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REF : 547954 EN (24 / 03 / 2006)

CD 15 P CG 15 P
CD 18 P CG 18 P
CD 20 P CG 20 P
CD 25 P CG 25 P
CD 30 P CG 30 P
CD 35 P CG 35 P

REPAIR MANUAL
1st DATE OF ISSUE 24 / 03 / 2006

DATE OF ISSUE OBSERVATION

24 / 03 / 2006 - 1st ISSUE

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY.
CONTENTS

CD 15 P
CD 18 P
CD 20 P
CD 25 P
CD 30 P
CD 35 P

CG 15 P
CG 18 P
CG 20 P
CG 25 P
CG 30 P
CG 35 P
GROUPS CHAPTERS

-0- - GENERAL POINTS -


0-1-M128 EN LIFT TRUCK CHARACTERISTICS • • • • • • • • • • • •

- 10 - - ENGINE -
10-3-70 EN ENGINE DISASSEMBLY • •
10-3-71 EN ENGINE DISASSEMBLY • • • •
10-3-75 EN ENGINE DISASSEMBLY • • • • • •

- 12 - - CARBURATION -
12-3-2 EN VACUUM FUELOCK FILTER REPAIR METHOD VFF30 • • • • • •
12-3-3 EN CARBURETTOR REPAIR METHOD CA55 • • • • • •
12-8-1 EN COBRA PRESSURE RELIEF VALVE OPERATION • • • • • •
12-8-20 EN GPL CARBURATION OPERATING • • • • • •

- 20 - - GEAR BOX -
20-3-18 EN GEAR BOX DISASSEMBLY • • • •
20-3-19 EN GEAR BOX DISASSEMBLY • • • • • • • •

- 70 - - HYDRAULIC -
70-6-M128 EN HYDRAULIC DIAGRAM • • • • • • • • • • • •

- 80 - - ELECTRIC -
80-6-M128 EN ELECTRIC DIAGRAM • • • • • • • • • • • •
GROUP 0

GENERAL POINTS
LIFT TRUCK CHARACTERISTICS

0-1-M128 EN

CD 15/18/20/25/30/35 P
CG 15/18/20/25/30/35 P

07 / 03 / 2006
2
TABLE OF CONTENTS

CHARACTERISTICS
CD 15/18/20/25/30/35 P 4
CG 15/18/20/25/30/35 P 28

DIMENSIONS AND LOAD CHART


CD 15/18/20/25/30/35 P 22
CG 15/18/20/25/30/35 P 46

FILTERS CARTRIDGES AND BELTS


CD 15/18/20/25/30/35 P 52
CG 15/18/20/25/30/35 P 56

LUBRICANTS AND FUEL


CD 15/18/20/25/30/35 P 54
CG 15/18/20/25/30/35 P 58

3
CHARACTERISTICS

I.C. ENGINE

CD 15 P CD 18 P ISUZU 4LE1
CD 20 P CD 25 P CD 30 P CD 35 P ISUZU 4JG2

- Type ISUZU 4LE1 ISUZU 4JG2


- Number of cylinders 4 in line 4 in line
- Number of strokes 4 4
- Suction Natural Natural
- Ignition sequence 1.3.4.2. 1.3.4.2.
- Clearance of rocker valve (cold)
. Inlet 0,40 mm 0,40 mm
. Exhaust 0,40 mm 0,40 mm
- Capacity 2179 cm3 3059 cm3
- Bore 85 mm 95,4 mm
- Stroke 92 mm 107 mm
- Compression ratio 21,5:1 20:1
- Nominal rating loaded 2400 rpm 2400 rpm
- Rating slow unladen 850 ± 25 rpm 700 ± 25 rpm
- Max. rating unladen 2640 ± 25 rpm 2690 ± 50 rpm
- Power ISO 3046-INF 32,7 kW 44,9 kW
- Maximum torque ISO 3046-INF 136 Nm at 1600 rpm 186,3 Nm at 1800 rpm
- Air cleaner Dry cartridge Dry cartridge

COOLING CIRCUIT

ISUZU 4LE1 ISUZU 4JG2


- Type With water With water
- Fan Blowing Blowing
. Number of blades 6 6
. Diameter 432 mm 432 mm
- Thermostat
. Start opening 74,5°C - 78,5°C 82°C
. Full opening 90°C 90°C

TRANSMISSION
- Type
CD 15 P CD 18 P GRAZIANO TRASMISSIONI GROUP TXL 25
CD 20 P CD 25 P CD 30 P CD 35 P GRAZIANO TRASMISSIONI GROUP TXL 30/ST

BRAKE
- Service brake Foot pedal. Hydraulic brake, applied on the front wheels.
. Type Drum.
- Parking brake Mechanical hand lever applied on the front wheels.
. Type Drum.

ELECTRIC CIRCUIT

- Earth Negative
- Battery
CD 15 P CD 18 P 12 V - 70 Ah - 600 A
CD 20 P CD 25 P CD 30 P CD 35 P 12 V - 90 Ah - 800 A
- Alternator 12 V
. Type Denso
. Tension regulator Incorporated into the alternator
- Starter 12 V
. Type Denso

4
5
CHARACTERISTICS CD 15 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.50-10 10PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
5.00-8 8PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 29,5 cm3
. Flow rate at full speed 88,5 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µ
. Suction µ

6
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 21 km/h
. Reverse unladen 20 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 1500 kg

- Load center 500 mm

- Weight of forks (each) 44,5 kg

- Lifting motions with standard mast


. Unladen lifting 0,78 m/s
. Rated load lifting 0,68 m/s
. Unladen lowering 0,50 m/s
. Rated load lowering 0,53 m/s

- Lift truck weight with standard mast


. Unladen 2900 kg
. Rated load 4400 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 8700 N
. Rated load 9820 N

- Maximum ramp negotiable in forward motion


. Unladen 27 % at 1 km/h
. Rated load 20,5 % at 1 km/h

7
CHARACTERISTICS CD 18 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.50-10 10PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
5.00-8 8PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 29,5 cm3
. Flow rate at full speed 88,5 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µ
. Suction µ

8
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 21 km/h
. Reverse unladen 20 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 1800 kg

- Load center 500 mm

- Weight of forks (each) 44,5 kg

- Lifting motions with standard mast


. Unladen lifting 0,78 m/s
. Rated load lifting 0,68 m/s
. Unladen lowering 0,50 m/s
. Rated load lowering 0,53 m/s

- Lift truck weight with standard mast


. Unladen 3100 kg
. Rated load 4900 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 8700 N
. Rated load 9820 N

- Maximum ramp negotiable in forward motion


. Unladen 24 % at 1 km/h
. Rated load 17,5 % at 1 km/h

9
CHARACTERISTICS CD 20 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
7.00-12 12PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.00-9 10PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 33,2 cm3
. Flow rate at full speed 99,6 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µ
. Suction µ

10
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 21 km/h
. Reverse unladen 20 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 2000 kg

- Load center 500 mm

- Weight of forks (each) 44,5 kg

- Lifting motions with standard mast


. Unladen lifting 0,73 m/s
. Rated load lifting 0,63 m/s
. Unladen lowering 0,48 m/s
. Rated load lowering 0,52 m/s

- Lift truck weight with standard mast


. Unladen 3804 kg
. Rated load 5804 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 13280 N
. Rated load 19780 N

- Maximum ramp negotiable in forward motion


. Unladen 23,1 % at 1 km/h
. Rated load 27,5 % at 1 km/h

11
CHARACTERISTICS CD 25 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
7.00-12 12PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.00-9 10PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 33,2 cm3
. Flow rate at full speed 99,6 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µ
. Suction µ

12
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 21 km/h
. Reverse unladen 20 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 2500 kg

- Load center 500 mm

- Weight of forks (each) 44,5 kg

- Lifting motions with standard mast


. Unladen lifting 0,73 m/s
. Rated load lifting 0,63 m/s
. Unladen lowering 0,48 m/s
. Rated load lowering 0,52 m/s

- Lift truck weight with standard mast


. Unladen 4080 kg
. Rated load 6580 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 13280 N
. Rated load 19780 N

- Maximum ramp negotiable in forward motion


. Unladen 23,1 % at 1 km/h
. Rated load 27,5 at 1 km/h

13
CHARACTERISTICS CD 30 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
28-9 15PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2
8.15-15 12PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.50-10 10PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 33,2 cm3
. Flow rate at full speed 99,6 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µ
. Suction µ

14
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 22 km/h
. Reverse unladen 21 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 3000 kg

- Load center 500 mm

- Weight of forks (each) 71 kg

- Lifting motions with standard mast


. Unladen lifting 0,60 m/s
. Rated load lifting 0,50 m/s
. Unladen lowering 0,46 m/s
. Rated load lowering 0,51 m/s

- Lift truck weight with standard mast


. Unladen 4510 kg
. Rated load 7510 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 14600 N
. Rated load 19300 N

- Maximum ramp negotiable in forward motion


. Unladen 32,9 % at 1 km/h
. Rated load 22,4 % at 1 km/h

15
CHARACTERISTICS CD 35 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
28X12.5-15 15PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
TONGYONG FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.50-10 10PR REAR UNLADEN KG KG/CM2 CM2
SOLID
TONGYONG REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 33,2 cm3
. Flow rate at full speed 99,6 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µ
. Suction µ

16
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 22 km/h
. Reverse unladen 21 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 3500 kg

- Load center 500 mm

- Weight of forks (each) 71 kg

- Lifting motions with standard mast


. Unladen lifting 0,60 m/s
. Rated load lifting 0,35 m/s
. Unladen lowering 0,46 m/s
. Rated load lowering 0,51 m/s

- Lift truck weight with standard mast


. Unladen 4940 kg
. Rated load 8440 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 14610 N
. Rated load 17800 N

- Maximum ramp negotiable in forward motion


. Unladen 29,6 % at 1 km/h
. Rated load 17,2 % at 1 km/h

17
CHARACTERISTICS OF MASTS WITH ROLLERS
CD 15 P
CD 18 P

DOUBLE MAST WITH ALL-ROUND VISION


MAST α β h2 h1 h4
2m70 6° 12° 195 1850 3625
3m00 6° 12° 195 2010 3945
3m30 6° 12° 195 2170 4265
3m70 6° 12° 195 2350 4625
4m00 6° 6° 195 2510 4945

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
2m70 6° 12° 1340 1850 3635
3m00 6° 12° 1500 2010 3955
3m30 6° 12° 1660 2170 4295
3m70 6° 12° 1840 2350 4635
4m00 6° 6° 2000 2510 4955

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
4m00 6° 6° 1340 1850 4975
4m50 6° 6° 1500 2010 5455
5m00 6° 6° 1660 2170 5955
5m50 6° 6° 1840 2350 6475
6m00 6° 6° 2000 2510 6955

α : Forward tilting
β : Backward tilting
h2 : Free-acting lift in mm
h1 : Overall height with folded mast in mm
h4 : Overall height with spreaded out mast in mm

18
CHARACTERISTICS OF MASTS WITH ROLLERS
CD 20 P
CD 25 P

DOUBLE MAST WITH ALL-ROUND VISION


MAST α β h2 h1 h4
2m70 6° 12° 200 1850 3630
3m00 6° 12° 200 2010 3950
3m30 6° 12° 200 2170 4270
3m70 6° 12° 200 2350 4630
4m00 6° 6° 200 2510 4950

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
2m70 6° 12° 1340 1850 3635
3m00 6° 12° 1500 2010 3955
3m30 6° 12° 1660 2170 4295
3m70 6° 12° 1840 2350 4635
4m00 6° 6° 2000 2510 4955

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
4m00 6° 6° 1340 1850 4975
4m50 6° 6° 1500 2010 5455
5m00 6° 6° 1660 2170 5955
5m50 6° 6° 1840 2350 6475
6m00 6° 6° 2000 2510 6955

α : Forward tilting
β : Backward tilting
h2 : Free-acting lift in mm
h1 : Overall height with folded mast in mm
h4 : Overall height with spreaded out mast in mm

19
CHARACTERISTICS OF MASTS WITH ROLLERS
CD 30 P
CD 35 P

DOUBLE MAST WITH ALL-ROUND VISION


MAST α β h2 h1 h4
2m70 6° 12° 160 1865 3205
3m00 6° 12° 160 2025 3525
3m30 6° 12° 160 2185 3845
3m70 6° 12° 160 2365 4205
4m00 6° 6° 160 2525 4525

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
2m70 6° 12° 1270 1875 3710
3m00 6° 12° 1430 2035 4030
3m30 6° 12° 1590 2195 4370
3m70 6° 12° 1770 2375 4710
4m00 6° 6° 1930 2535 5030

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
4m00 6° 6° 1270 1870 5050
4m50 6° 6° 1430 2030 5530
5m00 6° 6° 1590 2190 6030
5m50 6° 6° 1770 2370 6550
6m00 6° 6° 1930 2530 7030

α : Forward tilting
β : Backward tilting
h2 : Free-acting lift in mm
h1 : Overall height with folded mast in mm
h4 : Overall height with spreaded out mast in mm

20
21
DIMENSIONS AND LOAD CHART
CD 15 P (WITH STANDARD MAST)

Ast 3500 mm
b1 1050 mm
b3 1050 mm
b10 880 mm
b11 900 mm
b13 280 mm
c 500 mm
e 100 mm
h1 2170 mm
h2 195 mm
h3 3355 mm
h4 4265 mm
h6 2060 mm
h10 280 mm
l 1220 mm
l1 3460 mm
l2 2240 mm
m1 115 mm
m2 120 mm
Q 1500 kg
s 35 mm
Wa 1880 mm
x 420 mm
y 1400 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 1500 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 1500 1350
Q : kg 2 900

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257931

22
DIMENSIONS AND LOAD CHART
CD 18 P (WITH STANDARD MAST)

Ast 3535 mm
b1 1050 mm
b3 1050 mm
b10 880 mm
b11 900 mm
b13 280 mm
c 500 mm
e 100 mm
h1 2170 mm
h2 195 mm
h3 3355 mm
h4 4265 mm
h6 2060 mm
h10 280 mm
l 1220 mm
l1 3495 mm
l2 2275 mm
m1 115 mm
m2 120 mm
Q 1800 kg
s 35 mm
Wa 1915 mm
x 420 mm
y 1400 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 1800 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 1800 1620
Q : kg 2 1090

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257936

23
DIMENSIONS AND LOAD CHART
CD 20 P (WITH STANDARD MAST)

Ast 3755 mm
b1 1150 mm
b3 1150 mm
b10 960 mm
b11 970 mm
b13 320 mm
c 500 mm
e 120 mm
h1 2170 mm
h2 200 mm
h3 3360 mm
h4 4270 mm
h6 2120 mm
h10 300 mm
l 1220 mm
l1 3675 mm
l2 2455 mm
m1 120 mm
m2 140 mm
Q 2000 kg
s 40 mm
Wa 2100 mm
x 455 mm
y 1600 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 2000 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 2000 1810
Q : kg 2 1230

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257941

24
DIMENSIONS AND LOAD CHART
CD 25 P (WITH STANDARD MAST)

Ast 3815 mm
b1 1150 mm
b3 1150 mm
b10 960 mm
b11 970 mm
b13 320 mm
c 500 mm
e 120 mm
h1 2170 mm
h2 200 mm
h3 3360 mm
h4 4270 mm
h6 2120 mm
h10 300 mm
l 1220 mm
l1 3735 mm
l2 2515 mm
m1 120 mm
m2 140 mm
Q 2500 kg
s 40 mm
Wa 2160 mm
x 455 mm
y 1600 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 2500 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 2500 2260
Q : kg 2 1530

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257946

25
DIMENSIONS AND LOAD CHART
CD 30 P (WITH STANDARD MAST)

Ast 4015 mm
b1 1260 mm
b3 1260 mm
b10 1030 mm
b11 970 mm
b13 360 mm
c 500 mm
e 125 mm
h1 2185 mm
h2 160 mm
h3 3365 mm
h4 4347 mm
h6 2135 mm
h10 320 mm
l 1220 mm
l1 3870 mm
l2 2650 mm
m1 160 mm
m2 165 mm
Q 3000 kg
s 45 mm
Wa 2330 mm
x 485 mm
y 1700 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 3000 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 3000 2720
Q : kg 2 1860

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257951

26
DIMENSIONS AND LOAD CHART
CD 35 P (WITH STANDARD MAST)

Ast 4075 mm
b1 1390 mm
b3 1260 mm
b10 1100 mm
b11 970 mm
b13 360 mm
c 500 mm
e 125 mm
h1 2185 mm
h2 160 mm
h3 3365 mm
h4 4347 mm
h6 2135 mm
h10 320 mm
l 1220 mm
l1 3930 mm
l2 2710 mm
m1 160 mm
m2 165 mm
Q 3500 kg
s 45 mm
Wa 2390 mm
x 485 mm
y 1700 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 3500 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 3500 3175
Q : kg 2 2175

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257956

27
CARACTÉRISTIQUES

MOTEUR
CG 15 P CG 18 P NISSAN H20
CG 20 P CG 25 P CG 30 P CG 35 P NISSAN H25

- Type NISSAN H20 NISSAN H25


- Number of cylinders 4 in line 4 in line
- Number of strokes 4 4
- Suction Natural Natural
- Ignition sequence 1.3.4.2. 1.3.4.2.
- Clearance of rocker valve (hot)
. Inlet 0,38 mm 0,38 mm
. Exhaust 0,38 mm 0,38 mm
- Capacity 1982 cm3 2472 cm3
- Bore 87,2 mm 92 mm
- Stroke 83 mm 93 mm
- Compression ratio 8.7:1 8.7:1
- Nominal rating loaded 2600 - 3000 rpm 2300 rpm
- Rating slow unladen 650 - 750 rpm 750 - 800 rpm
- Max. rating unladen 3100 - 3300 rpm 2800 - 3000 rpm
- Power
- Maximum torque
- Air cleaner Dry cartridge Dry cartridge

COOLING CIRCUIT

NISSAN H20 NISSAN H25


- Type With water With water
- Fan Blowing Blowing
. Number of blades 6 6
. Diameter 432 mm 432 mm
- Thermostat
. Start opening 82°C 82°C
. Full opening 95°C 95°C

TRANSMISSION
- Type
CG 15 P CG 18 P GRAZIANO TRASMISSIONI GROUP TXL 25
CG 20 P CG 25 P CG 30 P CG 35 P GRAZIANO TRASMISSIONI GROUP TXL 30/ST

BRAKE
- Service brake Foot pedal. Hydraulic brake, applied on the front wheels.
. Type Drum.
- Parking brake Mechanical hand lever applied on the front wheels.
. Type Drum.

ELECTRIC CIRCUIT

- Earth Negative
- Battery
CG 15 P CG 18 P 12 V - 70 Ah - 600 A
CG 20 P CG 25 P CG 30 P CG 35 P 12 V - 90 Ah - 800 A
- Alternator 12 V - 50A
. Type Nissan
. Tension regulator Incorporated into the alternator
- Starter 12 V
. Type Nissan

28
29
CHARACTERISTICS CG 15 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.50-10 10PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
5.00-8 8PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 29,5 cm3
. Flow rate at full speed 88,5 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µm
. Suction µm

30
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 21 km/h
. Reverse unladen 20 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 1500 kg

- Load center 500 mm

- Weight of forks (each) 44,5 kg

- Lifting motions with standard mast


. Unladen lifting 0,78 m/s
. Rated load lifting 0,68 m/s
. Unladen lowering 0,50 m/s
. Rated load lowering 0,53 m/s

- Lift truck weight with standard mast


. Unladen 2790 kg
. Rated load 4290 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 8700 N
. Rated load 9820 N

- Maximum ramp negotiable in forward motion


. Unladen 27 % at 1 km/h
. Rated load 20,5 % at 1 km/h

31
CHARACTERISTICS CG 18 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.50-10 10PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
5.00-8 8PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 29,5 cm3
. Flow rate at full speed 88,5 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µm
. Suction µm

32
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 21 km/h
. Reverse unladen 20 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 1800 kg

- Load center 500 mm

- Weight of forks (each) 44,5 kg

- Lifting motions with standard mast


. Unladen lifting 0,78 m/s
. Rated load lifting 0,68 m/s
. Unladen lowering 0,50 m/s
. Rated load lowering 0,53 m/s

- Lift truck weight with standard mast


. Unladen 2990 kg
. Rated load 4790 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 8700 N
. Rated load 9820 N

- Maximum ramp negotiable in forward motion


. Unladen 24 % at 1 km/h
. Rated load 17,5 % at 1 km/h

33
CHARACTERISTICS CG 20 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
7.00-12 12PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.00-9 10PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 33,2 cm3
. Flow rate at full speed 99,6 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µm
. Suction µm

34
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 21 km/h
. Reverse unladen 20 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 2000 kg

- Load center 500 mm

- Weight of forks (each) 44,5 kg

- Lifting motions with standard mast


. Unladen lifting 0,73 m/s
. Rated load lifting 0,63 m/s
. Unladen lowering 0,48 m/s
. Rated load lowering 0,52 m/s

- Lift truck weight with standard mast


. Unladen 3639 kg
. Rated load 5639 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 13280 N
. Rated load 19780 N

- Maximum ramp negotiable in forward motion


. Unladen 23,1 % at 1 km/h
. Rated load 27,5 % at 1 km/h

35
CHARACTERISTICS CG 25 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
7.00-12 12PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.00-9 10PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 33,2 cm3
. Flow rate at full speed 99,6 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µm
. Suction µm

36
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 21 km/h
. Reverse unladen 20 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 2500 kg

- Load center 500 mm

- Weight of forks (each) 44,5 kg

- Lifting motions with standard mast


. Unladen lifting 0,73 m/s
. Rated load lifting 0,63 m/s
. Unladen lowering 0,48 m/s
. Rated load lowering 0,52 m/s

- Lift truck weight with standard mast


. Unladen 3915 kg
. Rated load 6415 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 13280 N
. Rated load 19780 N

- Maximum ramp negotiable in forward motion


. Unladen 23,1 % at 1 km/h
. Rated load 27,5 at 1 km/h

37
CHARACTERISTICS CG 30 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
28-9 15PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2
8.15-15 12PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.50-10 10PR REAR UNLADEN KG KG/CM2 CM2
SOLID
ZEETAH REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 33,2 cm3
. Flow rate at full speed 99,6 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µm
. Suction µm

38
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 22 km/h
. Reverse unladen 21 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 3000 kg

- Load center 500 mm

- Weight of forks (each) 71 kg

- Lifting motions with standard mast


. Unladen lifting 0,60 m/s
. Rated load lifting 0,50 m/s
. Unladen lowering 0,46 m/s
. Rated load lowering 0,51 m/s

- Lift truck weight with standard mast


. Unladen 4345 kg
. Rated load 7345 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 14600 N
. Rated load 19300 N

- Maximum ramp negotiable in forward motion


. Unladen 32,9 % at 1 km/h
. Rated load 22,4 % at 1 km/h

39
CHARACTERISTICS CG 35 P

FRONT TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
28X12.5-15 15PR FRONT UNLADEN KG KG/CM2 CM2
SOLID
TONGYONG FRONT LADEN KG KG/CM2 CM2

REAR TYRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
DIMENSIONS PRESSURE TYRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
6.50-10 10PR REAR UNLADEN KG KG/CM2 CM2
SOLID
TONGYONG REAR LADEN KG KG/CM2 CM2

HYDRAULIC CIRCUIT

- Type of pump Gear pump


. Capacity 33,2 cm3
. Flow rate at full speed 99,6 L/mn
- Pressure
. Lifting, tilting, attachment circuit 185 Bar
. Steering circuit Bar
- Filtration
. Return µm
. Suction µm

40
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard

- Level of sound power in the LwA environment dB


(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal


ground
(except particular conditions)
. Forward unladen 22 km/h
. Reverse unladen 21 km/h

- Standard lift height 3300 mm

- Rated capacity with standard mast 3500 kg

- Load center 500 mm

- Weight of forks (each) 71 kg

- Lifting motions with standard mast


. Unladen lifting 0,60 m/s
. Rated load lifting 0,35 m/s
. Unladen lowering 0,46 m/s
. Rated load lowering 0,51 m/s

- Lift truck weight with standard mast


. Unladen 4775 kg
. Rated load 8275 kg

- Axle weight with standard mast (transport position)


. Front unladen kg
rated load kg
. Rear unladen kg
rated load kg

- Tensible strain at coupling hook


. Unladen 14610 N
. Rated load 17800 N

- Maximum ramp negotiable in forward motion


. Unladen 29,6 % at 1 km/h
. Rated load 17,2 % at 1 km/h

41
CHARACTERISTICS OF MASTS WITH ROLLERS
CG 15 P
CG 18 P

DOUBLE MAST WITH ALL-ROUND VISION


MAST α β h2 h1 h4
2m70 6° 12° 195 1850 3625
3m00 6° 12° 195 2010 3945
3m30 6° 12° 195 2170 4265
3m70 6° 12° 195 2350 4625
4m00 6° 6° 195 2510 4945

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
2m70 6° 12° 1340 1850 3635
3m00 6° 12° 1500 2010 3955
3m30 6° 12° 1660 2170 4295
3m70 6° 12° 1840 2350 4635
4m00 6° 6° 2000 2510 4955

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
4m00 6° 6° 1340 1850 4975
4m50 6° 6° 1500 2010 5455
5m00 6° 6° 1660 2170 5955
5m50 6° 6° 1840 2350 6475
6m00 6° 6° 2000 2510 6955

α : Forward tilting
β : Backward tilting
h2 : Free-acting lift in mm
h1 : Overall height with folded mast in mm
h4 : Overall height with spreaded out mast in mm

42
CHARACTERISTICS OF MASTS WITH ROLLERS
CG 20 P
CG 25 P

DOUBLE MAST WITH ALL-ROUND VISION


MAST α β h2 h1 h4
2m70 6° 12° 200 1850 3630
3m00 6° 12° 200 2010 3950
3m30 6° 12° 200 2170 4270
3m70 6° 12° 200 2350 4630
4m00 6° 6° 200 2510 4950

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
2m70 6° 12° 1340 1850 3635
3m00 6° 12° 1500 2010 3955
3m30 6° 12° 1660 2170 4295
3m70 6° 12° 1840 2350 4635
4m00 6° 6° 2000 2510 4955

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
4m00 6° 6° 1340 1850 4975
4m50 6° 6° 1500 2010 5455
5m00 6° 6° 1660 2170 5955
5m50 6° 6° 1840 2350 6475
6m00 6° 6° 2000 2510 6955

α : Forward tilting
β : Backward tilting
h2 : Free-acting lift in mm
h1 : Overall height with folded mast in mm
h4 : Overall height with spreaded out mast in mm

43
CHARACTERISTICS OF MASTS WITH ROLLERS
CG 30 P
CG 35 P

DOUBLE MAST WITH ALL-ROUND VISION


MAST α β h2 h1 h4
2m70 6° 12° 160 1865 3205
3m00 6° 12° 160 2025 3525
3m30 6° 12° 160 2185 3845
3m70 6° 12° 160 2365 4205
4m00 6° 6° 160 2525 4525

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
2m70 6° 12° 1270 1875 3710
3m00 6° 12° 1430 2035 4030
3m30 6° 12° 1590 2195 4370
3m70 6° 12° 1770 2375 4710
4m00 6° 6° 1930 2535 5030

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT


MAST α β h2 h1 h4
4m00 6° 6° 1270 1870 5050
4m50 6° 6° 1430 2030 5530
5m00 6° 6° 1590 2190 6030
5m50 6° 6° 1770 2370 6550
6m00 6° 6° 1930 2530 7030

α : Forward tilting
β : Backward tilting
h2 : Free-acting lift in mm
h1 : Overall height with folded mast in mm
h4 : Overall height with spreaded out mast in mm

44
45
DIMENSIONS AND LOAD CHART
CG 15 P (WITH STANDARD MAST)

Ast 3500 mm
b1 1050 mm
b3 1050 mm
b10 880 mm
b11 900 mm
b13 280 mm
c 500 mm
e 100 mm
h1 2170 mm
h2 195 mm
h3 3355 mm
h4 4265 mm
h6 2060 mm
h10 280 mm
l 1220 mm
l1 3460 mm
l2 2240 mm
m1 115 mm
m2 120 mm
Q 1500 kg
s 35 mm
Wa 1880 mm
x 420 mm
y 1400 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 1500 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 1500 1350
Q : kg 2 900

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257931

46
DIMENSIONS AND LOAD CHART
CG 18 P (WITH STANDARD MAST)

Ast 3535 mm
b1 1050 mm
b3 1050 mm
b10 880 mm
b11 900 mm
b13 280 mm
c 500 mm
e 100 mm
h1 2170 mm
h2 195 mm
h3 3355 mm
h4 4265 mm
h6 2060 mm
h10 280 mm
l 1220 mm
l1 3495 mm
l2 2275 mm
m1 115 mm
m2 120 mm
Q 1800 kg
s 35 mm
Wa 1915 mm
x 420 mm
y 1400 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 1800 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 1800 1620
Q : kg 2 1090

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257936

47
DIMENSIONS AND LOAD CHART
CG 20 P (WITH STANDARD MAST)

Ast 3755 mm
b1 1150 mm
b3 1150 mm
b10 960 mm
b11 970 mm
b13 320 mm
c 500 mm
e 120 mm
h1 2170 mm
h2 200 mm
h3 3360 mm
h4 4270 mm
h6 2120 mm
h10 300 mm
l 1220 mm
l1 3675 mm
l2 2455 mm
m1 120 mm
m2 140 mm
Q 2000 kg
s 40 mm
Wa 2100 mm
x 455 mm
y 1600 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 2000 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 2000 1810
Q : kg 2 1230

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257941

48
DIMENSIONS AND LOAD CHART
CG 25 P (WITH STANDARD MAST)

Ast 3815 mm
b1 1150 mm
b3 1150 mm
b10 960 mm
b11 970 mm
b13 320 mm
c 500 mm
e 120 mm
h1 2170 mm
h2 200 mm
h3 3360 mm
h4 4270 mm
h6 2120 mm
h10 300 mm
l 1220 mm
l1 3735 mm
l2 2515 mm
m1 120 mm
m2 140 mm
Q 2500 kg
s 40 mm
Wa 2160 mm
x 455 mm
y 1600 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 2500 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 2500 2260
Q : kg 2 1530

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257946

49
DIMENSIONS AND LOAD CHART
CG 30 P (WITH STANDARD MAST)

Ast 4015 mm
b1 1260 mm
b3 1260 mm
b10 1030 mm
b11 970 mm
b13 360 mm
c 500 mm
e 125 mm
h1 2185 mm
h2 160 mm
h3 3365 mm
h4 4347 mm
h6 2135 mm
h10 320 mm
l 1220 mm
l1 3870 mm
l2 2650 mm
m1 160 mm
m2 165 mm
Q 3000 kg
s 45 mm
Wa 2330 mm
x 485 mm
y 1700 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 3000 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 3000 2720
Q : kg 2 1860

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257951

50
DIMENSIONS AND LOAD CHART
CG 35 P (WITH STANDARD MAST)

Ast 4075 mm
b1 1390 mm
b3 1260 mm
b10 1100 mm
b11 970 mm
b13 360 mm
c 500 mm
e 125 mm
h1 2185 mm
h2 160 mm
h3 3365 mm
h4 4347 mm
h6 2135 mm
h10 320 mm
l 1220 mm
l1 3930 mm
l2 2710 mm
m1 160 mm
m2 165 mm
Q 3500 kg
s 45 mm
Wa 2390 mm
x 485 mm
y 1700 mm
α 6 °
β 12 °

CAPACITE NOMINALE
RATED CAPACITY
RATED CAPACITY NENNKAPAZITÄT
CAPACIDAD NOMINAL 3500 kg
CAPACITÀ NOMINALE

CAPACITES EFFECTIVES
ACTUAL CAPACITIES ACTUAL CAPACITIES
EFFEKTIVE KAPAZITÄT SUIVANT NORME EN 1726-1 (ISO 1074)
(according to standard EN 1726-1) CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA

1- Jusqu'à hauteur de levée


Up to height of
1 - Up to height of Bis zur hubhöhe
Hasta altura de elevación
- mm
Sino ad altezza di sollevamento
2- Pour hauteur maximale de
For maximum height of
2 - For maximum height of Für maximale Höhe
Para altura máxima de
3300 mm
Per altezza massima di

MAT VERTICAL
VERTICAL MAST
- -
VERTICAL MAST VERTIKALER MAST
1 -
MASTIL VERTICAL
RAMPA VERTICALE 3500 3175
Q : kg 2 2175

D
D : mm
500 600 1100

EQUIPEMENT
-
ATTACHMENT -
ATTACHMENT ZUBEHÖR
EQUIPO -
ATTREZZATURA
-
CAPACITES EFFECTIVES
ACTUAL CAPACITIES
- -
ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT 1 -
CAPACIDAD EFECTIVA
CAPACITÀ EFFETTIVA - -
2 -
n°: 257956

51
FILTERS CARTRIDGES AND BELTS
CD 15 P
CD 18 P

I.C. ENGINE
I.C. ENGINE OIL FILTER
FAN BELT
Part number: 823090
Part number: 823058
Change: 500 H

DRY AIR FILTER CARTRIDGE


Part number: 820123
Clean: 50 H*
Change: 500 H*

FUEL FILTER CARTRIDGE


Part number: 822608
Change: 500 H

*: This periodicity is given for information only (see: 3 - MAINTENANCE: SERVICING SCHEDULE) for cleaning and changing.

HYDRAULIC
HYDRAULIC RETURN OIL FILTER
Part number: 820467
Change: 500 H

SUCTION STRAINER FOR HYDRAULIC OIL TANK


Part number: 820437
Clean: 1000 H

TRANSMISSION
TRANSMISSION OIL FILTER CARTRIDGE
Part number: 822045
Change: 500 H

52
FILTERS CARTRIDGES AND BELTS
CD 20 P
CD 25 P
CD 30 P
CD 35 P

I.C. ENGINE
I.C. ENGINE OIL FILTER
FAN BELT
Part number: 823324
Part number: 822569
Change: 500 H

DRY AIR FILTER CARTRIDGE


Part number: 820124
Clean: 50 H*
Change: 500 H*

FUEL FILTER CARTRIDGE


Part number: 822608
Change: 500 H

*: This periodicity is given for information only (see: 3 - MAINTENANCE: SERVICING SCHEDULE) for cleaning and changing.

HYDRAULIC
HYDRAULIC RETURN OIL FILTER CARTRIDGE
Part number: 820467
Change: 500 H

SUCTION STRAINER FOR HYDRAULIC OIL TANK


Part number: 820437
Clean: 1000 H

TRANSMISSION
TRANSMISSION OIL FILTER CARTRIDGE
Part number: 822270
Change: 500 H

53
LUBRICANTS AND FUEL

USE THE RECOMMENDED LUBRICANTS AND FUEL:


- For topping up, oils may not be miscible.
- For oil changes, MANITOU oils are perfectly appropriate.

DIAGNOSTIC ANALYSIS OF OILS


If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, transmission and axle
oils may be requested depending on the rate of use.

(*) FUEL CHARACTERISTICS


Use a high-quality fuel to obtain optimal performance of the I.C. engine.

CHARACTERISTICS OF RECOMMENDED FUEL:


• DERV to EN590
• BS2869 Class A2
• ASTM D975 - 91 Class 2D
• JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3.

I.C. ENGINE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
5 L. 661706
I.C. ENGINE
MANITOU Oil 20 L. 582357
CD 15 P CD 18 P 7,3 Liters
API CH4 55 L. 582358
CD 20 P CD 25 P CD 30 P CD 35 P 7,5 Liters
209 L. 582359
2 L. 473076
Cooling liquid
5 L. 470077
COOLING CIRCUIT (protection - 30°)
20 L. 470078
CD 15 P CD 18 P Liters
CD 20 P CD 25 P CD 30 P CD 35 P Liters 2 L. 554002
Cooling liquid
5 L. 554003
(protection - 25°)
20 L. 554004
FUEL TANK
CD 15 P CD 18 P 50 Liters
Diesel fuel (*)
CD 20 P CD 25 P 70 Liters
CD 30 P CD 35 P 75 Liters

TRANSMISSION
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
1 L. 62148
TRANSMISSION
MANITOU Oil 20 L. 546332
CD 15 P CD 18 P 6,5 Liters
Automatic transmission 55 L. 546217
CD 20 P CD 25 P CD 30 P CD 35 P 9 Liters
209 L. 546195
2 L. 499237
DIFFERENTIAL MANITOU Oil
20 L. 546330
CD 15 P CD 18 P 3 Liters SAE80W90
55 L. 546221
CD 20 P CD 25 P CD 30 P CD 35 P 6 Liters Mechanical transmission
209 L. 546220

MAST
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
MANITOU Lubricant
MAST LIFTING CHAINS 400 Ml. 554271
Chain special (aerosol)
400 g. 545996
MANITOU Grease
GREASING OF THE MAST 1 Kg. 161590
Multipurpose NLGI 2
50 Kg. 499235

HYDRAULIC
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
HYDRAULIC OIL TANK 5 L. 545500
CD 15 P CD 18 P 50 Liters MANITOU Oil 20 L. 582297
CD 20 P CD 25 P 70 Liters Hydraulic ISO 46 55 L. 546108
CD 30 P CD 35 P 75 Liters 209 L. 546109
54
BRAKE
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
MANITOU fluid 0,5 L. 473013
BRAKE CIRCUIT
DOT 4 brake fluid 1 L. 473014

REAR AXLE
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
400 g. 161589
SWIVEL PINS 1 Kg. 554973
MANITOU Grease
STEERING CONNECTING ROD 5 Kg. 554974
Multipurpose HD NLGI 2
REAR AXLE OSCILLATION 20 Kg. 499233
50 Kg. 489670

55
FILTERS CARTRIDGES AND BELTS
CG 15 P
CG 18 P

I.C. ENGINE
I.C. ENGINE OIL FILTER
FAN BELT
Part number: 823090
Part number: 821188
Change: 500 H

DRY AIR FILTER CARTRIDGE


Part number: 820123
Clean: 50 H*
Change: 500 H*

IN
RIGTS
E
PRESSURE REGULATOR REPAIR KIT
D'OPAR
S
CE INE
PIE NU
GE Part number: 602091
Change: 1000 H

IN
RIGTS
E
CARBURETOR REPAIR KIT
D'OPAR
S
CE INE
PIE NU
GE Part number: 04261F2010
Change: 1000 H

IN
RIGTS
E
FILTER VALVE REPAIR KIT
D'OPAR
S
CE INE
PIE NU
GE Part number: 550525
Change: 1000 H

SAFETY FILTER VALVE


Part number: 561480
Change: 500 H

*: This periodicity is given for information only (see: 3 - MAINTENANCE: SERVICING SCHEDULE) for cleaning and changing.

HYDRAULIC
HYDRAULIC RETURN OIL FILTER
Part number: 820467
Change: 500 H

SUCTION STRAINER FOR HYDRAULIC OIL TANK


Part number: 820437
Clean: 1000 H

TRANSMISSION
TRANSMISSION OIL FILTER CARTRIDGE
Part number: 822045
Change: 500 H

56
FILTERS CARTRIDGES AND BELTS
CG 20 P
CG 25 P
CG 30 P
CG 35 P

I.C. ENGINE
I.C. ENGINE OIL FILTER
FAN BELT
Part number: 823090
Part number: 821188
Change: 500 H

DRY AIR FILTER CARTRIDGE


Part number: 820123
Clean: 50 H*
Change: 500 H*

IN
RIGTS
E
PRESSURE REGULATOR REPAIR KIT
D'OPAR
S
CE INE
PIE NU
GE Part number: 602091
Change: 1000 H

IN
RIGTS
E
CARBURETOR REPAIR KIT
D'OPAR
S
CE INE
PIE NU
GE Part number: 04261F2010
Change: 1000 H

IN
RIGTS
E
FILTER VALVE REPAIR KIT
D'OPAR
S
CE INE
PIE NU
GE Part number: 550525
Change: 1000 H

SAFETY FILTER VALVE


Part number: 561480
Change: 500 H

*: This periodicity is given for information only (see: 3 - MAINTENANCE: SERVICING SCHEDULE) for cleaning and changing.

HYDRAULIC
HYDRAULIC RETURN OIL FILTER
Part number: 820467
Change: 500 H

SUCTION STRAINER FOR HYDRAULIC OIL TANK


Part number: 820437
Clean: 1000 H

TRANSMISSION
TRANSMISSION OIL FILTER CARTRIDGE
Part number: 822045
Change: 500 H

57
LUBRICANTS AND FUEL

USE THE RECOMMENDED LUBRICANTS AND FUEL:


- For topping up, oils may not be miscible.
- For oil changes, MANITOU oils are perfectly appropriate.

DIAGNOSTIC ANALYSIS OF OILS


If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, transmission and axle
oils may be requested depending on the rate of use.

I.C. ENGINE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
5 L. 661706
MANITOU Oil 20 L. 582357
I.C. ENGINE 3,8 Liters
API CH4 55 L. 582358
209 L. 582359
2 L. 473076
Cooling liquid
5 L. 470077
COOLING CIRCUIT (protection - 30°)
20 L. 470078
CG 15 P CG 18 P Liters
CG 20 P CG 25 P CG 30 P CG 35 P Liters 2 L. 554002
Cooling liquid
5 L. 554003
(protection - 25°)
20 L. 554004
GAS CYLINDER 13 Kg
LPG
GAS RESERVOIR (OPTION) 55 Liters

TRANSMISSION
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
1 L. 62148
TRANSMISSION
MANITOU Oil 20 L. 546332
CG 15 P CG 18 P 6,5 Liters
Automatic transmission 55 L. 546217
CG 20 P CG 25 P CG 30 P CG 35 P 9 Liters
209 L. 546195
2 L. 499237
DIFFERENTIAL MANITOU Oil
20 L. 546330
CG 15 P CG 18 P 3 Liters SAE80W90
55 L. 546221
CG 20 P CG 25 P CG 30 P CG 35 P 6 Liters Mechanical transmission
209 L. 546220

MAST
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
MANITOU Lubricant
MAST LIFTING CHAINS 400 Ml. 554271
Chain special (aerosol)
400 g. 545996
MANITOU Grease
GREASING OF THE MAST 1 Kg. 161590
Multipurpose NLGI 2
50 Kg. 499235

HYDRAULIC
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
HYDRAULIC OIL TANK 5 L. 545500
CG 15 P CG 18 P 50 Liters MANITOU Oil 20 L. 582297
CG 20 P CG 25 P 70 Liters Hydraulic ISO 46 55 L. 546108
CG 30 P CG 35 P 75 Liters 209 L. 546109

58
BRAKE
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
MANITOU fluid 0,5 L. 473013
BRAKE CIRCUIT
DOT 4 brake fluid 1 L. 473014

REAR AXLE
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
400 g. 161589
SWIVEL PINS 1 Kg. 554973
MANITOU Grease
STEERING CONNECTING ROD 5 Kg. 554974
Multipurpose HD NLGI 2
REAR AXLE OSCILLATION 20 Kg. 499233
50 Kg. 489670

59
60
GROUP 10

I. C. ENGINE
DISASSEMBLY OF THE I.C. ENGINE

10-3-70 EN

01 / 02 / 2006
IMPORTANT

To identify the I.C. engine on your lift truck, see the LIFT TRUCK CHARACTERISTICS chapter in section O - GENERAL.
TABLE OF CONTENTS

SECTION 1. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


SECTION 2. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 3. LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SECTION 4. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SECTION 5. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
SECTION 6. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
SECTION 7. SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SECTION 8. CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
GENERAL INFORMATION 1

SECTION 1

GENERAL INFORMATION
TABLE OF CONTENTS

CONTENTS PAGE

GENERAL REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


NOTES ON THE FORMAT OF THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
APPEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MAIN DATA AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ANGULAR NUT AND BOLT TIGHTENING METHOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TIGHTENING TORQUE ON MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GASKET LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
RECOMMENDED LUBRICATING OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2 GENERAL INFORMATION

GENERAL REPAIR INSTRUCTIONS


1. Before performing any service operation with the engine mounted, disconnect the grounding cable
from the battery.
This will reduce the chance of cable damage and burning due to short circuiting.
2. Always use the proper tool or tools for the job at hand.
Where specified, use the specially designed tool or tools.
3. Use genuine ISUZU parts referring ISUZU PARTS CATALOG for the engines.
4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you
remove them. Replace them with new ones.
5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation.
It is especially important to keep fastening parts separate. These parts vary in hardness and design,
depending on their installation position.
6. All parts should be carefully cleaned before inspection or reassembly.
Oil ports and other openings should be cleaned with compressed air to make sure that they are com-
pletely free of obstructions.
7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.
8. If necessary, use a sealer on gaskets to prevent leakage.
9. Nut and bolt torque specifications should be carefully followed.
10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine
or disconnecting pipes and hoses.
11. Always check and recheck your work. No service operation is complete until you have done this.
12. Information contained in the “Main Data and Specifications” of the Workshop Manual and the Instruc-
tion Book may differ. In this case, the information contained in the Instruction Book should be
considered applicable.

NOTES ON THE FORMAT OF THIS MANUAL


This Workshop Manual is applicable to the 3LA1, 3LB1, 3LD1 family of industrial diesel engines. Unless
otherwise specified, these engines have common parts and components as well as data and specifica-
tions.
Illustrations used in this Workshop Manual are based on the 3LB1 and 3LD1 engines.
1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.
2. Common technical data such as general maintenance items, service specifications, and tightening
torques are included in the “General Information” section.
3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and
reassembly.
4. When the same servicing operation is applicable to several different units, the manual will direct you
to the appropriate page.
5. For the sake of brevity, self-explanatory removal and installation procedures are omitted.
More complex procedures are covered in detail.
GENERAL INFORMATION 3

6. Each service operation section in this Workshop Manual begins with an exploded view of the applica-
ble area.

(Example)
Major components
Figures in parentheses “( )” show the order of disassembling or reassembling.

Water Outlet Pipe (5)


Packing (6)

Thermostat (7)

Water Pump ASM (8)

Pully; Fan (4)

Fan; Cooling (1)


Spacer (2)

Belt; Fan (3)

Fig. 1

7. Measurement criteria are defined by the terms “standard” and “limit”.


A measurement falling within the “standard” range indicates that the applicable part or parts are ser-
viceable.
“Limit” should be thought of as an absolute value.
A measurement which is outside the “limit” indicates that the applicable part or parts must be either
repaired or replaced.
8. Components and parts are listed in the singular form throughout the Manual.
4 GENERAL INFORMATION

9. The following symbols appear throughout this Worshop Manual. They tell you the type of service
operation or step to perform.

... Remove ... Adjustment

... Installation ... Cleaning

... Disassembly ... Important Operation Requiring Extra Care

... Reassembly ... Specified Torque (Tighten)

Special Tool Use Required for Recommended


... Alignment (Marks) ...
(Isuzu Tool or Tools)

... Directional Indication ... Commercially Available Tool Use Required or


Recommended

... Inspection ... Lubrication (Oil)

... Measurement ... Lubrication (Grease)

... Liquid Gasket Application

10. Direction used in this Manual are as follows:


Front
The cooling fan side of the engine viewed from the flywheel.
Right
The injection pump side of the engine.
Left
The exhaust manifold side of the engine.
Rear
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine.
The front most cylinder is No. 1 and rear most cylinder is No.
The engine’s direction of rotation is counterclockwise viewed from the flywheel.
GENERAL INFORMATION 5

APPEARANCE
1. MODELS 4LC1 AND 4LB1 AND 4LE1

(1) Left side view

Fig. 2

(2) Right side view

Fig. 3
6 GENERAL INFORMATION

2. MODEL 4LB1T (with turbocharger)

(1) Left side view

Fig. 4

(2) Right side view

Fig. 5
GENERAL INFORMATION 7

MAIN DATA AND SPECIFICATIONS


1. MODELS 4LB1 AND 4LB1T

Engine model(s)
4LB1 4LB1T
Item

Type In-line water cooled 4-cycle type, OHV: diesel engine

Timing drive system Gear drive

Number of piston rings Compression rings 2, and oil ring 1


No. of cylinders - bore × stroke mm 4 – 77.4 × 79.7

Displacement cc (cid) 1499 (92)

Compression ratio 22 : 1

Type of combustion chamber Swirl chamber


Overall length × width × height mm * 554 × 436 × 579 554 × 466 × 611

Dry weight kg (lb) * 130 (287) 137 (302)

Fuel injection timing (BTDC) (when at stop) * 16°

Firing order 1–3–4–2

Fuel Highspeed diesel fuel (SAE No.2)

Idling speed r.p.m * 850

Compression pressure kg/cm2 (psi/MPa) 31 (441/3) or more/250 r.p.m.

Valve clearance (cold) Intake 0.4 (0.0157)


mm (in) Exhaust 0.4 (0.0157)

Open (BTDC) 15°


Intake valve
Valve Close (ABDC) 29°
operating
timing Open (BBDC) 40°
Exhaust valve
Close (ATDC) 16°

Injection pump Bosch type

Governor Mechanical type

Nozzle Throttle type

Injection pressure kg/cm2 (psi/MPa) * 135 (1920/13.2)

Oil pump Trochoid type

Oil filter Cartridge type

Lubricant capacity: In total lit (qts) * About 7.3 (7.7)

Generator output (V – A) * 12 – 20

Starter output (V – KW) * 12 – 1.0


(Note) These specifications may be subject to change without notice.
Figures in the column with an asterisk (*) are different for each machine. Refer to the specifica-
tions provided by machine manufacturers.
8 GENERAL INFORMATION

2. MODELS 4LC1 AND 4LE1

Engine model(s)
4LC1 4LE1
Item

Type In-line water cooled 4-cycle type, OHV: diesel engine

Timing drive system Gear drive

Number of piston rings Compression rings 2, and oil ring 1


No. of cylinders - bore × stroke mm 4 – 77.4 × 92 4 – 85 × 92

Displacement cc (cid) 1731 (106) 2179 (133)

Compression ratio 22 : 1 21.5 : 1

Type of combustion chamber Swirl chamber


Overall length × width × height mm * 554 × 436 × 606 691 × 449 × 616

Dry weight kg (lb) * 143 (315) 155 (342)

Fuel injection timing (BTDC) (when at stop) * 16°

Firing order 1–3–4–2

Fuel Highspeed diesel fuel (SAE No.2)

Idling speed r.p.m * 850

Compression pressure kg/cm2 (psi/MPa) 31 (441/3) or more/250 r.p.m.

Valve clearance (cold) Intake 0.4 (0.0157)


mm (in) Exhaust 0.4 (0.0157)

Open (BTDC) 15°


Intake valve
Valve Close (ABDC) 29°
operating
timing Open (BBDC) 40°
Exhaust valve
Close (ATDC) 16°

Injection pump Bosch type

Governor Mechanical type

Nozzle Throttle type

Injection pressure kg/cm2 (psi/MPa) * 135 (1920/13.2)

Oil pump Trochoid type

Oil filter Cartridge type

Lubricant capacity: In total lit (qts) * About 7.3 (7.7) About 8.7 (9.2)

Generator output (V – A) * 12 – 20

Starter output (V – KW) * 12 – 1.0


(Note) These specifications may be subject to change without notice.
Figures in the column with an asterisk (*) are different for each machine. Refer to the specifica-
tions provided by machine manufacturers.
GENERAL INFORMATION 9

TIGHTENING TORQUE SPECIFICATIONS


The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.

STANDARD BOLT kg·m (lb.ft/N·m)


Strength
Class 4.8 (4T) (7T) 8.8 9.8 (9T)
Refined Non-Refined
Bolt
Identification

Bolt No mark
Diameter ×
pitch (mm)

0.4∼0.8 0.5∼1.0
M 6 × 1.0
(2.9∼5.8/3.9∼7.8) (3.6∼7.2/4.9∼9.8)
0.8∼1.8 1.2∼2.3 1.7∼3.1
M 8 × 1.25 (12.3∼22.4/16.7∼30.4)
(5.8∼13.0/7.8∼17.7) (8.7∼16.6/11.8∼22.6)
2.1∼3.5 2.8∼4.7 3.8∼6.4
M10 × 1.25 (27.5∼46.3/37.3∼62.8)
(15.2∼25.3/20.6∼34.3) (20.3∼34.0/27.5∼46.1)
5.0∼7.5 6.2∼9.3 7.7∼11.6
M12 × 1.25 (55.7∼83.9/75.5∼113.8)
(36.2∼54.2/49.0∼73.6) (44.8∼67.3/60.8∼91.2)
7.8∼11.7 9.5∼14.2 11.6∼17.4
M14 × 1.5 (83.9∼125.6/113.8∼170.6)
(56.4∼84.6/78.5∼114.7) (68.7∼102.7/93.2∼139.3)
10.6∼16.0 13.8∼20.8 16.3∼24.5
M16 × 1.5 (118.9∼177.2/159.9∼240.3)
(76.7∼115.7/103.0∼156.9) (99.8∼150.4/135.3∼204.0)
15.4∼23.0 19.9∼29.9 23.4∼35.2
M18 × 1.5 (169.3∼254.6/229.5∼345.2)
(111.1∼166.4/151.0∼225.6) (143.9∼216.3/195.2∼391.3)
21.0∼31.6 27.5∼41.3 32.3∼48.5
M20 × 1.5 (233.6∼350.8/316.8∼475.6)
(151.9∼228.6/205.9∼307.9) (198.9∼298.7/269.7∼405.0)
25.6∼42.2 37.0∼55.5 43.3∼64.9
M22 × 1.5 (313.2∼469.4/424.6∼636.5)
(185.2∼305.2/251.1∼413.8) (267.6∼401.4/362.9∼544.3)
36.6∼55.0 43.9∼72.5 56.5∼84.7
M24 × 2.0 (408.7∼612.6/554.1∼830.6)
(264.7∼397.8/358.9∼539.4) (317.5∼523.9/430.5∼711.0)
2.0∼3.4 2.8∼4.6 3.7∼6.1
*M10 × 1.5 (26.8∼44.1/36.3∼59.8)
(14.5∼24.6/19.6∼32.4) (20.3∼33.3/27.5∼45.1)
4.6∼7.0 5.8∼8.6 7.3∼10.9
*M12 × 1.5 (52.8∼78.8/71.6∼106.9)
(33.3∼50.6/45.1∼68.7) (42.0∼62.2/56.9∼84.3)
7.3∼10.9 9.0∼13.4 10.9∼16.3
*M14 × 2.0 (78.8∼118.9/106.9∼159.9)
(52.8∼78.8/71.6∼106.9) (65.1∼96.9/88.3∼131.4)
10.2∼15.2 13.2∼19.8 15.6∼23.4
*M16 × 2.0 (112.8∼169.3/162.8∼229.5)
(73.8∼110.0/100.0∼149.1) (95.5∼143.2/129.5∼194.2)

An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
10 GENERAL INFORMATION

TIGHTENING TORQUE SPECIFICATIONS


The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.

FLANGED HEAD BOLT kg·m (lb.ft/N·m)


Bolt head
marking
Nominal
size
(dia. x pitch)
0.5∼0.9 0.6∼1.2
M6 ×1
(3.61∼6.50/4.6∼8.5) (4.33∼8.67/5.88∼11.76)

1.1∼2.0 1.4∼2.9 1.9∼3.4


M 8 × 1.25
(7.95∼14.46/10.78∼19.61) (4.33∼8.67/5.88∼11.76) (13.74∼24.59/18.63∼33.34)

2.3∼3.9 3.6∼6.4 4.3∼7.2


M10 × 1.25
(17.35∼28.20/23.53∼38.24) (26.03∼44.12/35.30∼59.82) (31.10∼52.07/42.16∼70.60)

2.3∼3.8 3.5∼5.8 4.1∼6.8


*M10 × 1.5
(16.63∼27.48/22.55∼37.26) (25.31∼41.95/34.32∼56.87) (29.65∼49.18/40.20∼66.68)

5.6∼8.4 7.9∼11.9 8.7∼13.0


M12 × 1.25
(40.50∼60.75/54.91∼82.37) (57.14∼86.07/77.47∼116.69) (62.92∼94.02/85.31∼127.48)

3.5∼9.5 7.3∼10.9 8.1∼12.2


*M12 × 1.75
(37.61∼56.41/50.99∼76.49) (52.80∼78.83/71.58∼106.89) (58.58∼88.24/79.43∼119.64)

8.5∼12.7 11.7∼17.6 12.6∼18.9


M14 × 1.5
(61.48∼91.85/83.35∼124.54) (84.62∼127.30/114.73∼172.59) (91.13∼136.70/123.56∼185.34)

7.6∼11.5 11.1∼16.6 11.8∼17.7


*M14 × 2
(57.14∼85.34/77.47∼115.71) (80.28∼120.06/108.85∼162.79) (85.34∼128.02/115.71∼173.57)

11.8∼17.7 17.1∼26.5 18.0∼27.1


M16 × 1.5
(85.34∼128.02/115.71∼173.57) (125.85∼189.50/170.63∼256.93) (130.19∼196.01/176.52∼265.76)

11.2∼16.7 16.6∼24.9 17.2∼25.7


*M16 × 2
(81.00∼120.79/109.83∼163.77) (120.06∼180.10/162.79∼244.18) (124.40∼186.61/168.67∼253.01)

A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
GENERAL INFORMATION 11

ANGULAR NUT AND BOLT TIGHTENING METHOD

1. Carefully wash the nuts and bolts to remove all oil


and grease.

2. Apply a coat of molybdenum disulfide grease to the


threads and setting faces of the nuts and bolts.

Fig. 6
3. Tighten the nuts and bolts to the specified torque
(snug torque) with a torque wrench.

Snug torque

Fig. 7
4. Draw a line [A-B] across the center of each bolt.
Center line

Fig. 8
12 GENERAL INFORMATION

5. Draw another line [C-D] on the face of each of the


Line
parts to be clamped. This line should be an exten-
sion of the line [A-B].

A B C D

Fig. 9
6. Draw another line [F-G] on the face of each of the
parts to be clamped. This line will be in the direc-
tion of the specified angle [Q] across the center [E]
E of the nut or bolt.

Specified angle (Q)

Coinciding line G

Fig. 10
7. Use a socket wrench to tighten each nut or bolt to
Tighten the point where the line [A-B] is aligned with the line
[F-G].
A

C D

B
F

Fig. 11
Example: Specified Angle and Tightening Rotation

A 30° 1/12 of a turn


B C D E
A
B 60° 1/6 of a turn
C 90° 1/4 of a turn
D 180° 1/2 of a turn
E 360° One full turn

Fig. 12
GENERAL INFORMATION 13

TIGHTENING TORQUE ON MAJOR COMPONENTS


1. COOLING FAN AND WATER PUMP
kg·m (ft. lbs.)

1.9 - 2.9
(13.7 - 21.0)

1.2 - 1.8
(8.7 - 13.0)

1.2 - 1.8
(8.7 - 13.0)

1.9 - 2.9
(13.7 - 21.0)
To cylinder head

1.9 - 2.9
(13.7 - 21.0)
To cylinder block

1.9 - 2.9
(13.7 - 21.0)

1.9 - 2.9
(13.7 - 21.0)

3.5 - 4.7
(25.3 - 34.0)

Fig. 13
14 GENERAL INFORMATION

2. CYLINDER HEAD AND CYLINDER HEAD COVER


kg·m (ft. lbs.)

0.8 - 1.2
0.8 - 1.2 (5.8 - 8.7)
(5.8 - 8.7) (With turbocharger)
0.8 - 1.2
(5.8 - 8.7)
(Without turbocharger)
0.8 - 1.2
0.2 - 0.4
(5.8 - 8.7)
(1.4 - 2.9)

(Apply salant.)

8.5 - 9.5
(61.5 - 68.7)

60° - 90°
1.5 - 2.0 (Apply engine oil.)
(10.8 - 14.5)
1.9 - 2.9
(13.7 - 21.0)

0.09 - 0.11
(0.6 - 0.8)
(Apply locktite No. 262 to this part.)

2.5 - 3.5
(18.0 - 25.3)
(Apply engine oil.) 1.9 - 2.9
(13.7 - 21.0)

Fig. 14
GENERAL INFORMATION 15

3. CYLINDER BLOCK AND OTHER COMPONENTS (1)


kg·m (ft. lbs.)

4.2 - 5.6
(30.4 - 40.5)

9.5 - 11.5
(68.7 - 83.2)

( Don't remove this bolt


from connecting rod. )

3.8 - 4.2
4LB1
(27.5 - 30.4)
2.3 - 2.7
4LC1 (16.6 - 19.5)
110 - 115 deg.
7.5 - 8.5
4LE1
(54.2 - 61.5)
(Apply engine oil)

9.0 - 11.0
(65.0 - 79.5)
8.5 - 9.5
(61.5 - 68.7)
17.0 - 19.0 (Apply engine oil.)
(123.0 - 137.4)

0.8 - 1.2
(*): Apply Locktite No.262 to set up side of stud. (5.8 - 8.7)
(Impotant)

Fig. 15
16 GENERAL INFORMATION

4. CYLINDER BLOCK AND OTHER COMPONENTS (2)


kg·m (ft. lbs.)

2.5 - 3.5 2.0 - 2.5


(18.0 - 25.3) (14.5 - 18.0)

1.5 - 2.5
(10.8 - 18.0)

0.8 - 1.2
(5.8 - 8.7)
1.9 - 2.9 4.0 - 5.0
(13.7 - 21.0) (29.0 - 36.2)

0.8 - 1.2
(5.8 - 8.7)

1.9 - 2.9
(13.7 - 21.0)

( Positioning
pin. )

0.8 - 1.2
7.0 - 9.0 (5.8 - 8.4)
(50.6 - 65.0)

1.9 - 2.9
(13.7 - 21.0)
2.1 - 3.1
(15.2 - 22.4)
(Apply engine oil)

1.9 - 2.9
(13.7 - 21.0)

Fig. 16
GENERAL INFORMATION 17

5. CYLINDER BLOCK AND OTHER COMPONENTS (3)


kg·m (ft. lbs.)

( Apply Locktite
No.262 (2 locations) )

0.8 - 1.2
(5.8 - 8.7)

1.2 - 1.6
(8.7 - 11.6)

( )
Rocate 3/4 turn after
0.8 - 1.2 contacted with
(5.8 - 8.7) sealing surface.
1.5 - 2.5
(10.8 - 18.0)

(With PTO provided)

0.8 - 1.2 0.8 - 1.2


(5.8 - 8.7) (5.8 - 8.7)
1.9 - 2.9
(13.7 - 21.0)

4.2 - 5.6
(30.3 - 40.5)
0.8 - 1.2
(5.8 - 8.7)

1.9 - 2.9
(13.7 - 21.0)

Fig. 17
18 GENERAL INFORMATION

6. TURBOCHARGER
kg·m (ft. lbs.)

2.2 - 3.2
(15.9 - 23.1)

2.2 - 3.2
(15.9 - 23.1)

1.9 - 2.9
(13.7 - 21.0)

1.0 - 1.5
(7.2 - 10.8)

1.0 - 1.5
(7.2 - 10.8)

0.8 - 1.2
(5.9 - 8.7)

Fig. 18
GENERAL INFORMATION 19

GASKET LOCATION
1. LOCATIONS WHERE GASKETS ARE USED

Gasket; joint bolt


Gasket; nozzle holder

Gasket;
nozzle holder
Gasket; headcover
(※)Sealant should not be
Corrugated applied.
washer

Gasket; heat shield

Seal; valve

Gasket; Gasket;
water outlet pipe cylinder head

Gasket;
idle spring set screw

O-ring; Gasket;
fuel cut lever governor
cover
Oil seal;
crankshaft
O-ring; rear
control lever Gasket;
exhaust
manifold

Gasket;
rear cover
(PTO)

O-ring;
Oil strainer
O-ring; O-ring;
angleich cover Oil pump

Oil seal; Gasket;


crankshaft front exhaust silencer
O-ring;
Oil drain plug

Fig. 19
20 GENERAL INFORMATION

2. LOCATIONS WHERE SEALANT IS APPLIED

Location Condition for use


Name of
Name of Object to be Groove to be sealant
Name of part mating part sealed applied

Engine oil
1 Oil pan Cylinder block Not provided TB1207C
(10W-30)

Engine oil
2 Rocker bracket Cylinder head Provided TB1207C
(10W-30)

3 Air inlet pipe Cylinder head cover Air Provided TB1207C

Front plate Engine oil


4 Cylinder block Provided TB1207C
(with PTO provided) (10W-30)

Timing case (with Engine oil


5 Front plate Provided TB1207C
PTO provided) (10W-30)

Timing case (with Engine oil


6 Cylinder block Provided TB1207C
no PTO provided) (10W-30)

7 Water pump ASM Cylinder block Cooling water Not provided TB1207C

Rear cover;
8 Body; water pump Cooling water Provided TB1207B
water pump

Housing cover; Engine oil


9 Cylinder block Provided TB1207C
injection pump (10W-30)
Engine oil
10 Solenoid; fuel cut Cylinder block Provided TB1207C
(10W-30)

Engine oil
11 Retainer; oil seal Cylinder block Provided TB1207C
(10W-30)

12 Indicator; air cleaner Air cleaner Air Not provided (Sealing tape)

Fig. 20
GENERAL INFORMATION 21

MAINTENANCE
1. VALVE CLEARANCE AND ADJUSTMENT

Note:
The cylinder head bolts were previously tightened with
the “Angular Tightening Method”. Therefore, it is not
necessary to retighten the cylinder head bolts before
adjusting the valve clearance.

Fig. 21
1. Bring the piston in either the No. 1 cylinder or the
No. 3 cylinder to Top Dead Center on the compres-
Groove mark sion stroke by turning the crankshaft until the TDC
TDC mark mark on the front cover aligns with the groove mark
on the crankshaft pulley.
2. Check to see if there is play in the No. 1 intake and
exhaust valve rocker arms.
If the No. 1 cylinder intake and exhaust valve rocker
(Timing
case cover )
gear
Crank arms have play, the No. 1 piston is at TDC on the
pulley compression stroke.
Fig. 22 If the No. 1 cylinder intake and exhaust valve rocker
arms are depressed, the No. 4 piston is at TDC on
the compression stroke.
Adjust the circle or double circle marked valves as
shown in Fig. 24, while the No. 1 or the No.4 cylin-
der is at TDC on compression stroke.
mm (in.)
Intake and Exhaust
No.1 cylinder
0.40 ± 0.05 (0.015 ± 0.002)
Valve Clearance (cold)
No.1 cylinder exhaust
intake
Fig. 23 3. Loosen each valve clearance adjusting screw as
shown in the illustration.
Cylinder No. 1 2 3 4
4. Insert a 0.40 mm (0.015 in) feeler gauge between the
Valve
arrangement
I E I E I E I E rocker arm and the valve stem end.
No. 1 cylinder 5. Turn the valve clearance adjusting screw until a
TDC for com- ○ ○ ○ ○ slight drag can be belt on the feeler gauge.
pression
No. 4 cylinder 6. Tighten the lock nut securely.
TDC for com- ◎ ◎ ◎ ◎ 7. Rotate the crankshaft 360°.
pression
I ; Intake E ; Exhaust
Realign the crankshaft pulley.
8. Adjust the clearances for the remaining valves as
Fig. 24 shown in the illustration.
22 GENERAL INFORMATION

2. LUBRICATIN SYSTEM
Cartridge (Spin-On) Type
Cartridge
Removal
Remover and Installer: Filter Wrench
1. Loosen the used oil filter by turning it counterclock-
wise with the filter wrench.
2. Discard the used oil filter.

Installation
1. Wipe the oil filter mounting face with a clean rag.
Fig. 25
This will allow the new oil filter to seat properly.
2. Lightly oil the O-ring.
3. Turn in the new oil filter until the sealing face is fit-
ted against the O-ring.
4. Use the filter wrench to turn in the oil filter an addi-
tional 3/4 of a turn or one turn.
5. Check the engine oil level and replenish to the speci-
fied level if required.
6. Start the engine and check for oil leakage from the
oil filter.

3. COOLING SYSTEM
Cooling Fan Drive Belt

Fan pulley 1 Adjustment


Depress here 1. Check the cooling fan drive belt for cracking and
Cooling About 10 mm other damage.
fan drive 2. Check the drive belt tension by exerting a force of 10
belt
Generator pulley kg (22 lb) midway between the Fan pulley 1 and the
2 Generator pulley 2.
3. Adjust the belt tension by loosening the Generator
mounting bolt and the Generator adjusting bolt and
Crank pulley
pivoting the Generator.
Fig. 26 Be sure to retighten the bolts after adjusting the belt
tension.
mm (in.)
Cooling Fan Drive 8.0 – 12.0
Belt Deflection (0.3 – 0.5)
GENERAL INFORMATION 23

4. INJECTION TIMING
Note:
Take care to avoid entry of dust or foreign particles into
the pump interior when the timing adjustment is made.

1. Remove the injection pipe of the No. 1 cylinder.


Delivery valve Injection pump
holder 2. Remove the delivery valve holder of the injection
pump of the No. 1 cylinder, and then pull out the
Delivery
delivery spring.
spring 3. With the spring left removed, install the delivery
valve holder.
4. Slowly turn the crankshaft pulley clockwise, at the
same time, continue to feed the fuel.
When the fuel stop flowing out from the No. 1 deliv-
Fig. 27
ery valve holder, stop turning the crankshaft.
This crank angle position is the starting point of
injection.
5. In the condition at Step (4) above, confirm what
degree the “groove mark” of the crank pulley is at,
Groove mark when seen by the “timing mark”, provided in the
TDC mark timing gear case.
When the value is out of the range of the normal
injection timing, adjust it accordingly.

* Injection timing 4LB1, 4LC1, 4LE1 BTDC 16°


( Timing gear
case cover ) Crank
pulley Note:
Fig. 28 The injection timing varies according to the specifica-
tions of the machine.

6. Adjust the injection timing with a shim between the


Injection pump
injection pump and the cylinder block.
Cylinder block Shim is available in the following 9 types, and “iden-
Shim tification mark” is stamped (or imprinted) on the top
Identification
mark face.
Identification mark of shim and its thickness (mm)
Knock hole Mark Thickness Mark Thickness Mark Thickness
2 0.2 5 0.5 8 0.8

Fig. 29
3 0.3 6 0.6 10 1.0
4 0.4 7 0.7 12 1.2

Note:
For each of the injection pumps of three cylinders, the
shim adjustment is made at the same time.
When a shim is missing while overhauling the engine
and the shim thickness is unknown, assemble the
engine with provisional shim inserted. After assembling
the engine, check the injection timing and adjust the
shim until the normal injection timing is obtained.
Reference:
To add the 0.1 mm shim thickness corresponds to the 1
degree of crankshaft angle advance.
24 GENERAL INFORMATION

Air bleeding from fuel (automatic air-bleeding system)


1. For the automatic air-bleeding system
When the starter switch is set to “OPERATION”, the
electromagnetic pump is activated to force-feed fuel
to the fuel pipe and the leak-off pipe, and air in the
fuel system is automatically bled.
2. For non-automatic air-bleeding system
While sending fuel by means of the force of the elec-
Injection pump
tromagnetic pump, the fall from the fuel tank or the
Fig. 30 feed pump lever, bleed air out of the fuel pipe eye
bolt of the No. 1 cylinder injection pump, the leak-off
pipe eye bolt of the injection nozzle and the air-
bleeder plug of the fuel filter, starting with the one
installed the lower most and upward.

5. COMPRESSION PRESSURE MEASUREMENT


1. Operate the engine to warm-up until the coolant
Compression gauge temperature reachs to 75°C (167°F).
2. Remove all of the glow plugs and the injection
pipes.
Adapter; gauge 3. Attach a compression gauge to the No. 1 cylinder
glow plug installation threads.
Note:
Compression pressure may be measured starting at any
cylinder and in no particular cylinder order. However, it
is very important that the compression pressure be
measured in each cylinder.
Therefore, start at the No. 1 cylinder and work back. In
this way, you will be sure to measure the compression
pressure in each cylinder.
Fig. 31
Compression Gauge 5-8840-2675-0

Compression Gauge Adapter 5-8840-9026-0

4. Crank the engine with the starter motor and take the
compression gauge reading.
kg/cm2 (psi) at 250 rpm
Standard Limit
31.0 (441) 26.0 (370)

5. Repeat the procedure (.Steps 3 and 4.) for the


remaining cylinders.
Compression pressure should be approximately the
Fig. 32 same for each cylinder. A variation exceeding 2.0
kg/cm2 (.28 psi.) is unacceptable.
If the measured value exceeds the specified limit,
the related parts must be checked.
GENERAL INFORMATION 25

6. FUEL SYSTEM
Fuel Filter Replacement

Cartridge (Spin-On) Type


Removal
1. Loosen the fuel filter by turning it counterclockwise
with the filter wrench or your hand. Discard the
used filter.
Filter Wrench
2. Wipe the fuel filter fitting face clean with a rag.
This will allow the new fuel filter to seat properly.
Fig. 33 Installation
1. Apply a light coat of engine oil to the O-ring.
2. Supply fuel to the new filter.
This will facilitate air bleeding.
3. Turn in the new fuel filter until the filter O-ring is fit-
ted against the sealing face.
4. Use the filter wrench to turn in the fuel filter an addi-
tional 2/3 of a turn.

Injection nozzle
good no good no good no good
Check to see if the spray condition and the injection
pressure are normal. Adjust them to the specified value
respectively when they don’t meet the standard valve.
kg/cm2 (psi)
4LB1
Injection pressure 4LC1 135
(1920)
About 4 4LE1

Fig. 34
Using a nozzle tester, adjust the injection pressure with a
shim.
Special tool: Nozzle tester

Fig. 35
26 GENERAL INFORMATION

RECOMMENDED LUBRICATING OIL

TYPE OF LUBRICANTS (API) DIESEL ENGINE OIL; CC OR CD GRADE

ENGINE OIL VISCOSITY CHART

ENGINE OIL VISCOSITY GRADE – AMBIENT TEMPERATURE

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 5W–20
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

[Single grade] ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;


;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 20, 20W
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 40
;;;;;;;;;;;;;;;;;;;;;;;;;;

;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

Ambient –25°C –20°C –15°C –0°C 15°C 25°C 30°C


temperature (–13°F) (–4°F) (5°F) (32°F) (59°F) (77°F) (86°F)
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W–30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
[Multi grade]
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 15W–40, 20W–40
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

Fig. 36
ENGINE 27

SECTION 2

ENGINE
TABLE OF CONTENTS

CONTENTS PAGE

DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
28 ENGINE

DISASSEMBLY
1. EXTERNAL PARTS (Left-hand side)

(8) (7)
(1)

(6)
(3)

(9)
(5)

(4)

(2)

Fig. 37

(1) Cooling fan and spacer


(2) Fan belt
(3) Fan pulley
(4) Generator
(5) Starter
(6) Exhaust manifold and gasket
(7) Cylinder head cover and air intake pipe
(8) Water outlet pipe and thermostat
(9) Water pump assembly
ENGINE 29

2. EXTERNAL PARTS (Right-hand side)

(10) (12) (13)

(14) (11)

(16)

(17)
(15)

(18)

Fig. 38

(10) Injection pipe . . . . . . . . . 4 pcs.


(11) Fuel hose
(12) Fuel leak off pipe
(13) Fuel pipe
(14) Engine stop solenoid
(15) Injection pump housing cover
(16) Injection pump and shim . . . . . . . . . 4 set
(17) Oil filter
(18) Oil level gauge
30 ENGINE

Injection pipe
Injection pipe
Leak off pipe Leak off pipe
Eye bolt Fuel pipe
1. Loosen the sleeve nuts on the nozzle holder side and
on the injection pump side, and then disconnect the
Fuel pipe injection pipes.
Nozzle holder 2. Disconnect the leak off pipe together with gaskets.
Injection pump 3. Remove the eye bolt, and then disconnect the fuel
pipe.
Fig. 39

Fuel cut cover


Injection pump

Pin(6 φ)
1. Align the hole of the fuel cut lever with the hole of
the governor cover, and then insert a pin (6ø) into
this hole to hold the fuel cut lever.
2. Check to see if the pin groove of the control link is at
the center of the injection pump.
3. Remove the injection pump, and then take out the
shim.
Governor cover
Fig. 40
NOTE:
Injection pump
center position
1. Mark each injection pump as to which cylinder it
Control link
was removed from.
2. Do not reuse the shim, replace it with the same
thickness that was removed.

Injection pump
rack pin

Fig. 41

Injection pump ASM

Shim

* Stud
Cylinder block

Fig. 42
ENGINE 31

Backlash of timing gear


mm (in.)
STANDARD LIMIT
CRANK GEAR/ 0.04 0.2
IDLER GEAR (0.0017) (0.0079)
CAM GEAR/ 0.03 0.2
IDLER GEAR (0.0012) (0.0079)

IDLER GEAR END PLAY


mm (in.)
STANDARD LIMIT
0.058 – 0.115 (0.0023 – 0.0045) 0.2 (0.0079)

CRANKSHAFT END PLAY


mm (in.)
STANDARD LIMIT
0.058 – 0.208 (0.0023 – 0.0082) 0.3 (0.0118)

Return pipe
Fuel pipe
Feed pipe
Remove the return pipe and the feed pipe.
Return pipe

Turbocharger

Fig. 43
Exhaust pipe
Turbocharger
Inlet pipe
Turbocharger
Remove the exhaust pipe, the inlet pipe and turbo-
charger.

Inlet pipe

Exhaust pipe

Fig. 44
32 ENGINE

3. INTERNAL PARTS

Disassembly Steps
(1) Rocker Bracket Assembly
(2) Push Rods
(3) Rear Hanger
(4) Front Hanger
(5) Cylinder Head Assembly
(6) Cylinder Head Gasket
(7) Tappets
(8) Oil Pan
(9) Oil Strainer
(10) Oil Pipe
(11) Crank Pulley
(12) Flywheel
(13) Flywheel Housing
(14) Timing Gear Case (without PTO)
(15) Oil Pump Assembly
(16) Idler Gear and Shaft
(17) Cam Gear
(18) Camshaft
(19) Rear Seal Retainer
(20) Piston Assemblies
(21) Crankshaft
ENGINE 33

Internal Parts (1/3)

(14)

(1)

(3)

(2)

(5)
(18)

(17)

(7)
(4) (16)
(15)

(6)

Fig. 45
34 ENGINE

Internal Parts (2/3)

(20) (13)
Do not pull out
this bolt.


(9)
(12)

(21)

(10)

Rear

(19)

(11)

(8)

Fig. 46
ENGINE 35

Internal Parts (3/3)

When provided with PTO

(14-2)

(14-1)

(15)

Fig. 47
36 ENGINE

Rocker bracket
Install of
bolts (6) Push rod
1. Remove the rocker bracket assembly.
Install of
(M6 × 1 . . . . . 5 bolts and 6 nuts)
bolts (5)
2. Pull out the push rods (8 pcs.).

Rocker Bracket

Fig. 48
Cylinder head assembly
Rear
hanger 1. Remove the rear and front hangers.
Head bolt
Cylinder head (M12)
2. When removing the cylinder head bolts, loosen
ASM them slowly, a little at a time, starting with the
outside, working in a circular pattern inward.
3. Remove the cylinder head assembly and the head
(M8)
Head gasket gasket.
4. Pull out the tappet from the cylinder body.
Front hanger

Fig. 49

5 4 3 2 1

8 7
12 15 11

9 13 14 10 6

Fig. 50
ENGINE 37

Cylinder Head Assembly

Glow plug (2)


Split collar (4)
Connector (1) Seal; valve

Spring seat (5)


Guide; valve
Valve spring (6)

Studs are applied with


sealing agent.
Do not pull them out.
(5 locations)
Nozzle holder (3)

Valve (7)

Hot plug

Seat; valve insert

Fig. 51

Valve mechanism
1. Before disassembling the valve mechanism, remove
the connector, glow plug and nozzle holder as-
sembly.
2. Compressing the valve spring, remove the split col-
lar, spring seat, valve spring and valve.
38 ENGINE

Timing Gear

Bearing

Wear ring

Cam shaft (8)

Pin

Bearing

Snap ring (7)

Cam gear (6)

Fly weight ASM (5)

Shaft; idle gear (3)

Lock nut
Idle gear (2)
Sleeve (4)

Thrust collar

Crankshaft

Key

Crank gear

Crank pulley (1)

Washer

Fig. 52
ENGINE 39

Timing gear
1. Remove the idle gear and the idle gear shaft.
2. Pull out the sleeve from the tip end of the cam shaft.
3. Remove the lock nut of the cam shaft gear, and then
remove the flyweight assembly and the cam gear.

Camshaft
Crankshaft 1. Remove the snap ring which holds down the front
bearing of the cam shaft from the ring groove of the
cylinder block.
Snap ring
2. Pull out the cam shaft from the cylinder block,
together with the bearing.

Fig. 53
40 ENGINE

Piston and Connecting Rod

Piston ring (4)


Snap ring (5)

Piston

Bush
(The drawing-out of the bush must
Piston pin (6) be limited to only when replaced.)

Con'rod bolt
(The drawing-out of the con'rod bolt
must be limited to only when replaced.)

Connecting rod (7)

Cap (2)
Bearing (3)

Cap nut (1)

Fig. 54

Piston and connecting rod


Piston
1. Turning the crankshaft, position the piston to be
removed at the bottom dead center.
2. Loosen the cap nut of the connecting rod, and then
remove it.
3. Give another rotation to the crankshaft to position
Connecting rod the piston at the top dead center.
cap
4. With the handle of a hammer placed at the bottom
of the connecting rod, push the piston assembly
Fig. 55
upward out of the cylinder block.
Notes:
1. Before removing the piston, scrape the carbon
deposit off the cylinder wall.
2. When pushing out the piston assembly, care should
be taken not to damage the cylinder wall.
3. Attach a tag with a cylinder number to the removed
caps and bearings to keep them in order.
ENGINE 41

Piston ring
Remove the piston ring with a ring pliers.
Pliers: piston ring 1-85221-029-0

Fig. 56
Piston pin
Brass bar
1. Remove the snap rings with a commercially avail-
able tool.
2. With a brass bar attached to the piston pin, push it
out by hammering it lightly.
Note:
Keep the pistons, piston pins and connecting rods in
Piston pin order for each cylinder.

Fig. 57
42 ENGINE

INSPECTION AND REPAIR


Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis-
covered during inspection.

1. CYLINDER BLOCK
Cylinder block
Check the cylinder block for wear, damage or any other
defects.
Use the hydraulic gauge to check the water jacket water
pressure.
Apply water pressure to the water jacket at 5 kg/cm2
(71.1 psi) for three minutes.

Fig. 58

Cylinder bore
Y Measurement position: 13mm below the top
X X (Measure in X-X and
Y-Y directions.)
(Near the No. 1
compression ring)
mm (in.)
Engine Limit Repair method

4LB1 Perform boring and


Fig. 59 4LC1 0.2 (0.0079) honing of the inner
4LE1 diameter.

Cylinder bore diameter and grade mark


Bore grade mark
(Stamp position) The grade mark is stamped on the top surface of the
cylinder block (on the mating face with the cylinder
head).

Fig. 60
ENGINE 43

mm (in.)
Engine Bore Diameter Grade
77.400 – 77.410
A
(3.0472 – 3.0476)
4LB1 77.411 – 77.420
B
4LC1 (3.0476 – 3.0480)
77.421 – 77.430
C
(3.0480 – 3.0484)
85.000 – 85.010
A
(3.3464 – 3.3468)
85.011 – 85.020
4LE1 B
(3.3468 – 3.3472)
85.021 – 85.030
C
(3.3472 – 3.3476)

Cylinder Body Upper Face Warpage


1
Use a straight edge 1 and a feeler gauge 2 to measure
the four sides and the two diagonals of the cylinder
body upper face.
Regrind the cylinder body upper face if the measured
values are greater than the specified limit but less than
the maximum grinding allowance.

Fig. 61
If the measured values exceed the maximum grinding
allowance, the cylinder body must be replaced.

Cylinder Body Upper Face Warpage mm (in.)


A
Maximum Grinding
Standard Limit
E F Allowance
C D
0.075 (0.0029) 0.15 (0.0059) 0.3 (0.0118)
B
If the measured value is less than the limit, the cylinder
body may be reground.
Fig. 62
Cylinder Body Height H (Reference) mm (in.)
Engine Standard
280.94 – 281.06
4LB1
H (11.060 – 11.065)
4LC1 307.94 – 308.06
4LE1 (12.123 – 12.128)

Fig. 63
44 ENGINE

2. CYLINDER HEAD
Cylinder head inspection
Remove carbon deposit on the bottom surface of the
head with care not to damage the valve seat.
Leakage: Water pressure test 5kg/cm2 (for 3 minutes)

Fig. 64
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure
the four sides and the two diagonals of the cylinder
head lower face.
2. Regrind the cylinder head lower face if the mea-
sured values are greater than the specified limit but
less than the maximum grinding allowance.

Fig. 65
If the measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.

Cylinder Head Lower Face Warpage mm (in.)


A
Maximum Grinding
Standard Limit
E F Allwance
C D
0.075 (0.0029) 0.15 (0.0059) 0.3 (0.0118)
B

Fig. 66
Cylinder Head Height H (Reference) mm (in.)
Engine Standard
4LB1
63.90 – 64.10
4LC1
(2.515 – 2.523)
4LE1
H
Note:
If the cylinder head lower face is reground, valve
depression must be checked.
Fig. 67
ENGINE 45

HOT PLUG
Hot Plug Depression
1. Clean the cylinder head lower face, taking care not
to damage the hot plug surfaces.
2. Use a straight edge and a feeler gauge to measure
the hot plug depression in a straight line from the
No. 1 hot plug to the No. 3 hot plug.
If the measured value exceeds the specified limit,
the hot plugs must be replaced.
Fig. 68
Hot Plug Depression mm (in.)
Limit
0.05 (0.002)

Combustion Chamber Inspection


1. Remove the carbon adhering to the inside of the
combustion chamber. Take care not to damage the
hot plug fitting positions.
2. Inspect the combustion chamber, the hot plug hole,
and the hot plug machined faces for cracking and
other damage.
If cracking or damage is present, the cylinder head
must be replaced.

Fig. 69
Note:
Be absolutely certain that there are no scratches or
protuberances on the combustion chamber surfaces
which will be in contact with the hot plug after it is in-
stalled. These flaws will prevent the hot plug from
seating correctly.

Hot Plug Replacement

Hot Plug Removal


1. Insert a 3.0 – 5.0 mm (0.12 – 0.20 in) diameter brass
bar into the nozzle holder fitting hole until it makes
contact with the hot plug.
2. Lightly tap the bar with a hammer to drive the hot
plug free.

Fig. 70
Hot Plug Inspection
Inspect the hot plugs for excessive wear and other dam-
age. Replace the hot plugs if either of these conditions
are discovered.
Refer to “Hot Plug Installation”.
46 ENGINE

2
Hot Plug Installation
1. Align the hot plug knock ball 1 with the cylinder
head groove 2 and tap it temporarily into position
with a plastic hammer.
1

Fig. 71
2. Place a metal plate 3 approximately 25 mm (1 in)
thick over the hot plug upper surface 4.
5
3. Use a bench press 5 to exert a pressure of 4,000 –
5,000 kg (8,819 – 11,023 lb/39,227 – 49,033 N) on the
3 metal plate covering the hot plug upper surface.
4
This will drive the hot plug into position.
4. Lightly tap the hot plug head to make sure that it is
firmly seated.
5. Repeat the procedure (Steps 1 – 4) for the remaining
hot plugs.
Fig. 72
Note:
Do not apply pressure greater than that specified.
Damage to the cylinder head will result.
6. Use a surface grinder to grind off any hot plug sur-
face protuberances.
The hot plug surfaces must be perfectly flush with
the cylinder head lower face.

7. After grinding, make sure that the hot plug surfaces


are completely free of protuberances.
The hot plug surfaces must also be free of depres-
sions.
Once again, lightly tap the hot plug heads to make
sure that they are firmly seated.

Fig. 73
Heat Shield Replacement
1 2
Heat Shield Removal
After removing the hot plugs, use a hammer 1 and a
brass bar 2 to lightly tap the lower side of the heat
shield 3 and drive it free.

Fig. 74
ENGINE 47

Heat Shield Installation


Install the heat shield to the cylinder head from the noz-
zle holder installation hole side. Lightly tap the heat
shield flange into place with a hammer and a brass bar.
The heat shield flange side must be facing up.
Note:
Always install a new heat shield. Never reuse the old
heat shield.

Fig. 75

3. VALVE, VALVE SEAT INSERT AND VALVE SEAL


Inspection of valve seat
Cylinder head
Valve 1. A – Contact width
2. B – Valve depression
mm (in.)
A

Standard Limit
Contact width 2.0 (0.0787) 2.5 (0.0984)
B
Valve depression 0.7 (0.0276) 1.2 (0.0427)
45°

Fig. 76
Valve thickness

Nominal Limit Repair method


1.0 0.7
Replace
(0.03937) (0.0276)

Fig. 77
Valve Stem Outside Diameter
Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the
valve must be replaced.

Valve Stem Outside Diameter mm (in.)


Standard Limit
7.0 6.85
Intake Valve
(0.2756) (0.2697)
7.0 6.80
Fig. 78 Exhaust Valve
(0.2756) (0.2677)
48 ENGINE

Valve Seat Insert Replacement


2 3
Valve Seat Insert Removal
1. Arc weld the entire inside circumference 1 of the
valve seat insert 2.
4
2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the
valve seat insert easier.
1 3. Use a screwdriver 3 to pry the valve seat insert
free.
Fig. 79
Take care not to damage the cylinder head 4.
4. Carefully remove carbon and other foreign material
from the cylinder head insert bore.

Valve Seat Insert Installation


3 1. Carefully place the attachment 1 (having a smaller
outside diameter than the valve seat insert) on the
1 valve seat insert 2.
Note:
2
The smooth side of the attachment must contact the
valve seat insert.
2. Use a bench press 3 to gradually apply pressure to
the attachment and press the valve seat insert into
Fig. 80
place. 4,000 kg (8,819 lbs.)
Note:
Do not apply an excessive amount of pressure with the
bench press. Damage to the valve seat insert will
result.

150°
Valve Seat Insert Correction
90° 1. Remove the carbon from the valve seat insert sur-
30° face.
2. Use a valve cutter (15°, 45°, and 75° blades) to mini-
mize scratches and other rough areas. This will
bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do not
.0 m
.)
(0 .0 m
in

cut away too much. Take care not to cut away


8
2

unblemished areas of the valve seat surface.

Fig. 81
Valve Seat Angle degree
45

Note:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.

Fig. 82
ENGINE 49

3. Apply abrasive compound to the valve seat insert


surface.
4. Insert the valve into the valve guide.
5. Apply light pressure to the valve while turning it to
fit the valve seat insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.
8. Clean the head and valves to remove the abrasive
Fig. 83 compound and metal particles.

4. VALVE SPRING
Valve Spring Inclination
Use a surface plate and a square to measure the valve
spring inclination.
If the measured value exceeds the specified limit, the
valve spring must be replaced.
mm (in.)
Standard Limit
Valve Spring 1.8 2.5
Inclination (0.0709) (0.0984)
Fig. 84
Valve Spring Tension
Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the
valve spring must be replaced.
kgf (lb)
Standard Limit
Valve Spring
17.0 15.0
Tension at 29.9 mm
(37.479) (33.069)
Set Length
Fig. 85
Valve Spring Free Length
Use a vernier caliper to measure the valve spring free
length.
If the measured value is less than the specified limit, the
valve spring must be replaced.
mm (in.)
Standard Limit
Exhaust and Intake
42.1 40.0
Valve Spring Free
(1.6575) (1.5748)
Fig. 86 Length
50 ENGINE

5. TAPPET (Cam Follower or Valve Lifter) AND PUSH ROD


TAPPET
Inspect the tappets for excessive wear, damage and any
abnormalities.
Use a micrometer to measure the tappet diameter.

mm (in.)
Standard
20.967 – 20.980
Tappet Diameter
(0.82547 – 0.82598)

Fig. 87
Use a dial indicator to measure the clearance between
the tappet and cylinder body tappet travelling bore.

mm (in.)
Standard Limit
Tappet and Tappet
0.020 – 0.054 0.08
Travelling Bore
(0.00079 – 0.00213) (0.00315)
Clearance

Fig. 88
PUSH ROD
Use a filler gauge to measure the valve push rod runout.
Roll the push rod along a smooth flat surface (illustra-
tion).

mm (in.)
Limit
Push Rod Run-Out 0.3 (0.0118)

Fig. 89
ENGINE 51

6. CAM SHAFT
Inspection of cam shaft

Camshaft Check the journal and the cam for evidence of wear,
damage or any other defect.
Note:
With the front and rear parts of camshaft pressed in
with ball bearings, and with the cylinder block pressed
in with roller bearings as the center bearing, check to
see if the camshaft rotates smoothly with no play at
each bearing.
Fig. 90
Measurement of journal and cam
1. Cam height (A – B) mm (in.)
Standard Limit Repair method
6.13 5.83
Intake Replace
(0.2413) (0.2295)
6.43 6.13
Exhaust Replace
(0.2531) (0.2413)

Fig. 91
2. Center journal diameter mm (in.)
Nominal Limit Repair method
I II
52 ø 51.92 ø
I II Replace
A' (2.0472) (2.0441)
A B' B'
3. Uneven wear of journal mm (in.)
B A'
Nominal Limit Repair method
52 ø
0.05 (0.002) Replace
Fig. 92 (2.0472)

4. Runout of cam shaft mm (in.)


Nominal Limit Repair method
0.02
0.1 (0.004) Replace
(0.008)

Fig. 93
52 ENGINE

7. ROCKER ARM SHAFT AND ROCKER ARM


Inspect all disassembled parts for wear, damage and any
abnormalities.

Fig. 94
Rocker Arm Shaft Outside Diameter
Use a micrometer to measure the rocker arm outside
diameter.
If the measured value is less than the specified limit, the
shaft must be replaced.

mm (in.)
Standard
Rocker Arm Shaft 11.935 – 11.955
Fig. 95 Diameter (0.4699 – 0.4707)

Rocker Arm Shaft and Rocker Arm Clearance


1. Use a vernier caliper to measure the rocker arm
bushing inside diameter.

mm (in.)
Standard
Rocker Arm Bushing 11.960 – 11.980
Inside Diameter (0.4709 – 0.4717)

Fig. 96 2. Measure the rocker arm shaft outside diameter.


Replace either the rocker arm or the rocker arm shaft
if the clearance exceeds the specified limit.

mm (in.)
Standard Limit
Rocker Arm Bushing
0.005 – 0.045 0.2
and Rocker Arm
(0.0002 – 0.0018) (0.0079)
Shaft Clearance

3. Check that the rocker arm oil port is free of obstruc-


tions.
If necessary, use compressed air to clean the rocker
Fig. 97
arm oil port.
ENGINE 53

8. PISTON, PISTON PIN AND PISTON RING


Clearance between piston and cylinder bore
1. Measure the outside diameter of the piston at about
60 mm from the top in a right angle to the piston pin
(in the unit of 1/1,000 mm).
2. Calculate the clearance based on the measurements
of the cylinder bore and the outside diameter of the
piston.
mm (in.)
About 60
Clearance 0.015 – 0.035 (0.0006 – 0.0014)

Fig. 98

Outside diameter of piston and grade mark


Grade mark The grade mark is stamped on the top surface of the
(Stamped) piston.
mm (in.)

Model Outside diameter of piston Grade

77.375 – 77.385
A
(3.0462 – 3.0466)
4LB1 77.386 – 77.395
B
Fig. 99 4LC1 (3.0467 – 3.0470)
77.396 – 77.405
C
(3.470 – 3.0474)
84.975 – 84.985
A
(3.3454 – 3.3458)
84.986 – 84.995
4LE1 B
(3.3459 – 3.3462)
84.996 – 85.005
C
(3.3463– 3.3466)

Wear of piston pin (outside diameter)


mm (in.)
Model Nominal Limit Remarks
21.0 20.97
4LB1
(0.8268) (0.8256)
Replace if worn
4LB1T beyond limit
25.0 24.97
4LC1
(0.9843) (0.9831)
4LE1

Fig. 100
54 ENGINE

Clearance between piston pin and piston pin hole


mm (in.)
Standard
0.002 – 0.012
4LB1, 4LC1, 4LE1
(0.00008 – 0.00047)

Piston ring gap


With the ring inserted into the cylinder bore, push it in
with the piston head so that it becomes a right angle to
the cylinder, and then measure the gap of the piston
ring.
If worn beyond the limit, replace the rings.
mm (in.)
Standard Limit
1st 0.2 – 0.35
Fig. 101 compression ring (0.0079 – 0.0138)
4LB1 0.2 – 0.4 1.5
2nd 4LC1 (0.0079 – 0.0157) (0.0590)
compression
ring 0.35 – 0.5
4LE1
(0.0138 – 0.0197)
0.2 – 0.4 1.0
Oil ring
(0.0079 – 0.0157) (0.03937)

Clearance between piston ring groove and ring


Measure clearance at several places on the circumfer-
ence.
If worn beyond the limit, replace the rings or piston.

4LB1 mm (in.)
Standard Limit
1st 0.065 – 0.100 0.2
compression ring (0.0026 – 0.0039) (0.0078)
Fig. 102 2nd 0.03 – 0.070
compression ring (0.0012 – 0.0027) 0.15
0.02 – 0.06 (0.0059)
Oil ring
(0.0008 – 0.0024)

4LB1T, 4LC1 mm (in.)


Standard Limit
1st 0.075 – 0.110 0.2
compression ring (0.0029 – 0.0043) 0.0078)
2nd 0.030 – 0.070
compression ring (0.0011 – 0.0027) 0.15
0.020 – 0.060 (0.0059)
Oil ring
(0.0007 – 0.0024)
ENGINE 55

4LE1 mm (in.)
Standard Limit
1st 0.085 – 0.105 0.2
compression ring (0.0033 – 0.0041) (0.0078)
2nd 0.050 – 0.085
compression ring (0.0020 – 0.0033) 0.15
0.030 – 0.070 (0.0059)
Oil ring
(0.0011 – 0.0027)
56 ENGINE

9. CONNECTING ROD AND CONNECTING ROD BEARING


Torsion and parallelism of connecting rod
If worn beyond the limit-repair or replace.
mm (in.)
Per 100 mm (3.94) Standard Limit
0.05 0.2
Torsion
(0.002) (0.0079)
0.05 0.15
Parallelism
(0.002) (0.0059)

Fig. 103
Clearance between small end pin hole of connecting rod
and piston pin, inside diameter of bushing
mm (in.)
Standard Limit
0.008 – 0.020 0.05
Clearance
(0.0003 – 0.0008) (0.0020)
4LB1 21 (0.8268) —

Inside diameter 4LB1T


4LC1 25 (0.9843) —
Fig. 104 4LE1
Connecting Rod Bearing Inspection
1. Fit the connecting rod bearing lower half into the
connecting rod bearing cap.
2. Check the connecting rod bearing lower half tension.
If the tension is insufficient, the bearing must be
replaced.
3. Tighten the connecting rod and the bearing cap to
the specified torque.

kg·m (ft. lbs.)


