem may be resolved by resetting the longitudinal stability
limiter and warning device (see: 3 - MAINTENANCE: G - OCCASIONAL MAINTENANCE).
- Contact your dealer, stating the error code or error codes (see following table).
NOTE: For the stage 3 test, specify the non-conforming aggravating hydraulic movements, if necessary.
3-15
The error codes are indicated by leds A3 to A7 on the warning device and longitudinal stability limiter.
A7
A6
A5
A4
A3
ERROR CODES
LEDS
DESIGNATIONS
A7 A6 A5 A4 A3
Regulating fault (fault detected during the test).
Lowering regulating valve fault.
Safety valve cut-off fault (fault detected during the test).
Safety valve fault.
Gauge calibration fault (fault detected during the test).
the problem may be resolved by resetting the longitudinal stability limiter and warning device
(see: 3 - MAINTENANCE: G - OCCASIONAL MAINTENANCE).
Angle calibration fault (fault detected during the test).
Inclination cut-off valve fault.
Strain gauge fault.
Jib angle sensor fault.
Telescope or attachment control fault.
Telescope retracted senor fault.
Computer earth output fault.
Aggravating hydraulic movement cut-off disable fault.
Stability indicator fault.
Electronic handling controller fault.
Hydraulic control lever control setting fault.
Transmission cut-off output fault.
Electronic handling controller supply fault.
Telescope retracted sensor fault (fault detected during the test).
Forward tilt cut-off valve fault. (according to model)
Jib head electrovalve fault. (OPTION)
Attachment easy hydraulic connection fault button. (OPTION)
Electrovalve attachment hydraulic control and electrical jib provision fault button. (OPTION)
Attachment forced operation indicator fault. (OPTION)
Electric handling controller 10V output fault.
Forced operation button fault. (OPTION)
3-16
LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
RESET
According to the use of the lift truck, the device may require to be periodically reset.
This operation can be easily performed by means of the following procedure.
- Provide a fork carrier or a bucket and a load corresponding to at least half the lift truck’s rated capacity.
- Preferably perform the reset when the lift truck is still cold (before it is used) or ensure that the temperature of the rear axle is not more
than 50°C.
- Place the lift truck on flat, level ground with the wheels straight.
Scrupulously follow the jib positioning instructions. Should you fail to follow these instructions, two audible beeps will be sounded and the fault
indicator lamp will come on. If in doubt, consult your dealer.
STAGE 1
START Simultaneously press and hold down the “BUCKET” MODE and TEST buttons.
- Two audible beeps will be sounded and all the leds will flash twice to confirm the start of the procedure.
- Without attachments.
- Jib fully retracted and raised.
Short press the test

1 button.
STAGE 2
- Without attachments.
- Carriage tilted fully backward.
- An audible beep. - Jib fully retracted and in the down position a few centimetres off the ground.
- First green led flashing.
- Flashing test button.
/
- With the fork carrier or the bucket and a load (keep jib retracted to allow all other Short press the test
hydraulic movements). button.
- Jib fully retracted and in the down position a few centimetres off the ground.
2
STAGE 3 1 - Two audible beeps
/ will be sounded and
- First green led continuously all the leds will flash
lit. Keep the load as close to the ground as possible throughout this operation. twice to confirm the
- Second green led flashing. - Hold down the disable the “aggravating” hydraulic movement cut-off button, and end of the procedure.
- - Flashing test button. telescope the jib until the rear wheels are off the ground.
NOTA: This stage consists in unloading the rear axle. It can be done using a jack
but without bearing on the rear axle.
STAGE 4
/
FINISH
- After completing the resetting procedure, the lift truck is in an overloaded condition. Retract the telescope to restore the
situation.
- All leds lit.
- A continuous audible beep.
When the reset is completed, check the operation of the longitudinal stability limiter and warning device (see: 3 - MAINTENANCE: A - DAILY OF EVERY 10
HOURS SERVICE).
4-72
3-47

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REPAIR MANUAL

This document has been printed from my e doc

AXLE ASSEMBLY - AXLE

MHT 780 T-E3

DATE PUBLICATION OBSERVATION

30/03/2012 1ST DATE OF ISSU

SPECIFICATIONS AND WEIGHTS

SPECIFICATIONS AND WEIGHTS

SPECIFICATIONS AND WEIGHTS

sur sol horizontal

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Specifications Section When the crankshaft is viewed from the front of

The front of the engine is opposite the flywheel end.

Fuel Injection Lines

Contact with high pressure fuel may cause fluid

Type of combustion ............................ Direct injection

Number of cylinders ................................................ 4

Valves per cylinder .................................................. 4

Firing order ................................................. 1, 3, 4, 2

Manifold to Injector i02519422

Fuel Injection Pump

Note: Before the pump is removed from the engine

Note: Refer to Systems Operation, Testing

(1) Locking screw

Locking the shaft

Note: The support bracket must be installed after i02519286

Note: Refer to Systems Operation, Testing

(4) Retaining setscrew ................... 30 N·m (22 lb ft)

i02519336 Hand Fuel Priming Pump

Note: Refer to Systems Operation, Testing

(1) The plunger that is hand operated.

Electric fuel Priming Pump

(2) The canister for the fuel filter

Fuel Priming Pump

Note: Refer to Systems Operation, Testing

(1) Diameter of the lifter body .. 18.987 to 19.012 mm

Bore diameter in the cylinder block

Clearance The service limit for both rocker arm

(7) Snap ring

(4) Exhaust rocker arm

Valve Mechanism Cover

Tighten the bolts for the valve mechanism cover in

Cylinder Head Valves

(2) Valve face angle

(3) Valve stem diameter

(5) Valve head

i02505671 Note: The maximum distortion of the bottom face of

Lubricate the threads and the underside of the head

Minimum thickness of cylinder head ....... 100.95 mm

(1) Valve guide bores

(2) Valve depths

Turbocharger The part number for

The movement for the rod actuator ................. 1 mm

Camshaft Camshaft Journals Standard Diameter

Maximum wear on the camshaft journals ... 0.05 mm

Check the camshaft lobes for visible damage. If a

(1) End play of a camshaft ......... 0.126 to 0.558 mm

Maximum permissible end play of a worn

(1) The diameter of the installed camshaft