Fig. 105
4LB1, 4LB1T 3.8 – 4.2
(27 – 30)
2.3 – 2.7
Tightening (17 – 20)
4LC1
torque ↓
100 – 115 deg.
7.5 – 8.5
4LE1
(54 – 61)

Clearance between bearing and crank pin, inside di-


ameter with bearing installed and without.
mm (in.)
Standard Limit
0.035 – 0.073 0.10
Clearance
(0.0014 – 0.0029) (0.0039)

Fig. 106
ENGINE 57

10.CRANKSHAFT AND CRANKSHAFT BEARING


Outside diameters of journal and pin
If worn beyond the limits-replace
Crank journal mm (in.)
Standard Limit
4LB1
56.0 (2.2047) 55.86 (2.1992)
4LC1
4LE1 60.0 (2.3622) 59.86 (2.3567)

Fig. 107 Crank pin mm (in.)


Standard Limit
4LB1 43.0 (1.6929) 41.87 (1.6484)
4LC1 46.0 (1.8110) 45.87 (1.8059)
4LE1 49.0 (1.9291) 48.87 (1.9240)

Note:
When there occurs an uneven wear to the crankshaft,
replace it with a new one without grinding it for reuse.
Clearance between journal and bearing inside diameter
with bearing installed and without
mm (in.)
Standard Limit
0.029 – 0.072 0.11
Clearance
(0.0011 – 0.0028) (0.0043)

Fig. 108
Runout of crankshaft
Replace if beyond limit
mm (in.)
Standard Limit
0.025 (0.001) 0.05 (0.002)

Fig. 109
Crankshaft gear
Check the crankshaft gear visually for damage and any
other defects.

Fig. 110
58 ENGINE

Oil seal
Timing gear case
When the lip of an oil seal is found defective, replace it
with a new one.

Installation

Front oil seal


Use the crankshaft front oil seal installer to install the
crankshaft front oil seal.

Fig. 111

11.FLYWHEEL AND RING GEAR


Ring Gear Replacement

Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the
ring gear must be replaced.

Ring Gear Removal


Strike around the edges of the ring gear with a hammer
and chisel to remove it.
Fig. 112
Ring Gear Installation
1. Heat the ring gear evenly with a gas burner to invite
thermal expansion.
Do not allow the temperature of the gas burner to
exceed 200°C (390°F).
2. Use a hammer to install the ring gear when it is suf-
ficiently heated.

Fig. 113

12.TIMING GEAR
Uneven wear of idle gear shaft
mm (in.)
Nominal Limit
45.0 (1.7717) 0.1 (0.0039)

Fig. 114
Clearance between idle gear bushing and shaft
mm (in.)
Standard Limit
0.025 – 0.085 (0.001 – 0.0033) 0.2 (0.0079)

Fig. 115
ENGINE 59

REASSEMBLY
1. CYLINDER HEAD ASSEMBLY

Glow plug (7)


Connector (8)
Seat valve (1)

Split cillar (5)

Spring seat (4)


Apply Locktite No.262
Valve spring (3)
to this portion.
(5 locations)

Nozzle holder (6)

Valve (2)

Hot plug

Seat; Valve insert

Fig. 116

Important Operations

Valve Stem Oil Seal


1. Lubricate the oil seals and valve stem sealing area
with engine oil.
2. Use a valve stem oil seal installer to install the oil
seal.
Valve Stem Oil Seal Installer: 5-8840-9033-0

Fig. 117
Intake and Exhaust Valves
1. Place the cylinder head on a flat wooden surface.
2. Lubricate valve stems with engine oil.
3. Install the valves to the intake or exhaust guides.
Install the valves to their original lapped valve seats.

Fig. 118
60 ENGINE

Intake and Exhaust Valve Springs


Install the valve springs with their painted end (the close
pitched end) facing down.

Painted potion

Fig. 119

Spring compressor Spring Seat Split Collar


Split collar
1. Use a spring compressor to push the valve spring
into position.
2. Install the spring seat split collar.
3. Set the spring seat split collar by tapping lightly
around the head of the collar with a rubber hammer.
Spring Compressor: 5-8840-9030-0

Fig. 120
Nozzle holder assembly
Nozzle holder ASM Before assembling the nozzle holder assembly, check to
see if the spray condition and the spray pressure of the
Gasket
injection nozzle are appropriate, (Refer to “INSPECTION
Corrugated washer AND SERVICE.”)
Assemble to the cylinder head the gasket (heat shield),
Heat shield
heat shield, corrugated washer and gasket (nozzle
holder) in this order.
Gasket
Install the nozzle holder assembly, and then tighten it to
the specified torque.
Fig. 121
kg·m (ft. lbs.)
Tightening torque 4.0 – 5.0 (29.0 – 36.0)

Glow plug and connector


Glow plug Assemble the glow plug to the cylinder head, and then
tighten it to the specified torque.
Install the connector to the glow plug, and then tighten
Connector until snug.

kg·m (ft. lbs.)


Parts Tightening torque
Glow plug 1.5 – 2.0 (11.0 – 14.0)
Fig. 122
ENGINE 61

2. PISTON AND CONNECTING ROD

Piston ring (5)

Snap ring (4)

Piston (1)

Bush (2)
Piston pin (3)

* Rod bolt removed


for clarity.

Connecting rod (2)

Cap (7) Bearing (6)

Cap nut (8)

Fig. 123

Important Operations
Conventional
piston heater
Piston
Use a piston heater to heat the pistons to approximately
100°C (212°F).

Connecting Rod
1. Install the connecting rod to the piston with setting
the marks as illustrated.
2. Install the piston pin into the piston and the connect-
Fig. 124
ing rod bushing.

(Hot plug side) Grade mark

Front mark

Engine
front
direction

Isuzu mark

Cylinder
number
stamped side

Fig. 125
62 ENGINE

Piston Pin Snap Ring


1. Use a pair of snap ring pliers to install the piston pin
snap ring.
2. Check that the piston moves smoothly on the piston
pin.

Fig. 126
Piston Ring
1 st 1. Use a piston ring installer to install the three piston
rings.
Piston Ring Installer
2 nd
Install the piston rings in the following order.
(1) Oil ring
(2) 2nd compression ring
Oil
(3) 1st compression ring

Fig. 127
The marked side of the two compression rings must
be facing up.
The undercut side of the second compression ring
will be facing down.
As the oil ring has no any facing mark, it may face in
either direction.
2. Lubricate the piston ring surfaces with engine oil.
3. Check that the piston rings rotate smoothly in the
piston ring grooves.
ENGINE 63

3. INTERNAL PARTS

Reassembly Steps
(1) Crankshaft
(2) Piston Assembly
(3) Rear Seal Retainer
(4) Camshaft
(5) Cam Gear
(6) Idler gear and Shaft
(7) Oil Pump Assembly
(8) Timing Gear Case (Without PTO)
(9) Flywheel Housing
(10) Flywheel
(11) Crank Pulley
(12) Oil Pipe
(13) Oil Strainer
(14) Oil Pan
(15) Tappets
(16) Cylinder Head Gasket
(17) Cylinder Head Assembly
(18) Push Rods
(19) Rocker Bracket Assembly
(20) Engine Hangers
64 ENGINE

Internal Parts (1/3)

(2) (9)

(13)

(10)

(1)

(12)

(3)

(11)

(14)

Fig. 128
ENGINE 65

Internal Parts (2/3)

(8)

(19)

(20)

(18)

(17) (4)

(5)

(15)
(20)
(6)

(7)

(16)

Fig. 129
66 ENGINE

Internal Parts (3/3)

(8-1)

(8-2)

(7)

Fig. 130
ENGINE 67

Crankshaft bearing
With oil hole
and groove Fit correctry
Note that there is an oil hole and an oil groove in the
(Upper)
upper bearing (on the block side), but not in the lower
bearing (on the bearing cap side).
Fit the bearing tang firmly into the slot machined on the
cylinder body bearing arches.

No oil groove and hole


(Lower)

Fig. 131
Crankshaft and bearing
Lubricate the bearings with engine oil, install the crank-
Thrust Bearing shaft, install the thrust bearings with the groove facing
the crankshaft.
Crankshaft

Bearing

Fig. 132

Arrow mark
Crankshaft Bearing Cap
10 6 7 1. Lubricate the bearing cap bolts with engine oil.
2 3
5 4 3 2 1 2. Install the bearing caps to the crankshaft.
5 4
The arrow mark must be pointing to the front of the
9 1 8 engine.
Front 3. Tighten the bearing cap bolts to the specified torque
a little at a time in the numerical order shown in the
illustration.

kg·m (ft. lbs.)


Fig. 133
Crankshaft Bearing Cap
8.5 – 9.5 (61.0 – 69.0)
Bolt Torque

4. Check that the crankshaft turns smoothly by manu-


ally rotating it.
68 ENGINE

Position the rings as shown making sure the ring gaps


are away from the thrust side.
1 st

2 nd

Oil

Fig. 134
Piston and Connecting Rod
Special tool
Lubricate the piston, the piston rings, and the connect-
ing rod bearings with engine oil.
Position the piston front mark towards the front of the
Front engine.
mark Use the piston ring compressor to compress the piston
rings.
Use a hammer grip to push the piston in until it makes
contact with the crank pin.
Fig. 135 At the same time, rotate the crankshaft until the crankpin
reaches its highest point.

Set the bearing cap cylinder number marks and the con-
necting rod cylinder number marks.
The marks must be facing the injection pump side.

kg·m (ft. lbs.)


Cylinder No. 3.8 – 4.2
4LB1
(27 – 30)
2.3 – 2.7
Tightening (17 – 20)
4LC1
torque ↓
Fig. 136 100 – 115 deg.
7.5 – 8.5
4LE1
(54 – 61)

Note:
After installation, confirm that the crankshaft rotates
smoothly.

Installation of retainer
5 3
After applying engine oil to the lip of the oil seal, install
the retainer. Apply sealant.
Tighten bolts on the retainer to the specified torque in
1 2 the order as shown in the figure left.
kg·m (ft. lbs.)
Tightening torque 0.8 – 1.2 (6.0 – 9.0)

4 6

Fig. 137
ENGINE 69

Camshaft assembly
1. Apply engine oil to the inside of the bearing of
the cylinder block, and then install the camshaft
assembly.
Note:
When installing the assembly, care should be taken not
to damage the bearing.
2. After installation of the snap ring to the outside of
the front bearing, check to see if the camshaft
Fig. 138 rotates smoothly.
Cam gear and sleeve
Cam gear
1. Install the cam gear to the camshaft so that the tim-
Timing point ing point (a dot mark “•“) comes to the front side.
2. With the flyweight installed, tighten the cam gear
Sleeve with a lock nut.
kg·m (ft. lbs.)
Tightening torque 7.0 – 9.0 (51.0 – 65.0)
Fly weight
Lock nut
3. Apply engine oil to the shaft of the sleeve and the
Fig. 139 slide of the flyweight.
4. With the lip of the sleeve placed in the cavity of the
flyweight, insert the shaft of the sleeve into the tip
end of the camshaft.
Note:
Check to see if the sleeve moves smoothly.

Idle Gear
Idle gear
Install the idler gear shaft with the oil hole facing up-
Timing point ward.
Lubricate the shaft with oil.
Thrust collar
Install the idler gear.
Idle gear shaft
Align the timing marks as shown in the illustration.
Install the thrust collar and tighten the bolts to the
Timing point specified torque.
kg·m (ft. lbs.)
Fig. 140
Tightening torque 2.1 – 3.1 (15.2 – 22.4)
Cam gear
Timing point

Idle gear

Crank gear
Fig. 141
70 ENGINE

Oil pump assembly


Cylinder block 1. When PTO is not provided, install the oil pump
assembly to the cylinder block.
PTO not provided kg·m (ft. lbs.)
Tightening torque 1.9 – 2.9 (14.0 – 21.0)

Fig. 142
2. When PTO is provided, install the oil pump to the
front plate.
Front plate PTO provided kg·m (ft. lbs.)
Tightening torque 0.8 – 1.2 (6.0 – 9.0)

Fig. 143
Front plate (only for those provided with PTO)
Front plate
Apply liquid gasket to the front plate incorporated with
the oil pump before installing it to the cylinder block.
kg·m (ft. lbs.)
Tightening torque 1.9 – 2.9 (14.0 – 21.0)

(with PTO)

Fig. 144
Front oil seal
Front oil seal Timing gear case
Install the front oil seal to the timing gear case.
Installation is made according to the “L” dimension
shown in the figure.
mm (in.)
L dimension
PTO not provided 60.2 – 60.8 (2.370 – 2.384)
PTO provided 40.2 – 40.8 (1.582 – 1.606)
Fig. 145
ENGINE 71

Timing gear case (with governor)


Governor cover When not provided with PTO, install the timing gear
case to the cylinder block. When provided with PTO,
install it to the front plate.
Timing gear case
1. Put the link plate of the governor incorporated in
the gear case through the connecting hole of the
injection pump in advance.
2. Apply engine oil to the bushes provided on both
ends of the main spring lever of the governor.
3. Apply sealant to the gear case, and then install it to
Front oil seal
the cylinder block or the front plate.
kg·m (ft. lbs.)
Case tightening torque 1.9 – 2.9 (14.0 – 21.0)

4. Assemble the gasket and the governor cover to the


Fig. 146 top of the gear case, and then tighten them to the
specified torque.
kg·m (ft. lbs.)
Cover tightening torque 0.8 – 1.2 (6.0 – 9.0)

Flywheel housing
Install the flywheel housing to the cylinder body.
kg·m (ft. lbs.)
Tightening torque 4.2 – 5.6 (30.0 – 40.0)

Fig. 147
Flywheel
Lubricate bolts with engine oil.
Tighten a little at a time in the sequence shown in the
illustration.
kg·m (ft. lbs.)
Tightening torque 9.0 – 11.0 (65.0 – 80.0)
Apply
engine oil

Fig. 148
72 ENGINE

Crank pulley
Lubricate the lip of the front, seal with oil
Crankshaft Install the crank pulley, lock the crankshaft and tighten
the front bolt.
kg·m (ft. lbs.)
Crank pulley
Tightening torque 17.0 – 19.0 (123.0 – 137.0)

Washer

Front oil seal

Fig. 149
Oil pipe and oil strainer
To 2nd bearing cap
1. Install the oil pipe from the oil pump assembly to
the cylinder block and tighten the sleeve nuts.
Oil strainer 2. Install the oil strainer to the oil pump, and then
tighten the bracket of the strainer to the No. 2 bear-
ing cap.
kg·m (ft. lbs.)

Oil pipe
Tightening torque 1.9 – 2.9 (14.0 – 21.0)

Fig. 150
Oil pan
1. Apply sealant to the oil pan.
2. Install the oil pan to the cylinder block and tighten
fixing bolts evenly.
kg·m (ft. lbs.)
Tightening torque 0.8 – 1.2 (6.0 – 9.0)

Fig. 151
Tappet and head gasket
1. Install the tappet to the cylinder block.
2. When installing the head gasket, turn up the stamp
mark of the parts number (last 4 digits) which is
between the No. 2 and No. 3 cylinders of the gasket.

Parts number (Last 4 digits)


Stamp mark position

Fig. 152
ENGINE 73

Cylinder head assembly


11 12 13 14 15 Lubricate the bolts with oil.
Tighten the bolts in the sequence shown in the illustra-
8 9 tion to the specified torque.
4 1 5
kg·m (ft. lbs.)
7 3 2 6 10
Bolt size Tightening torque
M12 × 1.5 8.5 – 9.5
60°∼90°
(8 each) (61 – 69)
M8 × 1.25 2.5 – 3.5
Fig. 153
(4 each) (18 – 25)

Push rod
Install the push rods.

Rocker arm bracket assembly


Rocker arm Apply liquid gasket to the the bottom of the rocker arm
bracket assembly, being careful not to get any in the
Rocker spring groove around the oil galley as shown in the illustration.
Install the rocker arm bracket assembly making sure the
push rods align with the rocker arms and tighten to the
specified torque.
kg·m (ft. lbs.)
Tightening torque 0.8 – 1.2 (6.0 – 9.0)
Rocker arm
bracket

Fig. 154

(Rocker bracket bottom surface)


Apply stem of sealant

{Avoid the application


of sealant to this groove.

Oil gallery

Fig. 155
74 ENGINE

Adjustment of valve clearance

Refer to Section “General


Information – Maintenance”
(on page 21).

Front hanger and rear hanger


Rear hanger Tighten them to the specified torque shown below.
kg·m (ft. lbs.)
Tightening torque 1.9 – 2.9 (14.0 – 21.0)

Front hanger

Fig. 156
ENGINE 75

4. EXTERNAL PARTS (Right-hand Side)

(8) (6) (5) (7)

(3)

(2)
(4)

(1)

Fig. 157

(1) Dipstick
(2) Oil Filter
(3) Injection Pump
(4) Injection Pump Housing Cover
(5) Fuel Pipe
(6) Leak Off Pipe
(7) Fuel Hose
(8) Injection Pipe
76 ENGINE

5. EXTERNAL PARTS (Left-hand Side)

(10) (11)
(17)

(12)
(16)

(9)

(16) (13)

(14)

Fig. 158

(9) Water Pump


(10) Thermostat and Water Outlet Pipe
(11) Cylinder Head Cover
(12) Exhaust Manifold
(13) Starter
(14) Generator
(15) Fan Pulley
(16) Fan Belt
(17) Cooling Fan
ENGINE 77

Dipstick
Cartridge Dipstick Oil filter (cartridge)
1. Insert the dipstick.
2. Install the cartridge with a filter wrench (commer-
cially available).
(1) Apply engine oil thinly to the gasket of the cartridge.
(2) Screw in the cartridge until the gasket comes into
contact with the seal, and then tighten it by giving it
about 3/4 turns.
Fig. 159
(Reference: Tightening torque 1.2 to 1.6 kg·m
(8.6 – 11.6 ft. lbs.))

Injection pump
Injection pump
Fuel cut lever
center position Align the two (2) holes in the fuel cut lever and the gov-
Pin ernor and lock into place with a pin.
Control link (6φ)
This will center and hold the control link for the installa-
tion of the injection pumps.

Fig. 160
Install a new shim with the same thickness as the one
Injection pump ASM that was removed. (Refer to the maintenance section on
shim selection).
Shim

Cylinder block

Fig. 161
Install the injection pump making sure the rack pin is in
Injection pump the groove of the control rack before tightening the
center position injection pump to the specified torque.
Control link kg·m (ft. lbs.)

Rack pin Tightening torque 1.9 – 2.9 (14.0 – 21.0)

Remove the rack pin (6ø) which is inserted into the fuel
cut lever, and then confirm that the fuel cut lever moves
smoothly.
Fig. 162
78 ENGINE

Injection pump housing cover


After applying sealant (TB1207C) to the housing cover,
Housing cover install it to the cylinder block by the side of the injection
pump.
kg·m (ft. lbs.)
Tightening torque 0.8 – 1.2 (6.0 – 9.0)

Note:
The areas of the housing cover to which liquid gasket is
Fig. 163 applied are about 4 mm in width from the cover edge
and about 2 mm around the bolts.
Housing cover Apply potion of sealant

About 4mm in width


About 2mm from the cover edge
around the bolt hole

Fig. 164
Solenoid assembly
1. Apply sealant (TB1207C) to the surface (bite groove)
in which the solenoid is installed.
Solenoid ASM
Note:
Avoid the application of sealant to the screw thread.
2. Screw in the solenoid from the rear of the cylinder
block (the rear of the No. 3 injection pump rack), and
then tighten it to the specified torque.
kg·m (ft. lbs.)
Fig. 165 Tightening torque 1.5 – 2.5 (11.0 – 18.0)
Installed surface
Solenoid ASM Apply surface
( of sealant )

Screw thread

( Avoid the application


of sealant )
Fig. 166
ENGINE 79

Leak off pipe


Fuel pipe
Leak off pipe
1. Install the fuel pipe to the injection pump and then
tighten it to the specified torque.
2. Install the leak off pipe to the nozzle holder and then
Fuel pipe tighten it to the specified torque.

Fuel hose
kg·m (ft. lbs.)
Injection
pump Tightening torque
Nozzle holder
Fuel pipe 2.0 – 2.5 (14.0 – 18.0)
Fig. 167
Leak off pipe 2.5 – 3.5 (18.0 – 25.0)

Note:
When tightening it, hold the pipe securely by hand so
that it will not rotate.
3. Connect the fuel pipe and the leak off pipe with the
fuel hose and fix them with clips.

Injection pipe
Injection pipe
Install the injection pipe to the injection pump and the
nozzle holder and tighten them up with sleeve nuts.
kg·m (ft. lbs.)
Nozzle holder Tightening torque 1.5 – 2.5 (11.0 – 18.0)
Injection pump

Note:
Set the thread of the sleeve nut securely before tighten-
ing it up.
Fig. 168
Water pump assembly
1. Put sealant on the water pump where it contacts the
block and head.
2. Tighten to the specified torque.
(L=60)
kg·m (ft. lbs.)
Tightening torque 1.9 – 2.9 (14.0 – 21.0)

(L=40) Tighten together with


adjusting plate
Fig. 169
Thermostat
Water outlet pipe
Water outlet pipe
Assemble the thermostat, install the gasket and the
water outlet pipe, and then tighten it to the specified
Thermostat Gasket torque.
kg·m (ft. lbs.)
Tightening torque 1.9 – 2.9 (14.0 – 21.0)
Water pump

Fig. 170
80 ENGINE

Adjustment of valve clearance


(Refer to Section “GENERAL INFORMATION – MAINTE-
NANCE.”)
Cylinder head cover
Cylinder cover 1. Install the gasket to the cylinder head cover.
Gasket Notes:
1. Much care should be taken for the gasket not to get
dislocated or twisted when installing the head
cover.
2. Avoid the application of sealant to the rubber gas-
Rocker arm ket.
bracket
2. Install the cylinder head cover to the rocker arm
Fig. 171 bracket, and tighten it to the specified torque.
kg·m (ft. lbs.)
Tightening torque 0.2 – 0.4 (1.4 – 2.9)

Air inlet pipe


Cylinder head
cover 1. Apply sealant (TB1207C) to the surface in which the
air inlet pipe is installed.
2. Install the air inlet pipe to the cylinder head cover,
and tighten it to the specified torque.
kg·m (ft. lbs.)
Air inlet pipe
Tightening torque 0.8 – 1.2 (6.0 – 9.0)

Fig. 172
Exhaust manifold
Gasket
Assemble the gasket to the cylinder head, install the
Exhaust
manifold exhaust manifold along the stud bolts and tighten it to
the specified torque.
kg·m (ft. lbs.)
Tightening torque 1.9 – 2.9 (14.0 – 21.0)

Cylinder head

Fig. 173
Starter
Install the starter to the flywheel housing, and tighten it
to the specified torque.
kg·m (ft. lbs.)
Tightening torque 9.5 – 11.5 (68.7 – 83.2)

Starter

Fig. 174
ENGINE 81

Generator
Water pump
1. Tighten the adjust plate together with the water
Adjusting plate
pump, and then install them temporarily.
2. Install the bottom of the generator to the timing gear
case, and then tighten it temporarily with bolts and
nuts.
3. Install the fixing bolts onto the top of the generator
through the adjusting plate. (Temporary tightening)
Generator
Fig. 175
Fan pulley and fan belt
Fan pulley
1. Install the fan pulley to the water pump and then
tighten it up. (2 locations)
2. Set the fan belt to each pulley.

Water pump

Fan belt
Fig. 176
Fan belt tension
Adjust the alternator as specified and tighten to the
specified torque.
mm (in.)

Deflection amount (Press the belt


8 to 10
at its center between the pulleys
(0.315 – 0.3937)
with 10kg (22 lbs.) force.)

mm (in.)
Fig. 177
Generator upper 1.9 – 2.9 (14.0 – 21.0)
Generator lower 3.5 – 4.7 (25.0 – 34.0)
Adjust plate 1.9 – 2.9 (14.0 – 21.0)

Cooling fan
Cooling fan Spacer
1. Assemble the spacer before tightening the cooling
fan.
2. Tighten it to the specified torque. (4 locations)

Fig. 178
MEMO
LUBRICATING SYSTEM 83

SECTION 3

LUBRICATING SYSTEM
TABLE OF CONTENTS

CONTENTS PAGE

LUBRICATING OIL CIRCULATION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84


OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
84 LUBRICATING SYSTEM

LUBRICATING OIL CIRCULATION DIAGRAM

Valve opening pressure 1kg/cm2 (14.0 PSI)

Oil filter Oil gallery

Main bearing Idle gear bush Cylinder head

Valve
opening
pressure Rocker arm
Crankshaft Timing gear
4.5kg/cm2 bracket
(64.0 PSI)

Connecting rod Governor Rocker shaft

Rocker arm
Oil pump

Injection pump

Strainer Piston

Tappet Valve stem end

Piston
pin boss

Oil pan

Pressure feeding Non pressure feeding

Fig. 179
LUBRICATING SYSTEM 85

OIL PUMP

Body; Oil pump With PTO Front plate


Pin (common) (Body; integral structure)
Without PTO
Rotor; outer

Roter; inner

O-ring (common)

Pump gear Relief valve


Spring
Plug
Oil pump Common
(common)

Fig. 180

Inspection and replacement


When there is wear, damages or any other defects
found, repair or replace the rotor.

Clearance between the outer rotor or inner rotor and


the pump cover
mm (in.)
Standard Limit
0.040 – 0.085 (0.0016 – 0.0033) 0.15 (0.0059)

Clearance between the periphery of the outer rotor and


the pump body
mm (in.)
Standard Limit
0.10 – 0.185 (0.0039 – 0.0073) 0.4 (0.0157)

Clearance between the inner rotor and the outer rotor


mm (in.)
Standard Limit
0.17 (0.0067) 0.2 (0.0079)
MEMO
COOLING SYSTEM 87

SECTION 4

COOLING SYSTEM
TABLE OF CONTENTS

CONTENTS PAGE

COOLING WATER CIRCULATION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88


WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
88 COOLING SYSTEM

COOLING WATER CIRCULATION SYSTEM DIAGRAM

Bottom bypass type


thermostat
Cyliner head

Cylinder block
Water pump ( bypass circuit)
Radiator

Fig. 181
COOLING SYSTEM 89

WATER PUMP
DISASSEMBLY

Seal unit Impeller

Bearing unit

Fan center

Cover

Body

Setscrew

Fig. 182

Fan center
Cover
Cover
1. Loosen the set screw.
2. Remove the cover.
Note:
The cover is applied with sealant (TB1207B). When re-
Setscrew moving the cover, much care should be taken not to
Fan center deform it by applying an excessive force to it.

Fig. 183
Impeller
Seal unit
Bearing unit

Bearing unit

Impeller

Seal unit

Fig. 184
90 COOLING SYSTEM

REASSEMBLY
Bearing unit
Align holes With a hole in the bearing unit set in line with one in the
Body body, lock the bearing unit with a setscrew.
Bearing unit kg·m (ft. lbs.)
Set screw tightening torque 0.8 – 1.2 (6.0 – 9.0)
Fan center

Setscrew

Fig. 185
Seal unit
Impeller
Impeller
1. Apply BELCO bond No. 4 to the surface where the
seal unit comes into contact with the body, and then
assemble the seal unit.
2. Press in the impeller with a press until the clearance
between the pump impeller and the body gets to the
Seal unit specified value.

Fig. 186
Cover
Cover
1. Apply liquid gasket to the surface to which the cover
is installed, and then install the cover.
2. Apply Screw-lock to the cover installation screws,
and then tighten them.

Fig. 187
Clearance, play and tightening allowance between parts
1. Clearance between the pump impeller and the body
mm (in.)
Standard 0.53 – 2.17 (0.0209 – 0.0854)

2. Play in the water pump ball bearing


mm (in.)
Standard Limit
0.008 – 0.010 (0.0003 – 0.0004) 0.2 (0.0079)

3. Tightening allowance between the fan center and


the bearing shaft
mm (in.)
Standard 0.026 – 0.061 (0.001 – 0.0024)
COOLING SYSTEM 91

THERMOSTAT
Inspection and replacement
Replace the thermostat when there is wear, damages or
any other defects found.

Opening temp. 74.5 – 78.5°C (166 – 174°F)


Thermometer
8mm or more at 90°C
Valve lift mm (in.)
(0.315 inch or more at 194°F)
Agitating rod
Thermostat

Wooden piece

Fig. 188
MEMO
FUEL SYSTEM 93

SECTION 5

FUEL SYSTEM
TABLE OF CONTENTS

CONTENTS PAGE

FUEL CIRCULATION SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94


GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
NOZZLE HOLDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
94 FUEL SYSTEM

FUEL CIRCULATION SYSTEM DIAGRAM

Fuel tank

Nozzle holder

Injection pump

Nozzle

Fuel filter

Fig. 189
FUEL SYSTEM 95

GOVERNOR
1. The adjustments of the governor-related parts require the engine performance test.
2. Before disassembling the governor, measure the dimensions “A” and “B” given in the structural
drawing to ensure the same dimensions in reassembly.
3. Do not disassemble the governor when the performance test cannot be conducted after reassembly.

1. STRUCTURAL DRAWING OF GOVERNOR (1)

Idle speed screw

Idle (sub) spring


Start spring
Fuel cut cover

A Governor shaft
Link plate

Set spring
Control link

Governor cover
Injection pump
Guide lever
Main spring lever

Main spring Timing gear case

Floating lever

B Tensioner lever
Camshaft

Angleich

Full load stopper


Sleeve

Flyweight

Shifter

Fig. 190
96 FUEL SYSTEM

2. STRUCTURAL DRAWING OF GOVERNOR (2)

Start spring
Control link
Set spring
Snap pin
Guide lever

Floating lever

Link plate
A
Cap nut Guide piece
Shifter
Setscrew

Shaft (floating)

Fuel cut lever Fuel cut shaft B Main


spring
Return spring Shifter shaft

O-ring Tensioner
lever
Lever;
Bracket; start spring main spring
Idle spring

Speed control screw


Angleich
Return spring
O-ring
A
Lever bush
Shaft

Sleeve

Lever bush B

Control lever Full load Cam gear


setscrew
Flyweight

Timing gear case

Fig. 191
FUEL SYSTEM 97

3. REASSEMBLY OF CONTROL LEVER RELATED PARTS


(1) Put the lever (main spring) through the hole of the timing gear case lever.
Note:
Before hammering in the bushes, put both shafts of the lever through the holes of the timing gear case
lever respectively.
(2) Put the return spring of the control lever through the shaft of the lever (main spring).
(3) Assemble the bushes.
Assemble the bush of the lever (main spring) first, and then the control lever bush.
Note:
When assembling the bushes, apply Loctite (#601) to the periphery of the bushes.

Lever; Main spring


Bush
Apply Loctite No.601
( to the peniphery ) Protrusion

Pin
Return spring
Bush
Apply Loctite No.601
Timing gear case ( to the peniphery )
Fig. 192

(4) Hook both ends of the return spring (control lever) securely to the protrusion and the pin of the lever
(main spring) respectively.
98 FUEL SYSTEM

(6) Assemble the control lever.


Assemble the O-ring to the groove of the bushes (control lever) first, and then assemble the washers
and the control lever before tightening up the control lever with a nut.
kg·m (ft. lbs.)
Control lever tightening torque 1.2 – 1.8 (9.0 – 13.0)

Control lever

O-ring Spring washer


Bush
Washer
Nut

Groove

Fig. 193

Notes:
1. Tighten the control lever after locking the control lever firmly.
(Do not tighten the control lever after locking the main spring lever.)
2. After assembly, confirm that the control lever moves smoothly.
FUEL SYSTEM 99

4. Reassembly of shifter
(1) Assemble the shifter to the guide lever, put the shaft through it, and then assemble the snap ring.
(2) After assembly, confirm that the shaft moves smoothly.
(3) Also, confirm that the shifter shakes smoothly.

Guide lever

Shifter

Snap ring

Shaft

Fig. 194
100 FUEL SYSTEM

5. Reassembly of governor cover


Assemble the related parts such as the fuel cut lever and the idle spring to the governor cover.

[Stop] [Operate]
Governor cover
22° 22°
Return spring
(Bent-up part) Governor
Thrust
washer Z

O-ring Nut Idle spring


Shaft Spring washer
(Notched groove) Fuel cut lever Z

Fig. 195

(1) When assembling the shaft, apply engine oil to the


Cap sliding portion with the governor cover.
(2) Set both ends of the return spring securely to the
Cap nut
notched groove at the bottom of the cover and the
Packing bent-up arm of the lever respectively.
(3) After reassembling the governor cover, confirm that
Lock nut
the governor moves smoothly.
(※) (4) When assembling the timing gear case to the gover-
nor cover, tighten the “A” dimension shown in the
Gasket
illustration to 2 – 3 mm temporarily.
The parts given in the square indicated by (*) are assem-
Idle screw
bled after performance test.
A

mm (in.)
(When assembling temporarily)
“A” dimension
Governor 2 – 3 (0.0787 – 0.0118)
lever

Tensioner lever
Washer
Idle spring
Washer
Snap ring

(Z view of the drawing above)

Fig. 196
FUEL SYSTEM 101

6. Reassembly of full-load stopper


Install the full-load stopper to the timing gear case, and then tighten it with a nut temporarily.

Timing gear case

Full load stopper

Nut; setscrew

Fig. 197
102 FUEL SYSTEM

7. Reassembly of governor lever related components


Assemble each lever and spring to the timing gear case.

Main spring lever


Lever shaft
Tensioner lever
Link plate
Main spring
Eye; start spring

Set spring
Guide piece
Start spring

Guide lever

Snap pin

Plug

Floating lever

Shaft;
floatong lever

Fig. 198

8. Notes when assembling governor related components


(1) When assembling components, apply engine oil to each slide (such as the end face of the lever, the
hole in the shaft, and the periphery of the shaft).
(2) Install the set spring securely to the groove of the pin connecting the floating lever, with much care to
its assembling direction.
(3) Confirm that each lever moves by its dead weight before installing the start spring.
(4) After assembly, confirm that each lever moves smoothly.
And also confirm that each spring operates properly.
FUEL SYSTEM 103

NOZZLE HOLDER ASSEMBLY


DISASSEMBLY

Injection pipe
Leak off pipe

Nozzle holder ASM

Packing Spring
Body
seat
Spacer

Nozzle
} Shim
Corrugated ASM Nozzle
washer
spring
Retairing
nut

Heat shield
Injection pump
Gasket

Fig. 199

NOZZLE ASSEMBLY
Inspection and replacement
Place the removed nozzle in the clean light oil, disas-
semble it into the nozzle body and the needle valve and
clean them thoroughly. Then check to see if the valve
moves smoothly in the body.
When it does not move smoothly, repair or replace the
nozzle.
Adjustment
Light oil
For the adjustment of the injection pressure and the
Fig. 200 spray condition of fuel, refer to Section 1 “INSPECTION
AND SERVICE.”
MEMO
TROUBLESHOOTING 105

SECTION 6

TROUBLESHOOTING

Engine does not start

Starter does not run Starter runs but does Engine starts but
not start does not run
continuously.
Check battery

Engine Fuel system Fuel injected Air mixed in


Battery in OK fuel pump
discharging Check
(Charge) compression
( ) No fuel Fuel injected
ratio * injected
Retighten, OK
Check wiring
replace
Check if fuel Check OK packing,
Low OK comes preheating bleed air
Loosened OK compression to fuel pump circuit
connector or ratio
broken wire
(Retighten or Check for air
replace with Defective mixing Poor Normal Disordered
new wiring) valve, spring, operation operation idling
gasket, etc. of glow of glow
(Overhaul) plug plug
Air mixed OK control control
Check starter switch resistance resistance
(Retighten it,
replace (Replace) OK
packing, bleed
air) OK
Defective OK Adjust
(Replace) Check idling
injection
Check fuel timing
filter
Check magnetic
switch Abnormal OK
Clogged OK (Adjust)
( ) (Clean)
*
Defective OK Check nozzle
(Replace)
Check engine stop
solenoid return
Defective OK
(Repair or
Check starter bush replace)
Check solenoid

OK Defective injection
Poor contact
Stuck solenoid or OK pump (Bring
(Repair or
poor operation it to a specialty
replace)
(Repair or replace) shop for repair)

Defective starter ★ Note: “Bring it to a specialty shop” means that defective parts of the injection pump
(Bring it to a specialty and electricals must be brought to a specialty shop for repair. (This note is
shop for repair) applicable to all the following procedures.)
106 TROUBLESHOOTING

Unstable engine rotation

Unstable engine Idling speed Unstable rotation at Unstable rotation at Engine does not
idling too high medium speed high speed change from high to
(Hunting) low rotation

Defective idling Defective control Governor spring Check fuel for air Check accelerator
adjustment lever adjustment deteriorated mixing pedal

Defective OK Defective OK Air mixed OK Pedal OK


valve return (Repair or (Bleed sticking or
(Adjust) replace) air)mixing hitching
(Clean or
replace)

Check high pressure Defective injection Check fuel pipe for Check fuel filter for
pipe for cracking, pump (Bring it to a crash clogging
clogging or bending specialty shop for Defective injection
repair) pump (Bring it to a
specialty shop for
repair)
Crash OK Clogged OK
Cracked, OK (Replace) (Clean or
clogged or replace)
bent
(Replace)

Check uneven fuel


injection
Check nozzle

Uneven OK
Defective OK
(Adjust)
(Repair or
replace)

Check valve clearance


Check cylinder for adjustment
uneven compression
pressure

Poor OK
adjustment
Uneven OK (Adjust)
compression
pressure
(Adjust)
Defective injection
pump (Bring it to a
specialty shop for
Defective injection repair)
pump (Bring it to a
specialty shop for
repair)
TROUBLESHOOTING 107

Insufficient output Overheat

Fuel system Mechanical Cooling system Handling


system

Check fuel for air Check cooling Check fan belt Check if oil used
mixing Check engine water level for slip is inferior quality,
control or engine oil is
too much

Air mixed OK Insufficient OK Slipping OK


(Bleed air) Poor OK (Adjust)
Care must OK
adjustment
be taken
(Adjust)
when
Check fuel filter Replenish Check Check thermostat replenishing
or fuel hose for for (Replace)
clogging Check inlet air leakage
temperature Malfunction OK
(Replace)
Clogged OK Engine Overloaded
(Clean or Leak to Leak to rotation
Temperatu OK
Replace) external internal too high
re too high
Check cooling
(Improve
system for stain,
ventilation)
and radiator for
Check high Repair or clogging
pressure pipe for Repair
replace Temperature
clogging or abnormally high
bending Insufficient inlet
air Stained or
clogged
(Clean) OK
OK Improve
Clogged OK ventilation
or bent Air cleaner
(Replace) stained
(Clean or
replace)

Check nozzle

Check valve
clearance and
Defective OK cam lift
(Repair or
replace)

Abnormal OK
(Adjust or
Check injection
replace)
timing

Abnormal OK Check compression


(Adjust) pressure

Low
Defective
injection pump
(Bring it to a
specialized shop
Low
for repair)
Excessive
blow-by Gas leak from
gas valve and gasket
(Overhaul) (Repair or replace)
108 TROUBLESHOOTING

Abnormal exhaust gas

White smoke too much Black smoke too much

Check if fuel used is of Check fuel for water Check nozzle Air cleaner clogged
inferior quality mixing

Defective OK Replace air OK


Change fuel OK Water mixed OK (Repair or replace) cleaner element
(Change fuel)

Check if engine oil is too Check injection timing Check air hose for crash
much Check injection timing

Advanced too much OK


OK (Adjust)
Delayed
(Adjust)

Check injection pump


Check compression ratio

Defective injection pump OK


Low OK (Bring it to a specialty
shop for repair)

Gas leak from


Check up and 1. Disordered valve timing
Excessive valve and
down 2. Broken piston ring or
blow-by gas gasket (Repair
movement of oil misassembly
(Overhaul) or replace)
3. Worn camshaft
4. Worn valve or insert
Stuck (Overhaul) (Overhaul)

Over-discharge of battery

Battery Wiring Regulator and generator

Check electrolyte level Check terminals for warp, Check belt for slip or damage
deformation or corrosion

Low OK Slipping or OK
OK damaged (Repair
Poor contact
or replace)
(Repair or replace)
Battery Natural
case consumpt Over
cracked ion charge Test charging condition
(Replace) (Replenish) Check for broken wire
(Repair or replace)
Note: Improper maintenance Abnormal OK

Bring it to a battery shop


Check specific gravity

Low

Recharging
Recharge impossible

Bring it to a battery specialty shop


TROUBLESHOOTING 109

Oil pressure too low Oil consumption too much Oil consumption too much

Check oil level Check for oil leakage Check for oil leakage

Low (Replenish) OK Leaking (Retighten, OK Leaking (Retighten, OK


replace packing seal) replace packing seal)

Check cooling water temperature


Check nozzle Check oil quality

High OK
(See “Overheat”) Defective OK Poor quality OK
(Repair or replace) (Change to specified oil)

Check oil in crankcase


Check injection timing Check bleeder for clogging
Improper OK
viscosity
Abnormal (Adjust) OK Clogged (Clean) OK
Water or fuel mixed. Check fuel
system and cooling system
Check compression ratio Check up and down movement of oil

Check relief valve


Low OK 1. Oil pump malfunction
2. Loosened or cracked pipe
3. Wear of sliding part
Defective OK Defective injection pump 4. Oil pump clogged
(Repair or replace) (Bring it to a specialty 5. Defective valve stem seal
shop for repair) (Overhaul)

1. Oil pump malfunction (*) Worn bore,and worn or broken


2. Loosened or cracked pipe Excessive Gas leak from ring (Measure compression
3. Wear of sliding part blow-by gas valve and gasket pressure, and check entrance of
4. Oil pump clogged (Repair or dust)
(Overhaul) replace)

Engine knocking

Mechanical system Fuel system

Check up movement of oil Check injection timing

Oil stained (Overhaul) OK Abnormal (Adjust) OK

Check compression pressure Check nozzle

Low OK Defective OK
(Repair or replace)
To fuel system
Note: Fuel used is of poor quality.

Excessive Gas leak from


blow-by gas valve and gasket
(Overhaul) (Repair or
replace)
MEMO
SPECIAL TOOLS 111

SECTION 7

SPECIAL TOOLS
The alphanumeric codes in parentheses “( )” are part numbers assigned by special tool manufacturers.
No. Illustration Part Number Part Name Page

1. 5-8840-2675-0 Compression gauge 24

2. 5-8840-9026-0 Compression gauge adapter 24

5-8840-9016-0
3. Nozzle tester 24
(J-28829)

5-8840-9015-0
4. Oil filter wrench —
(JKM-9004)

5. 5-8840-9030-0 Valve spring compressor 60

6. 1-85221-029-0 Piston ring pliers 42

5-8840-9018-0
7. Piston ring compressor —
(J-8037)

8. 5-8840-9031-0 Front oil seal installer —

9. 5-8840-9032-0 Rear oil seal installer —

10. 5-8840-9034-0 Camshaft bearing installer —

11. 5-8840-9035-0 Valve guide installer —

12. 5-8840-9033-0 Valve stem seal installer 59


MEMO
CONVERSION TABLE 113

SECTION 8

CONVERSION TABLE
TABLE OF CONTENTS

ITEM PAGE

LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
MASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

LENGTH
MILLIMETERS TO INCHES INCHES TO MILLIMETERS

mm in. mm in. mm in. mm in. in. mm in. mm

1 0.0394 26 1.0236 51 2.0079 76 2.9921 1/64 0.3969 33/64 13.0969


2 0.0787 27 1.0630 52 2.0472 77 3.0315 1/32 0.7938 17/32 13.4938
3 0.1181 28 1.1024 53 2.0866 78 3.0709 3/64 1.1906 35/64 13.8906
4 0.1575 29 1.1417 54 2.1260 79 3.1102 1/16 1.5875 9/16 14.2875
5 0.1969 30 1.1811 55 2.1654 80 3.1496 5/64 1.9844 37/64 14.6844
6 0.2362 31 1.2205 56 2.2047 81 3.1890 3/32 2.3813 19/32 15.0813
7 0.2756 32 1.2598 57 2.2441 82 3.2283 7/64 2.7781 39/64 15.4781
8 0.3150 33 1.2992 58 2.2835 83 3.2677 1/8 3.1750 5/8 15.8750
9 0.3543 34 1.3386 59 2.3228 84 3.3071 9/64 3.5719 41/64 16.2719
10 0.3937 35 1.3780 60 2.3622 85 3.3465 5/32 3.9688 21/32 16.6688
11 0.4331 36 1.4173 61 2.4016 86 3.3858 11/64 4.3656 43/64 17.0656
12 0.4724 37 1.4567 62 2.4409 87 3.4252 3/16 4.7625 11/16 17.4625
13 0.5118 38 1.4961 63 2.4803 88 3.4646 13/64 5.1594 45/64 17.8594
14 0.5512 39 1.5354 64 2.5197 89 3.5039 7/32 5.5563 23/32 18.2563
15 0.5906 40 1.5748 65 2.5591 90 3.5433 15/64 5.9531 47/64 18.6531
16 0.6299 41 1.6142 66 2.5984 91 3.5827 1/4 6.3500 3/4 19.0500
17 0.6693 42 1.6535 67 2.6378 92 3.6220 17/64 6.7469 49/64 19.4469
18 0.7087 43 1.6929 68 2.6772 93 3.6614 9/32 7.1438 25/32 19.8438
19 0.7480 44 1.7323 69 2.7165 94 3.7008 19/64 7.5406 51/64 20.2406
20 0.7874 45 1.7717 70 2.7559 95 3.7402 5/16 7.9375 13/16 20.6375
21 0.8268 46 1.8110 71 2.7953 96 3.7795 21/64 8.3344 53/64 21.0344
22 0.8661 47 1.8504 72 2.8346 97 3.8189 11/32 8.7313 27/32 21.4313
23 0.9055 48 1.8898 73 2.8740 98 3.8583 23/64 9.1281 55/64 21.8281
24 0.9449 49 1.9291 74 2.9134 99 3.8976 3/8 9.5250 7/8 22.2250
25 0.9843 50 1.9685 75 2.9528 100 3.9370 25/64 9.9219 57/64 22.6219
13/32 10.3188 29/32 23.0188
101 3.9764 111 4.3701 121 4.7638 131 5.1575 27/64 10.7156 59/64 23.4156
102 4.0157 112 4.4094 122 4.8031 132 5.1969 7/16 11.1125 15/16 23.8125
103 4.0551 113 4.4488 123 4.8425 133 5.2362 29/64 11.5094 61/64 24.2094
104 4.0945 114 4.4882 124 4.8819 134 5.2756 15/32 11.9063 31/32 24.6063
105 4.1339 115 4.5276 125 4.9213 135 5.3150 31/64 12.3031 63/64 25.0031
106 4.1732 116 4.5669 126 4.9606 136 5.3543 1/2 12.7000 1 25.4000
107 4.2126 117 4.6063 127 5.0000 137 5.3937
108 4.2520 118 4.6457 128 5.0394 138 5.4331
109 4.2913 119 4.6850 129 5.0787 139 5.4724
114 CONVERSION TABLE

LENGTH
FEET TO METERS

ft. 0 1 2 3 4 5 6 7 8 9 ft.
m m m m m m m m m m
––– –––0 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 –––
10 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 10
20 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 20
30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 11.278 11.582 11.887 30
40 12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935 40
50 15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50
60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031 60
70 21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70
80 24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127 80
90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90
100 30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223 100

METERS TO FEET

m 0 1 2 3 4 5 6 7 8 9
ft. ft. ft. ft. ft. ft. ft. ft. ft. ft.
––– –––00 3.2808 6.5617 9.8425 13.1234 16.4042 19.6850 22.9659 26.2467 29.5276 –––
10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10
20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20
30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30
40 131.2336 134.5144 137.7953 141.0761 144.3570 147.6378 150.9186 154.1995 157.4803 160.7612 40
50 164.0420 167.3228 170.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50
60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60
70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9055 259.1864 70
80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291.9948 80
90 295.2756 298.5564 301.8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90
100 328.0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100

MILES TO KILOMETERS

miles 0 1 2 3 4 5 6 7 8 9
km km km km km km km km km km
––– –––00 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 –––
10 16.093 17.703 19.312 20.921 22.531 24.140 25.749 27.359 28.968 30.577 10
20 32.187 33.796 35.405 37.015 38.624 40.234 41.843 43.452 45.062 46.671 20
30 48.280 49.890 51.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30
40 64.374 65.983 67.592 69.202 70.811 72.420 74.030 75.639 77.248 78.858 40
50 80.467 82.076 83.686 85.295 86.904 88.514 90.123 91.732 93.342 94.951 50
60 96.560 98.170 99.779 101.388 102.998 104.607 106.216 107.826 109.435 111.044 60
70 112.654 114.263 115.872 117.482 119.091 120.701 122.310 123.919 125.529 127.138 70
80 128.747 130.357 131.966 133.575 135.185 136.794 138.403 140.013 141.622 143.231 80
90 144.841 146.450 148.059 149.669 151.278 152.887 154.497 156.106 157.715 159.325 90
100 160.934 162.543 164.153 165.762 167.371 168.981 170.590 172.199 173.809 175.418 100

KILOMETERS TO MILES

km 0 1 2 3 4 5 6 7 8 9
miles miles miles miles miles miles miles miles miles miles
––– –––0 0.621 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592 –––
10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 11.185 11.806 10
20 12.427 13.049 13.670 14.292 14.913 15.534 16.156 16.777 17.398 18.020 20
30 18.641 19.262 19.884 20.505 21.127 21.748 22.369 22.991 23.612 24.233 30
40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30.447 40
50 31.069 31.690 32.311 32.933 33.554 34.175 34.797 35.418 36.039 36.661 50
60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60
70 43.496 44.117 44.739 45.360 45.981 46.603 47.224 47.845 48.467 49.088 70
80 49.710 50.331 50.952 51.574 52.195 52.816 53.438 54.059 54.681 55.302 80
90 55.923 56.545 57.166 57.787 58.409 59.030 59.652 60.273 60.894 61.516 90
100 62.137 62.758 63.380 64.001 64.622 65.244 65.865 66.487 67.108 67.729 100
CONVERSION TABLE 115

AREA
SQUARE INCHES TO SQUARE CENTIMETERS

in2 0 1 2 3 4 5 6 7 8 9 in2
cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2
––– –––00 6.452 12.903 19.355 25.806 32.258 38.710 45.161 51.613 58.064 –––
10 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.580 10
20 129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096 20
30 193.548 200.000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612 30
40 258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128 40
50 322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644 50
60 387.096 393.548 399.999 406.451 412.902 419.354 425.806 432.257 438.709 445.160 60
70 451.612 458.064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676 70
80 516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192 80
90 580.644 587.096 593.547 599.999 606.450 612.902 619.354 625.805 632.257 638.708 90
100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100

SQUARE CENTIMETERS TO SQUARE INCHES

cm2 0 1 2 3 4 5 6 7 8 9 cm2
in2 in2 in2 in2 in2 in2 in2 in2 in2 in2
––– –––0 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 –––
10 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 10
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
30 4.650 4.805 4.960 5.115 5.270 5.425 5.580 5.735 5.890 6.045 30
40 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
50 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8.990 9.145 50
60 9.300 9.455 9.610 9.765 9.920 10.075 10.230 10.385 10.540 10.695 60
70 10.850 11.005 11.160 11.315 11.470 11.625 11.780 11.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
100 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100

VOLUME
CUBIC INCHES TO CUBIC CENTIMETERS

in3 0 1 2 3 4 5 6 7 8 9 in3
cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc)
––– –––00 16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.097 147.484 –––
10 163.871 180.258 196.645 213.032 229.419 245.806 262.193 278.580 294.967 311.354 10
20 327.741 344.128 360.515 376.902 393.290 409.677 426.064 442.451 458.838 475.225 20
30 491.612 507.999 524.386 540.773 557.160 573.547 589.934 606.321 622.708 639.095 30
40 655.483 671.870 688.257 704.644 721.031 737.418 753.805 770.192 786.579 802.966 40
50 819.353 835.740 852.127 868.514 884.901 901.289 917.676 934.063 950.450 966.837 50
60 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60
70 1147.094 1163.482 1179.869 1196.256 1212.643 1229.030 1245.417 1261.804 1278.191 1294.578 70
80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.288 1425.675 1442.062 1458.449 80
90 1474.836 1491.223 1507.610 1523.997 1540.384 1556.771 1573.158 1589.545 1605.932 1622.319 90
100 1638.706 1655.093 1671.481 1687.868 1704.255 1720.642 1737.029 1753.416 1769.803 1786.190 100

CUBIC CENTIMETERS TO CUBIC INCHES

cm3(cc) 0 1 2 3 4 5 6 7 8 9 cm3(cc)
in3 in3 in3 in3 in3 in3 in3 in3 in3 in3
––– –––0 0.0610 0.1220 0.1831 0.2441 0.3051 0.3661 0.4272 0.4882 0.5492 –––
10 0.6102 0.6713 0.7323 0.7933 0.8543 0.9153 0.9764 1.0374 1.0984 1.1594 10
20 1.2205 1.2815 1.3425 1.4035 1.4646 1.5256 1.5866 1.6476 1.7086 1.7697 20
30 1.8307 1.8917 1.9527 2.0138 2.0748 2.1358 2.1968 2.2579 2.3189 2.3799 30
40 2.4409 2.5019 2.5630 2.6240 2.6850 2.7460 2.8071 2.8681 2.9291 2.9901 40
50 3.0512 3.1122 3.1732 3.2342 3.2952 3.3563 3.4173 3.4783 3.5393 3.6004 50
60 3.6614 3.7224 3.7834 3.8444 3.9055 3.9665 4.0275 4.0885 4.1496 4.2106 60
70 4.2716 4.3326 4.3937 4.4547 4.5157 4.5767 4.6377 4.6988 4.7598 4.8208 70
80 4.8818 4.9429 5.0039 5.0649 5.1259 5.1870 5.2480 5.3090 5.3700 5.4310 80
90 5.4921 5.5531 5.6141 5.6751 5.7362 5.7972 5.8582 5.9192 5.9803 6.0413 90
100 6.1023 6.1633 6.2243 6.2854 6.3464 6.4074 6.4684 6.5295 6.5905 6.6515 100
116 CONVERSION TABLE

VOLUME
GALLONS (U.S.) TO LITERS

U.S. gal. 0 1 2 3 4 5 6 7 8 9 U.S.gal.


liters liters liters liters liters liters liters liters liters liters
––– –––00 3.7854 7.5709 11.3563 15.1417 18.9271 22.7126 26.4980 30.2834 34.0688 –––
10 37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231 10
20 75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774 20
30 113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6317 30
40 151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859 40
50 189.2714 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402 50
60 227.1256 230.9110 234.6965 238.4819 242.2673 246.0528 249.8382 253.6236 257.4090 261.1945 60
70 264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6925 291.4779 295.2633 299.0487 70
80 302.8342 306.6196 310.4050 314.1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030 80
90 340.6884 344.4739 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573 90
100 378.5427 382.3281 386.1136 389.8990 393.6844 397.4698 401.2553 405.0407 408.8261 412.6115 100

LITERS TO GALLONS (U.S.)

liters 0 1 2 3 4 5 6 7 8 9 liters
gal. gal. gal. gal. gal. gal. gal. gal. gal. gal.
––– –––00 0.2642 0.5283 0.7925 1.0567 1.3209 1.5850 1.8492 2.1134 2.3775 –––
10 2.6417 2.9059 3.1701 3.4342 3.6984 3.9626 4.2268 4.4909 4.7551 5.0193 10
20 5.2834 5.5476 5.8118 6.0760 6.3401 6.6043 6.8685 7.1326 7.3968 7.6610 20
30 7.9252 8.1893 8.4535 8.7177 8.9818 9.2460 9.5102 9.7744 10.0385 10.3027 30
40 10.5669 10.8311 11.0952 11.3594 11.6236 11.8877 12.1519 12.4161 12.6803 12.9444 40
50 13.2086 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861 50
60 15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17.4354 17.6995 17.9637 18.2279 60
70 18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696 70
80 21.1338 21.3979 21.6621 21.9263 22.1904 22.4546 22.7188 22.9830 23.2471 23.5113 80
90 23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530 90
100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100

GALLONS (IMP.) TO LITERS

Imp gal. 0 1 2 3 4 5 6 7 8 9 Imp gal.


liters liters liters liters liters liters liters liters liters liters
––– –––00 4.5459 9.0918 13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131 –––
10 45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 81.8262 86.3721 10
20 90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311 20
30 136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.2901 30
40 181.8360 186.3819 190.9278 195.4737 200.0196 204.5655 209.1114 213.6573 218.2032 222.7491 40
50 227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254.5704 259.1163 263.6622 268.2081 50
60 272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309.1212 313.6671 60
70 318.2130 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261 70
80 363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851 80
90 409.1310 413.6769 418.2228 422.7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441 90
100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481.8654 486.4113 490.9572 495.5031 100

LITERS TO GALLONS (IMP.)

liters 0 1 2 3 4 5 6 7 8 9 liters
gal. gal. gal. gal. gal. gal. gal. gal. gal. gal.
––– –––00 0.2200 0.4400 0.6599 0.8799 1.0999 1.3199 1.5399 1.7598 1.9798 –––
10 2.1998 2.4198 2.6398 2.8597 3.0797 3.2997 3.5197 3.7397 3.9596 4.1796 10
20 4.3996 4.6196 4.8396 5.0595 5.2795 5.4995 5.7195 5.9395 6.1594 6.3794 20
30 6.5994 6.8194 7.0394 7.2593 7.4793 7.6993 7.9193 8.1393 8.3592 8.5792 30
40 8.7992 9.0192 9.2392 9.4591 9.6791 9.8991 10.1191 10.3391 10.5590 10.7790 40
50 10.9990 11.2190 11.4390 11.6589 11.8789 12.0989 12.3189 12.5389 12.7588 12.9788 50
60 13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786 60
70 15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784 70
80 17.5984 17.8184 18.0384 18.2583 18.4783 18.6983 18.9183 19.1383 19.3582 19.5782 80
90 19.7982 20.0182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 21.5580 21.7780 90
100 21.9980 22.2180 22.4380 22.6579 22.8779 23.0979 23.3179 23.5379 23.7578 23.9778 100
CONVERSION TABLE 117

MASS
POUNDS TO KILOGRAMS

lbs. 0 1 2 3 4 5 6 7 8 9 lbs.
kg kg kg kg kg kg kg kg kg kg
––– –––0 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 –––
10 4.536 4.989 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618 10
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154 20
30 13.608 14.061 14.515 14.968 15.422 15.876 16.329 16.783 17.236 17.690 30
40 18.144 18.597 19.051 19.504 19.958 20.412 20.865 21.319 21.772 22.226 40
50 22.680 23.133 23.587 24.040 24.494 24.947 25.401 25.855 26.308 26.762 50
60 27.215 27.669 28.123 28.576 29.030 29.483 29.937 30.391 30.844 31.298 60
70 31.751 32.205 32.658 33.112 33.566 34.019 34.473 34.926 35.380 35.834 70
80 36.287 36.741 37.194 37.648 38.102 38.555 39.009 39.462 39.916 40.370 80
90 40.823 41.277 41.730 42.184 42.637 43.091 43.545 43.998 44.452 44.905 90
100 45.359 45.813 46.266 46.720 47.173 47.627 48.081 48.534 48.988 49.441 100

KILOGRAMS TO POUNDS

kg 0 1 2 3 4 5 6 7 8 9 kg
lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.
––– –––00 2.205 4.409 6.614 8.818 11.023 13.228 15.432 17.637 19.842 –––
10 22.046 24.251 26.455 28.660 30.865 33.069 35.274 37.479 39.683 41.888 10
20 44.092 46.297 48.502 50.706 52.911 55.116 57.320 59.525 61.729 63.934 20
30 66.139 68.343 70.548 72.752 74.957 77.162 79.366 81.571 83.776 85.980 30
40 88.185 90.389 92.594 94.799 97.003 99.208 101.413 103.617 105.822 108.026 40
50 110.231 112.436 114.640 116.845 119.049 121.254 123.459 125.663 127.868 130.073 50
60 132.277 134.482 136.686 138.891 141.096 143.300 145.505 147.710 149.914 152.119 60
70 154.323 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165 70
80 176.370 178.574 180.779 182.983 185.188 187.393 189.597 191.802 194.007 196.211 80
90 198.416 200.620 202.825 205.030 207.234 209.439 211.644 213.848 216.053 218.257 90
100 220.462 222.667 224.871 227.076 229.280 231.485 233.690 235.894 238.099 240.304 100

KILOGRAMS TO NEWTON

kg 0 1 2 3 4 5 6 7 8 9 kg
N N N N N N N N N N
––– –––0 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 –––
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67 990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100

NEWTON TO KILOGRAMS

N 0 10 20 30 40 50 60 70 80 90 N
kg kg kg kg kg kg kg kg kg kg
––– –––00 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 –––
100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 100
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 200
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 300
400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 400
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 500
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 600
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 700
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 800
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 900
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 1000
118 CONVERSION TABLE

PRESSURE
POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS

lb/in2 0 1 2 3 4 5 6 7 8 9 lb/in2
(psi) kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 (psi)
––– –––0 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328 –––
10 0.7031 0.7734 0.8437 0.9140 0.9843 1.0546 1.1249 1.1952 1.2655 1.3358 10
20 1.4061 1.4764 1.5468 1.6171 1.6874 1.7577 1.8280 1.8983 1.9686 2.0389 20
30 2.1092 2.1795 2.2498 2.3201 2.3904 2.4607 2.5311 2.6014 2.6717 2.7420 30
40 2.8123 2.8826 2.9529 3.0232 3.0935 3.1638 3.2341 3.3044 3.3747 3.4450 40
50 3.5154 3.5857 3.6560 3.7263 3.7966 3.8669 3.9372 4.0075 4.0778 4.1481 50
60 4.2184 4.2887 4.3590 4.4293 4.4996 4.5700 4.6403 4.7106 4.7809 4.8512 60
70 4.9215 4.9918 5.0621 5.1324 5.2027 5.2730 5.3433 5.4136 5.4839 5.5543 70
80 5.6246 5.6949 5.7652 5.8355 5.9058 5.9761 6.0464 6.1167 6.1870 6.2573 80
90 6.3276 6.3979 6.4682 6.5386 6.6089 6.6792 6.7495 6.8198 6.8901 6.9604 90
100 7.0307 7.1010 7.1713 7.2416 7.3119 7.3822 7.4525 7.5228 7.5932 7.6635 100

KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES

kg/cm2 0 1 2 3 4 5 6 7 8 9 kg/cm2
lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi)
––– –––00 14.22 28.45 42.67 56.89 71.12 85.34 99.56 113.78 128.01 –––
10 142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24 10
20 284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47 20
30 426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70 30
40 568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93 40
50 711.15 725.37 739.60 753.82 768.04 782.27 796.49 810.71 824.93 839.16 50
60 853.38 867.60 881.83 896.05 910.27 924.50 938.72 952.94 967.16 981.39 60
70 995.61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62 70
80 1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85 80
90 1280.07 1294.29 1308.52 1322.74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08 90
100 1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31 100

KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL

kg/cm2 0 1 2 3 4 5 6 7 8 9 kg/cm2
KPa KPa KPa KPa KPa KPa KPa KPa KPa KPa
––– –––00 98.1 196.1 294.2 392.3 490.3 588.4 686.5 784.5 882.6 –––
10 980.7 1078.7 1176.8 1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 4118.8 4216.9 4314.9 4413.0 4511.1 4609.1 4707.2 4805.3 40
50 4903.4 5001.4 5099.5 5197.6 5295.6 5393.7 5491.8 5589.8 5687.9 5786.0 50
60 5884.0 5982.1 6080.2 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6 60
70 6864.7 6962.8 7060.8 7158.9 7257.0 7355.0 7453.1 7551.2 7649.2 7747.3 70
80 7845.4 7943.4 8041.5 8139.6 8237.6 8335.7 8433.8 8531.8 8629.9 8728.0 80
90 8826.0 8924.1 9022.2 9120.2 9218.3 9316.4 9414.4 9512.5 9610.6 9708.6 90
100 9806.7 9904.8 10002.8 10100.9 10199.0 10297.0 10395.1 10493.2 10591.2 10689.3 100

KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS

KPa 0 100 200 300 400 500 600 700 800 900 KPa
kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2
–––0 –––00 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 –––0
1000 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 1000
2000 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 2000
3000 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 3000
4000 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 4000
5000 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 5000
6000 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 6000
7000 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 7000
8000 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 8000
9000 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 9000
10000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 10000
CONVERSION TABLE 119

TORQUE
FOOT POUNDS TO KILOGRAMMETERS

ft. lbs. 0 1 2 3 4 5 6 7 8 9 ft lbs.


kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m
––– –––0 0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.244 –––
10 1.383 1.521 1.659 1.797 1.936 2.074 2.212 2.350 2.489 2.627 10
20 2.765 2.903 3.042 3.180 3.318 3.457 3.595 3.733 3.871 4.010 20
30 4.148 4.286 4.424 4.563 4.701 4.839 4.977 5.116 5.254 5.392 30
40 5.530 5.669 5.807 5.945 6.083 6.222 6.360 6.498 6.636 6.775 40
50 6.913 7.051 7.190 7.328 7.466 7.604 7.743 7.881 8.019 8.157 50
60 8.296 8.434 8.572 8.710 8.849 8.987 9.125 9.263 9.402 9.540 60
70 9.678 9.816 9.955 10.093 10.231 10.370 10.508 10.646 10.784 10.923 70
80 11.061 11.199 11.337 11.476 11.614 11.752 11.890 12.029 12.167 12.305 80
90 12.443 12.582 12.720 12.858 12.996 13.135 13.273 13.411 13.549 13.688 90
100 13.826 13.964 14.103 14.241 14.379 14.517 14.656 14.794 14.932 15.070 100

KILOGRAMMETERS TO FOOT POUNDS

kg-m 0 1 2 3 4 5 6 7 8 9 kg-m
ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs.
––– –––0 7.23 14.47 21.70 28.93 36.17 43.40 50.63 57.86 65.10 –––
10 72.33 79.56 86.80 94.03 101.26 108.50 115.73 122.96 130.19 137.43 10
20 144.66 151.89 159.13 166.36 173.59 180.83 188.06 195.29 202.52 209.76 20
30 216.99 224.22 231.46 238.69 245.92 253.16 260.39 267.62 274.85 282.09 30
40 289.32 296.55 303.79 311.02 318.25 325.49 332.72 339.95 347.18 354.42 40
50 361.65 368.88 376.12 383.35 390.58 397.82 405.05 412.28 419.51 426.75 50
60 433.98 441.21 448.45 455.68 462.91 470.15 477.38 484.61 491.84 499.08 60
70 506.31 513.54 520.78 528.01 535.24 542.48 549.71 556.94 564.17 571.41 70
80 578.64 585.87 593.11 600.34 607.57 614.81 622.04 629.27 636.50 643.74 80
90 650.97 658.20 665.44 672.67 679.90 687.14 694.37 701.60 708.83 716.07 90
100 723.30 730.53 737.77 745.00 752.23 759.47 766.70 773.93 781.16 788.40 100

KILOGRAMMETERS TO NEWTONMETERS

kg-m 0 1 2 3 4 5 6 7 8 9 kg-m
N-m N-m N-m N-m N-m N-m N-m N-m N-m N-m
––– –––00 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 –––
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67 990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100

NEWTONMETERS TO KILOGRAMMETERS

N-m 0 10 20 30 40 50 60 70 80 90 N-m
kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m
––– –––00 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 –––
100 10.197 11.217 12.236 13.256 14.276 15.296 16.315 17.335 18.355 19.374 100
200 20.394 21.414 22.433 23.453 24.473 25.493 26.512 27.532 28.552 29.571 200
300 30.591 31.611 32.630 33.650 34.670 35.690 36.709 37.729 38.749 39.768 300
400 40.788 41.808 42.827 43.847 44.867 45.887 46.906 47.926 48.946 49.965 400
500 50.985 52.005 53.024 54.044 55.064 56.084 57.103 58.123 59.143 60.162 500
600 61.182 62.202 63.221 64.241 65.261 66.281 67.300 68.320 69.340 70.359 600
700 71.379 72.399 73.418 74.438 75.458 76.478 77.497 78.517 79.537 80.556 700
800 81.576 82.596 83.615 84.635 85.655 86.675 87.694 88.714 89.734 90.753 800
900 91.773 92.793 93.812 94.832 95.852 96.872 97.891 98.911 99.931 100.950 900
1000 101.970 102.990 104.009 105.029 106.049 107.069 108.088 109.108 110.128 111.147 1000
120 CONVERSION TABLE

TEMPERATURE
FAHRENHEIT TO CENTIGRADE

°F °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C

-60 -51.1 -2 -18.9 56 13.3 114 45.6 172 77.8 230 110.0 288 142.2 346 174.4
-58 -50.0 0 -17.8 58 14.4 116 46.7 174 78.9 232 111.1 290 143.3 348 175.6
-56 -48.9 2 -16.7 60 15.6 118 47.8 176 80.0 234 112.2 292 144.4 350 176.7
-54 -47.8 4 -15.6 62 16.7 120 48.9 178 81.1 236 113.3 294 145.6 352 177.8
-52 -46.7 6 -14.4 64 17.8 122 50.0 180 82.2 238 114.4 296 146.7 354 178.9
-50 -45.6 8 -13.3 66 18.9 124 51.1 182 83.3 240 115.6 298 147.8 356 180.0
-48 -44.4 10 -12.2 68 20.0 126 52.2 184 84.4 242 116.7 300 148.9 358 181.1
-46 -43.3 12 -11.1 70 21.1 128 53.3 186 85.6 244 117.8 302 150.0 360 182.2
-44 -42.2 14 -10.0 72 22.2 130 54.4 188 86.7 246 118.9 304 151.1 362 183.3
-42 -41.1 16 -8.9 74 23.3 132 55.6 190 87.8 248 120.0 306 152.2 364 184.4
-40 -40.0 18 -7.8 76 24.4 134 56.7 192 88.9 250 121.1 308 153.3 366 185.6
-38 -38.9 20 -6.7 78 25.6 136 57.8 194 90.0 252 122.2 310 154.4 368 186.7
-36 -37.8 22 -5.6 80 26.7 138 58.9 196 91.1 254 123.3 312 155.6 370 187.8
-34 -36.7 24 -4.4 82 27.8 140 60.0 198 92.2 256 124.4 314 156.7 372 188.9
-32 -35.6 26 -3.3 84 28.9 142 61.1 200 93.3 258 125.6 316 157.8 374 190.0
-30 -34.4 28 -2.2 86 30.0 144 62.2 202 94.4 260 126.7 318 158.9 376 191.1
-28 -33.3 30 -1.1 88 31.1 146 63.3 204 95.6 262 127.8 320 160.0 378 192.2
-26 -32.2 32 0.0 90 32.2 148 64.4 206 96.7 264 128.9 322 161.1 380 193.3
-24 -31.1 34 1.1 92 33.3 150 65.6 208 97.8 266 130.0 324 162.2 382 194.4
-22 -30.0 36 2.2 94 34.4 152 66.7 210 98.9 268 131.1 326 163.3 384 195.6
-20 -28.9 38 3.3 96 35.6 154 67.8 212 100.0 270 132.2 328 164.4 386 196.7
-18 -27.8 40 4.4 98 36.7 156 68.9 214 101.1 272 133.3 330 165.6 388 197.8
-16 -26.7 42 5.6 100 37.8 158 70.0 216 102.2 274 134.4 332 166.7 390 198.9
-14 -25.6 44 6.7 102 38.9 160 71.1 218 103.3 276 135.6 334 167.8 392 200.0
-12 -24.4 46 7.8 104 40.0 162 72.2 220 104.4 278 136.7 336 168.9 400 204.4
-10 -23.3 48 8.9 106 41.1 164 73.3 222 105.6 280 137.8 338 170.0 410 210.0
-8 -22.2 50 10.0 108 42.2 166 74.4 224 106.7 282 138.9 340 171.1 420 215.6
-6 -21.1 52 11.1 110 43.3 168 75.6 226 107.8 284 140.0 342 172.2 430 221.1
-4 -20.0 54 12.2 112 44.4 170 76.7 228 108.9 286 141.1 344 173.3 440 226.7

CENTIGRADE TO FAHRENHEIT

°C °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F

-50 -58.0 -18 -0.4 14 57.2 46 114.8 78 172.4 110 230.0 142 287.6 174 345.2
-49 -56.2 -17 1.4 15 59.0 47 116.6 79 174.2 111 231.8 143 289.4 175 347.0
-48 -54.4 -16 3.2 16 60.8 48 118.4 80 176.0 112 233.6 144 291.2 176 348.8
-47 -52.6 -15 5.0 17 62.6 49 120.2 81 177.8 113 235.4 145 293.0 177 350.6
-46 -50.8 -14 6.8 18 64.4 50 122.0 82 179.6 114 237.2 146 294.8 178 352.4
-45 -49.0 -13 8.6 19 66.2 51 123.8 83 181.4 115 239.0 147 296.6 179 354.2
-44 -47.2 -12 10.4 20 68.0 52 125.6 84 183.2 116 240.8 148 298.4 180 356.0
-43 -45.4 -11 12.2 21 69.8 53 127.4 85 185.0 117 242.6 149 300.2 181 357.8
-42 -43.6 -10 14.0 22 71.6 54 129.2 86 186.8 118 244.4 150 302.0 182 359.6
-41 -41.8 -9 15.8 23 73.4 55 131.0 87 188.6 119 246.2 151 303.8 183 361.4
-40 -40.0 -8 17.6 24 75.2 56 132.8 88 190.4 120 248.0 152 305.6 184 363.2
-39 -38.2 -7 19.4 25 77.0 57 134.6 89 192.2 121 249.8 153 307.4 185 365.0
-38 -36.4 -6 21.2 26 78.8 58 136.4 90 194.0 122 251.6 154 309.2 186 366.8
-37 -34.6 -5 23.0 27 80.6 59 138.2 91 195.8 123 253.4 155 311.0 187 368.6
-36 -32.8 -4 24.8 28 82.4 60 140.0 92 197.6 124 255.2 156 312.8 188 370.4
-35 -31.0 -3 26.6 29 84.2 61 141.8 93 199.4 125 257.0 157 314.6 189 372.2
-34 -29.2 -2 28.4 30 86.0 62 143.6 94 201.2 126 258.8 158 316.4 190 374.0
-33 -27.4 -1 30.2 31 87.8 63 145.4 95 203.0 127 260.6 159 318.2 191 375.8
-32 -25.6 0 32.0 32 89.6 64 147.2 96 204.8 128 262.4 160 320.0 192 377.6
-31 -23.8 1 33.8 33 91.4 65 149.0 97 206.6 129 264.2 161 321.8 193 379.4
-30 -22.0 2 35.6 34 93.2 66 150.8 98 208.4 130 266.0 162 323.6 194 381.2
-29 -20.2 3 37.4 35 95.0 67 152.6 99 210.2 131 267.8 163 325.4 195 383.0
-28 -18.4 4 39.2 36 96.8 68 154.4 100 212.0 132 269.6 164 327.2 196 384.8
-27 -16.6 5 41.0 37 98.6 69 156.2 101 213.8 133 271.4 165 329.0 197 386.6
-26 -14.8 6 42.8 38 100.4 70 158.0 102 215.6 134 273.2 166 330.8 198 388.4
-25 -13.0 7 44.6 39 102.2 71 159.8 103 217.4 135 275.0 167 332.6 199 390.2
-24 -11.2 8 46.4 40 104.0 72 161.6 104 219.2 136 276.8 168 334.4 200 392.0
-23 -9.4 9 48.2 41 105.8 73 163.4 105 221.0 137 278.6 169 336.2 210 410.0
-22 -7.6 10 50.0 42 107.6 74 165.2 106 222.8 138 280.4 170 338.0 220 428.0
-21 -5.8 11 51.8 43 109.4 75 167.0 107 224.6 139 282.2 171 339.8 230 446.0
-20 -4.0 12 53.6 44 111.2 76 168.8 108 226.4 140 284.0 172 341.6 240 464.0
-19 -2.2 13 55.4 45 113.0 77 170.6 109 228.2 141 285.8 173 343.4 250 482.0
DISASSEMBLY OF THE I.C. ENGINE

10-3-71 EN

01 / 02 / 2006
IMPORTANT

To identify the I.C. engine on your lift truck, see the LIFT TRUCK CHARACTERISTICS chapter in section O - GENERAL.
TABLE OF CONTENTS

SECTION 1. GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


SECTION 2. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 3. ENGINE ASSEMBLY (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
(DISASSEMBLY)
SECTION 4. ENGINE ASSEMBLY (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
(INSPECTION AND REPAIR)
SECTION 5. ENGINE ASSEMBLY (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
(REASSEMBLY)
SECTION 6. LUBRICATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
SECTION 7. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
SECTION 8. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
SECTION 9. ENGINE ELECTRICALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
SECTION 10. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
SECTION 11. SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
SECTION 12. CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
GENERAL INFORMATION

SECTION 1

GENERAL INFORMATION
TABLE OF CONTENTS

ITEM PAGE

General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2


Notes on the format of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Main data and specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tightening torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Augular nut and bolt tightening method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Special parts fixing nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1
GENERAL INFORMATION

GENERAL REPAIR INSTRUCTIONS


1. Before performing any service operation with the engine mounted, disconnect the grounding cable
from the battery.
This will reduce the chance of cable damage and burning due to short circuiting.
2. Always use the proper tool or tools for the job at hand.
Where specified, use the specially designed tool or tools.
3. Use genuine ISUZU parts.
4. Never reuse cotter pins, gaskets, O-rings, lock washers, and self locking nuts. Discard them as you
remove them. Replace them with new ones.
5. Always keep disassembled parts neatly in groups. This will ensure a smooth reassembly operation.
It is especially important to keep fastening parts separate. These parts vary in hardness and design,
depending on their installation position.
6. All parts should be carefully cleaned before inspection or reassembly.
Oil ports and other openings should be cleaned with compressed air to make sure that they are
completely free of obstructions.
7. Rotating and sliding part surfaces should be lubricated with oil or grease before reassembly.
8. If necessary, use a sealer on gaskets to prevent leakage.
9. Nut and bolt torque specifications should be carefully followed.
10. Always release the air pressure from any machine-mounted air tank(s) before dismounting the engine
or disconnecting pipes and hoses. To not do so is extremely dangerous.
11. Always check and recheck your work. No service operation is complete until you have done this.

NOTES ON THE FORMAT OF THIS MANUAL


This Workshop Manual is applicable to ISUZU industrial engine or engines which is or are stated in the
title.
When more than two engine models are dealt in the manual, such engines have common parts and
components as well as data and specifications, unless otherwise specified.
1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.
2. Common technical data such as general maintenance items, service specifications, and tightening
torques are included in the "General Information" section.
The section ENGINE ASSEMBLY is an exception. This parts are divided in three sections to facilitates
indexing.
3. Each section is divided into sub-sections dealing with disassembly, inspection and repair, and
reassembly.

2
GENERAL INFORMATION

4. When the same servicing operation is applicable to several different units, the manual will direct you
to the appropriate page.
5. For the sake of brevity, self-explanatory removal and installation procedures are omitted.
More complex procedures are covered in detail.
6. Each service operation section in this Workshop Manual begins with an exploded view of the
applicable area. A brief explanation of the notation used follows.

Parts marked with an asterisk (*) are


included in the repair kit.

Parts within a square frame are to be


6
★ ★ removed and installed as a single unit,
2 7
and their disassembly steps or reas-
1
8
sembly steps are shown in the

illustrations respectively.

The number tells you the service oper-


3 9
13
ation sequence.
★ 10 ★

12 Removal of unnumbered parts is unne-


5 ★
cessary unless replacement is required.
11 4

16
17 The "* Repair Kit" indicates that a repair
kit is available.

The parts listed under "Disassembly


14
Steps" or "Reassembly Steps" are in the
service operation sequence.
15 ★ Repair kit

Disassembly Steps - 2
The removal or installation of parts
1. Water by-pass hose 10. Cylinder head gasket marked with a triangle ( ▲ ) is an
2. Thermostat housing ▲ 11. Crankshaft damper pulley with
3. Water pump dust seal important operation. Detailed infor-
▲ 4. Injection nozzle holder 12. Timing gear case cover
5. Glow plug and glow plug connector 13. Timing gear cover mation is given in the text.
6. Cylinder head cover 14. Timing gear oil pipe
▲ 7. Rocker arm shaft and rocker arm 15. Idler gear “B” and shaft
8. Push rod ▲ 16. Idler gear “A”
▲ 9. Cylinder head 17. Idler gear shaft

Inverted Engine

3
GENERAL INFORMATION

7. Below is a sample of the text of the Workshop Manual.


This is the item shown in the illus-
tration. It is marked with a triangle
4. Camshaft Timing Gear
(▲) on the Major Components page.
1) Install the thrust plate 1 .
2) Apply engine oil to the bolt threads 2 .
3) Install the camshaft timing gear with the timing Letters and numbers contained in a
2 mark stamped side facing out.
Camshaft Timing Gear Bolt Torque kg·m(lb.ft/N·m) circle refer to the illustration.
11.0 ± 1.0 (79.5 ± 7.2/107.8 ± 9.8)
1

Special tools are identified by the


13. Crankshaft Rear Oil Seal
1) Apply engine oil to the oil seal lip circumference
tool name and/or number.
and the oil seal outer circumference.
2) Use the oil seal installer to install the oil seal to The illustration shows how the spe-
the cylinder body.
Oil Seal Installer: 5-8840-0141-0
cial tool is to be used.

Symbols indicate the type of service


14. Flywheel Housing operation or step to be performed. A
6 10
8 1) Apply liquid gasket to the shaded area shown in
5
9 the illustration. detailed explanation of these
3
2) Tighten the flywheel housing bolts to the speci-
fied torque a little at a time in the sequence
symbols follows.
2
shown in the illustration.
7 1
Flywheel Housing Bolt Torque kg·m(lb.ft/N·m)
M10x1.25 (0.40x0.05) Bolt 5.6±1.0 (40.5±7.2/ 54.9±9.8) Service data and specifications are
4 M12x1.25 (0.47x0.05) Bolt 10.5±1.0 (76.0±7.2/103.0±9.8)
M12x1.75 (0.47x0.07) Bolt 9.8±1.0 (71.0±7.2/ 96.0±9.8)
given in this table.

8. The following symbols appear throughout this Workshop Manual. They tell you the type of service
operation or step to perform.

.... Removal .... Adjustment

.... Installation .... Cleaning

.... Disassembly ... Important operation requiring extra care

.... Reassembly .... Specified torque (tighten)

.... Alignment (marks) .... Special tool use required or


recommended(Isuzu tool or tools)

.... Directional indication .... Commercially available tool use


required or recommended

.... Inspection .... Lubrication (oil)

.... Measurement .... Lubrication (grease)

.... Sealant application

4
GENERAL INFORMATION

9. Measurement criteria are defined by the terms "standard" and "limit".


A measurement falling within the "standard" range indicates that the applicable part or parts are
serviceable.
"Limit" should be thought of as an absolute value.
A measurement which is outside the "limit" indicates that the applicable part or parts must be either
repaired or replaced.
10. Components and parts are listed in the singular form throughout the Manual.
11. Directions used in this Manual are as follows:
Front
The cooling fan side of the engine viewed from the flywheel.
Right
The right hand side viewed from the same position.
Left
The left hand side viewed from the same position.
Rear
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine.
The front most cylinder is No. 1 and rear most cylinder is the final cylinder number of the engine.
The engine's direction of rotation is counterclockwise viewed from the flywheel.

5
GENERAL INFORMATION

MAIN DATA AND SPECIFICATIONS

Engine Model
4JG2
Item

Engine type Water cooled, four-cycle, in-line, overhead valve


Combustion chamber type Swirl chamber
Cylinder liner type Dry
No. of cylinders - Bore x Stroke mm(in.) 4 - 95.4 x 107 (3.76 x 4.21)
Total piston displacement cc(cid) 3,059 (187)
Compression ratio (To 1) 20.1
*Engine dimensions mm(in.) 710 x 555 x 733 (28.0 x 21.9 x 28.9)
Length x Width x Height
*Engine weight (Dry) kg(lb.) 244 (538)
Fuel injection order 1 – 3– 4 – 2
*Fuel injection timing (B.T.D.C.) degrees 6
Specified fuel Diesel fuel
Injection pump Bosch VE type
Governor Mechanical, type
*Low idle speed rpm 675 – 725
Injection nozzle Throttle type
Injection starting pressure MPa(kg/cm2/psi) 14.7 (150/2,130)
Fuel filter type Cartridge paper element
Water sedimentor (if so equipped) Sediment/water level indicating type
Compression pressure MPa(kg/cm2/psi) 2.94 (30/427)
Valve clearance (at cold) Intake mm(in.) 0.40 (0.016)
Exhaust mm(in.) 0.40 (0.016)
Lubrication method Pressurized circulation
Oil pump Trochoid type
Main oil filter type Cartridge paper element, full flow
Partial oil filter Not equipped
*Lubricating oil volume lit.(US/gal.) 7.5 (1.98)
Oil cooler (if so equipped) Water cooled built in oil filter
Cooling method Pressurized forced circulation
Coolant volume (engine only) lit.(US/gal.) 4.5 (1.19)
Water pump Belt driven impeller type
Thermostat type Wax pellet type
*Alternator V-A 12 – 35
*Starter V-kW 12 – 2.2

Specifications marked with an asterisk (*) will vary according to engine application.

6
GENERAL INFORMATION

TIGHTENING TORQUE SPECIFICATIONS


The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.

STANDARD BOLT kg·m (lb.ft/N·m)


Strength
Class 4.8 (4T) (7T) 8.8 9.8 (9T)
Refined Non-Refined
Bolt
Identification

Bolt No mark
Diameter ×
pitch (mm)

0.4 ∼ 0.8 0.5 ∼ 1.0


M 6 × 1.0
(2.9 ∼ 5.8/3.9 ∼ 7.8) (3.6 ∼ 7.2/4.9 ∼ 9.8)
0.8 ∼ 1.8 1.2 ∼ 2.3 1.7 ∼ 3.1
M 8 × 1.25 (12.3 ∼ 22.4/16.7 ∼ 30.4)
(5.8 ∼ 13.0/7.8 ∼ 17.7) (8.7 ∼ 16.6/11.8 ∼ 22.6)
2.1 ∼ 3.5 2.8 ∼ 4.7 3.8 ∼ 6.4
M10 × 1.25 (27.5 ∼ 46.3/37.3 ∼ 62.8)
(15.2 ∼ 25.3/20.6 ∼ 34.3) (20.3 ∼ 34.0/27.5 ∼ 46.1)
5.0 ∼ 7.5 6.2 ∼ 9.3 7.7 ∼ 11.6
M12 × 1.25 (55.7 ∼ 83.9/75.5 ∼ 113.8)
(36.2 ∼ 54.2/49.0 ∼ 73.6) (44.8 ∼ 67.3/60.8 ∼ 91.2)
7.8 ∼ 11.7 9.5 ∼ 14.2 11.6 ∼ 17.4
M14 × 1.5 (83.9 ∼ 125.6/113.8 ∼ 170.6)
(56.4 ∼ 84.6/78.5 ∼ 114.7) (68.7 ∼ 102.7/93.2 ∼ 139.3)
10.6 ∼ 16.0 13.8 ∼ 20.8 16.3 ∼ 24.5
M16 × 1.5 (118.9 ∼ 177.2/159.9 ∼ 240.3)
(76.7 ∼ 115.7/103.0 ∼ 156.9) (99.8 ∼ 150.4/135.3 ∼ 204.0)
15.4 ∼ 23.0 19.9 ∼ 29.9 23.4 ∼ 35.2
M18 × 1.5 (169.3 ∼ 254.6/229.5 ∼ 345.2)
(111.1 ∼ 166.4/151.0 ∼ 225.6) (143.9 ∼ 216.3/195.2 ∼ 391.3)
21.0 ∼ 31.6 27.5 ∼ 41.3 32.3 ∼ 48.5
M20 × 1.5 (233.6 ∼ 350.8/316.8 ∼ 475.6)
(151.9 ∼ 228.6/205.9 ∼ 307.9) (198.9 ∼ 298.7/269.7 ∼ 405.0)
25.6 ∼ 42.2 37.0 ∼ 55.5 43.3 ∼ 64.9
M22 × 1.5 (313.2 ∼ 469.4/424.6 ∼ 636.5)
(185.2 ∼ 305.2/251.1 ∼ 413.8) (267.6 ∼ 401.4/362.9 ∼ 544.3)
36.6 ∼ 55.0 43.9 ∼ 72.5 56.5 ∼ 84.7
M24 × 2.0 (408.7 ∼ 612.6/554.1 ∼ 830.6)
(264.7 ∼ 397.8/358.9 ∼ 539.4) (317.5 ∼ 523.9/430.5 ∼ 711.0)
2.0 ∼ 3.4 2.8 ∼ 4.6 3.7 ∼ 6.1
*M10 × 1.5 (26.8 ∼ 44.1/36.3 ∼ 59.8)
(14.5 ∼ 24.6/19.6 ∼ 32.4) (20.3 ∼ 33.3/27.5 ∼ 45.1)
4.6 ∼ 7.0 5.8 ∼ 8.6 7.3 ∼ 10.9
*M12 × 1.5 (52.8 ∼ 78.8/71.6 ∼ 106.9)
(33.3 ∼ 50.6/45.1 ∼ 68.7) (42.0 ∼ 62.2/56.9 ∼ 84.3)
7.3 ∼ 10.9 9.0 ∼ 13.4 10.9 ∼ 16.3
*M14 × 2.0 (78.8 ∼ 118.9/106.9 ∼ 159.9)
(52.8 ∼ 78.8/71.6 ∼ 106.9) (65.1 ∼ 96.9/88.3 ∼ 131.4)
10.2 ∼ 15.2 13.2 ∼ 19.8 15.6 ∼ 23.4
*M16 × 2.0 (112.8 ∼ 169.3/162.8 ∼ 229.5)
(73.8 ∼ 110.0/100.0 ∼ 149.1) (95.5 ∼ 143.2/129.5 ∼ 194.2)

An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.

7
GENERAL INFORMATION

TIGHTENING TORQUE SPECIFICATIONS


The tightening torque values given in the table below are applicable to the bolts unless otherwise
specified.

FLANGED HEAD BOLT kg·m (lb.ft/N·m)


Bolt head
marking
Nominal
size
(dia. x pitch)
0.5 ∼ 0.9 0.6 ∼ 1.2
M6 ×1
(3.61 ∼ 6.50/4.6 ∼ 8.5) (4.33 ∼ 8.67/5.88 ∼ 11.76)

1.1 ∼ 2.0 1.4 ∼ 2.9 1.9 ∼ 3.4


M 8 × 1.25
(7.95 ∼ 14.46/10.78 ∼ 19.61) (4.33 ∼ 8.67/5.88 ∼ 11.76) (13.74 ∼ 24.59/18.63 ∼ 33.34)

2.3 ∼ 3.9 3.6 ∼ 6.4 4.3 ∼ 7.2


M10 × 1.25
(17.35 ∼ 28.20/23.53 ∼ 38.24) (26.03 ∼ 44.12/35.30 ∼ 59.82) (31.10 ∼ 52.07/42.16 ∼ 70.60)

2.3 ∼ 3.8 3.5 ∼ 5.8 4.1 ∼ 6.8


*M10 × 1.5
(16.63 ∼ 27.48/22.55 ∼ 37.26) (25.31 ∼ 41.95/34.32 ∼ 56.87) (29.65 ∼ 49.18/40.20 ∼ 66.68)

5.6 ∼ 8.4 7.9 ∼ 11.9 8.7 ∼ 13.0


M12 × 1.25
(40.50 ∼ 60.75/54.91 ∼ 82.37) (57.14 ∼ 86.07/77.47 ∼ 116.69) (62.92 ∼ 94.02/85.31 ∼ 127.48)

3.5 ∼ 9.5 7.3 ∼ 10.9 8.1 ∼ 12.2


*M12 × 1.75
(37.61 ∼ 56.41/50.99 ∼ 76.49) (52.80 ∼ 78.83/71.58 ∼ 106.89) (58.58 ∼ 88.24/79.43 ∼ 119.64)

8.5 ∼ 12.7 11.7 ∼ 17.6 12.6 ∼ 18.9


M14 × 1.5
(61.48 ∼ 91.85/83.35 ∼ 124.54) (84.62 ∼ 127.30/114.73 ∼ 172.59) (91.13 ∼ 136.70/123.56 ∼ 185.34)

7.6 ∼ 11.5 11.1 ∼ 16.6 11.8 ∼ 17.7


*M14 × 2
(57.14 ∼ 85.34/77.47 ∼ 115.71) (80.28 ∼ 120.06/108.85 ∼ 162.79) (85.34 ∼ 128.02/115.71 ∼ 173.57)

11.8 ∼ 17.7 17.1 ∼ 26.5 18.0 ∼ 27.1


M16 × 1.5
(85.34 ∼ 128.02/115.71 ∼ 173.57) (125.85 ∼ 189.50/170.63 ∼ 256.93) (130.19 ∼ 196.01/176.52 ∼ 265.76)

11.2 ∼ 16.7 16.6 ∼ 24.9 17.2 ∼ 25.7


*M16 × 2
(81.00 ∼ 120.79/109.83 ∼ 163.77) (120.06 ∼ 180.10/162.79 ∼ 244.18) (124.40 ∼ 186.61/168.67 ∼ 253.01)

A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.

8
GENERAL INFORMATION

ANGULAR NUT AND BOLT TIGHTENING METHOD

1. Carefully wash the nuts and bolts to remove all oil


and grease.

2. Apply a coat of molybdenum disulfide grease to the


threads and setting faces of the nuts and bolts.
um
d en de
i
yb lf e
ol su as
M di gre

3. Tighten the nuts and bolts to the specified torque


(snug torque) with a torque wrench.
NUT
OR
BOLT

Snug torque

4. Draw a line [A-B] across the center of each bolt.


Center line

A B

9
GENERAL INFORMATION

5. Draw another line (C-D) on the face of each of the


Line parts to be clamped. This line should be an
extension of the line [A-B].

A B C D

6. Draw another line [F-G] on the face of each of the


parts to be clamped. This line will be in the
direction of the specified angle (Q) across the center
E [E] of the nut or bolt.
Specified angle (Q)

Coinciding line G

7. Use a socket wrench to tighten each nut or bolt to


Tighten the point where the line [A-B] is aligned with the
A line [F-G].
C D

B
F

Example: Specified Angle and Tightening Rotation


A 30° 1/12 of a turn

A B C D E B 60° 1/6 of a turn


C 90° 1/4 of a turn
D 180° 1/2 of a turn
E 360° One full turn

10
GENERAL INFORMATION

SPECIAL PARTS FIXING NUTS AND BOLTS

Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
kg·m(lb.ft./N·m)

0.8 – 1.8
(5.8 – 13.0/8 – 18)

5.0 – 6.0
(36 –43/49 – 59)

1.0 – 2.0
(7 – 14/10 – 20)

1st 2nd 3rd

4.5 – 5.5
60 – 75° 60 – 75°
(33 – 40/44 – 54)
Apply engine oil to thread portion

11
GENERAL INFORMATION

Crankshaft Bearing Cap, Connecting Rod Bearing Cap,


Crankshaft Damper Pulley, Flywheel, and Oil Pan
kg·m(lb.ft./N·m)

11.5 – 12.5
(83 – 90/113 – 123)
2.8 – 3.2 → 45° – 60°
(20 – 23/27 – 31)
Apply engine oil to thread portion

16.0 – 18.0
(116 – 130/157 – 177)
Apply engine oil to thread portion

20.1 – 24.5
(145 – 177/197 – 240)

1.4 – 2.4
(10 – 17/14 – 24)

1.4 – 2.4
(10 – 17/14 – 24)

0.6 – 1.0
(4.4 – 7.2/5.9 – 9.8)

12
GENERAL INFORMATION

Timing Gear Case, Flywheel Housing, Camshaft, and Timing Gear

kg·m(lb.ft./N·m)

M10 x 1.25 3.6 – 4.6 (26 – 33/35 – 45)

M12 x 1.5 7.5 – 9.3 (54 – 67/74 – 91)

1.4 – 2.4
(10 – 17/14 – 24)

1.4 – 2.4
(10 – 17/14 – 24)

1.4 – 2.4
(10 – 17/14 – 24)

10.0 – 12.0 2.1 – 3.1


(72 – 87/98 – 118) (15 – 22/21 – 30)

(PKL)

1.0 – 1.5
(7 – 11/10 – 15) 9.5– 11.5
(69 – 83/93 – 113)

13
GENERAL INFORMATION

Cooling and Lubricating System

kg·m(lb.ft./N·m)

1.4 – 2.4
(10 – 17/14 – 24)

1.4 – 2.4
(10 – 17/14 – 24)

1.4 – 2.4
(10 – 17/14 – 24)

1.4 – 2.4
(10 – 17/14 – 24)

1.4 – 2.4
(10 – 17/14 – 24)

14
GENERAL INFORMATION

Intake and Exhaust Manifold

kg·m(lb.ft./N·m)

1.4 – 2.4
(10 – 17/14 – 24)

1.4 – 2.4
(10 – 17/14 – 24)

15
GENERAL INFORMATION

Engine Electrical

kg·m(lb.ft./N·m)

1.4 – 2.4 1.5 – 2.0


(10 – 17/14 – 24) (11 – 14/15 – 20)

1.4 – 2.4
(10 – 17/14 – 24)

6.7 – 8.7
(49 – 63/66 – 86)

16
GENERAL INFORMATION

Fuel Injection System

kg·m(lb.ft./N·m)

6.0 – 7.0
(43 – 51/59 – 69)

20 – 4.0
(14.4 – 28.9/19.6 – 39.2)

1.4 – 2.4
(10 – 17/14 – 24)

1.4 – 2.4
(10 – 17/14 – 24)

17
GENERAL INFORMATION

MEMO

18
MAINTENANCE

SECTION 2

MAINTENANCE
TABLE OF CONTENTS

ITEM PAGE

Model identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Injection pump identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lubricating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Compression pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Recommended lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Repair kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

19
MAINTENANCE

MAINTENANCE

Servicing refers to general maintenance procedures to be performed by qualified service personnel.


Maintenance interval such as fuel or oil filter changes should be refered to “INSTRUCTION MANUAL”.

MODEL IDENTIFICATION

Engine Serial Number


The engine number is stamped on the rear left hand side
of the cylinder body.

INJECTION PUMP IDENTIFICATION


Pump Serial Number
Injection volume should be adjusted after referring to
the adjustment data applicable to the injection pump
installed.
PUMP NO. 104646-1910 The injection pump identification number (A) is stamped
NP–VE4/11F1200LNP1593 on the injection pump identifications plate.
(LICENCE BOSCH) Note:
Always check the identification number before beginn-
ing a service operation.
Applicable service data will vary according to the ident-
ification number. Use of the wrong service data will
result in reduced engine performance and engine
damage.

LUBRICATING SYSTEM

Main Oil Filter


Replacement Procedure
1. Loosen the drain plug to drain the engine oil.
2. Wait a few minutes and then retighten the drain
plug.
3. Loosen the used oil filter by turning it counterclock-
wise with a filter wrench.
Filter Wrench

20
MAINTENANCE

4. Clean the oil filter fitting face.


This will allow the new oil filter to seat properly.
5. Apply a light coat of engine oil to the O-ring.
6. Turn in the new oil filter until the filter O-ring is
fitted against the sealing face.

7. Use a filter wrench to turn in the filter an additional


1 and 1/4 of a turn.
Filter Wrench
8. Check the engine oil level and replenish to the spec-
ified level if required.
9. Start the engine and check for oil leakage from the
main oil filter.

FUEL SYSTEM
Fuel Filter
Replacement Procedure
1. Loosen the used fuel filter by turning it counter-
clockwise with the filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)
2. Remove the level sensor from the filter by turning it
counterclockwise with a wrench.

3. Install the level sensor to the new fuel filter with a


wrench.
Level Sensor Torque kg·m (lb·ft/N·m)
1.3 (9/13)

4. Clean the filter cover fitting faces.


This will allow the new fuel filter to seat properly.

5. Apply a light coat of engine oil to the O-ring.


6. Turn in the fuel filter until the sealing face comes in
contact with the O-ring.
7. Turn in the fuel filter an additional 2/3 of a turn with
a filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)

21
MAINTENANCE

8. Loosen the bleeder plug on the injection pump


overflow valve.
9. Operate the priming pump until fuel begins to flow
from the fuel filter.
10. Retighten the bleeder plug.
11. Operate the priming pump several times and check
for fuel leakage.
NOTE:
The use of an ISUZU genuine fuel filter is strongly
recommended.
Water Separator (Water Sedimentor)
(Optional Equipment)

Check the water separator float 1 level.


If the float 1 has reached level 2 , loosen the drain plug
2
3 (at the bottom side of the water separator) to drain
1
the water.
Drain Plug Torque kg·m(lb.ft./N·m)
3 0.9 – 1.5 (6.5 – 10.9/8.8 – 14.7)

Fuel Filter with Water Level Sensor


Water Draining Procedure
The indicator light will come on when the water level in
the water separator exceeds the specified level.
Drain the water and foreign material from the water
separator with the following procedure.

1. Open the engine hood and place a container (Approxi-


mately 0.2 liter capacity) at the end of the vinyl hose
2
beneath the drain plug on the separator.
2. Loosen the drain plug by turning it counterclockwise
(Approximately 5-turns) and operate the priming
pump up and down about 10 times until water is
drained approximately 0.1 liter.
3. After draining, securely tighten the drain plug by
1 turning it clockwise and operate the priming pump
manually up and down several times.
4. After starting the engine, check to see that there is
no fuel leak from the drain plug.
Also check to see that the fuel filter water indicator
light has turned off.
If water separator requires frequent draining, have
the fuel tank drained fro removal of water at your
Isuzu Dealer.

22
MAINTENANCE

Air Bleeding
Air bleeding screw 1. Loosen the bleeder screw on the injection pump
overflow valve.
2. Operate the priming pump until fuel mixed with
foam flows from the bleeder screw.
3. Tighten the bleeder screw.
4. Operate the priming pump several times and check
for fuel leakage.

080ES004

Injection nozzle
good No good No good No good
Check to see if the spray condition and the injection
pressure are normal. Adjust them to the specified value
respectively when they don’t meet the standard valve.
kg/cm2 (psi/MPa)
Injection pressure 150 (2130/14.7)

Using a nozzle tester, adjust the injection pressure with a


About 4°
shim.
Special tool: Nozzle tester

WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER
WILL SPRAY OUT UNDER HIGH PRESSURE. IT CAN
EASILY PUNCTURE A PERSON’S SKIN. KEEP YOUR
HANDS AWAY FROM THE INJECTION NOZZLE TESTER
AT ALL TIMES.

23
MAINTENANCE

COOLING SYSTEM
D
Cooling Fan Drive Belt
C
Fan belt tension is adjusted by moving the alternator.
B A Crankshaft damper pulley
B Alternator pulley

A
C Cooling fan drive pulley
D Depress the drive belt mid-portion with a 10 kg (22
lb/98 N) force.
Drive Belt Deflection mm(in.)
10.0 (0.39)

Thermostat
Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.

1
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature °C(°F)
2
76.5 (170)

4. Check the thermostat full opening temperature.


Thermostat Full Opening Temperature °C(°F)
90 (194)
3

Valve Lift at Fully Open Position mm(in.)


8.0 (0.31)

1 Thermostat
2 Agitating Rod
3 Wooden Piece

24
MAINTENANCE

VALVE CLEARANCE ADJUSTMENT

1. Retighten the rocker arm shaft bracket bolts in


sequence as shown in the illustration.
Rocker Arm Shaft Bracket Bolt
Torque kg·m(lb.ft./N·m)
3 1 2 4
5.0 – 6.0 (36 – 43/49 – 59)

2. Bring the piston in either the No. 1 cylinder or the


No. 4 cylinder to TDC on the compression stroke by
turning the crankshaft until the crankshaft damper
TDC pulley TDC line is aligned with the timing pointer.

3. Check for play in the No. 1 intake and exhaust valve


push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
If the No. 1 cylinder intake and exhaust valve push
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.

Adjust the No. 1 or the No. 4 cylinder valve clearances


while their respective cylinders are at TDC on the com-
pression stroke.
Valve Clearance mm(in.)
0.40 (0.016)

Loosen each valve clearance adjusting screw as shown


in the illustration. (At TDC on the compression stroke of
the No. 1 cylinder)

Insert a feeler gauge of the appropriate thickness


between the rocker arm and the valve stem end.
4. Turn the valve clearance adjusting screw until a
slight drag can be felt on the feeler gauge.
5. Tighten the lock nut securely.

25
MAINTENANCE

Rotate the crankshaft 360°.


Realign the crankshaft damper pulley TDC line with the
timing pointer.
Adjust the clearances for the remaining valves as shown
in the illustration. (At TDC on the compression stroke of
the No. 4 stroke)

INJECTION TIMING

Injection Timing Confirmation Procedure


1. Rotate the crankshaft clockwise to align the cam-
shaft gear timing mark “O” with the timing gear
case cover pointer.
The No. 1 cylinder will now be at the point where
nearly injection timing.
2. Remove injector pump distributor head plug.
3. Fit a dial gauge and set lift to 1 mm.
4. Set crankshaft damper pulley Top Dead Center mark
about 45° before Top Dead Center from the pointer.
5. Set dial gauge in the “0” position.
Measuring device: 5-8840-0145-0
6. Turn the crankshaft a little rightwise and leftwise
and see if the pointer is stable in the “0” position.
7. Turn the crankshaft in the normal direction and read
the measuring device’s indication at TDC.
Starting Timing mm (in)
080ES002
0.5 (0.02)

8. If the injection timing is outside the specified range,


continue with the following steps.
9. Loosen the injection pump fixing nuts and bracket
bolts.
10. Adjust the injection pump setting angle.
• If injection timing will be advanced, move the
injection pump away from the engine.
• If injection timing will be retarded, move the
injection pump toward the engine.
Tighten the pump fixing nut, adjust bolt and pump
distribution head plug to the specified torque.

080ES003
Pump Fixing Bolt kg·m (lb·ft/N·m)
1.9 (13/19)

Injection Pump
Distributor Head Plug kg·m (lb·ft/N·m)
1.7 (12/17)

26
MAINTENANCE

COMPRESSION PRESSURE MEASUREMENT

1. Start the engine and allow it to run for several


minutes to warm it up.
2. Stop the engine and cut the fuel supply.
3. Remove all of the glow plugs from the engine.
Compression Gauge :5-8840-2008-0
Adapter :5-8531-7001-0

4. Set a comression gauge to the No. 1 cylinder glow


plug hole.
5. Turn the engine over with the starter motor and take
the compression gauge reading.
Compression Pressure kg/cm2(psi/MPa) at 250 rpm
Standard Limit
30 (427/2.94) 22 (313/2.16)

27
MAINTENANCE

RECOMMENDED LUBRICANTS
ENGINE TYPE TYPES OF LUBRICANTS
Diesel engine oil
Without turbocharger
CC or CD grade

ENGINE OIL VISCOSITY CHART

ENGINE OIL VISCOSITY GRADE – AMBIENT TEMPERATURE

[Single grade]

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 20, 20W ;;;;;;;;;;;;;;;;;;;;
SAE 40, 50
;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;

;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; SAE 30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

Ambient –30°C –15°C –0°C 15°C 25°C 30°C


temperature (–22°F) (0°F) (32°F) (60°F) (80°F) (90°F)
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
[Multi grade] ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W–30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 15W–40, 20W–40, 20W–50
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;

28
MAINTENANCE

ENGINE REPAIR KIT


All of the numbered parts listed below are included in the Engine Repair Kit.

3
19
2

17
18
19
20
14
15 10 5
13
12 11
1 6

7
9

8
16

1. Cylinder head gasket 11. Water pump gasket


2. Cylinder head cover gasket 12. Water outlet pipe gasket
3. Head cover cap nut gasket 13. Thermostat housing gasket
4. Drain cock gasket 14. Intake manifold gasket
5. Crankshaft rear oil seal 15. Exhaust manifold gasket
6. Gear case gasket 16. Crankshaft front oil seal
7. Gear case cover gasket 17. Nozzle holder washer
8. Oil pan drain plug gasket 18. Corrugated washer
9. Oil pan gasket 19. Heat shield
10. Oil filter gasket 20. Heat shield washer
21. Cyl. block side gasket

29
MAINTENANCE

MEMO

30
ENGINE ASSEMBLY ( 1 )

SECTION 3

ENGINE ASSEMBLY ( 1 )
TABLE OF CONTENTS

ITEM PAGE

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

31
ENGINE ASSEMBLY ( 1 )

DISASSEMBLY
These disassembly steps are based on the 4JG2PE engine.

14 13 3 58 9

10
7

15 4 2 1 11 6 12

Disassembly Steps - 1
1. Cooling fan and spacer 9. Breather hose
2. Cooling fan drive belt 10. Inlet manifold
3. Cooling fan drive pulley 11. Oil pipe
4. Alternator and adjusting plate 12. Starter motor
5. Fuel hose (Leak off) 13. Dipstick and guide tube
6. Injection pipe 14. Exhaust manifold
7. Fuel pipe 15. Oil filter
8. Injection pump

32
ENGINE ASSEMBLY ( 1 )

Important Operations (Disassembly Steps - 1)

6. Fuel Injection Pipe with Clip


1) Loosen the injection pipe sleeve nuts at the dalivery
valve side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipes.

8. Injection Pump
1) Remove the six injection pump bracket bolts from
the cylinder body timing gear case.
2) Pull the injection pump with the injection pump
1
timing gear free from the rear.

14. Exhaust Manifold


Loosen the exhaust manifold bolts a little at a time
in the numerical order shown in the illustration.
4 8 5 1

3 7 6 2

33
ENGINE ASSEMBLY ( 1 )

6
★ ★

2 7
1
8

3 9
13

★ 10 ★ 4

12
5
11

17
16

14

15 ★ Repair kit

Disassembly Steps - 2
1. Water by-pass hose 10. Cylinder head gasket
2. Thermostat housing ▲ 11. Crankshaft damper pulley
3. Water pump 12. Timing gear case cover
▲ 4. Injection nozzle holder 13. Timing gear cover
5. Glow plug and glow plug connector 14. Timing gear oil pipe
6. Cylinder head cover 15. Idler gear “B” and shaft
▲ 7. Rocker arm shaft and rocker arm ▲ 16. Idler gear “A”
8. Push rod 17. Idler gear shaft
▲ 9. Cylinder head
Inverted Engine

34
ENGINE ASSEMBLY ( 1 )

16 ★ 15

14
6 4

11
13

12

10
8

5

1 1a

★ Repair kit

Disassembly Steps - 3
1. Oil pan ▲ 9. Piston and connecting rod with
1a.Oil pan (If so crankcase equipped) upper bearing
2. Crankcase (If so equipped) ▲ 10. Crankshaft bearing cap with
▲ 3. Flywheel lower bearing
4. Flywheel housing 11. Crankshaft thrust bearing
5. Oil pump with oil pipe 12. Crankshaft with crankshaft timing gear
▲ 6. Camshaft with camshaft timing ▲ 13. Crankshaft upper bearing
gear and thrust plate ▲ 14. Tappet
7. Timing gear case 15. Crankshaft rear oil seal
▲ 8. Connecting rod cap with 16. Cylinder body
lower bearing

35
ENGINE ASSEMBLY ( 1 )

Important Operations (Disassembly Steps - 2)

4. Injection Nozzle Holder


1) Remove the nozzle holder fixing nuts.

7. Rocker Arm Shaft and Rocker Arm


Loosen the rocker arm shaft bracket bolts in numer-
ical order a little at a time.
Note:
Failure to loosen the rocker arm shaft bracket bolts in
1 3 4 2
numerical order a little at a time will adversely effect the
rocker arm shaft.

9. Cylinder Head
Loosen the cylinder head bolts in numerical order a
6 14 15 7 little at a time.
10 11
2 3 Note:
Failure to loosen the cylinder head bolts in numerical
17 order a little at a time will adversely effect the cylinder
1 5 13 16 12 4
9 head lower surface.
8

11. Crankshaft Damper Pulley


1) Block the flywheel with a piece of wood to pre-
vent it from turning.
2) Use the damper pulley remover to remove the
damper pulley.
Damper Pulley Remover

36
ENGINE ASSEMBLY ( 1 )

16. Idler Gear “A”


Measure the camshaft timing gear backlash, the
crankshaft timing gear backlash, and the idler gear
“A” end play before removing the idler gear “A”
and shaft.

Timing Gear Backlash Measurement


1) Set a dial indicator to the timing gear to be mea-
sured.
Hold both the gear to be checked and the adjoining
gear stationary.
2) Move the gear to be checked as far as possible to
both the right and the left.
Take the dial indicator reading.
If the measured value exceeds the specified limit,
the timing gear must be replaced.
Timing Gear Backlash mm(in.)
Standard Limit
0.10–0.17 (0.0039–0.0067) 0.30 (0.012)

Idler Gear “A” End Play Measurement


Insert a feeler gauge between the idler gear and the
thrust collar to measure the gap and determine the idler
gear end play.
If the measured value exceeds the specified limit, the
thrust collar must be replaced.
Idler Gear End Play mm(in.)
Standard Limit
0.080–0.18 (0.003–0.007) 0.003 (0.012)

37
ENGINE ASSEMBLY ( 1 )

Important Operations (Disassembly Steps - 3)

3. Flywheel
1) Block the flywheel with a piece of wood to pre-
vent it from turning.
1
5 4 2) Loosen the flywheel bolts a little at a time in the
numerical order shown in the illustration.
3 6
2

6. Camshaft with Camshaft Timing Gear and Thrust


Plate
1) Remove the thrust plate bolts.
2) Pull the camshaft free along with the camshaft
timing gear and the thrust plate.
Note:
Be careful not to damage the camshaft journal, the cam,
and the camshaft during the disassembly procedure.

8. Connecting Rod Cap with Lower Bearing


If the connecting rod lower bearings are to be rein-
stalled, mark their fitting positions by tagging each
bearing with the cylinder number from which it was
removed.

9. Piston and Connecting Rod with Upper Bearing


1) Remove carbon deposits from the upper portion
of the cylinder wall with a scraper before remov-
ing the piston and connecting rod.
2) Move the piston to the top of the cylinder and
tap it with a hammer grip or similar object from
the connecting rod lower side to drive it out.

38
ENGINE ASSEMBLY ( 1 )

If the connecting rod upper bearings are to be rein-


stalled, mark their fitting positions by tagging each
bearing with the cylinder number from which it was
removed.

10. Crankshaft Bearing Cap with Lower Bearing


1) Measure the crankshaft end play at the center
journal of the crankshaft.
Do this before removing the crankshaft bearing
caps.
If the measured value exceeds the specified
limit, the crankshaft thrust bearing must be
replaced.
Crankshaft End Play mm(in.)
Standard Limit
0.10 (0.004) 0.30 (0.012)

2) Loosen the crankshaft bearing cap bolts in


3 10 2 numerical order a little at a time.
7 6
If the crankshaft bearings are to be reinstalled,
mark their fitting positions by tagging each
8 9
4 5 1 bearing with the cylinder number from which it
was removed.

13. Crankshaft Upper Bearing


If the crankshaft upper bearings are to be reinstalled,
mark their fitting positions by tagging each bearing
with the cylinder number from which it was
removed.

14. Tappet
If the tappets are to be reinstalled, mark their fitting
positions by tagging each tappet with the cylinder
number from which it was removed.

39
ENGINE ASSEMBLY ( 1 )

15. Rear Oil Seal


With the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.
Oil Seal Remover: 5-8840-2362-0

40
ENGINE ASSEMBLY ( 1 )

DISASSEMBLY

SINGLE UNIT
ROCKER ARM SHAFT AND ROCKER ARM

5
1
4
3

Disassembly Steps
▲ 1. Rocker arm shaft snap ring 5. Rocker arm shaft spring
▲ 2. Rocker arm 6. Rocker arm shaft snap ring
▲ 3. Rocker arm shaft bracket 7. Rocker arm shaft
4. Rocker arm

41
ENGINE ASSEMBLY ( 1 )

Important Operations

1. Rocker Arm Shaft Snap Ring


2. Rocker Arm
3. Rocker Arm Shaft Bracket
1) Use a pair of snap ring pliers to remove the
snap rings.
2) Remove the rocker arms.
3) Remove the rocker arm shaft bracket.
If the rocker arms and rocker arm shaft brackets
are to be reinstalled, mark their installation
positions by tagging each rocker arm and rocker
arm shaft bracket with the cylinder number from
which it was removed.

42
ENGINE ASSEMBLY ( 1 )

CYLINDER HEAD

Disassembly Steps
▲ 1. Split collar 5. Valve stem oil seal
2. Valve spring upper seat 6. Valve spring lower seat
3. Valve spring 7. Cylinder head
▲ 4. Intake and exhaust valves

43
ENGINE ASSEMBLY ( 1 )

Important Operations

1. Split Collar
1) Place the cylinder head on a flat wooden
surface.
2) Use the spring compressor to remove the split
collar.
Do not allow the valve to fall from the cylinder
head.
Spring Compressor: 9-8523-1423-0

4. Intake and Exhaust Valve


If the intake and exhaust valves are to be reinstalled,
mark their installation positions by tagging each
valve with the cylinder number from which it was
removed.
If there is excessive valve wear or damage, the valve
must be replaced.
Refer to Page 54 of “Inspection and Repair” for the
valve and valve seat insert procedure.
Note:
If there is excessive valve guide wear or damage, the
valve guide must be replaced.
Refer to Page 53 of “Inspection and Repair” for the valve
guide replacement procedure.
The valve and the valve guides must be replaced as a
set. Never replace only one or the other.

44
ENGINE ASSEMBLY ( 1 )

PISTON AND CONNECTING ROD

4
7

Disassembly Steps
▲ 1. Connecting rod bearing 5. Connecting rod
▲ 2. Piston ring ▲ 6. Piston pin snap ring
▲ 3. Piston pin snap ring ▲ 7. Piston
▲ 4. Piston pin

45
ENGINE ASSEMBLY ( 1 )

Important Operations

1. Connecting Rod Bearing


If the connecting rod bearings are to be reinstalled,
mark their fitting positions by tagging each bearing
with the cylinder number from which it was
removed.

2. Piston Ring
1) Clamp the connecting rod in a vise.
Take care not to damge the connecting rod.
2) Use a piston pin replacer to remove the piston
rings.
Piston Ring Replacer
Do not attempt to use some other tool to
remove the piston rings. Piston ring stretching
will result in reduced piston ring tension.

3. Piston Pin Snap Ring


4. Piston Pin
Use a pair of snap ring pliers to remove the piston
pin snap rings.

5. Connecting Rod
7. Piston
Tap the piston pin out with a hammer and a brass
bar.
If the pistons are to be reinstalled, mark their instal-
lation positions by tagging each piston with the
cylinder number from which it was removed.

46
ENGINE ASSEMBLY ( 1 )

CAMSHAFT, CAMSHAFT TIMING GEAR, AND THRUST PLATE

3
2
1

Disassembly Steps
▲ 1. Camshaft timing gear 3. Feather key
▲ 2. Thrust plate 4. Camshaft

47
ENGINE ASSEMBLY ( 1 )

Important Operations

1. Camshaft Timing Gear


2. Thrust Plate
1) Clamp the camshaft in a vise.
Take care not to damage the camshaft.

3
2) Use the universal puller 1 to pull out the
2
camshaft timing gear 2 .
Universal Puller: 5-8840-0086-0
3) Remove the thrust plate 3 .

48
ENGINE ASSEMBLY ( 2 )

SECTION 4

ENGINE ASSEMBLY ( 2 )
TABLE OF CONTENTS

ITEM PAGE

Inspection and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

49
ENGINE ASSEMBLY ( 2 )

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.

CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure
the four sides and the two diagonals of the cylinder
head lower face.
2. Regrind the cylinder head lower face if the mea-
sured values are greater than the specified limit but
less than the maximum grinding allowance.

If the measured values exceed the maximum grind-


H ing allowance, the cylinder head must be replaced.
Cylinder Head Lower Face Warpage mm(in)
Maximum Grinding
Standard Limit
Allowance
A 0.05
0.2 (0.008) 0.3 (0.012)
E F (0.002) or less
C D
B
Cylinder Head Height (Reference) mm(in)
Standard Limit
91.95 (3.620) – 92.05 (3.624) 91.65 (3.60)

Note:
If the cylinder head lower face is reground, valve
depression must be checked.

Exhaust Manifold Fitting Face Warpage


Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
Regrind the manifold cylinder head fitting faces if the
measured values are greater than the specified limit but
less than the maximum grinding allowance.
If the measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.

50
ENGINE ASSEMBLY ( 2 )

Manifold Fitting Face Warpage mm (in)


Maximum Grinding
Standard Limit
Allowance
0.05
0.2 (0.008) 0.4 (0.016)
(0.002) or less

HOT PLUG
Hot plug depression
1. Clean the cylinder head lower side, taking care not
to damage the hot plug surfaces.
2. Use a straight edge and feeler gauge to measure hot
plug depression in a straight line from the No. 1 hot
plug to the No. 4 hot plug.
If the measured value exceeds the limit, the hot
plugs must be replaced.
Depression Limit mm (in)
0.02 (0.0008)

Hot plug removal


1. Insert a 3.0 – 5.0 (0.12 – 0.20 in.) diameter bar into
the nozzle holder fitting hole unit it makes contact
with the hot plug.
2. Lightly tap the bar with a hammer to drive the hot
plug free.
If the measured value exceeds the limit, the hot
plugs must be replaced.

Combustion chamber inspection


1. Remove the carbon adhering to the inside of the
combustion chamber. Take care not to damage the
hot plug fitting positions.
2. Inspect the inside of the combustion chamber, the
hot plug hole, and the hot plug machined faces for
cracking and other damage.
If cracking or damage is present, the cylinder head
must be replaced.
Note:
Be absolutely certain that there are not scratches or
protuberance on the combustion chamber surfaces which
will be in contact with the hot plug after it is installed.
There flaws will prevent the hot plug from seating
correctly.

51
ENGINE ASSEMBLY ( 2 )

Hot plug installation


2 Inspect the hot plugs for excessive wear and other
damage. Replace the hot plugs if either of these
conditions are discovered.
1. Align the hot plug knock ball 1 with the cylinder
head groove 2 and tap it temporarily into position
1
with a plastic hammer.

2. Place an appropriate metal plate 3 thick over the


hot plug upper surface 4.
5 3. Use a press 5 to exert a pressure of 44000 – 54000N
(4500 – 5500 kg) (9923 – 12128 lbs.) on the metal
3
4 plate covering the hot plug upper surface. This will
drive the hot plug into position.
4. Lightly tap the hot plug heads to make sure that they
are firmly seated.
5. Repeat the procedure Steps 1–4 for the remaining
hot plugs.

CAUTION:
Do not apply pressure greater than that specified. Dam-
age to the cylinder head will result.
6. Use a surface grinder to grind off any hot plug
surface protuberances.
The hot plug surfaces must be perfectly flush with
the cylinder head.
7. After grinding, make sure that the hot plug surfaces
are completely free of protuberances.
The hot plug surfaces must also be free of depres-
sions.
Once again, lightly tap the hot plug heads to make sure
that they are firmly seated.

Heat shield removal


After removing the hot plugs, use a hammer 1 and a
brass bar 2 to lightly tap the lower side of the seat
shield 3 and drive it free.

52
ENGINE ASSEMBLY ( 2 )

Heat shield installation


Gasket Install the heat shield washer and the heat shield to the
Nozzle
cylinder head from the nozzle holder installation hole
side. Lightly tap the flange into place with a brass bar.
The heat shield flange side must be facing up.
NOTE:
Always install a new heat shield. Never reuse the old
Colgate washer heat shield.
Nozzle heat shield Gasket heat shield

VALVE GUIDE
Valve Stem and Valve Guide Clearance
Measuring Method - I
1. With the valve stem inserted in the valve guide, set
the dial indicator needle to “0”.
2. Move the valve head from side to side.
Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit,
the valve and the valve guide must be replaced as a
set.
Valve Stem Clearance mm(in)
Standard Limit
0.039 – 0.071 0.20
Intake Valve (0.0015 – 0.0028) (0.008)
0.064 – 0.096 0.25
Exhaust Valve (0.0025 – 0.0038) (0.0098)

Measuring Method - II
1. Measure the valve stem outside diameter.
Refer to the Item “Valve Stem Outside Diameter”.
2. Use a caliper calibrator or a telescoping gauge to
measure the valve guide inside diameter.

Valve Guide Replacement


Valve Guide Removal
Use a hammer and the valve guide replacer to drive out
the valve guide from the cylinder head lower face.
Valve Guide Replacer: 9-8523-1212-0

53
ENGINE ASSEMBLY ( 2 )

Valve Guide Installation


1. Apply engine oil to the valve guide outer circumfer-
ence.
2. Attach the valve guide replacer to the valve guide.
3. Use a hammer to drive the valve guide into position
from the cylinder head upper face.
Valve Guide Replacer: 9-8523-1212-0

4. Measure the height of the valve guide upper end


from the upper face of the cylinder head.
Valve Guide Upper End Height (H)
(Reference) mm(in)
13.0 (0.51)
H
Note:
If the valve guide has been removed, both the valve and
the valve guide must be replaced as a set.

VALVE AND VALVE SEAT INSERT


Valve Stem Outside Diameter
Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Valve Stem Outside Diameter mm(in)
Standard Limit
7.946 – 7.961 7.88
Intake Valve (0.3128 – 0.3134) (0.3102)
7.921 – 7.936 7.850
Exhaust Valve (0.3118 – 0.3124) (0.3099)

Valve Thickness
Measure the valve thickness
If the measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Intake and Exhaust Valve Thickness mm(in)
Standard Limit
Inlet 1.41 1.1 (0.043)
Exhaust 1.39 1.1 (0.043)

54
ENGINE ASSEMBLY ( 2 )

Valve Depression
2
1. Install the valve 1 to the cylinder head 2 .
2. Use a depth gauge or a straight edge with steel rule
to measure the valve depression from the cylinder
head lower surface.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
1
Valve Depression mm(in)
Standard Limit
Intake 0.73 (0.029) 1.28 (0.050)
Exhaust 0.70 (0.028) 1.20 (0.047)

Valve Contact Width


1. Check the valve contact faces for roughness and
unevenness.
Make smooth the valve contact surfaces.
2. Measure the valve contact width.
If the measured value exceeds the specified limit,
the valve seat insert must be replaced.
Valve Contact Width mm(in)
Standard Limit
Intake 1.7 (0.067) 2.2 (0.087)
Exhaust 2.0 (0.079) 2.5 (0.078)

Valve Seat Insert Replacement


2 3 Valve Seat Insert Removal
1. Arc weld the entire inside circumference 1 of the
valve seat insert 2.
4 2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the
valve seat insert easier.
1

55
ENGINE ASSEMBLY ( 2 )

3. Use a screwdriver 3 to pry the valve seat insert


free.
Take care not to damage the cylinder head 4 .
4. Carefully remove carbon and other foreign material
from the cylinder head insert bore.

Valve Seat Insert Installation


3 1. Carefully place the attachment 1 (having a smaller
outside diameter than the valve seat insert) on the
1 valve seat insert 2 .
Note:
2
The smooth side of the attachment must contact the
valve seat insert.
2. Use a bench press 3 to gradually apply pressure to
the attachment and press the valve seat insert into
place.
Note:
Do not apply an excessive amount of pressure with the
bench press. Damage to the valve seat insert will result.

150˚
Valve Seat Insert Correction
90˚ 1. Remove the carbon from the valve seat insert sur-
30˚ face.
2. Use a valve cutter (15°, 45°, and 75° blades) to
minimize scratches and other rough areas. This will
bring the contact width back to the standard value.
Remove only the scratches and rough areas. Do not
cut away too much. Take care not to cut away
unblemished areas of the valve seat surface.

Valve Seat Angle 45°

Note:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.

56
ENGINE ASSEMBLY ( 2 )

3. Apply abrasive compound to the valve seat insert


surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact
with the entire circumference of the valve.

VALVE SPRING
Valve Spring Free Height
Use a vernier caliper to measure the valve spring free
height.
If the measured value is less than the specified limit, the
valve spring must be replaced.
Valve Spring Free Height mm(in)
Standard Limit
49.7 (1.96) 48.2 (1.90)

Valve Spring Inclination


Use a surface plate and a square to measure the valve
spring inclination.
If the measured value exceeds the specified limit, the
valve spring must be replaced.
Valve Spring Inclination mm(in)
Standard Limit
Square 1.5 (0.06) or less 2.5 (0.984) or more

Valve Spring Tension


Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the
valve spring must be replace.
Valve Spring Tension kg(lb)
Compressed Height Standard Limit
38.9 mm (1.53 in) 32.6 (71.7) 29.0 (63.8)

57
ENGINE ASSEMBLY ( 2 )

ROCKER ARM SHAFT AND ROCKER ARM


Rocker Arm Shaft Run-Out
1. Place the rocker arm shaft on a V-block.
2. Use a dial indicator to measure the rocker arm shaft
central portion run-out.
If the run-out is very slight, correct the rocker arm
shaft run-out with a bench press. The rocker arm
must be at cold condition.
If the measured rocker arm shaft run-out exceeds
the specified limit, the rocker arm shaft must be
replaced.
Rocker Arm Shaft Run-Out mm(in)
Standard Limit
0.2 (0.008) 0.6 (0.024)

Rocker Arm Shaft Outside Diameter


Use a micrometer to measure the rocker arm fitting
portion outside diameter.
If the measured value is less than the specified limit, the
rocker arm shaft must be replaced.
Rocker Arm Shaft Outside Diameter mm(in)
Standard Limit
18.98 – 19.00 (0.747 – 0.748) 18.85 (0.742)

Rocker Arm Shaft and Rocker Arm Clearance


1. Use either a vernier caliper or a dial indicator to
measure the rocker arm bushing inside diameter.
Rocker Arm Bushing Inside Diameter mm(in)
Standard Limit
19.01 – 19.03 (0.748 – 0.749) 19.05 (0.750)

2. Measure the rocker arm shaft outside diameter.


If the measured value exceeds the specified limit,
replace either the rocker arm or the rocker arm shaft.
Rocker Arm and Rocker Arm Shaft Clearance mm(in)
Standard Limit
0.01 – 0.05 (0.0004 – 0.002) 0.2 (0.008)

58
ENGINE ASSEMBLY ( 2 )

3. Check that the rocker arm oil port is free of obstruc-


tions.
If necessary, use compressed air to clean the rocker
arm oil port.

Rocker Arm Correction


2
Inspect the rocker arm valve stem contact surfaces for
step wear 1 and scoring 2 .
1 If the contact surfaces have light step wear or scoring,
they may be honed with an oil stone.
If the step wear or scoring is severe, the rocker arm must
be replaced.

X CYLINDER BODY
Y Y Cylinder Liner Bore Measurement
Use a cylinder indicator to measure the cylinder bore at
X
measuring point 1 in the thrust X – X and axial Y – Y
directions of the crankshaft.
1 Measuring Point 1 : Maximum wear portion
[11 ~ 15 mm (0.43 ~ 0.59 in)]
If the measured value exceeds the specified limit, the
cylinder liner must be replaced.
Cylinder Liner Bore mm(in)
Standard Limit
95.421 – 95.460 95.5
(3.7567 – 3.7583) (3.7598)

Note:
The inside of the dry type cylinder liner is chrome
plated. It cannot be rebored or honed.
If the inside of the cylinder liner is scored or scorched,
the cylinder liner must be replaced.

Cylinder Liner Projection Inspection


1 1. Hold a straight edge 1 along the top edge of the
cylinder liner to be measured.
2. Use a feeler gauge 2 to measure each cylinder liner
projection.
Cylinder Liner Projection mm(in)
Standard
2
0 – 0.10 (0 – 0.004)

The difference in the cylinder liner projection height


between any two adjacent cylinders must not
exceed 0.03 mm (0.0012 in).

59
ENGINE ASSEMBLY ( 2 )

Cylinder Liner Replacement


Cylinder Liner Removal
1. Remove the cylinder body dowel.
2. Set the cylinder liner remover to the cylinder liner.
3. Check that the remover shaft ankle is firmly gripping
the cylinder liner bottom edge.
4. Slowly turn the remover shaft handle counterclock-
wise to pull the cylinder liner free.
Cylinder Liner Remover Ankle: 5-8840-2304-0
Cylinder Liner Remover: 9-8523-1169-0
NOTE:
Take care not to damage the cylinder body upper during
the cylinder liner removal procedure.

1 Cylinder Body Upper Face Warpage


Use a straight edge 1 and a feeler gauge 2 to measure
the four sides and the two diagonals of the cylinder
body upper face.

Cylinder Body Upper Face Warpage mm(in)


Standard Limit
0.05 (0.002) or less 0.2 (0.008)

If the measured value is more than the limit, the cylinder


A body must be replaced.
E F
C D
B

Cylinder Body Height (Reference) mm(in)


Standard
272.945 – 273.105 (10.7458 – 10.7521)

60
ENGINE ASSEMBLY ( 2 )

Cylinder Liner Grade Selection


Measure the cylinder body inside diameter and select
the appropriate cylinder liner grade.
Standard Fitting Interference mm(in)
0.001 – 0.019 (0.0004 – 0.00075)
If the cylinder liner fitting interference is too small,
engine cooling efficiency will be adversely affected.
If the cylinder liner fitting interference is too large, it will
be difficult to insert the cylinder liner into the cylinder
body.
Cylinder Body Bore Measurement
X 1. Take measurements at measuring point 1 across
W Z positions (“W – W”), (“X – X”), (Y – Y) and (Z – Z).
Measuring Point 1 : 88 mm (3.46 in)
Y Y
2. Calculate the average value of the four measure-
Z
ments to determine the correct cylinder grade.
W
X

Cylinder Liner Outside Diameter Measurement


X
1
Y Y 1. Take two measurements each at measuring points
X 2 1 , 2 , and 3 .

X
Measuring Point 1 : 20 mm (0.79 in)
3 Measuring Point 2 : 50 mm (1.97 in)
Y Y
X Measuring Point 3 : 150 mm (5.90 in)
2. Calculate the average value of the six measure-
X
Y Y ments to determine the correct cylinder liner grade.
X

61
ENGINE ASSEMBLY ( 2 )

Cylinder Liner Installation


1. Cylinder Liner Installation Using The Special Tool.
1) Use new kerosene or diesel oil to thoroughly
clean the cylinder liners and bores.
2) Use compressed air to blow-dry the cylinder
liner and bore surfaces.
Note:
All foreign material must be carefully removed from the
cylinder liner and the cylinder bore before installation.

3) Insert the cylinder liner 1 into the cylinder body


3
2 from the top of the cylinder body.

1
2

4) Set the cylinder liner installer 3 to the top of the


4
3 cylinder liner.
Cylinder Liner Installer: 5-8840-2313-0
5) Position the cylinder body so that the installer
center 3 is directly beneath the bench press
shaft center 4.
Note:
Check that the cylinder liner is set perpendicular to the
bench press and that there is no wobble.
6) Use the bench press to apply a seating force of
500 kg (1,102.5 lb/4,900 N) to the cylinder liner.
7) Apply a force of 2,500 kg (5,512.5 lb/24,500 N) to
fully seat the cylinder liner.
8) After installing the cylinder liner, measure the
cylinder liner projection.
Refer to “Cylinder Liner Projection Inspection”.

2. Cylinder Liner Installation Using Dry Ice


If the cylinder liner is a chrome plated dry type, it is
advisable to use dry ice during the installation
procedure.
Cooling the cylinder liner with dry ice will cause the
cylinder liner to contact, thus making installation
easier.
Note:
It is important that the cylinder liner be inserted to the
cylinder body immediately after it has been cooled.

62
ENGINE ASSEMBLY ( 2 )

WARNING:
DRY ICE MUST BE USED WITH GREAT CARE. CARE-
LESS HANDLING OF DRY ICE CAN RESULT IN SEVERE
FROSTBITE.

Cylinder Bore and Cylinder Liner Outside Diameter


Combination (Reference)
mm(in)
Cylinder Liner
Cylinder Bore
Outside Diameter
97.001 – 97.010 97.011 – 97.020
1 (3.8189 – 3.8193) (3.8193 – 3.8197)
97.011 – 97.020 97.021 – 97.030
2 (3.8193 – 3.8197) (3.8197 – 3.8201)
97.021 – 97.030 97.031 – 97.040
3 (3.8197 – 3.8201) (3.8201 – 3.8205)

63
ENGINE ASSEMBLY ( 2 )

X Piston Grade Selection


W Z
Measure the cylinder liner bore after installing the
Y Y
cylinder liner. Then select the appropriate piston grade
Z W for the installed cylinder liner.
X
1. Measure the cylinder liner bore.
1
There are two measuring points ( 1 and 2 ).
2 Measure the cylinder liner bore in four different
direction (W – W, X – X, and Z – Z) at both mea-
suring points.
Calculate the average value of the eight measure-
ments to determine the correct cylinder liner bore.
Measuring Points 1 : 20 mm (0.79 in)
2 : 160 mm (6.30 in)

Cylinder Liner Bore mm(in)


Standard Limit
95.421 – 95.460 95.5
(3.7567 – 3.7583) (3.7598)

Note:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will result
in engine failure. Always measure the cylinder bore and
select the correct piston grade.

2. Measure the piston outside diameter.


Piston Measuring Point 1 : 71 mm (2.80 in)
Piston Grade mm(in)
Grade A Grade C
95.365 – 95.384 95.385 – 95.404
(3.7545 – 3.7553) (3.7553 – 3.7561)
1
Cylinder Liner and Piston Clearance mm(in)
0.037 – 0.075 (0.0015 – 0.0030)

Note:
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in slight
decreases in cylinder liner clearances. Always measure
the cylinder liner clearance after installation to be sure
that it is correct.

64
ENGINE ASSEMBLY ( 2 )

TAPPET AND PUSH ROD


Visually inspect the tappet camshaft contact surfaces for
pitting, cracking, and other abnormal conditions. The
tappet must be replaced if any of these conditions are
1 2 3
present.
Refer to the illustration at the left.
1 Normal contact
2 Cracking
4 5 3 Pitting
4 Irregular contact
5 Irregular contact
Note:
The tappet surfaces are spherical. Do not attempt to
grind them with an oil stone or similar tool in an effort to
repair the tappet. If the tappet is damaged, it must be
replaced.

Tappet Outside Diameter


Measure the tappet outside diameter with a micrometer.
If the measured value is less than the specified limit, the
tappet must be replaced.
Tappet Outside Diameter mm(in)
Standard Limit
12.97 – 12.99 (0.510 – 0.511) 12.95 (0.509)

Tappet and Cylinder Body Clearance mm(in)


Standard Limit
0.03 (0.001) 0.1 (0.004)

65
ENGINE ASSEMBLY ( 2 )

Push Rod Curvature


1. Lay the push rod on a surface plate.
2. Roll the push rod along the surface plate and mea-
sure the push rod curvature with a thickness gauge.
If the measured value exceeds the specified limit,
the push rod must be replaced.
Push Rod Curvature mm(in)
Limit
0.3 (0.012)

3. Visually inspect both ends of the push rod for


excessive wear and damage. The push rod must be
replaced if these conditions are discovered during
inspection.

CAMSHAFT
Visually inspect the journals, the cams, the oil pump
drive gear, and the camshaft bearings for excessive
wear and damage. The camshaft and the camshaft
bearings must be replaced if these conditions are
discovered during inspection.

Camshaft Journal Diameter


X
Use a micrometer to measure each camshaft journal
diameter in two directions ((X – X) and (Y – Y)). If the
Y Y
measured value is less than the specified limit, the
camshaft must be replaced.
X
Camshaft Journal Diameter mm(in)
Standard Limit
49.945 – 49.975 49.60
(1.966 – 1.968) (1.953)

66
ENGINE ASSEMBLY ( 2 )

Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the
camshaft must be replaced.

H
Cam Height H mm(in)
Standard Limit
42.08 (1.65) 41.65 (1.64)

Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
If the measured value exceeds the specified limit,
the camshaft must be replaced.
Camshaft Run-Out mm(in)
Standard Limit
0.02 (0.0008) 0.10 (0.004)

Camshaft and Camshaft Bearing Cleareance


Use an inside dial indicator to measure the camshaft
bearing inside diameter.
Camshaft Bearing Inside Diameter mm(in)
Standard Limit
50.0 – 50.03 50.08
(1.9685 – 1.9696) (1.9716)

If the clearance between the camshaft bearing inside


diameter and the journal exceeds the specified limit, the
camshaft bearing must be replaced.
Camshaft Bearing Clearance mm(in)
Standard Limit
0.025 – 0.085
0.12 (0.005)
(0.0010 – 0.0033)

Camshaft Bearing Replacement


Camshaft Bearing Removal
1. Remove the cylinder body plug plate.
2. Use the camshaft bearing replacer to remove the
camshaft bearing.
Bearing Replacer: 5-8840-2038-0

67
ENGINE ASSEMBLY ( 2 )

Camshaft Bearing Installation


1. Align the bearing oil holes with the cylinder body oil
holes.
2. Use the camshaft bearing replacer installer to install
the camshaft bearing.
Bearing Replacer: 5-8840-2038-0

Camshaft End Play


1. Before removing the camshaft gear 1, push the
1 thrust plate 2 as far as it will go toward the cam-
shaft gear.
2. Use a feeler gauge to measure the clearance
between the thrust plate and the camshaft journal.
If the measured value exceeds the specified limit,
3 the thrust plate must be replaced.
2
Camshaft End Play mm(in)
Standard Limit
0.050 – 0.114 (0.002 – 0.0044) 0.2 (0.008)

Thrust Plate Replacement


3 2
Thrust Plate Removal
1. Use the universal puller 1 to remove the camshaft
timing gear 2 .
Universal Puller: 5-8840-0086-0
2. Remove the thrust plate 3 .
1

Thrust Plate Installation

1. Install the thrust plate.


2. Apply engine oil to the bolt setting face and the bolt
threads.
3. Install the camshaft gear.
Camshaft Gear Torque kg·m(lb.ft/N·m)
10.0 – 12.0 (72 – 87/98 – 118)

68
ENGINE ASSEMBLY ( 2 )

CRANKSHAFT AND BEARING

Inspect the surface of the crankshaft journals and


crankpins for excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear
and damege.
Inspect the oil ports for obstructions.
Note:
To increase crankshaft strength, tufftriding (Nitrizing
Treatment) has been applied. Because of this, it is not
possible to regrind the crankshaft surfaces.

Crankshaft Tufftriding Inspection


The portion to be tested 1. Use an organic cleaner to thoroughly clean the
shall be held horizontally Test liquid should
so as not to let the test not be applied to
crankshaft. There must be no traces of oil on the
solution flow. the area around the surfaces to be inspected.
oil port.
The sliding surface 2. Prepare a 5 – 10% solution of ammonium cuprous
of the pin chloride (dissolved in distilled water).
or journal.
Approximately 3. Use a syringe to apply the solution to the surface to
10mm be inspected.
Hold the surface to be inspected perfectly horizontal
to prevent the solution from running.
Note:
Do not allow the solution to come in contact with the oil
ports and their surrounding area.

Judgement
1. Wait for thirty to forty seconds.
If there is no discoloration after thirty or forty sec-
onds, the crankshaft is usable.
If discoloration appears (the surface being tested
will become the color of copper), the crankshaft
must be replaced.
2. Steam clean the crankshaft surface immediately
after completing the test.

69
ENGINE ASSEMBLY ( 2 )

Note:
The ammonium cuprous chloride solution is highly cor-
rosive. Because of this, it is imperative that the surfaces
being tested be cleaned immediately after completing
the test.

Crankshaft Run-Out
1. Set a dial indicator to the center of the crankshaft
journal.
2. Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
If the measured value exceeds the specified limit,
the crankshaft must be replaced.
Crankshaft Run-Out mm(in)
Standard Limit
0.05 (0.002) or less 0.08 (0.003)

Bearing Tension
Check to see if the bearing has enough tension, so that a
good finger pressure is needed to fit the bearing into
position.

Crankshaft Journal and Crankpin Diameter


1 3 4
1. Use a micrometer to measure the crankshaft journal
diameter across points (“1 – 1”) and (“2 – 2”).
2 2
2. Use the micrometer to measure the crankshaft
1
journal diameter at the two points ( 3 and 4 ).
3. Repeat Steps 1 and 2 to measure the crankpin
diameter.
If the measured values are less than the limit, the
crankshaft must be replaced.

70
ENGINE ASSEMBLY ( 2 )

Crankshaft Journal Diameter mm(in)


Standard Limit
69.917 – 69.932 69.910
(2.7526 – 2.7531) (2.7524)

Crankpin Diameter mm(in)


Standard Limit
52.915 – 52.930 52.906
(2.0833 – 2.0839) (2.0829)

Crankshaft Journal and Crankpin


Uneven Wear mm(in)
Standard Limit
0.05 (0.002) or less 0.08 (0.003)

Crankshaft Journal and Bearing Clearance


If the clearance between the measured bearing inside
diameter and the crankshaft journal diameter exceeds
the specified limit, the bearing and/or the crankshaft
must be replaced.
Crankshaft Bearing Cap Bolt
Torque kg·m(lb.ft./N·m)
16.0 – 18.0 (116 – 130/157 – 177)

Crankshaft Journal and


Bearing Clearance mm(in)
Standard Limit
0.031 – 0.063 (0.0012 – 0.0025) 0.11 (0.0043)

Connecting Rod Bearing Inside Diameter


1. Install the bearing to the connecting rod big end.
2. Tighten the bearing cap to the specified torque.
Connecting Rod Bearing Cap Bolt
Torque kg·m(lb.ft/N·m)
2.8 – 3.2 → 45° – 60°
(20 – 23/727 – 31)

3. Use a inside dial indicator to measure the connect-


ing rod bearing inside diameter.

71
ENGINE ASSEMBLY ( 2 )

Crankpin and Bearing Clearance


If the clearance between the measured bearing inside
diameter and the crankpin exceeds the specified limit,
the bearing and/or the crankshaft must be replaced.
Crankpin and Bearing Clearance mm(in)
Standard Limit
0.029 – 0.083 (0.0011 – 0.0033) 0.10 (0.0039)

Clearance Measurements (With Plastigage)


Crankshaft Journal and Bearing Clearance
1. Clean the cylinder body, the journal bearing fitting
surface, the bearing caps, and the bearings.
2. Install the bearings to the cylinder body.
3. Carefully place the crankshaft on the bearings.
4. Rotate the crankshaft approximately 30° to seat the
bearing.
5. Place the Plastigage (arrow) over the crankshaft
journal across the full width of the bearing.
6. Install the bearing caps with the bearing.

7. Tighten the bearing caps to the specified torque.


Crankshaft Bearing Cap Bolt
Torque kg·m(lb.ft/N·m)
16.0 – 18.0 (116 – 130/157 – 177)

Do not allow the crankshaft to turn during bearing


cap installation and tightening.
8. Remove the bearing cap.

72
ENGINE ASSEMBLY ( 2 )

9. Compare the width of the Plastigage attached to


either the crankshaft or the bearing against the scale
printed on the Plastigage container.
If the measured value exceeds the limit, perform the
following additionsl steps.
1) Use a micrometer to measure the crankshaft
outside diameter.
2) Use an inside dial indicator to measure the
bearing inside diameter.
If the crankshaft journal and bearing clearance
exceeds the limit, the crankshaft and/or the
bearing must be replaced.
Crankshaft Journal and Bearing Clearance mm(in)
Standard Limit
0.031 – 0.063 0.11
(0.0012 – 0.0025) (0.0043)

Crankshaft Bearing Selection


When installing new crankshaft bearings or replacing
old bearings, select and install bearing part No. 897063-
2590 (Identification color: “Black”)

Crankpin and Bearing Clearance


1. Clean the crankshaft, the connecting rod, the bear-
ing cap, and the bearings.
2. Install the bearing to the connecting rod and the
bearing cap.
Do not allow the crankshaft to move when installing
the bearing cap.
3. Prevent the connecting rod from moving.
4. Attach the Plastigage to the crankpin.
Apply engine oil to the Plastigage to keep it from
falling.

73
ENGINE ASSEMBLY ( 2 )

5. Install the bearing cap and tighten it to the specified


torque.
Do not allow the connecting rod to move when
installing and tightening the bearing cap.
Connecting Rod Bearing Cap Bolt
Torque kg·m(lb.ft/N·m)
2.8 – 3.2 (20 – 23/727 – 31) → 45° – 60°

6. Remove the bearing cap.


7. Compare the width of the Plastigage attached to
either the crankshaft or the bearing against the scale
printed on the Plastigage container.
If the measured value exceeds the specified limit,
perform the following additional steps.
1) Use a micrometer to measure the crankpin out-
side diameter.
2) Use an inside dial indicator to measure the
bearing inside diameter.
If the crankpin and bearing clearance exceeds
the specified limit, the crankshaft and/or the
bearing must be replaced.
Crankpin and Bearing Clearance mm(in)
Standard Limit
0.029 – 0.066 0.10
(0.0011 – 0.0026) (0.0039)

Crankshaft Timing Gear Replacement


1 Crankshaft Timing Gear Removal
1. Use the crankshaft gear remover 1 to remove the
crankshaft gear 2 .
2. Remove the crankshaft feather key.
Crankshaft Timing Gear Remover: 9-8840-2057-0

Crankshaft Timing Gear Installation


1. Install the crankshaft gear.
2. Use the crankshaft gear installer 1 to install the
crankshaft gear 2 .
The crankshaft gear timing mark (“X – X”) must be
1 facing outward.
2 Crankshaft Gear Installer: 9-8522-0020-0

74
ENGINE ASSEMBLY ( 2 )

CRANKSHAFT PILOT BEARING


Check the crankshaft pilot bearing for excessive wear
and damage and replace it if necessary.

Crankshaft Pilot Bearing Replacement


Crankshaft Pilot Bearing Removal
Use the pilot bearing remover to remove the pilot bear-
ing.
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0

Crankshaft Pilot Bearing Installation


1. Place the crankshaft pilot bearing horizontally across
the crankshaft bearing installation hole.
2. Tap around the edges of the crankshaft pilot bearing
outer races with a brass hammer to drive the bear-
ing into the crankshaft bearing installation hole.
Pilot Bearing Installer: 5-8522-0024-0
Note:
Strike only the crankshaft pilot bearing outer races with
the hammer. Do not strike the bearing inner races.
Bearing damage and reduced bearing service life will
result.

75
ENGINE ASSEMBLY ( 2 )

FLYWHEEL AND RING GEAR


1 Flywheel
1. Inspect the flywheel friction surface for excessive
wear and heat cracks.
2. Measure the flywheel friction surface wear amount
(depth)
The flywheel friction surface area actually making
contact with the clutch driven plate (the shaded area
in the illustration) will be smaller than the original
machined surface area.
There will be a ridge on the flywheel surface area.
Be sure to measure the surface wear in the area
inside the ridge.
If the measured value is between the standard and
the specified limit, the flywheel may be reground.
If the measured value exceeds the specified limit,
the flywheel must be replaced.
Flywheel Friction Surface Depth 1 mm(in)
Limit
1.0 (0.04) or more

Note:
Because a ridge is produced at the flywheel friction sur-
face as illustrated, do not measure the friction surface
wear amount at the non-ridge area but be sure to
measure it at the rear-friction surface which is shown in
the illustration by shaded area.

Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the
ring gear must be replaced.

Ring Gear Replacement


Ring Gear Removal
Strike around the edges of the ring gear with a hammer
and chisel to remove it.

76
ENGINE ASSEMBLY ( 2 )

Ring Gear Installation


1. Heat the ring gear evenly with a gas burner to invite
thermal expansion.
Do not allow the temperature of the gas burner to
exceed 200°C (390°F).
2. Install the ring gear when it is sufficiently heated.
The ring gear must be installed with the chamfer
facing the clutch.
Note:
Another method of heating the ring gear to invite ther-
mal expansion is to soak a rag in diesel fuel, wrap the
diesel fuel soaked rag around the rim of the ring gear,
and then light the rag.

PISTON
Piston Grade Selection and Cylinder Liner Bore
Measurement
Refer to the Section “CYLINDER BODY”, Item “Cylinder
Liner Bore Measurement” for details on piston grade
selection and cylinder or liner bore measurement.

PISTON RING
Piston Ring Gap
1. Insert the piston ring horizontally into the cylinder
liner.
2. Use a piston inserted upside down to push the
piston ring into the cylinder liner until it reaches
either measuring point 1 or measuring point 2.
Cylinder liner diameter is the smallest at these two
points.
Do not allow the piston ring to slant to one side or
the other. It must be perfectly horizontal.
3. Use a feeler gauge to measure the piston ring gap.
2 Measuring Point 1 : 10 mm (0.39 in)
1 or
Measuring Point 2 : 120 mm (4.72 in)
If the piston ring gap exceeds the specified limit, the
piston ring must be replaced.

77
ENGINE ASSEMBLY ( 2 )

Piston Ring Gap mm(in)


Standard Limit

1 s t Compression Ring 0.2 – 0.35


(0.008 – 0.014)

2nd Compression Ring 0.37 – 0.52 1.5


(0.015 – 0.020) (0.059)
0.2 – 0.4
Oil Ring
(0.008 – 0.016)

Piston Ring and Piston Ring Groove Clearance


Use a feeler gauge to measure the clearance between
the piston ring and the piston ring groove at several
points around the piston.
If the clearance between the piston ring and the piston
ring groove exceeds the specified limit, the piston ring
must be replaced.
Piston Ring and Piston Ring Groove
Clearance mm(in)
Standard Limit
0.09 – 0.130
1 s t Compression Ring
(0.0035 – 0.0051)
0.05 – 0.090 0.15
2nd Compression Ring (0.002 – 0.0035) (0.006)
0.03 – 0.07
Oil Ring (0.0012 – 0.0028)

Visually inspect the piston. If a piston ring groove is


damaged or distorted, the piston must be replaced.

78
ENGINE ASSEMBLY ( 2 )

PISTON PIN
Piston Pin Diameter
Use a micrometer to measure the piston pin outside
diameter at several points.
If the measured value is less than the specified limit, the
piston pin must be replaced.
Piston Pin Diameter mm(in)
Standard Limit
33.995 – 34.000 (1.3384 – 1.3386) 33.970 (1.3374)
Piston Pin and Piston Clearance
Use an inside dial indicator to measure the piston pin
hole (in the piston).
Piston Pin Hole mm(in)
Standard
34.004 – 34.012 (1.3387 – 1.3391)
Piston Pin and Piston Pin Hole
Clearance mm(in)
0.004 – 0.015 (0.0002 – 0.0006)
Piston Pin and Connecting Rod Small End Bushing
Clearance
Use a caliper calibrator and a dial indicator to measure
the piston pin and connecting rod small end bushing
clearance.
If the clearance between the piston pin and the connect-
ing rod small end bushing exceeds the specified limit,
replace the piston pin and/or the connecting rod
bushing.
Piston Pin and Connecting Rod Small
End Bushing Clearance mm(in)
Standard Limit
0.008 – 0.019 0.05
(0.0003 – 0.0007) (0.002)

Connecting Rod Bushing Replacement


Connecting Rod Bushing Removal
1. Clamp the connecting rod in a vise.
2. Use the connecting rod bushing remover to remove
the connecting rod bushing.
Connecting Rod Bushing Replacer

79
ENGINE ASSEMBLY ( 2 )

Connecting Rod Bushing Installation


1. Clamp the connecting rod in a vice.
2. Use the connecting rod bushing installer to install
the connecting rod bushing.
Connecting Rod Bushing Replacer:

3. Use a piston pin hole grinder 1 fitted with a reamer


2 to ream the piston pin hole.
1 Inner Diamter of Small End Bushing mm(in)
Standard
34.008 – 34.015 (1.3389 – 1.3392)

CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the distortion
and the parallelism between the connecting rod big end
hole and the connecting rod small end hole.
If either the measured distortion or parallelism exceed
the specified limit, the connecting rod must be replaced.
Connecting Rod Alignment
Per Length of 100 mm (3.94 in) mm(in)
Standard Limit
0.20
Distortion
0.05 or Less (0.008)
(0.0020) 0.15
Parallelism
(0.006)

80
ENGINE ASSEMBLY ( 2 )

Connecting Rod Side Face Clearance


1. Install the connecting rod to the crankpin.
2. Use a feeler gauge to measure the clearance
between the connecting rod big end side face and
the crankpin side face.
If the measured value exceeds the specified limit,
the connecting rod must be replaced.
Connecting Rod and Crankpin Side Face
Clearance mm(in)
Standard Limit
0.175 – 0.290 (0.0069 – 0.0114) 0.35 (0.014)

IDLER GEAR SHAFT AND IDLER GEAR


Idler Gear Shaft Outside Diameter
Use a micrometer to measure the idler gear shaft out-
side diameter.
If the measured value is less than the specified limit, the
idler gear must be replaced.
Idler Gear Shaft Outside Diameter mm(in)
Standard Limit
44.945 – 44.975 44.90
(1.769 – 1.771) (1.767)

81
ENGINE ASSEMBLY ( 2 )

Idler Gear “A” Inside Diameter


1. Use an inside dial indicator to measure the idler
gear

Idler Gear Inside Diameter mm(in)


Standard Limit
45.0 – 45.03 45.10
(1.7717 – 1.7718) (1.7756)

If the clearance between the idler gear shaft outside


diamerer and the idler gear inside diameter exceeds the
limit, the idler gear must be replaced.
Idler Gear Shaft and Idler Gear
Clearance mm(in)
Standard Limit
0.025 – 0.085 0.2
(0.0010 – 0.0033) (0.008)

Idler Gear “B”


Bearing replacement
Use a suitable bar and a bench press or hammer.
1 Bearing projection amount should be within the spec-
2
ified height.
mm(in)
Projection 1 0.4 – 0.6 (0.016 – 0.024)
Height 2 23.7 – 24.0 (0.933 – 0.945)

TIMING GEAR CASE COVER


Replace the crankshaft front oil seal if it is excessively
worn or damaged.

Crankshaft Front Oil Seal Replacement


Oil Seal Removal
Use a plastic hammer and a screwdriver to tap around
the oil seal to free it from the gear case.
Take care not to damage the oil seal fitting surfaces.

82
ENGINE ASSEMBLY ( 2 )

Oil Seal Installation


1. Apply a coat of engine oil to the oil seal lip circum-
ference.
2. Use the oil seal installer and the installer grip to
insert the oil seal 1 mm (0.039 in) into the front por-
tion of the timing gear case.
Oil Seal Installer: 5-8840-2061-0

83
ENGINE ASSEMBLY ( 2 )

MEMO

84
ENGINE ASSEMBLY ( 3 )

SECTION 5

ENGINE ASSEMBLY ( 3 )
TABLE OF CONTENTS

ITEM PAGE

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

85
ENGINE ASSEMBLY ( 3 )

REASSEMBLY

SINGLE UNIT
ROCKER ARM SHAFT AND ROCKER ARM

3 2

4
5
6

Reassembly Steps
▲ 1. Rocker arm shaft 5. Rocker arm
2. Rocker arm shaft snap ring 6. Rocker arm shaft spring
3. Rocker arm 7. Rocker arm shaft snap ring
4. Rocker arm shaft bracket

86
ENGINE ASSEMBLY ( 3 )

Important Operations

1. Rocker Arm Shaft


1) Position the rocker arm shaft with the large oil
hole (4ø) facing the front of the engine.
2) Install the rocker arm shaft together with the
rocker arm, the rocker arm shaft bracket, and
the spring.

87
ENGINE ASSEMBLY ( 3 )

CYLINDER HEAD

Reassembly Steps
1. Cylinder head ▲ 5. Valve spring
2. Valve spring lower seat 6. Valve spring upper seat
▲ 3. Valve stem oil seal ▲ 7. Split collar
▲ 4. Intake and exhaust valve

88
ENGINE ASSEMBLY ( 3 )

Important Operations

3. Valve Stem Oil Seal


1) Apply a coat engine oil to the oil seal inner face.
2) Use an oil seal installer to install the oil seal to
the valve guide.
Oil Seal Installer: 5-8840-2033-0

4. Intake and Exhaust Valve


1) Apply a coat of engine oil to valve stem.
2) Install the intake and exhaust valves.
3) Turn the cylinder head up to install the valve
springs.
Take care not to allow the installed valves to fall
free.

5. Valve Spring
1) Turn the cylinder head up to install the valve
springs.
2) Install the valve springs with the fine pitched
end (painted pink) facing down.
Take care not to allow the installed valves to fall
free.

7. Split Collar
1) Use the spring compressor to push the valve
spring into position.
Spring Compressor: 9-8523-1423-0
2) Install the split collar to the valve stem.
3) Set the split collar by tapping around the bead
of the collar with a rubber hammer.

89
ENGINE ASSEMBLY ( 3 )

PISTON AND CONNECTING ROD

4
1

Reassembly Steps
▲ 1. Piston 5. Piston pin snap ring
▲ 2. Piston pin snap ring ▲ 6. Piston ring
▲ 3. Connecting rod ▲ 7. Connecting rod bearing
▲ 4. Piston pin

90
ENGINE ASSEMBLY ( 3 )

Important Operations

1. Piston
2. Piston pin snap ring
3. Connecting rod
1) Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2) Use a pair of snap ring pliers to install the piston
pin snap ring to the piston.

3) Install the piston to the connecting rod.


The piston head front mark and the connecting
Front mark rod “ISUZU” casting mark must be facing the
same direction.

ISUZU mark

4. Piston pin
1) Apply a coat of engine oil to the piston pin and
the piston pin hole.
2) Use your fingers to force the piston pin into the
piston until it makes contact with the snap ring.

3) Use your fingers to force the piston pin snap


ring into the piston snap ring groove.
4) Check that the connecting rod moves smoothly
on the piston pin.

91
ENGINE ASSEMBLY ( 3 )

6. Piston Ring
3
1) Use a piston ring replacer to install the three
piston rings.
2 Piston Ring Replacer:
Install the piston rings in the order shown in the
illustration.
1
1 1 Oil ring (Coil expander type)
2 2nd compression ring (Taper type)
3 1st compression ring (Barrel face type)
Note:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil before
installing the oil ring.
2) Apply engine oil to the piston ring surfaces.
3) Check that the piston rings rotate smoothly in
the piston ring grooves.

7. Connecting Rod Bearing


Carefully wipe any oil or other foreign material from
the connecting rod bearing back face and the
connecting rod bearing fitting surface.

92
ENGINE ASSEMBLY ( 3 )

CAMSHAFT, CAMSHAFT TIMING GEAR, AND THRUST PLATE

2
3
4

Reassembly Steps
1. Camshaft 3. Thrust plate
2. Feather key ▲ 4. Camshaft timing gear

93
ENGINE ASSEMBLY ( 3 )

Important Operations

4. Camshaft Timing Gear


1) Install the thrust plate 1 .
2) Apply engine oil to the bolt threads 2 .
3) Install the camshaft timing gear with the timing
2 mark stamped side facing out.
Camshaft Timing Gear Bolt Torque kg·m(lb.ft/N·m)
10.0 – 12.0 (72 – 87/98 – 118)
1

94
ENGINE ASSEMBLY ( 3 )

MEMO

95
ENGINE ASSEMBLY ( 3 )

REASSEMBLY

1 ★ 13

2
8 14

15

5
3

6
10

11

12

16 16a

★ Repair kit

Reassembly Steps – 1
▲ 1.
Cylinder body ▲ 10. Connecting rod cap with lower bearing
▲ 2.
Tappet ▲ 11. Crankcase (If so equipped)
▲ 3.
Crankshaft upper bearing ▲ 12. Oil pump with oil pipe
▲ 4.
Crankshaft with crankshaft timing gear ▲ 13. Crankshaft rear oil seal
▲ 5.
Crankshaft thrust bearing ▲ 14. Flywheel housing
▲ 6.
Crahkshaft bearing cap with lower ▲ 15. Flywheel
bearing ▲ 16. Oil pan
▲ 7. Timing gear case 16a Oil pan (If so crankcase equipped)
▲ 8. Camshaft with camshaft timing gear
and thrust plate Inverted Engine
▲ 9. Piston and connecting rod with upper
bearing

96
ENGINE ASSEMBLY ( 3 )

17
★ ★

13 11
14
10

12 9
5

★ 8 ★ 16

6
15
7

1
2

3 ★ Repair kit

Reassembly Steps – 2
▲ 1. Idler gear shaft 10. Push rod
▲ 2. Idler gear “A” ▲ 11. Rocker arm shaft and rocker arm
▲ 3. Idler gear “B” ▲ 12. Water pump
4. Timing gear oil pipe ▲ 13. Thermostat housing
▲ 5. Timing case cover 14. Water by-pass hose
6. Timing gear case cover ▲ 15. Glow plug and glow plug connector
▲ 7. Crankshaft damper pulley seal
▲ 8. Cylinder head gasket ▲ 16. Injection nozzle holder
▲ 9. Cylinder head 17. Cylinder head cover

97
ENGINE ASSEMBLY ( 3 )

Reassembly Steps – 2a: Timing Gear Case PTO


1. Timing gear case 4. PTO Gear
2. Under plate 5. Adapter : PTO
3. PTO Idle gear 6. Timing case cover

98
ENGINE ASSEMBLY ( 3 )

Important Operations (Reassembly Steps-1)

1. Cylinder Body
Use compressed air to thoroughly clean the inside
and outside surfaces of the cylinder body, the oil
holes, and the water jackets.

2. Tappet
1) Apply a coat of engine oil to the tappet 1 and
the cylinder body tappet insert holes 2 .
1 2) Locate the position mark applied at disassembly
(if the tappet is to be reused).
Note:
The tappet must be installed before installing the
2 camshaft.

3. Crankshaft Upper Bearing


The crankshaft upper bearings have an oil hole and
an oil groove. The lower bearings do not.
1) Carefully wipe any foreign material from the
crankshaft upper bearing and the crankshaft
upper bearing fitting surfaces.
2) Locate the position mark applied at disassembly
if the removed crankshaft upper bearings are to
be reused.

4. Crankshaft with Crankshaft Timing Gear


Apply an ample coat of engine oil to the crankshaft
journals and the crankshaft bearing surfaces before
installing the crankshaft.
Note:
Do not apply engine oil to the bearing back faces and the
cylinder body bearing fitting surfaces.

99
ENGINE ASSEMBLY ( 3 )

5. Crankshaft Thrust Bearing


1) Apply an ample coat of engine oil to the crank-
shaft thrust bearings.
2) Install the crankshaft thrust bearings to the
crankshaft center journal.
The crankshaft thrust bearing oil groove must
be facing the sliding face.

6. Crankshaft Bearing Cap with Lower Bearing


1) Apply silicon adhesive to the cylinder body No.
5 bearing cap fitting surface at the points shown
in the illustration.
Note:
Be sure that the bearing cap fitting surface is completely
free of oil before applying the silicon adhesive.
Do not allow the silicon adhesive to obstruct the cylinder
thread holes and bearings.

2) Install the bearing caps.


The bearing cap arrow marks must be facing the
front of the engine.
The arrow mark journal number must corre-
spond to the journal to which the bearing cap is
installed.

1 2 3 4 5

3) Apply a coat of engine oil to the bearing cap


bolts.
4) Tighten the crankshaft bearing cap bolts to the
specified torque a little at a time in the sequence
shown in the illustration.
8 1 9
4 5 Crankshaft Bearing Cap Torque kg·m(lb.ft/N·m)
16.0 – 18.0 (116 – 130/157 – 177)
3 2
6
7 10 5) Check to see that the crankshaft turns smoothly
by rotating it manually.

7. Timing Gear Case


1) Tighten the timing gear case with timing gear
case gasket to the specified torque.
Timing Gear Case Bolt Torque kg·m(lb.ft/N·m)
1.4 – 2.4 (10 – 17/14 – 24)

2) Cut away any excessive flash from the timing


gear gasket.

100
ENGINE ASSEMBLY ( 3 )

8. Camshaft with Camshaft Timing Gear and Thrust


Plate
1) Apply a coat of engine oil to the camshaft and
the camshaft bearings.
2) Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
3) Tighten the thrust plate to the specified torque.
Thrust Plate Bolt Torque kg·m(lb.ft/N·m)
1.4 – 2.4 (10 – 17/14 – 24)

4) Check to see that the camshaft turns smoothly


by rotating it manually.

9. Piston and Connecting Rod with Upper Bearing


3
10. Connecting Rod Bearing Cap with Lower Bearing
1) Apply a coat of engine oil to the circumference
2 of each piston ring and piston.

1
1

2) Position the piston ring gaps as shown in the


2
illustration.
1 1st compression ring
2 2nd compression ring
3 Oil ring
3) Apply a coat of molybdenum disulfide grease to
the two piston skirts.
This will faciliate smooth break-in when the
1 engine is first started after reassembly.
3

4) Apply a coat of engine oil to the upper bearing


surfaces.
Note:
Do not apply engine oil to the bearing back faces and the
connecting rod bearing fitting surfaces.
5) Apply a coat of engine oil to the cylinder wall.

101
ENGINE ASSEMBLY ( 3 )

6) Position the piston head front mark so that it is


Front mark facing the front of the cylinder body.
7) Use a piston ring compressor to compress the
piston rings.
Piston Ring Compressor
8) Use a hammer grip to push the piston in until
the connecting rod makes contact with the
crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.
9) Install the connecting rod bearing caps.
The bearing cap front marks must be facing the
front of the engine.
The bearing cap number (at the side of the
bearing cap) and the connecting rod number
must be the same.
Note:
It is absolutely essential that the bearing caps be
installed in the correct direction. Reversing the bearing
cap direction will result in serious engine damage.
10) Apply a coat of engine oil to the threads and
setting faces of each connecting rod cap bolt.
11) Tighten the connecting rod caps to the specified
torque.
Connecting Rod Cap Bolt Torque kg·m(lb.ft/N·m)
2.8 – 3.2 → 45° – 60°
(20 – 23/27 – 31)

11. Crankcase (if so equipped)


1) Apply sealant to the No. 5 bearing cap arches,
the bearing grooves, and the timing gear case
arches at the positions shown in the illustration.

2) Apply lsealant to the crankcase cylinder body


5 fitting area.
1 3) Tighten the crankcase bolts to the specified
8 6 torque a little at a time in the sequence shown
in the illustration.
4
Crankcase Bolt Torque kg·m(lb.ft/N·m)
2
7 1.4 – 2.4 (10.1 – 17.3/13.7 – 23.5)
3

102
ENGINE ASSEMBLY ( 3 )

12. Oil Pump with Oil Pipe


Install the oil pump with the oil pipe and tighten the
bolts to the specified torque.
Oil Pump Bolt Torque kg·m(lb.ft/N·m)
1.4 – 2.4 (10 – 17/14 – 24)

Note:
Take care not to damage the O-rings when tightening
the oil pipe bolts.

13. Crankshaft Rear Oil Seal (TYPE I)


1) Apply engine oil to the oil seal lip circumference
and the oil seal outer circumference.
2) Use the oil seal installer to install the oil seal to
the cylinder body.
Oil Seal Installer: 5-8840-0141-0

13. Crankshaft Rear Oil Seal (TYPE II)


12.5±0.3
1) Tighten the adapter to the crankshaft rear and
section with 2 bolts.
2) Insert the oil seal into the peripheral section of
adapter.
3) Insert the sleeve into the adapter section, and 1)
tighten it with a bolt (M12 x 1.75L = 70) until the
adapter section hits the sleeve.
4) Remove the adapter and the sleeve.
5) With the seal pressed in, check the dimension of
the oil seal section.
Standard Dimension = 12.5 ± 0.3 mm
Oil Seal Installer: 5-8840-9057-0

14. Flywheel Housing


6
8 10 1) Apply sealant to the shaded area shown in the
5
9 illustration.
3
2) Tighten the flywheel housing bolts to the speci-
2
fied torque a little at a time in the sequence
shown in the illustration.
7 1
Flywheel Housing Bolt Torque kg·m(lb.ft/N·m)
M10x1.25 3.6 – 4.6 (26 – 33/35 – 45)
4 M12x1.5 7.5 – 9.3 (54 – 67/74 – 91)

103
ENGINE ASSEMBLY ( 3 )

15. Flywheel
1) Block the flywheel with a piece of wood to pre-
vent it from turning.
1
7 6 2) Apply a coat of engine oil to the threads of the
3 4 flywheel bolts.
5 8 3) Tighten the flywheel bolts in the numerical
2
order shown in the illustration.
Flywheel Bolt Torque kg·m(lb.ft/N·m)
11.5 – 12.5 (83 – 90/113 – 123)

16. Oil Pan


1) Apply sealant to the No. 5 bearing cap arches,
the bearing grooves, and the timing gear case
arches at the positions shown in the illustration.

2) Fit the gasket rear lipped portion into the No. 5


bearing cap groove.
Be absolutely sure that the lipped portion is
fitted snugly in the groove.

3) Tighten the oil pan bolts to the specified torque


5 a little at a time in the sequence shown in the
illustration.
1 6
8 Oil Pan Bolt Torque kg·m(lb.ft/N·m)
1.4 – 2.4 (10 – 17/14 – 24)
4

2
7
3

Oil pan fixing torque in case of the engine


specification which is equipped with the crankcase.
1 Tighten the oil pan bolts to the specified torque
starting from 1 and 2 alternately, as shown in the
illustration and, work out toward the arrow
2 directions.
Oil Pan Bolt Torque kg·m(lb.ft/N·m)
0.6 – 1.0 (4.4 – 7.2/5.9 – 9.8)

104
ENGINE ASSEMBLY ( 3 )

Important Operations (Reassembly Steps-2)

1. Idler Gear Shaft


The idler gear shaft oil hole must be facing up.

2. Idler Gear “A”


1) Apply engine oil to the idler gear 1 and the
1 2 idler gear shaft 2 .
2) Position the idler gear setting marks “X” and
“Y” so that they are facing the front of the
engine.

“Y” 3) Align the idler gear “X – X” setting mark with


the crankshaft timing gear 3 “X” setting mark.
1 4) Align the idler gear “Y – Y” setting mark with
4 the camshaft timing gear 4 “Y” setting mark.
5) Tighten the idler gear bolt to the specified
torque.
Idler Gear “A” Bolt Torque kg·m(lb.ft/N·m)
“X” 2.1 – 3.1 (15 – 22/21 – 30)
3

3. Idler Gear “B”


1
1) Apply engine oil to the idler gear and the idler
5 gear shaft.
2) Align the idler gear 5 “Z” setting mark with the
idler gear 1 “Z – Z” setting mark.
Idler Gear “B” Bolt Torque kg·m(lb.ft/N·m)
“Z”
9.5 – 11.5 (69 – 83/93 – 113)

105
ENGINE ASSEMBLY ( 3 )

3. Idler Gear “B” and PTO Gear

5. Timing Case Cover


1) Before installing the timing gear case, apply a 3
mm x 5 mm (0.12 in x 0.20 in) strip of sealant to
the portion of the feather key indicated by the
arrow in the illustration.
2) Check that the timing case cover O-ring is firmly
inserted into the gear case groove.
3) Tighten the timing case cover bolts to the speci-
fied torque.
Timing Case Cover Bolt Torque kg·m(lb.ft/N·m)
M 8x1.25 (0.31x0.05)
1.4 – 2.4 (10 – 17/14 – 24)
Bolt

7. Crankshaft Damper Pully


1) Block the flywheel ring gear with a piece of
wood to prevent it from turning.
2) Tighten the crankshaft damper pulley to the
specified torque.
Crankshaft Damper Pulley Bolt Torque kg·m(lb.ft/N·m)
20.1 – 24.5 (145 – 177/197 – 240)

Take care not to damage the crankshaft damper


pulley boss.

8. Cylinder Head Gasket


TOP The cylinder gasket “TOP” mark must be facing up.
Use the head gasket of the thickness 1.65 mm.
T O P

(Part No. 897066-1970)


Front

106
ENGINE ASSEMBLY ( 3 )

9. Cylinder Head
1) Align the cylinder body dowels and the cylinder
head dowel holes.
Carefully set the cylinder head to the cylinder
head gasket.
2) Apply engine oil to the cylinder head fixing bolt
threads and setting faces.

3) Tighten the cylinder head bolts to the specified


torque in two steps following the numerical
13 5 4 12 order shown in the illustration.
17 9
1
8 Cylinder Head Bolt Torque kg·m(lb.ft/N·m)
16
1st stop 2nd stop 3rd stop
2 15
4.5 – 5.5
18 14 7 60 – 75° 60 – 75°
10 (33 – 40/44 – 54)
6 3 11

11. Rocker Arm Shaft and Rocker Arm


Tighten the rocker arm shaft bracket bolts in the
numerical order shown in the illustration.
Rocker Arm Shaft Bracket Bolt Torque kg·m(lb.ft/N·m)
5.0 – 6.0 (36 – 43/49 – 59)

12. Water Pump


1) Temporarily tighten the water pump bolt
marked with an arrow in the illustration.
This bolt will be tightened to the specified to
torque when the alternator adjusting plate is
installed.
2) Tighten the other water pump bolts to the speci-
fied torque.
Water Pump Bolt Torque kg·m(lb.ft/N·m)
1.4 – 2.4 (10 – 17/14 – 24)
13. Thermostat Housing
1) Install the thermostat housing.
2) Tighten the thermostat housing bolts to the
specified torque.
Thermostat Housing Bolt Torque kg.m(lb.ft/N.m)
1.4 – 2.4 (10 – 17/14 – 24)

107
ENGINE ASSEMBLY ( 3 )

15. Glow Plug and Glow Plug Connector


1) Tighten the glow plugs to the specified torque.
Glow Plug Torque kg·m(lb.ft/N·m)
1.5 – 2.0 (11 – 14/15 – 20)

2) Install the glow plug connectors.

16. Injection Nozzle Holder


Gasket 1) Install the heat shield washer and the heat shield
Nozzle
to the cylinder head from the nozzle holder
installation hole side. Lightly tap the flange into
place with a brass bar.
The heat shield flange side must be facing up.
NOTE:
Colgate washer Always install a new heat shield. Never reuse the old
Nozzle heat shield Gasket heat shield heat shield.
2) Tighten the holder nut to the specified torque.
kg·m(lb.ft/N·m)
6.0 – 7.0 (43 – 51/59 – 69)

108
ENGINE ASSEMBLY ( 3 )

ALUMINUM DYECAST TYPE GEARCASE PTO AND RELATED PARTS

1
2

7 4

5
16

10
9
12
14

11

13

15

F06E100046

Reassembly Steps – 2b: Timing Gearcase PTO


1. Locating pin 9. Idler gear B
2. Idler gear shaft A 10. Idler gear C
3. Gasket 11. PTO gear
4. Gearcase 12. Gearcase cover
5. Locating pin 13. Oil feed pipe
6. Stud bolt 14. Gasket
7. Idler gear A 15. Oil pan
8. Oil pipe 16. Cover

109
ENGINE ASSEMBLY ( 3 )

Idler gear shaft


1. Install the idler gear shaft A with facing up oil hole
to the cylinder block.
2. Install the locating pin to the cylinder block.
Note:
The gearcase is positioned by the locating pin and idler
gear shaft A.

014E100055

Gearcase
1. Install the gearcase with new gasket to the cylinder
block. Tighten the bolts to the specified torque.
N·m (kgf·m/lb.ft)
Gearcase Bolt Torque 14 – 24 (1.4 – 2.4/10 – 17)

2. Install the locating pin to the gearcase.


3. Install the stud bolts to the gearcase.
• Apply Loctite 262 or equivalent to the thread
020E100018 portion of stud bolt.

Idler gear A
1. Install the camshaft with cam gear.
2. Install the idler gear and thrust washer to the idler
gear shaft.
• Apply engine oil to the idler gear shaft.
• Install the thrust washers with the dimple of
thrust washer facing to gear side.
• Tighten the bolts to the specified torque.
N·m (kgf·m/lb.ft)
014E100065

Bolt Torque 21 – 30 (2.1 – 3.1/15 – 22)

3. Install the oil pipe (gearcase to idler gear shaft).


Tighten the bolts to the specified torque.
N·m (kgf·m/lb.ft)
Bolt Torque 10 – 15 (1.0 – 1.5/7.2 – 11)

110
ENGINE ASSEMBLY ( 3 )

Ft Rr Idler gear B
1. Press the bearing to the idler gear until the gear
Timing contacts into bearing stopper (1).
gear mark
• Use the bearing with spacers (2).
• Apply load only on the outer race of bearing,
when the bearing will be pressed to the gear.
2. Install the idler gear shaft (3) to the gear.
3
3. Install the idler gear asm to the gearcase.
1 2
020E100027
4. Tighten the bolt to the spacified torque.
N·m (kgf·m/lb.ft)
Bolt Torque 93 – 113 (9.5 – 11.5/69 – 83)

"O"
Timing gear mark
"O" Align the timing mark X, Y, Z.
"V"

"Y" "Z"
"X"
014E100058

Ft Rr Idler gear C
Sub-assemble the bearing to the gear.
Narrow • Apply load only on the inner race of bearing,
when the bearing will be pressed to the gear.

020E100028

PTO gear
Ft Rr
Sub-assemble the bearing to the gear.
• Apply load only on the inner race of bearing,
when the bearing will be pressed to the gear.

020E100020

111
ENGINE ASSEMBLY ( 3 )

"O" Gearcase PTO


"O"
Install the idler gear C and PTO gear to the gearcase.
"V"

"Y" "Z" PTO gear


"X" PTO idler gear
020E100029

Gearcase cover
1. Apply sealant to the gearcase.
2. Install the gearcase cover to the gearcase.
3. Tighten the bolts to the specified torque.

N·m (kgf·m/lb.ft)
M8 14–24 (1.4–2.4/10–17)
Bolt Torque
M12 75–91 (7.6–9.3/55–67)
020E100022

4. Install the oil feed pipe to the gearcase cover.

Oil pan
1. Apply sealant TB1207B or equivalant to the No.5
bearing cap arches, the bearing grooves, and the
timing gearcase arches as shown in the illustration.

013E100004

2. Fit the gasket rear lipped portion into the No.5


bearing cap groove.
Be absolutely sure that the lipped portion is fitted
snugly in the groove.

013E100005

5 3. Tighten the oil pan nuts and bolts to the specified


torque a little at a time in the sequence shown in the
1 6
illustration.
8 N·m (kgf·m/lb.ft)

4 Oil Pan Nut and


14 – 24 (1.4 – 2.4/10 – 17)
Bolt Torque
2
7

013E100007

112
ENGINE ASSEMBLY ( 3 )

10 11 14 2 31 7 4

5
6

13 12 15 16 8 9

Reassembly Steps – 3
▲ 1. Intake manifold 11. Dipstick and guide tube
▲ 2. Injection pump ▲ 12. Alternator
▲ 3. Fuel injection pipe with clip ▲ 13. Oil filter
4. Fuel leak off pipe 14. Fan pulley
5. Fuel pipe (IN) 15. Cooling fan belt
6. Fuel pipe (OUT) 16. Cooling fan and spacer
7. Breather hose
8. Oil pipe
▲ 9. Starter motor
▲ 10. Exhaust manifold

113
ENGINE ASSEMBLY ( 3 )

Important Operations (Reassembly Steps-3)

1. Intake Manifold
Install the intake manifold gasket with the end hav-
ing the sharp corners facing the front of the engine.

2. Injection Pump Installation


1) Turn the crankshaft slowly clockwise to align the
1
camshaft timing check hole pointer 1 with the
camshaft timing gear “O” mark 2 .

2) Install the injection pump to the timing gear


case.
3
Align the injection pump timing check hole
pointer 3 with the timing gear “O” mark 4 .
3) Tighten the injection pump bracket bolt 5 to the
specified torque.
4

Injection Pump Bracket Bolt Torque kg·m(lb.ft/N·m)


1.4 –2.4 (10 – 1714 – 24)

114
ENGINE ASSEMBLY ( 3 )

3. Fuel Injection Pipe with Clip


1) Temporarily tighten the injection pipe sleeve
nut.
2) Set the clip in the prescribed position.
Note:
Make absolutely sure that the clip is correctly positioned.
An improperly positioned clip will result in injection pipe
breakage and fuel pulsing noise.

3) Tighten the injection pipe sleeve nut to the


specified torque.
Injection Pipe Sleeve Nut Torque kg·m(lb.ft/N·m)
2.0 – 4.0(14 – 29/20 – 39)

9. Starter motor
Tighten the starter bolts to the specified torque.
Starter Bolt Torque kg·m(lb.ft/N·m)
6.7 – 8.7 (48 – 63/60 – 85)

10. Exhaust Manifold


Tighten the exhaust manifold bolts to the specified
torque a little at a time in the numerical order shown
5 1 4 8
in the illustration.
Exhaust Manifold Bolt Torque kg.m(lb·ft/N·m)
1.4 – 2.4 (10 – 17/14 – 24)
6 2 3 7

12. Alternator and Adjusting Plate


Tighten the alternator bolts and the adjusting plate
bolts to the specified torque.
Alternator Bolt Torque kg·m(lb.ft/N·m)
1.4 – 2.4 (10 – 17/14 – 24)
Tighten the adjusting plate bolts to the specified
torque after cooling drive belt installation.
Adjusting Plate Bolt Torque kg·m(lb.ft/N·m)
1.4 – 2.4 (10 – 17/14 – 24)

115
ENGINE ASSEMBLY ( 3 )

13. Oil Filter


Tighten the oil filter bolts to the specified torque.
Oil Filter Bolt Torque kg·m(lb.ft/N·m)
1.4 – 2.4 (10 – 17/14 – 24)

116
LUBRICATING SYSTEM

SECTION 6

LUBRICATING SYSTEM
TABLE OF CONTENTS

ITEM PAGE

Main data and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118


General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Oil filter with built-in oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

117
LUBRICATING SYSTEM

MAIN DATA AND SPECIFICATIONS

Item 4JG2
Oil pump type Trochoid
Delivery volume Lit(US/UK gal)/min. 17.5 (4.61/3.85)
Pump speed rpm 1000
2
Delivery pressure kg/cm (psi/kPa) 4.0 (57/392)
Oil temperature °C(°F) 47 – 53 (116.6 – 127.4)
Engine oil SAE 30
Oil filter type Full flow with cartridge paper element
2
Relief valve opening kg/cm (psi/kPa) 4.3 – 4.7 (61 – 67/422 – 461)
pressure
Safety valve opening kg/cm2(psi/kPa) 0.8 – 1.2 (11 – 17/78 – 118)
pressure
Oil cooler type (if so equipped) Water-cooled
2
Safety valve opening kg/cm (psi/kPa) 2.3 – 2.7 (33 – 38/225 – 265)
pressure

118
LUBRICATING SYSTEM

GENERAL DESCRIPTION
LUBRICATING OIL FLOW

Battery Warning
Light

Oil pressure switch

Cylinder block oil gallery

Idle gear
Oil filter and cooler assembly. shaft

Filter cartridge
Crank shaft Camshaft Vacuum
Partial flow bearing bearing pump
Main flow
oil filter Oil pipe
oil filter
(If so equipped)
Rocker arm
shaft

Oil cooler Relief valve Connecting


rod bearing
Timing Rocker arm
gears

Oil pump Regulating


valve
(Orifice)

Oil strainer

Oil pan

The 4J Series engine lubricating system is a full flow type.


Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the
oil filter. It is then delivered to the vital parts of the engine from the cylinder body oil gallery.

119
LUBRICATING SYSTEM

OIL PUMP

4J Series engine are equipped with a trochoid type oil pump.


The oil filter and the water cooled oil cooler are a single unit to increase the cooling effect.

120
LUBRICATING SYSTEM

MAIN OIL FILTER

OIL FILTER WITH BUILT-IN OIL COOLER (Option)

121
LUBRICATING SYSTEM

OIL PUMP
DISASSEMBLY

051ET001

Disassembly Steps
4. Vane
1. Oil pipe
▲ 5. Pump body with rotor and pinion
2. Strainer case
3. Pump cover

122
LUBRICATING SYSTEM

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis-
covered during inspection.

Vane, Rotor, and Cover Clearance


Use a feeler gauge to measure the clearance between
the vane, the rotor, and the cover.
If the clearance between the vane, the rotor, and the
cover exceeds the specified limit, the rotor set (pin,
shaft, rotor, and vane) must be replaced.
Vane, Rotor, and Cover Clearance mm(in)
Standard Limit
0.02 – 0.07 (0.0008 – 0.0026) 0.15 (0.006)

Rotor and Vane Clearance


Use a feeler gauge to measure the clearance between
the rotor and the vane.
If the clearance between the rotor and the exceeds the
specified limit, the rotor kit (shaft, rotor, and vane) must
be replaced.
Rotor and Vane Clearance mm(in)
Standard Limit
0.14 (0.006) or less 0.20 (0.008)

Vane and Pump Body Clearance


Use a feeler gauge to measure the clearance between
the vane and the pump body.
If the clearance between the vane and the pump body
exceeds the specified limit, the entire pump assembly
must be replaced.
Vane and Pump Body Clearance mm(in)
Standard Limit
0.20 – 0.27 (0.008 – 0.011) 0.40 (0.016)

123
LUBRICATING SYSTEM

REASSEMBLY

051ET002

Reassembly Steps
4. Strainer case
1. Pump body with rotor and pinion
5. Oil pipe
2. Vane
3. Pump cover

124
LUBRICATING SYSTEM

OIL FILTER WITH BUILT-IN OIL COOLER (Option)

DISASSEMBLY

7
1

Disassembly Steps
1. Drain plug 5. Safety valve
2. Cartridge oil filter 6. Relief valve
3. Oil cooler 7. Oil filter body
4. O-ring

125
LUBRICATING SYSTEM

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.

Relief Valve
1. Attach an oil pressure gauge to the oil gallery near
the oil filter.
2. Start the engine to check the relief valve opening
pressure.
Relief Valve Opening Pressure kg/cm2(psi/kPa)
5.8 – 6.2 (82 – 88/569 – 608)

Oil Cooler
Water Leakage At Water Passage
1. Plug one side of the oil cooler water passage.
2. Submerge the oil cooler in water.
3. Apply compressed air (2 kg/cm2 (28 psi/196 kPa)) to
the other side of the oil cooler water passage.
If air bubbles rise to the surface, there is water lea-
kage.

126
LUBRICATING SYSTEM

REASSEMBLY

7
1

Reassembly Steps
1. Oil filter body ▲ 5. Oil cooler
▲ 2. Relief valve ▲ 6. Oil filter cartridge
▲ 3. Safety valve ▲ 7. Drain plug
4. O-ring

127
LUBRICATING SYSTEM

Important Operations

2. Relief Vale
Tighten the relief valve to the specified torque.
Relief Valve Torque kg·m(lb.ft/N·m)
2.5 – 3.5 (18 – 25/25 – 34)

5. Oil Cooler
1) Align the oil filter holes with the body knock
pins at installation.
2) Tighten the oil cooler to the specified torque.
Oil Cooler Torque kg·m(lb.ft/N·m)
2.5 – 3.5 (18 – 25/25 – 34)

6. Oil Filter Cartridge


1) Apply engine oil to the O-ring.
2) Turn in the cartridge oil filter until the filter seal-
ing face makes contact with the O-ring.
3) Turn in the cartridge oil filter an additional 1 and
1/4 of a turn.

7. Drain Plug
Tighten the drain plug to the specified torque.
Drain Plug Torque kg·m(lb.ft/N·m)
1.0 – 2.0 (7.2 – 14/9.8 – 20)

128
COOLING SYSTEM

SECTION 7

COOLING SYSTEM
TABLE OF CONTENTS

ITEM PAGE

Main data and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130


General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

129
COOLING SYSTEM

MAIN DATA AND SPECIFICATIONS

Item

Water pump type Centrifugal impeller


Pump to crankshaft speed ratio (To 1) 1.1
Delivery volume Lit(US/UK gal)/min. 100 (26.3/22.2)
Pump speed at 3000 rpm
Water temperature at 30°C (86°F)
Pump bearing type Double row shaft
Thermostat type Wax pellet with jiggle valve
Valve initial opening temperature °C(°F) 76.5 (170)
Valve full opening temperature °C(°F) 90 (194)
Valve lift at fully open position mm(in.) 8.0 (0.31)

130
COOLING SYSTEM

GENERAL DESCRIPTION
COOLANT FLOW

The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated
by the water pump and thermostat through the by-pass hose and back to the cylinder body. The coolant
does not circulate through the radiator.
When the coolant temperature reaches 76.5°C (170°F), the thermostat will begin to open and a gradually
increasing amount of coolant will circulate through the radiator.
The thermostat will be fully open when the coolant temperature reaches 90°C (194°F). All of the coolant is
now circulating through the radiator for effective engine coolant.

131
COOLING SYSTEM

WATER PUMP

THERMOSTAT

A centrifugal type water pump forcefully circulates the coolant through the cooling system.
A wax pellet type thermostat is used.
The jiggle valve accelerates engine warm-up.

132
COOLING SYSTEM

WATER PUMP
DISASSEMBLY


★ 1

4


6
★ 7
5

Disassembly Steps
▲ 1. O-ring ▲ 5. Bearing unit
2. Set screw 6. Thrower
▲ 3. Cooling fan center 7. Water pump body
▲ 4. Impeller and seal unit

133
COOLING SYSTEM

Important Operations

3. Cooling Fan Center


Remove the fan center with a bench press and a bar.

4. Impeller and Seal Unit


Remove the impeller and seal unit with a bench
press and bar.
Note:
Do not drive out the impeller with a hammer. Damage to
the impeller will result.

134
COOLING SYSTEM

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.

Bearing Unit
Check the bearing for abnormal noise, biding, and other
abnormal conditions.

135
COOLING SYSTEM

REASSEMBLY


★ 7

5


2
★ 1
3

Reassembly Steps
1. Water pump body ▲ 5. Impeller and seal unit
2. Thrower ▲ 6. Cooling fan center
▲ 3. Bearing unit 7. O-ring
▲ 4. Set screw

136
COOLING SYSTEM

Important Operations

3. Bearing Unit
4. Set Screw
1) Align the bearing set screw hole with the pump
body set screw hole.
2) Press the bearing unit into place.
3) Secure the bearing with the set screw.

5. Impeller and Seal Unit


1) Apply a thin coat of liquid gasket to the seal unit
outer periphery.
2) Install the seal unit.

Note:
1. The fan center and the impeller are installed to the
water pump shaft with a press.
Never attempt to remove and reinstall the fan center
and the impeller a second time. Replace the entire
water pump assembly.
Removing and reinstalling the fan center and the
impeller a second time may result in the breakdown
of the water pump during engine operation and
subsequent serious overheating problems.
2. The water pump assembly must be replaced
whenever the fan center and impeller pressure force
falls below 200 kg.
3. Do not attempt to strike the bearing into position
with a hammer or similar object. Damage to the
bearing will result.

137
COOLING SYSTEM

THERMOSTAT

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.

Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.

3. Check the thermostat initial opening temperature.


1
Thermostat Initial Opening Temperature °C(°F)
2
76.5 (170)

4. Check the thermostat full opening temperature.


Thermostat Full Opening Temperature °C(°F)
3 90 (194)

Valve Lift at Fully Open Position mm(in.)


8.0 (0.31)

1 Thermostat
2 Agitating Rod
3 Wooden Piece

138
FUEL SYSTEM

SECTION 8

FUEL SYSTEM
TABLE OF CONTENTS

ITEM PAGE

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140


Injection nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Injection pump data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

139
FUEL SYSTEM

GENERAL DESCRIPTION
FUEL FLOW

Water separator Fuel filter Over flow pipe

Fuel cut
solenoid
Injection nozzle

VE. Type Injection pump

Fuel tank

The fuel system consists of the fuel tank, the water separator (if so equipped), the fuel filter, the injection
pump, and the injection nozzle.
The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and
other foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the
optimum timing for efficient engine operation.

140
FUEL SYSTEM

INJECTION NOZZLE

Nut

Gasket

Adjust shim Nozzle holder

Spring

Push rod

Spacer

Retaining nut

Nozzle

080ET002

The injection nozzle sprays pressurized fuel from the injection pump through the injection nozzle orifices
and into the combustion chamber.

141
FUEL SYSTEM

FUEL FILTER AND WATER SEPARATOR

;@;@;@
041ET003 041ET004

A cartridge type fuel filter and a water separator are used.


As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly
clean. The fuel filter and the water separator remove water particles and other foreign material from the
fuel before it reaches the injection pump.
The water separator has an internal float. When the float reaches the drain level, remind you to drain the
water from the water separator.

142
FUEL SYSTEM

INJECTION NOZZLE

DISASSEMBLY

7
6

5
4
3

Disassembly Steps
1. Retaining nut 5. Push rod
2. Holder nut 6. Spring
▲ 3. Injection nozzle 7. Adjusting shim
4. Spacer 8. Nozzle holder

143
FUEL SYSTEM

Important Operations

Performance this test before disassembling the injection


nozzle.
1) Install the injection nozzle to the nozzle tester.
2) Use the nozzle tester to apply compressed fuel at
14.7 MPa (150 kg/cm2/2,130 psi) to the injection
nozzle.
3) Check the area around the nozzle seat for fuel
leakage.
If there is fuel leakage, the injection nozzle and the
injection body must be replaced as a set.

3. Injection Nozzle
1) Remove the injection nozzles from the nozzle
holders.
The nozzle needle valve and nozzle body
combinations must be interchange.
2) Immerse the injection nozzles in a tool tray filled
with clean diesel fuel to protect them from dust.

144
FUEL SYSTEM

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
discovered during inspection.

Injection Nozzle Needle Inspection


1. Remove the nozzle needle from the nozzle body.
2. Carefully wash the nozzle needle and the nozzle
body in clean diesel fuel.
3. Check that the nozzle needle moves smoothly inside
the injection nozzle body.
If the nozzle needle does not moves smoothly, it
must be repaired (See “Nozzle Lapping Procedure”
below.)

Nozzle Lapping Procedure


1. Lap the nozzle needle 1 and the nozzle body 2 by
3
applying a compound of oxidized chrome and
animal oil 3.
Note:
Do not apply an excessive amount of the oxidized
chrome and animal oil compound to the injection needle
2 1 valve seat area.
2. Carefully wash the needle valve and the nozzle body
in clean diesel fuel after lapping.

Nozzle Body and Needle Valve Inspection


Check the nozzle body and the needle valve for damage
and deformation.
The nozzle and body must be replaced if either of these
two conditions are discovered during inspection.

080ET003

145
FUEL SYSTEM

REASSEMBLY

2
3

4
5
6

Reassembly Steps
1. Nozzle holder 5. Spacer
▲ 2. Adjusting shim 6. Injection nozzle
3. Spring 7. Holder nut
4. Push rod ▲ 8. Retaining nut

146
FUEL SYSTEM

Important Operations

2. Adjust Shim
Adjust Shim Availability mm(in.)
Range 0.10 – 0.50 (0.004 – 0.020)
Increment 0.1 (0.004)

8. Retaining Nut
Tighten to the retaining nut to the specified torque.
Retaining Nut Torque kg·m(lbs.ft./N·m)
4 (35/39)

Injection Nozzle Adjustment


1. Attach the injection nozzle holder to the injection
nozzle tester.
2. Apply pressure to the nozzle tester to check that the
injection nozzle opens at the specified pressure.
If the injection nozzle does not open at the specified
pressure, install or remove the appropriate number
of adjusting shims to adjust it.

WARNING:
TEST FLUID FROM THE INJECTION NOZZLE TESTER
WILL SPRAY OUT UNDER GREAT PRESSURE. IT CAN
EASILY PUNCTURE A PERSON’S SKIN. KEEP YOUR
HANDS AWAY FROM THE INJECTION NOZZLE TESTER
AT ALL TIMES.

147
FUEL SYSTEM

INJ. PUMP CALIBRATION DATA


ZEXEL No. 104746–1910
ISUZU Part No. : 897136-6800 Date : 15 FEB. 1996
Injection pump No. : 104646-1910 (NP–VE4/11F1200LNP1593) Company : ISUZU
Pump rotation : Counterclockwise-viewed from drive side Maker No. : 8-97136-680-0
Refer to the service manual (VE pump B.I.S; Pub. No. EE14E-11041) for all procedures and details other than the following.
1. Test condition
1-1 Nozzle : 105780-0060 (NP–DN0SD1510) Injection pipe : 157805-7320 (φ 2 x φ 6–450mm)
1-2 Nozzle holder : 105780-2150 Fuel oil temperature : 45+5 °C
1-3 Nozzle opening pressure : 13.0+3 MPa (133+3 kgf/cm2) Supply pump pressure : 20 kPa (0.2 kgf/cm2)
1-4 Joint ass’y : 157641-4720 Tube ass’y : 157641-4020
1-5 Test oil : ISO4113 or SAE J967d

Pump seed Charge air press. Difference in


2. Adjustment (r/min) Settings kPa (mmHg) delivery (cm3)
2-1 Full-load adjustment 900 58.1 ±0.5 cm3/1,000 st 3.5
2-2 Supply pump 900 392 ±20 (4.0 ±0.2) kPa (kgf/cm2)
2-3 Timing device travel 900 0.6 ±0.2 mm
2-4 Idling adjustment 350 21.8 ±2.0 cm3/1,000 st 4.5
2-5 Start fuel adj. 100 68.0 ±3.0 cm3/1,000 st FULL
2-6 Maximum speed adj. 1,320 16.5 ±3.0 cm3/1,000 st 5.5

3. Test specification
3-1 Timing device N = r/min 900 1,325
mm 0.6 ±0.2 1.2+0.4
–0.3
3-2 Supply pump N = r/min 900
392 ±29
kPa(kgf/cm2) (4.0 ±0.3)
3-3 Overflow delivery N = r/min 900
cm3/min (360 ±130)

3-4 Fuel injection quantities


Control lever Pump speed Fuel delivery Charge air press.
position (r/min) (cm3/1,000 st) kPa (mmHg)
Max. speed 500 (58.1)
600 (60.4)
900 58.1 ±1.0
1,000 (58.5)
1,200 (58.5)
1,320 16.5 ±3.0
1,400 Below 5.0
Idling 350 21.8 ±2.0
450 Below 5.0
Switch OFF 350 0 IDLE
Magnet valve
Solenoid Max. cut-in voltage : 8 V, Test voltage : 12 ~ 14 V

148
FUEL SYSTEM

4. Control lever angle

1 6 ± 4°

°
35.5±5 Full-speed
Idling

Starting injection quantity adjustment


Adjust the specified starting injection quantity (Item 2-5) using the adjusting bolt and then lock the nut.

BOLT

T=6∼9N・m NUT
0.6∼0.9Kgf・m
L

L=7.4∼11.1

149
FUEL SYSTEM

MEMO

150
ENGINE ELECTRICALS

SECTION 9

ENGINE ELECTRICALS
TABLE OF CONTENTS

ITEM PAGE

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

151
ENGINE ELECTRICALS

STARTER

STARTER IDENTIFICATION
NIPPON DENSO starter are identified by name plate
attached to the yoke. (Illustration)
1
1 Isuzu part number
2 2 NIPPON DENSO part number
Note:
Always check the identification number before begin-
ning a service operation.
Applicable service data will vary according to the ident-
ification number. Use of the wrong service data will
result in starter damage.

152
ENGINE ELECTRICALS

MAIN DATA AND SPECIFICATION

Isuzu Part No. 8-97042-997-0

NIPPON DENSO Part No. 228000-1890

Rated voltage V 12
Rated output kW 2.2
Rating
Direction of rotation
(Viewed from the pinion side) Clockwise
Clutch type Roller
Terminal voltage (No. Load) V 11.5
Minimum current (No. Load) A 120
Starter motor minimum operating speed
(No. Load) rpm 4000

Pinion gear
Modules 2.75
Number of teeth 9
Outside diameter mm(in.) 33.0 (4.3)
Travel distance mm(in.) 1.51 (0.059)

Yoke outside diameter mm(in.) 83.0 (3.27)

Number of poles 4

Brush length
Standard mm(in.) 16.5 (0.65)
Limit mm(in.) 13.0 (0.51)

Brush spring standard fitting load kg(lb./N) (3.52/15.7–4.4/19.6)

Commutator
Outside diameter
Standard mm(in.) 35.0 (1.38)
Limit mm(in.) 34.0 (1.34)
Depth of undercut mica
Standard mm(in.) 0.7 – 0.9 (0.027 – 0.035)
Limit mm(in.) 0.2 (0.008)

153
ENGINE ELECTRICALS

CIRCUIT ARRANGEMENT

BRUSH
FIELD COIL

ARMATURE
PINION

IDLE GEAR

BALL
BEARING
PLUNGER

MAIN
CONTACTS
PINION
RING CLUTCH
CLUTCH
GEAR GEAR STARTER
SWITCH BATTERY

154
ENGINE ELECTRICALS

DISASSEMBLY

7 4

6 12

2
13
15
14

17 1
16
11

10

8
9

Disassembly Steps
1. Hexagon nut ▲ 11. Steel ball
2. Connecting lead wire ▲ 12. Starter pinion
3. Through bolt ▲ 13. Idle gear
4. Starter seal ▲ 14. Retainer
▲ 5. Yoke ▲ 15. Clutch roller
▲ 6. Brush holder 16. Compression return spring
▲ 7. Armature ▲ 17. Magnetic switch body
8. Screw
▲ 9. Starter housing
▲ 10. Pinion clutch

155
ENGINE ELECTRICALS

Important Operations

5. Yoke
9. Starter Housing
17. Magnetic Switch Body
Apply setting marks across the end frame, the yoke,
and the magnetic switch body.
This will ensure reassembly of the parts in their
original positions.

5. Yoke
1
Remove the yoke 1 from the magntic switch 2.

6. Brushes and Brush Holder


Use a pair of long nose pliers to remove the brushes
and pull out the brush holder.

7. Armature
Remove the armature from the yoke.
Note:
If necessary, tap the yoke end with a plastic hammer to
remove the armature.

156
ENGINE ELECTRICALS

10. Pinion Clutch


Remove the magnetic sub-switch from the starter
housing.
Note:
If the pinion is installed to the starter housing (exter-
nally attached to the magnetic sub-switch shaft, it must
be removed before the magnetic sub-switch.

11. Steel Ball


Remove the steel ball from the pinion clutch.

12. Starter Pinion


13. Idler gear
Remove the starter pinion and the idler gear from
the starter housing.

14. Retainer
15. Clutch Roller
Remove the retainer and clutch roller from the
starter housing.

157
ENGINE ELECTRICALS

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis-
covered during inspection.

2
ARMATURE
Armature Short Circuit Test
1. Place the armature on a growler tester 1.
1
2. Hold a hack saw blade 2 against the armature core
while slowly rotating the armature.
If the armature is short circuited, the hack saw blade
will vibrate and will be attracted to the armature
core.
A short circuited armature must be replaced.

Armature Winding Ground Test


Check for continuity across the commutator segments
and the core.
If there is continuity, the armature is internally grounded
due to insulation failure and must be replaced.

Armature Winding Continuity Test


Check for continuity across the commutator segment.
If there is no continuity, the armature coil is open and
must be replaced.

158
ENGINE ELECTRICALS

Commutator Run-Out Test


Use a dial indicator and a V-block to measure the com-
mutator runout.
If the measured value exceeds the limit, the commutator
must be replaced.
Commutator Run-Out mm(in.)
Standard Limit
0.02 (0.0008) 0.05 (0.002)

Commutator Outside Diameter Measurement


Use a vernier caliper to measure the commutator out-
side diameter.
If the measured value exceeds the limit, the armature
must be replaced.
Commutator Outside Diameter mm(in.)
Standard Limit
35.0 (1.38) 34.0 (1.34)

Segment Mica Depth Measurement


Use a depth gauge to measure the segment mica depth.
If the measured value exceeds the limit, the segment
mica must be undercut.
Segment Mica Depth mm(in.)
Standard Limit
0.5 – 0.8
0.2 (0.008)
(0.02 – 0.03)

Bearing Inspection
Visually inspect the bearing.
If the bearing is worn or damaged, it must be replaced.

159
ENGINE ELECTRICALS

YOKE
Field Winding Ground Test
Use a circuit tester to check the field winding ground.
1. Touch one probe to the brush field winding end.
2. Touch the other probe to the bare surface of the
yoke body.
There should be no continuity.
If there is continuity, the field windings are grounded.
Repair or replace the field windings.

Field Winding Continuity Test


Use a circuit tester to check the field winding continuity.
1. Touch one probe to the field winding lead wire.
2. Touch the other probe to the brush.
There should be continuity.
If there is no continuity, the field windings are open.
Repair or replace the field windings.

BRUSH AND BRUSH HOLDER


Brush Length Measurement
Use a vernier caliper to measure the brush length.
If the measured value exceeds the limit, the brush and/
or the yoke must be replaced.
Brush Length mm(in.)
Standard Limit
16.5 (0.65) 13.0 (0.51)

160
ENGINE ELECTRICALS

Brush Spring Inspection


Visually check the brush spring for weakness and rust-
ing.
Replace the brush spring if it is weak or rusted.
Use a spring balancer to measure the spring tension.
If the measured valve exceeds the limit, the brush spring
must be replaced.

Brush Holder Insulation Test


Use a circuit tester to check the brush holder insulation.
1. Touch one probe to the field winding lead wire.
2. Touch the other probe to the brush.
There should be no continuity.
If there is continuity, the brush holder must be
repaired or replaced.

PINION CLUTCH
Pinion Inspection
Use your hand to turn the pinion in the direction of star-
ter motor rotation. The pinion should turn freely.
Try to turn the pinion in the opposite direction. The
pinion should lock.

161
ENGINE ELECTRICALS

REASSEMBLY

13

12

11 14

12 6

16 5
3
4

15

1 17
2
7

14

10
9

Reassembly Steps
1. Magnetic switch body 11. Armature
▲ 2. Compression return spring ▲ 12. Brush holder
▲ 3. Clutch roller ▲ 13. Yoke
▲ 4. Retainer 14. Starter seal
5. Idler gear ▲ 15. Through bolt
6. Starter pinion 16. Connecting lead wire
7. Steel ball 17. Hexagon nut
8. Pinion clutch
9. Starter housing
10. Screw

162
ENGINE ELECTRICALS

Important Operations

2. Compression Return Spring


Apply a coat of engine oil to the compression return
spring.

3. Clutch Roller
4. Retainer
Apply a coat of engine oil to the clutch roller and the
retainer.

12. Brushes and Brush Holder


3 1) Install the negative brush 1 on the brush holder
INSULATOR
side to the brush holder negative hole 2.
BRUSH SPRING 1 The brush holder negative hole is not insulated.
2) Install the positive brush 3 on the yoke side to
the brush holder positive hole 4.
The brush holder positive hole is separated
4 2
from the plate with the insulator.
3) Check that the positive brush lead wires are not
grounded.
4) Install the brush holder to the yoke.
Take care not to damage the brush holder or the
yoke.
Do not spill oil on the brush holder or the yoke.

163
ENGINE ELECTRICALS

13. Yoke
TAB 1) Install the yoke to the magnetic switch.
The yoke must engage the notch on the magnetic
switch.
2) Securely set the rubber boot to the magnetic
switch C-terminal.

15. Throttle Bolt


Tighten the through bolt to the specified torque.
Through Bolt Torque kg·m(lb.ft./N·m)
1.1 – 1.5 (8.0 – 10.8/11 – 15)

164
ENGINE ELECTRICALS

ALTERNATOR

ALTERNATOR IDENTIFICATION
Hitachi generators are identified by name plate attached
2 4 to the rear cover. (Illustration)
1 1 Isuzu part number
3 2 Manufacturer‘s code number
3 Rated output
4 Manufacturer‘s production mark
Note:
Always check the identification number before begin-
ning a service operation.
Applicable service data will vary according to the ident-
ification number. Use of the wrong service data will
result alternator damaged.

165
ENGINE ELECTRICALS

MAIN DATA AND SPECIFICATION

Engine Model to be Equipped 4JG2

Manufacturer‘s name HITACHI

Isuzu Part No. 8-94423-756-0

Manufacturer‘s Code No. LR135-127

Rated voltage V 12
Rated output A 35
Operating speed rpm 1000–13500
Rated output at rpm A/V/rpm 33-37/13.5/5000
No-load output at 0 amperes V/rpm 13.5/1000 or less

Direction of rotation (viewed from the Clockwise


pulley side)
Polarity grounded Negative
Pulley diameter (P.C.D.) mm(in.) 80 (3.15)

Coil resistance at 20°C


Rotor coil Ω 3.11
Stator coil Ω 0.13

Brush length
Standard mm(in.) 14.5 (0.57)
Limit mm(in.) 7.5 (0.30)

Slip ring diameter:


Standard mm(in.) 31.6 (1.24)
Limit mm(in.) 30.6 (1.20)

Shaft diameter
Front mm(in.) 15.0 (0.59)
Rear mm(in.) 12.0 (0.47)

Regulator(s) applicable Built-in


Isuzu Part No. 5-81270-004-0
Manufacturer(s) code No. TR1Z-63

166
ENGINE ELECTRICALS

GENERAL DESCRIPTION

The alternator consists of the front cover, the rotor, the stator, the built-in IC regulator (some engines use a
Tirrell alternator with separate regulator), and the rear cover.
This small size and light weight alternator provides excellent reliability. Its simple construction makes it
very easy to service. The built-in IC regulator minimizes circuit wiring.

167
ENGINE ELECTRICALS

DISASSEMBLY

These disassembly steps are based on the built-in IC regulator type.

5
6
3 7
8

12
11

10
2

Disassembly Steps
1. Through bolt 7. Ball bearing
2. Rear cover and stator 8. Front cover
▲ 3. Pulley and fan ▲ 9. Stator
▲ 4. Spacer collar ▲ 10. Rectifier with brush holder
5. Rotor with bearing 11. IC regulator
6. Bearing retainer 12. Rear cover

168
ENGINE ELECTRICALS

Important Operations

3. Pulley and Fan


(1) Clamp the rotor shaft in a soft jaw vise.
(2) Loosen the pulley lock nut 1.
1 (3) Remove the pulley 2 along with the spacer
collar.

4. Rotor and Bearing


(1) Use a plastic hammer or a press 1 to remove
1 the rotor from the front cover 2.
(2) Remove the spacer collar.

8. Front Cover
Use screwdrivers to pry the front cover 1 from the
1 stator 2.
Note:
Do not attempt to pry the coil wires from the stator.

9. Stator
10. Rectifier with Brush Holder
Use a soldering iron 1 and a pair of long nose pliers
2 to remove the rectifiers.
2 Note:
1 Hold the rectifier leads between the rectifier and the
soldering iron with the long nose pliers. This will
protect the rectifier from the heat.

169
ENGINE ELECTRICALS

INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis-
covered during inspection.

ROTOR AND BEARING

Check the face of the slip rings for contamination and


roughness. If found to be roughened, dress with a fine
sand paper (#500 – 600). If found to be contaminated,
clean with a cloth saturated with alcohol.

Ball Bearing
Check that the ball bearings rotate smoothly.
If the ball bearings are noisy, they must be replaced.

Use a vernier caliper to measure the slip ring outside


diameter.
If the measured value exceeds the limit, the rotor must
be replaced.
Slip Ring Outside Diameter mm(in.)
Standard Limit
31.6 (1.24) 30.6 (1.20)

170
ENGINE ELECTRICALS

Rotor Coil Continuity Test


Use an circuit tester to test the rotor coil continuity.
1. Touch both circuit tester probes to the rotor coil slip
rings.
2. Note the circuit tester reading.
The circuit tester should register approximately 9
ohms.
3. If the circuit tester does not show continuity, check
the connections between the lead wire and the slip
rings.
If breaks are founded, repair and repeat the rotor
coil continuity test.
If there is still no rotor coil continuity, the rotor must
be replaced.

Rotor Coil Ground Test


Use an circuit tester to test the rotor coil for grounding.
1. Touch one of the circuit tester probes to the rotor
shaft.
2. Touch the other circuit tester probe to one of slip
rings.
3. Note the circuit tester reading.
4. Touch the circuit tester probe to the other slip ring.
5. Note the circuit tester reading.
The circuit tester should show infinity (no needle
movement) at both measuring points.
If the circuit tester does not show infinity (the needle
moves) at both measuring points, the rotor is
grounded and must be replaced.

STATOR COIL
Stator Coil Continuity Test
Use an circuit tester to test the stator coil continuity.
1. Touch the circuit tester probes to two of the bare
stator wires.
2. Note the circuit tester reading.
3. Move one of the circuit tester probes to a third wire.

171
ENGINE ELECTRICALS

4. Note the circuit tester reading.


If the two readings (Steps 2 and 4) are identical, the
stator coil has continuity.
If the two circuit tester readings are different, there
is no stator continuity.
5. Check the neutral junction (arrow mark) for breaks.
If breaks are found, repair and repeat the stator coil
continuity test.
If there is still no stator coil continuity, the stator
must be replaced.

Stator Coil Ground Test


Use an circuit tester to test the stator coil for grounding.
1. Touch one circuit tester probe to the bear metal
surface of the stator.
2. Touch the other circuit tester probe to a bare stator
lead wire.
3. Note the circuit tester reading.
The circuit tester should show infinity (no needle
movement).
If the circuit tester shows a value other than infinity
(the needle moves), the stator is grounded and must
be replaced.

RECTIFIER
Rectifier (Positive Diode) Continuity Test
BAD GOOD
Use an circuit tester to test rectifier continuity.
1. Touch the circuit tester positive probe to the rectifier
holder.
2. Touch the circuit tester negative probe to each of the
diode terminals in turns.

172
ENGINE ELECTRICALS

3. Note the meter reading for each diode terminal.


All of the diode should show continuity.
If a diode shows no continuity, it is open circuit. The
rectifier assembly must be replaced.

4. Touch the circuit tester negative probe to the recti-


fier holder.
GOOD BAD
5. Touch the circuit tester positive probe to each of the
diode terminals in turn.
6. Note the meter reading for each diode terminal.
None of the diodes should show continuity.
If a diode shows continuity, it is shorted. The recti-
fier assembly must be replaced.

Rectifier (Negative Diode) Continuity Test

BAD GOOD Use a circuit tester to test the rectifier continuity.


1. Touch the circuit tester negative probe to the recti-
fier holder.
2. Touch the circuit tester positive probe to each of the
diode terminals in turn.
3. Note the meter reading for each diode terminal.
All of the diode should show continuity.
If a diode shows no continuity, it is open. The rec-
tifier assembly must be replaced.
4. Touch the circuit tester positive probe to the rectifier
GOOD
BAD
holder.
5. Touch the circuit tester negative probe to each of the
diode terminals in turn.
6. Note the meter reading for each diode terminal.
None of the diode should show continuity.
If a diode shows continuity, it is shorted. The recti-
fier assembly must be replaced.

1 Rectifier Assembly Replacement Procedure


Use the Rectifier Service Kit to replace the rectifier
assembly in the following steps.
1. Connect the three inside lead wires to the “N” termi-
nals 1.
2. Connect the three outside lead wires 2 to the out-
side terminals.
3. Wind the stator lead wires around the rectifier lead
2 wires (included in the Rectifier Service Kit) and sol-
der them.

173
ENGINE ELECTRICALS

Note:
1. The stator lead wires must be cut to the proper
length before they are connected to the rectifier
lead wires. If the stator lead wires are too long or
too short, trouble may occur.
Stator Lead Wire Length mm(in.)
33.5 (1.32)

2. Take care not to damage the rectifier paint surfaces.

BRUSH

Use a vernier caliper to measure the brush.


If the measured value exceeds the limit, the brush must
be replaced.
Brush Length mm(in.)
Standard Limit
8-94423-756-0 14.5 (0.57) 7.5 (0.30)

Brushes are provided with a line which indicates the


limit of usage.

174
ENGINE ELECTRICALS

REASSEMBLY

9
8
11 7
6

10

1
2

12

3
5

Reassembly Steps
1. Rear cover ▲ 7. Ball bearing
2. IC regulator 8. Bearing retainer
▲ 3. Rectifier with brush holder 9. Rotor with bearing
▲ 4. Stator 10. Spacer collar
5. Rear cover and stator ▲ 11. Pulley and fan
6. Front cover 12. Through bolt

175
ENGINE ELECTRICALS

Important Operations

3. Rectifier with Brush Holder


4. Stator
When connecting stator coil leads and diode leads
using solder, use long-nose pliers and finish the
work as quickly as possible to prevent the heat from
being transferred to the diodes.

11. Pulley and Fan


Tighten the pulley and fan to the specified torque.
Pulley and Fan Nut Torque kg·m(lb.ft./N·m)
5.0 – 6.5 (36 – 47/49 – 64)

176
TROUBLESHOOTING

SECTION 10

TROUBLESHOOTING
TABLE OF CONTENTS

ITEM PAGE

Hard starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179


Unstable idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Insufficient power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Excessive fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Excessive oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
White exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Dark exhaust smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Oil pressure does not rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Abnormal engine noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

177
TROUBLESHOOTING

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair engine problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) Checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into ten sub-sections:
1. Hard Starting
1) Starter inoperative
2) Starter operates but engine does not turn over
3) Engine turns over but does not start
2. Unstable Idling
3. Insufficient Power
4. Excessive Fuel Consumption
5. Excessive Oil Consumption
6. Overheating
7. White Exhaust Smoke
8. Dark Exhaust Smoke
9. Oil Pressure Does Not Rise
10. Abnormal Engine Noise

178
TROUBLESHOOTING

1. HARD STARTING
1. STARTER INOPERATIVE

Checkpoint Trouble Cause Countermeasure

NG NG
Neutral switch (If so equipped) Defective neutral switch Replace the neutral switch

NG Loose battery cable terminals NG Clean and/or retighten the bat-


Battery
Poor connections due to rusting tery cable terminals

NG NG
Battery discharged or weak Recharge or replace the battery

NG NG
Fan belt loose or broken Adjust or replace the fan belt

OK

NG NG
Fusible link Fusible link shorted Replace the fusible link

OK

NG Defective starter switch or NG Replace the starter switch or


Starter switch
starter relay the starter relay

OK

NG Defective magnetic switch or NG Repair or replace the magnetic


Starter
starter relay switch

OK

NG NG
Starter Defective starter Repair or replace the starter motor

179
TROUBLESHOOTING

1. HARD STARTING
2. STARTER OPERATES BUT ENGINE DOES NOT TURN OVER

Checkpoint Trouble Cause Countermeasure

NG Loose battery cable terminals NG Clean and/or retighten the bat-


Battery
Poor connections due to rusting tery cable terminals

NG NG
Battery discharged or weak Recharge or replace the battery

NG NG
Fan belt loose or broken Adjust or replace the fan belt

OK

NG NG
Starter Defective pinion gear Replace the pinion gear

NG NG Repair or replace the magnetic


Defective magnetic switch
switch

NG Brush wear NG Replace the brush and/or the


Weak brush spring brush spring

OK

NG Piston, crank bearing seizure, NG Repair or replace the related


Engine
or other damage parts

180
TROUBLESHOOTING

1. HARD STARTING
3. ENGINE TURNS OVER BUT DOES NOT START

Checkpoint Trouble Cause Countermeasure

Defective engine stop mechanism Replace the engine stop


NG NG
Engine stop mechanism control wire improperly adjusted mechanism
(In line pump) Adjust the control wire

NG Defective fuel cut solenoid valve NG Replace the fuel cut solenoid
(VE pump) valve

FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP

NG NG
Fuel Fuel tank is empty Fill the fuel tank

OK

Repair or replace the fuel lines


NG Clogged or damaged fuel lines NG
Fuel piping Retighten the fuel line
Loose fuel line connections
connections

OK

NG Fuel filter overflow valve does NG Repair or replace the fuel filter
Fuel filter
not close overflow valve

NG NG Replace the fuel filter element or


Clogged fuel filter element
the fuel filter cartridge

OK

NG NG
Fuel system Air in the fuel system Bleed the air from the fuel system

Continued on the next page

181
TROUBLESHOOTING

1. HARD STARTING
3. ENGINE TURNS OVER BUT DOES NOT START
FUEL IS BEING DELIVERED TO THE INJECTION PUMP

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK

Injection nozzle injection starting


NG NG Adjust or replace the injection
Injection nozzle pressure too low
nozzle
Improper spray condition

OK

Defective fuel injection nozzle


NG NG
Injection pump resulting in fuel drippage after Replace the delivery valve
fuel injection

NG Defective injection pump control NG Repair or replace the injection


rack operation pump control rack

NG Injection pump plunger worn or NG Replace the injection pump


stuck plunger assembly

OK

NG Injection pump drive shaft NG Replace the injection pump drive


Injection pump (VE pump)
seizure or other damage shaft

NG Injection pump governor spring NG Replace the injection pump


seizure governor spring

182
TROUBLESHOOTING

2. UNSTABLE IDLING

Checkpoint Trouble Cause Countermeasure

NG NG
Idling system Idling improperly adjusted Adjust the idling

OK

NG Defective fast idling speed NG Repair or replace the fast idling


Fast idling speed control device
control device speed control device

OK

NG Accelerator control system NG Adjust the accelerator control


Accelerator control system
improperly adjusted system

OK

NG NG
Fuel system Fuel system leakage or blockage Repair or replace the fuel system

NG NG
Air in the fuel system Bleed the air from the fuel system

NG NG
Water particles in the fuel system Change the fuel

OK

NG NG Replace the fuel filter element or


Fuel filter Clogged fuel filter element
the fuel filter cartridge

Continued on the next page

183
TROUBLESHOOTING

2. UNSTABLE IDLING

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK

NG NG Repair or replace the governor


Injection pump Defective governor lever operation
lever

NG Regulator valve improperly NG Adjust or replace the regulator


adjusted (VE pump only) valve

NG NG
Broken plunger spring Replace the plunger spring

NG NG
Worn plunger Replace the plunger assembly

NG NG
Worn camshaft (In-line pump only) Replace the camshaft

NG Worn roller tappet (In-line pump NG


Replace the roller tappet
only)

NG NG
Worn cam disc (VE pump only) Replace the cam disc

Continued on the next page

184
TROUBLESHOOTING

2. UNSTABLE IDLING

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK

NG Valve clearance improperly NG


Valve clearance Adjust the valve clearance
adjusted

OK
Blown out cylinder head gasket
Worn cylinder liner
NG NG
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat

185
TROUBLESHOOTING

3. INSUFFICIENT POWER

Checkpoint Trouble Cause Countermeasure

NG NG Clean or replace the air cleaner


Air cleaner Clogged air cleaner element
element

OK

NG NG
Fuel Water particles in the fuel Replace the fuel

OK

NG NG Replace the fuel filter element or


Fuel filter Clogged fuel filter element
the fuel filter cartridge

OK

NG NG Repair or replace the fuel feed


Fuel feed pump Defective fuel feed pump
pump

OK

NG NG
Injection nozzle Injection nozzle sticking Replace the injection nozzle

Injection nozzle injection starting


NG NG Adjust or replace the injection
pressure too low
nozzle
Improper spray condition

OK

NG Fuel injection pipes damaged or NG


Fuel injection pipes Replace the fuel injection pipes
obstructed

Continued on the next page

186
TROUBLESHOOTING

3. INSUFFICIENT POWER

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK

NG Defective regulating valve NG Repair or replace the regulating


Injection pump
(VE pump only) valve

NG NG
Defective delivery valve Replace the delivery valve

NG NG
Defective timer Repair or replace the timer

NG NG
Worn cam disc (VE pump only) Replace the cam disc

NG NG Adjust or replace the control


Improper control lever operation
lever

Adjust the injection timing


NG NG
Defective injection timing Repair or replace the injection
pump timer

NG NG
Weak governor spring Replace the governor spring

Continued on the next page

187
TROUBLESHOOTING

3. INSUFFICIENT POWER

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK

NG NG
Injection pump Worn plunger Replace the plunger assembly

NG NG
Worn camshaft (In-line pump only) Replace the camshaft

NG Worn roller tappet (In-line pump NG


Replace the roller tappet
only)

NG NG
Worn cam disc (VE pump only) Replace the cam disc

OK
Blown out cylinder head gasket
Worn cylinder liner
NG NG
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat

OK

NG Valve clearance improperly NG


Valve clearance Adjust the valve clearance
adjusted

OK

NG NG
Valve spring Valve spring weak or broken Replace the valve spring

Continued on the next page

188
TROUBLESHOOTING

3. INSUFFICIENT POWER

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK

NG NG
Exhaust system Exhaust pipe clogged Clean the exhaust pipe

OK

NG Open and improperly set NG Adjust and reseal the adjusting


Full load adjusting screw seal
adjusting screw seal screw

189
TROUBLESHOOTING

4. EXCESSIVE FUEL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

NG NG Repair or replace the fuel system


Fuel system Fuel leakage
related parts

OK

NG NG Clean or replace the air cleaner


Air cleaner Clogged air cleaner element
element

OK

NG NG
Idling speed Poorly adjusted idling speed Adjust the idling speed

OK

Injection nozzle injection starting


NG NG Adjust or replace the injection
Injection nozzle pressure too low
nozzle
Improper spray condition

OK

NG Fuel injection timing improperly NG


Fuel injection timing Adjust the fuel injection timing
adjusted

OK

Defective delivery valve resulting


NG NG
Injection pump is fuel drippage after fuel Replace the delivery valve
injection

OK

NG Valve clearance improperly NG


Valve clearance Adjust the valve clearance
adjusted

Continued on the next page

190
TROUBLESHOOTING

4. EXCESSIVE FUEL CONSUMPTION

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK
Blown out cylinder head gasket
Worn cylinder liner
NG NG
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat

OK

NG NG
Valve spring Valve spring weak or broken Replace the valve spring

191
TROUBLESHOOTING

5. EXCESSIVE OIL CONSUMPTION

Checkpoint Trouble Cause Countermeasure

NG Engine oil unsuitable NG Replace the engine oil


Engine oil
Too much engine oil Correct the engine oil volume

OK

NG Oil leakage from the oil seal NG Replace the oil seal and/or the
Oil seal and gasket
and/or the gasket gasket

OK

NG NG
Air breather Clogged air breather Clean the air breather

OK

Defective valve seals


Inlet and exhaust valves NG NG Replace the valve seals, the
Worn valves stems and valve
Valve seals valves, and the valve guides
guides

OK

NG Piston rings worn, broken or NG Replace the piston rings or


Piston rings
improperly installed properly install

OK

NG Cylinder lines scored or NG


Cylinder liners Replace the cylinder liners
worn

192
TROUBLESHOOTING

6. OVERHEATING

Checkpoint Trouble Cause Countermeasure

NG NG
Cooling water Insufficient cooling water Replenish the cooling water

OK

NG NG
Fan coupling (if so equipped) Oil leakage from the fan coupling Replace the fan coupling

OK

NG Fan belt loose or cracked causing NG


Fan belt Replace the fan belt
slippage

OK

NG Defective radiator cap or clogged NG Replace the radiator cap or clean


Radiator
radiator core the radiator core

OK

NG NG
Water pump Defective water pump Repair or replace the water pump

OK

Cylinder head and cylinder body NG Defective sealing cap resulting in NG


Replace the sealing cap
sealing cap water leakage

OK

NG NG
Thermostat Defective thermostat Replace the thermostat

Continued on the next page

193
TROUBLESHOOTING

6. OVERHEATING

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK

NG Cooling system clogged by NG Clean the foreign material from


Cooling system
foreign material the cooling system

OK

NG Fuel injection timing improperly NG


Fuel injection timing Adjust the fuel injection timing
adjusted

194
TROUBLESHOOTING

7. WHITE EXHAUST SMOKE

Checkpoint Trouble Cause Countermeasure

NG NG
Fuel Water particles in the fuel Replace the fuel

OK

NG NG
Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing

OK
Blown out cylinder head gasket
Worn cylinder liner
NG NG
Compression pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the valve seat

OK

Defective valve seals


Inlet and exhaust valves NG NG Replace the valve seals, the
Worn valves stems and valve
Valve seals valves, and the valve guides
guides

OK

NG Piston rings worn, broken or NG Replace the piston rings or


Piston rings
improperly installed properly install

OK

NG Cylinder lines scored or NG


Cylinder liners Replace the cylinder liners
worn

195
TROUBLESHOOTING

8. DARK EXHAUST SMOKE

Checkpoint Trouble Cause Countermeasure

NG NG Clean or replace the air cleaner


Air cleaner Clogged air cleaner element
element

OK

Injection nozzle injection starting


NG NG Adjust or replace the injection
Injection nozzle pressure too low
nozzle
Improper spray condition

OK

NG Fuel injection timing improperly NG


Fuel injection timing Adjust the fuel injection timing
adjusted

OK

Defective delivery valve resulting


NG NG
Injection pump in fuel drippage after fuel Replace the delivery valve
injection

NG NG
Excessive injection volume Adjust the injection volume

196
TROUBLESHOOTING

9. OIL PRESSURE DOES NOT RISE

Checkpoint Trouble Cause Countermeasure

NG Improper viscosity engine oil NG Replace the engine oil


Engine oil
Too much engine oil Correct the engine oil volume

OK

Defective oil pressure gauge or Repair or replace the oil pres-


Oil pressure gauge or unit NG NG
unit sure gauge or unit
Oil pressure indicator light
Defective indicator light Replace the indicator light

OK

NG NG Replace the oil filter element or


Oil filter Clogged oil filter element
the oil filter cartridge

OK

NG Relief valve sticking and/or weak NG Replace the relief valve and/or
Relief valve and by-pass valve
by-pass valve spring the by-pass valve spring

OK

NG NG
Oil pump Clogged oil pump strainer Clean the oil pump strainer

NG NG Replace the oil pump related


Worn oil pump related parts
parts

OK

NG NG
Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing

Continued on the next page

197
TROUBLESHOOTING

9. OIL PRESSURE DOES NOT RISE

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK

NG Worn camshaft and camshaft NG Replace the camshaft and the


Camshaft
bearing camshaft bearings

OK

NG NG Replace the crankshaft and/or


Crankshaft and bearings Worn crankshaft and bearings
the bearings

198
TROUBLESHOOTING

10. ABNORMAL ENGINE NOISE


1. Engine Knocking

Checkpoint Trouble Cause Countermeasure


Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

NG NG
Fuel Fuel unsuitable Replace the fuel

OK

NG Fuel injection timing improperly NG


Fuel injection timing Adjust the fuel injection timing
adjusted

OK

NG Improper injection nozzle starting NG Adjust or replace the injection


Injection nozzle
pressure and spray condition nozzle

OK

NG Blown out head gasket NG Replace the head gasket or the


Compression pressure
Broken piston ring piston ring

2. Gas Leakage Noise

Tighten the exhaust pipe


NG Loosely connected exhaust pipes NG
Exhaust pipes connections
Broken exhaust pipes
Replace the exhaust pipes

OK

Replace the washers


Injection nozzles and/or glow NG Loose injection nozzles and/or NG
Tighten the injection nozzles
plugs glow plugs
and/or the glow plugs

Continued on the next page

199
TROUBLESHOOTING

10. ABNORMAL ENGINE NOISE


2. Gas Leakage Noise

Checkpoint Trouble Cause Countermeasure


Continued from the previous page
OK

NG Loosely connected exhaust mani- NG Tighten the exhaust manifold


Exhaust manifold
fold and/or glow plugs connections

OK

NG NG
Cylinder head gasket Damaged cylinder head gasket Replace the cylinder head gasket

3. Continuous Noise

NG NG
Fan belt Loose fan belt Readjust the fan belt tension

OK

NG NG
Cooling fan Loose cooling fan Retighten the cooling fan

OK

NG Worn or damaged water pump NG


Water pump bearing Replace the water pump bearing
bearing

OK

NG Defective alternator or vacuum NG Repair or replace the alternator


Alternator or vacuum pump
pump or the vacuum pump

OK

NG Valve clearance improperly NG


Valve clearance Adjust the valve clearance
adjusted

200
TROUBLESHOOTING

10. ABNORMAL ENGINE NOISE


4. Slapping Noise

Checkpoint Trouble Cause Countermeasure

NG Valve clearance improperly NG


Valve clearance Adjust the valve clearance
adjusted

OK

NG NG
Rocker arm Damaged rocker arm Replace the rocker arm

OK

NG NG
Flywheel Loose flywheel bolts Retighten the flywheel bolts

OK

NG Worn or damaged crankshaft NG Replace the crankshaft and/or the


Crankshaft and thrust bearings
and/or thrust bearings thrust bearings

OK

Crankshaft and connecting rod NG Worn or damaged crankshaft NG Replace the crankshaft and/or the
bearings and/or connecting rod bearings connecting rod bearings

OK

Connecting rod bushing and NG Worn or damaged connecting NG Replace the connecting rod
piston pin rod bushing and piston pin bushing and/or the piston pin

OK

Worn or damaged piston and


NG NG Replace the piston and the cylin-
Piston and cylinder liner cylinder liner
der liner
Foreign material in the cylinder

201
TROUBLESHOOTING

MEMO

202
SPECIAL TOOL LIST

SECTION 11

SPECIAL TOOL LIST

203
SPECIAL TOOL LIST

SPECIAL TOOL LIST

ITEM NO. ILLUSTRATION PART NO. PARTS NAME PAGE

1 5-8840-2008-1 Compression Gauge 27

2 5-8531-7001-0 Compression Gauge Adaptor 27

44
3 9-8523-1423-0 Valve Spring Compressor
89

4 9-8523-1212-0 Valve Guide Replacer 53


54

5 5-8840-2313-0 Cylinder Liner Installer 62

67
6 5-8840-2038-0 Camshaft Bearing Replacer
68

Camshaft Timing Gear 48


7 5-8840-0086-0
Universal Puller 68

Crankshaft Timing Gear


8 9-8840-2057-0 74
Remover

Crankshaft Timing Gear


9 9-8522-0020-0 74
Installer

Crankshaft Pilot Bearing


10 9-8840-2000-0 75
Remover

204
SPECIAL TOOL LIST

ITEM NO. ILLUSTRATION PART NO. PARTS NAME PAGE

11 5-8840-0019-0 Sliding Hammer 75

Crankshaft Pilot Bearing


12 5-8522-0024-0 75
Installer

Crankshaft Front Oil Seal


13 5-8840-2061-0 83
Installer

Valve Stem Oil Seal


14 5-8840-2033-0 89
Installer

Crankshaft Rear Oil Seal


15 5-8840-0141-0 102
Installer

16 5-8840-2304-0 Cylinder Liner Remover Ankle 60

17 9-8523-1169-0 Cylinder Liner Remover 60

18 5-8840-2362-0 Rear Oil Seal Remover 40

19 5-8840-9057-0 Rear Oil Seal Installer 103

205
SPECIAL TOOL LIST

MEMO

206
CONVERSION TABLE

SECTION 12

CONVERSION TABLES
INDEX

CONTENTS PAGE
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

LENGTH
MILLIMETERS TO INCHES INCHES TO MILLIMETERS

mm in. mm in. mm in. mm in. in. mm in. mm

1 0.0394 26 1.0236 51 2.0079 76 2.9921 1/64 0.3969 33/64 13.0969


2 0.0787 27 1.0630 52 2.0472 77 3.0315 1/32 0.7938 17/32 13.4938
3 0.1181 28 1.1024 53 2.0866 78 3.0709 3/64 1.1906 35/64 13.8906
4 0.1575 29 1.1417 54 2.1260 79 3.1102 1/16 1.5875 9/16 14.2875
5 0.1969 30 1.1811 55 2.1654 80 3.1496 5/64 1.9844 37/64 14.6844
6 0.2362 31 1.2205 56 2.2047 81 3.1890 3/32 2.3813 19/32 15.0813
7 0.2756 32 1.2598 57 2.2441 82 3.2283 7/64 2.7781 39/64 15.4781
8 0.3150 33 1.2992 58 2.2835 83 3.2677 1/8 3.1750 5/8 15.8750
9 0.3543 34 1.3386 59 2.3228 84 3.3071 9/64 3.5719 41/64 16.2719
10 0.3937 35 1.3780 60 2.3622 85 3.3465 5/32 3.9688 21/32 16.6688
11 0.4331 36 1.4173 61 2.4016 86 3.3858 11/64 4.3656 43/64 17.0656
12 0.4724 37 1.4567 62 2.4409 87 3.4252 3/16 4.7625 11/16 17.4625
13 0.5118 38 1.4961 63 2.4803 88 3.4646 13/64 5.1594 45/64 17.8594
14 0.5512 39 1.5354 64 2.5197 89 3.5039 7/32 5.5563 23/32 18.2563
15 0.5906 40 1.5748 65 2.5591 90 3.5433 15/64 5.9531 47/64 18.6531
16 0.6299 41 1.6142 66 2.5984 91 3.5827 1/4 6.3500 3/4 19.0500
17 0.6693 42 1.6535 67 2.6378 92 3.6220 17/64 6.7469 49/64 19.4469
18 0.7087 43 1.6929 68 2.6772 93 3.6614 9/32 7.1438 25/32 19.8438
19 0.7480 44 1.7323 69 2.7165 94 3.7008 19/64 7.5406 51/64 20.2406
20 0.7874 45 1.7717 70 2.7559 95 3.7402 5/16 7.9375 13/16 20.6375
21 0.8268 46 1.8110 71 2.7953 96 3.7795 21/64 8.3344 53/64 21.0344
22 0.8661 47 1.8504 72 2.8346 97 3.8189 11/32 8.7313 27/32 21.4313
23 0.9055 48 1.8898 73 2.8740 98 3.8583 23/64 9.1281 55/64 21.8281
24 0.9449 49 1.9291 74 2.9134 99 3.8976 3/8 9.5250 7/8 22.2250
25 0.9843 50 1.9685 75 2.9528 100 3.9370 25/64 9.9219 57/64 22.6219
13/32 10.3188 29/32 23.0188
101 3.9764 111 4.3701 121 4.7638 131 5.1575 27/64 10.7156 59/64 23.4156
102 4.0157 112 4.4094 122 4.8031 132 5.1968 7/16 11.1125 15/16 23.8125
103 4.0551 113 4.4488 123 4.8425 133 5.2362 29/64 11.5094 61/64 24.2094
104 4.0945 114 4.4882 124 4.8819 134 5.2756 15/32 11.9063 31/32 24.6063
105 4.1339 115 4.5276 125 4.9213 135 5.3150 31/64 12.3031 63/64 25.0031
106 4.1732 116 4.5669 126 4.9606 136 5.3543 1/2 12.7000 1 25.4000
107 4.2126 117 4.6063 127 5.0000 137 5.3937
108 4.2520 118 4.6457 128 5.0394 138 5.4331
109 4.2913 119 4.6850 129 5.0787 139 5.4724

207
CONVERSION TABLE

LENGTH
FEET TO METERS

ft. 0 1 2 3 4 5 6 7 8 9 ft.
m m m m m m m m m m
––– –––0 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 –––
10 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 10
20 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 20
30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 11.278 11.582 11.887 30
40 12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935 40
50 15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50
60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031 60
70 21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70
80 24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127 80
90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90
100 30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223 100

METERS TO FEET

m 0 1 2 3 4 5 6 7 8 9
ft. ft. ft. ft. ft. ft. ft. ft. ft. ft.
––– –––00 3.2808 6.5617 9.8425 13.1234 16.4042 19.6850 22.9659 26.2467 29.5276 –––
10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10
20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20
30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30
40 131.2336 134.5144 137.7953 141.0761 144.3570 147.6378 150.9186 154.1995 157.4803 160.7612 40
50 164.0420 167.3228 170.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50
60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60
70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9055 259.1864 70
80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291.9948 80
90 295.2756 298.5564 301.8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90
100 328.0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100

MILES TO KILOMETERS

miles 0 1 2 3 4 5 6 7 8 9
km km km km km km km km km km
––– –––00 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 –––
10 16.093 17.703 19.312 20.921 22.531 24.140 25.749 27.359 28.968 30.577 10
20 32.187 33.796 35.405 37.015 38.624 40.234 41.843 43.452 45.062 46.671 20
30 48.280 49.890 51.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30
40 64.374 65.983 67.592 69.202 70.811 72.420 74.030 75.639 77.248 78.858 40
50 80.467 82.076 83.686 85.295 86.904 88.514 90.123 91.732 93.342 94.951 50
60 96.560 98.170 99.779 101.388 102.998 104.607 106.216 107.826 109.435 111.044 60
70 112.654 114.263 115.872 117.482 119.091 120.701 122.310 123.919 125.529 127.138 70
80 128.747 130.357 131.966 133.575 135.185 136.794 138.403 140.013 141.622 143.231 80
90 144.841 146.450 148.059 149.669 151.278 152.887 154.497 156.106 157.715 159.325 90
100 160.934 162.543 164.153 165.762 167.371 168.981 170.590 172.199 173.809 175.418 100

KILOMETERS TO MILES

km 0 1 2 3 4 5 6 7 8 9
miles miles miles miles miles miles miles miles miles miles
––– –––0 0.621 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592 –––
10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 11.185 11.806 10
20 12.427 13.049 13.670 14.292 14.913 15.534 16.156 16.777 17.398 18.020 20
30 18.641 19.262 19.884 20.505 21.127 21.748 22.369 22.991 23.612 24.233 30
40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30.447 40
50 31.069 31.690 32.311 32.933 33.554 34.175 34.797 35.418 36.039 36.661 50
60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60
70 43.496 44.117 44.739 45.360 45.981 46.603 47.224 47.845 48.467 49.088 70
80 49.710 50.331 50.952 51.574 52.195 52.816 53.438 54.059 54.681 55.302 80
90 55.923 56.545 57.166 57.787 58.409 59.030 59.652 60.273 60.894 61.516 90
100 62.137 62.758 63.380 64.001 64.622 65.244 65.865 66.487 67.108 67.729 100

208
CONVERSION TABLE

AREA
SQUARE INCHES TO SQUARE CENTIMETERS

in2 0 1 2 3 4 5 6 7 8 9 in2
cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2
––– –––00 6.452 12.903 19.355 25.806 32.258 38.710 45.161 51.613 58.064 –––
10 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.580 10
20 129.032 135.484 141.935 148.387 154.838 161.290 167.742 174.193 180.645 187.096 20
30 193.548 200.000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612 30
40 258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128 40
50 322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644 50
60 387.096 393.548 399.999 406.451 412.902 419.354 425.806 432.257 438.709 445.160 60
70 451.612 458.064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676 70
80 516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192 80
90 580.644 587.096 593.547 599.999 606.450 612.902 619.354 625.805 632.257 638.708 90
100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100

SQUARE CENTIMETERS TO SQUARE INCHES

cm2 0 1 2 3 4 5 6 7 8 9 cm2
in2 in2 in2 in2 in2 in2 in2 in2 in2 in2
––– –––0 0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395 –––
10 1.550 1.705 1.860 2.015 2.170 2.325 2.480 2.635 2.790 2.945 10
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
30 4.650 4.805 4.960 5.115 5.270 5.425 5.580 5.735 5.890 6.045 30
40 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
50 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8.990 9.145 50
60 9.300 9.455 9.610 9.765 9.920 10.075 10.230 10.385 10.540 10.695 60
70 10.850 11.005 11.160 11.315 11.470 11.625 11.780 11.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
100 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100

VOLUME
CUBIC INCHES TO CUBIC CENTIMETERS

in3 0 1 2 3 4 5 6 7 8 9 in3
cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc)
––– –––00 16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.097 147.484 –––
10 163.871 180.258 196.645 213.032 229.419 245.806 262.193 278.580 294.967 311.354 10
20 327.741 344.128 360.515 376.902 393.290 409.677 426.064 442.451 458.838 475.225 20
30 491.612 507.999 524.386 540.773 557.160 573.547 589.934 606.321 622.708 639.095 30
40 655.483 671.870 688.257 704.644 721.031 737.418 753.805 770.192 786.579 802.966 40
50 819.353 835.740 852.127 868.514 884.901 901.289 917.676 934.063 950.450 966.837 50
60 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60
70 1147.094 1163.482 1179.869 1196.256 1212.643 1229.030 1245.417 1261.804 1278.191 1294.578 70
80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.288 1425.675 1442.062 1458.449 80
90 1474.836 1491.223 1507.610 1523.997 1540.384 1556.771 1573.158 1589.545 1605.932 1622.319 90
100 1638.706 1655.093 1671.481 1687.868 1704.255 1720.642 1737.029 1753.416 1769.803 1786.190 100

CUBIC CENTIMETERS TO CUBIC INCHES

cm3(cc) 0 1 2 3 4 5 6 7 8 9 cm3(cc)
in3 in3 in3 in3 in3 in3 in3 in3 in3 in3
––– –––0 0.0610 0.1220 0.1831 0.2441 0.3051 0.3661 0.4272 0.4882 0.5492 –––
10 0.6102 0.6713 0.7323 0.7933 0.8543 0.9153 0.9764 1.0374 1.0984 1.1594 10
20 1.2205 1.2815 1.3425 1.4035 1.4646 1.5256 1.5866 1.6476 1.7086 1.7697 20
30 1.8307 1.8917 1.9527 2.0138 2.0748 2.1358 2.1968 2.2579 2.3189 2.3799 30
40 2.4409 2.5019 2.5630 2.6240 2.6850 2.7460 2.8071 2.8681 2.9291 2.9901 40
50 3.0512 3.1122 3.1732 3.2342 3.2952 3.3563 3.4173 3.4783 3.5393 3.6004 50
60 3.6614 3.7224 3.7834 3.8444 3.9055 3.9665 4.0275 4.0885 4.1496 4.2106 60
70 4.2716 4.3326 4.3937 4.4547 4.5157 4.5767 4.6377 4.6988 4.7598 4.8208 70
80 4.8818 4.9429 5.0039 5.0649 5.1259 5.1870 5.2480 5.3090 5.3700 5.4310 80
90 5.4921 5.5531 5.6141 5.6751 5.7362 5.7972 5.8582 5.9192 5.9803 6.0413 90
100 6.1023 6.1633 6.2243 6.2854 6.3464 6.4074 6.4684 6.5295 6.5905 6.6515 100

209
CONVERSION TABLE

VOLUME
GALLONS (U.S.) TO LITERS

U.S. gal. 0 1 2 3 4 5 6 7 8 9 U.S.gal.


liters liters liters liters liters liters liters liters liters liters
––– –––00 3.7854 7.5709 11.3563 15.1417 18.9271 22.7126 26.4980 30.2834 34.0688 –––
10 37.8543 41.6397 45.4251 49.2106 52.9960 56.7814 60.5668 64.3523 68.1377 71.9231 10
20 75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774 20
30 113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6317 30
40 151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859 40
50 189.2714 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402 50
60 227.1256 230.9110 234.6965 238.4819 242.2673 246.0528 249.8382 253.6236 257.4090 261.1945 60
70 264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6925 291.4779 295.2633 299.0487 70
80 302.8342 306.6196 310.4050 314.1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030 80
90 340.6884 344.4739 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573 90
100 378.5427 382.3281 386.1136 389.8990 393.6844 397.4698 401.2553 405.0407 408.8261 412.6115 100

LITERS TO GALLONS (U.S.)

liters 0 1 2 3 4 5 6 7 8 9 liters
gal. gal. gal. gal. gal. gal. gal. gal. gal. gal.
––– –––00 0.2642 0.5283 0.7925 1.0567 1.3209 1.5850 1.8492 2.1134 2.3775 –––
10 2.6417 2.9059 3.1701 3.4342 3.6984 3.9626 4.2268 4.4909 4.7551 5.0193 10
20 5.2834 5.5476 5.8118 6.0760 6.3401 6.6043 6.8685 7.1326 7.3968 7.6610 20
30 7.9252 8.1893 8.4535 8.7177 8.9818 9.2460 9.5102 9.7744 10.0385 10.3027 30
40 10.5669 10.8311 11.0952 11.3594 11.6236 11.8877 12.1519 12.4161 12.6803 12.9444 40
50 13.2086 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861 50
60 15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17.4354 17.6995 17.9637 18.2279 60
70 18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696 70
80 21.1338 21.3979 21.6621 21.9263 22.1904 22.4546 22.7188 22.9830 23.2471 23.5113 80
90 23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530 90
100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100

GALLONS (IMP.) TO LITERS

Imp gal. 0 1 2 3 4 5 6 7 8 9 Imp gal.


liters liters liters liters liters liters liters liters liters liters
––– –––00 4.5459 9.0918 13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131 –––
10 45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 81.8262 86.3721 10
20 90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311 20
30 136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.2901 30
40 181.8360 186.3819 190.9278 195.4737 200.0196 204.5655 209.1114 213.6573 218.2032 222.7491 40
50 227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254.5704 259.1163 263.6622 268.2081 50
60 272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309.1212 313.6671 60
70 318.2130 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261 70
80 363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851 80
90 409.1310 413.6769 418.2228 422.7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441 90
100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481.8654 486.4113 490.9572 495.5031 100

LITERS TO GALLONS (IMP.)

liters 0 1 2 3 4 5 6 7 8 9 liters
gal. gal. gal. gal. gal. gal. gal. gal. gal. gal.
––– –––00 0.2200 0.4400 0.6599 0.8799 1.0999 1.3199 1.5399 1.7598 1.9798 –––
10 2.1998 2.4198 2.6398 2.8597 3.0797 3.2997 3.5197 3.7397 3.9596 4.1796 10
20 4.3996 4.6196 4.8396 5.0595 5.2795 5.4995 5.7195 5.9395 6.1594 6.3794 20
30 6.5994 6.8194 7.0394 7.2593 7.4793 7.6993 7.9193 8.1393 8.3592 8.5792 30
40 8.7992 9.0192 9.2392 9.4591 9.6791 9.8991 10.1191 10.3391 10.5590 10.7790 40
50 10.9990 11.2190 11.4390 11.6589 11.8789 12.0989 12.3189 12.5389 12.7588 12.9788 50
60 13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786 60
70 15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784 70
80 17.5984 17.8184 18.0384 18.2583 18.4783 18.6983 18.9183 19.1383 19.3582 19.5782 80
90 19.7982 20.0182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 21.5580 21.7780 90
100 21.9980 22.2180 22.4380 22.6579 22.8779 23.0979 23.3179 23.5379 23.7578 23.9778 100

210
CONVERSION TABLE

MASS
POUNDS TO KILOGRAMS

lbs. 0 1 2 3 4 5 6 7 8 9 lbs.
kg kg kg kg kg kg kg kg kg kg
––– –––0 0.454 0.907 1.361 1.814 2.268 2.722 3.175 3.629 4.082 –––
10 4.536 4.989 5.443 5.897 6.350 6.804 7.257 7.711 8.165 8.618 10
20 9.072 9.525 9.979 10.433 10.886 11.340 11.793 12.247 12.701 13.154 20
30 13.608 14.061 14.515 14.968 15.422 15.876 16.329 16.783 17.236 17.690 30
40 18.144 18.597 19.051 19.504 19.958 20.412 20.865 21.319 21.772 22.226 40
50 22.680 23.133 23.587 24.040 24.494 24.947 25.401 25.855 26.308 26.762 50
60 27.215 27.669 28.123 28.576 29.030 29.483 29.937 30.391 30.844 31.298 60
70 31.751 32.205 32.658 33.112 33.566 34.019 34.473 34.926 35.380 35.834 70
80 36.287 36.741 37.194 37.648 38.102 38.555 39.009 39.462 39.916 40.370 80
90 40.823 41.277 41.730 42.184 42.637 43.091 43.545 43.998 44.452 44.905 90
100 45.359 45.813 46.266 46.720 47.173 47.627 48.081 48.534 48.988 49.441 100

KILOGRAMS TO POUNDS

kg 0 1 2 3 4 5 6 7 8 9 kg
lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.
––– –––00 2.205 4.409 6.614 8.818 11.023 13.228 15.432 17.637 19.842 –––
10 22.046 24.251 26.455 28.660 30.865 33.069 35.274 37.479 39.683 41.888 10
20 44.092 46.297 48.502 50.706 52.911 55.116 57.320 59.525 61.729 63.934 20
30 66.139 68.343 70.548 72.752 74.957 77.162 79.366 81.571 83.776 85.980 30
40 88.185 90.389 92.594 94.799 97.003 99.208 101.413 103.617 105.822 108.026 40
50 110.231 112.436 114.640 116.845 119.049 121.254 123.459 125.663 127.868 130.073 50
60 132.277 134.482 136.686 138.891 141.096 143.300 145.505 147.710 149.914 152.119 60
70 154.323 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165 70
80 176.370 178.574 180.779 182.983 185.188 187.393 189.597 191.802 194.007 196.211 80
90 198.416 200.620 202.825 205.030 207.234 209.439 211.644 213.848 216.053 218.257 90
100 220.462 222.667 224.871 227.076 229.280 231.485 233.690 235.894 238.099 240.304 100

KILOGRAMS TO NEWTON

kg 0 1 2 3 4 5 6 7 8 9 kg
N N N N N N N N N N
––– –––0 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 –––
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67 990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100

NEWTON TO KILOGRAMS

N 0 10 20 30 40 50 60 70 80 90 N
kg kg kg kg kg kg kg kg kg kg
––– –––00 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 –––
100 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 100
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 200
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 300
400 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 400
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 500
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 600
700 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 700
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 800
900 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 900
1000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 1000

211
CONVERSION TABLE

PRESSURE
POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS

lb/in2 0 1 2 3 4 5 6 7 8 9 lb/in2
(psi) kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 (psi)
––– –––0 0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328 –––
10 0.7031 0.7734 0.8437 0.9140 0.9843 1.0546 1.1249 1.1952 1.2655 1.3358 10
20 1.4061 1.4764 1.5468 1.6171 1.6874 1.7577 1.8280 1.8983 1.9686 2.0389 20
30 2.1092 2.1795 2.2498 2.3201 2.3904 2.4607 2.5311 2.6014 2.6717 2.7420 30
40 2.8123 2.8826 2.9529 3.0232 3.0935 3.1638 3.2341 3.3044 3.3747 3.4450 40
50 3.5154 3.5857 3.6560 3.7263 3.7966 3.8669 3.9372 4.0075 4.0778 4.1481 50
60 4.2184 4.2887 4.3590 4.4293 4.4996 4.5700 4.6403 4.7106 4.7809 4.8512 60
70 4.9215 4.9918 5.0621 5.1324 5.2027 5.2730 5.3433 5.4136 5.4839 5.5543 70
80 5.6246 5.6949 5.7652 5.8355 5.9058 5.9761 6.0464 6.1167 6.1870 6.2573 80
90 6.3276 6.3979 6.4682 6.5386 6.6089 6.6792 6.7495 6.8198 6.8901 6.9604 90
100 7.0307 7.1010 7.1713 7.2416 7.3119 7.3822 7.4525 7.5228 7.5932 7.6635 100

KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES

kg/cm2 0 1 2 3 4 5 6 7 8 9 kg/cm2
lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi) lb/in2(psi)
––– –––00 14.22 28.45 42.67 56.89 71.12 85.34 99.56 113.78 128.01 –––
10 142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24 10
20 284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47 20
30 426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70 30
40 568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93 40
50 711.15 725.37 739.60 753.82 768.04 782.27 796.49 810.71 824.93 839.16 50
60 853.38 867.60 881.83 896.05 910.27 924.50 938.72 952.94 967.16 981.39 60
70 995.61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62 70
80 1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85 80
90 1280.07 1294.29 1308.52 1322.74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08 90
100 1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31 100

KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL

kg/cm2 0 1 2 3 4 5 6 7 8 9 kg/cm2
KPa KPa KPa KPa KPa KPa KPa KPa KPa KPa
––– –––00 98.1 196.1 294.2 392.3 490.3 588.4 686.5 784.5 882.6 –––
10 980.7 1078.7 1176.8 1274.9 1372.9 1471.0 1569.1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353.6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 4118.8 4216.9 4314.9 4413.0 4511.1 4609.1 4707.2 4805.3 40
50 4903.4 5001.4 5099.5 5197.6 5295.6 5393.7 5491.8 5589.8 5687.9 5786.0 50
60 5884.0 5982.1 6080.2 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6 60
70 6864.7 6962.8 7060.8 7158.9 7257.0 7355.0 7453.1 7551.2 7649.2 7747.3 70
80 7845.4 7943.4 8041.5 8139.6 8237.6 8335.7 8433.8 8531.8 8629.9 8728.0 80
90 8826.0 8924.1 9022.2 9120.2 9218.3 9316.4 9414.4 9512.5 9610.6 9708.6 90
100 9806.7 9904.8 10002.8 10100.9 10199.0 10297.0 10395.1 10493.2 10591.2 10689.3 100

KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS

KPa 0 100 200 300 400 500 600 700 800 900 KPa
kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2
–––0 –––00 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 –––0
1000 10.197 11.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 1000
2000 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 2000
3000 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 3000
4000 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 4000
5000 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 5000
6000 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 6000
7000 71.380 72.400 73.420 74.440 75.459 76.479 77.499 78.518 79.538 80.558 7000
8000 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 8000
9000 91.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 9000
10000 101.972 102.992 104.011 105.031 106.051 107.071 108.090 109.110 110.130 111.149 10000

212
CONVERSION TABLE

TORQUE
FOOT POUNDS TO KILOGRAMMETERS

ft. lbs. 0 1 2 3 4 5 6 7 8 9 ft lbs.


kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m
––– –––0 0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.244 –––
10 1.383 1.521 1.659 1.797 1.936 2.074 2.212 2.350 2.489 2.627 10
20 2.765 2.903 3.042 3.180 3.318 3.457 3.595 3.733 3.871 4.010 20
30 4.148 4.286 4.424 4.563 4.701 4.839 4.977 5.116 5.254 5.392 30
40 5.530 5.669 5.807 5.945 6.083 6.222 6.360 6.498 6.636 6.775 40
50 6.913 7.051 7.190 7.328 7.466 7.604 7.743 7.881 8.019 8.157 50
60 8.296 8.434 8.572 8.710 8.849 8.987 9.125 9.263 9.402 9.540 60
70 9.678 9.816 9.955 10.093 10.231 10.370 10.508 10.646 10.784 10.923 70
80 11.061 11.199 11.337 11.476 11.614 11.752 11.890 12.029 12.167 12.305 80
90 12.443 12.582 12.720 12.858 12.996 13.135 13.273 13.411 13.549 13.688 90
100 13.826 13.964 14.103 14.241 14.379 14.517 14.656 14.794 14.932 15.070 100

KILOGRAMMETERS TO FOOT POUNDS

kg-m 0 1 2 3 4 5 6 7 8 9 kg-m
ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs. ft. lbs.
––– –––0 7.23 14.47 21.70 28.93 36.17 43.40 50.63 57.86 65.10 –––
10 72.33 79.56 86.80 94.03 101.26 108.50 115.73 122.96 130.19 137.43 10
20 144.66 151.89 159.13 166.36 173.59 180.83 188.06 195.29 202.52 209.76 20
30 216.99 224.22 231.46 238.69 245.92 253.16 260.39 267.62 274.85 282.09 30
40 289.32 296.55 303.79 311.02 318.25 325.49 332.72 339.95 347.18 354.42 40
50 361.65 368.88 376.12 383.35 390.58 397.82 405.05 412.28 419.51 426.75 50
60 433.98 441.21 448.45 455.68 462.91 470.15 477.38 484.61 491.84 499.08 60
70 506.31 513.54 520.78 528.01 535.24 542.48 549.71 556.94 564.17 571.41 70
80 578.64 585.87 593.11 600.34 607.57 614.81 622.04 629.27 636.50 643.74 80
90 650.97 658.20 665.44 672.67 679.90 687.14 694.37 701.60 708.83 716.07 90
100 723.30 730.53 737.77 745.00 752.23 759.47 766.70 773.93 781.16 788.40 100

KILOGRAMMETERS TO NEWTONMETERS

kg-m 0 1 2 3 4 5 6 7 8 9 kg-m
N-m N-m N-m N-m N-m N-m N-m N-m N-m N-m
––– –––00 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26 –––
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53 40
50 490.34 500.14 509.95 519.76 529.56 539.37 549.18 558.98 568.79 578.60 50
60 588.40 598.21 608.02 617.82 627.63 637.44 647.24 657.05 666.86 676.66 60
70 686.47 696.28 706.08 715.89 725.70 735.50 745.31 755.12 764.92 774.73 70
80 784.54 794.34 804.15 813.96 823.76 833.57 843.38 853.18 862.99 872.80 80
90 882.60 892.41 902.22 912.02 921.83 931.64 941.44 951.25 961.06 970.86 90
100 980.67 990.48 1000.28 1010.09 1019.90 1029.70 1039.51 1049.32 1059.12 1068.93 100

NEWTONMETERS TO KILOGRAMMETERS

N-m 0 10 20 30 40 50 60 70 80 90 N-m
kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m
––– –––00 1.020 2.039 3.059 4.079 5.099 6.118 7.138 8.158 9.177 –––
100 10.197 11.217 12.236 13.256 14.276 15.296 16.315 17.335 18.355 19.374 100
200 20.394 21.414 22.433 23.453 24.473 25.493 26.512 27.532 28.552 29.571 200
300 30.591 31.611 32.630 33.650 34.670 35.690 36.709 37.729 38.749 39.768 300
400 40.788 41.808 42.827 43.847 44.867 45.887 46.906 47.926 48.946 49.965 400
500 50.985 52.005 53.024 54.044 55.064 56.084 57.103 58.123 59.143 60.162 500
600 61.182 62.202 63.221 64.241 65.261 66.281 67.300 68.320 69.340 70.359 600
700 71.379 72.399 73.418 74.438 75.458 76.478 77.497 78.517 79.537 80.556 700
800 81.576 82.596 83.615 84.635 85.655 86.675 87.694 88.714 89.734 90.753 800
900 91.773 92.793 93.812 94.832 95.852 96.872 97.891 98.911 99.931 100.950 900
1000 101.970 102.990 104.009 105.029 106.049 107.069 108.088 109.108 110.128 111.147 1000

213
CONVERSION TABLE

TEMPERATURE
FAHRENHEIT TO CENTIGRADE

°F °C °F °C °F °C °F °C °F °C °F °C °F °C °F °C

-60 -51.1 -2 -18.9 56 13.3 114 45.6 172 77.8 230 110.0 288 142.2 346 174.4
-58 -50.0 0 -17.8 58 14.4 116 46.7 174 78.9 232 111.1 290 143.3 348 175.6
-56 -48.9 2 -16.7 60 15.6 118 47.8 176 80.0 234 112.2 292 144.4 350 176.7
-54 -47.8 4 -15.6 62 16.7 120 48.9 178 81.1 236 113.3 294 145.6 352 177.8
-52 -46.7 6 -14.4 64 17.8 122 50.0 180 82.2 238 114.4 296 146.7 354 178.9
-50 -45.6 8 -13.3 66 18.9 124 51.1 182 83.3 240 115.6 298 147.8 356 180.0
-48 -44.4 10 -12.2 68 20.0 126 52.2 184 84.4 242 116.7 300 148.9 358 181.1
-46 -43.3 12 -11.1 70 21.1 128 53.3 186 85.6 244 117.8 302 150.0 360 182.2
-44 -42.2 14 -10.0 72 22.2 130 54.4 188 86.7 246 118.9 304 151.1 362 183.3
-42 -41.1 16 -8.9 74 23.3 132 55.6 190 87.8 248 120.0 306 152.2 364 184.4
-40 -40.0 18 -7.8 76 24.4 134 56.7 192 88.9 250 121.1 308 153.3 366 185.6
-38 -38.9 20 -6.7 78 25.6 136 57.8 194 90.0 252 122.2 310 154.4 368 186.7
-36 -37.8 22 -5.6 80 26.7 138 58.9 196 91.1 254 123.3 312 155.6 370 187.8
-34 -36.7 24 -4.4 82 27.8 140 60.0 198 92.2 256 124.4 314 156.7 372 188.9
-32 -35.6 26 -3.3 84 28.9 142 61.1 200 93.3 258 125.6 316 157.8 374 190.0
-30 -34.4 28 -2.2 86 30.0 144 62.2 202 94.4 260 126.7 318 158.9 376 191.1
-28 -33.3 30 -1.1 88 31.1 146 63.3 204 95.6 262 127.8 320 160.0 378 192.2
-26 -32.2 32 0.0 90 32.2 148 64.4 206 96.7 264 128.9 322 161.1 380 193.3
-24 -31.1 34 1.1 92 33.3 150 65.6 208 97.8 266 130.0 324 162.2 382 194.4
-22 -30.0 36 2.2 94 34.4 152 66.7 210 98.9 268 131.1 326 163.3 384 195.6
-20 -28.9 38 3.3 96 35.6 154 67.8 212 100.0 270 132.2 328 164.4 386 196.7
-18 -27.8 40 4.4 98 36.7 156 68.9 214 101.1 272 133.3 330 165.6 388 197.8
-16 -26.7 42 5.6 100 37.8 158 70.0 216 102.2 274 134.4 332 166.7 390 198.9
-14 -25.6 44 6.7 102 38.9 160 71.1 218 103.3 276 135.6 334 167.8 392 200.0
-12 -24.4 46 7.8 104 40.0 162 72.2 220 104.4 278 136.7 336 168.9 400 204.4
-10 -23.3 48 8.9 106 41.1 164 73.3 222 105.6 280 137.8 338 170.0 410 210.0
-8 -22.2 50 10.0 108 42.2 166 74.4 224 106.7 282 138.9 340 171.1 420 215.6
-6 -21.1 52 11.1 110 43.3 168 75.6 226 107.8 284 140.0 342 172.2 430 221.1
-4 -20.0 54 12.2 112 44.4 170 76.7 228 108.9 286 141.1 344 173.3 440 226.7

CENTIGRADE TO FAHRENHEIT

°C °F °C °F °C °F °C °F °C °F °C °F °C °F °C °F

-50 -58.0 -18 -0.4 14 57.2 46 114.8 78 172.4 110 230.0 142 287.6 174 345.2
-49 -56.2 -17 1.4 15 59.0 47 116.6 79 174.2 111 231.8 143 289.4 175 347.0
-48 -54.4 -16 3.2 16 60.8 48 118.4 80 176.0 112 233.6 144 291.2 176 348.8
-47 -52.6 -15 5.0 17 62.6 49 120.2 81 177.8 113 235.4 145 293.0 177 350.6
-46 -50.8 -14 6.8 18 64.4 50 122.0 82 179.6 114 237.2 146 294.8 178 352.4
-45 -49.0 -13 8.6 19 66.2 51 123.8 83 181.4 115 239.0 147 296.6 179 354.2
-44 -47.2 -12 10.4 20 68.0 52 125.6 84 183.2 116 240.8 148 298.4 180 356.0
-43 -45.4 -11 12.2 21 69.8 53 127.4 85 185.0 117 242.6 149 300.2 181 357.8
-42 -43.6 -10 14.0 22 71.6 54 129.2 86 186.8 118 244.4 150 302.0 182 359.6
-41 -41.8 -9 15.8 23 73.4 55 131.0 87 188.6 119 246.2 151 303.8 183 361.4
-40 -40.0 -8 17.6 24 75.2 56 132.8 88 190.4 120 248.0 152 305.6 184 363.2
-39 -38.2 -7 19.4 25 77.0 57 134.6 89 192.2 121 249.8 153 307.4 185 365.0
-38 -36.4 -6 21.2 26 78.8 58 136.4 90 194.0 122 251.6 154 309.2 186 366.8
-37 -34.6 -5 23.0 27 80.6 59 138.2 91 195.8 123 253.4 155 311.0 187 368.6
-36 -32.8 -4 24.8 28 82.4 60 140.0 92 197.6 124 255.2 156 312.8 188 370.4
-35 -31.0 -3 26.6 29 84.2 61 141.8 93 199.4 125 257.0 157 314.6 189 372.2
-34 -29.2 -2 28.4 30 86.0 62 143.6 94 201.2 126 258.8 158 316.4 190 374.0
-33 -27.4 -1 30.2 31 87.8 63 145.4 95 203.0 127 260.6 159 318.2 191 375.8
-32 -25.6 0 32.0 32 89.6 64 147.2 96 204.8 128 262.4 160 320.0 192 377.6
-31 -23.8 1 33.8 33 91.4 65 149.0 97 206.6 129 264.2 161 321.8 193 379.4
-30 -22.0 2 35.6 34 93.2 66 150.8 98 208.4 130 266.0 162 323.6 194 381.2
-29 -20.2 3 37.4 35 95.0 67 152.6 99 210.2 131 267.8 163 325.4 195 383.0
-28 -18.4 4 39.2 36 96.8 68 154.4 100 212.0 132 269.6 164 327.2 196 384.8
-27 -16.6 5 41.0 37 98.6 69 156.2 101 213.8 133 271.4 165 329.0 197 386.6
-26 -14.8 6 42.8 38 100.4 70 158.0 102 215.6 134 273.2 166 330.8 198 388.4
-25 -13.0 7 44.6 39 102.2 71 159.8 103 217.4 135 275.0 167 332.6 199 390.2
-24 -11.2 8 46.4 40 104.0 72 161.6 104 219.2 136 276.8 168 334.4 200 392.0
-23 -9.4 9 48.2 41 105.8 73 163.4 105 221.0 137 278.6 169 336.2 210 410.0
-22 -7.6 10 50.0 42 107.6 74 165.2 106 222.8 138 280.4 170 338.0 220 428.0
-21 -5.8 11 51.8 43 109.4 75 167.0 107 224.6 139 282.2 171 339.8 230 446.0
-20 -4.0 12 53.6 44 111.2 76 168.8 108 226.4 140 284.0 172 341.6 240 464.0
-19 -2.2 13 55.4 45 113.0 77 170.6 109 228.2 141 285.8 173 343.4 250 482.0

214
ENGINE DISASSEMBLY

10-3-75 EN

23 / 03 / 2006
ENGINE TUNE-UP

(ET)

-- H15/H20 - II/H25 ENGINE --

CONTENTS

SERVICE DATA AND SPECIFICATIONS................................................. ET-2


INSPECTION AND ADJUSTMENT...................................................................... ET-2
TIGHTENING TORQUE..................................................................................... ET-2
TROUBLE DIAGNOSES AND CORRECTIONS..................................... ET-3
ENGINE TUNE-UP......................................................................................... ET-9
BASIC MECHANICAL SYSTEM.......................................................................... ET-9
IGNITION AND FUEL SYSTEM........................................................................... ET-11
GOVERNOR SYSTEM....................................................................................... ET-16
FAST IDLE CONTROL DEVICE........................................................................... ET-17
SPECIAL SERVICE TOOL........................................................................... ET-18
ET-1
SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS


INSPECTION AND ADJUSTMENT

TIGHTENING TORQUE

ET-2
TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

CANNOT CRANK
ENGINE OR SLOW
CRANKING

ENGINE WILL CRANK NORMALLY BUT WILL NOT START

ET-3
TROUBLE DIAGNOSES AND CORRECTIONS

ET-4
TROUBLE DIAGNOSES AND CORRECTIONS

IMPROPER ENGINE
IDLING

ENGINE POWER NOT


UP TO NORMAL

ET-5
TROUBLE DIAGNOSES AND CORRECTIONS

NOISY ENGINE

ET-6
TROUBLE DIAGNOSES AND CORRECTIONS

ABNORMAL
COMBUSTION

EXCESSIVE OIL
CONSUMPTION

ET-7
TROUBLE DIAGNOSES AND CORRECTIONS

POOR FUEL
ECONOMY

TROUBLE IN OTHER
FUNCTIONS

ET-8
ENGINE TUNE-UP

ENGINE TUNE-UP
BASIC MECHANICAL
SYSTEM
RETIGHTENING CYLINDER
HEAD BOLTS

CHANGING ENGINE OIL AND


OIL FILTER

WARNING

RETIGHTENING MANIFOLD
NUTS

CHECKING AND ADJUSTING


ADJUSTING INTAKE AND FAN BELT
EXHAUST VALVE CLEARANCE

ET-9
ENGINE TUNE-UP

CHANGING ENGINE COOLANT

WARNING

CLEANING RADIATOR OUTSIDE

CHECKING COOLING SYSTEM


HOSES AND CONNECTIONS

CHECKING ENGINE
COMPRESSION PRESSURE

ET-10
ENGINE TUNE-UP

CHECKING FUEL LINES

CHECKING CARBURETOR
IGNITION AND FUEL
SYSTEM
CLEANING OR REPLACING AIR
CLEANING FILTER

CHECKING LINKAGE AND


VALVE

CLEANING OR REPLACING
FUEL STRAINER ELEMENT

ET-11
ENGINE TUNE-UP

CHECKING AUTO-CHECK
MECHANISM

CHECKING BIMETAL

ET-12
ENGINE TUNE-UP

CHECKING THERMOWAX

CHECKING DISTRIBUTOR

CHOKE VALVE CHECKING AND REPLACING


SPARK PLUGS

ET-13
ENGINE TUNE-UP

ENGINE RPM MEASUREMENT

CLEANING DISTRIBUTOR INSIDE

ET-14
ENGINE TUNE-UP

CHECKING AND ADJUSTING


IGNITION TIMING, IDLE-RPM AND
MIXTURE RATIO

ET-15
ENGINE TUNE-UP

GOVERNOR SYSTEM ADJUSTING MAXIMUM ENGINE


SPEED UNDER LOAD

ADJUSTING MAXIMUM ENGINE


SPEED UNDER NO LOAD

ET-16
ENGINE TUNE-UP

FAST IDLE CONTROL DEVICE

ADJUSTMENT OF IDLE SPEED

ET-17
SPECIAL SERVICE TOOL

SPECIAL SERVICE TOOL

ET-18
ET-19
ENGINE FUEL

(EF)

-- H15/H20 - II/H25 ENGINE --

CONTENTS

SERVICE DATA AND SPECIFICATIONS................................................. EF-2


FUEL PUMP................................................................................................... EF-2
CARBURETOR................................................................................................ EF-2
GOVERNOR................................................................................................... EF-2
TROUBLE DIAGNOSES AND CORRECTIONS..................................... EF-3
CARBURETOR................................................................................................ EF-3
AUTO-CHOKE MECHANISM............................................................................. EF-4
GOVERNOR................................................................................................... EF-5
FUEL PUMP.................................................................................................... EF-6
OPERATING TEST............................................................................................ EF-6
INSPECTION................................................................................................... EF-6
CARBURETOR............................................................................................... EF-7
INSPECTION AND ADJUSTMENT...................................................................... EF-8
MAJOR SERVICE OPERATION.......................................................................... EF-10
GOVERNOR.................................................................................................... EF-11
DISASSEMBLY............................................................................................... EF-12
INSPECTION.................................................................................................. EF-12
ASSEMBLY.................................................................................................... EF-12
ADJUSTMENT................................................................................................ EF-13
EF-1
SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS


FUEL PUMP

CARBURETOR

GOVERNOR

EF-2
TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS


CARBURETOR

EF-3
TROUBLE DIAGNOSES AND CORRECTIONS

AUTO-CHOKE MECHANISM

INSPECTION AND MAINTENANCE PROCEDURES

EF-4
TROUBLE DIAGNOSES AND CORRECTIONS

GOVERNOR

EF-5
FUEL PUMP

FUEL PUMP

INSPECTION

OPERATING TEST
WARNING
FUEL PRESSURE TEST

EF-6
CARBURETOR

CARBURETOR

WARNING

EF-7
CARBURETOR

INSPECTION AND
ADJUSTMENT
IDLE RPM AND MIXTURE RATIO

FUEL LEVEL

EF-8
CARBURETOR

JET AND AIR BLEED DASH POT FUEL CUT SOLENOID VALVE
CAUTION :

AUTO-CHOKE MECHANISM

ACCELERATOR PUMP

EF-9
CARBURETOR

THERMOSTATIC COIL THERMOWAX MAJOR SERVICE


OPERATION

CAM LEVER

EF-10
GOVERNOR

GOVERNOR

EF-11
GOVERNOR

DISASSEMBLY

INSPECTION

ASSEMBLY

EF-12
GOVERNOR

ADJUSTMENT

FINAL ADJUSTMENT

EF-13
ENGINE LUBRICATION AND
COOLING SYSTEMS
(LC)

-- H15/H20 - II/H25 ENGINE --

CONTENTS

SERVICE DATA AND SPECIFICATIONS................................................. LC-2


ENGINE LUBRICATION SYSTEM....................................................................... LC-2
ENGINE COOLING SYSTEM............................................................................. LC-2
TROUBLE DIAGNOSES AND CORRECTIONS..................................... LC-3
ENGINE LUBRICATION SYSTEM....................................................................... LC-3
ENGINE COOLING SYSTEM............................................................................. LC-4
ENGINE LUBRICATION SYSTEM............................................................ LC-5
LUBRICATION CIRCUIT.................................................................................... LC-5
OIL PUMP...................................................................................................... LC-6
OIL FILTER..................................................................................................... LC-7
OIL PRESSURE RELIEF VALVE.......................................................................... LC-7
ENGINE COOLING SYSTEM..................................................................... LC-8
COOLING CIRCUIT.......................................................................................... LC-8
WATER PUMP................................................................................................. LC-8
THERMOSTAT................................................................................................ LC-9
RADIATOR..................................................................................................... LC-9
LC-1
SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS


ENGINE LUBRICATION SYSTEM INSPECTION AND ADJUSTMENT

GENERAL SPECIFICATIONS

INSPECTION AND ADJUSTMENT

TIGHTENING TORQUE

TIGHTENING TORQUE

ENGINE COOLING SYSTEM


GENERAL SPECIFICATIONS

LC-2
TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS


ENGINE LUBRICATION SYSTEM

LC-3
TROUBLE DIAGNOSES AND CORRECTIONS

ENGINE COOLING SYSTEM

LC-4
ENGINE LUBRICATION SYSTEM

ENGINE LUBRICATION SYSTEM


LUBRICATION CIRCUIT

Oil pan

Oil strainer

Oil pump

Oil filter

Main bearing Oil pump Cam bearing Cylinder head


drive spindle

Chain tensioner Crankshaft Rear rocker


Oil pump bracket
drive gear

Timing chain Connecting rod


Rocker shaft
bearing

Connecting rod Rocker arm


oil jet

Push rod Valve


Piston pin and
cylinder wall

LC-5
ENGINE LUBRICATION SYSTEM

OIL PUMP
REMOVAL

DISASSEMBLY AND ASSEMBLY

INSPECTION

INSTALLATION

LC-6
ENGINE LUBRICATION SYSTEM

OIL FILTER OIL PRESSURE RELIEF VALVE


REPLACEMENT

LC-7
ENGINE COOLING SYSTEM

ENGINE COOLING SYSTEM


COOLING CIRCUIT

WATER PUMP

REMOVAL

INSTALLATION
WARNING

INSPECTION

LC-8
ENGINE COOLING SYSTEM

THERMOSTAT
REMOVAL AND INSTALLATION

WARNING
THERMOSTAT
REMOVAL

WARNING

INSPECTION

INSPECTION
INSTALLATION

LC-9
ENGINE ELECTRICAL SYSTEM

(EE)

-- H15/H20 - II/H25 ENGINE --

CONTENTS

SERVICE DATA AND SPECIFICATIONS................................................. EE-2


BATTERY......................................................................................................... EE-4
CHECKING ELECTROLYTE LEVEL..................................................................... EE-4
CHECKING SPECIFIC GRAVITY......................................................................... EE-4
CHARGING.................................................................................................... EE-5
BATTERY FREEZING........................................................................................ EE-5
STARTING SYSTEM..................................................................................... EE-6
WIRING DIAGRAM........................................................................................... EE-6
STARTING SYSTEM TROUBLESHOOTING.......................................................... EE-7
STARTER MOTOR........................................................................................... EE-8
CHARGING SYSTEM................................................................................... EE-14
WIRING DIAGRAM.......................................................................................... EE-14
CHARGING SYSTEM TROUBLESHOOTING......................................................... EE-15
ALTERNATOR................................................................................................. EE-16
IGNITION SYSTEM...................................................................................... EE-19
WIRING DIAGRAM.......................................................................................... EE-19
IC IGNITION SYSTEM..................................................................................... EE-20
DISTRIBUTOR................................................................................................ EE-23
EE-1
SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS


BATTERY ALTERNATOR

STARTER MOTOR

EE-2
SERVICE DATA AND SPECIFICATIONS

DISTRIBUTOR

SPARK PLUG

EE-3
BATTERY

BATTERY
WARNING
CHECKING SPECIFIC GRAVITY

CHECKING ELECTROLYTE LEVEL

EE-4
BATTERY

CHARGING BATTERY FREEZING

WARNING

EE-5
STARTING SYSTEM

STARTING SYSTEM
WARNING

WIRING DIAGRAM

EE-6
STARTING SYSTEM

STARTING SYSTEM TROUBLESHOOTING

EE-7
STARTING SYSTEM

STARTER MOTOR
REDUCTION GEAR TYPE

EE-8
STARTING SYSTEM

INSPECTION

EE-9
STARTING SYSTEM

ASSEMBLY

EE-10
STARTING SYSTEM

PLANETARY GEAR TYPE

EE-11
STARTING SYSTEM

INSPECTION

EE-12
STARTING SYSTEM

ASSEMBLY

EE-13
CHARGING SYSTEM

CHARGING SYSTEM
WARNING

WIRING DIAGRAM

EE-14
CHARGING SYSTEM

CHARGING SYSTEM
TROUBLESHOOTING

EE-15
CHARGING SYSTEM

ALTERNATOR

EE-16
CHARGING SYSTEM

INSPECTION

EE-17
CHARGING SYSTEM

ASSEMBLY

EE-18
IGNITION SYSTEM

IGNITION SYSTEM
WARNING

WIRING DIAGRAM

EE-19
IGNITION SYSTEM

IC IGNITION SYSTEM
IC IGNITION SYSTEM TROUBLESHOOTING

WARNING

EE-20
IGNITION SYSTEM

EE-21
IGNITION SYSTEM

EE-22
IGNITION SYSTEM

DISTRIBUTOR

EE-23
IGNITION SYSTEM

DISASSEMBLY

EE-24
IGNITION SYSTEM

INSPECTION

ASSEMBLY

EE-25
ENGINE MECHANICAL

(EM)

-- H15/H20 - II/H25 ENGINE --

CONTENTS

SERVICE DATA AND SPECIFICATIONS................................................. EM-2


TROUBLE DIAGNOSES AND CORRECTIONS..................................... EM-6
ENGINE DISASSEMBLY............................................................................. EM-8
INSPECTION AND REPAIR........................................................................ EM-12
PREPARATIONS FOR INSPECTION.................................................................... EM-12
INTAKE MANIFOLD WATER JACKET.................................................................. EM-12
CYLINDER HEAD............................................................................................ EM-12
VALVE........................................................................................................... EM-13
VALVE SPRINGS............................................................................................. EM-13
CYLINDER BLOCK.......................................................................................... EM-14
PISTON, PISTON PIN AND PISTON RINGS......................................................... EM-15
CONNECTING RODS....................................................................................... EM-16
CRANKSHAFT................................................................................................ EM-18
MAIN BEARING SHELLS................................................................................. EM-19
CANSHAFT.................................................................................................... EM-20
VALVE ROCKER MACHANISM.......................................................................... EM-21
DRIVING PLATE, RING GEAR AND FLYWHEEL.................................................... EM-22
ENGINE ASSEMBLY.................................................................................... EM-22
PRECAUTIONS............................................................................................... EM-22
PISTON AND CONNECTING RODS.................................................................... EM-22
ASSEMBLING OF ENGINE............................................................................... EM-23
SPECIAL SERVICE TOOLS....................................................................... EM-29
EM-1
SERVICE DATA AND SPECIFICATIONS

SERVICE DATA AND SPECIFICATIONS


GENERAL SPECIFICATIONS

INSPECTION AND ADJUSTMENT

EM-2
SERVICE DATA AND SPECIFICATIONS

EM-3
SERVICE DATA AND SPECIFICATIONS

EM-4
SERVICE DATA AND SPECIFICATIONS

TIGHTENING TORQUE

EM-5
TROUBLE DIAGNOSES AND CORRECTIONS

TROUBLE DIAGNOSES AND CORRECTIONS

EM-6
TROUBLE DIAGNOSES AND CORRECTIONS

EM-7
ENGINE DISASSEMBLY

ENGINE DISASSEMBLY

EM-8
ENGINE DISASSEMBLY

EM-9
ENGINE DISASSEMBLY

EM-10
ENGINE DISASSEMBLY

EM-11
INSPECTION AND REPAIR

INSPECTION AND REPAIR


PREPARATIONS FOR INSPECTION MEASURING CYLINDER HEAD MEASURING VALVE GUIDES
FOR WARPAGE

INTAKE MANIFOLD
WATER JACKET

CYLINDER HEAD

REMOVING CARBON

EM-12
INSPECTION AND REPAIR

CORRECTING (GRINDING)
VALVE SEATS

VALVE

VALVE SPRINGS

EM-13
INSPECTION AND REPAIR

MEASURING CYLINDER BORE

CYLINDER BLOCK

EM-14
INSPECTION AND REPAIR

BORING AND HONING

PISTON, PISTON PIN,


AND PISTON RINGS

MEASURING PISTON WEAR

EM-15
INSPECTION AND REPAIR

PISTON PIN

PISTON RINGS

CONNECTING RODS

CORRECTION FOR BENDING


OR TWISTING
(Parallel alignment)

EM-16
INSPECTION AND REPAIR

CONNECTING ROD WEIGHT

MEASURING CONNECTING ROD END PLAY

CONNECTING ROD BUSHINGS

EM-17
INSPECTION AND REPAIR

CRANKSHAFT
INSPECTION

MEASURING CRANKSHAFT FOR BENDING

JOURNAL AND PIN DIAMETER


MEASUREMENT

EM-18
INSPECTION AND REPAIR

MEASURING END PLAY

MAIN BEARING SHELLS

INSPECTING BEARINGS SURFACES

EM-19
INSPECTION AND REPAIR

CAMSHAFT INSPECTING CAM SURFACES

CHECKING CAMSHAFT FOR BENDING

INSPECTING DRIVE GEAR

VALVE TIMING

INSPECTING CAMSHAFT JOURNALS

CAM BUSHING

EM-20
INSPECTION AND REPAIR

PUSH RODS

TIMING SPROCKET

ROCKER SHAFT
VALVE ROCKER MECHANISM

VALVE LIFTERS

ROCKER ARM AND ADJUSTING BOLT

FRONT COVER AND HYDRAULIC


PUMP CHAIN COVER

EM-21
INSPECTION AND REPAIR / ENGINE ASSEMBLY

DRIVING PLATE, RING GEAR


AND FLYWHEEL

MEASURING RUNOUT

ENGINE ASSEMBLY
PRECAUTIONS
PISTON AND CONNECTING RODS

ASSEMBLY

EM-22
ENGINE ASSEMBLY

INSTALLING VALVE ROCKER SHAFT

INSTALLING CAM BUSHING

ASSEMBLING OF ENGINE

INSTALLING VALVES AND VALVE SPRINGS

INSTALLING PISTON RINGS

EM-23
ENGINE ASSEMBLY

INSTALLING CRANKSHAFT
INSTALLING REAR OIL SEAL RETAINER

INSTALLING PISTONS

INSTALLING DRIVING PLATE AND FLYWHEEL

EM-24
ENGINE ASSEMBLY

INSTALLING CAMSHAFT
INSTALLING TIMING CHAIN TENSIONER

INSTALLING CONNECTING ROD CAPS

INSTALLING FRONT COVER

INSTALLING VALVE LIFTERS

INSTALLING COVER, SPROCKETS AND


CHAIN FOR HYDRAULIC OIL PUMP

EM-25
ENGINE ASSEMBLY

INSTALLING CRANK PULLEY

INSTALLING OIL PUMP

INSTALLING CYLINDER HEAD

EM-26
ENGINE ASSEMBLY

OTHER PARTS

INSTALLING ROCKER SHAFT ASSEMBLY INSTALLING ENGINE ACCESSORY

INSTALLING DISTRIBUTOR

EM-27
ENGINE ASSEMBLY

EM-28
SPECIAL SERVICE TOOLS

SPECIAL SERVICE TOOLS

EM-29
GROUP 12

CARBURATION
VACUUM FUELOCK FILTER REPAIR METHOD
VFF30
12-3-2 EN

20 / 02 / 2002
CONTENTS

1 – DIAGRAM........................................................................................................... 4

2 – OPERATION...................................................................................................... 5

3 – REPAIR METHOD ........................................................................................... 6

4 – TECHNICAL SHEET ....................................................................................... 17

3
1 – DIAGRAM

Valve

Gas
inlet

Gas
outlet

1. Filter cover screw. 10. Operating pin.


2. Filter cover. 11. Retaining washer.
3. Seal. 12. Lip seal.
4. Felt filter. 13. Screw.
5. Screen back-up filter. 14. Cover.
6. Filter housing. 15. Complete diaphragm assembly.
7. Screw. 16. Valve spring.
8. Spring. 17. Vacuum port.
9. Valve.

4
2 – OPERATION

LPG in the liquid phase enters through the cover, passes through the felt filter which traps all impurities. The fue-
lock filter is held in place by the screen back-up filter.

The gas is stopped in front of the valve and the gas pressure then closes the valve (positive safety).

The carburettor creates a vacuum in chamber A through vacuum port 17 which draws up diaphragm assembly 15.
This operates valve spring 16 which moves operating pin 10 thus opening valve 9. Once open, this allows gas to
pass through to the fuelock filter outlet to the pressure relief valve.

5
3 – DEMONTAGE

1. Remove screws from (Fuel in) cover.

2. Remove cover and gasket.

3. Remove filter and screen.

4. Remove screw holding valve spring.

6
5. Remove valve spring.

6. Remove valve seat.

7. Remove valve operating pin.

8. With paper clip or wire, fashion a hook as shown.

7
9. Cutaway shows assembly of valve spring, valve
seat, valve operating pin, seal retaining washer and
"O" ring seal.

10. Insert hook in hole in seal retaining washer and


remove.

11. Washer removed.

12. Same hook tool ready to remove "O" ring seal


through valve jet.

8
13. Insert tool through jet.

14. Pick out "O" ring. Wash body, cover and jet area
clean as needed. (Use kerosene or equivalent
petroleum solvent. Do not use carburettor cleaner
as it will attack synthetic rubber seals).

15. Repair kit Ref. 550525 of fuelock filter VFF30


includes :
1 . . . . . .Gasket.
1 . . . . . .Filter + cover gasket.
1 . . . . . .Screen.
1 . . . . . .Diaphragm Assy.
1 . . . . . .Screws 8-32 x 16mm.
1 . . . . . .Screws 12-24 x 16mm.
1 . . . . . .Seat (viton bonded to aluminium)
1 . . . . . .Seal lip.
1 . . . . . .Pin, valve operating.
1 . . . . . .Retainer washer.
1 . . . . . .Repair instructions.
1 . . . . . .Holder, for seal lip.
1 . . . . . .Pin, installation.

16. Seal holder, should be placed as shown in photo.


The seal holder passage is tapered. The wide ope-
ning of the seal holder should be facing up as
shown in the photo. Seal must be coated with sili-
lone grease prior to being inserted into the holder.
Place the seal into the holder as shown, using the
installation pin. Re-coat the seal with silicone grea-
se.
The seal must be in the position shown in the
photo. The groove in the seal, must be visible from
the top of the taper of the seal holder to function
properly.

9
17. Place the body with the filter side up, as shown in
the photo, on a flat surface.

18. With the holder in the up position, and the groove


seal visible.
Look through the fuel port to position the seal
above the cavity of the seal recess.

19. Coat the installation pin with silicone grease and


and push the seal through the holder and into the
seal recess of the body.

20. With "O" ring in place in its recess, use needle nose
pliers to hold seal retainer washer.

10
21. Insert seal retainer washer in slot to hold "O" ring
in place.

22. Insertion of valve operating pin will retain washer


and "O" ring in place.

23. Insert pin, lubricated with silicone grease, through


hole in retainer washer and "O" ring. Again rotate
head of pin gently in a circular motion to ease pin
into place through washer, "O" ring and body hou-
sing.

24. Shows valve operating pin in place in valve jet.

11
25. Valve seat shown with aluminium side up ready to
be placed on jet.

26. Seat, viton (rubber) side down, in position on jet.

27. Spring ready to be fastened in place.

28. Spring fastened in place by screw tightening screw,


in tightening screw, hold tip of spring (over valve)
centered between the 3 guide fins as shown here to
avoid friction.

12
29. With spring in place, lift it slightly to assure free-
dom of travel.

30. Insert screen in recess as shown.

31. Insert filter in recess over screen.

32. Place gasket in place. Align with screw holes.

13
33. With 2 opposite screws in "Fuel In" cover, lower
cover on to gasket and start two screws in their
threads.

34. After examining position of gasket through remai-


ning open holes to insure correct alignment, insert
remaining 8 screws in their openings.

35. Tighten screws, alternating from side on opposite


sides of the cover until all screws are solidly set.

36. Fully loosen 6 screws on diaphragm cover side as


shown.

14
37. Remove cover and diaphragm assy.

38. Clean parts as necessary.

39. Turn diaphragm to position where its screw hole


pattern matches holes in body. There is only one
position in which the holes will line up.

40. Place cover in correct position.

15
41. Tighten screws alternately from side to side across
cover until all are solidly fastened. Pressurize the
"Fuel In" opening with air or fuel. Check fuel out-
let and fuel inlet cover gasket for leaks with soap
suds or testing solution.

16
4 – TECHNICAL SHEET

FUELOCK FILTER CONDITION CHECK

Proceed as follows to check the condition of the vacuum fuelock filter (VFF-30).
- start the engine,
- clamp the line between the vacuum fuelock filter (VFF-30) and the carburettor (CA55).

If the engine continues to run, the vacuum fuelock filter is not leaking.
If the engine stalls, there is a leak on the vacuumfuelock filter.
The gas mixture is too rich.

➞ Fit a new kit RK-VFF-30-2, Ref. 550525 remembering to replace the lip seal and refit the small retaining washer.

VACUUM FUELOCK FILTER ICING UP PROBLEM

There may be several reasons for the vacuum fuelock filter icing up :
- either the vacuum fuelock filter lip seal is no longer sealed (proceed as above to check it),
- or the LPG tank has been fitted the wrong way round. Consequently, the suction pipe inside the tank is drawing
off gas in the gaseous phase instead of in the liquid phase.

17
18
CARBURETTOR REPAIR METHOD CA55

12-3-3 EN

20 / 02 / 2002
CONTENTS

1 – REPAIR ADVICE ............................................................................................ 4

2 – REPAIR METHOD .......................................................................................... 5

3 – TECHNICAL SHEET ....................................................................................... 9

4 – SERVICING ....................................................................................................... 10

3
1 – REPAIR ADVICE

Warning :
Before starting to repair a CA55 type carburettor, check that the repair kit matches the references given by the
constructor. There are several types of CA55 carburettor and an incorrect repair kit may cause serious damage to
the engine.

Seal kit: reference : 588 670

4
2 – DEMONTAGE

u u s p c p u g g sp
1. With carburettor removed from engine, remove 4
screws holding throttle body to mixer bowl.

2. With throttle body removed, note that gasket retains


idle cutoff piston in place (under finger tip).

3. Remove gasket. Idle cutoff piston and spring are


released. Do not lose either one.

4. Remove check valve plate and air valve spring. Lift


air/gas valve from mixer bowl.

5
5. Clean mixer bowl assembly in kerosene or equiva-
lent petroleum solvent. Do not use carburettor clea-
ner as it will attack synthetic rubber seals.

6. Kit includes RK-CA55 ref. 588670 includes :


1 . . . . . .Air-gas valve assy
1 . . . . . .Ring, sealing
1 . . . . . .Plate, check valve
1 . . . . . .Gasket, TB to mixer
4 . . . . . .Screw 10-24 x 16 mm
1 . . . . . .Piston, idle cutoff
1 . . . . . .Spring, idle cutoff
1 . . . . . .Instruction

7. Install sealing ring in piston groove. Install one end


in groove and coax the ring in spirally to avoid brea-
king or creasing the ring.

8. Replace air/gas valve assembly in mixer bowl. Tilt


valve slightly to insert one end of the split sealing
ring into the cylinder of the bowl. Then, using pen-
cil lead or similar point, slide around circumferen-
ce of sealing ring pressing it in until ring and
assembly drop into the bowl.

Note :
When installing the air/gas valve assembly it is
recommended that a lubricant such as WD-40 be
sprayed onto the mixer body well. This elimi-
nates the possibility of the air/gas valve assembly
sticking to the body.
6
9. Replace air/valve spring and check valve plate in
the mixer bowl.

10. Shows mixer bowl assembled with check valve


assembly centered towards air horn. The idle
cutoff piston and spring are shown in place ready
for assembly to the mixer bowl.

11. Gasket in place retaining idle cutoff piston in its


recess (under thumb).

12. Invert throttle body, holding gasket and idle cutoff


piston in place. Note cutoff of gasket to clear check
valve assembly on plate.

7
13. Lower throttle body gently onto mixer bowl
making sure idle cutoff piston does not escape
from its recess. With throttle body flush on the
mixer bowl, align the holes and start the 4 screws.

14. Tighten 4 screws.

15. With assembly completed, reach a forefinger into


the carburettor air horn and lift air valve several
times to check free movement. Air valve should lift
easily and return slowly due to action of check
valve.

8
3 – TECHNICAL SHEET

CARBURETTOR CHECK

The only way to check the carburettor condition is to remove it and simply look at the condition of the diaphragm
or piston.

9
4 – SERVICING

FITTING
250 500 750 1000 1500 2000
DATE

FUEL SECTION

Adjust idle mixture X X X X

Adjust full load mixture X X X X X

Check air/gas diaphragm X X X

Replace air/gas diaphragm X X

Service air filter X X X X X X

Check seal between air filter and carburettor X X X X X X

Clean inside carburettor X X X X X X

Check seal between carburettor and engine, inlet side X X X X

PRESSURE RELIEF SECTION

Check secondary diaphragm X X X X

Check primary pressure (0.1 bar with engine idling) X X X

Replace repair kit X X

FUELOCK FILTER SECTION

Replace filter X X X X

Replace repair kit X X

GENERAL MAINTENANCE

Check all vacuum pipes X X X X X X X

Check gas and water pipes and connectors X X X X X X X

10
COBRA PRESSURE RELIEF VALVE OPERATION

12-8-1 EN

20 / 02 / 2002
2
CONTENTS

1 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 – DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 – DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 – TECHNICAL SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3
1 – SPECIFICATIONS

COBRA SÉRIES
TWO-STAGE CONVERTER
FOR 3.7 TO 75 KW (5 TO 100 HP)
LP-GAS ENGINES

The COBRA series converters deliver superior performance and excellent pressure output consistency throughout
service life. Three vapor outlet pressure are available. Use of the standard blue secondary spring provides negative
0.37 kPa (- 1.5 inches w.c.) The optional orange secondary spring provides negative 0.12 kPa (- 0.5 inch w.c.) and the
red secondary spring negative 0.05 kPa (- 0.2 inch w.c.) output.

SPECIFICATIONS

Fuel Type............................................................................................................................................. Liquid / Vapor Propane


Max. Intel Pressure ....................................................................................................................................... 2151 kPa (312 psi)
Min. Intel Pressure............................................................................................................................................ 207 kPa (30 psi)
Primary Pressure ....................................................................................................................... 6.9 to 13.8 kPa (1.0 to 2.0 psi)
Nominal Outlet Pressure................................................................................ Standard (blue spring) - 0.37 kPa (- 1.5 w.c.)
.......................................................................................................................... Cobra I (orange spring) - 0.12 kPa (- 0.5 w.c.)
............................................................................................................................... Cobra II (red spring) - 0.05 kPa (- 0.2 w.c.)
Horsepower Rating ......................................................................................................................... 3.7 to 75 kW (5 to 100 hp)
Temperature Range ........................................................................................................... - 40° to + 121° C (- 40 to + 250° F)
Filtration Requirement ............................................................................................................................................... 40 micron
Heating Chamber Source, Engine Coolant, Engine Oil, Exhaust Heat can be used w/B3-20 baffle
Mounting Position Vertical (outlet down) recommended. Horizontal (secondary cover up) position can be used
when fuel contamination can be controlled with HD-5 specified propane fuel.
Weight ................................................................................................................................................................. 0.86 kg (1.9 Ibs)
Applications................................................................Open Loop, Closed Loop, Forced Induction up to 34.4 kPa (5 psi)

4
2 – DIMENSIONS

A B C D E F G H J K L
Back of Back of Vent/
Converter Converter Balance
to Ctr. of to Ctr. Mounting Coolant Liquid Primary Vapor Line
Overall Overall Overall Vapor Fuel Water Holes Ctr. Intel & Fuel y Test Fuel Con-
Height Depth Width Outlet Outlet to Ctr. Outlet Intel Port Outlet nection
(mm) (mm) (mm) (mm) (mm) (mm) (NPT) (NPT) (NPT) (NPT) (NPT)
108 70,3 117 41,3 34,9 41,3 3/8” 1/4” 1/8” 1/2” 1/8”

5
3 – DIAGRAM

Gas
outlet
Liquid
gas

1. Cover, secondary. 10. Housing, intermediate (with connecting hole).


2. Vacuum port. 11. Diaphragm ass'y, primary.
3. Diaphragm ass'y, secondary. 12. Cover, primary.
4. Outlet, gas drawn in by engine. 13. Coolant channel.
5. Body. 14-15. Valve, primary.
6-7-8. Regulation valve, secondary. 16. Gas inlet.
9. Seal. 17. Manual control

6
7
4 – OPERATION

The liquefied gas must be converted from the liquid state to the gaseous state so that it can be turned into a com-
bustible mixture in the gas/air mixer with the inlet air. This is obtained using a vacuum fuelock filter heated by the
engine coolant.

It operates as follows :

The vacuum fuelock filter is a two-phase combined regulator with vacuum fuelock filter. It receives the pressurised
liquefied gas through the solenoid valve fitted with a cleaning filter from the tank and reduces this pressure in two
stages to a pressure slightly below atmospheric pressure (vacuum).

When the engine is running (the gas/air mixing butterfly is open), a vacuum is created in the inlet manifold to the
carburettor which opens the secondary valve of the relief valve through which the gaseous gas can pass to the car-
burettor, through the primary valve. The secondary valve is controlled by the secondary diaphragm assembly.

At rest (engine off), the primary valve is open and the secondary valve closed. The secondary valve prevents gas
from escaping when the engine is off. The spring located under the lever helps the valve to perform this.

The primary valve is controlled by the pressure inside the vaporization chamber which acts on the primary dia-
phragm assembly. This pressure enters the chamber in front of the diaphragm assembly through the orifice. The
needle transmits the movement to the primary valve. The spring under the needle opposes the movement. The side
opposite the primary diaphragm assembly is subject to atmospheric pressure transmitted through the vent hole.

The secondary valve can be manually operated for cold starting.

When the engine is running (the mixer butterfly is open), a vacuum forms inside the inlet manifold. This vacuum
opens the secondary valve which allows liquid gas to escape into the vacuum fuelock filter through the primary
valve. The secondary valve is controlled by the secondary diaphragm assembly.

8
The drop in liquid gas pressure (approximately 6 bars inside the tank) to atmospheric pressure expands the liquid
gas and results in cooling. The vacuum fuelock filter is heated to compensate for this cooling and to speed up eva-
poration. Consequently, the coolant is directed to the vacuum fuelock filter via the heating duct. Depending on but-
terfly position (which depends on the accelerator pedal position), the secondary diaphragm assembly is attracted
by varying amounts, thus controlling the opening of the secondary valve.

1 - Primary valve
2 - Rod with spring Vacuum fuelock filter at rest
3 - Primary diaphragm assembly
4 - Exhaust duct
5 - Expansion hole
6 - Secondary diaphragm assembly
7 - Manual control
8 - Secondary valve
9 - Vacuum duct connector
10 - Spring lever
11 - Bore
12 - Vacuum fuelock filter chamber

9
ITEM DESCRIPTION

1 Screen atmospheric vent


2 Screw 8-32 x 5/8" *
3 Cover ass'y, secondary
4 Diaphragm ass'y, secondary, fluorosilicone *
5 Screw 8-32x3/8" *
6 Lever secondary
7 Pin secondary fulcrum
8 Seat secondary *
9 Spring blue secondary - standard
Spring orange secondary - optional
10 Body ass'y, W/jet
11 Screw 1/4 - 20 x 5/8" (2)
12 Gasket, body to body cover plate *
13 Pin valve primary *
14 Plate body cover
15 Plug 1/8" NPT
16 Spring primary
17 E-ring external *
18 Diaphragm ass'y, primary *
19 Cover primary
20 Screw 8-32 x 1 *

* Delivered with kit

10
5 – TECHNICAL SHEET

PRESSURE RELIEF VALVE STATUS CHECK

Proceed as follows to check the operation of the pressure relief valve :

- remove the hose between the pressure relief valve and the carburettor,
- create a vacuum in the fuelock filter (VFF30) by using a vacuum pump connected to the hose. If the pressure relief
valve is in good condition, no gas will exit the pressure relief valve.

CHECK 2

With the vacuum pump still connected, gas should come out of the pressure relief valve when the starter button is
pressed. Gas flow should stop when the button is released.

CHECK 3

To check the pressure relief valve primary pressure :

- drain the gas from the circuit,


- undo plug no. 16,
- connect a 0 - 1 bar pressure gauge,
- with the engine idling, the pressure should be 0.1 bar.
If the pressure is too high, valve no. 13 or diaphragm assembly no. 19 may be faulty.

11
12
LPG CARBURETION SYSTEM

12-8-20 EN

23 / 03 / 2006
2
TABLE OF CONTENTS

1 - HOW THE LPG CARBURETION SYSTEM WORKS ................ 4

2 - SCHEMATIC OF LPG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 - POSITION OF COMPONENTS ON MACHINE . . . . . . . . . . . . . . . . . . . . 6

4 - MAINTENANCE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3
1 - HOW THE LPG CARBURETION SYSTEM WORKS

STARTING

On starting, the vacuum created in the carburettor is transmitted to the pressure reducer
secondary membrane through the vacuum manifold.
This membrane opens a valve that releases LPG in gas form into the carburettor.
This LPG mixes with air in the carburettor and then goes into the engine through the inlet mani-
fold.

OPERATION

The carburettor vacuum from the running engine acts on the secondary membrane of the
valve, which regulates the LPG gas flow according to the level of vacuum registered.
Any clogging up of the filter will increase the vacuum. A compensation duct transmits this increa-
sed vacuum to the secondary membrane of the pressure reducing valve, limiting the valve ope-
ning and reducing LPG gas flow and thus maintaining the ideal Air/Gas ratio.

SHUT DOWN

In turning off the ignition, the solenoid shuts off or the filter-valve closes on no vacuum
(fail-safe condition).

REMINDER

PLEASE NOTE :
If LPG source is gaseous Valve lever C13 should be up
If LPG source is liquid Valve lever C13 should be down

4
2 -- LPG SYSTEM SCHEMATIC

Assembly including
filter valve

Carburettor LPG storage

Filter valve Pressure


solenoid reducer

1. Air filter 5,6. Liquid gas circuit 10. Engine


2. Ignition key 7. Pressure reducer 11. Exhaust manifold
3. C13 bottle 8.. Compensation duct 12.Carburettor
4. Filter solenoid 9. . Gaseous gas circuit

5
3 - MACHINE COMPONENT LAYOUT

C13 Bottle
(13kg of gas)

Air filter assembly

Carburettor

COBRA pressure reducer

Filter valve VFF30

6
4 - MAINTENANCE GUIDE
PROBLEMS PROBABLE CAUSES PROBABLE SOLUTIONS
Does not start Reservoir or C13 bottle empty Change C13 bottle
Fill reservoir (80% max)
C13 bottle valve or reservoir valve closed Open valve
Flow limiter malfunction Close valve. Open valve slowly
Liquid-phase LPG loop or line blocked Remove blockage. Test for leakage
LPG filter solenoid or filter valve clogged Change filter
Pressure reducer primary valve out Test primary valve using TK-1000-F kit
Use repair kit
Pressure reducer-to-carburettor connection fault Check pressure reducer-to-carburettor connection
Filter valve fault Check filter valve-to-carburettor line vacuum
Test filter valve using TK-1000-F kit
Use repair kit if necessary
Solenoid fault Check electric circuit
Check safety relay
Test solenoid using TK-1000-F kit
Replace solenoid if necessary
Pressure reducer malfunction Test pressure reducer using TK-1000-F kit
Use repair kit if necessary
Carburettor malfunction Clean carburettor
Test carburettor using TK-1000-F kit
Use repair kit if necessary
Replace carburettor (worn out) if necessary
Clogged air filter Replace air filter
Ignition fault Check ignition
Repair or replace if necessary
Difficulty in starting Reservoir bottle almost empty LPG gas-phase reservoir or bottle distribution outlet
Fill reservoir (80% max)
Change bottle
Flow limiter malfunction Close valve
LPG liquid-phase loop or line blocked Remove blockage. Test for leakage
LPG filter solenoid or filter valve clogged Change filter
Pressure reducer primary valve out Test primary valve using TK-1000-F kit
Use repair kit
Pressure reducer-to-carburettor connection fault Check pressure reducer-to-carburettor connection
Filter valve fault Check filter valve-to-carburettor line vacuum
Test filter valve using TK-1000-F kit
Use repair kit if necessary
Carburettor malfunction Clean carburettor
Test carburettor using TK-1000-F kit
Use repair kit if necessary
Replace carburettor (worn out) if necessary
Clogged air filter Replace air filter
Ignition fault Check ignition
Repair or replace if necessary
Doesn’t work continuously Reservoir bottle almost empty LPG gas-phase reservoir or bottle distribution outlet
Fill reservoir (80% max)
Change bottle
Flow limiter malfunction Close valve
LPG liquid-phase loop or line blocked Remove blockage. Test for leakage
LPG filter solenoid or filter valve clogged Change filter
Pressure reducer-to-carburettor connection fault Check pressure reducer-to-carburettor connection
Pressure reducer icing Check cooling circuit antifreeze (in Winter)
Check pressure reducer is physically below radiator water
level
Check cooling circuit hosing feeding the pressure reducer
Check pressure reducer using TK-1000-F kit

7
4 - - MAINTENANCE GUIDE (continued)
PROBLEMS PROBABLE CAUSES PROBABLE SOLUTIONS
Doesn’t work continuously Incorrect idling speed Check and adjust engine idling speed
(contd) Check engine speed regulator
Doesn’t accelerate Reservoir or C13 bottle empty Change C13 bottle
Fill reservoir (80% max)
C13 bottle valve or reservoir valve closed Open valve
Flow limiter malfunction Close valve. Open valve slowly
LPG liquid-phase loop or line blocked Remove blockage. Test for leakage
LPG filter solenoid or filter valve clogged Change filter
Pressure reducer-to-carburettor connection fault Check pressure reducer-to-carburettor connection
Carburettor butterfly valve does not work Check carburettor mounting assembly
Replace mounting or carburettor as necessary
Engine stall Reservoir or C13 bottle empty Change C13 bottle
Fill reservoir (80% max))
C13 bottle valve or reservoir valve closed Open valve
Flow limiter malfunction Close valve. Open valve slowly
Liquid-phase LPG loop or line blocked Remove blockage. Test for leakage
LPG filter solenoid or filter valve clogged Change filter
Pressure reducer-to-carburettor connection fault Check pressure reducer-to-carburettor connection
Vacuum leak fault Check circuit vacuum
Check mixer-to-carburettor line vacuum
Check speed regulator
Check intake manifold
Filter valve fault Check filter valve-to-carburettor line vacuum
Test filter valve using TK-1000-F kit
Use repair kit if necessary
Solenoid fault Check electric circuit
Check safety relay
Test solenoid using TK-1000-F kit
Replace solenoid if necessary
Pressure reducer malfunction Test pressure reducer using TK-1000-F kit
Use repair kit if necessary
Pressure reducer icing Check cooling circuit radiator water
Check cooling circuit antifreeze (in Winter) Check pressure
reducer position is below radiator water level
Check cooling circuit hosing feeding the pressure reducer
Check pressure reducer using TK-1000-F kit
Pressure reducer-to-carburettor connection fault Check pressure reducer-to-carburettor connection
Carburettor malfunction Clean carburettor
Test carburettor using TK-1000-F kit
Use repair kit if necessary
Replace carburettor (worn out) if necessary
Idling speed too low Incorrect idling speed Check and adjust engine idling speed
Check engine speed regulator
Pressure reducer-to-carburettor connection fault Check pressure reducer-to-carburettor connection
Vacuum leak fault Check circuit vacuum
Check mixer-to-carburettor line vacuum
Check speed regulator
Check intake manifold
Global check Consult page 10
Idling speed too high Incorrect idling speed Check and adjust engine idling speed
Check engine speed regulator
Carburettor butterfly valve jammed Check valve
Change carburettor mounting assembly if necessary

8
4 - - MAINTENANCE GUIDE (continued)
PROBLEMS PROBABLE CAUSES PROBABLE SOLUTIONS
Carburettor flame back Incorrect full load adjustment Adjust full load carburetion
Adjust idling speed
Pressure reducer-to-carburettor connection fault Check pressure reducer-to-carburettor connection
Ignition fault Check ignition
Check ignition advance
Check vacuum on ignition
Repair or replace if necessary
Global check Consult page 10
Operating fault at full Liquid-phase LPG loop or line blocked Remove blockage. Test for leakage
speed
LPG filter solenoid or filter valve clogged Change filter
Pressure reducer-to-carburettor connection fault Check pressure reducer-to-carburettor connection
Carburettor butterfly valve opening fault Check valve Change carburettor mounting or carburettor if
necessary
Carburettor malfunction Clean carburettor
Test carburettor using TK-1000-F kit
Use repair kit if necessary
Replace carburettor (worn out) if necessary
Pressure reducer malfunction Test pressure reducer using TK-1000-F kit
Use repair kit if necessary
Ignition fault Check ignition
Check ignition advance
Check vacuum on ignition
Repair or replace if necessary
Clogged Air filter Check air filter
Change if necessary
Exhaust line blockage or partial blockage Check exhaust line
Check exhaust line counter-pressure
Global check Consult page 10
Excessive fuel consump- Carburettor malfunction Clean carburettor
tion Test carburettor using TK-1000-F kit
Use repair kit if necessary
Replace carburettor (worn out) if necessary
Ignition fault Check ignition
Check ignition advance
Check vacuum on ignition
Repair or replace if necessary
Global check Consult page 10
Pressure reducer malfunction Test pressure reducer using TK-1000-F kit
Use repair kit if necessary
Clogged Air filter Check air filter
Change if necessary

9
4 - - MAINTENANCE GUIDE (continued)

ENGINE SHUT DOWN ENGINE RUNNING


Check Carburetion circuit air tightness Check Thermostat functioning
Check LPG level in bottle or reservoir Check Alternator charging
Clean Battery Check Engine vacuum line
Check Battery cable Check Gas phase carburetion line
Clean Battery connections Check Ignition
Check Battery voltage Check Vacuum on ignition
Clean Battery earth line Check. Solenoid
Clean Starter motor power connections Check Carburettor idling setting
Clean Starter-to-engine block earth connection Check Carburettor full load setting
Check Radiator water Check 3-way catalyst system
Check Cooling water level
Check Radiator anti-freeze
Check Radiator internal clogging
Check Cooling circuit flexible hosing
Check Radiator fan
Check Water pump
Check Water pump drive belt
Check Electric circuit
Check Starter electric circuit
Check Ignition coil
Check Distributor system
Check Sparking plug leads
Check Sparking plugs
Check Alternator electric circuit
Check Alternator charging circuit
Check Fresh air aspiration
Check Air filter
Check Intake circuit
Check Bottle or reservoir positioning
Check LPG carburetion circuit
Check Solenoid or filter valve filtration
Check Solenoid electric circuit
Check Filter valve-to-carburettor line vacuum
Check Pressure reducer
Check Carburettor
Check Engine cylinder valves
Check Engine compression
Check Leaks in greasing lines

10
GROUP 20

GEAR BOX /
CONVERTER
GEAR BOX DISASSEMBLY/
TRANSMISSION
20-3-18 EN

16 / 01 / 2006
MANUALE NORME DI RIPARAZIONI
REPAIR INSTRUCTIONS
REPARATURANLEITUNG
NORMES DE REPARATION

TXL 15 - 25

3
TXL 15/25

I PREFAZIONE

Il presente manuale, destinato alla clientela ed al personale addetto alla manutenzione, contiene le infor-
mazioni e istruzioni per la manutenzione e la riparazione della trasmissione GRAZIANO Trasmissioni.
È tassativamente raccomandato ai meccanici di leggere attentamente le istruzioni riprese nel presente
manuale, al fine di familiarizzarsi con i vari elementi della trasmissione, con il funzionamento delle parti,
con la procedura da adottarsi, per la ricerca di guasti e delle messe a punto da effettuare; i meccanici
sono inoltre invitati a riferirsi al presente manuale ogni volta che eseguiranno operazioni di manutenzione
o di riparazione.
Nel caso che si necessiti di pezzi per la riparazione o la sostituzione di elementi, si dovranno utilizzare
soltanto pezzi approvati per GRAZIANO Trasmissioni, cioè i pezzi indicati nella nomenclatura dei pezzi
di ricambio in vigore. L’impiego di pezzi approssimativamente equivalenti o non approvati può portare
pregiudizio al funzionamento ed alle prestazioni del materiale. GRAZIANO Trasmissioni Equipment
Company non garantisce i pezzi utilizzati per la riparazione o la sostituzione che non siano quelli da lei
forniti o approvati; inoltre la sua garanzia non interverrà in caso di incidenti provocati dall’impiego di tali
pezzi.
Importante:
Ad ogni ordine di pezzi, indicare al concessionario il numero di serie ed il numero della
trasmissione.

GB FOREWORD

This manual has been prepared to provide the customer and the maintenance personnel with information
and instructions on the maintenance and repair of the transmission GRAZIANO Trasmissioni.

In order to become familiar with the various parts of the transmission, its principle of operation, trouble
shooting and adjustments, it is important for the mechanic to study the instructiotns of in this manual
carefully and use it as a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only GRAZIANO Trasmissioni appro-
ved spares as listed in the applicable spare catalogue should be used. Use of “will-fit” or non-approved
parts may endanger proper operation and performance of the equipment.
GRAZIANO Trasmissioni Equipment Company does not warrant repair or replacement parts; nor failures
resulting from the use thereof, which are not supplied by or approved by the GRAZIANO Trasmissioni
Equipment Company.
Important:
Always furnish the Distributor with the transmission serial and model number when ordering
parts.

D VORWORT
Diese Handbuch soll dem Kunden und dem Wartungspersonal zur Information und Hilfestellung in Bezug
auf Wartung und Instandsetzung des GRAZIANO Trasmissioni -Getriebes dienen.
Der Aufwand für die regelmässige Wartung und Überprüfung des Ölstandes und der Einstellungen zahlt
sich durch störungsfreien Betrieb aus. Es ist zu empfehlen, dass die Mechaniker sich mit dem Handbuch
und der Funktion des Getriebes vertraut machen, sowie die Anweisungen befolgen. Bei der Instandsetzung
oder dem Austausch von Einzelteilen müssen ausschliesslich GRAZIANO Trasmissioni -Originalteile
verwendet werden, die im Ersatzteilverzeichnis aufgeführt sind.
Bei Verwendung von Nicht- GRAZIANO Trasmissioni -Originalteilen ist die optimale Funktion nicht
gewährleistet. Fernerhin erlischt jeglicher Garantieanspruch.
Wichtig:
Bei der Bestellung von Ersatzteilen bitten wir Gerätetyp und Seriennummer des Getriebes
anzugeben. Technische Änderungen vorbehalten.

iii
TXL 15/25

F PREFACE

Ce manuel, destiné à la clientèle et au personnel préposé à l’entretien, contient tous les renseignements
et les instructions pour l’entretien et la réparation de la transmission GRAZIANO Trasmissioni.
C’est rigoureusement récommandé aux mécaniciens de lire soigneusement les instructions reprises dans
ce manuel, pour mieux comprendre les plusieurs éléments qui composent la transmission, le fonctionne-
ment del pièces, la procédure plus propre à suivre, pour la recherche de dérangements et des mises au
point à effectuer; en outre, les mécaniciens sont invités à consulter ce manuel en vue de chaque opéra-
tion d’entretien ou de réparation. Pour éventuelles réparations ou substitutions d’éléments, on devra utili-
ser uniquement des pièces approuvées pour GRAZIANO Trasmissioni, c’est à dire les pièces indiquées
dans la nomenclature des pièces de rechange en vigueur.
L’emploi de pièces approximativement équivalentes ou pas approuvées, peut compromettre le fonction-
nement et les performances du matériel. GRAZIANO Trasmissioni Equipment Company ne garanti
pas les pièces utilisées pour la réparation ou la substitution qui ne soient pas celles par elle fournies ou
approuvées; en outre, sa garantie n’est pas valable en cas d’incidents causés de l’emploi de ces pièces.
Important:
Dans chaque ordre de pièces, indiquer au concessionaire le numéro de série et le numéro de la
transmission.

iv
TXL 15/25

INDICE I

///
! NORME DI SICUREZZA

DATI TECNICI
ix

1
1 Trasmissione TXL 15/25 - Distributore Standard 1
Trasmissione TXL 15/25 - Distributore Supermodulato 3
Schema elettrico della trasmissione 5
Schema cinematico della trasmissione 6
Descrizione generale della trasmissione 7
Viste generali TXL 15/25 - Distributore Standard 10
Viste generali TXL 15/25 - Distributore Supermodulato 12
Sezione generale 14
CIRCUITO IDRAULICO DELLA TRASMISSIONE - DISTRIBUTORE STANDARD 16
2 Schema circuito idraulico
Schema A - Cambio in Folle
20
21
Schema B - Marcia Avanti Fase di avvio 22
Schema C - Marcia Avanti Carrello avviato 24
Schema D - Marcia Avanti in Inching 25
CIRCUITO IDRAULICO DELLA TRASMISSIONE - DISTRIB. SUPERMODULATO 26
Schema circuito idraulico 31
Schema A - Cambio in Folle 32
Schema B - Retromarcia, Carrello avviato 34
Schema C - Retromarcia in Inching 36
SMONTAGGIO E MONTAGGIO TRASMISSIONE 38
3 Istruzioni generali
Conservazione ed utilizzo del prodotto
38
42
Attrezzi speciali 44
Smontaggio e montaggio trasmissione 47
Smontaggio e rimontaggio distributore Standard 48
Smontaggio e rimontaggio gruppo valvola antishock 56
Smontaggio e rimontaggio distributore Supermodulato 59
Smontaggio e rimontaggio gruppi ruote 75
Sostituzione ganasce 76
Smontaggio mozzi ruote 83
Rimontaggio mozzi ruote 88
Smontaggio trasmissione 91
Rimontaggio trasmissione 106
Montaggio coppia conica 106
Controllo dentatura coppia conica 119
Rimontaggio distributore Standard 131
Rimontaggio distributore Supermodulato 133
TIPO OLIO 137
4 DATI ACCOPPIAMENTO MOTORE
Controllo accoppiamento motore-cambio
138
141
DATI TECNICI - PRELIEVO PRESSIONE Distributore Standard 142
DATI TECNICI - PRELIEVO PRESSIONE Distributore Supermodulato 144
RODAGGIO 146
5 MANUTENZIONE PERIODICA 147
RICERCA DIFETTI DI FUNZIONAMENTO 149
6 A - Indicazioni generali
B - Indicazioni di intervento
149
149
C - Diagnostica 153
Difetti di funzionamento comuni a tutte le marce 155
Anomalie di funzionamento a marce innestate 159
Problemi vari 161
Cattivo funzionamento in Folle 162
Surriscaldamento della trasmissione 163
ATTREZZI SPECIALI - DISEGNI 165
7
v
TXL 15/25

GB INDEX

///
! SAFETY RULES xi

TECHNICAL DATA 1
1 Transmission TXL 15 / 25 - Standard Distributor 1
Transmission TXL 15 / 25 -Supermodulating 3
Circuitry of the transmission 5
Kinematic diagram of the transmission 6
General description of the transmission 7
TXL 15/25 General views - Standard Distributor 10
TXL 15/25 General views - Supermodulating Distributor 12
General section 14
TRANSMISSION HYDRAULIC SYSTEM - STANDARD DISTRIBUTOR 17
2 Hydraulic diagram 20
Diagram A - Gear in Neutral position 21
Diagram B - Forward Gear (Starting) 22
Diagram C - Forward Gear Truck started 24
Diagram D - Reverse Gear in Inching 25
TRANSMISSION HYDRAULIC SYSTEM - SUPERMODULATING DISTRIBUTOR 27
Hydraulic diagram 31
Diagram A - Gear in Neutral position 32
Diagram B - Reverse gear, Started lift truck 34
Diagram C - Marche Arrière en Inching 36
DISMANTLING AND RE-ASSEMBLING OF THE TRANSMISSION 38
3 General instructions 39
Storage and service instructions 42
Tools 44
Dismantle and assemble transmission 47
Dismantling and re-assembling of the Standard Distributor 48
Dismantling and re-assembling of the antishock valve assembly 56
Dismantling and re-assembling of the Supermodulating Distributor 59
Wheel assembly dismantling and re-assembling 75
Shoes replacement 76
Wheel hub dismantly 83
Wheel hubs reassembling 88
Dismantling transmission 91
Reassebling transmission 106
Assembly of bevel gear 106
Bevel pinion-and-ring gear set inspection 119
Standard Distributor reassembly 131
Supermodulating Distributor reassembly 133
OIL SPECIFICATIONS 137
4 DATA FOR COUPLING TO ENGINE 138
Engine gearbox coupling check-up 141
TECHNICAL DATA - Standard Distributor pressure measurement 142
TECHNICAL DATA - Supermodulating Distributor pressure measurement 144
RUNNING-IN 146
5 PERIODIC SERVICING 147
TROUBLESHOOTING PROCEDURE 150
6 A - General information 150
B - Diagnosis of problems 150
C - Inspection 153
Common running faults in all gears 156
Running faults with gears engaged 159
Further problems 161
Bad working in idle 162
Transmission overheating 163
SPECIFIC TOOLS - DRAWINGS 165
7
vi
TXL 15/25

INHALTSVERZEICHNIS D

///
!
SICHERHEITS VORSCHRIFTEN xiii

TECHNISCHE DATEN 1
1 Getriebe TXL 15 / 25 - Standard-Steuerblock 2
Getriebe TXL 15 / 25 - Steuerblock Supermoduliert 4
Schaltplan des Getriebes 5
Kinematikdiagramm des Getriebes 6
Allgemeine Beschreibung 7
Generelle Ansicht TXL 15/25 - Standard-Steuerblock 10
Generelle Ansicht TXL 15/25 - Steuerblock Supermoduliert 12
Allgemeine Hinweise 14
GETRIEBE HYDRAULIKSYSTEM - STANDARD-STEUERBLOCK 18
2 Hydraulikschema 20
Schema A - Getriebe in Neutralstellung 21
Schema B - Vorwärtsgang - Startphase 22
Schema C - Vorwärtsgang Fahrzustand 24
Schema D - Inching Vorwärtsgang 25
GETRIEBE HYDRAULIK SYSTEM - STEUERBLOCK SUPERMODULIERT 28
Hydraulikschema 31
Schema A - Getriebe in Neutralstellung 32
Schema B - Getriebe in Rückwärtsgang, Fahrzustand 34
Schema C - Getriebe in Rückwärtsgang Inching 36
GETRIEBE DEMONTAGE UND MONTAGE 40
3 Allgemeine Anweisungen 40
Lager - und Service Hinweise 43
Montagewerkzeug 44
Getriebe Demontage und Montage 47
Demontage und Zusammenbau der Standard-Steuerblock 48
Demontage und Montage vom Antischockventil 56
Demontage und Zusammenbau der Steuerblock Supermoduliert 59
Bremsgruppe Demontage und Montage 75
Austausch Backen 76
Ausbau Radnaben 83
Einbau Bremstrommel 89
Getriebe Demontage 91
Getriebe Montage 106
Einbau der Kegelräder 106
Tragbildkontrolle der Kegelräder und Fehlersuche 119
Standard-Steuerblock Montage 131
Standard-Steuerblock Supermoduliert 133
GETRIEBE ÖLSPEZIFIKATION 137
4 EINBAUANWEISUNG 138
Rundlaufkontrolle 141
TECHNISCHE DATEN - Druckmessung Standard-Steuerblock 142
TECHNISCHE DATEN - Druckmessung Steuerblock Supermoduliert 144
INBETRIEBNAHME 146
5 REGELMÄßIGE WARTUNG 148
FEHLERSUCHE 151
6 A - Allgemeines 151
B - Schadenssuche bzw. -Behebung 151
C - Untersuchung 154
Gilt für alle funktionsstörungen 157
Funktionsstörungen bei eingelegtem gang 160
Sonstige probleme 161
Schlechter leerlaufbetrieb 162
Getribeüberhitzung 164
SPEZIALWERKZEUG - ZEICHNUNG 165
7
vii
TXL 15/25

F INDEX

///
! NORMES DE SURETE

DONNEES TECHNIQUES
xiii

1
1 Transmission TXL 15 / 25 - Distributeur Standard
Transmission TXL 15 / 25 - Distributeur Supermodulé
2
4
Schéma électrique de la transmission 5
Schéma cinematique de la transmission 6
Description générale 7
Vues générales TXL 15/25 - Distributeur Standard 10
Vues générales TXL 15/25 - Distributeur Supemodulé 12
Section générale 14
CIRCUIT HYDRAULIQUE DE LA TRANSMISSION - DISTRIBUTEUR STANDARD 19
2 Schéma du circuit hydraulique
Schéma A - Bôite de vitesse en position de Point Mort
20
21
Schéma B - Marche Avant Démarrage 22
Schéma C - Marche Avant Chariot en marche 24
Schéma D - Marche Avant en Inching 25
CIRCUIT HYDRAULIQUE DE LA TRANSMISSION - DISTRIBUTEUR SUPERMODULE 29
Schéma du circuit hydraulique 31
Schéma A - Bôite de vitesse en position de Point Mort 32
Schéma B - Marche arrière, Chariot en marche 34
Schéma C - Marche Arrière en Inching 36
DEMONTAGE ET REMONTAGE DE LA TRANSMISSION 41
3 Généralites
Conservation et utilisation du produit
41
43
Outils 44
Demontage et montage de la transmission 47
Demontage et remontage du Distributeur Standard 48
Demontage et remontage du groupe de vanne antichoc 56
Demontage et remontage du Distributeur Supemodulé 59
Démontage et Remontage des groupe des roues 75
Substitution des mâchoires 76
Démontage des moyeux des roues 83
Rémontage des moyeux des roues 89
Demontage de la transmission 91
Montage de la transmission 106
Montage du couple conique 106
Contrôle denture couple conique 119
Remontage du Distributeur Standard 131
Remontage du Distributeur Supemodulé 133
TYPE HUILE 137
4 DONNEES D’ACCOUPLEMENT MOTEUR
Contrôle accouplement moteur-bôite
138
141
DONNEES TECHNIQUES - Prelevement de pression Distributeur Standard 142
DONNEES TECHNIQUES - Prelevement de pression Distributeur Supemodulé 144
RODAGE 146
5 ENTRETIEN PERIODIQUE 148
RECHERCHE DE PANNES DE FONCTIONNEMENT 152
6 A - Généralites
B - Indications d’intervention
152
152
C - Diagnostic 154
Defauts de fonctionnement pour toutes les vitesse 158
Anomalies de fonctionnement avec marches mises 160
Problemes divers 161
Mauvais fonctionnement au Point Mort 162
Surcharge de la transmission 164
OUTILS SPECIAUX - PLAN 165
7
viii
TXL 15/25

I NORME DI SICUREZZA
///////
!

! ATTENZIONE A QUESTO SIMBOLO !


Questo simbolo di avvertimento segnala messaggi importanti che interessano la vostra sicurezza.
Leggete attentamente le norme di sicurezza riportate ed attenetevi alle precauzioni consiglia-
te al fine di evitare pericoli potenziali e salvaguardare la vostra salute ed incolumità personale.

EVITARE GLI INCIDENTI


La maggior parte degli incidenti ed infortuni che si verificano nelle officine sono causati dalla
mancata osservanza di qualche semplice e fondamentale regola di prudenza e sicurezza.
Per questa ragione nella maggior parte dei casi essi possono essere evitati: basta prevederne
le possibili cause ed agire di conseguenza con la necessaria cautela e prudenza.
Con qualsiasi tipo di macchina, per quanto ben progettata e costruita, non è possibile esclu-
dere in assoluto ogni eventualità di incidente.
Un meccanico attento e prudente è la migliore garanzia contro gli incidenti.
L’osservanza scrupolosa di una sola ed elementare norma di sicurezza sarebbe già suffi-
ciente ad evitare molti infortuni gravi.

PERICOLO! Non eseguire mai alcun intervento di pulizia, lubrificazione o manutenzione con
il motore in moto.

NORME DI SICUREZZA
GENERALITÀ

! Seguire attentamente le procedure di manutenzione e di riparazione prescritte.

Non indossare anelli, orologi da polso, gioielli, capi di vestiario slacciati o penzolanti quali
!
ad esempio: cravatte, indumenti strappati, sciarpe, giacche sbottonate o bluse con chiu-
sura a lampo aperte che possono impigliarsi nelle parti in movimento. Si consiglia invece
di usare capi appropriati ai fini antinfortunistici, ad esempio: scarpe antiscivolo, guanti, occhiali
di sicurezza, elmetti, ecc.

Non eseguire alcun intervento assistenziale sulla macchina con persone sul sedile conduttore,
! salvo che siano operatori abilitati e coadiuvino all’operazione da svolgere.

Non far funzionare la macchina od usare i relativi attrezzi da altra posizione che non sia
! quella a sedere del posto di guida.

Non eseguire mai alcun intervento sulla macchina quando il motore è in moto, salvo che
! ciò risulti prescritto.

Arrestare il motore ed accertarsi che non vi sia più pressione prima di staccare tubazioni,
! cappellotti, coperchi, valvole, etc.

! Tutti gli interventi assistenziali devono essere eseguiti con la massima cura ed attenzione.

Scollegare le batterie ed etichettare tutti i comandi per segnalare che un intervento è in


! corso.
Bloccare la macchina e ogni attrezzatura che deve essere sollevata.

ix
TXL 15/25

\\\\\\\\ !

I freni sono inattivi quando vengono rilasciati manualmente per interventi assistenziali: in
! tali casi occorre provvedere a mantenere il controllo della macchina mediante opportuni
bloccaggi o simili.

Dovendo sollevare o trasportare delle parti pesanti, servirsi di paranchi e simili di adeguata
! capacità.

! Prestare particolare attenzione alla presenza di persone nelle vicinanze.

! Non versare mai benzina o gasolio in recipienti aperti, ampi e bassi.

Non utilizzare mai benzina, gasolio od altri liquidi infiammabili come detergenti: ricorrere
! invece ai solventi commerciali ininfiammabili e non tossici.

Impiegando aria compressa per la pulizia dei particolari, proteggersi con occhiali aventi
! ripari laterali.

! Limitare la pressione ad un massimo di 2,1 bar secondo le norme vigenti locali o nazionali.

Non servirsi di fiamme come mezzo di illuminazione quando si procede ad operazioni o


! si ricercano perdite sulla macchina.

Spostarsi con ogni cautela quando si debbano eseguire lavori sotto la macchina, indos-
! sare gli equipaggiamenti di sicurezza previsti: elmetti, occhiali e scarpe speciali.

La zona dove si svolgono operazioni di manutenzione deve essere tenuta sempre PULITA
! ed ASCIUTTA. Eliminare immediatamente eventuali pozze dʼacqua o macchie dʼolio.

In caso di avaria il carrello può essere trainato per distanze inferiori a 2 km a velocità non
! superiore a 10 km/h. Non è consentito accendere il motore del veicolo in fase di rimorchio,
questo potrebbe causare danno alla trasmissione.

x
TXL 15/25

GB SAFETY RULES
///////
!

! WATCH FOR THIS SIGN !


This sign identify important messages devoted to your safety.
Read carefully safety rules reported here and follow with the greatest care all recommended sugge-
stion to avoid potential dangers and protect your health and personal safety.

AVOID CAUSALITIES

Most of all injuries and accidents that are encountered in workshops are caused by disre-
garding some simple and basic caution and safety rule.
For this reason most of these events can be avoided. To anticipate possible causes will suffice and
acting accordingly with proper care and caution.
Each kind of operating machine, even if correctly planned and assembled, cannot be abso-
lutely safe.
A cautious and careful operator is the best warrant against injuries.
Following scrupulously safety rule will be sufficient to prevent many dangerous injuries.

DANGER! Don’t clean, lubricate or service with engine running.

SAFETY RULES
GENERAL

! Follow strictly directions reported for servicing and repair operations.

Don’t wear rings, wrist watches, loose clothes, i.e.: neckties, torn clothing, scarves,
!
unbuttoned jackets or overall with open zip that could be entangled in moving parts.
It is recommended use of proper accident preventing clothing, i.e.: anti-slip shoes,
gloves, goggles helmets, etc.

Don’t start any servicing operation on machine with anyone on driver seat, except for
!
authorized operator that cooperate for the work to be done.

! Don’t operate machine or use relevant equipment from position other than driver’s seat.

! Don’t service machine with engine running, if not specified by repair instructions.

Stop engine and make sure there is no pressure when disconnecting piping, caps, covers,
! valves, etc.

! All servicing operations must be performed with best attention and care.

Disconnect batteries and mark all controls to point out that servicing operations are on
! course. Block machine, all equipment must be lifted up, and mechanically secured accor-
dingly, with the appropriate device.

Brakes are inoperative when hand released for servicing operations: in such a condition machine
! control should be provided by proper blocks or similar equipment.

! Should heavy components be displaced or moved, use proper hoist or similar equipment.

xi
TXL 15/25

\\\\\\\\ !

! Care for people near operation areas.

! Never pour gasoline or diesel fuel in open, large and low vessels.

Never use gasoline, diesel fuel or other inflammable fluids as detergent. Use only commer-
! cial non toxic, uninflammable cleaning compounds.

! When using compressed air for cleaning purposes wear goggles with side shields.

! Pressure must be limited to 2.1 bar max., according current safety rules.

! Never use free flame for illumination when operations are devoted to repair or locate leaks.

Caution when repair shall be carried out working under machine, wear safety equipment:
! helmets, goggles and safety shoes.

Area where servicing operations are carried out must be always kept CLEAN and DRY.
! Clean and dry immediately any oil or water puddle.

In case of problem, towing of vehicle is only allowed for a distance of less than 2 km with
! maximum towing speed of 10 km/h. It is not possible to start the engine through towing
the vehicle, this can cause damage to the transmission.

xii
TXL 15/25

D SICHERHEITS VORSCHRIFTEN
///////
!

! BEACHTE DIESES ZEICHEN !


Dieses Zeichen bedeutet wichtige Information bezüglich Sicherheit. Lese und Beachte unbedingt
die Sicherheitsbestimmungen die hier beschrieben sind und folge mit größter Aufmerksamkeit allen
Anweisungen um potentielle Gefahren zu vermeiden sowie zum Schutz von Gesundheit und persönli-
cher Sicherheit.

VERMEIDE KAUSALITÄTEN

Die meisten Unfälle und Verwundungen in Werkstätten entstehen durch Ignoranz und Nichtbeachtung
der einfachsten und grundlegenden Vorsichts- und Sicherheitsbestimmungen.
Die meisten dieser Vorkommnisse können vermieden werden. Durch Abschätzung möglicher
Gefahren kann entsprechend verfahren werden und richtiges Verhalten vermeidet Gefahr.
Jede Art von Maschine, selbst wenn richtig geplant und gebaut, kann nicht absolut sicher sein.
Ein Verantwortungsvoller und Sicherheitsbewußter Fahrer ist die beste Garantie gegen Unfälle.
Die strikte Anwendung einfacher elementarer Sicherheitsregeln ist ausreichend um viele gefährliche
Unfälle zu vermeiden.

GEFAHR! Alle Reinigungs-Abschmier-oder Service Arbeiten sollen nicht bei Laufendem Motor
vorgenommen werden.

SICHERHEITS BESTIMMUNGEN
GENERELL

! Folge strikt den Anweisungen für Service - und Reparaturarbeiten.

Trage keine Ringe, Armbanduhren, lose Kleidung, wie zum Beispiel Krawatten, zerrissene
! Kleidung, Schales, ungeknöpfte Jacken oder Overalls mit offenem Reißverschluß welche
durch rotierende / bewegte Teile erfasst werden können.

Beginne keine Service Arbeiten, wenn jemand im Fahrersitz ist, Ausnahme nach Absprache
! für Funktionen zur Durchführung einer Arbeit.

! Bewege keine Maschine oder Komponenten von einer Position anders als vom Fahrersitz.

Führe keine Service Arbeiten durch wenn der Motor läuft, es sei denn es ist in den
! Reparaturanweisungen spezifiziert.

Stelle den Motor ab und stelle sicher, daß kein Druck vorhanden ist wenn Rohre,
! Schläuche, Kappen, Deckel, Ventile oder ähnliches abgeschraubt wird.

Alle Service Operationen müssen mit der größtmöglichen Aufmerksamkeit und Vorsicht
! ausgeführt werden.

Trenne Batterie Verbindungen und markiere alle Kontroll Instrumente um anzuzeigen, daß
! Service Arbeiten ausgeführt werden.

Blockiere die Maschine, alle Anbauten müssen in oberste Stellung gebracht werden und mecha-
! nisch gesichert mit den entsprechenden Stützen.

xiii
TXL 15/25

\\\\\\\\ !

Bremsen sind nicht in Funktion wenn durch Hand freigegeben für Service arbeiten. In
! diesem Zustand muß die Maschine durch entsprechende vorgeschriebene Keile oder Blöcke
gesichert sein.

Zum Bewegen von schweren Teilen wenn erforderlich, muß das entsprechende Hebezeug
! verwendet werden.

! Vorsicht für Leute die in unmittelbarer Umgebung arbeiten.

! Benütze und fülle niemals Benzin oder Diesel in offenen großen und niedrigen Behältern.

Benütze niemals Benzin, Diesel oder andere entzündbare Flüssigkeiten als Reinigungsmittel,
! benütze nur kommerzielle, ungiftige, nichtbrennbare Reinigungsmittel.

! Bei Benützung von Druckluft zur Reinigung trage Schutzbrille mit Seitenschutz.

Druck muß reduziert sein auf 2,1 bar Maximum, entsprechend der momentanen
! Sicherheitsvorschriften.

Benütze niemals eine offene Flamme zur Beleuchtung wenn Arbeiten notwendig sind um
! Leckagen zu finden oder zu Reparieren.

Vorsicht wenn Arbeiten unter der Maschine notwendig sind, trage Sicherheitskleidung wie Helm,
! Sicherheitsbrille und Sicherheitsschuhe.

Der Arbeitsplatz wo Service Arbeiten durchgeführt werden muß immer sauber und trocken sein.
! Beseitige unmittelbar Öl oder Wasser Pfützen.

Im Schadensfall darf Fahrzeug über eine Stecke von weniger als 2 km mit einer maximalen
! Geschwindigkeit von 10 km/h abgeschleppt werden.
Durch Schleppen des Fahrzeuges kann der Motor nicht angeworfen werden.
Jeder Anschleppversuch kann Schäden im Getriebe hervorrufen und muß deshalb unter-
bleiben.

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TXL 15/25

F NORMES DE SURETE
///////
!

! ATTENTION A CE SYMBOL !
Ce symbol d’avertissement signale des messages importants concernants votre sûreté. Lire soigneuse-
ment les normes de sûreté mentionnées et se conformer aux précautions conseillées au but d’éviter dan-
gers éventuels et sauvegarder votre santé et votre sûreté personnelles.

EVITER LES ACCIDENTS

Les accidents les plus fréquents dans les usines se vérifient à cause de la manquée observation de
quelques simples et fondamentales règles de prudence et sûreté.
Pour cette raison presque toujours est possible de les éviter: il suffit prévoir les causes possibles et
agir par conséquent avec la prudence nécessaire.
Pour tous les modèles de machine, même si bien projetée et construite, il n’est pas possible
d’exclure du tout les éventualités d’accident.
Un mécanicien diligent et prudent est la meilleure garantie contre les accidents.
L’observation scrupuleuse d’une seule et élementaire norme de sûreté serait déjà suffisante à éviter
beaucoup d’accidents graves.

DANGER! Ne jamais exécuter aucune intervention de nettoyage, lubrification ou entretien à


moteur en marche.

NORMES DE SURETE
GENERALITES

! Suivre soigneusement les procédures d’entretien et de réparation prescrittes.

Ne pas mettre de bagues, montres, bijoux, pièces déboutonnés ou pendillantes, par


! exemple: cravates, vêtements déchirés, écharpes, vestes déboutonnées ou blouses
avec charnieres ouvertes qui peuvent s’accrocher dans les parties en mouvement.
Il est conseillé plutôt d’ utiliser des pièces appropriées anti-accidents, par exemple chaussures
antiglisse, gants, lunettes de sûreté, casques, etc.

N’exécuter aucune intervention d’assistance sur la machine avec des personnes à la


! place du conducteur à moins qu’ils soyent des opérateurs certifiés coadjuvants à l’opé-
ration à effectuer.

Ne pas actionner la machine ou utiliser les relatifs outils d’une position différente de la
! place du conducteur.

Ne jamais exécuter aucune intervention sur la machine à moteur en marche si non


! demandé.

Arrêter le moteur et s’assurer qu’il n’y a plus de pression avant de détacher tuyauteries,
! capuchons, couvercles, soupapes, etc.

Toutes les interventions d’assistance doivent être effectuées avec le plus grand soin et
! attention.

Disjoindre les batteries et étiquetter toutes les commandes pour signaler qu’une interven-
! tion est en cours. Bloquer la machine et tous les outillages qui doivent être soulevés.

xv
TXL 15/25

\\\\\\\\ !

! Les freins sont inactifs quand on les rêlache manuelment à cause d’interventions d’assi-
stance: dans ces cas il faut s’occuper de maintenir le contrôle de la machine au moyen
d’ opportuns blocages ou similaires.

Pour soulever ou transporter des parties lourdes se servir de palans et similaires d’adé-
!
quate capacité.

! Faire beaucoup d’attention à la présence de personnes dans les voisinages.

! Ne jamais verser d’essence ou gaz-oil dans des récipients ouverts, amples et bas.

Ne jamais utiliser d’essence, gaz-oil ou autres liquides inflammables comme détergents:


!
utiliser plutôt des solvants commerciaux ni inflammables ni toxiques.

En employant de l’air comprimé pour le nettoyage des éléments, se protéger par des
!
lunettes avec protection de chaque côté.

Limiter la pression à un maximum de 2,1 bar selon les lois en vigueur du lieu ou natio-
! nales.

Ne pas se servir de flammes comme moyen d’éclairage quand on procède à opérations


!
ou on recherche des pertes sur la machine.

Se déplacer avec beaucoup de prudence quand on doit exécuter des travaux sous la
!
machine, utiliser les équipements de sûreté prévus: casques, lunettes et chaussures
spéciales.

La zone ou se déroulent les opérations d’entretien doit être tenue toujours propre et
!
seche. Éliminer immédiatement éventuelles flaques d’eau ou taches d’huile.

En cas de panne, le chariot, peut être traîné pour des distances inférieures à 2 km et une
!
vitesse non supérieure à 10 km/h. La mise en marche du véhicule est interdite en phase de
remolque: cela pourrait provoquear un dommage à la transmission.

xvi
TXL 15/25

DATI TECNICI
TECHNICAL DATA
TECHNISCHE DATEN
DONNEES TECHNIQUES
1

Trasmissione TXL 15 / 25 - Distributore Standard I

Frizioni cambio powershift: pressione di comando min. 10 bar, max. 11 bar


Convertitore: ■ pressione ingresso min. 4 bar, max. 5 bar
■ pressione uscita min. 2 bar, max. 3 bar
Lubrificazione: pressione lubrificazione 0,8 ÷ 1,2 bar
Nota: i dati riportati sono riferiti alla trasmissione in condizioni di temperatura di regime (80 - 100°C)
e regime motore di circa 2.000 giri al minuto e comunque prossimo al regime massimo.
Temperatura: ■ funzionamento di regime: 80 - 100°C
■ picco: 120°C

Tipo, qualità d’olio e quantità: Vedere pag. 137


Filtro olio: ■ filtro in aspirazione alla pompa a rete grado di filtraggio
50 µm.

filtro interno al distributore, ! ATTENZIONE !
da eliminare al termine del rodaggio (dopo 60÷80
ore), grado di filtraggio 30 µm (Vedere pag. 132).
Impianto elettrico: ■ tensione: 12 V C.C. (24 V C.C.)
■ potenza: 5 W

Transmission TXL 15 / 25 - Standard Distributor GB

Powershift transmission clutches: operational pressure min. 10 bar, max 11 bar


Converter: input pressure min. 4 bar, max. 5 bar

■ output pressure min. 2 bar, max. 3 bar

Lubrication: pressure 0.8 - 1.2 bar


Note: the above mentioned data refer to an operative temperature of 80 - 100°C and a engine speed
of about 2000 r.p.m.
Temperature: ■ normal operation: 80 - 100°C
■ peak: 120°C

Oil type, quality and quantity: see page 137


Oil filter: ■ pump mesh intake filter, filtering capacity 50 µm

■ filter inside distributor, ! WARNING !


which must be removed at the end of the running-in
period (60-80 hrs. after), filtering capacity 30 µm
(see page 132).

Electrical installation: ■ voltage: 12 V d.c. (24 V d.c.)


■ power: 5 W

1
TXL 15/25

D Getriebe TXL 15 / 25 - Standard-Steuerblock


Lastschaltgetriebe-Kupplungen: Betriebsdruck min. 10 bar, max. 11 bar
Drehmomentwandler: Eingangsdruck min. 4 bar, max. 5 bar

■ Ausgangsdruck min. 2 bar, max. 3 bar

Schmierung: Druck 0,8 - 1,2 bar


Anmerkung: obige Daten beziehen sich auf eine Getriebeöltemperatur von ~ 80 - 100°C
und eine Motordrehzahl ~ 2000 U/min.
Temperatur: ■ normale Betrebsbedingunge: 80 - 100°C
■ max.: 120°C

Ölsorte, Ölqualität und Ölmenge: Siehe Seite 137


Ölfilter: ■ Pumpenansaug-Siebfilter Filterfeinheit 50 µm

■ Filter im Innern des Verteilers, ! ACHTUNG !


das nach der Einfahrzeit zu entfernen ist (nach
60-80 Stunden), Filtrierfeinheit 30 µm (Siehe Seite
132).

Elektrische Installation: ■ Spannung: 12 V Gleichstrom (24 V Gleichstrom)


■ Leistung: 5 W

F Transmission TXL 15 / 25 - Distributeur Standard


Embrayages: pression de commande 10 bar mini, 11 bar maxi
Convertisseur: ■pression d’entrée 4 bar mini, 5 bar maxi
■ pression sortie 2 bar mini, 3 bar maxi

Lubrification: pression 0,8 à 1,2 bar


Note: les données susmentionnées se rapportent à la transmission utilisée dans des conditions
de température normales (80 à 100°C) et à un régime moteur maxi de 2000 tr/min.
Température: ■ fonctionnement en régime constant 80 - 100°C
■ en charge: 120°C

Type d’huile, genre et quantité: voir page 137


Filtre à huile: ■ filtre à tamis monté sur l’aspiration de la pompe, degré

de filtration 50 µm
■ filtre à l’interieur du distributeur, ! ATTENTION !
à retirer à la fin du rodage (après 60-80 heures),
degré de filtration 30 µm (voir page 132)
Equipment électrique: ■ Tension: 12 V C.C. (24 V C.C.)
■ Puissance: 5 W

2
TXL 15/25

DATI TECNICI
TECHNICAL DATA
TECHNISCHE DATEN
DONNEES TECHNIQUES
1

Trasmissione TXL 15 / 25 - Distributore Supermodulato I

Frizioni cambio powershift: pressione di comando min. 10 bar, max. 11 bar

Convertitore: ■ pressione ingresso min. 4 bar, max. 5 bar


■ pressione uscita min. 2 bar, max. 3 bar
Lubrificazione: pressione lubrificazione 0,8 ÷ 1,2 bar
Nota: i dati riportati sono riferiti alla trasmissione in condizioni di temperatura di regime (80 - 100°C)
e regime motore di circa 2.000 giri al minuto e comunque prossimo al regime massimo.
Temperatura: ■ funzionamento di regime: 80 - 100°C
■ picco: 120°C

Tipo, qualità d’olio e quantità: Vedere pag. 137


Filtro olio: ■ filtro in aspirazione alla pompa a rete grado di filtraggio
25 µm.
Impianto elettrico: ■ tensione: 12 V C.C. (24 V C.C.)
■ potenza: 26 W

Transmission TXL 15 / 25 -Supermodulating Distributor GB

Powershift transmission clutches: operational pressure min. 10 bar, max 11 bar


Converter: input pressure min. 4 bar, max. 5 bar

■ output pressure min. 2 bar, max. 3 bar

Lubrication: pressure 0.8 - 1.2 bar


Note: the above mentioned data refer to an operative temperature of 80 - 100°C and a engine speed
of about 2000 r.p.m.
Temperature: ■ normal operation: 80 - 100°C
■ peak: 120°C
Oil type, quality and quantity: see page 137
Oil filter: ■ pump mesh intake filter, filtering capacity 25 µm
Electrical installation: ■ voltage: 12 V d.c. (24 V d.c.)
■ power: 26 W

3
TXL 15/25

D Getriebe TXL 15 / 25 - Steuerblock Supermoduliert


Lastschaltgetriebe-Kupplungen: Betriebsdruck min. 10 bar, max. 11 bar
Drehmomentwandler: Eingangsdruck min. 4 bar, max. 5 bar

■ Ausgangsdruck min. 2 bar, max. 3 bar

Schmierung: Druck 0,8 - 1,2 bar


Anmerkung: obige Daten beziehen sich auf eine Getriebeöltemperatur von ~ 80 - 100°C
und eine Motordrehzahl ~ 2000 U/min.
Temperatur: ■ normale Betrebsbedingunge: 80 - 100°C
■ max.: 120°C

Ölsorte, Ölqualität und Ölmenge: Siehe Seite 137


Ölfilter: ■ Pumpenansaug-Siebfilter Filterfeinheit 25 µm

Elektrische Installation: ■ Spannung: 12 V Gleichstrom (24 V Gleichstrom)


■ Leistung: 26 W

F Transmission TXL 15 / 25 - Distributeur Supermodulé


Embrayages: pression de commande 10 bar mini, 11 bar maxi
Convertisseur: ■pression d’entrée 4 bar mini, 5 bar maxi
■ pression sortie 2 bar mini, 3 bar maxi

Lubrification: pression 0,8 à 1,2 bar


Note: les données susmentionnées se rapportent à la transmission utilisée dans des conditions
de température normales (80 à 100°C) et à un régime moteur maxi de 2000 tr/min.
Température: ■ fonctionnement en régime constant 80 - 100°C
■ en charge: 120°C

Type d’huile, genre et quantité: voir page 137


Filtre à huile: ■ filtre à tamis monté sur l’aspiration de la pompe, degré

de filtration 25 µm
Equipment électrique: ■ Tension: 12 V C.C. (24 V C.C.)
■ Puissance: 5 W

4
TXL 15/25

Schema elettrico
Circuitry
Schaltplan
Schéma électrique
1
Distributore standard
2
Standard distributor
Standard-Steuerblock
Distributeur standard I 1 -Commutatore
2 -Fusibile
3 -Lampadina
1 4 -Elettrovalvola
Tensione 12/24 V CC/DC
Potenza 5 W
3 5 -Distributore
3
6 -Elettrovalvola
Marcia Avanti Retromarcia Tensione 12/24 V CC/DC
Forward Clutch Reverse Clutch Potenza 26 W
Vorwärts Rückwärts
Marche Avant Marche Arrière GB 1 - Commutator
2 - Fuse
3 - Electric Bulb
4 - Solenoid valve
Voltage 12/24 V CC/DC
Power 5 W
4 4 5 - Valves body
6 - Solenoid valve
Voltage 12/24 V CC/DC
5 Power 26 W
D 1 - Schalter
P. P.
2 - Sicherung
M.A R.M. 3 - Kontrolleuchte
4 - Magnetventil
Spannung 12/24 V CC/DC
Distributore supermodulato Leistung 5 W
Supermodulating distributor 5 - Steuerblock
Steuerblock supermoduliert 6 - Magnetventil
Distributeur supermodulé Spannung 12/24 V CC/DC
2 Leistung 26 W

- F 1 - Commutateur
+
2 - Fusible
1 3 - Ampoule
Marcia Avanti Retromarcia
4 - Electrovannes
Forward Clutch Reverse Clutch
Vorwärts Rückwärts Tension 12/24 V CC/DC
Marche Avant Marche Arrière Puissance 5 W
5 - Distributeur
3 3 6 - Electrovannes
Tension 12/24 V CC/DC
Puissance 26 W

Marcia Avanti
6 Forward Clutch
Vorwärts
Marche Avant

Retromarcia
Reverse Clutch
Rückwärts
Marche Arrière
5

5
TXL 15/25

Schema cinematico della trasmissione


Kinematic diagram of the transmission
Kinematikdiagramm des Getriebes
Schéma cinematique de la transmission

Retromarcia Marcia Avanti


Reverse Clutch Forward Clutch
Rückwärts Vorwärts
Marche Arrière Marche Avant

Presa di Forza
Power take off
Nebenabtrieb
Prise de force

Entrata
Input
Eingang
Entrée

Uscita
Output
Ausgang
Sortie

6
TXL 15/25

I Descrizione generale
La trasmissione è dotata di convertitore monostadio con ruota libera per ottenere i massimi rendi-
menti con bassi rapporti di slittamento. Ha due frizioni idrauliche (una avanti, una indietro) a dischi
1
multipli in bagno d’olio con ingranaggi sempre in presa, aventi rapporti uguali per l’avanti e per l’indietro.
La selezione del senso di marcia è ottenuta per mezzo di selettori idraulici servocomandati elettri-
camente. Il gruppo è racchiuso in una scatola nella quale sono incorporati sistemi idraulici per l’at-
tuazione delle frizioni e la coppa dell’olio.

GB General description
The transmission is equipped with a single-stage converter with free wheel. Thus a high efficiency over
the whole range of operation is achieved. It has two hydraulic clutches (one for Forward Gear and
one for Reverse Gear) with multiple wet disks, while the constant mesh gears have the same ratio in
Forward and Reverse Gear. The selection of direction is effected by hydraulic selectors, which are
controlled electrically.
The group is fitted into a housing equipped with hydraulic pistons for the actuation of the clutches.

D Allgemeine Beschreibung
Das Getriebe ist mit einem eistufigen Wandler mit Leitradfreilauf ausgerüstet. Damit wird ein hoher
Wirkungsgrad über den gesamten Betriebsbereich erreicht. Es hat zwei hydraulische Lamellen
Kupplungen (eine für den Vorwärtsgang und eine für den Rückwärtsgang), wobei die ständig im
Eingriff befindlichen Zahnräder für Vorwärts- und Rückwärtsgang dasselbe Übersetzungsverhältnis
haben.
Die Lamellenkupplungen werden hydraulisch geschlossen.
Die Schaltung erfolgt über elektrisch betätigte Magnetventile.

F Description générale
La transmission comprend un convertisseur de couple monoétage, une bôite à inverseur mono-vitesse,
embrayable sous charge grâce à deux embrayages hydrauliques multi-disques (un pour la Marche
Avant et un pour la Marche Arrière).
Les engrenages sont tous en prise constante et supportés par des roulements tournants.
La sélection du sens de marche s’effectue au moyen de sélecteurs hydrauliques électro-pilotés.

I Accoppiamento al motore
Un accoppiamento al motore mediante piatto flessibile collega direttamente il convertitore di cop-
pia con il volano motore (vedi pag. 138 - 139).

GB Connection engine - converter


The converter is connected to the engine flywheel via flexible drive plate (see page 138 - 139).

D Verbindung Motor - Wandler


Der Drehmomentwandler wird mit einer axial-elastischen Membrane am Motorschwungrad
angeflanscht (siehe Seite 138 - 139).

F Accouplement au moteur
Un accouplement à plateau élastique relie directement le convertisseur de couple au volant-moteur
(voir page 138 - 139).

I Convertitore di coppia
Il convertitore monostadio è studiato per ottenere la massima flessibilità e le massime prestazioni
in accoppiamento al motore termico. Esso è in grado di trasmettere coppie ben superiori a quelle
fornite dal motore e di conseguenza garantisce la massima affidabilità.

GB Torque converter
The single-stage converter has been designed to obtain maximum flexibility when being connected
to different engines with different performances. It is able to transmit considerable power and
guarantees maximum reliability.

7
TXL 15/25

D Drehmomentwandler
Der einstufige Drehmomentwandler wurde so ausgelegt, daß grüßtmögliche Flexibilität beim Anbau an
verschiedene Motoren unterschiedlicher Leistung erreicht wird.

F Convertisseur de couple
Le convertisseur mono-étage à roue libre est conçu pour obtenir une souplesse, un rendement, et des
performances optima, dans son accouplement au moteur thermique. Cet organe, qui permet de
transmettre des couples supérieurs à ceux fournis par le moteur, garantit donc une fiabilité maximale.

MARCIA AVANTI RETROMARCIA


FORWARD GEAR REVERSE GEAR
VORWÄRTSGANG RÜCKWÄRTSGANG
MARCHE AVANT MARCHE ARRIERE

I Frizioni
Sono ad azionamento idraulico. La trasmissione del moto avviene tramite 3 dischi (6 superfici di
attrito attive) a lubrificazione e raffreddamento forzati. Oltre ad una elevata capacità di coppia tra-
smissibile statica e dinamica, dispongono di una elevata capacità di assorbimento di energia cinetica
durante i cambi di marce. L’impacchettamento delle frizioni viene effettuato dallo spostamento assia-
le di un pistone sotto la spinta di olio in pressione, mentre il ritorno del pistone, e quindi di distacco
dei dischi, è assicurato da una molla.

GB Clutches
These are hydraulically operated. The drive is transmitted via force-lubricated, force-cooled plates (6
active friction surfaces). In addition to high static and dynamic transmissible torque capacity, they also
have a high kinetic energy absorption capacity during gearchanges. Clutch engagement is through
piston displaced axially under fluid pressure. A spring pushes the piston back and the plates are then
released.

D Kupplungen
Sie werden hydraulisch beaufschlagt. Das Drehmoment erfolgt über 3 zwangsgeschmierte
und gekühlte Lamellen (6 aktive Reibflächen). Sie bieten eine hohe statische und dynamische
Drehmomentenkapazität.

F Embrayages
Hydrauliques. La transmission du mouvement est assurée apr 3 disques (6 surfaces de friction
actives), à graissage et refroidissement forcés. En plus d’une capacité élevée de couple statique et
dynamique transmissible, les embrayages possèdent une capacité également élevée d’absorption
d’énergie cinétique, pendant les changements de marche. Le pack d’embrayages est réalisé par
déplacement axial d’un piston sous la poussée de l’huile sous pression, alors que le retour au repos
du piston et des disques est assuré par un ressort.

8
TXL 15/25

Presa di forza
1
I
È azionata direttamente dal motore termico. Alla presa di forza è flangiata la pompa idraulica per
l’impianto idraulico di sollevamento e di sterzatura.
Pompa
Una pompa olio a ingranaggi con velocità di rotazione pari a quella del motore è montata coassia-
le all’albero di ingresso all’esterno della trasmissione per facilitare la manutenzione. L’aspirazione
dell’olio dalla coppa avviene tramite condotto ricavato nella fusione del carter con filtro a rete.
Distributore di comando e controllo
Il distributore è situato esternamente sul carter della trasmissione. Riceve la portata di olio dalla
pompa e incorpora dispositivi che controllano il flusso e la pressione della medesima per il corret-
to funzionamento del convertitore, delle frizioni e della lubrificazione. È dotato di valvola modula-
trice e valvola antishock (solo per versione distributore standard) che permettono cambi di dire-
zione e avviamenti graduali senza urti.

GB Power take-off
It is driven by the thermic motor. The rotating direction as well as the speed correspond to that of
the engine. The hydraulic pump for the lifting and steering system is flanged to the PTO.
Pump
A gear oil pump that rotates at the same speed as the engine, is mounted coaxially with the direct
drive shaft outside the transmission so as to facilitate maintenance. Oil is sucked from the sump
via a tube in the transmission case casting, and passes through a mesh filter.
Control distributor
The distributor is situated on the outside of the transmission case. It receives the oil delivered by
the pump and incorporates devices that control the flow and pressure of the oil to ensure that the
converter, the clutches and the lubrication system all operate correctly. It is provided with a modu-
lator valve and anti-shock valve (standard distributor version only), which ensure gradual, shock-
free gear changes and start-ups.

D Nebenabtrieb (PTO)
Er wird über die Wärmerkraftmaschine. Die Drehzahl, sowie die Drehrichtung entsprechen denen
des Motors. Die Hydraulikpumpe für das Hub- und Lenksystem kann an den Nebenabtrieb ange-
flanscht werden.
Pumpe
Koaxial (hinter dem Nebenabtrieb) ist eine Zahnradpumpe angebracht, die über den Wandler und
einer Welle in abhängigkeit der Motordrehzahl angetrieben wird. Die Ölansaugung vom Sumpf
erfolgt über einen Filter.
Getriebesteuerung
Das Steuerventil ist außen seitlich am Getriebegehäuse angebracht. Es leitet den Ölstrom von
der Pumpe über einen Filter. Es hat Meßstellen für Ölfluß und Drücke, damit der korrekte Betrieb
des Wandlers, der Schaltkupplungen, der Inchsteuerung und des Schmiersystems kontrolliert
werden kann. Es ist mit einem Modulations- und einem Anti-Schock-Ventil ausgerüstet (Nur
Standardversion-Steuerblock), welche Fahrtrichtungswechsel und Anfahren ohne Stöße ermögli-
chen.

F Prise de force
Elle est actionnée par le moteur termique. A la prise de force est bridée la pompe hydraulique
pour l’installation hydraulique de soulèvement et de coup de volant.
Pompe
Une pompe à huile à engrenages à vitesse de rotation égale à celle du moteur, est montée coaxia-
lement sur l’arbre d’entrée, à l’extérieur de la transmission, pour faciliter l’entretien. L’aspiration de
l’huile dans le carter es assurée par un conduit venu de fonderie du carter de transmission, avec
filtre à tamis.
Distributeur de commande et de controle
Le distributeur est placé extérieurement au carter de la transmission. Il reçoit le débit d’huile de la
pompe par le filtre et incorpore des dispositifs qui contrôlent le flux et les pressions du fluide pour
assurer un correct fonctionnement du convertisseur, des embrayages, de l’Inching contrôle et de
la lubrification. Il est équipé d’une vanne modulatrice et d’une vanne anti-choc (seulement version
Distributeur standard) qui permettent des changements de direction et démarrages graduels et
sans coups.
9
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Viste generali TXL 15/25 - Distributore Standard


TXL 15/25 General views - Standard Distributor
Generelle Ansicht TXL 15/25 - Standard-Steuerblock
Vues générales TXL 15/25 - Distributeur Standard

L C R P G B INCHING MECCANICO G
MECHANICAL INCHING
MECHANISCHES INCHING
INCHING MECANIQUE
INCHING IDRAULICO
HYDRAULIC INCHING
HYDRAULISCHES INCHING
INCHING HYDRAULIQUE

S D M N D

I A - Tappo intr. e filtro olio cambio 50µ D A - Einfüllstutzen und Ölfilter Getriebe 50µ
B - Elettrovalvola Marcia Avanti B - Elektromagnetventil Vorwärtsgang
C - Elettrovalvola Retromarcia C - Elektromagnetventil Rückwärtsgang
D - Tappi scarico olio D - Ölablaßschraube
E - Sfiati E - Entlüfter
F - Tappo riemp. livello olio ponte F - Einfüllstutzen - Ölstand Achse
G - Comando Inching G - Inchsteuerung
H - Convertitore H - Wandler
K - Presa pressione principale K - Hauptdruckmeßstelle
L - Asta livello olio L - Ölpeilstab
M - Ritorno scambiatore M - Vom Kühler
N - Mandata scambiatore N - Zum Kühler
P - Filtro 30µ P - Filter 30µ
R - Valvola antishock R - Antischockventil
S - Interruttore termometrico: 115° ± 3°C S - Temperaturfühler 115° ±3°C
optional: 125° ± 3°C auf Wunsch 125° ± 3°C
T - Presa di forza T - Nebenabtrieb

GB A - Filler plug and 50µ gear box oil filter F A - Bouchon de remplissage d’huile et filtre à
B - Forward gear electrical valve huile de bôite 50µ
C - Reverse gear electrical valve B - Electro-vanne Marche Avant
D - Oil drain plugs C - Electro-vanne Marche Arrière
E - Breathers D - Bouchons de vidange d’huile
F - Drive axle oil level plug E - Reniflards
G - Inching control F - Bouchon de remplissage - niveau d’huile pont
H - Converter G - Commande d’approche lente
K - Main pressure intake H - Convertisseur
L - Dipstick K - Prise de pression principale
M - Exchanger return L - Jauge de niveau
N - Exchanger delivery M - Retour échangeur
P - 30µ filter N - Alimentation échangeur
R - Antishock valve P - Filtre 30µ
S - Temp. switch: 115° ±3°C R - Vanne antichoc
optional: 125° ± 3°C S - Interrupteur thermométrique: 115° ±3°C
T - Power take-off opcional: 125° ± 3°C
T - Prise de force

10
TXL 15/25

Viste generali TXL 15/25 - Distributore Standard


TXL 15/25 General views - Standard Distributor
Generelle Ansicht TXL 15/25 - Standard-Steuerblock
Vues générales TXL 15/25 - Distributeur Standard
1
P G T A

F H

Dx Sx
Rh Lh

A
K

11
TXL 15/25

Viste generali TXL 15/25 - Distributore Supermodulato


TXL 15/25 General views - Supermodulating Distributor
Generelle Ansicht TXL 15/25 - Steuerblock Supermoduliert
Vues générales TXL 15/25 - Distributeur Supemodulé

L B C

INCHING MECCANICO INCHING IDRAULICO


MECHANICAL INCHING HYDRAULIC INCHING
MECHANISCHES INCHING HYDRAULISCHES INCHING
INCHING MECANIQUE INCHING HYDRAULIQUE

MAIN

MOD
G

S D M N D

I A - Filtro olio cambio 25µ D A Ölfilter Getriebe 25µ


B - Elettrodistributore Marcia Avanti B - Elektromagnetventil Vorwärtsgang
C - Elettrodistributore Retromarcia C - Elektromagnetventil Rückwärtsgang
D - Tappi scarico olio D - Ölablaßschraube
E - Sfiati E - Entlüfter
F - Tappo riemp. livello olio ponte F - Einfüllstutzen - Ölstand Achse
G - Comando Inching G - Inchsteuerung
H - Convertitore H - Wandler
J - Tappo introduzione olio J - Einfüllstutzen
K - Presa pressione principale K - Hauptdruckmeßstelle
L - Asta livello olio L - Ölpeilstab
M - Ritorno scambiatore M - Vom Kühler
N - Mandata scambiatore N - Zum Kühler
P - Comando azionamento inching (optional) P - Inching steuerwerk (auf Wunsch)
R - Sensore d’usura freno R - Sensor f. Bremsverschleiss
S - Interruttore termometrico: 125° ± 3°C S - Temperaturfühler 125° ±3°C
T - Presa di forza T - Nebenabtrieb
U - Pressostato (optional) U - Druckfuehler (auf Wunsch)

GB A - Oil filter for transmission 25µ F A - Filtre huile de bôite 25µ


B - Forward gear electrodistributor B - Electro-vanne Marche Avant
C - Reverse gear electrodistributor C - Electro-vanne Marche Arrière
D - Oil drain plugs D - Bouchons de vidange d’huile
E - Breathers E - Reniflards
F - Drive axle oil level plug F - Bouchon de remplissage - niveau d’huile pont
G - Inching control G - Commande d’approche lente
H - Converter H - Convertisseur
J - Transsmission oil inlet plug J - Bouchon de remplissage d’huile
K - Main pressure intake K - Prise de pression principale
L - Dipstick L - Jauge de niveau
M - Exchanger return M - Retour échangeur
N - Exchanger delivery N - Alimentation échangeur
P - Inching drive control (optional) P - Commande d’action inching (opcional)
R - Wear brake sensor R - Capteur d’usure frein
S - Temp. switch: 115° ±3°C S - Interrupteur thermométrique: 125° ±3°C
T - Power take-off T - Prise de force
U - Pressure switch (optional) U - Pressostat (opcional)

12
TXL 15/25

Viste generali TXL 15/25 - Distributore Supermodulato


TXL 15/25 General views - Supermodulating Distributor
Generelle Ansicht TXL 15/25 - Steuerblock Supermoduliert
Vues générales TXL 15/25 - Distributeur Supemodulé
1
P G U T A

F H

Dx Sx
Rh Lh

K K

E J A

13
TXL 15/25

Sezione generale
General section
Allgemeine Hinweise
Section générale

10

11 12

I 1 - Convertitore D 1 - Drehmomentwandler
2 - Pompa trasmissione 2 - Pumpe
3 - Frizione di Retromarcia 3 - Kupplung für Rückwärtsfahrt
4 - Frizione di Marcia Avanti 4 - Kupplung für Vörwärtsfahrt
5 - Ingranaggio conduttore Marcia Avanti 5 - Antriebrad für Vörwärtsfahrt
6 - Ingranaggio conduttore Retromarcia 6 - Antriebrad für Rückwärtsfahrt
7 - Albero presa di forza 7 - Nebenabtriebswelle
8 - Ingranaggio di inversione 8 - Wendezahnrad für R. G.
9 - Ingranaggio trascinamento pignone 9 - Kegelritzelantriebszahnrad
10 - Gruppo freno 10 - Bremsgruppe
11 - Differenziale 11 - Differential
12 - Gruppo ruota 12 - Achsgruppe
GB 1 - Converter 1 - Convertisseur
F
2 - Pump 2 - Pompe transmission
3 - Reverse clutch 3 - Embrayage de Marche Arrière
4 - Forward clutch 4 - Embrayage de Marche Avant
5 - Forward drive gear 5 - Engrenage Marche Avant
6 - Reverse drive gear 6 - Engrenage Marche Arrière
7 - Power take-off shaft 7 - Arbre de prise de force
8 - Reverse Gear 8 - Engrenage d’inversion
9 - Pinion drive gear 9 - Engrenage de transmission
10 - Brake Assembly 10 - Groupe freinage
11 - Differential Unit 11 - Différentiel
12 - Wheel Assembly 12 - Groupe pont

14
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Sezione generale
General section
Allgemeine Hinweise
Section générale
1

3 4 8

5 6 7

13 9 13

15
TXL 15/25

CIRCUITO IDRAULICO DELLA TRASMISSIONE - DISTRIBUTORE STANDARD

2 TRANSMISSION HYDRAULIC SYSTEM - STANDARD DISTRIBUTOR


GETRIEBE-HYDRAULIKSYSTEM - STANDARD-STEUERBLOCK
CIRCUIT HYDRAULIQUE DE LA TRANSMISSION - DISTRIBUTEUR STANDARD

I Il corretto funzionamento di tutta la trasmissione è essenzialmente affidato ai vari organi costituenti il


circuito idraulico che provvedono a:
- Garantire una determinata pressione allʼinterno del convertitore.
- Garantire un continuo ricambio dellʼolio nel convertitore ed al suo raffreddamento mediante lo scam-
biatore di calore.
- Fornire olio in pressione al pacco frizione di trasmissioni MA e RM.
- Lubrificare i dischi della frizione di trasmissione MA e RM.
Le principali parti costituenti lʼimpianto idraulico sono:
a. POMPA OLIO DELLA TRASMISSIONE
Una pompa olio del tipo a dentatura interna è montata internamente alla trasmissione ed ha una
velocità di rotazione pari a quella del motore. L’aspirazione dell’olio dalla coppa avviene tramite
un condotto con filtro a rete.
b. FILTRO OLIO
Uno montato sul condotto di aspirazione della pompa assicura il filtraggio dell’olio destinato
ai vari organi, con una capacità di 50 micron. Un secondo filtro con capacità di filtraggio di 30
micron garantisce un’ulteriore protezione agli organi interni del distributore (vedi pag. 1).
c. CONVERTITORE IDRODINAMICO DI COPPIA
Montato fra il motore e l’inversore, permette mediante l’azione dinamica di un fluido (olio) di
moltiplicare la coppia in uscita dal motore, adeguandola alle richieste di lavoro del carrello.
d. SCAMBIATORE DI CALORE
Situato sul condotto in entrata al convertitore provvede ad asportare il calore sviluppatosi
durante il funzionamento del cambio.
e. INVERSORE
Il gruppo di inversione è costituito da due pacchi di frizioni a dischi multipli in bagno di olio
comandate idraulicamente mediante l’azionamento dell’elettrovalvole.
f. GRUPPO DISTRIBUTORE
È montato all’esterno della scatola cambio, ed in esso sono incorporati:
Valvola massima pressione
Tale valvola ha il compito di controllare il valore della pressione di impacco delle frizioni di tra-
smissione.
Valvola modulatrice
Posta sul circuito d’alimentazione delle frizioni ha il compito di controllare l’incremento del valo-
re della pressione di impacco, allo scopo di ottenere un graduale impaccamento della frizione
interessata all’atto del comando indipendentemente dalla rapidità della manovra.
Valvola Inching
Ha il compito di intercettare la pressione di impacco frizioni e di disimpegnare gradualmente la
frizione innestata. Viene quindi ridotta, in modo continuo e senza cambiare il regime del motore,
la velocità di marcia fino al punto da poter avanzare con il veicolo in modo lentissimo.
Elettrovalvole selettrici
Situate sui condotti di alimentazione dei pacchi frizione permettono di inviare o intercettare l’olio
in pressione per il posizionamento del cassetto distributore.
Cassetto di distribuzione
Le diverse posizioni che può assumere il cassetto in seguito alla spinta dell’olio proveniente
dalle elettrovalvole, determinano le condizioni di Marcia Avanti - Folle - Retromarcia.
Valvola sicurezza convertitore
Posta sul condotto in entrata al convertitore provvede a salvaguardare quest’ultimo da acciden-
tali aumenti di pressione.
Valvola antishock
Abbinata alla valvola modulatrice ha lo scopo di annullare l’urto che si viene a creare sugli orga-
ni della trasmissione all’inserzione delle marce.
Valvola sicurezza lubrificazione
Situata sul circuito di lubrificazione provvede ad eliminare in tale circuito eventuali aumenti di
pressione.

16
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GB TRANSMISSION HYDRAULIC SYSTEM - STANDARD DISTRIBUTOR

2
The whole transmission system relies for its trouble-free operation on the various components of the
hydraulic system which perform the following functions:
- Ensure a given pressure inside the converter.
- Ensure a continuous exchange of converter oil and cooling through heat exchanger.
- Provide oil pressure to Forward and Reverse Clutch pack
- Lubricate clutch plates.
The main components of the hydraulic system are:
a. TRANSMISSION OIL PUMP
An internal-tooth oil pump is fitted inside the transmission and has the same speed as the engi-
ne. Oil suction from the sump is through a line incorporating a gauze filter.
b. OIL FILTER
One 50-micron filter, fitted to the pump section line filters the oil for the various components. A
second 30-micron filter provides further protection for valve block components (See page 1).
c. HYDRAULIC TORQUE CONVERTER
Fitted between engine and reverser the converter uses the dynamic action of the oil to multiply
engine output torque in line with truck work requirements.
d. HEAT EXCHANGER
Located on converter inlet line the exchanger dissipates the heat produced during gearbox opera-
tion.
e. REVERSER
The reverser unit consists of two oil bath, multiplate clutch packs controlled hydraulically through
the electrovalves.
f. VALVE BLOCK
This unit is fitted on the gearbox and incorporates:
Max pressure valve (regulator)
This valve regulates clutch pressure.
Modulating valve
Located on the clutch supply circuit, this valve controls the increase in clutch pressure so that
the clutch in question is fed gradually regardless of speed of manoeuvre.
Inching valve
It cuts off clutch pack pressure and gradually disengages the engaged clutch. Running speed
is constantly reduced without changing engine speed so that the vehicle can be moved forward
very slowly.
Selector solenoid valves
Located on the clutch pack supply lines, these valves control the oil pressure to be supplied or
cut off for valve spool positioning.
Selector spool
The valve spool can be in one of three positions as a result of the oil pressure coming from the
solenoid valve. These represent Forward - Neutral - Reverse.
Converter safety valve
Located on converter inlet line, this valve protects the converter from accidental over pressure.
Anti-shock valve
Linked to the pressure modulating valve, this valve is designed to eliminate the impact created
on the transmission components when the gears are engaged.
Lubrication safety valve
Located on the lubrication circuit this valve eliminates increases in pressure in this circuit.

17
TXL 15/25

D GETRIEBE HYDRAULIKSYSTEM - STANDARD-STEUERBLOCK

Die einwandreie Funktion des Getriebes ist von dem Hydraulik-Kreislauf abhängig, der folgendes
gewährleistet:
- Wandlerdruck.
- Ständiger Ölkühlkreislauf.
- Druckölbereitstellung und Schmierung für die Vorwärtsgang-und Rückwärtsgangkupplung.
Folgend die für das Hydrauliksystem erforderlichen Bauelemente:
a. ZAHNRADPUMPE
Die Pumpe ist als Innenzahnradpumpe ausgeführt und ist Motordrehzahl abhängig. Die
Ölansaugung vom Sumpf erfolgt über einer Filter.
b. ÖLFILTER
Der Ölkreislauf ist mit 2 Filtern gegen Schmutz abgesichert. 1 Filter mit einer Filterfeinheit
von 50 my ist im Ölsumpf für die Ansaugung der Zahnradpumpe der zweite Filter mit 30 my
Filterfeinheit ist in der Steuerung im Druckölkreislauf eingebaut (diesere Filter muß nach einer
Getriebe Einlaufzeit von 60-80 Bh wieder entfernt werden).
c. HYDRODYNAMISCHER DREHMOMENTWANDLER
Ist zwischen Motor und Wenedegetriebe eingebaut, vervielfacht über die mit der Wandlerpumpe
und der Betriebsflüssigkeit (Öl) erzeugten Flüssigkeitsstrom angetriebene Turbine und dem
Reaktionsglied das Motordrehmoment. Der Drehmomentwandler gewährleistet eine stoßfreies
beschleunigen und selbsttätige Anpassung an die Belastung.
d. KÜHLER
Der Anschluss für den Kühler ist in der Zuleitung des Wandlers installiert.
e. WENDEGETRIEBE
Der Fahrtrichtungswechsel wird durch 2 im Ölbad laufende Lamellenpakete, die über ein
Elektromagnetventil hydraulisch beaufschlagt werden und dessen verbundenen Zahnräder
b.z.w. Wendezahnrad durchgeführt.
f. GETRIEBESTEUERUNG
Die Steuerung ist oben auf dem Getriebegehäuse montiert mit folgenden Funktionen:
Hauptdruckbegrenzungsventil
Dieses Ventil regelt den Druck in den Lamellenkupplungen mit Überdruckabsicherung.
Modulationsventil
Dieses Ventil reguliert drehzahlabhängige Druckschwankungen im Druckaufbau für die
Kupplungen.
Inchventil
Über ein Pedal oder Bremsylinder (bei hydraulischer Ausführung) steuert dieses Ventil stu-
fenlos den Anpressdruck im Kupplungslamellenpaket, damit das Fahrzeug unabhängig von der
Motordrehzahl mit geringer Geschwindigkeit (kriechen) gefahren werden kann.
Elektromagnetventile
Über ein Fußwahlpedal-oder Handwahlschalter wird das für die jeweilige Fahrtrichtung bestim-
mte Magnetventil angesteuert, damit der Druckaufbau zum Beaufschlagen der Lamellenkupplung
erfolgen kann.
Steuerkolben
Regelt in Abhängigkeit von den Elektromagnetventile den Fahrzustand Vorwärts-Neutral-
Rückwärts.
Wandlerdruckbegrenzungsventil
Absicherung vom Wandler gegen Überdruck.
Antiscockventil
Steuert stoßfreies Fahren beim Anfahren und beim Schalten.
Schmierdruckventil
Überdruck- und Druckhalteventil für das Ölschmiersystem.

18
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CIRCUIT HYDRAULIQUE DE LA TRANSMISSION - DISTRIBUTEUR STANDARD

2
F

Le bon fonctionnement de toute la transmission est dû aux organes constituant le circuit hydraulique
qui doivent:
- Garantir une pression déterminée à l’intérieur du convertisseur.
- Garantir le renouvellement de l’huile du convertisseur de façon continue et son refroidissement par
l’échangeur de température.
- Fournir de l’huile sous pression au piston de l’embrayage Marche Avant ou Marche Arrière.
- Lubrifier les disques de l’embrayage.
Les parties principales de la partie hydraulique sont:
a. LA POMPE A HUILE DE LA TRANSMISSION
Une pompe à huile, du type à denture interne, est montée à l’intérieur de la transmission. Sa
vitesse de rotation est celle du moteur. L’aspiration de l’huile est faite par une conduite avec filtre
(50 microns).
b. FILTRE A HUILE
Il est monté sur la conduite d’aspiration et assure le filtrage de l’huile destinée aux différents orga-
nes avec une capacité de 50 microns. Un second filtre d’une capacité de 30 microns garanti une
protection ultérieure aux organes internes du distributeur (voir page 2).
c. CONVERTISSEUR DE COUPLE HYDRAULIQUE
Monté entre le moteur et l’inverseur, il permet par l’action dynamique d’un fluide (I’huile) de multi-
plier le couple à la sortie du moteur en l’adaptant aux demandes de travail du chariot.
d. ECHANGEUR DE TEMPERATURE
Situé sur le conduit d’entrée du convertisseur il pourvoit à retirer la chaleur qui se crée lors du
fonctionnement de la bôite de vitesse.
e. INVERSEUR
Le groupe d’inversion est constitué de deux paquets d’embrayages à disques multiples, à bains
d’huile,commandés hydrauliquement au moyen des électrovannes.
f. LE GROUPE DISTRIBUTEUR
Il est monté à l’extérieur de la bôite, il comprend:
Vanne de pression maxi
Elle doit contrôler la valeur de la pression de blocage des embrayages de la transmission (tarée à
11- 13 bar).
Vanne modulatrice
Placée sur le circuit d’alimentation des embrayages, elle doit contrôler l’accroissement de la pres-
sion dans le but d’obtenir une application progressive de l’embrayage intéressé indépendem-
ment de la rapidité de la manoeuvre.
Vanne d’Inching
Elle a la charge de diminuer la pression de blocage des embrayages et de dégager ainsi les
disques graduellement et donc de réduire de façon continue, sans changer le régime moteur, la
vitesse de marche jusqu’au point de pouvoir avancer de façon tres lente.
Electrovannes selectrices
Elles sont placées sur les conduits d’alimentation des embrayages et permettent d’envoyer ou
d’intercepter l’huile sous pression pour le positionnement du tiroir distributeur.
Tiroir du distributeur
La Marche Avant - le Point Mort et la Marche Arrière sont determinés par les différents positions
du tiroir conséquent a la poussée de l’huile en provenance des électrovannes.
Vanne de sûreté du convertisseur
Elle est placée sur le conduit à l’entrée du convertisseur et le protège contre les variations excessi-
ves de pression.
Vanne antichock
Jumelèe à la vanne modulatrice, cette vanne élimine le choc qui est provoqué sur les organes de la
transmission au moment du passage de vitesses.
Vanne de sûreté de graissage
Elle est située sur le circuit de graissage et élimine la pression exessive du circuit pendant le
fonctionnement de la bôite.

19
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Schema circuito idraulico - Distributore Standard


Hydraulic diagram - Standard Distributor
Hydraulikdiagramm - Standard-Steuerblock
Schéma du circuit hydraulique - Distributeur Standard
CADUTA
CADUTA DI PRESSIONE
DI PRESSIONE 1,5 bar1,5
max.bar max.
PRESSURE
PRESSUREDROP 1,5 bar
DROP 1,5max.
bar max.
9 DRUCKABFALL
DRUCKABFALL1,5 bar1,5
max.
bar max.
CHUTE
CHUTEDEDEPRESSION
PRESSION 1,51,5
barbar
max.
max.

8 10
7

11 LUBRIFICAZIONE
LUBRIFICAZIONE
LUBRICATION
LUBRICATION
SCHMIERUNG
4.5 bar LUBRIFICATION
CONTROL VALVE BLOCK
CORPO DISTRIBUTORE

CORPS DISTRIBUTEUR

12
STEUERBLOCK

15 2.5+1 bar
20
19

16 21 RETROMARCIA
RETROMARCIA
REVERSE GEAR
REVERSE GEAR
RÜCKWÄRTSGANG
6
MARCHE ARRIERE
18
11 bar
14 17
MARCIA AVANTI
MARCIA AVANTI
FORWARD
FORWARD
VORWÄRTSGANG
MARCHE AVANT

2
13
GRADO DI FILTRAGGIO 50µ
FILTERING CAPACITY 50µ
FILTRIERGRAD 50µ
1 DEGRÉ DE FILTRATION 50µ

POS. I LEGENDA GB KEY TO DRAWING D LEGENDE F LEGENDE


1 FILTRO DI ASPIRAZIONE 50µ SUCTION FILTER SAUGFILTER FILTRE D’ASPIRATION
2 POMPA PUMP PUMPE POMPE
6 VALVOLA MASSIMA PRESSIONE MAXIMUM PRESSURE VALVE HAUPTDRUCKBEGRENZUNGSVENTIL VANNE DE PRESSION MAXIMALE

7 ATTACCO ALLO SCAMBIATORE ATTACHMENT TO EXCHANGER ZUM KÜHLER RACCORDEMENT EN ENTREE


DE L’ECHANGEUR

8 ATTACCO DALLO SCAMBIATORE ATTACHMENT FROM EXCHANGER VOM KÜHLER RACCORDEMENT EN SORTIE
DE L’ECHANGEUR
9 SCAMBIATORE DI CALORE HEAT EXCHANGER WÄRMEAUSTAUSCHER/KÜHLER ECHANGEUR DE CHALEUR
10 CONVERTITORE DI COPPIA TORQUE CONVERTER DREHMOMENTWANDLER CONVERTISSEUR DE COUPLE

11 VALVOLA SICUREZZA CONVERTER SAFETY VALVE WANDLERDRUCKBEGRENZUNGSVENTIL VANNE DE SURETE


CONVERTITORE DE CONVERTISSEUR

12 VALVOLA SICUREZZA LUBRICATION SAFETY VALVE SCHMIERDRUCKBEGRENZUNGSVENTIL VANNE DE SURETE DE


LUBRIFICAZIONE LUBRIFICATION
13 VALVOLA ANTISCHOCK ANTISHOCK VALVE ANTISCHOCKVENTIL VANNE ANTICHOC
14 FILTRO DISTRIBUTORE 30µ DISTRIBUTOR FILTER FILTER FÜR STEUERUNG FILTRE DE DISTRIBUTEUR
15 VALVOLA MODULATRICE MODULATOR VALVE MODULATIONSVENTIL VANNE MODULATRICE

16 VALVOLA INCHING INCHING VALVE INCHVENTIL VANNE DE COMMANDE


D’APPROCHE LENTE

17 ELETTROVALVOLA PER FORWARD GEAR ELEKTROMAGNETVENTIL ELECTROVANNE DE


MARCIA AVANTI ELECTRICAL VALVE VORWÄRTSGANG MARCHE AVANT
18 VALVOLA PER MARCIA AVANTI FORWARD GEAR VALVE VENTIL VORWÄRTSGANG VANNE DE MARCHE AVANT

19 ELETTROVALVOLA PER REVERSE GEAR ELEKTROMAGNETVENTIL ELECTROVANNE DE


RETROMARCIA ELECTRICAL VALVE RÜCKWÄRTSGANG MARCHE ARRIERE
20 VALVOLA RETROMARCIA REVERSE GEAR VALVE VENTIL RÜCKWÄRTSGANG VANNE DE MARCHE ARRIERE
21 VALVOLA PILOTAGGIO ANTISHOCK ANTISHOCK PILOT VALVE VERSTEUERVENTIL DER ANTISHOCK VANNE PILOTAGE ANTICHOC

20
TXL 15/25

Distributore Standard - Cambio in folle / SCHEMA A


Standard Distributor - Gear in neutral position / SCHEME A
Standard-Steuerblock - Getriebe in neutralstellung / SCHEMA A
Boîte de vitesses au point mort - Distributeur Standard / SCHEMA A
2
I Condizione di Folle
L’olio aspirato dalla pompa attraverso un filtro a rete di 50µ viene inviato nel circuito di comando fri-
zioni all’interno del distributore. La successiva apertura della valvola di massima pressione permette
all’olio di defluire completamente verso lo scambiatore, il convertitore e il circuito di lubrificazione.
Dopo aver interessato i pacchi frizione di MA e RM l’olio cade liberamente nella coppa.

GB Neutral position
The pumped oil first passes through a 50µ mesh filter and then it is conveyed into the clutch circuit
inside the distributor. Subsequent opening of the pressure control valve allows the oil to flow freely to
the exchanger, converter and lubrication circuit. After flowing through the FG and RG clutch packs,
the oil drops freely into the sump.

D Neutralstellung
Das von der Innenzahnradpumpe über den 50 my Filter angesaugte Öl wird zum Hauptdruckventil
und von dort zur Bereitstellung weiterer Funktionen zu den Elektromagnetventilen geleitet. Gleichzeitig
wird das Öl von der Pumpe über eine Drossel durch den Kühler zum Wandler zur Schmierung der
Kupplungen und zurück in den Ölsumpf geleitet.

F Au Point Mort
L’huile aspirée par la pompe à travers un filtre avec un maillage de 50 µ est envoyée dans le circuit de
commande des embrayages à l’interieur du distributeur. L’ouverture de la soupape de pression maximum
permet à l’huile de s’écouler vers l’échangeur, le convertisseur et le circuit de lubrification. Après avoir
traversé les groupes embrayages de Marche Avant et Marche Arrière, I’huile tombe dans le carter.

CADUTADIDI
CADUTA PRESSIONE
PRESSIONE 1,51,5
barbar max.
max.
PRESSURE
PRESSURE DROP
DROP 1,5
1,5bar
bar max.
max.
9 DRUCKABFALL
DRUCKABFALL 1,51,5
barbar
max.
max.
CHUTE
CHUTEDEDEPRESSION
PRESSION 1,51,5bar
bar max.
max.

10
7 8

11 LUBRIFICAZIONE
LUBRIFICAZIONE
LUBRICATION
LUBRICATION
SCHMIERUNG
SCHMIERUNG
4.5 bar LUBRIFICATION
LUBRIFICATION
CONTROL VALVE BLOCK
CORPO DISTRIBUTORE

CORPS DISTRIBUTEUR

12
STEUERBLOCK

15 2.5+1 bar
20
19 Scarico
Exhaust
Entlastung
16 21 RETROMARCIA Echappement
RETROMARCIA
REVERSE GEAR
6 REVERSE GEAR
RÜCKWÄRTSGANG
Principale impacco
impac frizioni
MARCHE ARRIERE
18 Clutch pressure
11 bar Kupplungsdruck
14 17 Principal groupe embrayages
MARCIA AVANTI
MARCIA
FORWARDAVANTI Entrata convertitore
convertit
FORWARD
VORWÄRTSGANG
MARCHE AVANT Converter inlet
Wandlereingang
convertis
Entrée convertisseur
Entrata scambiatore
scambia
Exchanger inlet
Austaus
Eingang Austausches
2 échangeu
Entrée échangeur
13
GRADO DI FILTRAGGIO 50µ Lubrificazione
FILTERING CAPACITY 50µ Lubrication
FILTRIERGRAD 50µ
1 DEGRÉ DE FILTRATION 50µ Schmierung
Graissage

21
TXL 15/25

Distributore Standard - Marcia Avanti, Fase di avvio / SCHEMA B


Standard Distributor - Forward Gear, Start phase / SCHEME B
Standard-Steuerblock - Getriebe in Vorwärtsgang, Startphase / SCHEMA B
Distributeur Standard - Marche Avant, Démarrage / SCHEMA B

I Condizioni di avviamento
Con l’eccitazione della relativa elettrovalvola viene posizionato il cassetto di selezione della
Retromarcia restando identiche le condizioni di funzionamento della parte riguardante il circuito con-
vertitore e lubrificazione frizioni. Intervengono durante questa fase la valvola antishock e la valvola
modulatrice. Ambedue con il preciso compito di permettere un graduale avvio dal carrello. La prima
interviene sull’alimentazione frizione quando il valore della pressione è da 0 a 2,5 bar, la seconda
interviene regolando l’incremento della pressione di innesto frizioni da 2,5 bar al valore massimo.
GB Start conditions
When the appropriate solenoid valve is energised the reverse selection spool is positioned, the ope-
rating conditions of the converter and clutch lubrication section remaining the same. The antishock
valve and modulating valve operate during this stage. They are both designed to allow the truck to
start gradually. The antishock valve operates on the clutch supply when the pressure ragnes from 0 to
2.5 bar. The modulating valve works by increasing the clutch engagement pressure from 2.5 bar to
the maximum value in a gradual manner.
D Startphase
Durch des Aktivieren des Elektromagnetventiles vom Rückwärtsgang wird über das vorher anstehen-
de Öl die Vorwärtsgangkupplung mit Druck beaufschlagt. Der Ölkreisaluf Pumpe - Kühler-Wandler-
Schmierung bleibt unverändert. Um ein stoßfreies Anfahren zu erreichen, wird der Druckaufbau der
Kupplung erstens von dem Antischockventil und zweitens von dem Modulationsventil gesteuert. Das
Antischockventil steuert den Druckaufbau von 0 auf 2,5 bar. Das Modulationsventil steuert über eine
Drossel und Feder des Haupdruckventiles ein verzögertes Ansteigen des Kupplungdruckes bis zum
maximale Kupplungsdruck.
F Mise en route
Par l’excitation de l’électrovanne corréspondante, le tiroir de sélection de la Marche Arrière est posi-
tionné, en restant inchangées les conditions de fonctionnement du circuit convertisseur et de lubri-
fication des embrayages. Pendant cette opération la vanne antichoc et la vanne modulatrice entrent
en fonctionnement, avec la stricte tâche de permettre un graduel départ du chariot. La vanne antichoc
intervient sur l’alimentation des embrayages quand la valeur de la pression est de 0 à 2,5 bar la vanne
modulatrice charge graduellement le ressort de la vanne de pression maximum et en élevant ainsi gra-
duellement la pression des embrayages de 2,5 bar à la valeur maximum.

22
TXL 15/25

SCHEMA B circuito idraulico - Distributore Standard


SCHEME B of hydraulic diagram - Standard Distributor
SCHEMA B Hydraulikdiagramm - Standard-Steuerblock
SCHEMA B du circuit hydraulique - Distributeur Standard
2

CADUTA
CADUTADI
DIPRESSIONE
PRESSIONE1,51,5bar
barmax.
max.
PRESSURE
PRESSUREDROP
DROP1,5
1,5 bar max.
bar max.
9 DRUCKABFALL 1,51,5
DRUCKABFALL bar
barmax.
max.
CHUTE
CHUTEDE
DE PRESSION
PRESSION 1,5 1,5
barbar max.
max.

10
7 8

11 LUBRIFICAZIONE
LUBRIFICAZIONE
LUBRICATION
LUBRICATION
SCHMIERUNG
SCHMIERUNG
4.5 bar LUBRIFICATION
LUBRIFICATION
CONTROL VALVE BLOCK
CORPO DISTRIBUTORE

CORPS DISTRIBUTEUR

12 Scarico
Exhaust
STEUERBLOCK

15 2.5+1 bar Exhaust


20 Entlastun
Entlastung
19 Echappe
Echappement
Principal impacco frizioni
Principale
RETROMARCIA
p
Clutch pressure
16 21 Kupplung
REVERSE GEAR
RETROMARCIA Kupplungsdruck
RÜCKWÄRTSGANG
6 REVERSE GEAR
MARCHE ARRIERE
Principal groupe embrayages
18 Entrata convertitore
c
11 bar Converte inlet
Converter
14 17 Wandlere
MARCIA AVANTI Wandlereingang
FORWARD
MARCIA AVANTI Entrée convertisseur
co
VORWÄRTSGANG
FORWARD
MARCHE AVANT Entrata scambiatore
s
Exchang inlet
Exchanger
Eingang Austausches
éc
Entrée échangeur
Lubrificazione
Lubrifica
Lubricati
Lubrication
2 Schmieru
Schmierung
13
GRADO DI FILTRAGGIO 50µ
Graissag
Graissage
FILTERING CAPACITY 50µ
FILTRIERGRAD 50µ Pressione
Pression modulata
1 DEGRÉ DE FILTRATION 50µ Modulate pressure
Modulated
Gemode
Gemodelter Druck
Pression modulée

23
TXL 15/25

Distributore Standard - Marcia Avanti - Carrello avviato / SCHEMA C


Standard Distributor - Forward Gear - Started lift truck / SCHEME C
Standard-Steuerblock - Vorwärtsgang - Fahrzustand / SCHEMA C
Distributeur Standard - Marche Avant - Chariot en marche / SCHEMA C

I Marcia Avanti
Si ha durante questa fase lʼalimentazione delle frizioni alla massima pressione. Tale valore viene rego-
lato dalla valvola 6.

GB Forward Gear
Dunng this stage the clutches are supplied at maximum pressure. This value is regulated by valve 6.

D Vorwärtsgang
Während dieser Phase hat man im Ölzufuhrkreis für die Kupplungen den höchsten Druck. Dieser Wert
wird vom Ventil 6 geregelt.
F Marche Avant
Pendant cette phase de fonctionnement l’alimentation des embrayages est à la pression maximum.
Cette valeur est reglée par la soupape 6.

CADUTADI
CADUTA DIPRESSIONE
PRESSIONE1,51,5bar
bar max.
max.
PRESSURE
PRESSUREDROP
DROP1,5
1,5 bar max.
bar max.
9 DRUCKABFALL 1,51,5
DRUCKABFALL barbarmax.
max.
CHUTE
CHUTEDE
DE PRESSION
PRESSION 1,51,5barbar max.
max.

10
7 8

11 LUBRIFICAZIONE
LUBRIFICAZIONE
LUBRICATION
LUBRICATION
SCHMIERUNG
SCHMIERUNG
4.5 bar LUBRIFICATION
LUBRIFICATION
CONTROL VALVE BLOCK
CORPO DISTRIBUTORE

CORPS DISTRIBUTEUR

12
STEUERBLOCK

15 2.5+1 bar
20
19 Scarico
Exhaust
Entlastung
16 21 RETROMARCIA Echappement
RETROMARCIA
REVERSE GEAR
6 REVERSE GEAR
RÜCKWÄRTSGANG
impacco friz
Principale impacco frizioni
MARCHE ARRIERE
18 Clutch pressure
11 bar Kupplungsdruck
14 17 Principal groupe embra
embrayages
MARCIA AVANTI
MARCIA AVANTI
FORWARD Entrata convertitore
FORWARD
VORWÄRTSGANG
MARCHE AVANT Converter inlet
Wandlereingang
Entrée convertisseur
Entrata scambiatore
Exchanger inlet
Eingang Austausches
2 Entrée échangeur
13
GRADO DI FILTRAGGIO 50µ Lubrificazione
FILTERING CAPACITY 50µ Lubrication
FILTRIERGRAD 50µ
1 DEGRÉ DE FILTRATION 50µ Schmierung
Graissage

24
TXL 15/25

Distributore Standard - Marcia Avanti in Inching / SCHEMA D


Standard Distributor - Inching Forward Gear / SCHEME D
Standard-Steuerblock - Inching Vorwärtsgang/ SCHEMA D
Distributeur Standard - Marche Avant en Inching / SCHEMA D
2
I Manovra Inching
La manovra del pedale Inching attuata per abbinare piccoli accostamenti del carrello con elevato regi-
me di rotazione motore parzializza lʼalimentazione della frizione interessata, mettendola in comunica-
zione con lo scarico. Viene inoltre bloccata la valvola antishock.

GB Inching manoeuvre
When the Inching pedal is operated so that the truck can be inched forward or backward it shuts off
the supply to the clutch in question and connects it to the exhaust.

D Inchbetätigung
Durch betätigen des Inchpedales wird die jeweils beaufschlagte Kupplung so gesteuert, daß mit
dem Fahrzeug unabhängig von der Motordrehzahl eine Kriechfahrt durchgeführt werden kann. Eine
Kriechfahrt (Inchen) kann stufenlos variiert werden. Das Antischockventil wird beim Inchen automatisch
geschlossen.

F Manoeuvre Inching
On utilise la pédale Inching pour jumeler les approches courtes et lentes du chariot avec un régime
de rotahon moteur élevé. On repartit l’alimentation de l’embrayage concerné en la maintenant en
communication avec l’échappement. La soupape antichoc est également bloquée.

CADUTADIDIPRESSIONE
CADUTA PRESSIONE 1,51,5bar
bar max.
max.
PRESSURE
PRESSURE DROP
DROP1,5
1,5bar
bar max.
max.
9 DRUCKABFALL
DRUCKABFALL1,51,5
barbarmax.
max.
CHUTE
CHUTEDE
DE PRESSION
PRESSION 1,5 1,5 barbar max.
max.

10
7 8

11 LUBRIFICAZIONE
LUBRIFICAZIONE
LUBRICATION
LUBRICATION
SCHMIERUNG
SCHMIERUNG
4.5 bar LUBRIFICATION
LUBRIFICATION
CONTROL VALVE BLOCK
CORPO DISTRIBUTORE

CORPS DISTRIBUTEUR

12
STEUERBLOCK

15 2.5+1 bar Scarico


20 Exhaust
19 Entlastung
Echappement
Principale impacco
impacco frizioni
frizioni
16 RETROMARCIA
21 REVERSE GEAR
RETROMARCIA Clutch pressure
6 RÜCKWÄRTSGANG
REVERSE GEAR Kupplungsdruck
MARCHE ARRIERE
Principal groupe embrayages
18
11 bar Entrata convertitore
14 17 Converter inlet
MARCIA AVANTI
MARCIA AVANTI
FORWARD Wandlereingang
FORWARD
VORWÄRTSGANG Entrée convertisseur
MARCHE AVANT
Entrata scambiatore
Exchanger inlet
Eingang Austausches
Entrée échangeur
Lubrificazione
2 Lubrication
13 Schmierung
GRADO DI FILTRAGGIO 50µ
FILTERING CAPACITY 50µ Graissage
FILTRIERGRAD 50µ
1 DEGRÉ DE FILTRATION 50µ Inching
Inching
Inching
Inching

25
TXL 15/25

CIRCUITO IDRAULICO DELLA TRASMISSIONE - DISTRIBUTORE SUPERMODULATO


TRANSMISSION HYDRAULIC SYSTEM - SUPERMODULATING DISTRIBUTOR
GETRIEBE-HYDRAULIKSYSTEM - STEUERBLOCK SUPERMODULIERT
CIRCUIT HYDRAULIQUE DE LA TRANSMISSION - DISTRIBUTEUR SUPERMODULE

I Il corretto funzionamento di tutta la trasmissione è essenzialmente affidato ai vari organi costituenti il


circuito idraulico che provvedono a:
- Garantire una determinata pressione all’interno del convertitore.
- Garantire un continuo ricambio dell’olio nel convertitore ed al suo raffreddamento mediante lo scam-
biatore di calore.
- Fornire olio in pressione al pacco frizione di trasmissioni MA e RM.
- Lubrificare i dischi della frizione di trasmissione MA e RM.
Le principali parti costituenti l’impianto idraulico sono:
a. POMPA OLIO DELLA TRASMISSIONE
Una pompa olio del tipo a dentatura interna è montata internamente alla trasmissione ed ha una
velocità di rotazione pari a quella del motore. L’aspirazione dell’olio dalla coppa avviene tramite un
condotto con filtro a rete.
b. FILTRO OLIO
Montato sul condotto di aspirazione della pompa assicura il filtraggio dell’olio destinato ai vari orga-
ni, con una capacità di 25 micron.
c. CONVERTITORE IDRODINAMICO DI COPPIA
Montato fra il motore e l’inversore, permette mediante l’azione dinamica di un fluido (olio) di molti-
plicare la coppia in uscita dal motore, adeguandola alle richieste di lavoro del carrello.
d. SCAMBIATORE DI CALORE
Situato sul condotto in uscita al convertitore provvede ad asportare il calore sviluppatosi durante il
funzionamento del cambio.
e. INVERSORE
Il gruppo di inversione è costituito da due pacchi di frizioni a dischi multipli in bagno di olio coman-
date idraulicamente mediante l’azionamento dell’elettrovalvole.
f. GRUPPO DISTRIBUTORE SUPERMODULATO
È montato all’esterno della scatola cambio, ed in esso sono incorporati:
Valvola massima pressione
Tale valvola ha il compito di controllare il valore della pressione di impacco delle frizioni di tra-
smissione.
Valvola modulatrice
Posta sul circuito d’alimentazione delle frizioni ha il compito di controllare l’incremento del valore
della pressione di impacco, allo scopo di ottenere un graduale impaccamento della frizione inte-
ressata all’atto del comando indipendentemente dalla rapidità della manovra.
Valvola Inching
Ha il compito di parzializzare la pressione di impacco frizioni e di disimpegnare gradualmente la
frizione innestata. Viene quindi ridotta in modo continuo e senza cambiare regime del motore, la
velocità di marcia fino al punto di poter avanzare con il veicolo in modo lentissimo.
Elettrodistributore selettore
Situato sui condotti di alimentazione dei pacchi frizione, permette di inviare l’olio alle marce o di
lasciarlo defluire in scarico.
Valvola sicurezza convertitore
Posta sul circuito del convertitore provvede a regolarne la pressione in ingresso e a salvaguardar-
lo da accidentali aumenti di pressione.
Valvola sicurezza lubrificazione
Situata sul circuito di lubrificazione provvede a controllare in tale circuito eventuali aumenti di
pressione.

26
TXL 15/25

TRANSMISSION HYDRAULIC SYSTEM - SUPERMODULATING DISTRIBUTOR

2
GB The whole transmission system relies for its trouble-free operation on the various components of the
hydraulic system which perform the following functions:
- Ensure a given pressure inside the converter.
- Ensure a continuous exchange of converter oil and cooling through heat exchanger.
- Provide oil pressure to forward and reverse clutch pack.
- Lubricate clutch plates.
The main components of the hydraulic system are:
a. TRANSMISSION OIL PUMP
An internal-tooth oil pump is fitted inside the transmission and has the same speed as the engi-
ne. Oil suction from the sump is through a line incorporating a gauze filter.
b. OIL FILTER
Fitted in the inlet duct, it filters the oil for various utilities. Its net size is 25 micron.
c. HYDRAULIC TORQUE CONVERTER
Fitted between engine and reverser the converter uses the dynamic action of the oil to multiply
engine output torque in line with truck work requirements.
d. HEAT EXCHANGER
Located on circuit in exit at the converter the exchanger dissipates the heat produced during
gearbox operation.
e. REVERSER
The reverser unit consists of two oil bath, multiplate clutch packs controlled hydraulically throu-
gh the electrovalves.
f. SUPERMODULATING VALVE BLOCK
This unit is fitted on the gearbox and incorporates:
Max pressure valve (regulator)
This valve regulates clutch pressure.
Modulating valve
Located on the clutch supply circuit, this valve controls the increase in clutch pressure so that
the clutch in question is fed gradually regardless of speed of manoeuvre.
Inching valve
It cloke clutch pack pressure and gradually disengages the engaged clutch. Running speed is
constantly reduced without changing engine speed so that the vehicle can be moved forward
very slowly.
Electrodistributor selector
Situated on the feeding ducts of the clutch units, allows to convey oil to gears and to let it flow
to exhaust.
Converter safety valve
Located on converter inlet line, this valve settles the input pressure and protects the converter
from accidental over pressure.
Lubrication safety valve
Located on the lubrication circuit this valve checks increases in pressure in this circuit.

27
TXL 15/25

GETRIEBE HYDRAULIK SYSTEM - STEUERBLOCK SUPERMODULIERT

D Die einwandreie Funktion des Getriebes ist von dem Hydraulik-Kreislauf abhängig, der folgendes
gewährleistet:
- Wandlerdruck.
- Ständiger Ölkühlkreislauf.
- Druckölbereitstellung und Schmierung für die Vorwärtsgang-und Rückwärtsgangkupplung.
Folgend die für das Hydrauliksystem erforderlichen Bauelemente:
a. ZAHNRADPUMPE
Die Pumpe ist als Innenzahnradpumpe ausgeführt und ist Motordrehzahl abhängig. Die
Ölansaugung vom Sumpf erfolgt über einer Filter.
b. ÖLFILTER
Der Ölfilter ist in der Absaugungsleitung der Pumpe eingebaut und sichert das Filtern des Öls
für die unterschiedlichen Elemente, mit einer Kapazität 25 Mikron zu.
c. HYDRODYNAMISCHER DREHMOMENTWANDLER
Ist zwischen Motor und Wenedegetriebe eingebaut, vervielfacht über die mit der Wandlerpumpe
und der Betriebsflüssigkeit (Öl) erzeugten Flüssigkeitsstrom angetriebene Turbine und dem
Reaktionsglied das Motordrehmoment. Der Drehmomentwandler gewährleistet eine stoßfreies
beschleunigen und selbsttätige Anpassung an die Belastung.
d. KÜHLER
Der Anschluss für den Kühler ist in der Zuleitung des Wandlers installiert.
e. WENDEGETRIEBE
Der Fahrtrichtungswechsel wird durch 2 im Ölbad laufende Lamellenpakete, die über ein
Elektromagnetventil hydraulisch beaufschlagt werden und dessen verbundenen Zahnräder
b.z.w. Wendezahnrad durchgeführt.
f. GETRIEBESTEUERUNG SUPERMODULIERT
Die Steuerung ist oben auf dem Getriebegehäuse montiert mit folgenden Funktionen:
Hauptdruckbegrenzungsventil
Dieses Ventil regelt den Druck in den Lamellenkupplungen mit Überdruckabsicherung.
Modulationsventil
Dieses Ventil reguliert drehzahlabhängige Druckschwankungen im Druckaufbau für die
Kupplungen.
Inchventil
Über ein Pedal oder Bremsylinder (bei hydraulischer Ausführung) steuert dieses Ventil stu-
fenlos den Anpressdruck im Kupplungslamellenpaket, damit das Fahrzeug unabhängig von der
Motordrehzahl mit geringer Geschwindigkeit (kriechen) gefahren werden kann.
Elektrowählschieber
Auf den Versorgungsleitungen der Kupplungsblöcke angebracht, ermöglicht er, das Öl an die
Gänge oder in den Abluß zu leiten.
Wandlerdruckbegrenzungsventil
Absicherung vom Wandler gegen Überdruck.
Schmierdruckventil
Überdruck- und Druckhalteventil für das Ölschmiersystem.

28
TXL 15/25

CIRCUIT HYDRAULIQUE DE LA TRANSMISSION - DISTRIBUTEUR SUPERMODULE

2
F Le bon fonctionnement de toute la transmission est dû aux organes constituant le circuit hydraulique
qui doivent:
- Garantir une pression déterminée à l’intérieur du convertisseur.
- Garantir le renouvellement de l’huile du convertisseur de façon continue et son refroidissement par
l’échangeur de température.
- Fournir de l’huile sous pression au piston de l’embrayage marche avant ou Marche Arrière.
- Lubrifier les disques de l’embrayage.
Les parties principales de l’equipement hydraulique sont:

a. LA POMPE A HUILE DE LA TRANSMISSION


Une pompe à huile, du type à denture intérieure, est montée dans la transmission. Sa vitesse de
rotation est égale à celle du moteur. L’aspiration de l’huile se vérifie par un conduit avec filtre.
b. FILTRE A HUILE
Etant monté sur le conduit d’aspiration de la pompe, il permet une filtration adéquate de l’huile
destinée aux différents groupes, sa capacité est de 25 microns.
c. CONVERTISSEUR DE COUPLE HYDRAULIQUE
Monté entre le moteur et l’inverseur, il permet par l’action dynamique d’un fluide (I’huile) de multi-
plier le couple à la sortie du moteur en l’adaptant aux demandes de travail du chariot.
d. ECHANGEUR DE TEMPERATURE
Situé sur le conduit de sortie du convertisseur il pourvoit à retirer la chaleur qui se crée lors du
fonctionnement de la boîte de vitesse.
e. INVERSEUR
Le groupe d’inversion est constitué de deux paquets d’embrayages à disques multiples, à bains
d’huile, commandés hydrauliquement par des électrovannes.
f. LE GROUPE DISTRIBUTEUR SUPERMODULE
Monté à l’extérieur de la boîte, il comprend:
Vanne de pression maxi
Elle doit contrôler la valeur de la pression de blocage des embrayages de la transmission (tarée à
11- 13 bar).
Vanne modulatrice
Placée sur le circuit d’alimentation des embrayages, elle doit contrôler l’augmentation de la pres-
sion dans le but d’obtenir une application progressive de l’embrayage intéressé indépendamment
de la rapidité de la manoeuvre.
Vanne d’Inching
Elle a la charge de partialiser la pression de blocage des embrayages et de dégager ainsi les
disques graduellement et donc de réduire de façon continue, sans changer le régime moteur, la
vitesse de marche jusqu’au point de pouvoir avancer très lentement.
Electrodistributeur sélecteur
Placé sur les conduits d’alimentation des packs embrayage, permet d’envoyer l’huile aux mar-
ches.
Vanne de sûreté du convertisseur
Elle est placée sur le conduit à l’entrée du convertisseur en règlant la pression d’entrée et le pro-
tège contre les variations excessives de pression.
Vanne de sûreté de graissage
Située sur le circuit de graissage, elle amortit la pression excessive dans ce circuit.

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Descrizione circuito idraulico - Distributore Supermodulato


Hydraulic diagram description - Supermodulating Distributor
Beschreibung Hydraulikschema - Steuerblock Supermoduliert
Schéma du circuit hydraulique - Distributeur Supermodulé

I 1 - FILTRO DI ASPIRAZIONE
2 - POMPA
3 - VALVOLA MAX. PRESSIONE
4 - VALVOLA MODULATRICE
5 - STROZZATURA
6 - CONVERTITORE DI COPPIA
7 - SCAMBIATORE DI CALORE
8 - VALVOLA DI SICUREZZA CONVERTITORE
9 - VALVOLA INCHING MECCANICA
10 - VALVOLA MARCIA AVANTI E RETROMARCIA
11 - VALVOLA DI SICUREZZA LUBRIFICAZIONE

GB 1 - SUCTION FILTER
2 - PUMP
3 - SHIFT PRESSURE VALVE
4 - PRESSURE CONTROL VALVE
5 - THROTTLE VALVE
6 - TORQUE CONVERTER
7 - HEAT EXCHANGER (COOLER)
8 - CONVERTER SAFETY VALVE
9 - MECHANICAL INCHING VALVEL
10 - FORWARD AND REVERSE SPEED VALVEL
11 - LUBRICATION SAFETY VALVE

D 1 - SAUGFILTER
2 - PUMPE
3 - SCHALTDRUCKVENTIL
4 - MODULATIONSVENTIL
5 - DROSSELVENTIL
6 - DREHMOMENTWANDLER
7 - KÜHLER
8 - WANDLERDRUCKBEGRENZUNGSVENTIL
9 - MECHANISCHES INCHVENTIL
10 - VORWÄRTS- UND RÜCKWÄRTSGANGVENTIL
11 - SCHMIERDRUCKVENTIL

F 1 - FILTRE D’ASPIRATION
2 - POMPE
3 - VANNE DE PRESSION MAXI
4 - VANNE MODULATRICE
5 - ETRANGLEMENT
6 - CONVERTISSEUR DE COUPLE
7 - ECHANGEUR DE CHALEUR
8 - VANNE DE SECURITE CONVERTISSEUR
9 - VANNE INCHING MECHANIQUE
10 - VANNE DE MARCHE AVANT ET MARCHE ARRIERE
11 - VANNE DE SECURITE LUBRIFICATION

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TXL 15/25

Schema circuito idraulico - Distributore Supermodulato


Hydraulic diagram - Supermodulating Distributor
Hydraulikdiagramm - Steuerblock Supermoduliert
Schéma du circuit hydraulique - Distributeur Supermodulé
2

LUBRIFICAZIONE
LUBRICATION
6 2.5 bar
SCHMIERUNG
LUBRIFICATION
11
All’aspirazione della pompa
All'aspirazione
Inlet to pump della pompa
CADUTA DI PRESSIONE 2 bar max.

Zur Pumpenabsaugung
A l’aspiration de la pompe
CHUTE DE PRESSION 2 bar maxi.

MARCIA AVANTI
PRESSURE DROP 2 bar max.

FORWARD GEAR
DRUCKABFALL 2 bar max.

10 VORWÄRTSGANG
MARCHE AVANT

RETROMARCIA
REVERSE GEAR
RÜCKWÄRTSGANG
MARCHE ARRIERE

8
7 4

5
11±0.5 BAR

9
3

CORPODISTRIBUTORE
CORPO DISTRIBUTORE
CONTROL VALVE BLOCK
BODY VALVES
1 STEUERBLOCK
CORPS DISTRIBUTEUR

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Distributore Supermodulato - Cambio in folle / SCHEMA A


Supermodulating Distributor - Gear in neutral position / SCHEME A
Steuerblock Supermoduliert - Getriebe in Neutralstellung / SCHEMA A
Distributeur Supermodulé - BoÎte de vitesses au point mort / SCHEMA A

I Condizione di folle
L’olio aspirato dalla pompa viene inviato, dopo essere stato filtrato, alla valvola di massima pressione
e, tramite la strozzatura (5), al convertitore. Da quest’ultimo dopo aver attraversato lo scambiatore, tra-
mite il circuito di lubrificazione, raggiunge i pacchi frizione marcia avanti e retromarcia e dopo averli
attraversati cade liberamente nella coppa.
La vena d’olio che è regolata dalla valvola principale, viene mandata in scarico tramite la selettrice.
L’olio che arriva in eccesso alla valvola principale alimenta il convertitore, la cui pressione è regolata
dalla valvola di max. pressione covertitore che devia il flusso eccedente al circuito di lubrificazione.

GB Neutral position
The oil suction by the pump, after filtration, is conducted to the pressure control valve and the, by way
of the throttle valve (5), to the converter. From there, after having passed through cooler, the oil reaches
the clutch for forward and reverse Gear through the lubrification circuit and then oil sump.
The oil flow, regulated by the main valve, is conveyed to exhaust by the selection valve.
The exceeding oil reaching the main valve feeds the converter. The converter pressure is regulated by
the converter pressure control valve that diverts the exceeding flow to the lubrication circuit.

D Neutralstellung
Das von der Pumpe angesaugte Öl wird durch den Filter zum Hauptdruckventil und zum Vorwärtsgang-
und Rückwärtsgangventil geleitet. Gleichzeitig wird das Öl von der Pumpe über eine Drossel (5)
zum Wandler durch den Kühler zur Schmierung der Kupplungen für den Vorwärtsgang und den
Rückwärtsgang und zurück in den Ölsumpf geleitet.
Der Ölfluß, der vom Hauptventil reguliert wird, wird durch den Wählschieber zum Abfluß geleitet.
Das überschüssige Öl, das am Hauptventil ankommt, versorgt den Umwandler, dessen Druck vom
Ventil für den Umwandlerhöchstdruck reguliert wird. Dieses leitet den überschüssigen Ölstrom zum
Schmierkreislauf.

F Au point mort
L’huile aspirée par la pompe est envoyée, une fois filtrée, à la vanne de pression maxi et par l’étrangle-
ment (5), au convertisseur. Après avoir passé l’échangeur, par le circuit de lubrification elle arrive aux
packs d’embrayages marche avant et marche arrière et, une fois passés, elle tombe librement dans le
carter.
L’huile dosée par la vanne principale est envoyée en vidange par la sélectrice.
L’huile qui arrive en excès à la vanne principale ravitaille le convertisseur la pression auquel est réglée
par la vanne de pression maxi convertisseur qui pousse le flux excédant au circuit de lubrification.

32
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SCHEMA A circuito idraulico - Distributore Supermodulato


SCHEME A of hydraulic diagram - Supermodulating Distributor
SCHEMA A Hydraulikdiagramm - Steuerblock Supermoduliert
SCHEMA A du circuit hydraulique - Distributeur Supermodulé
2

LUBRIFICAZIONE
LUBRICATION
6 2.5 bar
SCHMIERUNG
LUBRIFICATION
11
All’aspirazione dellapompa
All'aspirazione della pompa
CADUTA DI PRESSIONE 1,5 bar max.

Inlet to pump
Zur Pumpenabsaugung
CHUTE DE PRESSION 1,5 bar maxi.

A l’aspiration de la pompe
PRESSURE DROP 1.5 bar max.
DRUCKABFALL 1,5 bar max.

MARCIA AVANTI
FORWARD GEAR
10 VORWÄRTSGANG
MARCHE
MARCIAAVANT
AVANTI
FORWARD GEAR
RETROMARCIA
VORWÄRTSGANG
REVERSE
MARCHEGEAR
AVANT
RÜCKWÄRTSGANG
MARCHE ARRIERE
RETROMARCIA
REVERSE GEAR
8 RÜCKWÄRTSGANG
MARCHE ARRIERE
7 4

Scarico
Scarico
Exhaust
Exhaust
5 Entlastung
Entlastung
Echappement
Déchargement

Principale
Principaleimpacco
impaccofrizioni
frizioni
5 Clutch
Clutchpressure
pressure
Kupplungsdruck
Kupplungsdruck
11±0.5 BAR Principal groupe embrayages
Groupe embrayages principal
9
3 Entrata
Entrataconvertitore
convertitore
Converter
Converterinlet
inlet
Wandlereingang
Wandlereingang
2 Entrée
Entréeconvertisseur
convertisseur

CORPO
CORPODISTRIBUTORE
DISTRIBUTORE
BODY VALVES
CONTROL VALVE BLOCK
Entrata scambiatore
Uscita convertitore
1 Exchanger
Converter inlet
outlet
STEUERBLOCK
Eingang Austausches
Wandlerausgang
CORPS DISTRIBUTEUR
Entrée
Sortie échangeur
convertisseur

Lubrificazione
Lubrificazione
Lubrication
Lubrication
Schmierung
Schmierung
Graissage
Lubrification

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Distributore Supermodulato - Retromarcia, Carrello avviato / SCHEMA B


Supermodulating Distributor - Reverse gear, Started lift truck / SCHEME B
Steuerblock Supermoduliert - Getriebe in Rückwärtsgang, Fahrzustand / SCHEMA B
Distributeur Supermodulé - Marche arrière, Chariot en marche / SCHEMA B

I Marcia
Si ha durante questa fase l’alimentazione delle frizioni alla massima pressione. Tale valore viene rego-
lato dalla valvola 3.

GB Running
During this stage the clutches are supplied at maximum pressure. This value is regulated by valve 3.

D Gang
Während dieser Phase hat man im Ölzufuhrkreis für die Kupplungen den höchsten Druck. Dieser Wert
wird vom Ventil 3 geregelt.

F Marche
Pendant cette opération l’alimentation des embrayages est à la pression maxi. Cette valeur est reglée
par la vanne 3.

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SCHEMA B circuito idraulico - Distributore Supermodulato


SCHEME B of hydraulic diagram - Supermodulating Distributor
SCHEMA B Hydraulikdiagramm - Steuerblock Supermoduliert
SCHEMA B du circuit hydraulique - Distributeur Supermodulé
2

LUBRIFICAZIONE
LUBRICATION
6 2.5 bar
SCHMIERUNG
LUBRIFICATION
11
All’aspirazione della pompa
All'aspirazione della pompa
CADUTA DI PRESSIONE 1,5 bar max.

Inlet to pump
Zur Pumpenabsaugung
CHUTE DE PRESSION 1,5 bar maxi.

A l’aspiration de la pompe
PRESSURE DROP 1.5 bar max.
DRUCKABFALL 1,5 bar max.

MARCIA AVANTI
FORWARD GEAR
10 VORWÄRTSGANG
MARCHE AVANT

RETROMARCIA
REVERSE GEAR
RÜCKWÄRTSGANG
MARCHE ARRIERE

8
7 4

Scarico
Scarico
Exhaust
Exhaust
5 Entlastung
Entlastung
Echappement
Déchargement

Principale impacco
Principale impaccofrizioni
frizioni
5 Clutch pressure
Clutch pressure
Kupplungsdruck
Kupplungsdruck
11±0.5 BAR Principalembrayages
groupe embrayages
Groupe principal
9
3 Entrata convertitore
Entrata convertitore
Converter inlet
Converter inlet
Wandlereingang
Wandlereingang
2 Entrée convertisseur
Entrée convertisseur

CORPODISTRIBUTORE
CORPO DISTRIBUTORE
CONTROL VALVE BLOCK
BODY VALVES Entrata convertitore
Uscita scambiatore
1 Exchanger inlet
Converter outlet
STEUERBLOCK
CORPS DISTRIBUTEUR
Eingang Austausches
Wandlerausgang
Entrée convertisseur
Sortie échangeur

Lubrificazione
Lubrificazione
Lubrication
Lubrication
Schmierung
Schmierung
Graissage
Lubrification

35
TXL 15/25

Distributore Supermodulato - Retromarcia in Inching / SCHEMA C


Supermodulating Distributor - Inching reverse gear / SCHEME C
Steuerblock Supermoduliert - Getriebe in Rückwärtsgang Inching / SCHEMA C
Distributeur Supermodulé - Marche Arrière en Inching / SCHEMA C

I Manovra Inching
La manovra del pedale Inching attuata per abbinare piccoli accostamenti del carrello con elevato
regime di rotazione motore parzializza l’alimentazione della frizione interessata, riducendo la pres-
sione di lavoro e quindi la coppia trasmessa.

GB Inching manoeuver
The Inching control allows precise movement of the vehicle, irrespective of engine speed. The oil
feed to the clutch is controlled, lowering the operating pressure, allowing slipping to occur according
to pedal position.

D Inchbetätigung
Durch Betätigung des Inchpedals, wird der Druck der jeweils beaufschlagten Kupplung so gesteuert,
dass mit dem Stapler eine Kriechfahrt durchgeführt und stufenlos variiert werden.

F Manoeuvre Inching
La manoeuvre de la pédale Inching réalisée pour jumeler petits rapprochements du chariot à régime
de rotation moteur élevé, partialise l’alimentation de l’embrayage intéressé en réduisant la pression
de travail et donc le couple transmis.

36
TXL 15/25

SCHEMA C circuito idraulico - Distributore Supermodulato


SCHEME C of hydraulic diagram - Supermodulating Distributor
SCHEMA C Hydraulikdiagramm - Steuerblock Supermoduliert
SCHEMA C du circuit hydraulique - Distributeur Supermodulé
2

LUBRIFICAZIONE
LUBRICATION
6 2.5 bar
SCHMIERUNG
LUBRIFICATION
11
All’aspirazione della pompa
All'aspirazione della pompa
CADUTA DI PRESSIONE 1,5 bar max.

Inlet to pump
Zur Pumpenabsaugung
CHUTE DE PRESSION 1,5 bar maxi.

A l’aspiration de la pompe
PRESSURE DROP 1.5 bar max.
DRUCKABFALL 1,5 bar max.

MARCIA AVANTI
FORWARD GEAR
10 VORWÄRTSGANG
MARCHE AVANT

RETROMARCIA
REVERSE GEAR
RÜCKWÄRTSGANG
MARCHE ARRIERE

8
7 4

Scarico
Scarico
Exhaust
Exhaust
5 Entlastung
Entlastung
Echappement
Déchargement

Principale impacco
Principale impaccofrizioni
frizioni
5 Clutch pressure
Clutch pressure
Kupplungsdruck
Kupplungsdruck
11±0.5 BAR Principalembrayages
Groupe groupe embrayages
principal
9
3 Entrata convertitore
Entrata convertitore
Converter inlet
Converter inlet
Wandlereingang
Wandlereingang
2 Entrée convertisseur
Entrée convertisseur

CORPODISTRIBUTORE
CORPO DISTRIBUTORE
BODY VALVES
CONTROL VALVE BLOCK Entrataconvertitore
Uscita scambiatore
1 Exchanger outlet
Converter inlet
STEUERBLOCK
CORPS DISTRIBUTEUR
Eingang Austausches
Wandlerausgang
Entrée convertisseur
Sortie échangeur

Lubrificazione
Lubrificazione
Lubrication
Lubrication
Schmierung
Schmierung
Graissage
Lubrification

Inching
Inching

37
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SMONTAGGIO E MONTAGGIO TRASMISSIONE - ISTRUZIONI GENERALI

I Istruzioni generali
Prima di iniziare il lavoro di smontaggio e montaggio della trasmissione bisogna tener presente i seguenti punti:
1) Si raccomanda la massima pulizia durante il lavoro sulla trasmissione, per cui prima del montaggio tutti i
componenti devono essere accuratamente puliti.
2) Il luogo dove dovrà essere effettuato il lavoro dovrà essere privo di polvere e pulito al massimo.
3) Assicurarsi che si abbiano a disposizione tutti gli attrezzi necessari, ed in particolare quelli riportati in questo
manuale. Particolari non perfettamente montati possono infatti provocare gravi danni nella trasmissione,
come anche trucioli o corpi estranei.
4) Durante la revisione della trasmissione si consiglia di sostituire con pezzi nuovi le seguenti parti:
anelli di tenuta olio, guarnizioni, fasce elastiche ed eventuali particolari danneggiati durante lo smontaggio.
5) Nel caso di rotture all’interno della trasmissione, tutti i condotti, le scatole e lo scambiatore di calore devono
essere accuratamente puliti per evitare danni provocati dai residui rimasti nel circuito.

SPESSORI DI REGISTRO
Ad ogni registrazione selezionare gli spessori di registro misurandoli uno ad uno con micrometro e sommando
successivamente i valori rilevati: non fidarsi dell’erronea misurazione del pacco completo oppure del valore
nominale indicato per ciascun anello.
GUARNIZIONI DI TENUTA PER ALBERI ROTANTI
Per il corretto montaggio delle guarnizioni di tenuta per alberi rotanti, attenersi alle seguenti avvertenze:
▲ prima del montaggio, mantenere le guarnizioni a bagno per almeno mezz’ora nello stesso olio di cui faranno
tenuta;
▲ pulire accuratamente lʼalbero ed assicurarsi che la superficie di lavoro dello stesso non risulti danneggiata;
▲ orientare il labbro di tenuta verso il fluido; nel caso di labbro idrodinamico le rigature devono
risultare orientate in modo che, considerando il senso di rotazione dell’albero, tendano a
riportare il fluido verso l’interno del mezzo di tenuta;
▲ spalmare sul labbro di tenuta un velo di lubrificante (l’olio è da preferire al grasso) e riempire
con grasso il vano tra labbro di tenuta e labbro parapolvere delle guarnizioni a doppio labbro;
▲ introdurre la guarnizione nella relativa sede pressandola oppure impiegando un punzone con superficie di
contatto piana, evitare in modo assoluto di colpirla con martello o mazzuolo;
▲ durante il piantaggio, assicurarsi che la guarnizione venga introdotta perpendicolarmente
rispetto alla sede ed, a piantaggio ultimato, accertarsi che, nei casi richiesti, risulti a contatto
dello spallamento;
▲ ad evitare che il labbro di tenuta della guarnizione possa venire danneggiato dall’albero, inter-
porre una protezione adeguata durante il montaggio delle due parti.

GUARNIZIONI TOROIDALI O-RING


Lubrificare le guarnizioni O-RING prima di inserirle nelle rispettive sedi per evitare che, duran-
te la fase di montaggio, rotolino su se stesse ed assumano una posizione attorcigliata che ne
pregiudicherebbe la tenuta.
MASTICI DI TENUTA
Sulle superfici da accoppiare applicare il mastice di tenuta LOCTITE 510 o similare.
Prima di procedere all’ applicazione del mastice, preparare le superfici nel modo seguente:
▲ asportare eventuali incrostazioni mediante spazzola metallica;
▲ sgrassare accuratamente le superfici.

CUSCINETTI
Nel montaggio dei cuscinetti è consigliabile:
▲ riscaldarli ad 80-90° C prima di montarli sui rispettivi alberi;
▲ raffreddarli prima di inserirli nelle relative sedi con piantaggio esterno.

SPINE ELASTICHE
Al montaggio delle spine elastiche a tubo spaccato assicurarsi che l’intaglio delle stesse sia orientato nel
senso dello sforzo, sollecitante la spina.
Le spine elastiche a spirale invece non necessitano di alcun orientamento di montaggio.

IMPORTANTE: L’eliminazione fisica dei materiali usurati e sostituiti deve avvenire nel
rispetto delle leggi locali vigenti.

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DISASSEMBLING AND RE-ASSEMBLING OF TRANSMISSION - GENERAL INSTRUCTIONS

3
GB General instructions
Prior to starting work on the dismantling or assembing of the transmission, bear in mind the following points:
1) When working on the transmission observe high standards of cleanliness. All parts should be cleaned
throughly prior to assembly.
2) The location where the work is to be carried out should be dust-free clean.
3) Make sure that all the necessary tools are available, particularly those mentioned in this manual. Parts fitted
incorrectly can cause serious damage to the transmission, in the same way as metal chips or foreign
bodies.
4) During the transmission overhaul, you are advised tu substitute the following with new parts: oil sealing
rings, gaskets, retaining rings and any parts damaged during dismantling.
5) If breakage occurs inside the transmission, all lines, casing and heat echanger should be cleaned thoroughly
to prevent damage caused by residues left inside the system.

SHIMS
All adjustments shall be carried out after all adjustment shims have been selected measuring them one by
one with a micrometer gauge and, then, summing up all values measured; don’t trust incorrect measure-
ment of pack as a unit or sum of nominal value printed on each shim.

SEALS FOR REVOLVING SHAFTS


Proceed as follows for proper fitting of captioned seals:
▲ prior assembly, seals should be kept, for at least half an hour, in a bath with the same oil to be sealed;
▲ clean thoroughly shaft and make that working surface be not damaged;
▲ position sealing lip against the fluid to be sealed; in case of hydrodynamic lip lines should be oriented so
as that, considering direction of revolving shaft, they lead fluid inside of sealing means;
▲ smear sealing lip with a film of lubricant (oil is better than grease) and fill up with grease the space
between sealing lip and dust shield lip, if using double sealing lip type seals;
▲ press seal in relevant seat or use a proper fitter with flat contact surface; never use hammer or mallet to
mount seal;
▲ when press fitting seal make sure that it be correctly driven in relevant seat, i.e., perpendicular with res-
pect to its seat, as fitting is completed make sure, if required, that seal itself be in contact with relevant
shoulder;
▲ to prevent damage of seal lip when inserting shaft, duly protect component during assembly.

O-RING SEALS
Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.

SEALING COMPOUNDS
For matching surfaces identified by X use compound LOCTITE 510 or similar one.
Clean matching surface as follows prior, smearing compound:
▲ remove old deposits using a metal brush;
▲ degrease surfaces by one the following cleaners: trichloroethylene, kerosene or a warm water and
soda solution.

BEARINGS
When assembling them it is advisable to proceed as follows:
▲ heat them at 80 to 90 °C before fitting on relevant shafts;
▲ cool them before inserting in relevant external seats.

SPRING PINS
When using split pins be sure that lengthwise cleft be positioned toward stress on pin.
Coil pins don’t require specific position.

IMPORTANT: Dispose of worn and replaced materials according to local regulation.

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D GETRIEBE DEMONTAGE UND MONTAGE - HAUPT INSTRUKTIONEN

Algemeine anweisungen
Von dem Ein- oder Ausbau der Kraftübertragung müssen folgende punkte beachtet werden:
1) Sauberkeit ist für die Arbeit an der Kraftübertragung sehr wichtig, deshalb müssen alle Teile vor
dem Einbau sorgfältig gereinigt werden.
2) Der dafür vorgesehene Arbeitsplatz muß staubfrei und gereinigt sein.
3) Prüfen, ob die notwendigen und in diesem Handbuch beschrieben Werkzeuge verfügbar sind. Nicht
einwandfrei eingebaute Teile, sowie Spähne und Fremdkörper können schwere Schäden im Getriebe
verursachen.
4) Bei der Wartung der Getriebe wird empfohlen, folgende Teile durch neue zu ersetzen: Alle
Dichtungen und eventuell die Teile, die beim Ausbau beschädigt worden sind.
5) Bei Defekten Getrieben müssen alle Leitungen, das Gehäuse und der Wärmetauscher sorgfältig
gereinigt werden, damit Schäden durch zurückgebliebene Fremdkörper vermieden werden.

AUSGLEICHSSCHEIBEN
Alle Einstellungen sollen vorgenommen werden, nachdem alle Ausgleichsscheiben, gemes-
sen mit einem Mikrometer, auf die benötigte Distanz zusammengestellt wurden. Vertraue
nie möglichen inkorrekten Messungen eines Paketes als ganzes, oder der Angabe eines nominellen Wertes,
angegeben auf den Ausgleichsscheiben.

DICHTUNGEN FÜR DREHENDE WELLEN


Für richtigen Einbau beachte folgende Schritte:
▲ Vor dem Einbau sollte die Dichtung mindestens eine halbe Stunde im selben Öl gelegen haben das
auch abgedichtetwerden soll.
▲ Reinige die Welle und stelle sicher, daß die Dichtfläche nicht beschädigt ist.
▲ Die Dichtlippe muß immer in Richtung der abzudichtenden Flüssigkeit eingebaut werden. Bei
Verwendung von Labyrinthdichtungen müssen die Rillen unter Beachtung der Drehrichtung der Welle so
eingebaut werden , daß das rücklaufende Öl immer in Richtung der abzudichtenden Seite fließt.
▲ Schmiere die Dichtlippe mit einem Film Öl ein und fülle den Raum zwischen Dichtlippe und
Staubdichtung mit Fett, wenn Doppel-Dichtringe verwendet werden.
▲ Presse die Dichtung in den entsprechenden Sitz oder benütze ein entsprechendes Montage
Werkzeug, niemals Hammer oder Dorn zur Montage benutzen.
▲ Bei der Montage beachten und sicherstellen, daß die Dichtung richtig im dafür vorgesehenen Platz
sitzt. Überprüfe, daß die Dichtung richtig an der Dichtfläche arbeitet.
▲ Um Beschädigungen der Dichtlippe zu vermeiden bei der Montage der Welle, schütze das Teil so
gut wie möglich.

O-RING DICHTUNGEN
Der O-Ring soll vor Montage eingeölt werden um ein Verdrehen und dadurch Leckagen zu vermeiden.

DICHTUNGS - MITTEL
Für Rontaktflächen bezeichnet mit X sollten nur folgende Mittel verwendet werden: LOCTITE 510.
Reinige die Kontaktflächen wie folgt vor Anwendung von Dichtmittel:
▲ Reinige Kontaktflächen von altem Dichtmittel Entfette Kontaktflächen mit:
▲ Trichloräthylene, Benzin oder warmem Wasser mit Soda Lösung.

LAGER
Bei der Lagermontage soll wie folgt verfahren werden:
▲ Erwärmung auf 80 bis 90 Grad Celsius für Montage auf Welle Kühlung vor Einbau in entsprechenden Sitz.

FEDERSTIFTE
Bei Verwendung von Spannstiften soll die Öffnung in Richtung Kraftwirkung eingebaut werden.
Federstifte erfordern keine spezifische Richtung.

HAUPTSACHE: die Elimination der ausgelaufenen und erneuerten Stoffe muß entsprechend
der örtlichen geltenden Gesetze zustande kommen.

40
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DEMONTAGE ET MONTAGE DE LA TRANSMISSION - GENERALITES

F Généralites
3
Avant de démonter ou de monter la bôite de vitesse il faut tenir compte des éléments suivants:
1) On recommande le maximum de propreté et de soin pendant l’intervention, c’est pour cette raison
qu’avant le montage tous les composants devront être soigneusement nettoyés.
2) L’endroit où l’on effectue le travail doit être propre et sans poussière.
3) Vérifier que tous les accessoires dont on a besoin sont disponibles et particulièrement ceux qui sont
mentionnés dans ce manuel. Des pièces mal montées peuvent en effet causer des dommages
importants dans la transmission.
4) Pendant la révision de la transmission nous vous conseillons de remplacer les pièces suivantes:
joints étanchéite d’huile, joints elastiques, joints toriques et toutes les pièces qui ont été éventuellement
déteriorées pendant le démontage.
5) En cas de rupture à l’intérieur de la transmission, tous les conduits, les carters et l’échangeur de chaleur
doivent être bien nettoyés afin d’éviter des dommages provoqués par des résidus restés dans le circuit.
CALES DE REGLAGE
A chaque réglage sélectionner les cales de réglage en les mesurant un à un par micromètre et en aditionnant
par la suite les valeurs relevées: ne pas compter sur l’erronée mesurage du paquet complet ou de la valeur
nominale indiquée pour chaque bague.
JOINTS D’ETANCHEITE POUR ARBRES ROULANTS
Pour un correct montage des joints d’étanchéité pour arbres roulants s’en tenir aux instructions suivates:
▲ avant le montage, maintenir les joints à bain pour au moins une demi-heure dans le même huile dont ils
feront étanchéité;
▲ nettoyer soigneusement l’arbre et s’assurer que la surface de travail du même ne pas résulte endommagée;
▲ orienter le bord dʼétanchéité vers le fluide; si le bord est hydrodynamique les rayures doivent
être orientées de façon que, tenu compte du sens de rotation de l’arbre, elles tendent à reporter le fluide
vers l’intérieur du moyen d’étanchéité;
▲ étaler sur le bord d’étanchéité un voile de lubrifiant (l’huile est à préférer au gras) et remplir
avec du gras le siège entre le bord d’étanchéité et le bord parapoussière des joints à bord double;
▲ introduire le joint dans le relatif siège en le pressant ou en utilisant un poinçon avec une
surface de contact plane, éviter absolument de le frapper par marteau ou massette;
▲ pendant le plantage, s’assurer que le joint soit introduit perpendiculaire par rapport au
siège et, à plantage achevé, s’assurer que, dans les cas demandés, il résulte à contact de
l’épaulement;
▲ afin d’éviter que le bord d’étanchéité du joint soit endommagé par l’arbre, interposer une
protection appropriée pendant le montage des deux parts.
JOINTS TOROIDALS O-RING
Lubrifier les joints O-RING avant de les insérer dans les respectifs sièges afin d’éviter
que, pendant la phase de montage, ils roulent sur eux-mêmes et assument une position
enroulée qui serait nocive pour son étanchéité.
PATES A JOINT
Sur les surfaces qu’il faut accoupler appliquer la pâte à joint LOCTITE 510 ou similaires.
Avant de procéder à lʼapplication de la pâte à joint, préparer les surfaces de cette façon:
▲ emporter éventuelles incrustations par une brosse métallique;
▲ dégraisser soigneusement les surfaces.
ROULEMENTS
Pendant le montage des roulements il est conseillable:
▲ les chauffer à 80-90°C avant de les monter sur les respectifs arbres;
▲ les refroidir avant de les insérer dans les sièges relatifs par plantage extérieur.
GOUPILLES ELASTIQUES
Au montage des goupilles élastiques à tuyau fendu s’assurer que l’entaille des mêmes soit orienté vers l’ef-
fort, en activant la goupille.
Pour les goupilles élastiques à spiral au contraire il ne faut pas d’orientation de montage.

IMPORTANT: L’ èlimination physique des vieux matériaux ou de ceux qui ont ètè remplacés doit
être faite dans le respect des lois en vigueur.

41
TXL 15/25

ISTRUZIONI GENERALI / Conservazione ed utilizzo del prodotto


GENERAL INSTRUCTIONS / Storage and service instructions
HAUPT INSTRUKTIONEN / Lager- und Service Hinweise
GENERALITES / Conservation et utilisation du produit

I Per garantire la corretta conservazione, manipolazione ed utilizzo del prodotto occorre attenersi alle
seguenti istruzioni:

TEMPERATURA AMBIENTE

• di immagazzinamento - 40 + 60° C
• di lavoro - 30 + 60° C

Durante la manipolazione del prodotto evitare urti che potrebbero danneggiare componenti ester-
!
ni ed interni.

In caso di fermate prolungate prima dell’installazione o del riavviamento assicurarsi che il prodotto
!
non abbia subito danni.

! Non sottoporre i componenti elettrici a tensioni incompatibili con le loro caratteristiche

Non utilizzare mai benzina, gasolio o altri liquidi infiammabili come detergenti: ricorrere invece ai
!
solventi commerciali ininfiammabili e non tossici.

! In caso di arresto e di abbandono del veicolo assicurarsi che il freno di stazionamento sia inserito.

Il mancato rispetto di queste istruzioni oppure l’uso non corretto del prodotto può
produrre danni a cose o persone.

GB In order to assure the right condition, handling and utilization of the product, perform the following
instruction:

TEMPERATURE CONDITIONS

• Storage - 40 + 60° C
• Working - 30 + 60° C

During the handling of the product avoid any collision in order not to damage the external and
!
internal components.

In case of long inactivity of the product, before installing or starting, beware that the product has
! not suffered any damage.

! Do not energize the electrical components with incompatible voltage.

Never use petrol, solvents or other inflammable fluids, use only approved commercial solvents
! that are both non-inflammable and not-toxic.

! In case of stopping and before living the vehicle, make sure the parking brake is engaged.

Failing to follow these instructions or an unproper use of the product may result in harm to per-
sons and objects damages.

42
TXL 15/25

HAUPT INSTRUKTIONEN / Lager- und Service Hinweise


GENERALITES / Conservation et utilisation du produit
3
D Um die angemessene Lagerung, Behandlung und Verwendung der Produkte zu garantieren, müssen
folgende Hinweise beachtet werden:

TEMPERATURBEDINGUNGEN

• Bei Lagerung - 40 + 60° C


• Im Einsatz - 30 + 60° C

! Innere und äußere Beschädigungen sind zu vermeiden

ßei Längerer Lagerung des Produktes, muß sichergestellt sein, daß keine Beschädigung auf-
!
getreten ist.

! Elektrische Komponenten sind nur mit der vorgeschriebenen Spannung zu belasten.

Niemals Benzin, Lösungsmittel oder entflammbare Flüssigkeiten verwenden.


!
Handelsübliche, nicht ent-flammbare und ungiftige Reinigungsmittel benützen.

! Beim Abstellen und vor dem Verlassen des Fahrzeuges ist die Parkbremse zu betätigen.

Durch Nichtbeachtung dieser Instruktionen oder einer ungeeigneten Verwendung dieses


Produktes kann Gefahr für Menschen oder Sachschaden an Objekten entstehen.

F Pour garantir une correcte conservation, manipulation et utilisation du produit, il faut s’en tenir aux
instructions suivantes:

TEMPERATURE AMBIANTE

• Stockage - 40 + 60°C
• de travail - 30 + 60°C

Pendant la manipulation du produit éviter les coups qui pourraient endommager les components
!
extérieurs et intérieurs.

En cas d’arrêts prolongés avant de l’installation ou du redémarrage s’assurer que le produit ne


!
soit pas endommagé.

! Ne pas soumettre les éléments électriques à tensions incompatibles avec leurs caractéristiques.

Ne jamais utliser de l‘essence, gas-oil ou des autres liquides inflammables comme détergents:
! utiliser plutôt des solvents commerciaux ni inflammables ni toxiques.

! En cas d’arrêt et d’abandon du vehicule s’assurer que le frein de stationnement soit inséré.

Le manqué respect des instructions ou un usage pas approprié du produit peut provoquer des
dommages à choses ou personnes.

43
TXL 15/25

SMONTAGGIO E MONTAGGIO TRASMISSIONE - Attrezzi speciali


DISASSEMBLING AND RE-ASSEMBLING OF TRANSMISSION - Specific tools
GETRIEBE DEMONTAGE UND MONTAGE - Montagewerkzeug
DEMONTAGE ET MONTAGE DE LA TRANSMISSION - Outils

1 - Attrezzo per montaggio piatto di trascinamento


Bolt for assemble the flexi plate
Bolzen zur Montage der Membrane
Outil pour positionnement de plateau d’entraînement.
2 - Attrezzo per smontaggio e montaggio anello elastico
Holder for compress the platespring to assembly or deassembly the snap ring
Halter zum Niederdrücken der Flachfeder, damit Sicherungsring montiert oder entferntwerden kann
Outil pour démontage et montage de segment.
3/A - Anello montaggio cuscinetto e seeger su manicotto
Bolt and sleeve for assembly of bearing with circlip
Bolzen und Hülse zur Montage von Rillenkugellager mit Sicherungsring
Bague de montage roulement et seeger sur manchon.
3/B - Punzone montaggio cuscinetto su manicotto
Bolt for assembly of bearing
Bolzen zur Montage von Rillenkugellager
Poinçon de montage de roulement sur manchon.
4 - Punzone per piantaggio cuscinetto a sfere
Forcing bearing tool
Bolzen fur Montage von Rillenkugellager
Poinçon pour positionnement de roulement à billes.
5 - Attrezzo per posizionamento assiale pignone conico
Pipe for bevel pinion assembly
Rohr für Montage des Kegelritzel
Outil pour positionnement axial de pignon conique.
6 - Punzone per piantaggio anello di tenuta su carter
Bolt for assembly a shaft seal
Bolzen zur Montage von Wellendichtring
Poinçon pour positionnement de bague d’étanchéité sur carter.
7 - Punzone per piantaggio cuscinetto a sfere
Bolt for assembly of bearing
Bolzen zur Montage von Rillenkugellager
Poinçon pour positionnement de roulement a billes.
8/A - Chiave per chiusura ghiera pignone
Slotted nut spanner for bevel pinion
Nutmutterschlüssel für kegelritzel
Clef de fermeture de frette de pignon.
8/B - Attrezzo per bloccaggio e sbloccaggio ghiera pignone conico
Retaining ring in the clutch to release/look the slotted nut
Haltering in der kupplung zum offnen/anziehen der Nutmutte
Outil pour blocage et deblocage de frette de pignon conique.
9 - Punzone per montaggio anello di tenuta
Bolt to assemble shaft seal
Bolzen zur Montage von Wellendichtring
Poinçon pour montage bague d’étanchéité.
10 - Punzone per piantaggio pista interna cuscinetto testa pignone
Bolt for assembly tapered roller bearing
Bolzen zur Montage von Kegelrollenlager
Poinçon pour positionnement de piste intérieure de roulement de tête pignon.

44
TXL 15/25

Attrezzi / Tools / Werkzeug / Outils

1 2 3A 3B 4
3
5
4902403/1

4903030 48A11850 4902403(2/2) 4902404 4902082

4A42440/1

6 7 8A 8B 9 10

4902058 4902107 4902836 4A2440/2 4902081 4902076

45
TXL 15/25

SMONTAGGIO E MONTAGGIO PONTE - Attrezzi speciali


DISASSEMBLING AND RE-ASSEMBLING OF AXLE - Specific tools
ACHSE DEMONTAGE UND MONTAGE - Montagewerkzeug
DEMONTAGE ET MONTAGE DE PONT - Outils

12 13

48A12093 48A12125

11

3VT00293

11 - Attrezzo per bloccaggio e sbloccaggio ghiera mozzo ruota


Retaining ring in the clutch to release/look the wheel hub
Haltering in der kupplung zum Öffnen/Anziehen der Nutmutte
Outil pour blocage et deblocage de frette moyeu de la roue.
12 - Punzone per montaggio anello di tenuta
Bolt to assemble shaft seal
Bolzen zur Montage von Wellendichtring
Poinçon pour montage bague d’étanchéité.
13 - Punzone per montaggio anello di tenuta
Bolt to assemble shaft seal
Bolzen zur Montage von Wellendichtring
Poinçon pour montage bague d’étanchéité.

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TXL 15/25

Smontaggio e montaggio trasmissione


Dismantle and assemble transmission
Getriebe Demontage und Montage
Demontage et montage de la transmission
3
! SICUREZZA GENERALE !
Prima di eseguire qualsiasi intervento di riparazione, predisporre le adeguate misure di
I
sicurezza indicate nel capitolo “Norme di sicurezza” e rispettare le leggi vigenti in materia di sicu-
rezza nei posti di lavoro.

! GENERAL SAFETY !
Before undertaking any repair, follow safety rules indicated in chapter “Safety rules” in accor-
GB
dance with specific local regulation about safety on work places.

!
ALLGEMEINE SICHERHEIT !
Vor jeder Ausbesserung vorbereiten die Sicherheitsmaßnahme, die im Kapitel “Sicherheit
D
sbestimmungen” angegeben sind und achten die besonderen Gesetze über die Sicherheit im
Arbeitsplätze.

!
SURETE GENERALE !
Avant d’effectuer toute intervention de réparation, préparer les mesures de sûreté les plus
F
adéquates, indiquées au chapitre “Normes de sûreté” et respecter les réglementations en vigueur
en matière de sûreté sur les lieux de travail.

I Scarico olio: Scaricare l’olio attraverso il tappo


B, della scatola ponte ed il tappo A, della scatola
centrale .

GB Oil draining: Drain oil thru plug B of axle casing


and plug A of central body.
D Ölablassen: Schrauben B Achsgehäuse und
Schrauben A Getriebegehäuse.
F Dégorgement huile: Dégorger l’huile par le bou-
chon B, du carter pont et les bouchons A, du car-
ter central. 1a

I In figura è rappresentato il filtro posto sull’ aspira-


zione della pompa. È opportuno che in occasione
di una revisione esso venga sostituito completo di
anello di tenuta O-RING.

GB The diagram shows the filter placed on the


pump intake. When any overhaul is carried out
the filter should be replaced complete with its
O-Ring seal.

D Vor der Demontage Öl vom Getriebe und Achse


ablassen. Falls der Wandler nicht am Schwungrad 1b
montiert bleibt, Wandler abziehen. Filter kom-
plett herausschrauben O-RING und Filtereinsatz
erneuern.
F La figure représente le filtre placeé côte aspiration
de la pompe. A l’occasion d’une révision, il est
conseillé de remplacer le filtre avec le joint torique.

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TXL 15/25

Smontaggio e rimontaggio Distributore Standard


Dismantling and re-assembling of the Standard Distributor
Demontage und Zusammenbau der Standard-Steuerblock
Démontage et rémontage du Distributeur Standard

I Stacco distributore
Smontare il gruppo valvola antishock e la relativa
guarnizione, rimuovendo le viti di ritegno.

GB Distributor removal
Dismantle the antishock valve assembly and its
gasket, removing the retaining screws.

D Ausbau Steuerblock
Vier Befestigungsschrauben vom Antischockventil
lösen und Antischockventil komplett abheben.
2 F Détachement du distributeur
Démonter le groupe de vanne antichoc et le joint
correspondant, après avoir enlevé les vis de fixation.

I Sbloccare e svitare le viti di fissaggio e smontare il


distributore completo.
GB Unscrew the fixing screws and dismantle the com-
plete distributor.

D Zwölf Befestigungsschrauben lösen und


Steuerblock komplett abheben.

F Débloquer et desserrer les vis de fixation, puis


3 déposer le distributeur complet.

I Smontare la piastra di collegamento del distribu-


tore al carter inversore e la relativa guarnizione di
tenuta in carta, svitando le viti di ritegno.

GB Remove the plate that connects the distributor to


the reversing gear case, together with its paper
gasket, unscrewing the retaining screws.

D 2 Befestigungsschrauben lösen und


Olverteilerplatte mit Dichtung abheben.

F Démonter la plaque d’assemblage du distributeur


4 au carter d’inverseur, ainsi que le joint d’étanchéité
en papier, après desserrage des vis de fixation.

48
TXL 15/25

Revisione distributore standard


Standard distributor overhauling
Nachprüfung Standard-Steuerblock
Révision du distributeur standard
3
7 6 5

2
INCHING IDRAULICO INCHING MECCANICO
HYDRAULIC INCHING MECHANICAL INCHING
3 HYDRAULISCHES INCHING MECHANISCHES INCHING
INCHING HYDRAULIQUE INCHING MECANIQUE

I Smontaggio distributore standard D Demontage Standard-Steuerblock


Nella figura sono individuabili, i quattro assi del Das Bild zeigt die 4 Schaltebenen des
distributore: Steuerblocks (von unten nach oben):

1) asse Inching control 1) Inchkolben


2) asse selettrice Marcia Avanti - Retromarcia 2) Schaltmagnetventile für den Vorwärts-und
3) asse valvola modulatrice. Rückwärtsgang
4) asse valvola pressione convertitore e 3) Modulationsventil
pressione principale. 4) Wandlerdruck und Hauptdruck
5) Gruppo valvola antishock 5) Antischockventil
6) Presa pressione Marcia Avanti 6) Kupplungsdruck VORWÄRTSGANG
7) Presa pressione Retromarcia 7) Kupplungsdruck RÜCKWÄRTSGANG

GB Standard distributor dismantling F Demontage du distributeur standard


Distributor shafts are shown as follows from bottom Dans la figure on peut voir, du bas vers l’haut,
to top: les quatre axes du distributeur:
1) axe contrôle Inching
1) Inching control shaft 2) axe sélecteur avant-arrière
2) forward-reverse shifting shaft 3) axe vanne modulatrice
3) Modulating valve. 4) axe vanne pression convertisseur et pression
4) Converter pressure shaft and main pressure principale
5) Antishock valve 5) Groupe vanne antichoc
6) Forward pressure 6) Prise de pression avant
7) Reverse pressure 7) Prise de pression arrière

49
TXL 15/25

Inching Idraulico Inching Meccanlco I Smontaggio Asse Inching - Versione Comando


Hydraulic Inching Mechanical Inching Idraulico
Hydraulisches Inching Mechanisches Inching
Svitare il bocchettone (a) dal distributore e il boc-
Inching Hidraulique Inching Mecanique
chettone dal corpo Inching, rimuovere rosette di
tenuta e tubo.
Svitare le quattro viti (b) di fissaggio corpo Inching
al distributore.
GB Inching Axle Dismantling - Hydraulic Inching
Version
a
Unscrew connector (a) from distributor and con-
nector from Inching body, remove rubber seals
and pipe.
Undo fixing screws (b) of Inching body to distributor.

D Ausbau Inching-Achse - Version hydraulische


Schaltung
b Den Stutzen (a) vom Verteiler und den Stutzen
vom Inching-Körper abschrauben, Dichtringe und
Leitung abnehmen.
5 5a Die vier Befestigungsschrauben (b) Körper Inching
am Verteiler abschrauben.
F Démontage Axe Inching - Versión Commande
Hydraulique
Dévisser le raccord (a) du distributeur et le raccord
du corps Inching, enlever joints et tuyau.
Dévisser les quatre vis de fixation (b) corps Inching
au distributeur.

I Staccare dal corpo distributore il corpo Inching


completo (con relativa guarnizione di tenuta in
carta), svitando le viti di fissaggio.
Sfilare assialmente i componenti dell’asse Inching-
control.

GB Detach the complete Inching body (together


with its paper gasket) from the distributor body,
unscrewing the fixing screws.
Remove axially the components of the Inching-
control axle.
6 6a
D Rohrleitung entfernen und Befestigungsschrauben
lösen.
IMPORTANTE: Il comando Inching idraulico Inchgehäuse komplett mit Dichtung abnehmen
non è revisionabile, in caso di usura o malfun- und Kolben vom Steuerungsgehäuse heraus-
zionamento, sostituire. ziehen.

IMPORTANT: The inching control assy is not F Retirer le corps de la commande d’approche
repairable. In case of wear or malfunction a lente complet du corps de distributeur (avec le joint
new assy must be fitted. d’étanchéité en papier), après desserrage des vis
de fixation.
HAUPTSACHE: Der Inching-Hydraulik-Befehl Dégager les composants de l’axe de commande
kann nicht instandgesetzt werden: beim d’approche lente.
Verschleiss oder Störung austauschen

IMPORTANT: La commande Inching


hydraulique ne peut pas être inspectée, en
cas d’usure ou de mauvais fonctionnement, la
remplacer.

50
TXL 15/25

I Smontaggio valvola selettrice Marcia Avanti-


Retromarcia: svitare le viti a testa cilindrica dei
coperchietti di ritegno elettrovalvole, quindi estrar-
le dalle proprie sedi, unitamente all’anello di tenu-
3
ta O-Ring.

GB Dismantling the Forward / Reverse Gear


selectorvalve: unscrew the cap screws of the
electrical valve retaining covers, then remove them
from their seatings, together with the O-Ring seal.

D Befestigungsschrauben vom Halteblech für die


Vorwärts-und Rückwärtsgang: 7
Elektromagnetventile herausschrauben.
Halteblech abnehmen und Magnetventile mit O-
Ring herausziehen.

F Démontage de la vanne de sélection de


Marche Avant-Arrière: desserrer les vis à tête
cylindrique des couvercles de fixation des
électrovannes, puis les sortir avec le joint torique.

I Estrarre i pistoncini e la reativa molla di richiamo,


quindi sfilare i lamierini di arresto corsa assiale
delle valvole.

GB Extract the pistons and their return springs, then


remove the axial valve travel stop blades.

D 2 Kolben und Feder herausnehmen sowie


Anschlagblech herausziehen.

F Sortir les pistons et le ressort de rappel corre-


spondant, puis retirer les butées d’arrêt de course
axiale des vannes. 8

I Sbloccare e svitare la vite di fine corsa valvola


modulatrice.

GB Release and unscrew the modulator valve end-of-


travel screw.

D Fixierschraube für Kolben im Modulationsventil


herausschrauben.

F Débloquer et desserrer la vis de fin de course de


la vanne modulatrice.
9

I Sfilare assialmente la valvola modulatrice da


corpo distributore, dopo aver rimosso il tappo di
estremità.

GB Remove the modulator valve axially from the distri-


butor body, after having removed the end plug.

D Verschluß-Schraube herausschrauben Kolben


herausziehen.

F Dégager axialement la vanne modulatrice du corps


du distributeur, après avoir retiré le bouchon d’extré-
mité. 10

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TXL 15/25

I Svitare il tappo lato astuccio modulatrice ed


11 estrarlo unitamente alle molle.

GB Undo the plug on the modulator casin side and


remove it together with the springs.

D Verschluß-Schraube auf der anderen Seite heraus-


schrauben, Kolben und Federn herausziehen.

F Desserrer le bouchon côté boîtier modulateur, et le


sortir avec les ressorts.

I Svitare i tappi filettati di estremità dell’asse valvole


di massima pressione e pressione convertitore;
12 estrarre assialmente i pistoncini e le relative molle,
avendo cura di non smarrire o Invertire le posizioni
di eventuali spessori di registro. Sfilare quindi dal
corpo distributore i lamierini di reazione molle di
regolazione pressione.
GB Unscrew the threaded end plugs of the maximum
pressure and converter pressure valve axle; remove
the pistons and their springs axially, taking care not
to lose or reverse the positions of any adjustment
shims. Then remove from the distributor body the
reaction blades and pressure regulator springs.
D Verschluß-Schrauben herausschrauben Kolben
und Federn herausziehen. Haltebleche heraus-
ziehen.
F Desserrer les bouchons filetés d extrémité de
l’axe des vannes de pression maxi et de pression du
convertisseur; extraire axialement les pistons et les
ressorts correspondants, en veillant à ne pas per-
dre ni inverser les positions des éventuelles cales
de réglage. Retirer ensuite les plaques de réaction
des ressorts de réglage de pression du corps du
distributeur.

I Montaggio asse valvole pressione convertitore


e massima pressione: montare i lamienni nella
propria sede sul corpo distributore, inserire la val-
vola di regolazione pressione convertitore completa
di molla ed eventuali spessori nella relativa sede e
fermare avvitando il tappo di estremità (da 6 Nm).
GB Assembly of converter pressure and maximum
pressure valve: fit the blades in their seating on
the distributor body, insert the converter pressu-
re regulator valve complete with its spring and any
shims in its seating and fix in position by tightening
13 the end plug (daNm 6).
D Montage vom Wandlerdruck-und Hauptdruckventil:
Halteblech einsetzen, auf richtigen Sitz und Ort
achten. Wandlerdruckkolben mit Feder einsetzen,
Dichtung, Verschulß-Schraube montieren und mit
einem Drehmoment von da 6 Nm anziehen.
F Montage de l’axe des vannes de pression du
convertisseur et de pression maxi: monter les
plaques en position sur le corps du distributeur, intro-
duire la vanne de réglage de pression du convertis-
seur avec son ressort, et les éventuelles cales, puis
bloquer en serrant le bouchon d’extrémité (daNm 6).
52
TXL 15/25

I Procedere al montaggio della valvola di massima


pressione in modo analogo a quella del convertitore.
GB Fit the maximum pressure valve in the same way as
the converter valve.
3
D Hauptdruckkolben mit Feder einsetzen, Dichtung,
Verschluß-Schraube montieren und mit einem
Drehmoment von 60 Nm anziehen.
F Pour le montage de la vanne de pression maxi, sui-
vre les instructions relatives à celui de la vanne de
pression du convertisseur.

14

I Montaggio asse valvola modulatrice: inserire il


pistoncino nella propria sede, posizionandolo in
modo da far coincidere la gola con la vite di fine
corsa e bloccare; avvitare quindi il tappo di estre-
mità (daNm 6).
GB Assembly of modulator valve: insert the piston
in its seating, positioning it so that the groove is
against the end-of-travel screw and, keeping it in
that position, tighten the end plug (daNm 6).
D Montage vom Modulationsventil: Kolben mit
größerer Bohrung für die Stiftführung zuerst
soweit einführen, daß die erste Aussparung 15
unter der Gewindebohrung für die Fixierschraube
steht. Fixierschraube mit Dichtring vorsichtig
mit Hand eindrehen, wenn Kolben sich mit
Hand von Anschlag zu Anschlag bewegen lässt
Schraube mit einem Drehmoment von 20 Nm
festziehen.Verschluß-Schraube mit Dichtung mon-
tieren und mit einem Drehmoment von da 6 Nm
festziehen.
F Montage de l’axe de la vanne modulatrice:
mettre le cylindre en place, en le positionnant de
manière à faire coincider la gorge avec la vis de fin
de course, puis bloquer; desserrer ensuite le bou-
chon d’extrémité (daNm 6).

I Operando sul lato opposto del distributore, intro-


durre l’astuccio modulatrice completo di molle e
perno con relativi distanziali di regolazione; serrare 16
quindi il tappo di estremità (daNm 6).
GB Working on the opposite side of the distributor,
insert the modulator case complete with springs
and stud and respective adjustment shims; then
tighten the end plug (daNm 6).
D Kleine Feder auf den Bolzen setzen und mit der
Schlitzscheibe arretieren. Bolzen komplett mit
großer Feder in die Kolbenbohrung einsetzen und
alles zusammen auf der gegeüberliegende Seite
in das Steuerungsgehäuse einführen. Verschluß-
Schraube mit Dichtung montieren und mit einem
Drehmoment von da 6 Nm festziehen.
F En opérant côté opposé du distributeur, introduire le
boîtier modulateur avec les ressorts et l’axe avec
les entretoises de réglage correspondantes; serrer
ensuite le bouchon d’extrémité (daNm 6).
53
TXL 15/25

I Montaggio asse valvole selettrici marce avanti-


indietro: introdurre i lamierini nel corpo distributore
assicurandosi del corretto posizionamento in sede.
Infilare quindi la molla e le valvole selettrici.

GB Assembly of Forward/Reverse Gear selector


valve: insert the blades in the dlstributor body,
taking care that they are placed correctly In posi-
tion. Then insert the spring and selector valves.

D Montage der Schalteinheit für den Vorwärts-


und Rückwärtsgang: Haltebleche in das
17 Steuerungsgehäuse einsetzen auf richtigen Sitz und
Ort achten. Feder und von je einer Seite Kolben in
das Steuerungsgehäuse einführen.

F Montage de l’axe de vannes de sélection de


Marche Avant-Arrière: introduire les plaques dans
le corps du distributeur, en veillant à leur position-
nement correct. Placer ensuite le ressort et les
vannes de sélection.

I Montare le elettrovalvole nelle relative sedi previo


posizionamento dell’ anello O-Ring di tenuta ester-
na; fermare con i coperchetti di ritegno bloccando-
ne le viti di fissaggio alla coppia di 3 daNm.

GB Place the outer O-Ring in position and fit the


electrical valves in their respective seatings; fix
them with the retaining covers, tightening the fixing
screws to a torque of 3 daNm.

D Von je einer Seite Elektromagnetventile mit O-Ring


einsetzen. Haltedeckel und Schrauben einsetzen.
18 Schrauben mit einem Drehmoment von 3 daNm
anziehen.

F Mettre en place les électrovannes dans leurs siè-


ges respectifs, après positionnement du joint torique
extérieur; immobiliser avec les couvercles de rete-
nue, en bloquant les vis de fixation au couple de 3
daNm.

I Montaggio asse Inching:


19 inserire sul pistoncino Inching gli spessori di rego-
lazione e la molla quindi introdurre a fondo nella
propria sede.

GB Assembly of Inching:
insert the adjusting shims and spring on the Inching
piston, then fit this fully into its own seating.

D Montage des Inchventils:


Einstellscheiben und Feder in die Bohrung
vom kleinen Kolben einsetzen und In das
Steuerungsgehäuse bis zum Anschlag einführen.

F Montage de l’axe de commande d’approche lente:


engager les cales de réglage et le ressort sur le
piston d’approche lente, puis les introduire à fond
en place.

54
TXL 15/25

Infilare nella propria sede su corpo distributore la Inching Idraulico Inching Meccanlco

3
I
bussola punteria Inching completa. Hydraulic Inching Mechanical Inching
Hydraulisches Inching Mechanisches Inching
Inching Hidraulique Inching Mecanique
GB Fit the complete Inching sleeve into its seating on
the distributor body.

D In Inchkolben Feder und kleinen Kolben einsetzen


dann mit Sicherungsring sichern. Inchkolben kom-
plett in Steuerungsgehäuse einführen.
F Mettre en place la douille du poussoir d’approche
lente complète sur le corps du distributeur.
20 20a

I Accostare al corpo distributore il gruppo Inching


completo con relativa guarnizione di tenuta in
carta, che è consigliabile sostituire ad ogni smon-
taggio; umettare le quattro viti con Loctite 242 e
bloccare alla coppia di 1,8 ÷ 2,0 daNm il corpo
Inching al distributore.
Avvitare i bocchettoni con tubo e relative rosette
di tenuta al distributore e al corpo Inching (solo
per versione Inching Idraulico).
Inching Idraulico
Hydraulic Inching
Hydraulisches Inching
GB Offer up to the distributor body the Inching Inching Hidraulique
21
assembly complete with its paper gasket, which
It is recommended shoud be replaced every time
the assembly is dismantled.
Smear the four screws with Loctite 242 and lock
Inching body to distributor with a torque of 1.8 ÷
2.0 daNm.
Screw in the connectors with pipe and relevant
rubber seals to distributor and Inching body
(Hydraulic Inching version only).

Inching Meccanlco
D Gehäuse für die lnchbetätigung (mechanisch Mechanical Inching
oder hydraulisch) mit Dichtung montieren, Die Mechanisches Inching
Inching Mecanique
21a
vier Schrauben mit Loctite 242 benetzen und
mit einem Drehmoment von 1,8 ÷ 2,0 daNm den
Inching-Körper am Verteiler festziehen.
Die Anschlusstutzen mit dem Rohr und der ent-
sprechenden Dichtung-Unterlegscheibe an dem
Verteiler und komplett Inching zusammenschrau-
ben (Nur Hydraulischesversion Inching).

F Amener le groupe d approche lente complet


avec joint d étanchéité en papier correspondant,
joint qu’il est préférable de remplacer à chaque
démontage,contre le corps de distribution;
humecter les quatre vis par Loctite 242 et bloquer
au couple de 1,8 ÷ 2,0 daNm le corps Inching au
distributeur.
Visser les raccords avec tuyau et joints corres-
spondantes au distributeur et au corps Inching
(Seulement version Inching Hidraulique).

55
TXL 15/25

Smontaggio e rimontaggio gruppo valvola antishock


Dismantling and re-assembling the antishock valve assembly
Demontage und Montage vom Antischockventil
Demontage et remontage du groupe de vanne antichoc

I Svitare e togliere il tappo asse valvola antishock


quindi estrarre assialmente dalla propria sede i
relativi componenti avendo cura di non smarrire
o cambiare la, posizione di eventuali spessori di
taratura. Controllare visivamente l’anello di tenuta
O-Ring posizionato su tappo e sostituirlo se dan-
neggiato.
GB Unscrew and remove the antishock valve axle
plug, then remove the respective components
axially from their seating, taking care not to lose
or change the position of any calibration shims.
Inspect the O-Ring seal on the plug visually and
22 replace it if damaged.
D Verschluß-Schraube mit Schlitz herausschrau-
ben und Kolben Einstellscheiben, Feder und
Drosselkolben herausziehen. Auf die Anzahl und
Einbaulage der Einstellscheiben achten.
F Desserrer et retirer le bouchon de l’axe de vanne
anti-choc, puis sortir axialement les composan-
ts correspondants, en veillant à ne pas perdre
ni interchanger les éventuelles cales de réglage
Contrôler visuellement le joint torique placé sur le
bouchon; le remplacer le cas échéant.

I Svitare e togliere il tappo asse valvola con sfera


selettrice; quindi estrarre assialmente dalla propria
sede i relativi componenti.
GB Unscrew and remove the selector ball valve axle
plug; then remove the respective components
axially from their seating.
D Verschlauß-Schraube vom Wechselventil heraus-
schrauben. Blattfedern, Kugelsitz, Kugelführung
mit Kugel und Kugelsitz herausziehen.
F Desserrer et retirer le bouchon de l’axe de la vanne
de sélection à bille, puis sortir axialement les com-
23 posants correspondants.

I Montaggio asse valvola antishock: infilare nella


propria sede i relativi componenti, avendo cura
di rispettare a posizione e le sequenze illustrate,
quindi introdurre l’anello O-RING nella propria
sede sul tappo e serrare a fondo con cacciavite.
GB Assembly of antishock valve: insert the respective
components in their seating, taking care to con-
form to the placing and sequences shown, then
insert the O-RING in its own seating on the plug
and tighten fully with screwdriver.
D Montage vom Antischockventil: Drosselkolben,
24 Kolben mit Einstellscheiben und Feder in das
Gehäuse einführen. Verschluß-Schraube mit Schlitz
und O-RING montieren und festziehen.
F Montage de l’axe de vanne anti-choc: mettre en
place les composants correspondants, en veillant
à respecter la position et les séquences illustrées,
puis introduire le joint torique sur le bouchon, et
serrer à fond au moyen d’un tournevis.

56
TXL 15/25

Quota montaggio molle


2

Sezione "A-A"
Section
3
1.7-2.25 Springs mounting dim. Teilschnift
Einbaumass der Feder Section
Côte montage du ressort B

1
C 3

Sezione "C"
Section
Teilschnift
Section A A Sezione "B-B"
Section
Teilschnift
Section
B

1 Presa pressione Marcia Avanti 2 Asse valvola con sfera selettrice 3 Asse valvola antishock
Forward pressure Selector ball valve axle Antishock valve axle
Kupplungsdruck VORWÄRTSGANG Wechselventil heraus-schrauben Antischockventil
Prise de pression avant Axe de la vanne de sélection à bille Axe de vanne anti-choc

I Controllo valvola antishock


1) Applicare sulla presa di pressione Marcia Avanti un manometro che consenta di leggere il decimo
di bar nel campo 0-4 bar e con fondo scala <15 bar e sul motore un contagiri per il controllo del
regime.
2) Inserire il pistoncino con foro calibrato, la molla con relativo precarico e richiudere il sistema.
3) Verificare che con il motore al minimo (~750 rpm) e la trasmissione ad una temperatura compresa
tra 60 e 80°C in coppa, la pressione sulla marcia sia compresa tra 1 e 1,2 bar. Nel caso fosse più
elevata occorre aumentare la dimensione del foro sul pistoncino.
4) Verificata la pressione al minimo, passiamo a controllare il regime motore a cui l’antishock si chiude
Accelerare dolcemente e gradualmente il motore controllando contemporaneamente il numero di
giri e la pressione sulla Marcia Avanti. Il numero di giri del motore a cui si vedrà la pressione salire
di colpo fino a valore max (10-11 bar) corrisponde al regime di chiusura dell’antishock, mentre la
pressione letta un attimo prima del balzo alla pressione max é la pressione di chiusura.
5) Il regime di chiusura dell’antishock deve stare tra i 1200 e i 1300 rpm, e la pressione deve essere
compresa tra 2,5 e 3,5 bar. Nel caso il regime di chiusura fosse troppo basso occorre aumentare
il precarico della molla, mentre se è troppo alto occorre diminuirlo.
GB Antishock valve check-up
1) Measurement instruments: install a pressure manometer with a deci scale of 0 to 4 bar with maximum
range of 15 bar to the pressure test port of Forward Gear. Also for speed respectively rpm reading
install a revolution counter.
2) Basic adjustment: antishock valve to be equiped in standard version with a piston with a calibrated
throttle port, plus adjustment shims of 2 mm thickness for spring preload.
3) Pressure adjustment: the pressure on Forward Gear should be between 1 and 1.2 bar at oil
temperature of 60°-80°C and 750 engine rpm. In case of pressure exceeding 1.2 bar the throttle
port on the antishock piston has to be enlarged, respectively replace piston for one with larger
port. In case of pressure is lower than 1 bar replace piston for one with reduced port.4) Check
pressure and engine rpm when antishock valve is closing: increase engine rpm gradually and
record the rpm and pressure when pressure jump up to 10 to 11 bar.
5) Adjustment of antishock valve closing, in relation to engine rpm: the antishock valve closing
setting depend on Customer specification and should close at a pressure between 2.5 to 3.5 bar
and at engine rpm between 1200 and 1300. The adjustment for correct engine rpm can be achie-
ved by omiting some of the adjustment shims behind the spring at high rpm, respectively adding
shims in case of to low rpm.

57
TXL 15/25

D Antischockventil Kontroll
1) Messgeräte: Druckmanometer mit Zehntelscala von 0 - 4 bar und einem gesamt Bereich bis 15 bar
an der Mess-Stelle Vorwärtsgang anschließen und einen Motordrehzahlmesser Instalieren.
2) Grundeinstellung: Antischockventil mit abgelehrter Kolben Drosselbohrung und Einstellscheiben
2 mm für Federvorspannung montieren.
3) Druckeinstellung: Vorwärtsgang Druck soll bei einer Öltemperatur von ca. 60°-80°C und einer
Motordrehzahl von 750 U/min zwischen 1 und 1,2 bar betragen, ist der Vorwärtsgangdruck höher
muß Kolben mit einer größeren Drosselbohrung und ist der Druck zu niedrig muß ein Kolben mit
einer kleineren Drosselbohrung eigebaut werden.
4) Prüfen von Druck und Motordrehzahl im Schließpunkt: Motordrehzahl langsam erhöhen und wenn der
Druck schnell auf den max. Druck von 10-11 bar steigt ist der Schließpunkt des Antischockventiles
erreicht. Druck-und Drehzahlwert vor dem schnellen ansteigen des Druckes ablesen.
5) Schließpunkteinstellung abhängig von der Motordrehzahl: Das Antischockventil muß abhängig
von der Kundenspezifischen Ausführung bei einem Druck von 2,5 - 3,5 bar und einer
Motordrehzahl von 1200-1300 U/min schließen. Die Motordrehzahlabhängige Einstellung des
Schließpunktes erfolgt durch entfernen von Elnstellscheiben bei zu hoher und einlegen von
Einstellscheiben bei zu niedriger Motordrehzahl.
F Control de vanne antichoc
1) Appliquer sur la prise de pression Marche Avant un manomètre qui permet de lire le dixièm de bar
dans le champ 0-4 bar et avec fond échelle >15 bar et sur le moteur un compte-tours pour le
contrôle du régime.
2) Insérer le piston avec trou calibrè, le ressort préchargé avec 2 mm, au deuxième piston et refermer
le système.
3) Verifier que avec le moteur au ralenti (~750 tr/mn) et la transmission à une température comprise
entre 60° et 80°C en couple, la pression sur la marche soit comprise entre 1 et 1,2 bar. Si elle est
plus élevée, il faut augmenter la dimension du trou sur le piston.
4) Verifiée la pression au ralenti, procédons au contrôle du régime moteur auquel l’antichoc se
ferme. Accelerer doucement et lentement le moteur en veillant en même temps le nombre de
tours et la pression sur la Marche Avant. Le nombre de tours du moteur auquel on verra la pres-
sion monter tout à coup jusqu’à la valeur max (10-11 bar) correspond au régime de fermeture de
l’antichoc, alors que la pression lue un instant avant du bond à la pression max, c’est la pression
de fermeture.
5) Le régime de fermeture de l’antichoc doit se trouver entre 1200 et 1300 rpm, et la pression doit
être comprise entre 2,5 et 3,5 bar. Si le régime de fermeture est trop bas, il faut augmenter la pré-
charge au contraire s’il est trop élevé, il faut la réduire.

I Montaggio asse valvola sfera selettrice: infilare


nella propria sede i componenti avendo cura di
accostare le rondelle a tazza nella loro corretta
posizione di montaggio (facendo combaciare i
diametri esterni), quindi serrare a fondo il tappo
completo di rondella di tenuta in rame.
GB Assembly of selector ball valve: insert the compo-
nents in their positions, taking care to place the
cup washers together in their correct assembly
position (with their external diameters against one
another), then fully tighten down the plug comple-
te with its copper sealing washer.
D Montage vom Wechselventil: Kugelsitz,
Kugelführung, Kugel, Kugelsitz und Tellerfedem
(großer Durchmesser zusammen) in das Gehäuse
einführen. Verschluß-Schraube mit Dichtring mon-
tieren und festziehen.
25 F Montage de l’axe de la vanne de sélection à bille:
mettre en place les composants, en veillant à
appuyer les rondelles concaves dans leur position
correcte de montage (en faisant coincider les dia-
mètres extérieurs), puis serrer à fond le bouchon
avec rondelle d’étanchéité en cuivre.

58
TXL 15/25

Smontaggio e rimontaggio Distributore Supermodulato


Dismantling and re-assembling of Supermodulating Distributor
Demontage und Zusammenbau Steuerblock Supermoduliert
Démontage et rémontage Distributeur Supermodulé
3
I Smontaggio comando azionamento inching (a
secondo della versione):
Sganciare la molla dai perni.

GB Removal of the inching control mechanism (accor-


ding to various configuration)
Unhook the spring from pin

D Demontage des Inching-Hydraulik-Befehls (je nach


Version):
Feder von den Stiften entriegeln.
26
F Démontage commande actionnement inching
(selon la version):
décrocher le ressort des pivots.

I Stacco distributore
Sbloccare e svitare le viti di fissaggio e smontare il
distributore completo.

GB Distributor removal
Unscrew the fixing screws and dismantle the com-
plete distributor.

D Ausbau Steuerblock
Zwölf Befestigungsschrauben lösen und
Steuerblock komplett abheben.

F Détachement du distributeur 27
Débloquer et desserrer les vis de fixation, puis
déposer le distributeur complet.

I Rimuovere la guarnizione di tenuta in carta.

GB Remove the paper gasket

D Entfernen der Dichtung.

F Enlever le joint d’étanchéité en papier

28

59
TXL 15/25

I Smontare la piastra di collegamento del distribu-


tore al carter inversore e la relativa guarnizione di
tenuta in carta, svitando le viti di ritegno.

GB Remove the plate that connects the distributor to


the reversing gear case, together with its paper
gasket, unscrewing the retaining screws.

D 2 Befestigungsschrauben lösen und


Olverteilerplatte mit Dichtung abheben.

29 F Démonter la plaque d’assemblage du distributeur


au carter d’inverseur, ainsi que le joint d’étanchéité
en papier, après desserrage des vis de fixation.

I Sbloccare e svitare le viti di fissaggio e smontare


il il gruppo azionamento inching (secondo il tipo di
versione).

GB Unscrew the fixing screws and dismantle the


inching drive control (according type version).

D Anschlussplatte des Verteilers zur


Schutzabdeckung und die entsprechende
Dichtung aus Papier abmontieren, wobei die
Halteschrauben gelöst werden
30 Die Befestigungsschrauben lösen und den
Inching-Antrieb abmontieren (je nach der Version).

F Débloquer et desserrer les vis de fixation, puis


déposer le commande d’action inching (selon le
type de version).

60
TXL 15/25

Revisione distributore Supermodulato


Supermodulating distributor overhauling
Nachprüfung Steuerblock Supermoduliert
Révision du distributeur Supermodulé
3
Inching Idraulico Inching Meccanlco
INCHING IDRAULICO INCHING MECCANICO
Hydraulic Inching Mechanical Inching
HYDRAULIC INCHING
Hydraulisches Inching MECHANICAL INCHING
Mechanisches Inching
HYDRAULIK INCHING
Inching Hidraulique Inching Mecanique
MECHANISCHES INCHING

I Nella figura sono individuabili, i quattro assi del D Das Bild zeigt die 4 Schaltebenen des
distributore: Steuerblocks:
1) asse selettrice avanti-indietro 1) Schaltmagnetventile für den Vorwärts-und
2) asse Inching control Rückwärtsgang
3) asse valvola principale - valvola convertitore 2) Inchkolben
4) asse valvola modulatrice 3) Achse Hauptventil - Umwandlerventil
4) Modulatorachse.
GB The figure shows from top to bottom the four
distributor axis: F Dans la figure on peut voir, les quatre axes du
1) forward-reverse shifting shaft distributeur:
2) Inching control shaft 1) axe sélecteur avant-arrière
3) main valve - converter valve axle 2) axe contrôle Inching
4) Modulating Axle. 3) axe vanne convertisseur et vanne principale
4) axe vanne modulatrice

I Smontaggio asse selettrice avanti-indietro


Svitare il dado di fissaggio elettrovalvola.

GB Disassembly of forward-reverse shifting shaft


Undo nut securing electrovalve.

D Ausbau Wechselachse vor-zurück


Die Befestigungsmutter Magnetventil abschrau-
ben.

F Démontage de l’axe sélecteur avant-arrière


31
Dévisser l’ecrou de fixation électrovanne.

61
TXL 15/25

I Estrarre le elettrovalvole complete di anelli di


32 tenuta O-Ring.
Controllare i componenti, l’integrità della parti e
l’eventuale impurità (in presenza di residui metal-
lici sostituire l’elettrovalvola completa).
Pulire perfettamente tutti i particolari, in caso di
usura, sostituire.
Riassemblare i componenti bloccando la ghiera
del solenoide alla coppia di 1 daNm.

GB Remove the electrovalves complete with O-Rings.


Check components, clean full each component,
replace if required (if there are metallic residues,
replace the electrovalve complete).
Reassemble components locking solenoid nut
with a torque of 1 daNm.

D Magnetventile komplett mit O-Dichtringen herau-


sziehen.
Die Bauteile, die Unversehrtheit der Einzelteile
und eventuelle Unreinheiten kontrollieren
(falls Metallreste vorhanden sein sollten, das
Magnetventil komplett ersetzen).
Alle Bestandteile sorgfältig reinigen; im Falle von
Verschleiß ersetzen.
Die Bestandteile wieder zusammensetzen,
dabei die Nutmutter des Solenoids mit einem
Drehmoment von 1 Nm festziehen.

F Extraire les électrovannes complètes des segmen-


ts de retenue O-Ring.
Contrôler les composants, que toutes les parties
ne soient pas endommagées et les impurétés
éventuelles (en cas de résidus métalliques, rem-
placer l’électrovanne complète).
Nettoyer soigneusement tout les composants et,
en cas d’usure, substituer.
Réassembler les composants en bloquant la frette
au couple de 1 daNm.

I Smontaggio Asse Inching - Versione Comando


33 Meccanico
Svitare le quattro viti di fissaggio coperchio.

GB Inching Axle dismantling - Mechanical Inching


Version
Undo the four screws securing cover.

D Ausbau Inching-Achse - Version mechanische


Schaltung
Die vier Befestigungsschrauben des Deckels
abschrauben.

F Démontage Axe Inching - Version Commande


Mécanique
Dévisser les quatre vis de fixation du couvercle.

62
TXL 15/25

I Sfilare i componenti asse Inching.

GB Remove Inching control components. 3


D Die Bauteile Achse Inching herausziehen.

F Enlever les composants de l’axe Inching.

34

I N. B.: Per lo smontaggio dell’asse Inching non è


necessario smontare il dado di regolazione: nel
caso si rendesse necessario, svitare il dado com-
pleto e relativa rosetta di tenuta.

GB Note: To dismantle Inching axle it isn’t necessary


to dismantle regulating nut: if required, unscrew
nut complete and relevant rubber seal.

D Hinweis: Für den Ausbau der Inching-Achse ist es


nicht erforderlich, die Einstellmutter abzubauen:
falls es aber notwendig sein sollte, muß die kom-
plette Mutter mit Dichtscheibe herausgeschraubt 35
werden.

F Note: Pour le démontage de l’axe Inching démon-


ter l’écrou de réglage n’est pas nécessaire: si
nécessaire, dévisser l’écrou complet et la rondelle
de retenue.

ATTENZIONE! Per non pregiudicare il corretto


! funzionamento dell’asse Inching, non manomet-
tere e non smontare il tappo di regolazione dal
dado.

WARNING! To not prejudice right working of


! Inching axle, don’t tamper and don’t dismantle
regulating plug of nut.

ACHTUNG! Um das korrekte Funktionieren


! der Inching-Achse nicht zu beeinträchtigen,
den Einstellverschluß nicht verändern und
nicht von der Mutter abbauen. 35a
ATTENTION! Ne pas compromettre le fon-
! ctionnement correct de l’axe Inching, ne pas
toucher le bouchon de réglage de l’écrou.

63
TXL 15/25

I Rimuovere e sostituire la guarnizione O-Ring.

GB Remove and replace O-Ring seal.

D Den Dichtungs-O-Ring entfernen und ersetzen.

F Enlever et remplacer le joint O-Ring.

36

I Pulire perfettamente tutti i particolari, verificarli,


37 sostituirli secondo necessità.

GB Clean full each component, check them, replace if


required.

F Alle Bestandteile sorgfältig reinigen, prüfen, bei


Bedarf ersetzen.

F Nettoyer soigneusement tout les composants,


vérifier et, si nécessaire, remplacer.

I Smontaggio asse valvola principale - valvola


convertitore
Svitare il tappo ed estrarre il pistoncino della val-
vola di regolazione della pressione convertitore
con relativa molla ed eventuali spessori di rego-
lazione.

GB Dismantling of main valve - converter valve


axle
Unscrew plug and remove small piston of conver-
ter pressure regulating valve with relevant spring
38 and possible thicknesses.

D Zerlegen Achse Hauptventil - Umwandlerventil


Verschluß abschrauben und den Steuerkolben des
Konverter-Druckregelventils mit entsprechender
Feder und eventuellen Einstellscheiben heraus-
ziehen.

F Démontage axe vanne principale - vanne


Convertisseur
Dévisser le bouchon et extraire le petit piston de la
vanne de réglage de la pression du convertisseur
avec relatif ressort et cales de réglage éventuels.

64
TXL 15/25

Svitare il tappo posteriore, estrarre il pistoncino


3
I
della valvola di pressione principale con relativa
molla ed eventuali spessori di regolazione.

GB Undo rear plug, extract small piston from main


pressure valve with relevant spring and probable
thicknesses.

D Den hinteren Verschluß abschrauben und den


Kolben des Hauptdruckventils mit entsprechender
Feder und Einstellscheibe herausziehen.

F Dévisser le bouchon postérieur, extraire le petit 39


piston de la vanne de pression principale avec
relatif ressort et cale de réglage.

I Per rimuovere la boccola centrale dell’asse, allen-


tare la vite posta sotto il distributore.
GB To remove central bush of axle, undo screw placed
under distributor.

D Um die mittlere Buchse der Achse zu entfernen,


die Schraube unter dem Verteiler lockern.

F Pour enlever la douille centrale de l’axe, desserrer


la vis placée sous le distributeur.
40

I Componenti asse valvola convertitore - valvola


principale
Pulire perfettamente tutti i particolari, verificarli,
sostituirli secondo necessità.
GB Components of converter valve - main valve axle
Clean full each component, check them, replace if
required.

D Bauteile Achse Wandlerventil - Hauptventil


Alle Bestandteile sorgfältig reinigen, prüfen, bei
Bedarf ersetzen. 41
F Composants axe vanne convertisseur - vanne
principale
Nettoyer soigneusement tout les composants, véri-
fier et, si nécessaire, remplacer.

65
TXL 15/25

I Smontaggio e rimontaggio Asse Modulatrice


Premere la bussola e sganciare l’anello elastico
anteriore.

GB Dismantling and re-assembling Modulating Axle


Push bushing and unhook front lock ring.

D Ausbau und Einbau Modulatorachse


Auf die Buchse drücken und den vorderen
Sprengring aushaken.
42
F Démontage et rémontage Axe Modulatrice
Pousser la douille et décrocher le segment de
retenue.

I Estrarre la bussola e rimuovere la guarnizione O-


43 Ring.
GB Extract bushing and remove O-Ring seal.

D Die Buchse herausziehen und Die O-Ring-


Dichtung entfernen.

F Extraire la douille et enlever le joint O-Ring.

I Sfilare il pistone e le due molle.

GB Remove piston and the two springs.

D Den Kolben und die beiden Federn herausziehen.

F Dévisser le piston et les deux ressorts.

44

I Sganciare l’anello elastico posteriore, rimuo-


vere la guarnizione O-Ring e il coperchio Asse
45 Modulatrice.

GB Unhook rear lock ring, remove O-Ring seal and


Modulating Axle cover.

D Den hinteren Sprengring aushaken, die O-Ring-


Dichtung und den Deckel Modulatorachse entfer-
nen.

F Décrocher le segment de retenue postérieur,


enlever le joint O-Ring et le couvercle Axe
Modulatrice.

66
TXL 15/25

Componenti Asse Valvola Modulatrice


3
I

Pulire perfettamente tutti i particolari, verificarli,


sostituirli secondo necessità.
GB Components of Modulating Valve Axle
Clean full each component, check them, replace if
required.
D Bestandteile Achse Modulatorventil
Alle Bestandteile sorgfältig reinigen, prüfen, bei
Bedarf ersetzen.
F Composants Axe Vanne Modulatrice 46
Nettoyer soigneusement tout les composants,
vérifier et, si nécessaire, remplacer.

I Particolare attenzione si dovrà dedicare alla bus-


sola completa: 47 47a
svitare il tappo, controllare l’interno della stessa e
sulla sfera che non vi siano impurità, pulire perfet-
tamente e rimontare.

GB Special care has required for bushing complete:


unscrew plug, check inside of the same and on
the ball that there aren’t impurities, clean full and
reassemble.

D Besondere Aufmerksamkeit muß der kompletten


Buchse gewidmet werden:
Den Verschluß abschrauben, das innere dersel-
ben sowie die Kugel kontrollieren, damit keine
Unreinheiten vorhanden sind, vollkommen reinigen
und wieder einsetzen.

F Prêter beaucoup d’attention à la douille complète:


dévisser le bouchon, en contrôler la partie
intérieure et pue sur la bille il n’y pas d’impurétés,
nettoyer parfaitement et remonter.

I Montare nella propria sede la guarnizione O-Ring,


inserire il coperchio e nel posizionarlo prestare
attenzione a non superare la battuta dell’anello
elastico.

GB Assemble the O-Ring seal into its seat, insert


cover and positionning it, take care not to overtake
lock ring seat.

D Die O-Ring-Dichtung in ihren Sitz einbauen, den


Deckel einsetzen und bei der Positionierung darauf
achten, daß der Anschlag nicht überschritten wird,
um eine eventuelle Beschädigung des O-Rings 48
und des Sprengrings zu vermeiden.

F Monter le joint O-Ring dans son propre siège,


insérer le couvercle et, en le positionnant, faire
attention à ne pas dépasser anneau de sûreté du
segment de retenue.

67
TXL 15/25

I Inserire l’anello elastico.


49
GB Insert lock ring.

D Den Sprengring einführen.

F Insérer le segment de retenue.

I Rimontare le molle e il pistone.

GB Reassemble springs and piston.

D Die Federn und den Kolben wieder einbauen.

F Remonter le ressort et le piston.

50

I Montare nella propria sede la guarnizione O-Ring.

GB Assemble into its seat O-Ring seal.

D Die O-Ring-Dichtung in ihren Sitz einbauen.

F Monter dans son propre siège le joint O-Ring.

51

I Infilare la bussola completa, avendo cura di non


52 danneggiare la guarnizione O-Ring, premere la
bussola e inserire l’anello elastico.

GB Assemble the bushing complete, taking care not


to damage the O-Ring seal, push bushing and
insert lock ring.

D Die komplette Buchse einsetzen, dabei darauf


achten, den O-Ring nicht zu beschädigen, die
Buchse eindrücken und den Sprengring einsetzen.

F Insérer la douille coplète, en ayant soin de ne pas


endommager le joint O-Ring, pousser la douille et
insérer le segment de retenue.

68
TXL 15/25

Rimontaggio Asse Valvola Principale - Valvola


3
I
Convertitore
- Posizionare la boccola centrale;
- umettare la vite di fermo con Loctite 242;
- bloccare la boccola;
- rimontare lo spessore di regolazione;
- infilare molla e pistoncino Valvola di Pressione
Principale;
- serrare il tappo con rosetta di tenuta.
53
Procedere in modo analogo per il montaggio nella
parte anteriore della valvola convertitore.

GB Reassembling of Main Valve - Converter Valve


Axle
- Position the central bushing:
- smear locking screw with Loctite 242;
- lock bushing;
- reassemble thickness;
- insert spring and small piston of Main Pressure
Valve;
- lock plug with rubber seal.
Follow the same procedure to assemble front part
of converter valve.

D Wiedereinbau Achse Hauptventil -


Wandlerventil
- Die mittlere Buchse einsetzen;
- die Halteschraube mit Loctite 242 benetzen;
- die Buchse befestigen;
- die Einstellscheiben wieder einbauen;
- die Feder und den Kolben Hauptdruckventil
einführen;
- den Verschluß mit Scheibe festziehen.
In analoger Weise für den Einbau des vorderen
Teils des Wandlerventils vorgehen.

F Rémontage Axe Vanne Principale - Vanne


Convertisseur
- Placer la douille centrale;
- humecter la vis de fermeture avec Loctite 242;
- bloquer la douille;
- Remonter la cale de réglage;
- Insérer le ressort et le petit piston vanne de
pression principale;
- Serrer le bouchon en se servant d’une rondelle
de sûreté.
Procéder de manière analogue pour le montage
dans la partie antérieure de la vanne convertisseur.

69
TXL 15/25

I Rimontaggio Asse Inching - Versione Comando


Meccanico
Rimontare il dado di regolazione con la relativa
rosetta di tenuta e serrare.
GB Reassembling Inching Axle - Mechanical Drive
Version
Reassemble regulating nut with relevant rubber
seal and lock.
D Einbau Inching-Achse - Version mechanische
Schaltung
54 Die Einstellmutter mit der entsprechenden
Dichtscheibe einbauen und festziehen.
F Rémontage Axe Inching - Version Commande
Mecanique
Remonter l’écrou de réglage en se servant de la
rondelle de retenue correspondant et serrer.

ATTENZIONE! Per non pregiudicare il corret-


! to funzionamento dell’asse Inching, non mano-
mettere il tappo di regolazione del dado.
WARNING! To not prejudice right working of
! Inching axle, don’t tamper and don’t dismantle
regulating plug of nut.
ACHTUNG! Um den korrekten Betrieb der
! Inching-Achse nicht zu beeinträchtigen, den
Einstellstopfen der Mutter nicht verletzen.
ATTENTION! Ne pas compromettre le fon-
54a
! ctionnement correct de l’axe Inching, ne pas
toucher le bouchon de réglage de l’écrou.

I Inserire i componenti Asse Inching.

GB Insert components of Inching Axle.

D Die Bestandteile der Inching-Achse einführen.

F Insérer les composants de l’axe Inching.

55

70
TXL 15/25

Umettare le quattro viti con Loctite 242 e bloccare


3
I
alla coppia di 0,5 daNm il coperchio.

GB Smear the four screws with Loctite 242 and lock


the cover with a torque of 0.5 daNm.

D Die vier Schrauben mit Loctite 242 benetzen und


mit einem Drehmoment von 0,5 daNm den Deckel
festziehen.

F Humecter les quatre vis avec Loctite 242 et blo-


quer le couvercle au couple de 0,5 daNm.
56

I Smontaggio Asse Inching - Versione Comando


Idraulico
Svitare le quattro viti di fissaggio corpo Inching al
distributore.
GB Inching Axle Dismantling - Hydraulic Inching
Version
Undo fixing screws of Inching body to distributor.

D Ausbau Inching-Achse - Version hydraulische


Schaltung
Die vier Befestigungsschrauben Körper Inching am 57
Verteiler abschrauben.

F Démontage Axe Inching - Versión Commande


Hydraulique
Dévisser les quatre vis de fixation corps Inching au
distributeur.

I Sfilare i componenti asse Inching.


IMPORTANTE: Il comando Inching idraulico 58
non è revisionabile, in caso di usura o malfun-
zionamento, sostituire.

GB Remove components of Inching axle.


IMPORTANT: The inching control assy is not
repairable. In case of wear or malfunction a
new assy must be fitted.

D Die Bauteile der Inching-Achse herausziehen.


HAUPTSACHE: Der Inching-Hydraulik-Befehl
kann nicht instandgesetzt werden: beim
Verschleiss oder Störung austauschen
F Enlever les composants de l’axe Inching.
IMPORTANT: La commande Inching
hydraulique ne peut pas être inspectée, en
cas d’usure ou de mauvais fonctionnement, la
remplacer.

71
TXL 15/25

I N. B.: Per lo smontaggio dell’asse Inching non è


necessario smontare il dado di regolazione: nel
caso si rendesse necessario, svitare il dado com-
pleto e relativa rosetta di tenuta.
GB Note: To dismantle Inching axle it isn’t necessary
to dismantle regulating nut: if required, unscrew
nut complete and relevant rubber seal.
D Hinweis: Für den Ausbau der Inching-Achse ist es
nicht erforderlich, die Einstellmutter abzubauen:
falls es aber notwendig sein sollte, muß die kom-
plette Mutter mit Dichtscheibe herausgeschraubt
59 werden.
F Note: Pour le démontage de l’axe Inching démon-
ter l’écrou de réglage n’est pas nécessaire: si
nécessaire, dévisser l’écrou complet et la rondelle
de retenue.

ATTENZIONE! Per non pregiudicare il corretto


! funzionamento dell’asse Inching, non manomet-
tere e non smontare il tappo di regolazione dal
dado.
WARNING! To not prejudice right working of
! Inching axle, don’t tamper and don’t dismantle
regulating plug of nut.
ACHTUNG! Um das korrekte Funktionieren
! der Inching-Achse nicht zu beeinträchtigen,
den Einstellverschluß nicht verändern und
nicht von der Mutter abbauen.
59a ATTENTION! Ne pas compromettre le fon-
ctionnement correct de l’axe Inching, ne pas
! toucher le bouchon de réglage de l’écrou.

I Pulire perfettamente tutti i particolari, verificarli,


sostituirli secondo necessità.

GB Clean full each component, check them, replace if


required.

D Alle Bestandteile sorgfältig reinigen, prüfen, bei


Bedarf ersetzen.

F Nettoyer soigneusement tout les composants, véri-


fier et, si nécessaire, remplacer.

60

I Rimuovere e sostituire la guarnizione O-Ring.

GB Remove and replace O-Ring seal.

D Den Dichtungs-O-Ring entfernen und ersetzen.

F Enlever et remplacer le joint O-Ring.

61

72
TXL 15/25

Rimontaggio Asse Inching - Versione Comando


3
I
Idraulico
Rimontare il dado di regolazione con la relativa
rosetta di tenuta e serrare.

GB Reassembling Inching Axle - Hydraulic Drive


Version
Reassemble regulating nut with relevant securing
washer and lock.

D Einbau Inching-Achse - Version hydraulische


Steuerung 62
Die Einstellmutter mit der entsprechenden
Dichtscheibe einbauen und festziehen.

F Rémontage Axe Inching - Version Commande


Hydraulique
Remonter l’écrou de réglage en se servant de la
rondelle de retenue correspondant et serrer.

! ATTENZIONE !
I Per non pregiudicare il corretto funzionamento
dell’asse Inching, non manomettere il tappo di
regolazione del dado.

! WARNING !
GB To not prejudice right working of Inching axle,
don’t tamper and don’t dismantle regulating
plug of nut.

! ACHTUNG ! 62a
D Um den korrekten Betrieb der Inching-Achse
nicht zu beeinträchtigen, den Einstellstopfen
der Mutter nicht verletzen.

! ATTENTION !
F Ne pas compromettre le fonctionnement cor-
rect de l’axe Inching, ne pas toucher le bou-
chon de réglage de l’écrou.

I Inserire i componenti Asse Inching.

GB Insert components of Inching Axle.

D Die Bestandteile der Inching-Achse einführen.

F Insérer les composants de l’Axe Inching.

63

73
TXL 15/25

I Umettare le quattro viti con Loctite 242 e bloccare


64 alla coppia di 0,5 daNm il corpo Inching al distri-
butore.

GB Smear the four screws with Loctite 242 and lock


Inching body to distributor with a torque of 0.5
daNm.

D Die vier Schrauben mit Loctite 242 benetzen


und mit einem Drehmoment von 0,5 daNm den
Inching-Körper am Verteiler festziehen.

F Humecter les quatre vis par Loctite 242 et bloquer


au couple de 0,5 daNm le corps Inching au distri-
buteur.

I Rimontaggio selettrice avanti - indietro


Infilare l’elettrovalvola con le relative guarnizioni
(opportunamente lubrificate).
Bloccare il dado alla coppia di serraggio di ~ 7
daNm.

GB Re-assembling of front - back selection valve


Insert electrovalve with relevant seals (righting
smeared).
Lock nut with a torque of ~ 7 daNm.

65 D Einbau Wechselvorrichtung vor-zurück


Das Magnetventil mit den entsprechenden
Dichtungen (angemessenen geschmiert) einführen.

F Rémontage Selectrice avant - arrière


Enfiler l’électrovanne et les relatifs joints (oppor-
tunément lubrifiés).
Bloquer l’écrou au couple de serrage de ~ 7
daNm.

74
TXL 15/25

Smontaggio e Rimontaggio gruppi ruote


Wheel assembly dismantling and re-assembling
Bremsgruppe Demontage und Montage
Démontage et Remontage des groupe des roues
3
! ATTENZIONE ! ! ACHTUNG !
Maneggiare tutti i particolari con opportuni Schwere Teile nur mit geeignetem Hebe-und
mezzi e con grande attenzione. Non mettere Transportwerkzeug transportieren.
le mani e le dita tra un pezzo e l’altro Vorsicht auf Hände und Finger

! WARNING ! ! ATTENTION !
Manipuler tout les composants par oppor-
Handle all heavy parts with the appropriate
tuns outils et avec beaucoup d’attention.
equipment and with the utmost care. Never
Ne jamais glisser les mains ou les doigts entre
put your hands and fingers in between parts
les différents éléments

I Svitare le due viti fissaggio tamburo freno al mozzo


ruota.
Sfilare il tamburo freno. Verificare il diametro e lo
stato di usura dei rivestimenti ganasce freno.

GB Undo screws securing brake drum to wheel hub.


Remove brake. Check diameter and wear condi-
tions of shoes lining.

D Befestigungsschrauben lösen und entfernen.


Bremstrommel abziehen und Trommel innen kon-
trollieren.
68
F Dévisser les deux vis de fixation du tambour du
frein au moyeu de la roue.
Enlever le tambour du frein. Vérifier le diamètre et
l’état d’usure des revêtements des mâchoires du
frein.

I Smontaggio semiassi
Svitare le viti fissaggio semiassi al mozzo ruota,
sbloccare e sfilare il semiasse.
GB Wheel shaft disassembly
Undo screws securing shaft to wheel hub on both
side, unlock and remove the half shaft.

D Ausbau Achswelle
Befestigungsschrauben au beiden Sieten lösen
und entfernen, die Achswelle freilegen und herau-
sziehen. 69
F Démontage des demi-axes
Dévisser les vis de fixation des demi-axes au
moyeu de la roue, débloquer et enlever le demi-
essieu.

75
TXL 15/25

I IMPORTANTE: Usare esclusivamente ricambi


originali
Sostituzione ganasce
Sganciare la molla richiamo ganasce lato disposi-
tivo ripresa automatica gioco.

GB IMPORTANT: Use only genuine spare parts


Shoes replacement
Unhook shoe return spring on automatic brake
clereance take-up device side.
70
D HAUPTSACHE: Ausschliesslich Original-
Ersatzteile verwenden
Austausch Backen
Die Rückholfeder Bremsbacken auf der Seite auto-
matische Spieleinstellvorrichtung aushaken.

F IMPORTANT: Utiliser exclusivement les


pièces de rechange originales
Substitution des mâchoires
Décrocher le ressort de rappel des mâchoires côté
dispositif de reprise automatique du jeu.

I Sganciare le due molle richiamo ganasce lato cilin-


dretto.

GB Unhook the two shoe return spring on side of


wheel brake cylinder.

D Untere Haltefedern Lösen.

F Décrocher les deux ressorts de rappel des mâchoi-


res côté petit cylindre.

71

I Sfilare le molle ritegno ganasce, staccare ganasce,


fulcro rinvio, comando freno a mano e cavo della leva.
Nell’eventualità di sostituzione del cavo freno a
mano togliere la rosetta a forcella per appoggio di
reazione molla ritorno cavo.

GB Remove brake shoes retaining springs, brake shoes,


return fulcrum, hand brake drive and lever cable.
Should hand control cable be replaced, remove
fork washer backing cable return spring.

D Die Haltefedern Bremsbacken herauziehen,


72 72a die Bremsbacken, Umlenkdrehbolzen,
Handbremsensteuerung und Hebelkabel abziehen.
Beim Entfernen des Handbremsseiles.

F Enlever les ressorts de retenue des mâchoires,


détacher les mâchoires, le pivot de renvoi, la
commande du frein à main et le cåble du levier.
En cas de substitution du câble du frein à main,
enlever la rondelle à fourche pour appui de réac-
tion du ressort de retour du câble.

76
TXL 15/25

In caso di sostituzione del cilindro freno, svitare


3
I
le due viti (a) di fermo piastrina aggancio molla 73
richiamo ganasce.
Svitare lo spurgo olio freno (b) e le due viti (c) di
tenuta cilindretto poste dietro il piatto freno, con
relative rosette (vedi fig. 73a).

GB Should brake cylinder be changed, undo the two


screws (a) retaining small plate of spring hooking
of shoes return.
Unscrew brake oil bleeder (b) and the two screws
(c) retaining small cylinder placed behind brake
plate, with relevant washers (see fig. 73a).

D Bei einem Austausch des Bremszylinders die


beiden Halteschrauben (a) der Einhakplatte
Rückholfeder Bremsbacken anschrauben.
Ölauslaßschraube Bremse (b) und die beiden
Schrauben (c) der Zylinderdichtung hinter der
Bremsplatte mit den jeweiligen Unterlegscheiben
abschrauben (siehe Abb. 73a).

F En cas de substitution du cylindre du frein, dévis-


ser les deux vis (a) de férmeture de la plaque d’ac-
crocage du ressort de rappel des mâchoires.
Dévisser le vidange d’huile du frein (b) et les deux
vis d’étanchéité (c) du petit cylindre placées der-
rière le plateau du frein, avec les relatives rondelles
(voir fig. 73a).

c fig. 73a
b

77
TXL 15/25

I IMPORTANTE: Non smontare il cilindro freno


74 per ripararlo; se è malfunzionante, sostituirlo
completo.

GB IMPORTANT: Don’t dismantle the brake


cylinder to repair it, in case of malfunction,
changed.

D HAUPTSACHE: Die Bremszylinder nicht zer-


legen, um sie zu reparieren; sollte sie schlecht
funktionieren, muß sie ausgetauscht werden.

F IMPORTANT: Ne pas démonter le cylindre du


frein pour le réparer; en cas de fonctionnement
mauvais, remplacer.

I - Posizionare il cilindro freno nella relativa sede;


- avvitare le due viti con rosette alla coppia di
2,0 ÷ 2,5 daNm;
- montare e avvitare lo spurgo olio alla coppia di
0,4 ÷ 0,6 daNm;
- rimontare la piastrina aggancio molle e avvitare
le viti con rosette alla coppia di 2,0 ÷ 2,5 daNm.

GB - Position brake cylinder into relevant seat;


- screw in the two screws with washers with a
torque of 2.0 ÷ 2.5 daNm;
- mount and screw in oil bleeder with a torque of
0.4 ÷ 0.6 daNm;
- reassemble small plate hooking springs and
screw in the screws with washers with a torque
74a of 2.0 ÷ 2.5 daNm.

D - Den Bremszylinder in seinen Sitz einsetzen, die


beiden Schrauben mit Unterlegscheiben
mit einem Drehmoment von 2,0 ÷ 2,5 daNm
festziehen;
- den Ölauslaß einsetzen und mit einem
Drehmoment von 0,4 ÷ 0,6 daNm festziehen,
- die Einhakplatte Federn wieder einbauen und
die Schrauben mit Unterlegscheiben mit einem
Drehmoment von 2,0 ÷ 2,5 daNm festziehen.

F - Placer le cylindre du frein dans son siège


- visser les deux vis avec rondelles au couple de
2,0 ÷ 2,5 daNm;
- monter et visser le vidange d’huile au couple de
0,4 ÷ 0,6 daNm;
- remonter la plaque d’accrochage des ressorts et
visser les vis avec rondelles au couple de 2,0 ÷
2,5 daNm.

78
TXL 15/25

In caso di sostituzione del registro automatico,


3
I
avvitare e chiudere la vite con relative rosette alla
coppia di 9 ÷ 10 daNm.
IMPORTANTE: Non smontare il registro
automatico per ripararlo; se è malfunzionante,
sostituire.
GB Should automatic adjusting be replaced, screw in
and lock screw with relevant washers with a torque
of 9 ÷ 10 daNm.
IMPORTANT: Don’t dismantle the automatic
adjusting to repair it, in case of malfunction, 75
changed.
D Bei einem Austausch der automatischen
Einstellung, die Schraube mit entsprechender
Unterlegscheibe mit einem Drehmoment von 9 ÷
10 daNm festziehen.
HAUPTSACHE : Die Automatikeinstellung
nicht zerlegen, um sie zu reparieren; sollte sie
schlecht funktionieren, muß sie ausgetauscht
werden.
F En cas de sustitution du registre automatique,
visser et fermer la vis avec les relatifs rondelles au
couple de 9 ÷ 10 daNm. 75a
IMPORTANT: Ne pas démonter le registre
automatique pour le réparer; en cas de fonc-
tionnement mauvais, remplacer.

I Prima del montaggio delle ganasce registrare


larghezza “a” dell’autoregistro a 60 mm per freno 75b
203x60 (per freni con dimensioni diverse vedere la
tabella), intervenendo in uguale misura su entrambi
i registri.

GB Before mounting the shoes adjust width “a” at 60


mm for brake size 203 x 60. Be careful to operate
evenly on both adjusting screws. For other brake
sizes, please refer to the table underneath.
a
D Vor der Montage der Backen, die Breite des
Registers auf 60 mm bei Bremse 203x60 mm
einstellen (bei Bremsen mit unterschiedlichen
Abmessungen s. Tabelle), wobei man gleichmässig
auf beiden Registern eingreifft. Dimensioni freno
Brake size
a Bremsabemessungen
F Avant le démontage des mâchoires, insérer la lar-
geur “a” dans l’autoregistre à 60mm pour le frein Dimension frein
203x60 (pour freins ayant des dimensions différen- 54 170 x 40
tes, voir tableau), en intervenant identiquement
dans les deux registres. 60 200 x 40
60/79 203 x 40/60
79 230 x 50
85 245 x 60
79 250 x 45/50
84/80 270 x 60

79
TXL 15/25

I Rimontare la ganascia destra, agganciare il flessi-


bile comando freno a mano sulla leva e inserire la
molla di ritegno.

GB Refit right shoe, hook brake hand control cable on


lever and insert retaining spring.

D Die rechte Bremsbacke wieder einbauen, den


Schlauch Steuerung Handbremse auf dem Hebel
einhaken und die Haltefeder einführen.

F Remonter la mâchoire droite, accrocher le flexible


76 de la commande du frein à main sur le levier et
insérer le ressort de retenue.

I Montare la ganascia sinistra e la molla di ritegno


77 inserendo il fulcro rinvio comando freno a mano.
GB Refit left shoe and retaining spring fitting in the
strut of hand brake control.

D Die linke Bremsbacke und die Haltefeder ein-


bauen, dabei den Umlenkdrehbolzen Steuerung
Handbremse einführen.

F Monter la mâchoire gauche et le ressort de rete-


nue en insérant le pivot de renvoi de la commande
du frein à main.

I Agganciare le due molle richiamo ganasce lato


cilindretto.
78
GB Hook the two shoe return spring on side of wheel
brake cylinder.

D Montage Haltefedern Lösen.

F Accrocher les deux ressorts de rappel des mâchoi-


res côté petit cylindre.

I Agganciare la molla richiamo ganasce lato disposi-


tivo ripresa automatica gioco (A).

GB Hook shoe return spring on automatic brake cle-


reance take-up device side (A).

D Die Rückholfeder Bremsbacken auf der Seite auto-


matische Spieleinstellvorrichtung aushaken.

F Accrocher le ressort de rappel des mâchoires côté


dispositif de reprise automatique du jeu (A).
79

80
TXL 15/25

Registrazione accoppiamento ganasce


3
I Dimensioni freno Quota di Preregistrazione
- Assicurarsi che il freno a mano o i cavi siano a Brake size Presetting width
Bremsabemessungen Voreinstellungsgrad
riposo Dimensions frein Côte de Pré-enregistrement
- Misurare il diametro delle ganasce e quello dei
170 x 40 169,2 - 0.2
tamburi. Il gioco corretto è di 1-1,4 mm, per
freno 203x60 (per freni con dimensioni diverse 200 x 40 199 - 0.4
vedere la tabella)
203 x 40/60 201.8 +/- 0.2
Se da correggere intervenire in maniera uguale
sui 2 registri laterali . 230 x 50 228.7 +/- 0.2
Nota bene: la precisa registrazione del gioco 245 x 60 243.6 +/- 0.3
tamburo/ganasce è determinante ai fini del corret-
to funzionamento dell’autoregistro (A). 250 x 45/50 248.6 +/- 0.3

ATTENZIONE! Un gioco eccessivamente ampio 270 x 60 268.6 +/- 0.3


! può danneggiare irrimediabilmente l’autoregistro
Colludo del funzionamento del freno
Effettuare 10 frenate moderate (non frenate Tamburo fig. 80
d’emergenza) sia in marcia avanti che in retromar- Drum
cia alla velocità di circa 10 Km/h. Trommel
Questa manovra permette l’assestamento dell’au- Tambour
toregistro e di verificare l’efficacia dei freni.

GB Shoes setting procedure.


- Release the parking brake and relieve the cables
tension.
- Measure the diameter of the shoes and of the
drum. The correct gap is 1-14, for brake 203x60
(for different brake size see table); If not within A
limit adjust it acting evenly on both adjusting
wheels (A).
Remark: Precise adjustment of the brake shoes
diameter is vital to the correct functioning of the
automatic adjuster.
WARNING! A too small diameter could damage
! permanently the automatic adjuster.
Gioco
Gap
Gioco
Gap
Spiels Spiels
Jeu Jeu
Check the brake efficiency Ø DI PREREGISTRAZIONE
PRESETTING
Carry out approximately 10 braking moderate
VOREINSTELLUNGSGRAD
manoeuvres ( no emergency braking ) at a speed
DI PRE-ENREGISTREMENT
of 10 Km/h forth and back. This will ideally set the
automatic adjuster and enable to check the brake
efficiency.

81
TXL 15/25

Dimensioni freno Quota di Preregistrazione D Einstellung der Backen-Zufügung


Brake size Presetting width
Bremsabemessungen Voreinstellungsgrad - Sich vergewissern, dass die Handbreme bzw. die
Dimensions frein Côte de Pré-enregistrement
Kabel auf Ruheposition sind
170 x 40 169,2 - 0.2
- Den Durchmesser der Backen und der Trommeln
200 x 40 199 - 0.4 messen. Das richtige Speil beträgt 1-1,4 mm,
bei einer Bremse von 203x60 mm (bei Bremsen
203 x 40/60 201.8 +/- 0.2
mit unterschiedlichen Abmessungen s. Tabelle).
230 x 50 228.7 +/- 0.2 Beim Eingriff, beide seitliche Register gleichmäs-
sig einstellen.
245 x 60 243.6 +/- 0.3
Anm.: Die genaue Einstellung des Spiels Trommel
250 x 45/50 248.6 +/- 0.3
/ Backen ist massgebend für die korrekte Funktion
270 x 60 268.6 +/- 0.3 des Registers (A).

ACHTUNG! Ein zu grosses Spiel kann den


! Register beschädigen.
Tamburo fig. 80
Drum Die Bremsefunktion auf Richtigkeit prüfen:
Trommel
10 mässige Bremsungen (keine Not-Bremsung)
Tambour
sowohl beim Vorwärtsgang als auch beim
Rückwärtsgang bei einer Geschwindigkeit von ca.
10 Km/h durchführen. Durch diese Manöver ist es
möglich, den Register zu richten und die Wirkung
der Bremsen zu prüfen.

F Enregistrement accouplement mâchoires


A
- S’assurer que le frein à main ou que les câbles
ne soient pas en fonction.
- Mesurer le diamètre des mâchoires et celui
des tambours. Le jeu correct doit être de 1-1,4
mm, pour le frein 203x60 (pour freins ayant des
dimensions différentes, voir tableau). Si une cor-
Gioco Gioco rection est nécessaire, intervenir identiquement
Gap Gap sur les deux registres latéraux.
Spiels Spiels
Jeu Jeu N.B.: le bon enregistrement du jeu tambour/
Ø DI PREREGISTRAZIONE mâchoires est déterminant pour le bon
PRESETTING fonctionnement de l’auto-registre (A).
VOREINSTELLUNGSGRAD
ATTENTION! Un jeu excessif peut endommager
DI PRE-ENREGISTREMENT
! definitivement l’auto-registre.

Vérification du fonctionnement du frein:

Effectuer 10 freinades modérées (non pas des


freinades d’urgence) que ce soit en marche avant
et en marche arrière à la vitesse de 10km/H envi-
ron. Cette manoeuvre permet la bonne mise en
place de l’auto-registre et de vérifier l’efficacité
des freins.

82
TXL 15/25

Smontaggio mozzi ruote


Wheel hub dismantly
Ausbau Radnaben
Démontage des moyeux des roues
3
I Raddrizzare l’aletta della rosetta di bloccaggio
sulla ghiera fissaggio mozzo ruota.

GB Straighten up the tab of the locking washer.

D Sicherungsnase auf der Ringmutter der Radnabe


aufbiegen.

F Soulever l’entaille de blocage sur le collier de fixa-


tion du moyeu de la roue.

81

I Sbloccare e svitare completamente la ghiera fis-


saggio mozzo ruota (con attrezzo speciale dis.
3VT00293).

GB Undo and unscrew completely ring nut securing


wheel hub (with special tool dwg. 3VT00293).

D Ringmutter entfernen (mit spezial Werkzeung


3VT00293).

F Débloquer et dévisser complètement le collier de


fixation du moyeu de la roue (par outil spécial plan
3VT00293). 82

I Sfilare la rosetta di sicurezza, distanziale, cuscinet-


to e mozzo ruota.

GB Remove the tab washer, distance washer, bearing


and hub.

D Entferne die Sicherungsscheibe, Distanzscheibe,


Lager und Radnabe.

F Enlever la rondelle de blocage, l’entretoise, le rou-


lement et le moyeu de la roue.
83

I Con l’estrattore sbloccare la pista interna del


cuscinetto interno ruota.

GB Pull out the inner race of wheel inner bearing.

D Innenring des inneren Kegelrollenlagers abziehen.

F Débloquer la piste intérieure du roulement intérieur


de la roue.

84

83
TXL 15/25

I Spiantare l’anello di tenuta

GB Remove the seal

D Den Haltring entfernen

F Enlever la bague d’ètanchéité

85

I Smontaggio freni
Per lo smontaggio freni eseguire la procedura da punto 70 a 75, pag. 76 - 77 - 78 - 79.

GB Brakes disassembly
To disassemble brakes follow the procedure from step 70 to 75, page 76 - 77 - 78 - 79.

D Bremsendemontage
Für den Bremsendemontage das Verfahren von Punkt 70 bis 75 aus Seite 76 - 77 - 78 - 79 ausführen.

F Démontage des freins


Pour le démontage des freins suivre la procédure de point 70 à 75, pages 76 - 77 - 78 - 79.

I Nell’eventualità di sostituzione del cavo freno a


mano togliere la rosetta a forcella per appoggio di
reazione molla ritorno cavo.

GB Should hand control cable be replaced. remove


fork washer backing cable return spring.

D Beim Entfernen des Handbremsseiles.

F En cas de substitution du câble du frein à main


enlever la rondelle à fourche pour appui de réac-
tion du ressort de retour du câble.
86

I Svitare viti fissaggio piatto freno al supporto


attacco al telaio e sfilarlo.
Per svitare le viti vicino all’ autoregistro, sfilare i
due gruppetti di registro.

GB Undo screws securing brake back plate


to frame mounting support and remove it.
To gain access to the 2 bolts near the adjuster,
both adjusting screws must be removed.

D Lösen der Befestigungsschrauben der Bremse


vom Achsgehäuse.
87 Um die Schrauben neben dem Register zu klösen,
die zwei Registereinheiten entfernen.

F Dévisser les vis de fixation du plateau du frein au


support de raccordement au cadre et l’enlever.
Pour dévisser les vis qui se trouvent à côté de
l’auto-registre, enlever les deux groupes de regi-
stre.

84
TXL 15/25

Smontaggio supporti attacco telaio


3
I

Sbloccare e sfilare il supporto attacco al telaio.


GB Frame mount support disassembly
Release and remove frame mount support.

D Demontage Flansch für Achsbefestigung


Entfernen Achsbefestigungflansch.

F Démontage des supports de raccordement du


cadre
Débloquer et enlever le support de raccordement 88
au cadre.

Rimontaggio gruppi ruote


Wheel assembly reassembly
Bremsgruppe Montage
Remontage des groupe des roues
I In caso di smontaggio o sostituzione del
manicotto, sostituire la guarnizione O-Ring.
Applicare frenafiletti medio sulle viti di fissaggio
manicotto; avvitare e bloccare le viti complete di
rosetta elastica alla coppia di 23,8÷26,2 daNm

GB In case of spindle removal replace the oring seal.


Coat the screws with medium grade fastener. Fit
the washer and tighten to torque of 23,8÷26,2
daNm.

D Bei Demontage oder Austausch der Muffe, die


Dichtung des O-Rings austauschen. Eine mittlere
89
Gewindesicherung auf den Befestigungsschrauben
der Muffe aufbringen; die Schrauben komplett mit
Federscheibe bei einem Drehmoment von 23,8 bis
26,2 daNm festziehen und spannen.

F En cas de démontage ou remplacement du four-


reau, remplacer le joint torique O-Ring. Appliquer
le frein-filets moyen sur les vis de fixation du four-
reau; visser et bloquer les vis avec rondelle èlasti-
que et serrer au couple de 23,8÷26,2 daNm

I Rimontaggio supporti attacco telaio


Togliere l’anello O-Ring di tenuta a grasso e sosti-
tuirlo.

GB Frame mount support reassembly


Remove grease seal and replace.

D Montage Achsbefestigungsflansch
Dichtring entfernen.

F Remontage des supports de raccordement du


cadre 90
Enlever la bague O-Ring d’étanchéité à graisse et
substituer.

85
TXL 15/25

I Lubrificare con Molikote P40 il manicotto del


ponte e installare il supporto attacco telaio.
Verificare che la rotazione sia libera, esente da
attriti o giochi.

GB Lubricate with Molikote P40 axle sleeve and install


frame mount support. Check that support rotation
be smooth and free from friction or play.

D 5t Molikote P40 d5e Brückenmuffe schmieren und


den Halter zum Rahmenanschluss installieren.
Prüfen, dass die Drehung frei erfolgt und weder
91 Reibung noch Spiele vorhanden sind.

F Lubrifier avec Molikote P40 le manchon du pont


et installer le support de raccordement du cadre.
Vérifier que la rotation soie exempt de frottements
ou jeux.

I Rimontare il piatto freno, applicare frenafiletti medio


sulle viti di fissaggio al supporto attacco telaio.
Avvitare e bloccare le viti M12 x 1,25x35 alla cop-
pia di 76,5 ÷ 94,5 Nm.

GB Remount brake back plate, smear medium locking


compound on screws fixing plate to frame mount
support.
Tighten screws M12 x 1.25x35 with a torque of
76,5 ÷ 94,5 Nm.

D Montage Bremsplatte. Befestigungsschrauben mit


92 Loctite 242 sichern.
Schrauben M12 x 1.25x35 mit einem Drehmoment
76,5 ÷ 94,5 Nm.

F Remonter le plateau du frein, appliquer le frein-à-


filets moyen sur les vis de fixation au support de
raccordement du cadre.
Visser et bloquer les vis M12 x 1.25x35 au couple
de 76,5 ÷ 94,5 Nm.

I Rimontaggio freni
Per il rimontaggio freni eseguire la procedura da punto 73 a 80, da pag. 77 - 82.

GB Brake reassembly
To reassemble brakes follow the procedure from step 73 to 80, from page 77 to 82.

D Zusammensetzen der Bremse


Für den Wiedereinbau das Verfahren von Punkt 73 bis 80 aus Seite 77 bis 82 ausführen.

F Remontage des freins


Pour le rémontage des freins suivre la procédure de point 73 à 80, de pages 77 à 82.

86
TXL 15/25

I Umettare con olio l’anello di tenuta (a) prima del


montaggio, e utilizzare l’attrezzo speciale dis.
48A12093 per il montaggio.
N. B.: Rispettare la quota di montaggio per evitare
a 3
48A12093
eventuali danneggiamenti dell’anello di tenuta, vedi
figura 93.
Spiantare e sostituire l’ anello di tenuta (b) sul mani-
cotto del ponte; umettare con olio prima del mon-
taggio, e utilizzare l’attrezzo speciale dis. 48A12125
per il montaggio, vedi figura 93a.

GB Apply oil to the shaft seal (a) before wheel hub


assembly, by using special tool dwg. 48A12093 for
assembly.
0,5 mm
Note: Respect assembling quota to avoid possible
damage to seal ring, see figure 93.
Remove and replace seal ring (b) on spindle of
axle; apply oil to the shaft ring before wheel hub
assembly, by using special tool dwg. 48A12125 for
93
assembly, see figure 93a.

D Vor dem Einbau den Dichtring (a) mit Öl benetzen,


mit spezial Werkzeung 48A12093 .
Hinweis: Das Einbaumaß beachten, um eventuel-
le Beschädigungen des Dichtrings zu vermeiden,
(siehe Abb. 93).
b 48A12125

Den Haltering (b) auf der Brückenmuffe entfernen


und austauschen. Vor der Montage mit Öl benetzen
und für die Montage das Speziellwerkzeug nach
Zchn. 48A12125 verwenden, (siehe Abb. 93a).

F Humecter par huile la bague d’étanchéité (a) avant


le montage, et utiliser outil spécial plan 48A12093
pour le montage.
Note: Respecter la partie de montage afin d’évi-
ter des endommagements éventuels de la bague
d’étanchéité voir figure 93.

Enlever et remplacer la bague d’étanchéité (b) sur 93a


le manchon du pont; humecter par huile avant le
montage, et utiliser outil spécial plan 48A12125
pour le montage voir figure 93a.

87
TXL 15/25

Rimontaggio mozzi ruote


Wheel hubs reassembling

I Norme registrazione cuscinetti


b
1) Lavare i cuscinetti con petrolio caldo ed asciu-
garli con aria compressa e lubrificarli immergen-
doli in grasso fuso.
2) Montare i cuscinetti con relativo mozzo dopo
averne riempito di grasso (del tipo FIAT MR2 o
similari) ogni cavità interna (a).
Attenzione! L’eccesso di grasso può causare il
! rovesciamento del labbro della guarnizione (b).
Montare la rondella dentata e quindi avvitare la
ghiera.
3) Ruotare e martellare il mozzo per favorire l’as-
sestamento dei rulli conici sulle piste e, nel frat-
tempo, serrare la ghiera progressivamente fino
alla coppia di serraggio di 14,7 daNm.
4) Allentare la ghiera e quindi riavvitarla successi-
vamente incrementando progressivamente la cop-
pia di serraggio fino al valore di 1 daNm.
94 a
5) Riallentare la ghiera in modo da assicurare un
gioco max. sui cuscinetti di 0,05 mm, corrispon-
dente a circa 1/32 di giro della ghiera. Fermare
quindi la ghiera come indicato al punto 6.
6) A registrazione avvenuta assicurare la ghiera
ripiegando uno dei lobi della rosetta di sicurezza
in uno degli intagli della ghiera (vedere foto 96).
Se ciò non fosse possibilile continuare ad avvitare
la ghiera fino a raggiungere la posizione di mon-
taggio.

GB Bearings adjustment specifications


1) Wash the bearings with hot petroleum and dry
them by immersion in melted grease.
95 2) Assemble the bearings with the related hub,
after filling with grease (FIAT MR2 or similar) each
internal cavity (a).
Attention! Too much grease can cause the over-
! turning of the lip of the seal (b). Assemble the
toothed washer and the screw the ring nut.
3) Rotated and hammer the hub to make easier
the bedding of the conical rollers on the tracks,
and at the same time screw gradually the ring nut
to the driving torque of 14.7 daNm.
4) Loosen the ring nut and then screw it increasing
gradually the driving torque to 1 daNm.
5) Loosen again the ring nut in a way to assure a
max. play on the bearings of 0.05 mm, correspon-
96 dent to about 1/32 of turn of the ring nut. Lock
then the ring nut in the way explained in step 6.
6) If no tab mates the slot, tighten slightly the nut
to match the nearest tab (see photo 96).

88
TXL 15/25

Einbau Bremstrommel
Rémontage des moyeux des roues
3
Vorschriften für Lagermontage
b
D

1) Reinige die Lager mit entsprechenden


Reinigungsmitteln und schmiere sie mit geeigne-
tem Lagerfett.
2) Montiere die Lager mit der Radnabe, die vorher
mit Fett (Fiat MR 2 oder vergleichbaires Fett) gefüllt
wurden.
Achtung! Zuviel Fett kann die Wellendichtringfunktion
! beeinträchtigen.
3) Drehe die Radnabe einige Male, um einen
guten Sitz der Kugelrollenlager zu glewährleisten.
Gleichzeitiges Anziehen der Ringmutter bis zu
einem Drehmoment von 14,7 daNm.
4) Löse die Ringmutter und erhöhe das
Anziehdrehmoment um weitere 1 daNm.
5) Löse die Mutter nochmals um ein max.
Lagerspiel von 0,05 mm (entsprechend 1/32
Umdrehung der Ringmutter) sicher zustellen.
a 94
6) Drehe die Ringmutter in eine Position, in der die
Nase des Sicherungsringes umgelegt werden kann
(Siehe Foto 96).

F Normes de réglage des roulements


1) Laver les roulements par pétrole chaud et les
sécher à l’air comprimé et les lubrifier en les trem-
pant dans du gras fondu.
2) Monter les roulements avec le relatif moyeu
après avoir graissée (modèle FIAT MR2 ou similai-
res) chaque cavité intérieure (a).
Attention! L’eccès de gras peut provoquer le ren-
! versement du bord du joint (b).
Monter la rondelle dentée et puis visser le collier. 95
3) Tourner et marteler le moyeu pour faciliter la
mise en état des rouleaux coniques sur les pistes
et, entre-temps, serrer le collier progressivement
jusqu’au couple de serrage de 14,7 daNm.
4) Desserrer le collier et puis le revisser par la suite
en augmentant progressivement le couple de ser-
rage jusqu’à la valeur de 1 daNm.
5) Redesserrer le collier de façon à garantir un jeu
maxi de 0,05 mm sur les roulements, correspon-
dant à 1/32 environ de tour du collier; Ensuite fixer
le collier comme indiqué au point 6.
6) A réglage effectué, assurer le collier en repliant
l’un des lobes de la rondelle de blocage dans l’un
des entailles du collier. Si cela n’était pas possible, 96
continuer à visser le collier jusqu’à arriver à la posi-
tion de montage (voir photo 96).

89
TXL 15/25

I Rimontaggio semiassi
Infilare il semiasse facendo attenzione a non dan-
neggiare l’anello di tenuta, come indicato.

GB Wheel shaft reassembly


Install the half shaft, taking care not to damage the
seal ring.

D Montage Achswelle
Montiere die Achswelle. Vorsicht, daß der
Dichtring nicht beschädigt wird.
97
F Remontage des demi-axes
Monter le demi-essieu en faisant attention à ne pas
endommager pas la bague d’étanchéité, comme
indiqué.

I Applicare frenafiletti, avvitare e bloccare le dodici


viti complete di rosetta elastica alla coppia di ser-
raggio di 25,5 ÷ 31,5 Nm.
GB Screw in twelve bolts with spring washer and
tighten with 25.5 ÷ 31.5 Nm.

D Schraube die 12 Schrauben mit Federring ein und


ziehe an mit einem Drehmoment von 25.5 ÷ 31.5
Nm.

F Appliquer le frein-à-filets, visser et bloquer les


98 douze vis complètes de rondelle-ressort au couple
de serrage 25,5 ÷ 31,5 Nm.

I Montare il tamburo freni, umettare la filettatura


delle due viti con Loctite 242 e avvitare le due viti.
N. B.: assicurarsi che non ci sia strisciamento
delle ganasce del freno sul tamburo.

GB Install the brake drum using Loctite 242 for the


two fixing screw.
Note: Make sure that the brake shoes are not in
contact with the drum.
99
D Die Bremstrommel einbauen, das Gewinde der
beiden Schrauben mit Loctite 242 benetzen und
die beiden Schrauben.
Hinweis: Sicherstellen, daß bei der Montage
die Bremsschuhe keinen Kontakt mit der
Bremstrommel haben.

F Monter le tambour du frein, humecter le filetage


des deux vis par Loctite 242 et visser les deux vis.
Note: s’assurer qu’il n’y a pas de frottement des
mâchoires du frein sur le tambour.

90
TXL 15/25

Smontaggio trasmissione
Dismantle transmission
Getriebe Demontage
Demontage de la transmission
3
I Per la revisione della trasmissione, si può proce-
dere rimuovendo i gruppi ruota completi o revisio-
nando gli stessi, come descritto precedentemente
Per rimuovere i gruppi ruota completi, sbloccare
e svitare le viti di fissaggio manicotti al gruppo
centrale.

GB The wheel side assays can be removed complete,


if necessary.
To remove them, undo the screws holding the
spindle to rear case.
100
D Zur Überholung des Antriebs kann man wie folgt
vorgehen: die Rädergruppen komplett ausbauen
oder sie überprüfen, wie vorher beschrieben.
Um die Rädergruppen komplett auszubauen,
die Befestigungsschrauben der Muffen in der
Zentraleinheit lösen.

F Pour la révision de la transmission, il est possible


de procéder ainsi: enlever les groupes roue en
entier ou bien les contrôler, comme décrit pré-
cédemment.
Pour enlever les groupes roue en entier, débloquer
et dévisser les vis de fixation des fourreaux au
groupe central.

I Svitare le viti di ritegno e smontare il tubo Iivello


olio completo di asta.

GB Unscrew the retaining screws and dismantle the


oil level pipe complete with dipstick.

D Die Halterungsschrauben lösen und das


Ölstandrohr mit Ölpeilstab abheben.

F Desserrer les vis de fixation, puis démonter le tube


de niveau d’huile avec la jauge.
101

I Dopo aver contrassegnato la posizione da rispet-


tare al successivo montaggio, sbloccare e svitare 102
le viti di fissaggio del coperchio supporto differen-
ziale al corpo centrale ed estrarlo.

GB After having marked the position for its subse-


quent re-assembly, unscrew the screws that attach
the differential support cover to the central body
and remove it.
D Vor Demontage vom Deckel des Hauptgehäuses,
Einbaulage kennzeichnen. Befestigungsschrauben
lösen und Deckel abnehmen.
F Après avoir repéré la position à respecter au mon-
tage suivant, débloquer et desserrer les vis de
fixation du couvercle de support de différentiel au
corps central, puis le dégager.

91
TXL 15/25

I Sfilare il differenziale completo di corona conica


dal corpo centrale.
GB Remove the differential from the central body,
complete with crown wheel.
D Das Differential mit Tellerrad aus dem
Zentralgehäuse nehmen.
F Dègager le différentiel complet avec la couronne
conique du corps central.

103

I Rimuovere le viti di unione delle semiscatole diffe-


renziale e contrassegnare la posizione da rispetta-
re in sede di rimontaggio.

GB Remove the junction screws of the differential hal-


fboxes and mark the position that must be strictly
adhered to when re-assembling.

D Einbaulage kennzeichnen. Verbindungsschrauben


der Differenzialgehäusehälften lösen.

F Retirer les vis d’assemblage des demi-carters de


104 104a différentiel, et repérer la position à respecter au
moment du remontage.
Versione con corona Versione con corona
saldata bullonata

Welded crown version Bolted crown version

Version mit Version mit


geschweißtem Tellerad verschraubtem Tellerad

Version avec couronne Version avec couronne


sondèe boulonnèe

I Aprire il differenziale per il controllo delle usure,


relativamente ai satelliti e planetari conici e rela-
tive ralle.

GB Open the differential so as to check the crown


wheels, pinions and bearings for wear.

D Differentialgehäusehälfte abheben, Kegelräder,


Kegelritzel, Differentialkreuz, Scheiben und
Kugelscheiben prüfen.

F Ouvrir le différentiel pour contrôler l’usure des


pignons satellites et planétaires coniques, ainsi
que des butées correspondantes.

105 105a

92
TXL 15/25

Nel caso di sostituzione dei cuscinetti conici,


3
I
spiantare con normale estrattore e rimontare a
caldo o con opportuno attrezzo.

GB If the tapered bearings have to be replaced, remo-


ve them with a normal extractor and re-assemble
hot or with the appropriate tool.

D Falls Kegelrollenlager getauscht werden muß,


Lager mit 2-armigen Abzieher abziehen. Bei
Montage den Kegelradinnenring im Ofen
erwärmen.

F En cas de remplacement des roulements


coniques, les enlever à l’aide d’un extracteur nor-
mal, puis les remonter à chaud ou avec un outil
approprié.
106

I Posizionare i componenti del differenziale nelle


proprie sedi, quindi unire le semiscatole facendo 107 107a
coincidere i segni precedentemente effettuati,
inserire le viti di unione e bloccare alla coppia
di 4,8 ÷ 5,2 daNm (Figura 107), 11 ± 5% daNm
(Figura 107a).

GB Position the differential components in their sea-


tings, then joint the half-boxes together, making
sure that the marks previously made on them
coincide, insert the junction screws and tighten to
a torque of 4.8 ÷ 5,2 daNm (Picture 107), 11 ± 5%
daNm (Picture 107a).

D In Differentialgehäusehälfte Scheibe, Kegelrad, Versione con corona Versione con corona


Differentialkreuz mit Kegelrtizel und Kugelscheiben saldata bullonata
einlegen zweites Differentialgehäuse aufsetzen
(Markierung beachten), Schrauben montieren und Welded crown version Bolted crown version
mit einem Drehmoment von 4,8 ÷ 5,2 daNm (Bild
Version mit Version mit
107), 11± 5% daNm (Bild 107a). geschweißtem Tellerad verschraubtem Tellerad
F Mettre en place les composants du différentiel, Version avec couronne Version avec couronne
puis assembler les demi-carters en faisant coïnci- sondèe boulonnèe
der les repères précédemment marqués; introduire
ensuite les vis d’assemblage et bloquer au couple
de 4,8 à 5,2 daNm (Figure 107), 11± 5% daNm
(Figure 107a).

I Sbloccare le viti di fissaggio del carter convertitore


alla scatola inversore.

GB Undo the screws that fix the converter casing to


the reversing gearbox.

D 12 Befestigungsschrauben des Wandlergehäuses


herausschrauben.

F Débloquer les vis de fixation du carter du convertis-


seur au boîtier d’inverseur.

108

93
TXL 15/25

I Sbloccare e svitare le 3 viti di ritegno del coper-


chietto del cuscinetto coperchio tamburo frizioni.

GB Unscrew the 3 screws retaining the cover of the


clutch drum cover bearing.

D 3 Halteschrauben del Lagerhalteringes vom Deckel


des Außenlamellenträgers herausschrauben.

F Débloquer et desserrer les 3 vis de fixation du cou-


vercle du roulement de couvercle de cloche d’em-
109 brayage.

I Staccare il carter convertitore completo della sca-


tola inversore.
110
GB Detach the complete converter case from the
reversing gearbox.

D Das Wandlergehäuse komplett durch leichte


Schloge mit dem Gummihammer herunterklopfen.

F Dégager le carter du convertisseur complet du


boîtier d’inverseur.

I Spiantare e sostituire, se necessario, la guarnizio-


ne a labbro lato convertitore, utilizzare per il mon-
111 taggio l’attrezzo speciale 4902058.

GB Remove and replace, if necessary, the lip seal on


the converter side be necessary, use specific tool
4902058.

D Wellendichtring entfernen und grundsätzlich


austauschen, mub man für die Montage das spe-
zielle Werkzeug verwenden 4902058.

F Dégager et remplacer, si besoin est, le joint à lévre


côté convertisseur, pour le montage utiliser l’outil
spécial 4902058.

94
TXL 15/25

Pulire accuratamente le sedi delle tenute sui con-


3
I
dotti di mandata olio al convertitore (foro grande)
e alla frizione Retromarcia (foro piccolo), quindi
posizionare le guarnizioni O-Ring; per evitarne la
fuoriuscita dalle sedi, in fase di montaggio, è con-
sigliablle applicare un leggero velo di grasso.
GB Carefully clean the seats of the seals on the oil
supply channels to the converter (large hole) and
the Reverse Gear clutch (small hole) then put the
O-RING seals in position; to avoid their displace-
ment from their seatings during assembly, it is advi-
sable to apply a thin film of grease.
D O-RINGE der Druckbohrungen prüfen bei Bedarf
erneuern oder reinigen und mit Fett wieder einsetzen.
F Nettoyer méticuleusement les sièges des joints
d’étanchéité sur les tuyaux de refoulement d’huile
au convertisseur (grand trou) et à l’embrayage de
Marche Arrière (petit trou), puis positionner le joint 112
torique; pour éviter la sortie du siège, au moment
du montage, il est conseillé d’appliquer une légère
couche de graisse.

I Sganciare l’anello di tenuta idraulica in ghisa;


rimontare prestando particolare attenzione e fis-
sare per mezzo di grasso in posizione concentrica
all’albero per evitare il danneggiamento nel mon-
taggio in sede.
GB Disconnect the cast iron hydraulic ring seal: re-
assemble, taking particular care and setting it with
grease in position concentric to the shaft, so as to
avoid damage when fitting it to its seating.
D Dichtbuchse vorsichtig herausnehmen prüfen und
mit Fett wieder einsetzen.
113
F Dégager la bague d’étanchéité hydraulique en
fonte; la remonter avec précaution, puis la fixer, en
graissant, en position concentrique à l’arbre, pour
éviter tout endommagement lors du montage.

I Estrarre l’anello elastico e spiantare l’albero P.T.O.


completo di cuscinetto.

GB Extract the retaining ring and remove the P.T.O.


shaft complete with bearing.

D Springring entfernen und die Welle zusammen mit


dem Lager herausnehmen.

F Extraire le circlips et dégager l’arbre de prise de


force complet avèc son roulement.

114

95
TXL 15/25

I Per l’eventuale sostituzione del cuscinetto, rimuo-


115 vere dall’albero l’anello elastico di ritegno.

GB If it is necessary to replace the bearing, remove


the retaining ring from the shaft.

D Lager prüfen, sollte Lager getauscht werden


Sicherungsring von de Welle entfernen.

F Si le roulement doit être remplacé, retirer le circli-


ps de I’arbre.

I Sbloccare e svitare le viti di ritegno e smontare il


gruppo pompa completo.

GB Unscrew the retaining screws and remove the com-


plete pump assembly.

D Halteschrauben Lösen und abschrauben und


Pumpen komplett abheben.

F Débloquer et desserrer les vis de fixahon, puis


démonter le groupe de pompe complet.
116

I Estrarre l’anello di centraggio pompa e staccare


dalla facciata di appoggio la guarnizione in carta.

GB Extract the pump centering ring and remove the


paper gasket from the surface on which it rests.

D Pumpenzentrierring und Dichtung abnehmen.

F Extraire la bague de centrage de pompe, et retirer le


joint en papier de la face d’appui.

117

I Smontare il coperchio dal corpo pompa.

GB Remove the pump body cover.

D Den Deckel vom Pumpengehäuse trennen.

F Démonter le couvercle du corps de pompe.

118

96
TXL 15/25

Estrarre gli ingranaggi da corpo pompa e control-


3
I
lare visivamente le usure degli stessi e delle relati-
ve sedi; rimontare nella corretta posizione.

GB Remove the gears from the pomp body and check


visually for wear on the gears and their seatings;
re-assemble in the correct position.

D Innenzahnradpumpe auf Verschleiß prüfen, bei


Bedarf defekte Teile tauschen. Hohlrad und Ritzel
wieder einsetzen.

F Extraire les engrenages du corps de pompe, 119


et contrôler visuellement leur usure et celle des
sièges correspondants; remonter en position cor-
recte.

I Estrarre l’anello elastico di reazione dello stantuffo


Retromarcia, quindi sfilare iI coperchio tamburo
frizione completo.

GB Remove the reaction ring from the Reverse Gear


position, then remove the complete clutch drum
cover.

D Sicherungsring am Außenlamellenträger entfer-


ner, Turbinenträgerwelle mit Deckel vom
Außenlamellenträger und Kolben herausziehen.

F Extraire le circlips de pression du piston de Marche


Arrière, puis retirer le couvercle de la cloche d’em-
brayage complète.

120

I Estrarre l’anello elastico di ritegno coperchio tam-


buro sul lato interno, quindi sfilare assialmente i
tre dischi frizione e i tre controdischi in acciaio del
pacco frizione Retromarcia.

GB Extract the inner cover retaining ring, then remo-


ve axially the three clutch plates and the three steel
counter-plates from the Reverse Gear clutch
package.

D Sicherungsring zur Fixierung des Deckels


am Außenlamellenträger entfernen und
Rückwärtsganglamellen heraus nehmen.
121

F Extraire le circlips du couvercle de cloche, côté


intérieur, puis dégager axialement les trois disques
d’embrayage et les trois plateaux de pression
d’embrayage en acier du groupe d’embrayage de
Marche Arrière.

97
TXL 15/25

I Smontare il mozzo portadischi frizioni Retromarcia,


dopo aver estratto l’anello elastico di ritegno.

GB Remove the Reverse Gear clutch plate hub, after


having extracted the retaining ring.

D Sicherungsring auf der Rückwärtsgangzahnradw


elle entfernen und RG Innenlamellenträger heraus
nehmen.

F Déposer le moyeu d’embrayage de Marche Arrière,


122 après avoir extrait le circlips.

I Estrarre l’anello elastico di fermo assiale (lato


esterno) delI’anello di reazione frizioni e smontarlo
dalla campana.

GB Extract the clutch reaction ring outer retaining ring


and remove it from the bell.

D Sicherungsring am Außenlamellenträger für die


Trennscheibe entfernen und Trennscheibe heraus
nehmen.

F Extraire le circlips d’essieu (côté extérieur) de la


bague de pression d’embrayage, puis le retirer de
la cloche.

123

I Estrarre l’anello elastico di fermo assiale (lato inter-


no) dell’anello di reazione, quindi smontare i tre
dischi e i tre controdischi del pacco frizione Marcia
Avanti.

GB Extract the reaction ring inner retaining ring, then


dismantle the three plates and three counter-plates
of the Forward Gear c!utch package

D Sicherungsring für die Fixierung der, Trennscheibe am


Außenlamellenträger entfernen und Vor-wärtsgan-
glamellen heraus nehmen.

F Extraire le clrclips d’essieu (côté intérieur) de la


bague de pression, puis démonter les trois disques
et les trois plateaux de pression du groupe d’em-
brayage de Marche Avant.

124

98
TXL 15/25

Smontare dall’albero Retromarcia, l’anello elastico


3
I
di ritegno del mozzo portadischi, lato interno.

GB Remove the inner clutch plate hub retaining ring


from the Reverse Gear shaft.

D Sicherungsring von der Rückwärtsgangzahnradwelle


entfernen.

F Démonter le circlips du moyeu d’embrayage, côté


intérieur, de l’arbre de Marche Arrière.

125

I Smontare dall’ albero il mozzo portadischi frizione


Marcia Avanti, dopo aver rimosso l’anello elastico 126
di ritegno.

GB After having removed its retaining ring, remove the


Forward Gear clutch plate hub from the shaft.

D Sicherungsring von der Vorwärtsgangzahnradwelle


entfernen und Vorwärtsganginnenlamellenträger
abziehen.

F Démonter le moyeu d’embrayage de Marche


Avant de l’arbre, après avoir déposé le circlip.

I Sfilare il gruppo tamburo frizione completo.


127
GB Remove the complete clutch drum assembly.

D Außenlamellenträger komplett herausziehen.

F Déposer le groupe de la cloche d’embrayage com-


plète.

99
TXL 15/25

I Recuperare dall’albero Marcia Avanti la gabbia a


rulli del tamburo frizioni.

GB Remove the clutch drum roller cage from the


Forward Gear shaft.

D Nadellager des Außenlamellenträgers von der


Vorwärtsgangzahnradwelle abnehmen.

F Récupérer la cage à du roulement aiguilles de la


cloche d’embrayage sur l’arbre de Marche Avant.

128

I Nell’eventualità di sostituzione dell’albero con-


duttore, spiantarlo dal coperchio tamburo frizioni,
dopo l’estrazione dell’anello elastico di ritegno.
GB If the drive shaft has to be replaced, remove it from
the clutch drum cover, after extracting the retaining
ring.
D Turbinenträgerwelle prüfen, bei Bedarf austau-
schen, in diesem Fall Sicherungsring entfernen und
Welle vom Deckel herausziehen.
F En cas de remplacement de l’arbre primaire, le
129 dégager du couvercle de cloche d’embrayage,
après extraction du circlips.

! ATTENZIONE ! ! ACHTUNG !
Impiegare gli utensili adatti. Schwere Teile nur mit geeignetem Hebe-und
NON USARE MAI DITA O MANI Transportwerkzeug transportieren.
o attrezzi non idonei Vorsicht auf Hände und Finger

! WARNING ! ! ATTENTION !
Use the proper tools. Utiliser les outils appropriés.
NEVER USE FINGERS OR HANDS NE JAMAIS UTILISER DE DOIGTS OU MAINS
or incorrect tools ou d’outils pas appropriés

I Mediante apposito attrezzo (48A11850), com-


primere la molla a tazza di richiamo stantuffo il
necessario per permettere l’estrazione dell’anello
elastico.
GB Using the special tool (48A11850), compress the
piston return cup spring sufficiently to allow the
retaining ring to be removed.
D Tellerfeder mit Spezialwerkzeug (48A11850) soweit
herunterpressen, bis Sicherungsring frei ist dann
Sicherungsring entfernen.
130 F Au moyen de l’outil approprié (48A11850), compri-
mer le ressort à coupelle de rappel de piston de
la valeur nécessaire pour permettre l’extraction du
circlips.

100
TXL 15/25

Sfilare lo stantuffo della frizione Retromarcia dal


3
I
coperchio tamburo e sostituire la guarnizione
O-Ring di tenuta interna ed esterna.

GB Remove the Reverse Gear clutch piston from the


drum cover and replace the inner and outer O-Ring
seals.

D Kolben vom Dechel abziehen und O-Ringe


erneuern.

F Dégager le piston de l’embrayage de Marche


Arrière du couvercle de cloche, et remplacer les
131
joints toriques intérieur et extérieur.

I Rimontare lo stantuffo sul coperchio tamburo;


posizionare la molla a tazza di richiamo e la roset-
ta di sicurezza, quindi mediante l’attrezzo, com-
primere fino a permettere l’inserimento dell’anello
elastico di ritegno.

GB Re-assemble the piston on the drum cover; place


the return cup spring and tab washer in position,
then, using the tool compress the spring sufficien-
tly to allow the retaining ring to be inserted.

D Kolben und Tellerfeder in den Deckel vom


Außenlamellenträger einlegen Tellerfeder mit
Spezialwerkzeug niederdrücken bis Nut für den
Sicherungsring frei ist Sicherungsring einlegen
und sichern.

F Remonter le piston sur le couvercle de cloche;


positionner le ressort à coupelle de rappel et la
rondelle de sûreté, puis, au moyen de l’outil, com- 132
primer pour permettre l’insertion du circlips.

I Dopo aver estratto l’anello elastico, introdurre


sul coperchietto n. 3 viti di servizio (M5), avvitare 133
alternativamente per l’estrazione del cuscinetto
dal coperchio tamburo.
GB After having extracted the retaining ring, insert qty.
3 service screws (M5) in the cover, and alternately
tighten the screws so as to extract the bearing
from the drum cover.
D Sicherungsring entfernen mit 3 Schrauben M5
Kugelrollenlager abdrücken.
F Après avoir extait le circlips introduire sur le cou-
vercle trois vis de service (M5), et les serrer alter-
nativement pour extraire le roulement du couvercle
de cloche.

101
TXL 15/25

I Posizionare correttamente il coperchietto, calettare


a caldo o mediante attrezzo il cuscinetto ed intro-
durre l’anello elastico di ritegno, prima dell’inseri-
mento dell’albero conduttore.

GB Place the cover in the correct position, shrink the


bearing on or fit it with a tool and insert the retaining
ring, before inserting the drive shaft.

D Haltering einlegen, Lager erwärmen dann montie-


ren und mit Sicherungsring sichern.
134 Positionner correctement le couvercle, caler le rou-
F
lement à chaud ou à l’aide de l’outil et introduire le
circlips avant d’insérer celui-ci sur l’arbre primaire.

I Sostituire la guarnizione O-RING nella propria sede


del coperchio tamburo; fermare con l’introduzione
dell’anello elastico.

GB Replace the O-RING seal in its seating on the drum


cover; retain it in position by inserting the retaining
ring.

D O-RING austauschen, Turbinenträgerwelle einset-


zen und mit Sicherungsring sichern.

135 F Mettre un nouveau joint torique sur le couvercle de


cloche, bloquer e introduisant le circlips.

I Sganciare e sfilare dalle relative sedi sul tamburo


frizioni gli anelli di tenuta idraulica.

GB Release the hydraulic sealing rings and slide them


from their respective seatings on the clutch drum.

Am Außenlamellenträger Kolbendichtringe montieren.


D
Dégager les bagues d’étanchéité hydraulique en
F fonte de la cloche d’embrayage, et les faire glisser
pour les retirer.
136

102
TXL 15/25

Nell’operazione di rimontaggio degli anelli di tenu-


3
I
ta idraulica in ghisa, prestare particolare cura e
fermare, mediante grasso, in posizione concentri-
ca; posizionare nella propria sede la gabbia a rulli.
Note: Per quanto riguarda l’operazione di smon-
taggio e rimontaggio dello stantuffo Marcia Avanti
alloggiato all’interno del tamburo frizioni, proce-
dere analogamente a quello della Retromarcia
precedentemente illustrato, utilizzando la stessa
attrezzatura.

GB When re-assembling the cast iron hydraulic sealing 137


rings, take particular care and use grease to keep
them in a concentric position; position the roller
cage in its seating.
Note: With regard to the dismanting and re-
assembly of the Forward Gear piston, which is
housed inside the clutch drum, the procedure is
the same as for Reverse Gear outlined above,
using the same equipment.

D Kolbenringe einfetten und Nadellager einsetzen.


Anmerkung: Der Aus-und Einbau des Vorwärts-
gangkolben wird genau so wie beim Rückwärts-
gangkolben durchgeführt.

F Effectuer méticuleusement l’opération de remonta-


ge des bagues d’étanchéité hydraulique en fonte,
et bloquer à la graisse, en position concentrique,
positionner correctement la cage à rouleaux.
Note: En ce qui concerne l’opération de démontage
et de remontage du piston de Marche Avant, logé
à l’intérieur de la cloche d’embrayage, procedér
comme illustré précédemment pour la Marche
Arrière, en utilisant un outillage identique.

I Sollevare le acciaccature della ghiera pignone;


sbloccarlo e svitarlo: per permettere questa ope-
razione, è necessario contrastare la rotazione del
pignone tramite specifico attrezzo (4A42440/2) da
inserire sui mozzi portadischi frizione per rendere
solidali gli alberi delle due marce.

GB Raise the stake on the pinion lock nut; release and


unscrew it. To carry out this operation, it is neces-
sary to prevent the pinion rotating by means of a
speclal tool (4A42440/2), which is inserted on the
clutch plate hubs and locks them to the shafts of
the two gears.

D Sicherungsring der Nutmutter aufbördeln. Damit


die Nutmutter mit Hilfe eines Nutmutterschlüssel
(Siehe Spezialwerkzeug 4A42440/2) gelöst
und herausgeschraubt werden kann muß mit
den beiden Innenlamellenträgern und einem
Spezialwerkzeug das Kegelradpaar gegen 138
verdrehen gesichert werden.

F Défreiner l’écrou de pignon, puis le débloquer et


le desserrer: pour permettre cette opération, il
est nécessaire d’immobiliser le pignon à l’aide de
l’outil approprié (4A42440/2), placé sur les moyeux
d’embrayage, afin de rendre solidaires les arbres
des deux marches.

103
TXL 15/25

I Spiantare, con appropriato punzone, il pignone


139 conico dell’anello interno del cuscinetto di coda.

GB Using the appropriate punch, remove the bevelled


pinion from the inner ring of the tail bearing.

D Kegelritzelwelle mit einem Dorn aus der Kegelrollen


lagerinnenringführung herausschlagen.

F Avec le poinçon approprié, chasser le pignon coni-


que de la bague interne du roulement d’extrémité.

! ATTENZIONE ! ! ACHTUNG !
Maneggiare tutti i particolari con opportuni Schwere Teile nur mit geeignetem Hebe-und
mezzi e con grande attenzione. Non mettere Transportwerkzeug transportieren.
le mani e le dita tra un pezzo e l’altro Vorsicht auf Hände und Finger

! WARNING ! ! ATTENTION !
Manipuler tout les composants par oppor-
Handle all heavy parts with the appropriate
tuns outils et avec beaucoup d’attention.
equipment and with the utmost care. Never
Ne jamais glisser les mains ou les doigts entre
put your hands and fingers in between parts
les différents éléments

I Sbloccare e svitare le viti di unione e separare il


140 carter intermedio dal corpo centrale rendendo
possibile il recupero dell’ingranaggio condotto
(calettato sul pignone conico) e lo smontaggio del
gruppo ingranaggio intermedio.

GB Release and unscrew the junction screws and sepa-


rate the intermediate casing from the central body,
which makes it possible to remove the driven gear
(shrunk onto the bevelled pinion) and dismantle the
intermediate gear assembly.

D Verbindungsschrauben vom Zwischengehäuse


und Hauptgehäuse herausschrauben, dann die
Gehäuse trennen.

F Débloquer et desserrer les vis d’assemblage, puis


séparer le carter intermédiaire du corps central, en
permettant la récupération de l’engrenage mené
(calé sur le pignon conique), et le démontage du
groupe d’engrenage intermédiaire.

104
TXL 15/25

Controllare i componenti dell’ingranaggio interme-


3
I
dio: gabbie a rulli, ralle di spallamento e relative
superfici di lavoro; sostituire secondo esigenza e
rimontare.
GB Check the components of the intermediate gear
assembly: roller cages, shoulder bearings and their
respective working surfaces. Replace as necessary
and re-assemble.
D Wendezahnrad vom Rückwärtsgang, Nadellager,
Welle und Anlaufscheiben prüfen bei Bedarf
erneuern.
141
F Contrôler les composants de l’engrenage intermé-
diaire: cages à rouleaux, rondelles à épaulement,
et surfaces de travail correspondantes; remplacer,
si besoin est, puis remonter.

I Smontare dal corpo centrale l’albero Retromarcia:


allargare l’anello elastico montato sul carter fino a
permettere lo spiantaggio dell’albero completo di
cuscinetto.
Nota: Per quanto riguarda lo smontaggio dell’al-
bero Marcia Avanti sul carter intermedio procede-
re analogamente a quello della Retromarcia.

GB Remove the Reverse Gear shaft from the cen-


tral body: widen the retaining ring on the casing
sufficiently to allows the shaft to be removed com-
plete with bearing.
Note: with regard to dismantling the Forward Gear 142
shaft on the intermediate casing, the procedure is
the same as for the Reverse Gear shaft.
D Sicherungsring der Rückwärtsgangwelle entsichern
damit die Welle mit einem Gummihammer heraus
geschlagen werden kann.
Anmerkung: Gleicher Arbeitsablauf mit der
Vorwärtsgangwelle im Zwischengehäuse.
F Démonter l’arbre de Marche Arrière du corps
central: élargir le circlips monté sur le carter pour
permettre le dégagement de l’arbre complet avec
son roulement.
Note: En ce qui concerne le démontage de l’ar-
bre de Marche Avant du canter intermédiaire,
procéder comme pour la Marche Arrière.

I Sbloccare e svitare le viti di fissaggio del coper-


chio di spallamento cuscinetto sottotesta pignone
e quindi estrarlo dalla sede; spiantare e sostituire
la guarnizione a labbro e l’anello O-Ring.
GB Release and unscrew the head pinion bearing
shoulder cover fixing screws and remove the
cover from its seating; remove and replace the lip
seal and the O-Ring.
D Befestigungsschrauben vom Deckel heraus-
schrauben und Deckel abnehmen. Wellendichtring
und O-Ring erneuern.
143
F Débloquer et desserrer les vis de fixation du cou-
vercle à épaulement du roulement sous tête de
pignon, puis l’extraire de son logement; retirer et
remplacer le joint à lèvre et le joint torique.

105
TXL 15/25

I Rimuovere lo spessore di registro assiale pignone


e spiantare a mezzo punzone l’anello esterno del
cuscinetto sottotesta.
GB Remove the pinion axial adjustment shim and,
using a punch, remove the outer ring of the head
bearing.
D Die Distanzscheibe entfernen und mit Hilfe eines
Dorns den Lageraußenring entfernen.
F Retirer la cale de réglage axial du pignon, et déga-
ger au moyen d’un poinçon la bague extérieure du
144 roulement sous la tête.

Rimontaggio trasmissione
Reassebling transmission
Getriebe Montage
Remontage de la transmission

I Montaggio coppia conica


Prima di iniziare il montaggio, è necessario rilevare
alcune quote per determinare lo spessore di regi-
stro del posizionamento assiale del pignone.
Posizionare al posto del differenziale centrato sulle
sedi dei cuscinetti l’attrezzo speciale (4A42440/1)
di diametro noto D.
GB
Assembly of bevel gear
Before commencing assembly, it is necessary to
take certain measurements in order to determine
the thickness of the bevel pinion axial adjusting
shim.
Place use specific tool (4A42440/1) of known dia-
meter D in place of the differential, centered on the
bearing seatings.
D Einbau des Teller- U. Kegelrades
Vor Montage des Kegelradpaares muß das
145 Gehäuse, die Kegelrollenlager, Deckel und
Zahnräder zum Einstellen des Flankenspiels,
Tragbild und Vorspannung der Kegelrollenlager
ausgemessen werden. Als Hilfswerkzeug wird ein
Zylinder (wird in der Berechnung als D bezeich-
net) zum Ausmessen benötigt, der anstatt des
Differential eingebaut wird.
F
Montage du couple conique
Avant de procéder au montage, il est indispensa-
ble de mesurer quelques cotes pour déterminer
l’épaisseur de réglage du positionnement axial du
4A42440/1
pignon conique.
Positionner l’outil spécial (4A42440/1) de diamètre
connu D en lieu et place du différentiel, centré sur
les logements des roulements.
145a

106
TXL 15/25

Rilevare la quota dalla facciata di appoggio del


3
I
coperchio di spallamento cuscinetto sottotesta a
filo esterno dell’attrezzo D e contrassegnare con
la lettera A.
Si può determinare ora la distanza dalla facciata
di appoggio coperchio all’asse corona che chia-
meremo B: B = A + (D : 2)
GB Measure the distance from the bearing surface of
the head bearing shoulder cover to the outer edge
of specific tool D, and call this A.
The distance from the bearing surface of the cover
to the crown wheel axis can now be determined, 146
which we will call B: B = A + (D : 2)
D Maß B bestimmen: B = A + 1/2 D
B bezeichnet das Maß von der Auflagefläche
des Deckels bis zur Achsmitte. A bezeichnet das
Maß von der Auflagefläche des Deckels bis zum
Durchmesser des Zylinders (Hilfsmesswerkzeug).
D bezeichnet den Durchmesser vom Zylinder.
F Mesurer la côte de la face d’appui du couvercle à
épaulement de roulement sous tête, au droit de la
partie extérieure du l’outil spécial D, et marquer de
la lettre A.
On peut alors déterminer la distance de la face
d’appui du couvercle à l’axe de couronne, que
nous appellerons B: B = A + (D : 2)

I Frontalmente, sulla testa di ogni pignone conico,


oltre a numero di serie, è stampigliato un numero
preceduto da segno +. Tale numero, espresso in
decimi di millimetro, indica lo scostamento della
quota teorica da sottotesta pignone all’asse della
corona (es. + 2,5 = + 0,25 mm).
Pertanto la quota reale che chiameremo F sarà:
F = 115 + scostamento.
Nel nostro caso: F = 115 + 0,25 = 115,25
GB At the front on the head of each bevel pinion is
punched the serial number and a number preceded
by the + sign. This number, expressed in tenths of 147
a millimetre, indicates the deviation from the theo-
retical distance from the pinion head bearing to
the axis of the crown wheel (e.g. + 2.5 = + 0.25 mm).
Therefore the real distance, which we will call F,
will be: F = 115 + deviation.
In our case this will be F = 115 + 0.25 = 115.25
D Auf der Stirnseite des Kegelritzels ist das theore-
tische Maß F mit Toleranzen (z.B. 2,5 = 0,25 mm)
eigraviert.
F bezeichnet das Maß von der Anlageflache
des Kegelrollenlagers an dem Kegelritzel bis zur
Achsmitte. Als Rechenbeispiel ist hier das Maß
115 + 0,25 = 115,25
F En plus du numéro de série, la tête de chaque
pignon conique porte, estampé sur la face, un
numéro précédé du signe +. Ce numéro, exprimé
en dixièmes de millimètres, indique la dérive de la
côté théorique entre la sous tête du pignon et l’axe
de la couronne (par exemple,+ 2,5 = + 0,25 mm).
La côté réelle, que nous appellerons F, sera donc:
F = 115 + dérive.
Dans notre cas: F = 115 + 0,25 = 115,25
107
TXL 15/25

I Rilevare lo spessore del cuscinetto sottotesta


pignone quota H.
GB Measure the thickness of the head pinion bearing,
which we will call H.
D Höhe von dem Kegelrollenlager mit Außenring mes-
sen = H.
F Mesurer l’épaisseur du roulement sous tête du
pignon, côté H.

148
I Rilevare la quota su coperchio di spallamento
cuscinetto sottotesta pignone, da facciata appog-
gio spessore di registro a facciata di fissaggio su
carter centrale quota P. È possibile a questo punto
determinare lo spessore di registro S da interporre
fra iI coperchio e il cuscinetto sottotesta pignone: S
= B - (F + H + P). Maggiorare di 0,03 mm lo spes-
sore calcolato per compensare iI successivo preca-
rico dei cuscinetti.
GB Measure the distance, on the head pinion bearing
shoulder cover, from the bearing surface for the
shim to the surface on which the cover is fixed to
the central casing: we will call this measurement P.
At this point, it is possible to determine the thick-
ness of the shim S to be placed between the cover
and the head pinion bearings: S = B - (F + H + P).
Increase this calculated thickness by 0.03 mm in
order to compensate for subsequent pre-loading of
the bearings.
149 D Höhe an dem DeckeI von der Anlagefläche des
Deckels bis zur Anlagefläche des Distanzringes
messen = P.
Maß S bestimmen S = Stärke des Distanzringes
S = [B - (F + H + P)] + 0,03 mm Lagervorspannung.
F Mesurer la côté sur le couvercle a épaulement du rou-
lement sous tête de pignon, entre la face d’appui
de la cale de réglage et la face de fixation sur le
carter central: côté P. A ce stade, il est possible
de déterminer la cale de réglage S à Insérer entre
Ie couvercle et le roulement sous tête de pignon:
S = B - (F + H + P). Augmenter l’épaisseur calculée
de 0,03 mm pour compenser la précharge ultérieu-
re des roulements.

I Montare sul carter centrale I’anello estemo del


cuscinetto sottotesta pignone il distanziale di regi-
stro con quota risultante dai rilievi precedenti S, il
coperchio di spallamento completo di guarnizione
a labbro e di anello di tenuta O-Ring.
GB On the central casing fit the outer ring of the head
pinion bearing, the shim of thickness S as determi-
ned by the previous measurements and the shoul-
der cover complete with lip seal and O-Ring.
D In das Hauptgehäuse Kegelrollenlageraußenring
montieren und Distanzscheibe mit dem vorher
150 ausgemessenem und ausgerechnetem Maß einle-
gen. Deckel mit Wellendichtring und O-RING auf-
setzen.
F Monter sur le carter central la bague extérieure du
roulement sous tête de pignon, I’entretoise de
réglage, dont la côté résulte des mesures pré-
cédentes S, le couvercle à épaulement complet
avec le joint à lèvre et le joint torique.
108
TXL 15/25

Applicare sulle viti di fissaggio coperchio frenafi-

3
I
letti medio; avvitare e bloccare alla coppia di
4,8 ÷ 5,2 daNm.

GB Apply sealant to the cover fixing screws; tighten


and lock at a torque of 4.8 ÷ 5.2 daNm.

D Schrauben mit Loctite medium einsetzen und mit


einem Drehmoment von 4,8 ÷ 5,2 daNm anziehen.

F Enduire les vis de fixation du couvercle de frein à


filets normal; serrer et bloquer au couple de 4,8 à
5,2 daNm. 151

I Dopo la rimozione della vite, che ne occlude il


foro, spiantare la spina elastica di fermo ghiera, 152
quindi svitare la stessa, arretrandola del necessa-
rio per fare le operazioni di registro previste.
GB After removing the screws that closes its hole,
remove the flexible pin that locks the locking ring,
then unscrew the ring as for as is necessary to
make the requisite adjustments.
D Verschluß-Schraube herausschrauben und
Sicherungsstift herausschlagen dann Nutmutter
etwas herausdrehen, damit neu eingestellt werden
kann.

F Après dépose de la vis, qui en obstrue le trou,


dégager la goupille élastique de blocage d’écrou,
puis desserrer ce dernier de la valeur nécessaire,
pour effectuer les opérations de réglage prévues.

I Introdurre nella propria sede l’anello esterno del


cuscinetto differenziale lato ghiera. 153
GB Fit the outer ring of the differential bearing on the
locking ring side into its seating.

D Den Außenring des Kegelrollenlagers vom


Differential auf der Seite der Nutmutter einsetzen.

F Mettre en place la bague extérieure du roulement


de différentiel, côte écrou.

109
TXL 15/25

I Posizionare nella sede del cuscinetto differenziale


lato corona gli spessori di registro e quindi pianta-
re l’anello esterno del cuscinetto.
N.B.: Per semplificare le operazioni di registro, è
opportuno inserire degli spessori di misura infe-
riore al necessario, tali da garantire del gioco fra
pignone e corona.

GB Put the shims in the seating of the crown wheel


side differential bearing, and then place the outer
ring of the bearing in position.
154 N.B.: To simplify the adjustment operations it is best
to insert thinner shims than necessary, so as to ensu-
re play between the pinion and the crown wheel.

D Die Einstellscheiben des Differentiallagers auf der


Tellerradseite einlegen, dann den Lageraußenring
einsetzen.
Anmerkung: Um die Einstellarbeiten zu vereinfa-
chen, müssen dünnere Einstellscheiben verwendet
werden um das Spiel zwischen Kegel- und Tellerad
zu gewährleisten.

F Mettre en place dans le logement du roulement de


différentiel, côté couronne, les cales de réglage,
puis positionner la bague extérieure du roulement.
Note: Pour simplifier les opérations de réglage, il
est indispensable d’introduire des cales de valeur
inférieure à celle nécessaire, afin de garantir un jeu
entre le pignon et la couronne.

I Introdurre nella scatola il gruppo differenziale com-


pleto.

GB Insert the complete differential assembly in the


box.

D Differential komplett in das Gehäuse einsetzen.

F Introduire dans le boîtier le groupe de différentiel


complet.

155

I Montare il coperchio (privo di OR) e fissarlo con


alcune viti.
GB Fit the cover (without OR) and fix it in position with
screws.
D Deckel ohne O-RING montieren und mit drei
Schrauben diagonal befestigen.
F Monter le couvercle (sans joint torique) et le fixer
avec quelques vis.

156

110
TXL 15/25

Avvitare la ghiera e girare il differenziale per asse-


3
I
stare i cuscinetti, precaricare i cuscinetti del diffe- 157
renziale fino ad ottenere una coppia di rotolamen-
to del diffenziale pari a 0,15 ÷ 0,35 daNm.
GB Pre-load the differential bearings while turning the
differential to bed the bearings by tightening the
locking ring until the differential shows a rolling
torque of 0.15 ÷ 0.35 daNm.
D Nutmutter schliessen und Differentialgetriebe
drehen um die Lager zu richten, die
Differentiallager bis zu einem Kippmoment des
Differentials von 0,15 bis 0,35 daNm vorbelasten.
F Visser le collier de fixation et tourner le différentiel
pour bien mettre en place les roule, précharger les
roulements du différentiel pour obtenir un couple
de roulement du différentiel compris entre 0,15 et
0,35 daNm.

I Bloccare la posizione della ghiera per mezzo della


spina elastica.

GB Lock the locking ring by means of the flexible pin.

D Zur Sicherung der Position von der Nutmutter


Spannstift einschlagen.

F Bloquer la position de l’écrou au moyen de la gou-


pille élastique.

158

! ATTENZIONE ! ! ACHTUNG !
Maneggiare tutti i particolari con opportuni Schwere Teile nur mit geeignetem Hebe-und
mezzi e con grande attenzione. Non mettere Transportwerkzeug transportieren.
le mani e le dita tra un pezzo e l’altro Vorsicht auf Hände und Finger

! WARNING ! ! ATTENTION !
Manipuler tout les composants par oppor-
Handle all heavy parts with the appropriate
tuns outils et avec beaucoup d’attention.
equipment and with the utmost care. Never
Ne jamais glisser les mains ou les doigts entre
put your hands and fingers in between parts
les différents éléments

I Allentare le viti di fissaggio del coperchio, togliere


quest’ultimo ed estrarre il differenziale dalla sca-
tola.

GB Loosen the cover fixing screws, remove the cover


and take the differential out of the box.

D Drei Befestigungsschrauben wieder herausschrau-


ben Deckel abnehmen und Differential heraushe-
ben.

F Desserrer les vis de fixation du couvercle, déposer


ce dernier, puis extraire le différentiel du boîtier.
159

111
TXL 15/25

I Inserire sul carter intermedio l’anello elastico


160 allargandolo nella propria sede fino a permettere
il piantaggio delI’albero Marcia Avanti completo di
cuscinetto e relativo anello elastico di ritegno su
albero. Piantare sul carter, con apposito punzone,
I’anello esterno del cuscinetto coda pignone.
Nota: Per quanto riguarda il montaggio dell’albero
Retromarcia sul carter centrale, procedere analo-
gamente a quello della Marcia Avanti.

GB Insert the retaining ring on the intermediate casing,


widening it in its seating, to allow the Forward
Gear shaft to be placed in position complete with
bearing and its retaining ring. Using the special
punch, set the outher ring of the pinion tail bearing
in position on the casing.
Note: With regard to the assembly of the Reverse
Gear shaft on the central casing, the procedure is
the same as for Forward Gear.

D In das Zwischengehäuse Sicherungsring mon-


tieren, Sicherungs soweit aufweiten, daß
Vorwärtsgangwelle komplett montiert werden
kann.
Anmerkung: Gleicher Arbeitsablauf mit der Rück-
wärtsgangwelle im Hauptgehäuse.

F Introduire l’anneau ressort sur le carter intermé-


diaire, en l’élargissant en place, pour permettre le
positionnement de l’arbre de Marche Avant, avec
roulement, et l’engagement du circlips sur l’arbre.
Bloquer la bague extérieure du roulement d’extré-
mité de pignon sur le carter, au moyen du poinçon
approprié.
Note: En ce qui concerne le montage de l’arbre
de Marche Arrière sur le carter central, procéder
de la même manière que pour la Marche Avant.

I Inserire il gruppo ingranaggio intermedio sul corpo


161 centrale, avendo cura di posizionare la spina di
riferimento montata sull’alberino, nella propria
sede.

GB Place the intermediate gear assembly in position on


the central body, taking care to locate the reference
pin which is mounted on the shaft, in its seating.

D Wendezahnrad komplett vom Rückwärtsgang ein-


setzen. Auf richtige Einbaulage von Spannstift und
Nut achten.

F Introduire le groupe d’engrenage intermédiaire sur


le corps central, en veillant à positionner la goupille
de référence montée sur l’axe, dans son logement.

112
TXL 15/25

Introdurre nella propria sede sull’albero Marcia


3
I
Avanti le relative gabbie a rulli e fissare con un
velo di grasso l’anello O-RING nella propria sede
sul carter intermedio.

GB Fit the respective roller cages into their seatings


on the Forward Gear shaft, smear the O-RING
with a thin film of grease and fix it in its seating on
the intermediate casing.

D Nadellager auf die Vorwärtsgangzahnradwelle und


den O-RING im Zwischengehäuse mit Fett einsetzen.

F Mettre en place les cages à rouleaux sur l’arbre


de Marche Avant, et bloquer avec une couche de
graisse le joint torique dans son logement, sur le
carter intermédiaire.

162

I Posizionare l’ingranaggio condotto sul corpo


centrale rispettandone la corretta posizione di 163
montaggio, applicare sulle superfici di unione dei
carter un cordone di mastice di tenuta del diame-
tro di circa due mm, seguendo il tracciato indicato
in figura. Applicare frenafiletti medio sulle viti di
fissaggio e serrare sulla coppia di 4,8 ÷ 5,2 daNm.

GB Place the driven gear in position on the central


body, taking care to ensure that it is in the correct
position, coat one mating flange with a continuous
bead of sealant, wide 2 mm. Follow path shown
in picture 163. Apply medium grade sealant to the
fixing screws, and tighten to a torque of 4.8÷5.2
daNm.

D Der Antrieb in die Zentraleinheit positionieren und


dabei die richtige Montageposition beachten, auf
den Verbindungsflächen des Schutzgehäuses
163a
Dichtmasse (ca. 2 mm dick) auftragen, wie im Bild
gezeigt. Die mittlere Gewindesincherung auf die
Befestigungsschrauben aufbringen und bei einem
Drehmoment von 4,8 bis 5,2 daNm anziehen.

F Positionner l’engrenage mené sur le corps central,


en respectant la position de montage correcte,
appliquer sur les surfaces d’assemblage des car-
ters un filet de mastic pour l’ètanchéité de deux
mm environ de diamètre, en suivant le tracé indi-
qué sur le dessin. Enduire les vis de fixation de
frein à filets normal, et serrer au couple de. 4,8 à
5,2 daNm.

113
TXL 15/25

I Calettare a caldo o mediante appropriato attrezzo


(4902076) sul pignone l’anello interno del cuscinet-
to sottotesta e relativo distanziale.
GB Heat shrink or press with the appropriate tool
(4902076) the inner ring of the head bearing and
spacer onto the pinion.
D Den Innenring vom Kegelrollenlager erwärmen und
auf das Kegelritzel montieren (4902076), sowie den
Distanzring aufschieben.
F Caler à chaud, ou avec un outil approprié
164 (4902076), sur le pignon, la bague intérieure du rou-
lement sous tête, et l’entretoise correspondante.

I Introdurre il pignone dal corpo centrale, avendo cura


di allineare lo scanalato dell’ingranaggio condotto;
inserire il distanziale rigido e l’anello collassabile di
precarico; fermare assialmente dal lato testa con
opportuno attrezzo per contrastare il piantaggio del-
l’anello interno cuscinetto coda pignone.
Avvertenza: È necessario sostituire ad ogni
rimontaggio il distanziale collassabile.
GB Insert the pinion in the central body, taking care to
align the groove of the driven gear; insert the rigid spa-
cer and the collapsible pre-loading ring; lock the pinion
165 from the head side with appropriate tool to enable the
installation of the inner ring bearing on the pinion tail
side.
Note: every time this re-assembling operation is
carried out the collapsible pre-loading ring must
be replaced.
D Kegelritzel vom Hauptgehäuse aus einschieben,
Distanzscheibe und Distanzring einlegen. Den
Innenrirng vom Kegelrollenlager erwärmen und
montieren.
Anmerkung: Der elastische Distanzring muß
Grundsätzlich bei jeder Demontage erneuert werden.
F Introduire le pignon par le corps central, en veillant à
aligner les cannelures de l’engrenage mené; insérer
l’entretoise rigide et la bague-frein de précharge;
bloquer axialement côté tête avec l’outil approprié,
pour garantir le positionnement de la bague intérieu-
re du roulement d’extrémité de pignon.
Avertissement: L’entretoise-frein doit être rem-
placée à chaque remontage.

I Accostare la ghiera pignone per misurare la cop-


pia passiva determinata dalla guarnizione al lab-
bro, e dalla catena in presa in assenza di precari-
co assiale. Prendere nota del valore misurato “a”.
GB Hand tighten only the pinion locking nut, in order
to measure the passive torque determined by the
lip seal and the engaged chain reaction, in the
absence of any axial pre-loading. Take note of the
measured value “a”.
D Nutmutter montieren, leicht festziehen, dann
Reibwiederstände testen und höhe des
Reibwertes messen. Der Messwert “a” notieren.
F Ecarter l’écrou de pignon pour mesurer le cou-
ple passif déterminé par le joint à l’èvre, et par la
chaîne en prise, en l’absence de précharge axiale.
Prendre note de la valeur “a” qui vient d’être
166 mesurée.
114
TXL 15/25

Inserire nei relativi scanalati i due mozzi portadi-


3
I
schi frizioni Marcia Avanti e Retromarcia, quindi
vincolarli tramite attrezzo specifico.
GB Insert the two Forward Gear and Reverse Gear
clutch-plate hubs in their respective grooves and
then fix them by means of the special tool.
D Beide Innenlamellenträger auf die Vorwärts-
gangwelle bzw Rückwärtsgangwelle stecken
und mit dem Spezialwerkzeug miteinander
verbinden, damit die Nudmutter vom Kegelritzel
mit Drehmoment angezogen werden kann. 167
F Engager sur les cannelures corlespondantes les
deux moyeux d’embrayage de Marche Avant et
de Marche Arrière, puis le bloquer au moyen d’un
outil spécifique.

I Serrare la ghiera pignone fino ad ottenere un


incremento di coppia rotolamento cuscinetti di
0,15 ÷ 0,25 daNm rispetto alla coppia passiva
precedentemente rilevata “a”.
Coppia da rilevare “b”= Coppia passiva “a”+(0,15
÷ 0,35) daNm.
Avvertenza: Durante questa operazione aumen-
tare gradatamente ed a più riprese la coppia di
serraggio, fino a raggiungere la coppia di roto-
lamento “b”. E’ indispensabile assestare i cusci-
netti pignone, battendo il pignone da entrambi
i lati e facendo fare alcuni giri, prima di proce-
dere al rilevamento della coppia di rotolamento. 168
Attenzione a non superare il valore massimo
previsto. Nel caso di superamento di tale valore,
non è sufficiente allentare a ghiera pignone, ma
occorre sostituire iI distanziale collassabile di regi-
stro.

GB Tighten the pinion locking nut until an increase of 0.15 ÷ 0.35 daNm bearing rolling torque is obtained,
above the passive torque previously measured “a”.
Final torque “b”= Passive torque “a”+ ( 0,15 ÷ 0,35) daNm.
Note: During this operation Increase the tightening torque gradually and in several steps until the pro-
per rolling torque “b” is obtained. It is compulsory to set the bearings by pounding the pinion on both
sides and turning it a few times before taking any reading. Care must be taken not to exceed the maxi-
mum permissible torque. Should the maximum permissible torque be exceeded it is necessary to repla-
ce the collapsible pre-loading ring.
D Nutmutter soweit fest ziehen, daß nach entfernen von dem Arretierwerkzeug ein Rollwiederstand
von 0,15 ÷ 0,35 daNm im Vergleich mit dem vorhergehenden Reibwiderstand “a” erreicht wird.
Zu ermittelder Widerstand “b”= Reibwiderstand “a” + (0,15 ÷ 0,35) daNm.
Achtung: Dieser Arbeitsvorgang bedarf mehrerer Versuche, da sich an den richtigen Wert des
Anzugsmoments bis zur Erreichung des Rollwiederstands “b” heran getastet werden muß. Der
Grenzwert darf nicht überschritten werden. Sollte das geforderte Drehmoment einmal überschritten
werden, muß nicht nur die Nutmutter lösen, sondern auch der elastische Distanzring erneuert werden.
F Serrer l’écrou du pignon jusqu’à obtenir une augmentation du couple de roulement des roulements de
0,15 à 0,35 daNm par rapport au couple passif précédemment mesuré et relevé “a”.
Couple à relever “b”= Couple passif “a” + (0.15 ÷ 0.35) daNm.
Avertissement: Pendant l’opération, augmenter progressivement et à plusieurs reprises
le couple de serrage, afin d’arriver au couple de roulement “b”, Il est indispensable
de bien caler les roulements de pignon, en battant le pignon sur ses deux côtés et en
le faisant tourner plusieurs fois avant de relever la mesure du couple de roulement.
Attention à ne pas dépasser la valeur maximale prévue. En cas de dépassement de cette valeur,
desserrer l’écrou de pignon, et procéder à la substitution de l’entretoise-frein de réglage

115
TXL 15/25

I Applicare sui denti della corona conica del minio


per evidenziare il contatto.
GB Coat red lead to the teeth of the bevel pinion, to
show contact.
D Zum Feststellen des Tragbildes die Zähne vom
Tellerrad mit Tuschierfarbe bestreichen.
F Appliquer du minium sur les dents de la couronne
conique pour indiquer le contact.

169

I Introdurre nel corpo centrale il gruppo differenziale


completo.
GB Insert the complete differential assembly into the
central body.
D Differential komplett in das Hauptgehäuse einsetzen.
F Introduire le group différentiel complet dans le
corps central.

170

I Montare (privo di OR) il coperchio scatola differen-


ziale fissandolo con alcune viti.

GB Fit the differential box cover (without OR), fixing it


with several screws.

D Deckel ohne O-RING mit sechs Schrauben mon-


tieren.

F Monter (sans joint torique) le couvercle du carter


de différentiel, en le fixant avec quelques vis.
171
I Registrare la posizione assiale del gruppo differen-
ziale per ottenere il corretto gioco di funzionamen-
to tra i fianchi dei denti coppia conica che dovrà
risultare pari a 0,13 ÷ 0,18 mm.
GB Adjust the axial position of the differential assembly,
so as to obtain the correct operating play between
the sides of the teeth of the bevel gear, which must
be equal to 0.13 ÷ 0.18 mm. During this operation it
will be necessary to move the crown wheel closer to
or further from the pinion, keeping the pre-loading
of the bearings unchanged.
172 D Die Axialposition vom Differential kompl. über die
Einstellschraube so ausmitteln, daß das Flankenspiel
der Kegelräder 0,13 ÷ 0,18 mm beträgt. Sollte auf
Grund der Reparatur, Lager Differentialgehäuse oder
Deckel erneuert werden, müssen die neuen und alten
Teile gegeneinander ausgemessen werden und das
Differenzmaß bei den Einstellscheiben berücksichtigt
werden (sind im Deckel hinter dem Kegelrollenlagera
ußenring eingebaut).
F Régler la position axiale du groupe différentiel afin
d’obtenir le jeu de fonctionnement correct entre les
flancs des dents du couple conique, à savoir, com-
pris entre 0,13 et 0,18 mm. Aù cours de l’opéra-
tion, il faudra rapprocher ou écarter la couronne du
pignon, sans modifier la précharge des roulements.
116
TXL 15/25

Togliere o aggiungere spessore dalla sede cusci-


3
I
netto del coperchio ed avvitare o svitare la ghiera
in misura tale da avere uno spostamento assiale
pari alla variazione degli spessori.
Nota: Ogni tacca sull’attrezzo corrisponde ad uno
spostamento assiale della ghiera di 0,1 mm.
Avvertenza: È opportuno nella fase finale della
registrazione far coincidere uno scanso della ghie-
ra con il foro sul carter per il successivo piantag-
gio della spina elastica.
173
GB Add shims to or remove them from the bearing
seating of the cover, and slacken or tighten the
locking nut so as to produce the same axial displa-
cement as the alteration in thickness of the shims.
Note: Each notch on the tool corresponds to an
axial displacemente of 0.1 mm of the locking ring.
Attention: at the final stage of the adjustment, it
is necessary to ensure that one of the notch of the
locking ring coincides with the hole on the casing,
to allow the installation of the spring pin.

D Muß auf Grund der Einstellung Distanzscheiben


entnommen oder dazu gelegt werden muß die
Einstellschraube dementsprechend nachjustiert
werden.
Anmerkung: Jede Einkerbung auf dem Werkzeug
entspricht einer Axialverschiebung von 0,1 mm
Achtung: Die Einstellung am Ende muß so sein,
daß eine Nut der Einstellschraube mit der Bohrung
für den Spannstift übereinander steht.

F Retirer ou ajouter des cales du logement de roule-


ment du couvercle, puis serrer ou desserrer l’écrou
de manière à obtenir un déplacement axial égal à
la variation des épaisseurs.
Note: Chaque cran de l’outil correspond à un
déplacement axial de l’écrou de 0,1 mm.
Avertissement: A la fin du réglage, il est recom-
mandé de faire coincider une échancrure de
l’écrou avec le trou du carter, pour permettre la
mise en place ultérieure de la goupille élastique.

117
TXL 15/25

I A registrazione ultimata (per evitare movimenti


174 casuali della ghiera), piantare la spina elastica fino
a interporsi rigidamente in uno scanso della ghiera.

GB In order to avoid unintentional movement of the


locking ring, when the adjustment is completed fit
spring pin so that it mats firmly the notch.

D Zum Abschluß die Nutmutter mit Spannhülse


sichern.

F Lorsque le réglage est terminé (pour éviter des


déplacements éventuels de l’écrou), mettre en
place la goupille élastique, et l’introduire solidement
dans une échancrure de l’écrou.

I Ruotare più volte pignone e corona in modo da


evidenziare sui denti i segni del contatto con il
minio precedentemente applicato. Estrarre dal
corpo centrale il gruppo differenziale per valutare
visivamente la posizione del contatto. Sui denti di
una coppia conica nuova, sono visibili i segni di
contatto, che sono il risultato ottimale ottenuto al
tester, pertanto un corretto posizionamento assiale
del pignone, evidenzierà una rimarcatura di tale
contatto (vedere pag. 119-120 Controllo dentatura
coppia conica).
175 GB Rotate the pinion and crown wheel a number
of times, to enable the teeth to show the signs
of contact with the red lead previosly applied.
Remove the differential assembly from the cen-
tral body, in order to inspect, visually, the contact
pattern. The contact pattern representing the best
result obtained by the tester are visible on a new
bevel gear, and therefore if the pinion is positioned
correctly, those contact pattern will be repeated
(see pag. 119-120 Bevel pinion-and-ring gear set
inspection).

D Zum Prüfen des Tragbildes der


Kegelradverzahnung müssen die Kegelräder öfters
durchgedreht werden. Differentialgehäuse komplett
ausbauen und Tragbild anhand der vorher
aufgetragener Tuschierfarbe prüfen (Siehe Seite
119-120 Tragbildkontrolle).

F Tourner plusieurs fois le pignon et la couronne


pour faire apparaître, sur les dents, les marques de
contact avec le minium appliqué précédemment.
Extraire du corps central le groupe différentiel,
pour évaluer visuellement la position du contact.
Les marques de contact résultant d’un contrôle
optimal à l’appareil de mesure, apparaissent sur
les dents d’un couple conique neuf; un positionne-
ment axial correct du pignon laissera donc appa-
raître un nouveau marquage du contact (voir pages
119-120 Contrôle denture couple conique).

118
TXL 15/25

Controllo dentatura coppia conica


Bevel pinion-and-ring gear set inspection
Tragbildkontrolle der Kegelräder und Fehlersuche
Contrôle denture couple conique
3
I Zona di contatto della dentatura della coppia
conica 176
La zona di contatto dovrà risultare come indicato
in figura.
Contatto corretto
La distanza del pignone dal centro corona è esatta.

GB Bevel drive tooth contact


Tooth contact should be as shown in the figure.
Correct contact
Distance of pinion from ring gear centerlines is
correct. Fianco concavo (corona)
Concave side (crown wheel)
D Tragbilder des Kegel- Tellerradantriebes Schubflanke (konkav) (Zahnkranz)
Das Tragbild muß dem Bild entsprechen. Coté concave (couronne)
Ideales Tragbild
(d. h., die Ritzeldistanz stimmt).

F Zone de contact de la denture du couple coni-


que: 176a
La zone de contact devra resulter comme indiqué
sur la figure.
Bon contact
La distance du pignon du centre est exacte.

Fianco convesso (corona)


Convex side (crown wheel)
Zugflanke (konkav) (Zahnkranz)
Coté convexe (couronne)

119
TXL 15/25

I Contatto errato
177 La distanza del pignone dal centro corona deve
essere diminuita.

GB Incorrect tooth contact


Distance of pinion from ring gear centerline must
be reduced.

D Ritzeldistanz
Muß kleiner werden.

F Contact errone
Fianco concavo (corona)
Concave side (crown wheel) La distance du pignon du centre couronne doit
Schubflanke (konkav) (Zahnkranz) être diminuée.
Coté concave (couronne)

177a

Fianco convesso (corona)


Convex side (crown wheel)
Zugflanke (konkav) (Zahnkranz)
Coté convexe (couronne)

I Contatto errato
177b La distanza del pignone dal centro corona deve
essere aumentata.
GB Incorrect tooth contact
Distance of pinion from ring gear centerline must
be increased.

D Ritzeldistanz
Muß größer werden.

F Contact errone
Fianco concavo (corona)
La distance du pignon du centre couronne doit
Concave side (crown wheel)
être augmentée.
Schubflanke (konkav) (Zahnkranz)
Coté concave (couronne)

177c

Fianco convesso (corona)


Convex side (crown wheel)
Zugflanke (konkav) (Zahnkranz)
Coté convexe (couronne)
120
TXL 15/25

Montare il coperchio completo di OR sulla sca-


3
I
tola rispettando la posizione di fasatura prece-
dentemente contrassegnata, applicare frenafiletti
medio sulle viti di fissaggio e serrarle alla coppia
di 6,2÷6,8 daNm.

GB Fit the cover, complete with OR, on the box, in


the same phasing position as previously marked;
apply medium grade sealant to the fixing screws
and tighten them to a torque of 6.2 - 6.8 daNm.

D Deckel komplett mit O-RING aufsetzen dabei


auf die Markierung der Einbaulage achten.
178
Befestigungsschrauben mit Loctite medium ein-
setzen und mit einem Drehmoment von 6,2-6,8
daNm anziehen.

F Monter le couvercle avec joint torique sur le


boîtier, en respectant la position de calage pré-
cédemment repérée, appliquer du frein à filets nor-
mal sur les vis de fixation, puis les serrer au couple
de 6,2 à 6,8 daNm.

I Tappare esternamente il foro radiale della sede


spina elastica, per fermo ghiera sul corpo ponte,
con apposita vite.

GB Using the special screw, plug externally the radial


hole of the seating of the flexible pin for locking
ring on the drive axle body.

D Verschluß-Schraube an der Bohrung für den


Spannstift montieren.

F Obturer extérieurement le trou radial du logement


de la goupille élastique, pour bloquer l’écrou sur le
corps du pont, avec la vis appropriée.

179

I Praticare le due acciaccature, di sicurezza antisvi-


tamento, sulla ghiera pignone.

GB Stake the pinion locking ring in two places to prevent


its unscrewing.

D Nutmutter am Kegelritzel durch umbördeln des


Bundes gegen verdrehen sichern.

F Pratiquer deux rabattements de métal sur l’écrou


du pignon, pour garantir le non dévissage.
180

121
TXL 15/25

I Infilare nella propria sede il tamburo per frizioni (già


completo di gabbia a rulli e anelli di tenuta idrau-
lica inseriti e posizionati correttamente nella fase
precedentemente illustrata, foto 137) prestando
particolare attenzione agli anelli di tenuta in ghisa,
poichè un loro danneggiamento pregiudica grave-
mente il funzionamento idraulico della trasmissio-
ne.

GB Insert in its seating the clutch drum (already with


roller cage hydraulic sealing rings, fitted and cor-
rectly positioned in the stage previously illustrated,
photo 137) paying particular attention to the cast
iron sealing rings, since if they are damaged it will
seriously impair the hydraulic functioning of the
transmission.

D Außenlamellenträger komplett einsetzen. Darauf


achten, daß Kolbenringe und Nadellager nicht
181 beschädigt werden.

F Introduire dans son logement la cloche d’embra-


yage (avec cage à rouleaux et bagues d’étanchéité
hydraulique en fonte déjà introduites et position-
nées correctement lors de la phase précédente,
photo 137), en veillant à ne pas endommager les
bagues pour garantir un fonctionnement hydrauli-
que constant de la transmission.

I Infilare nella propria sede scanalata il mozzo porta-


dischi frizioni Marcia Avanti, e fermarlo assialmente
con relativo anello elastico di ritegno.

GB Insert the Forward Gear clutch-plates hub in its


grooved seating, and retain it axially with its retai-
ning ring.

D Innenlamellenträger vom Vorwärtsgang einsetzen


und mit Sicherungsring sichern.

F Introduire dans son logement cannelé le moyeu


d’embrayage de Marche Avant, puis le bloquer axiale-
ment avec le circlips correspondant.

182

122
TXL 15/25

Infilare nelle proprie sedi scanalate i tre contro-


3
I
dischi e tre dischi frizione, rispettando la corretta
sequenza di inserimento.
Nota: Per la corretta sequenza di inserimento
controdischi e dischi frizione, accostare per primo
il controdisco in acciaio a contatto dello stantuffo,
e completare il pacco inserendo alternativamente
un disco frizione e un controdisco in acciaio.
Importante: È necessario sostituire il pacco frizio-
ni completo.

GB Insert the three counter-plates and three clutch-


plates in their grooved seatings, taking care to
insert them in the correct sequence.
Note: To observe the correct insertion sequence
of clutch-plates and counter-plates, insert the steel
counter-plate in contact with the piston, and com-
plete the package by inserting alternately a clutch-
plate and a steel counter-plate. 183
Important: Only complete new clutch pack must
be fitted if disc are worn or damaged.

D Je drei Außen- und Innenlamellen einlegen.


Anmerkung: Auf richtige Reihenfolge achten.
Zuerst wird eine Stahlaußenlamelle dann eine
Innenlamelle und so weiter in dieser Reihenfolge
eingelegt.
Hauptsache: das Kupplungspaket muss komplett
ausgetauscht werden.

F Introduire dans leurs logements cannalés les trois


plateaux de pression d’embrayage et les trois
disques d’embrayage, en respectant la séquence
de mise en place correcte.
Note: Pour assurer une séquence de mise en
place adéquate des plateaux de pression et des
disques d’embrayage, amener d’abord le plateau
de pression en acier en contact avec le piston,
puis compléter l’empilage, en engagement alter-
nativement un disque d’embrayage et un plateau
de pression en acier.
Important: il est nécessaire de remplacer le grou-
pe frictions en entier.

123
TXL 15/25

I Inserire nella propria sede l’anello elastico di rite-


gno disco reazione.

GB Insert the reaction-plate retaining ring in its seating.

D Lamellenpaket mit Sicherungsring im


Außenlamellenträger sichern.

F Engager le circlips du disque de pression.

184

I Accostare, inserendolo nella sede scanalata, il


disco reazione contro l’anello elastico di ritegno.

GB Insert the reaction-plate in its grooved seating,


bringing it up against the retaining ring.

D Trennscheibe einlegen und mit Sicherungsring


sichern.

F Amener le disque de pression contre le circlips en


l’engageant dans le logement cannelé.

185

I Inserire nella propria sede il successivo anello


elastico di ritegno disco reazione e verificare (con
tappo sito spessimetro) che nel pacco frizioni vi sia
un gioco totale pari a: Minimo 1,7 mm - Massimo
3,0 mm.

GB Insert the next reaction-plate retaining ring in its


seating and check (with a feeler gauge) that there
is a minimum of 1.7 mm up to a maximum of 3.0
mm total play in the clutch package.

D Lamellenspiel prüfen Soll min. 1,7 mm und max.


3,0 mm betragen.

F Engager dans son logement le circlips sui-


vant du disque de pression et vérifier (avec une
jauge d’épaisseur appropriée) que le jeu total de
I’ensemble d’embrayage se trouve entre: 1,7 et 3,0
mm.
186

124
TXL 15/25

Inserire sullo scanalato dell’albero il mozzo por-


3
I
tadischi frizioni Retromarcia, dopo aver introdotto
nella propria sede l’anello elastico di spallamento;
quindi vincolare la corsa assiale del mozzo sullo
scanalato con il successivo anello elastico di rite-
gno.

GB Insert the Reverse Gear clutch-plates hub on the


shaft groove, after having inserted the shoulder
ring in its own seating; then restrain the axial travel
of the hub along the groove with the next retaining
ring. 187
D Sicherungsring von der Rückwärtsgangzahnwelle
montieren, Innenlamellenträger aufschieben und
mit Sicherungsring sichern.

F Engager sur la cannelure de l’arbre le moyeu d’em-


brayage de Marche Arrière, après avoir mis en
place la bague élastique d’épaulement, puis blo-
quer la course axiale du moyeu sur la cannelure
avec le circlips suivant.

I Infilare nella campana frizioni tre dischi frizione e


tre controdischi in acciaio, rispettando la corretta
sequenza d’inserimento.
Nota: Per la corretta sequenza d’inserimento
dischi e controdischi, accostare per primo il disco
frizione a contatto dell’anello dl reazione, e com-
pletare il pacco inserendo alternativamente un
disco in acciaio e un disco frizione in modo che
resti per ultimo un disco in acciaio.

GB Insert in the clutch bell three clutch-plates and


three steel counter-plates observing the correct
insertion sequence.
188
Note: To observe the correct sequence of inser-
tion of plates and counter-plates, place a clutch-
plate in contact with the reaction ring, and com-
plete the package by inserting alternately a steel
plate and a clutch-plate, so that the last to be
inserted is a steel plate.

D Für den Rückwärtsgang je drei Innen- und


Außenlamellen einlegen.
Anmerkung: Auf richtige Reihenfolge achten.
Zuerst wird eine Innenlamelle dann eine
Außenlamelle und so weiter in dieser Reihenfolge
eingelegt.

F Introduire dans la cloche d’embrayage trois


disques et trois plateaux de pression d’embrayage
en acier, en observant la séquence de mise en
place correcte.
Note: Pour garantir la séquence de montage
correcte de disques et de plateaux de pression,
amener d’abord le disque d’embrayage en contact
avec la bague de pression, et compléter l’ensem-
ble en introduisant, alternativement, un disque en
acier et un disque d’embrayage, pour que le der-
nier élément soit un disque en acier.

125
TXL 15/25

I Inserire nel tamburo frizioni il coperchio tamburo


frizioni completo, dopo aver introdotto nella pro-
pria sede l’anello elastico di spallamento; quindi
vincolare la corsa assiale del coperchio sullo sca-
nalato con il successivo anello elastico di ritegno.
Avvertenza: Prima di posizionare il tamburo fri-
zione completo, effettuare opportuni rilievi, per
la verifica finale, riguardante il gioco totale sulle
frizioni della Retromarcia che deve comunque
essere compreso nei valori di gioco indicati per la
Marcia Avanti.

GB Insert the complete friction drum cover in the


friction drum, after having inserted the shoulder
ring in its seating, then restrain the axial travel of
the cover along the groove with the next retaining
ring.
Note: Before positionning the complete clutch
189 drum, as a final check measure the total play
of the Reverse Gear clutches, which must lie
between the values indicated for Forward Gear.

D Sicherungsring im Außenlamellenträger einlegen.


Lamellenspiel ausmessen, Messwerte müssen
den gleichen Toleranzen wie im Vorwärtsgang
entsprechen. Dann Deckel komplett mit
Turbinenträgerwelle Kolben Lager usw montieren
und mit Sicherungsring sichern.

F Introduire dans la cloche d’embrayage le couvercle


complet, après avoir mis en place dans son loge-
ment la bague élastique d’épaulement, puis blo-
quer la course axiale du couvercle sur la cannelure
avec le circlips suivant.
Avertissement: Avant de positionner la cloche
d’embrayage complète, réaliser les mesures
adéquates pour la vérification finale du jeu total
de l’embrayage de Marche Arrière, qui doit, dans
tous les cas, être compris dans les valeurs de jeu
indiquées pur la Marche Avant.

126
TXL 15/25

Per facilitare il fissaggio delle tre viti, che uniscono


3
I
il carter convertitore completo con il distanziale di
spallamento cuscinetto, è opportuno avvitare tre
perni filettati di lunghezza idonea ad agevolarne
il centraggio con i relativi fori passanti sul carter;
quindi, dopo aver applicato del sigillante sulle
superfici esterne di unione, unire le parti avendo
cura di accostare il carter convertitore centrato
alle relative viti di fissaggio, prestando particolare
attenzione agli anelli O-Ring.
Avvertenza: Una eccessiva applicazione di sigil-
lante vicino alle sedi di tenuta O-Ring potrebbe 190
ostruire i fori di mandata olio, pregiudicando il
funzionamento della trasmissione.

GB To facilitate the fixing of the three screws that join


the complete converter case with the bearing
shoulder spacer, it is advisable to screw in three
threaded studs of a suitable length to facilitate
centering with the respective holes in the case;
then, after having applied sealant to the outer joint
surfaces, join the parts together taking care to keep
the converter case centered in relation to the fixing
screws, paying particular attention to the O-Ring.
Note: Excessive application of sealant close to the
O-Ring seatings could obstruct the oil delivery
holes, preventing the proper operation of the tran-
smission.

D An den Verbindungsflächen vom Zwischengehäuse


und Wandlergehäuse Hylomar anbringen und mit
Hilfe von drei Stiftschrauben im Lagerhaltering
zur besseren Zentrierung Wanldergehäuse auf-
stecken, Wandlergehäuse ausrichten, daß die
Schraubenbohrungen übereinander liegen.
Achtung: Darauf achten, daß die O-RINGE
richtig sitzen und im Bereich der O-RINGE das
Hylomar nicht zu dick aufgetragen wird, damit die
Öldruckbohrungen nicht verstopfen.

F Pour faciliter la fixation des trois vis d’assembla-


ge du carter du convertisseur, avec entretoise
d’épaulement de roulement, il est recommandé
de serrer trois goujons filetés de longueur adaptée
pour faciliter le centrage sur les trous traversants
du carter; puis, aprés avoir appliqué de la pâte à
joint sur les surfaces d’assemblage extérieures,
réunir les parties, en veillant à centrer le carter du
convertisseur sur les vis de fixation correspondan-
tes, sans endommager les joints toriques.
Avertissement: Une application excessive de pâte
à joint au voisinage des gorges des joints toriques
risquerait d’obstruer les trous d’alimentation d’hui-
le, et de nuire, par la suite, au bon fonctionnement
de la transmission.

127
TXL 15/25

I Sostituire i perni filettati con le viti e relative ron-


delle, avendo cura di applicare frenafiletti medio
sulle viti serrandole alla coppia di 0,5 ÷ 0,6 daNm.

GB Replace the thread studs individually with the


screws and their washers, taking care to apply
medium grade sealant to the screws, and
tightening them to a torque of 0.5 ÷ 0.6 daNm.

191 D Die als Montagehilfe eingesetzten Stiftschrauben


nacheinander gegen mit Loctite medium
eingesetzte Schrauben sowie Kupferdichtringe
ersetzen und mit einem Drehmoment von
0,5 ÷ 0,6 daNm anziehen.

F Remplacer chaque goujon fileté avec vis et ron-


delles correspondantes, en ayant soin d’appliquer
du frein à filets normal sur les vis, en les serrant au
couple de 0,5 à 0,6 daNm.

I Applicare frenafiletti medio sulle viti di fissaggio


carter convertitore e serrarle con relative rondelle
alla coppia di 4,8 ÷ 5,2 daNm.
GB Apply sealant to the converter case fixing screws,
and tighten them with their washers to a torque of
4.8 ÷ 5,2 daNm.
D Befestigungsschrauben mit Loctite medium ein-
setzen und mit einem Drehmoment von 4,8 - 5,2
daNm.
F Enduire les vis de fixation du carter de convertis-
192 seur de frein à filets, et les serrer avec les rondel-
les correspondantes au couple de 4,8 à 5,2 daNm.

I Introdurre nella propria sede, sul carter centrale,


l’anello di centraggio corpo pompa.

GB Insert the pump body centering ring in its seating


on the central case.

D Zentrierring für das Pumpengehäuse in das


Hauptgehäuse einsetzen.

F Introduire dans son logement la bague de centra-


ge du corps de pompe sur le carter central.

193

128
TXL 15/25

Introdurre nella propria sede, sull’albero


3
I
Retromarcia l’anello di tenuta in ghisa, avendo 194
cura di fissarlo mediante un velo di grasso.

GB Insert the cast iron seal on its seating on the


Reverse Gear shaft, taking care to fix it with a film
of grease.

D Den Kolbenring auf dle Rückwärtsgangwelle mit


etwas Fett elnsetzen.

F Introduire dans son logement la bague d’étanchéi-


té en fonte sur l’arbre de Marche Arrière, en veillant
à la bloquer au moyen d’une couche de graisse.

I Fissare mediante applicazione di grasso, la guarni-


zione in carta del corpo pompa sul carter centrale.
GB Fix the paper gasket of the pump body to the cen-
tral casing with a film of grease.

D Flachdichtung mit Hilfe einer dünnen Fettschicht


an das Hauptgehäuse anbringen.

F Fixer, par application de graisse, le joint en papier


du corps de pompe sur le carter central.
195

I Applicare sulla superficie di unione del coperchio


pompa un cordone di mastice di tenuta del diame-
tro di circa due mm, seguendo il tracciato indicato
in figura.

GB Coat the pump cover with a 2 mm wide bead of


sealant. Follow path shown in picture.

D Auf der Verbindungsfläche des Pumpendeckels


Dichtmasse (ca. 2 mm dick) auftragen, wie im Bild
gezeigt.

F Appliquer sur la surface de jointure du couvercle 196


de la pompe un filet de mastic pour l’ètanchéité de
deux mm environ de diamètre, en suivant le tracé
indiqué sur le dessin.

I Procedere al montaggio del gruppo pompa com-


pleto sul carter centrale, avendo cura di posizio-
nare in precedenza sul gruppo pompa la vite testa
cilindrica esagono incassato.

GB Fit the hex socket screw onto the pump assembly


and assemble the entire unit.

D Pumpengehäuse komplett vormontieren und


Zylinderkopfschraube einstecken.

F Procéder au montage du groupe de pompe com-


plet sur le carter central, en veillant à positionner, 197
préalablement, la vis à tête cylindnque à six pans
creux sur le groupe de pompe.

129
TXL 15/25

I Applicare frenafiletti medio sulle viti di fissag-


gio gruppo pompa, quindi serrarle alla coppia di
2,2 ÷ 2,4 daNm.
GB Fit a medium-size thread stopper on the pump
securing screws and tighten them to a torque of
2.2 ÷ 2.4 daNm.
D Pumpengehäuse komplett an das Hauptgehäuse
montieren, Schrauben mit Loctite einsetzen und
mit einem Drehmoment von 2,2 ÷ 2,4 daNm
anziehen.
198 F Enduire les vis de fixation du groupe pompe de
frein à filets normal, puis les serrer au couple
2,2 à 2,4 daNm.

I Prima di procedere al montaggio dell’albero P.d.F.


completo sulla trasmissione, verificare l’integri-
tà dell’anello di tenuta in ghisa, che deve essere
comunque fissato nella propria sede con un velo di
grasso.
GB Check integrity of the cast iron sela ring which must
be placed in its seat with a grease film and then
assemble the complete P.T.O. shaft on the tran-
smission.
D Kolbenring auf der Nebenabtriebswelle prüfen und
mit Fett einsetzen.
199
F Avant de procéder au montage de l’arbre de prise
de force complet sur la transmission, vérifier l’intégri-
té de la bague d’étanchéité en fonte, qui doit être
dans tous les cas bloquée dans son logement par
une couche de graisse.

I Introdurre l’albero P.d.F. completo sulla trasmissio-


ne, avendo cura di allineare il dente dell’ingranag-
gio conduttore pompa con la relativa sede sull’al-
bero P.d.F.
GB Fit the complete P.T.O. shaft on the transmission,
taking care to align the pump gear tooth with the
relevant slot on the P.T.O. shaft.
D Nebenabtriebswelle einschieben, darauf achten,
daß die Verzahnung aufeinander passt.
F Engager l’arbre de prise de force complet sur la
200 transmission, en veillant à aligner la dent de l’en-
grenage menant de la pompe et le logement corre-
spondant sur l’arbre de prise de force.

I Inserire l’anello elastico di ritegno assiale cuscinet-


to albero presa di forza.
GB Fit the snap stop ring of the power take-off shaft
bearing.
D Sicherungsring für das Rillenkugellager montieren.
F Engager le circlips axial de roulement d’arbre de
prise de force

201

130
TXL 15/25

Dopo avere sostituito l’anello O-Ring montare il


3
I
tubo livello olio completo di astina graduata appli-
cando sulle viti frenafiletti medio e serrandole alla
coppia di 0,95 ÷ 1,05 daNm.
GB Replace the O-Ring and then fit the oil gauge pipe
complete with its gauge rod and apply a medium
thread lock to the screws and tighten them to 0.95
÷ 1.05 daNm torque.
D Nach Austausch des O-RINGs, die Ölstandleitung
komplett mit Pegelstab montieren, wobei auf die
Schrauben Loctite aufgebracht wird und sie mit 202
einem Drehmoment von 0,95 ÷ 1,05 daNm ange-
zogen werden.
F Après avoir remplacé du joint torique, monter le
tube de niveau d’huile avec jauge graduée, en
enduisant les vis de frein à filets normal, et en les
serrant au couple de 0,95 à 1,05 daNm.

I Rimontaggio distributore standard


Applicare la guarnizione in carta sul carter interme-
dio mediante un velo di grasso e inserire l’anello
O-Ring nella propria sede sulla piastra distributore
fissandolo con grasso.

GB Standard distributor reassembly


Apply the paper gasket to the intermediate sump
with a film of grease and fit the O-Ring in place on
the pump plate and fix it with grease.

D Standard-Steuerblock montage 203


Flachdichtung für die Ölverteilerplatte mit Hilfe von
Fett an das Zwischengehäuse anbringen. O-RING
mit Fett in die Ölverteilerplatte einsetzen.

F Remontage du distributeur standard


Mettre en place le joint en papier sur le carter
intemédiaire, et le bloquer avec une couche de
graisse, puis immobiliser à la graisse le joint torique
dans son logement sur la plaque de distributeur.

I Installare la piastra distributore sul carter interme-


dio accostando a mano le due viti. 204
GB Place the pump plate onto the intermediate sump
and finger tighten the two screws.

D Ölverteilerplatte an das Zwischengehäuse mon-


tieren, die zwei Befestigungsschrauben handfest
einschrauben.

F Mettre en place la plaque du distributeur sur le car-


ter intermédiaire, en serrant les deux vis à la main.

131
TXL 15/25

I Montare il distributore completo accostando le due


viti.

GB Fit the complete distributor by finger tighten the


two screws.

D Steuerblock komplett mit zwei Schrauben montieren.

F Mettre en place le distributeur complet en serrant


les deux vis.

205

I Dopo aver interposto la guarnizione in carta mon-


tare il gruppo valvola antishock e serrare tutte le viti
alla coppia di 2,2 ÷ 2,4 daNm, applicando sulle viti
frenafiletti medio.
GB After having placed the paper gasket in position,
fit the antishock valve assembly and tighten all the
screws to a torque of 2.2 ÷ 2.4 daNm, applying to
the screws the locking liquid medium type.
D Flachdichtung für Antischockventil mit Fett
anbringen, Antischockventil montieren, Restliche
206 Schrauben einsetzen und alle Schrauben mit einem
Drehmoment von 2,2 ÷ 2,4 daNm anziehen, auf die
Gewindeschrauben einzusetzen.
F Après avoir mis en place le joint en papier, monter
le groupe de vannes antichoch, puis serrer toutes
les vis au couple de 2,2 à 2,4 daNm, en appliquant
sur les vis un frein-filets moyen.

I In figura è rappresentato il filtro che sulla trasmis-


207 sione nuova deve essere rimosso dopo circa 60 -
80 ore di funzionamento; un tempo di permanenza
superiore potrebbe, a causa del suo intasamento,
causare danni alla trasmissione. È consigliabile
rimontare un nuovo filtro, in occasione di una revi-
sione del gruppo e mantenerlo per un tempo analo-
go a quanto precedentemente detto.
GB The diagram shows the filter that is on a new tran-
smission and must be removed after about 60-80
hours in operation; leaving it longer might cause
damage to the transmission, through its becom-
ming clogged. It is advisable to fit a new filter when
overhauling the assembly, leaving it in place for the
same period of operation.
D Der auf dem Bild gezeigte Filter muß nach 60-80
Betriebsstunden ausgebaut werden. Dieser Filter
wird benötigt um eventuelle Fertigungsrückstände
zu filtern. Bleibt der Filter zu lange eingebaut
ist die Gefahr, daß er verstopft und ruft daher
Funktionsstörungen hervor. Hinweis: Der Filter muß
nach jeder Reperatur wieder eingebaut werden und
nach ca. 60 Betriebsstunden wieder entfernt werden.
F La figure représente le filtre qui doit être retiré sur
la transmission neuve, au bout de 60 à 80 heures
de fonctionnement environ; une durée d’utilisation
supérieure du filtre risquerait, par suite d’encrasse-
ment, d’endommager l’organe. Il est recommandé
de monter un nouveau filtre à l’occasion d’une révi-
sion du groupe, et de l’utiliser pour une durée analo-
gue à celle précédemment indiquée.
132
TXL 15/25

Rimontaggio distributore supermodulato


3
I
Applicare la guarnizione in carta sulla piastra
mediante un velo di grasso.

GB Supermodulating distributor reassembly


Apply the paper gasket to the plate with a film of
grease.

D Montage Steuerblock Supermoduliert


Flachdichtung für die Verteilerplatte mit Hilfe von
Fett an das Zwischengehäuse anbringen.
208
F Remontage du distributeur supermodulé
Mettre en place le joint en papier sur le plaque, et le
bloquer avec une couche de graisse.

I Installare la piastra distributore sul carter interme-


dio spalmare il frenafiletti medio sulle viti fissaggio
e bloccarle con una coppia di serraggio di 2,1 ÷
2,3 daNm.
GB Place the distributor plate onto the intermedia-
te sump and smear medium locking compound
on fixing screws, lock with a torque of 2.1 to 2.3
daNm.

D Ölverteilerplatte an das Zwischengehäuse montie-


ren, Befestigungsschrauben mit Sicherungsmittel
einseken und mit 2,1 bis 2,3 daNm.
209
F Mettre en place la plaque du distributeur sur le
carter intermédiaire, étaler le frein-à-filets moyen
sur les vis de fixation et les bloquer à un couple de
serrage de 2,1 ÷ 2,3 daNm.

I Dopo aver interposto la guarnizione in carta mon-


tare il distributore, spalmare il frenafiletti medio
sulle viti fissaggio e bloccarle con una coppia di
serraggio di 2,1 ÷ 2,3 daNm a partire dal centro
verso l’esterno.
GB After having placed the paper gasket in position, fit
the distributor, smear medium locking compound
on fixing screws, lock with a torque of 2.1 to 2.3
daNm from center to esternal side.
D Flachdichtung mit Fett anbringen,Montage
Seuergerät. Befestigungsschrauben mit 210
Sicherungsmittel einseken und mit 2,1 bis 2,3
daNm Vom Zentrum nach Aussen anziehen.
F Après avoir mis en place le joint en papier, monter
le distributeur, étaler le frein-à-filets moyen sur les
vis de fixation et les bloquer à un couple de serra-
ge de 2,1 ÷ 2,3 daNm du centre vers l’extérieur.

210a

133
TXL 15/25

I Montaggio comando azionamento inching (a


secondo della versione):
Nel caso di smontaggio o sostituzione dei perni
per molla e del perno per leva, al montaggio bloc-
care alla coppia di serraggio di 2,2 ÷ 2,4 Nm i perni
per molla, spalmare il frenafiletti medio il perno per
leva e avvitare il dado bloccandolo alla coppia di
serraggio di 2,1 ÷ 2,4 Nm .
Nell’ eventuale sostituzione del kit perni e della
leva completa, al montaggio umettare con grasso;
controllare che la rotella e la leva girino liberamen-
211 te sul proprio perno.
Montare il supporto completo sul distributore,
spalmare il frenafiletti medio sulle tre viti di fissag-
gio e bloccarle con una coppia di serraggio di 2,1
÷ 2,3 daNm, e agganciare la molla sui perni.
Per la registrazione e i giochi vedere disegno.

GB Inching control assay assemly (accordino to


configuration)
The spring hooking pins must be tightened to a
torque of 2,2 ÷ 2,4 daNm. Coat the lock nut with
medium grade fastener and tightene to the torque
of 2,1 ÷ 2,4 daNm. If a new pin/lever kit is fitted
211a coat all the parts with grease.
Fit the support assay to the valve control and
tighten the screws to the torque of 2,1 ÷ 2,3 daNm.
Hook the spring to pins.
Refer to picture for end play adjustement.

D Montage des Inching-Antriebs (je nach der


Version):
Bei Demontage oder Austauschen der Federstifte
oder de Heberstifte, sind die Federstifte bei der
Montage mit einem Anzugsmoment vom 21,85 ÷
24,15 Nm zu spannen, den mittleren Gewindehalter
und den Hebelstift mit Fett auftragen und die Mutter
festziehen, wobei sie bei einem Anzugsmoment von
21,43 ÷ 23,70 Nm gespannt wird.
Bei dem Austausch des Stiftsatzes und des kom-
pletten Hebels, bei der Montage mit Fett benetzen;
überprüfen, dass die Rolle und das Hebel um den
eigenen Stift frei drehen können.
Der komplette Halter auf den Verteiler montieren,
die gewindesicherung auftragen und bei einem
Anzugsmoment von 2,1 ÷ 2,3 daNm spannen, der
Feder auf den Stiften anhacken.
Für die Einstellung und zulaessige Spiele s. Bild.
F Montage commande actionnement inching
(selon la version):
En cas de démontage ou de remplacement des
pivots pour le ressort ou des pivots pour le levier,
pendant le montage, serrer les pivots pour ressort
au couple de 21,85 ÷ 24,15 Nm, ètaler le frein-filets
moyen sur le pivot pour levier et visser l’ècrou en le
serrant au couple de 21,43 ÷ 23,70 Nm .
Pour l’èventuel remplacement du kit entier pivots
et celui du levier, pendant le montage graisser
légèrement; contrôler que la roue et le levier tour-
nent librement sur leur pivot.

134
TXL 15/25

Monter le support complet sur le distributeur, èta-


ler le frein-filets moyen sur les trois vis de fixation
et les serrer au couple de 2,1 ÷ 2,3 daNm, enfin,
accrocher le ressort sur les pivots.
3
Pour l’enregistrement et le jeu, voir dessin.

Comando azionamento inching schema di registrazione


Control inching - assy
Inching- Antrieb Einstellplan
Commande actionnement inching schéma d’enregistrement

100

34 3 X.
A MA
CORS ROKE
T
6 33 MAX.S
A
1 CORS
KE
STRO
28.5 INGOMBRO MAX.
OVERALL DIMENSION
GIOCO
0.2-0.6 CLEARANCE FINE CORSA B
2 STROKE RETAINER

A
12

88
5

32
7

GIOCO
10
0.1-0.3 CLEARANCE

6 1 A
Sezione "A-A" CORSA
20
Section STROKE

13 11 45.5

DADO ESAGONALE M8 23.70


14
NUT
C.S. 21.43
Nm
DADO ESAGONALE BASSO M8 9 14
13
NUT
SPINA EL. SPACCATA n3.5X20
12
LOCK PIN
VITE T.E. M8x20
11
SCREW
SPINA EL. SPACCATA n3X16 1
10
LOCK PIN
PERNO LEVA
9
KNUCKLE PIN
ROTELLA
2 8
WHEEL
PERNO PER ROTELLA
2 7
PIVOT
PERNO MOLLA 24.15 Vista da "B"
1 6
PIN FOR SPRING
C.S. 21.85
Nm View from
PERNO LEVA
2 5
KNUCKLE PIN
MOLLA AZIONAMENTO INCHING
4
INCHING REACTION SPRING
LEVA COMPLETA
2 3
LEVER ASSY
- LA ROTELLA E LA LEVA DEVONO GIRARE LIBERAMENTE SUL PROPRIO PERNO
SUPPORTO PER LEVA BOTH WEEL AND LEVER MUST BE ROTATE FREELY ON THEIR OWN CENTER PIVOT
2
SUPPORT FOR LEVER
2 - UMETTARE DI GRASSO AL MONTAGGIO
STAFFA DI REAZIONE DURING THE ASSEMBLY MOISTEN BY GRASE
1
REACTION BRACKET
1 - UMETTARE LA FILETTATURA CON LOCTITE 242 O SIMILARI
POS
DENOMINAZIONE THREADS MOISTENING BY MEANS OF LOCTITE 242 OR SIMILAR
DENOMINATION NOTE

211a

135
TXL 15/25

I Installare e serrare il filtro posto sull’aspirazione


della pompa.

GB Install and tighten the filter placed on the pump


intake.

D Filter einbauen.

F Installer et serrer le filtre placé côté aspiration de


la pompe.

212

I Rimontare i Gruppi ruota come descritto e illustra-


to nel rimontaggio gruppi ruota

Per il montaggio della trasmissione al motore


vedere “Dati Accoppiamento Motore pag 138”

GB Reassemble the wheel sides as shown at wheel


assembly reassembly.

To reinstall the transmission to teh engine refer to


“engine installation data page 138”.

D Die Rädergruppen neu einbauen, wie auf den


Bremsgruppe Montage.

Für die Montage des Antriebs zum Motor s.


Motorblatt Seiten 138.

F Remonter les Groupes roue comme indiqué et illu-


stré dans Remontage des groupe des roues

Pour le montage de la transmission au moteur, voir


“Données Accouplement Moteur” page 138.

136
TXL 15/25

TIPO OLIO
OIL SPECIFICATIONS
ÖLSPEZIFIKATION
TYPE HUILE
4
I Tipo olio trasmissione

Appartenente alla classe ATF e rispondente alle specifiche DEXRON II D oppure TYPE “A” SUFFIX
A della General Motors oppure C3 della Detroit Diesel Allison (per esempio MOBIL ATF 220 e FIAT
TUTELA GI/A e GI/M) oppure corrispondente alle specifiche MIL-L2104B e API CC (per esempio
MOBIL DELVAC 1110) o specifiche MIL-L2104C e API CD (per esempio MOBIL DELVAC 1310) nella
gradazione 10W20.
Quantità: 1° riempimento ~ 7,6 lt.; cambio olio ~ 6,5 lt.
Tipo olio ponte
Secondo specifiche MIL-L2105B oppure API GL5 nella gradazione SAE90 oppure 80W90.
Quantità: cambio olio ~ 3 lt.
Circuito frenante più Inching idraulico
Secondo specifiche: SAE J1703, FMVSS 116 DOT 3, LUNA DOT 3 AB, FORD SAM 6C 9101A, ISO 4925.

GB Transmission oil specification


ATF oils corresponding to specifications DEXRON II D or TYPE “A” SUFFIX A of General Motors or
C3 of Detroit Diesel Allison (e.g. MOBIL ATF 220 and FIAT TUTELA GI/A and GI/M) or corresponding
to specifications MIL-L2104B and API CC (e.g. MOBIL DELVAC 1110) or to the specifications MIL-
L2104C and API CD (e.g. MOBIL DELVAC 1310) viscosity 10W20.
Quantity: 1st filling of ~ 7.6 liters; oil change of ~ 6.5 liters.
Axle oil specifications
By specifications: MIL-L2105B or API GL5 in the gradation SAE90 or 80W90.
Quantity: oil change of 3 liters.
Brake circuit plus hydraulic Inching
By specifications: SAE J1703, FMVSS 116 DOT 3, LUNA DOT 3 AB, FORD SAM 6C 9101A, ISO 4925.

D Getriebe Ölspezifikation
ATF-Öle entsprechend den Spezifikationen DEXRON II D oder TYP “A” SUFFIX A von General Motors
oder C3 von Detroit Diesel Allison (z.B. MOBIL ATF 220 und FIAT TUTELA GI/A und GI/M) oder
entsprechend den Spezifikationen MIL-L2104B und API CC (z.B. MOBIL DELVAC 1110) oder den
Spezifikationen AIL-L2104C und API CD (z.B. MOBIL DELVAC 1310) Viskosität 10W20.
Bedarf: 1° Öl-Füllung ~ 7,6 Lt.; Ölwechsel ~ 6,5 Lt.
Oelachse Typ
Bei Spezifikationen: MIL-L2105B oder API GL5 in der Gradation SAE90 oder 80W90.
Bedarf: Ölwechsel 3 Lt.
Bremskreis plus Hydraulisches Inching
Bei Spezifikationen: SAE J1703, FMVSS 116 DOT 3, LUNA DOT 3 AB, FORD SAM 6C 9101A, ISO 4925.

F Transmission type huile


Appartenante à la classe ATF et correspondante aux spécifiques DEXTRON II D ou TYPE “A” SUFFIX A
de la General Motors ou C3 de la Detroit Diesel Allison (par exemple MOBIL ATF 220 et FIAT TUTELA
GI/A et GI/M) ou correspondante aux spécifiques MIL-L2104B et API CC (par examble MOBIL
DELVAC 1110) ou spécifiques MIL-L2104C et API CD (par exemple MOBIL DELVAC 1310) dans la
gradation 10W20.
Quantité: 1ére remplissage ~ 7,6 litres; changement d’huile ~ 6,5 litres.
Type huile pont
Selon spécifiques: MIL-L2105B ou API GL5 dans la gradation SAE90 ou 80W90.
Quantité: changement d’huile 3 litres.
Circuit freinant plus Inching hydraulique
Selon spécifiques: SAE J1703, FMVSS 116 DOT 3, LUNA DOT 3 AB, FORD SAM 6C 9101A, ISO 4925.

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DATI ACCOPPIAMENTO MOTORE


DATA FOR COUPLING TO ENGINE
EINBAUANWEISUNG
DONNEES D’ACCOUPLEMENT MOTEUR

I Istruzioni di montaggio
a. Montare il piatto flessibile (1) sul volano avvitare le viti (3) di fermo complete di rondelle speciali (4).
Per la coppia di serraggio delle viti fare riferimento ai dati del veicolo.

b. Accoppiare motore e cambio, fare scorrere il convertitore verso il volano e fissarlo al piatto di
trascinamento con le viti (2), dopo avere interposto le rondelle speciali (4)

c. Applicazione: Qualora sia necessario controllare l’allineamenti trasmissione/cambio, assicurarsi


che i massimi errori di concentricità ed ortogonalità siano inferiori a 0,20 mm
(Dimensione consigliata del centraggio del carter coprivolano SAE 5 Ø314,32 F7).

GB Assembling instructions
a. Assemble drive plate (1) to flywheel ,fit the special washer (4) and tighten the bolts (3)
To torque recommended by vehicle manufacturer.

b. Assemble the transmission to engine, slide the converter towards the flywheel, fix the converter
to the drive plate with screws (2) and special washers (4).

c. Field service: concentricity and run out must be smaller then 0.20 mm (0.012 in) T.I.R.
(Recommended figure for flywheel bell housing SAE 5 Ø314,32 F7 U.D.)

D Einbauanweisung
a. Die Antriebsmembrane (1) an das Schwungrad montieren, Schrauben (3) komplett mit speziellen
Unterlegsscheiben (4) anziehen.
Für das Anzugsmoment der Schrauben s. Fahrzeugsdaten.

b. Antrieb und Kupplung zufügen. Wandler zum Schwungrad schieben und an der Membrane mit
Schrauben (2) befestigen, nachdem die speziellen (4) Unterlegsscheiben dazwischen gelegt wurden.

c. Toleranzvorschrift: Sollte erforderlich sein, die Ausrichtung Antrieb/Kupplung zu prüfen, soll


gewährleistet werden, dass die max. Rundlaufs- und Rechtwinkligkeitswerte max.
0,20 mm betragen darf. Normal wird ein SAE 5 Schwungradgehäuse verwendet
mit einem Zentrierdurchmesser von 314,32 mm F7.

F Mode de montage
a. Monter le plateau flexible (1) sur le volant , serrer les vis (3) avec des rondelles spéciales (4). Pour le
couple de serrage des vis, se référer aux données du véhicule.

b. Accoupler le moteur et le boîtier de direction, faire glisser le convertisseur vers le volant, le fixer au
plateau d’entraînement à l’aide de rondelles spéciales (4) puis de vis (2).

c. Application: si nécessaire, contrôler le bon alignement transmission/boîtier de direction, vérifier que


la marge d’erreur de la convergence et de la perpendicularité soit inférieure à 0,20 mm.
(Dimension conseillée du centrage sur carter couvre-volant SAE 5 Ø314,32 F7).

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Schema accoppiamento motore-cambio


Engine-gearbox coupling diagram
Einbau-Schema Motor-Getriebe
Schéma d’accouplement moteur-bôite
4
~15

1 1.5
4

3
4
3
Zetrierung
Trou

Welle
Arbre
Ø30 +0,022
+0,043

Ø29 g8
Albero
Shaft
Foro
Hole

1 - Piatto di trascinemento convertitore


Converter drive plate
Wandlerantriebsmembrane
Plateau d’entraînement du convertisseur.
2 - Viti di unione del piatto di trascinamento al convertitore
Bolts - drive plate to converter
Schrauben - Verbindung Antriebsmembrane mit Wandler
Vis d’union du plateau d’entraînement au volant - fournies du client.
3 - Viti di unione del piatto di trascinamento al volano - fornite dal cliente
Bolts - drive plate to flywheel - supplied byu customer
Schraube - Verbindung Antriebsmembrane mit Schwungrad - Kundenbeistellung
Vis d’union du plateau d’entraînement - fournies du client.
4 - Rondella speciale (Vedi pag. 140)
Special washer (See page 140)
Spezialscheibe (Siehe Seite 140)
Rondelle spéciale (Voir pag. 140).

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Rondella speciale per fissaggio piatto-volano


Special washer to fix drive plate to flywheel
Spezialscheibe zur Befestigung von der Membrane an das Schwungrad
Rondelle spéciale pour fixer le plateau au volant
17 +0.50

15° 15°
0

+0.30
9 - 0.20

R5 R5

1.5
1.5

Disegno N°
Drawing Nr. 3.16475.3
Zeichnung Nr.
Plan N.
Ø 24±0.65

Ø 13±0.27

15°
15°

R5
1.5

R5

2.5±0.22

Disegno N°
Drawing Nr. 3.17113.3
Zeichnung Nr.
Plan N.

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Controllo accoppiamento motore-cambio


Engine gearbox coupling check-up
Rundlaufkontrolle
Contrôle accouplement moteur-bôite
4

2 mm QUOTA MINIMA
MIN DIMENSION
MINDESTABSTAND
PART MINIMUM

PIANO DI APPOGGIO PIATTO DI RIFERIMENTO


LEVEL TO PLACE DRIVE PLATE

16.5 ± 0.5

D
B

Comparatore montato sul coprivolano Comparatore montato sul volano


Dial gauge mounted on flywheel cover Dial gauge mounted on flywheel
Rundlauftoleranzen Radrundlauftoleranzen
Comparateur monté sur le couvre-volant Comparateur monté sur le volant

Lettura totale Lettura totale


Total reading ≤ 0,15 mm Total reading ≤ 0,30 mm
A C
Ablesung Total Ablesung Total
Lecture totale Lecture totale
Lettura totale Lettura totale
Total reading ≤ 0,10 mm Total reading ≤ 0,20 mm
B D
Ablesung Total Ablesung Total
Lecture totale Lecture totale

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DATI TECNICI - Prelievo pressione Distributore Standard


TECHNICAL DATA - Standard Distributor pressure measurement
TECHNISCHE DATEN - Druckmessung Standard-Steuerblock
DONNEES TECHNIQUES - Prelevement de pression Distributeur Standard

10 corsa 12 Hub
stroke course

5 7
INCHING IDRAULICO
HYDRAULIC INCHING
6 HYDRAULISCHES INCHING
INCHING HYDRAULIQUE

B corsa
stroke
Hub
max. pressione course pressione zero
max. pressure 28 zero pressure
A max. Druck Drucklos
max. pression pression zéro

4
5 7
3
1 6
2
B
INCHING MECCANICO
MECHANICAL INCHING
MECHANISCHES INCHING
9 8 INCHING MECANIQUE

A
3
1
2
8
9

Diagramma intervento pressione - Corsa Inching meccanico


Pressure operating time diagram - Mechanical Inching travel
Diagramm Inchdruck - Hub mechanisches inchen
Diagramme de intervention pression - Course Inching mecanique

Pressione / Pressure / Druk / Pression


Pressione 0.5 ÷ 0.7 max
Pressure / Druk / Pression P./ P./ D. / P. max
bar
Coppia frenante (intervento freno)
Brake cut in (brake point)
Bremsdrehmoment (Bremseinsatz)
Couple de frein (intervention frein)

Corsa / Stroke / Hub / Course


0 4 10 20 22 28 mm
F

F / F / K / F max - 12 +2
0 Kg

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I Prelievo pressione distributore standard


1 - Presa pressione principale M 10×1
2 - Presa pressione convertitore M 10×1
3 - Presa pressione modulatrice M 10×1
6
7
8
- Presa pressione MARCIA INDIETRO M 10×1
- Filtro distributore (da eliminare al termine del rodaggio)
- Uscita olio alla scambiatore M 22×1,5
4
4 - Presa pressione Inching M 10×1 9 - Ingresso olio dallo scambiatore M 22×1,5
5 - Presa pressione MARCIA AVANTI M 10×1 10 - Spurgo olio freni

con corrente inserita innesta la Marcia Avanti


A Elettrovalvola AVANTI:
con corrente disinserita cambio in Folle.
con corrente inserita innesta la Retromarcia
B Elettrovalvola INDIETRO:
con corrente disinserita cambio in Folle.

Nel caso le viti di fissaggio del distributore al cambio dovessero essere utilizzate per ancorarvi altri elementi
occorrerà darne comunicazione a Graziano Trasmissioni S.p.A. (Ufficio Tecnico Progetti) per benestare. In ogni
caso le viti dovranno essere chiuse alla coppia di serraggio di 19÷21 Nm.

GB Standard distributor pressure measurement


1 - Main pressure intake M 10×1 7 - Distributor filter (which must be removed at the end of
2 - Converter pressure intake M 10×1 the running-in period)
3 - Modulator pressure M 10×1 8 - Oil outlet to the exchanger M 22×1.5
4 - Inching pressure M10×1 9 - Oil inlet from the exchanger M 22×1.5
5 - FORWARD pressure M 10×1 10 - Brake oil bleeder vent
6 - REVERSE pressure M 10×1

with current on, Forward Gear is engaged


A FORWARD electrovalve:
with current off, in Neutral.
B REVERSE electrovalve: with current on, Reverse Gear is engaged
with current off, in Neutral.

If the fixing bolts of the control valve on the transmission are used to locate other elements, please contact
Graziano Trasmissioni S.p.A. for approval. Bolts must be tightened with torque of 19÷21 Nm.

D Druckmessung Standard-Steuerblock
1 - Hauptdruckmeßstelle M 10×1 6 - Kupplungsdruck RÜCKWÄRTSGANG M 10×1
2 - Wandlerdruckmeßstelle M 10×1 7 - Kontrollventil - Filter (Nach Einlaufzeit entfernen)
3 - Modulatordruckmeßstelle M 10×1 8 - Öl Ausgang vom Austauschem M 22×1,5 Öl zum Kühler
4 - Inchdruckmeßstelle M 10×1 9 - Öl Eingang im Austauschem M 22×1,5 Öl vom Kühler
5 - Kupplungsdruck VORWÄRTSGANG M 10×1 10 - Bremsölentlüftungs ventil

Bei eingeschaltetem Strom wird der Vorwärts-Gang aktiviert


A Elektromagnetventi Vorwärtsgang:
Bei ausschaltetem Strom wird der Freilauf aktiviert.
Bei eingeschaltetem Strom wird der Rückwärts-Gang aktiviert
B Elektromagnetventil Rückwärtsgang:
Bei ausschaltetem Strom wird der Freilauf aktiviert.

Werden die Befestigungsschrauben des Steuerblocks am Getriebe zur Befestigung anderer Teile verwendet,
erfordert dies die Freigabe durch Graziano Trasmissioni S.p.A. Anzugsmoment der Schrauben: 19-21 Nm.

F Prélèvement de pression distributeur standard


1 - Prise de pression principale M 10×1 6 - Prise de pression Marche ARRIERE M 10×1
2 - Prise de pression convertisseur M 10×1 7 - Filtre de distributeur (à retirer à la fin du rodage)
3 - Prise de pression modulatrice M 10×1 8 - Sortie d’huile vers l’échangeur
4 - Prise de pression Inching M 10×1 9 - Entrée d’huile de l’échangeur
5 - Prise de pression Marche AVANT M 10×1 10 - Vis purge huile de frein

avec le courant branché elle met la Marche Avant


A Electrovanne AVANT:
avec le courant débranché elle met la bôite au Point Mort.
avec le courant branché elle met la Marche Arrière
B Electrovanne ARRIERE:
avec le courant débranché elle met la bôite au Point Mort.

Si les vis de serrage du distributeur sur la transmission sont utilisées pour y fixer des autres éléments, il faut le
communiquer à Graziano Trasmissioni S.p.A. (Bureau Technique Projets) pour l’approbation. En tout cas les vis
doivent être serrées à la couple de serrage de 19-21 Nm.

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DATI TECNICI - Prelievo pressione Distributore Supermodulato


TECHNICAL DATA - Supermodulating Distributor pressure measurement
TECHNISCHE DATEN - Druckmessung Steuerblock Supermoduliert
DONNEES TECHNIQUES - Prelevement de pression Distributeur Supermodulé

4 5
9

1 B A

MAIN

INCHING MECCANICO
MECHANICAL INCHING
8
MOD

MECHANISCHES INCHING
INCHING MECANIQUE
INCHING IDRAULICO
HYDRAULIC INCHING
HYDRAULISCHES INCHING
INCHING HYDRAULIQUE
20

2 3 max. pressione pressione zero


corsa
max. pressure zero pressure
stroke
max. Druck Drucklos
Hub
7 6 max. pression pression zéro
course

Diagramma intervento pressione - Corsa Inching meccanico


Pressure operating time diagram - Mechanical Inching travel
Diagramm Inchdruck - Hub mechanisches inchen
Diagramme d’intervention pression - Course Inching mécanique

Pressione / Pressure / Druk / Pression


Pressione 0.5 ÷ 0.7 max
Pressure / Druk / Pression P./ P./ D. / P. max
bar
Coppia frenante (intervento freno)
Brake cut in (brake point)
Bremsdrehmoment (Bremseinsatz)
Couple de frein (intervention frein)

Corsa / Stroke / Hub / Course


0 2 18 mm
5 10 15 20

F
F / F / K / F max - 13 +20 Kg

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I Prelievo pressione distributore supermodulato


1 - Presa pressione principale M 10×1
2 - Presa di pressione ingresso scambiatore di
calore M 10×1
6
7
8
- Uscita olio alla scambiatore M 22×1,5
- Ingresso olio dallo scambiatore M 22×1,5
- Spurgo olio freni
4
3 - Presa pressione modulata M 10×1 9 - Presa di pressione uscita scambiatore e
4 - Presa pressione MARCIA AVANTI M 10×1 convertitore M 10×1
5 - Presa pressione MARCIA INDIETRO M 10×1

con corrente inserita innesta la Marcia Avanti


A Elettrovalvola MARCIA AVANTI:
con corrente disinserita cambio in Folle.
con corrente inserita innesta la Retromarcia
B Elettrovalvola MARCIA INDIETRO:
con corrente disinserita cambio in Folle.

Nel caso le viti di fissaggio del distributore al cambio dovessero essere utilizzate per ancorarvi altri elementi
occorrerà darne comunicazione a Graziano Trasmissioni S.p.A. (Ufficio Tecnico Progetti) per benestare. In ogni
caso le viti dovranno essere chiuse alla coppia di serraggio di 21,4÷23,7 Nm.

GB Supermodulating distributor pressure measurement


1 - Main pressure intake M 10×1 6 - Oil outlet to the exchanger M 22×1.5
2 - Heat exchanger inlet pressure check M10×1 7 - Oil inlet from the exchanger M 22×1.5
3 - Modulator pressure M 10×1 8 - Brake oil bleeder vent
4 - FORWARD pressure M 10×1 9 - Heat exchanger outlet and converter inlet pressure
5 - REVERSE pressure M 10×1 check plug M 10×1

with current on, Forward Gear is engaged


A FORWARD electrovalve:
with current off, in Neutral.
B REVERSE electrovalve: with current on, Reverse Gear is engaged
with current off, in Neutral.

If the fixing bolts of the control valve on the transmission are used to locate other elements, please contact
Graziano Trasmissioni S.p.A. for approval. Bolts must be tightened with torque of 21,4÷23,7 Nm.

D Druckmessung Steuerblock Supermoduliert


1 - Hauptdruckmeßstelle M 10×1 6 - Öl Ausgang vom Austauschem M 22×1,5 Öl zum Kühler
2 - Lufteinlass Eingang Wärmetauscher M 10×1 7 - Öl Eingang im Austauschem M 22×1,5 Öl vom Kühler
3 - Modulatordruckmeßstelle M 10×1 8 - Bremsölentlüftungs ventil
4 - Kupplungsdruck VORWÄRTSGANG M 10×1 9 - Lufteinlass Ausgang Tauscher und Umformer M 10×1
5 - Kupplungsdruck RÜCKWÄRTSGANG M 10×1

Bei eingeschaltetem Strom wird der Vorwärts-Gang aktiviert


A Elektromagnetventi Vorwärtsgang:
Bei ausschaltetem Strom wird der Freilauf aktiviert.
Bei eingeschaltetem Strom wird der Rückwärts-Gang aktiviert
B Elektromagnetventil Rückwärtsgang:
Bei ausschaltetem Strom wird der Freilauf aktiviert.

Werden die Befestigungsschrauben des Steuerblocks am Getriebe zur Befestigung anderer Teile verwendet,
erfordert dies die Freigabe durch Graziano Trasmissioni S.p.A. Anzugsmoment der Schrauben: 21,4÷23,7 Nm.

F Prélèvement de pression distributeur supermodulé


1 - Prise de pression principale M 10×1 6 - Sortie d’huile vers l’échangeur
2 - Prise de pression entrée échangeur 7 - Entrée d’huile de l’échangeur
calorifique M 10×1 8 - Vis purge huile de frein
3 - Prise de pression modulatrice M 10×1 9 - Prise de pression sortie échangeur et convertisseur
4 - Prise de pression Marche AVANT M 10×1 M 10×1
5 - Prise de pression Marche ARRIERE M 10×1

avec le courant branché elle met la Marche Avant


A Electrovanne AVANT:
avec le courant débranché elle met la bôite au Point Mort.
avec le courant branché elle met la Marche Arrière
B Electrovanne ARRIERE:
avec le courant débranché elle met la bôite au Point Mort.

Si les vis de serrage du distributeur sur la transmission sont utilisées pour y fixer des autres éléments, il faut le
communiquer à Graziano Trasmissioni S.p.A. (Bureau Technique Projets) pour l’approbation. En tout cas les vis
doivent être serrées à la couple de serrage de 21,4÷23,7 Nm.

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RODAGGIO

5 RUNNING-IN
INBETRIEBNAHME
RODAGE

I Trasmissione idraulica
Il periodo di rodaggio è di 60-80 ore, durante le quali è necessario seguire le seguenti prescrizioni:
ispezionare frequentemente la trasmissione assicurandosi che non esistano perdite di olio.
Ogni 10 ore
Controllare il livello olio nella trasmissione ed eventualmente rabboccare. Il controllo del livello olio deve
essere effettuato con motore al minimo, olio caldo e cambio in Folle.
Al termine del periodo di rodaggio
a. sostituire lʼolio
b. sostituire il filtro dellʼolio
c. eliminare il filtro interno al distributore (solo versione standard)
Le suddette norme devono essere osservate anche dopo una revisione della trasmissione idraulica.

GB Hydraulic transmission
The running-in time is 60-80 hrs., during which it is necessary to perform the following operations:
check the transmission frequently to make sure that there are no oil leaks.
Every 10 hrs.
Check the oil level in the transmission and, if required, top up (for oil brand pls. refer to the supply list).
Oil level check must be performed at engine idle speed, transmission in neutral and with oil at rated
temperature (minimum 40°C).
At the end of the running-in period
a. change the oil
b. replace the oil filter
c. remove and eliminate the filter inside distributor (standard version only)
Above rules must be observed even after an overhaul of the hydraulic transmission.

D Hydraulikgetriebe
Die Einlaufzeit beträgt 60-80 Stunden, während der die folgenden Maßnahmen durchzuführen sind:
Getriebe mehrfach prüfen und sicherstellen, daß keine Leckagen auftreten.
Alle 10 Stunden
Getriebeölstand prüfen und gegebenenfalls nachfüllen. Die Ölstandskontrolle muß bei Motorleerlauf,
Getriebe in Neutral und betriebswarmem Öl erfolgen (Mindesten 40°C).
Am Ende der Einlaufphase
a. Ölwechsel
b. Filter wechseln
c. Filter ausschalten im Innern des Verteilers (Nur Standardversion).
Die obigen Regeln müssen auch nach einer Überholung des hydraulischen Getriebes befolgt werden.

F Transmission hydraulique
La période de rodage est de 60-80 heures, pendant lesquelles il faut suivre les prescriptions suivantes:
inspecter souvent la transmission pour s’assurer qu’il n’y a pas de pertes d’huile.
Toutes les 10 heures
Contrôler le niveau d’huile dans la transmission et éventuellement en ajouter. Le contrôle du niveau
d’huile doit être effectué avec le moteur au ralenti, l’huile chaude et la bôite au Point Mort (minimum
40°C).
A la fin de la période de rodage
a. remplacer l’huile
b. remplacer le filtre à l’huile
c. éliminer le filtre à l’interieur du distributor (seulement version standard).
Les susmentionées normes doivent être oservées aussi bien après une révision de la transmission
hydraulique.

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MANUTENZIONE PERIODICA
PERIODIC SERVICING
5
I Ogni 200 ore:
Trasmissione idraulica: verificare il livello olio con l’astina e se necessario aggiungerne.
Il controllo deve essere effettuato con il motore al minimo, olio caldo e
cambio in Folle (40°C minimo).
Ogni 500 ore:
Filtro olio cambio: sostituire la cartuccia filtrante; svitare la cartuccia dal relativo supporto.
Nota: ogni due sostituzioni della cartuccia occorre sostituire l’olio della tra-
smissione. La sostituzione dell’olio deve essere fatta non oltre 1 anno oppure
1000 ore.
Freni : Almeno ogni 500 ore sia i registri laterali che le boccole di scorrimento
dell’autoregistro devono essere ingrassate con grasso resistente alle alte tem-
perature. Si raccomanda di controllare anche le condizioni delle ganasce e la
tenuta dei cilindri e che i tappi di tenuta siano efficienti.
Si raccomanda inoltre di assicurasi che il vano freno sia ben stagno, se si deve
lavare con idropulitrice
Incernieramenti: Ingrassare gli incernieramenti supporti di attacco telaio.
Ogni 1500 ore:
Ponte: sostituire olio.

GB Every 200 hrs.:


Transmission: check oil level with oil dipsticks. If necessary, top up through the inlet plug. The oil
level check must be performed with engine at idle speed, transmission in neutral
and oil at operating temperature (minimum 40°C).
Every 500 hrs.:
Transmission oil filter: change the filtering cartridge by unscrewing it from support.
Note: As two cartridges have been replaced it is necessary to replace
transmission oil, drain thru plug. When oil is renewed clean also oil suction
filter. Oil replacement should be performed not over a year or 1000 hours.

Brake At least every 500 hours the automatic adjuster bolt threads and sliding
bushes are to be greased with heat resistance grease. Also the cylinders
and shoe lining must be inspected, check also for plugs installation, if
missing or loose must be replaced.
Care must be taken for water tightness of the brake compartment if steam
cleaner has to be used.
Henges: Grease the frame mount support.

Every 1500 hrs.:


Axle: oil change.

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REGELMÄßIGE WARTUNG
ENTRETIEN PERIODIQUE

D Alle 200 Stunden:


Getriebe: Prüfen Sie den Ölstand mit den Peilstäben. Gegebenenfalls nachfüllen.
Die Ölstandsprüfung muß bei Motorleerlauf, in Getriebeneutralstellung und bei
betriebswarmem Öl durchgeführt werden.
Hinweis: Bei Motorstillstand kann der Ölstand im Getriebe steigen (Rücklauf aus
Rohrleitungen und Wandler). (Mindestens 40°C).
Alle 500 Stunden:
Öl ablassen: Filter wechseln. Neues Öl einfüllen. Ölstand wie oben beschrieben kontrollieren.
Anmerkung: Der Ölwechsel muß mindestens 1 mal jährlich oder alle 500 Stunden
maximal durchgeführt werden. Beschädigte Filter dürfen nicht wieder verwendet
werden. Getriebeölmenge: 10 Liter.
Bremsen: Sowohl die seitlichen Register als auch die Schiebebuchsen des Registers sind
wenigstens alle 500 Betriebsstunden mit Hochtemperaturfett aufgetragen werden.
Es wird empfohlen, auch die Backen und die Zylinderdichtung zu prüfen, und dass
die Dichtungsstopfen ausreichend sind. Bitte prüfen, dass der Bremsraum dicht ist,
wenn mit Hydroreiniger zu waschen ist.
Träger: Schierung der Trägerbefestigung.
Alle 1500 Stunden:
Achse: Öl austauschen.

F Tous les 200 heures:


Transmission hydraulique: vérifier le niveau de l’huile par la fauge et, si nécessaire, en ajouter. Le
contrôle doit être effectué avec le moteur au ralenti, l’huile chaude et la
bôite au Point Mort (minimum 40°C).
Toutes les 500 heures:
Remplacement du filtre à huile: substituer la cartouche de filtrage; dévisser la cartouche du support
correspondant.
Remarque: toutes les deux substitutions de la cartouche, il faut
remplacer l’huile de la transmission; pour déverser l’huile, enlever le
bouchon au moment du vidange, nettoyer le filtre d’aspiration de la
pompe. Effectuer le vidange chaque année au moins ou 1000 heures.
Freins : Toutes les 500 heures, au moins, les registres latéraux et les guides
de coulissement de l’auto-registre doivent être graissés avec de la
graisse résistante aux hautes températures. Il est recommandé de
contrôler aussi l’ètat des mâchoires et la résistance des vérins, et
enfin que les bouchons d’ètanchéité soient encore efficaces.
En outre, ilest recommandé de vérifier que l’espace du frein soit
bien ètanche si le lavage avec un hydro-nettoyeur s’avère nécessai-
re.
Supports: Graissage charnières support de raccordement du cadre.
Tous les 1500 heures:
Pont: substituer l’huile.

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TROUBLESHOOTING PROCEDURE
FEHLERSUCHE
RECHERCHE DE PANNES DE FONCTIONNEMENT
6
I A. Indicazioni generali
Prima della localizzazione dei guasti della trasmissione occorre fare quanto segue:
• Controllare il livello dell’olio e le condizioni dell’olio. Vedere sezione manutenzione per dettagli.
• Controllare la trasmissione, radiatore dell’olio e linee degli scambiatori di calore dell’olio per dan-
neggiamenti o perdite. Rimediare ad ogni problema.
• Controllare che la causa del problema non sia il motore e/o il gruppo ponte.
Fare tutti i controlli di pressione alla temperatura di funzionamento normale. I misuratori di pressio-
ne usati devono aver un campo di misura di 0 - 15 bar e devono essere precisi.
Attenzione: mai mantenere in stallo la trasmissione per più di 10 secondi con regime motore ele-
! vato. Mettere in Folle e lasciar raffreddare la trasmissione. La mancanza di questa precauzione
può causare seri danni alla trasmissione.

B. Indicazioni di intervento
Durante la ricerca dei guasti inserire ogni posizione del selettore per stabilire quando si verificano
i problemi o i rumori. Determinare quali parti sono in movimento. Questo servirà come punto di
riferimento per individuare la causa. Utilizzare le seguenti informazioni come guida in caso di pro-
blemi.
Convertitore
Alcuni problemi di trasmissione sono legati al convertitore. Controllare e/o sostituire il convertitore
nei casi seguenti:
• accelerazione debole con velocità massima ridotta e surriscaldamento (velocità di stallo
normale): indica che la ruota libera dello statore si è bloccata.
• Un suono metallico proveniente dal convetitore indica un danneggiamento delle palette del con-
vertitore.
• Una notevole caduta della velocità di stallo indica che la ruota libera del convertitore non è in presa.
Frizioni
Controllare e/o sostituire le frizioni qualora si verifichino i seguenti inconvenienti.
• Alta velocità di stallo. Ciò può indicare che la frizione slitta. La frizione che slitta generalmente stride.
Nota: la frizione che slitta normalmente si surriscalda. Questo può produrre lo svergolamento dei
dischi. In caso di forte surriscaldamento i dischi possono saldarsi insieme. Questo può cau-
sare un arresto nella trasmissione se un’altra frizione viene innestata.
• Il movimento del carrello con Marcia in Folle può indicare danneggiamento della frizione (Svergo-
lamento dei dischi).

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GB A. General information
Before locating any fault, it is necessary to act as follows:
• check oil level and oil condition. For details, pls. see servicing section.
• Check transmission, oil cooler and oil cooler pipes to find any damage or leak. Repair if necessary.
• Make sure that the problem is not due to the engine and/or to the axle assy.
Proceed on all pressure checks at normal working temperature. The pressure gauges must have a
range of 0-15 bar and must be accurate.
Warning: never stall converter for more than 10 seconds with high engine r.p.m.. Select neutral
! and let transmission cool. Failure of this precaution can cause serious damage to the transmission.

B. Diagnosis of problems
During the diagnosis, switch the selector into all positions and try to find out in which position
the problems or noises appear. Determine which parts are in motion. This will be a useful point to
determinate the cause. Use the following as a guide in case of problems.
Converter
Some transmission problems are related to the converter. Check and/or replace the converter in
the following cases:
• weak acceleration with reduced max. speed and overheating (normal stall speed): it can indicate
that the one way clutch wheel is sticking.
• A metallic noise from the converter can indicate converter vane damage.
• Increased stall speed may indicate that the one way clutch is broken.
Clutches
Check and/or replace the clutches if the following abnormalties appear.
• High stall speed. This can indicate that the clutch is slipping. A slipping clutch generally squeals.
Note: generally a slipping clutch overheats. This can cause the disks to warp. In case of
overheating, the disks can stick together. This can stall the transmission if another clutch is
engaged.
• If the truck moves in neutral this can indicate clutch damage. Clutch plates warped.

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FEHLERSUCHE

6
D A. Allgemeines
Vor der Lokalisierung eines Fehler ist folgendes erforderlich:
• Ölstand und Ölzustand prüfen. Einselheiten gemäß Abschnitt “Wartung”.
• Getriebe, Ölkühler und Verrohrung auf Beschädigung oder Leckage prüfen. Falls notwendig,
reparieren.
• Prüfen, ob Fehler durch Motor und/oder Achsbaugruppe verursacht ist.
Alle Druckprüfungen sind bei normaler Betriebstemperatur vorzunehmen. Die Manometer müssen
einen Meßbereich von 0 - 15 bar haben.

Achtung: Getriebe niemals mehr als 10 sec. festbremsen mit hoher Drehzahl. Mißachtung dieser
! Anweisung kann schwere Schäden im Getriebe hervorrufen.

B. Schadenssuche bzw. -Behebung


Bei der Fehlersuche Wahlschalter in alle Stellungen schalten und versuchen herauszufinden, in
welcher Stellung die Probleme oder Geräusche auftreten.
Wandler
Einige Getriebeprobleme können vom Wandler verursacht werden.
• Schlechte Beschleunigung bei verringerter Höchstgeschwindigkeit und Überhitzung (normale
Festbremsdrehzahl). Dies zeigt an, daß sich bei höherer Fahrgeschwindigkeit das Leitrad nicht
löst. Der Freilauf blockiert.
• Ein metallisches Geräusch im Wandler zeigt eine Wandler-Schaufelbeschädigung an.
• Eine zu hohe Festbremsdrehzahl kann bedeuten, daß sich das in diesem Betriebsbereich
normalerweise feststehende Leitrad dreht. Der Leitradfreilauf hat keine Klemmwirkung mehr.
Schaltkupplungen.
Überprüfen und wenn erforderlich, austauschen. Folgendes Symptom kann einen Austausch
erforderlich machen:
• Zu hohe Festbremsdrehzahl. Dies kann anzeigen, daß die Kupplung rutscht. Schleifgeräusch.
Anmerkung: Im allgemeinen wird eine rutschende Kupplung zu heiß. Dies kann zur Vermormung
der Lamellen führen. Bei sehr starker Überhitzung können die Lamellen zusammen-
schweißen. Dies kann zu einer Blockierung des Getriebes führen, falls eine andere
Kupplung schaltet.
• Bewegt sich das Fahrzeug in Neutralstellung, so kann dies auf verschweißte Lamellen
hindeuten.

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F A. Généralites
Avant de localiser les pannes de la transmission il faut effectuer les opérations suivantes:
• Contrôler le niveau et l’état de l’huile. Reportez vous au chapitre entretien pour avoir plus de détails.
• Contrôler la transmission, le radiateur d’huile et lignes des échangeurs de chaleur de l’huile pour les
pannes ou les pertes. Résoudre chaque problème.
• Contrôler que la cause de la panne ne soit pas imputable au moteur et/ou au groupe pont.
Faire tous les contrôles de pression à la température de fonctionnement normale. Les dispositifs de
mesure pour la pression doivent posséder une plage de mesure de 0 à 15 bar et doivent être précis.
Attention: il ne faut pas mantenir le régime max. de la transmission pendant plus de 10 seconds
! avec régime-moteur élevée. Mettre au Point Mort et laisser refroidir la transmission, dans le cas
contraire on peut causer d’importants à la transmission.

B. Indications d’intervention
Pendant la recherche de la panne, enclencher toutes les positions du sélecteur afin de localiser les
problèmes ou des bruits anormaux. Déterminer quels sont les éléments qui sont en mouvement, ce
qui servira comme point de repère pour identifier la cause. Employez à titre indicatif les renseignements
suivants en cas de problème.
Convertisseur
Quelques problèmes de transmission sont liés au convertisseur. Contrôler et/ou remplacer le
convertisseur dans les cas suivantes:
• faible accéleration, la vitesse maximum est réduite, et surchauffe du moteur (vitesse normale).
Cet état indique que la roue libre du stator est bloquée.
• Un bruit métallique qui provient du convertisseur indique une déterioration des pales du convertisseur.
• Une baisse de vitesse important du régime max. indique que la roue libre du convertisseur n’èst
pas en prise.
Embrayages:
Contrôler et/ou remplacer les embrayages quand on a les inconvenients suivants:
• vitesse élévée du régime. Ceci peut indiquer que l’embrayage patine. Un embrayage qui patine
pent produire un sifflement.
Remarque: L’embrayage qui patine en général surchauffe. Ceci peut provoquer une déformation
des disques. Dans le cas de surchauffe importante, les disques peuvent se souder
entre eux. Ceci peut provoquer un blocage dans la transmission si un autre embrayage
est embrayé.
• Le mouvement du chariot au Point Mort est conséquent à une détérioration des embrayages
(déformatiotion des disques).

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C. Diagnostica
C. Inspection
C. Untersuchung
C. Diagnostic
6
I Problemi Cause Rimedi
PERDITE

1. Perdite della pompa dalla guar- - Guarnizione difettosa Sostituire


nizione dell’albero d’uscita o - Cattivo allineamento Correggere
dall’albero della P.d.F. - Albero danneggiato Sostituire.

2. Perdite tra l’esterno della guar- - Sede danneggiata Applicare sigillante sul diam. ester-
nizione e la sua sede no della guarnizione sostituendola.

3. Perdite dalle guarnizioni di - Allentamento viti di unione Stringere bene le viti.


unione carter

4. Perdite dai tappi scarico olio - Danneggiamento guarnizione in Sostituire.


rame

5. Perdita d’olio non localizzabile - Perdite d’olio dal radiatore o dal Sostituire componenti del circuito
sulla trasmissione circuito di raffreddamento olio difettosi.

6. Fuoriuscita olio dallo sfiato - Livello olio alto Correggere livello olio

GB Problems Causes Remedies


LEAKS

1. Pump output shaft gasket or - Faulty gasket Replace


PTO shaft leaks - Bad alignement Rectify
- Damaged shaft Replace.

2. Leaks between the outside of - Damaged seal seat in housing Change seal and apply sealant on
the gasket and its seating the outside diameter.

3. Leaks from the case sealing - Fixing screws loosened Tighten the screws.
gasket

4. Leaks from the drain plug - Copper gasket damaged Replace.

5. Not easy to locate oil leaks on - Oil leaks from the cooler or from Replace the faulty cooler or the faulty
the transmission the oil cooling circuit components of the circuit.

6. Oil leaks from the breather - High oil level Rectify the oil level.

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C. Diagnostica
C. Inspection
C. Untersuchung
C. Diagnostic

D Probleme Ursachen Abhife


UNDICHTIGKEIT

1. Pumpenabtriebswellen dichtung - Fehlerhafte Dichtung Austauschen


oder Nebenabtriebswellendich- - Schlechte Ausrichtung Korrigieren
tung undicht - Beschädigte Welle Ersetzen.

2. Leckage zwischen äußerer - Aufnahmebohrung für Dichtung Dichtung tauschen. Dichtmasse


Dichtung und Gehäuse Gehäuse beschädigt auf den Außendurchmesser der
Dichtung aufrbingen.

3. Undichtigkeit am Zwischen- - Verbindungsschrauben lösen sich Anziehen.


gehäuse

4. Undichter Ablaß - Kupferdichtung beschädigt Austauschen.

5. Nicht leicht zu lokalisierende - Ölleckage vom Kühler oder vom Fehlerhaften Kühler oder defekte
Ölleckagen am Getriebe Ölkühlkreislauf Teile des Kreislaufs ersetzen.

6. Ölausfluß vom Entlüfter - Zu hoher Ölstand Ölstand korrigieren.

F Problemes Causes Remedes


FUITES

1. Fuite de la pompe, du joint de - Joint déféctueux Remplacer


l’arbre de sortie ou de l’arbre de - Mauvais alignement Corrigere
la prise de force - Arbre endommagé Remplacer.

2. Fuites entre l’extérieur du joint - Siège endommagé Remplacer le joint.


et son siège

3. Fuites aux joints de jonction au - Desserage des vis de jonction Bien serrer les vis.

4. Fuites aux bouchons de vidange - Joint en cuivre endommagé Remplacer.


d’huile

5. Fuite d’huile non localisée sur la - Pertes d’huile du radiateur ou du Remplacer le radiateur ou la pièce
transmission circuit de refroidissement défectueuse du circuit.

6. Sortie d’huile du reniflard - Niveau d’huile trop haut Corriger le niveau d’huile.

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Difetti di funzionamento comuni a tutte le marce


Common running faults in all gears
Gilt für alle funktionsstörungen
Defauts de fonctionnement pour toutes les vitesse
6
I Problemi Cause Rimedi
1. Pressione olio bassa - Valvola regolatrice bloccata Pulire e lucidare la valvola
- Perdita interna Sostituire gli anelli di tenuta diffettosi
- Livello olio basso Aggiungere olio
- Pompa difettosa Sostituire la pompa
- Filtro d’aspirazione intasato Sostituire
- Comando Inching sregolato Regolare correttamente.

2. Mancanza di pressione olio - Perdita interna Sostituire le parti difettose


- Pompa danneggiata Sostituire la pompa
- Valvola regolatrice difettosa Pulire e lucidare la valvola.

3. Innesto violento - Alta pressione valvola regolatrice Pulire e lucidare


bloccata
- Minimo motore troppo alto Regolare
- Valvola modulatrice difettosa Revisionare
- Valvola antishock starata o bloccata Tarare o sostituire
- Impurità o corpi estranei nel Smontare e pulire.
distributore

4. Innesto lento - Bassa pressione alle frizioni Vedere “Pressione olio bassa”
- Minimo motore troppo basso Regolare
- Valvola modulatrice difettosa Revisionare
- Valvola antishock starata o bloccata Tarare o sostituire.

5. Alta pressione - Valvola regolatrice bloccata Pulire e lucidare.

6. Temperatura dell’olio alta - Linea di raffreddamento difettosa Sostituire le parti difettose


- Strozzatura nella linea di raffred- Rimuovere
damento
- Radiatore difettoso Sostituire
- Convertitore danneggiato Sostituire
- Livello olio alto Ripristinare livello.

7. Rumorosità con la Marcia Avanti - Cattivo allineamento del carter Allineare il gruppo del convertitore
e Retromarcia convertitore o del convertitore e il corpo
con il motore
- Ingranaggi danneggiati Sostituire
- Danneggiamento palette Sostituire convertitore.
convertitore

8. Assenza di movimento con le - Mancanza pressione Vedi “Mancanza pressione olio”


marce inserite - Albero d’ingresso rotto Sostituire
- Piatto di trascinamento converti- Sostituire
tore rotto
- Guasto all’impianto elettrico Riparare.

9. Cattivo funzionamento Inching - Valvola inceppata Riparare o sostituire.

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Common running faults in all gears

GB Problems Causes Remedies


1. Low oil pressure - Regulating valve sticked Clean and polish the valve
- Internal leakage Replace the faulty seal rings
- Low oil level Add oil
- Faulty pump Replace the pump
- Suction filter clogged Replace
- Misadjusted Inching control Adjust.

2. No oil pressure - Internal leakage Replace the faulty parts


- Damaged pump Replace the pump
- Damage in the regulating valve Clean and polish the valve.

3. Hard clutch engagement - Locked high pressure, regulating Clean and polish
valve
- Engine idling speed too high Rectify
- Faulty modulating valve Overhaul
- Sticking or unset anti-shock valve Reset or replace
- Impurity or foreign particles in Disassemble and clean.
the distributor

4. Slow clutch engagement - Low clutch pressure See “Low oil pressure”
- Too low idling speed engine Adjust
- Faulty modulating valve Overhaul
- Sticking or unset anti-shock valve Reset or replace.

5. High pressure - Sticking regulating valve Clean and polish.

6. High oil temperature - Faulty cooling circuit Replace the faulty parts
- Choke in the cooling circuit Remove
- Faulty cooler Replace
- Damaged converter Replace
- High oil level Restore the level.

7. Noises in Forward and Reverse - Bad alignment of the converter Align the converter group and the
housing or of the converter with case
the engine
- Damaged gears Replace the damaged gears
- Damaged converter vane Replace the converter.

8. No drive when gears are - Pressure lack See “Oil pressure lack”
engaged - Broken input shaft Replace
- Broken converter drive plate Replace
- Failure of the electric system Repair.

9. Bad Inching working - Sticking valve Repair or replace.

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Gilt für alle funktionsstörungen

6
D Probleme Ursachen Abhife
1. Zu niedriger Öldruck - Regelventil blockiert Ventil reinigen
- Innere Leckage Defekte Dichtringe austauschen
- Niedriger Ölstand Öl auffüllen
- Pumpenfehler Pumpe austauschen
- Saugfilter verstopft Austauschen
- Falsch eingestellte Inchsteuerung Korrigieren.

2. Fehlender Öldruck - Innere Leckage Defekte Teile ersetzen


- Pumpenfehler Pumpe austauschen
- Verschmutztes Ventil reinigen.

3. Rupfende Kupplung - Blockierter Hauptdruck, Regelvenil Reinigen


- Defektes Modulationsventil Überholen / Ersetzen
- Blockiertes oder falsch eingestelltes Einstellen oder austauschen
Anti-Schock-Ventil
- Schmutz oder Fremdkörper im Demontieren und reinigen.
Verteiler

4. Verzögertes Einschalten der - Niedriger Kupplungsdruck Siehe “Zu niedriger Öldruck”


Kupplung - Zu niedrige Leerlaufdrehzahl Motor Korrigieren
- Defektes Modulationsventil Überholen
- Blockiertes oder falsch eingestelltes Einstellen oder austauschen
Anti-Schock-Ventil
- Schmutz im Verteiler Reinigen.

5. Zu hoher Druck - Festsitzendes Regelventil Reinigen.

6. Hohe Öltemperatur - Defekter Kühlerkreis Defekte Teile austauschen


- Drossel im Kühlkreislauf Entfernen
- Defekter Kühler Austauschen
- Beschädigter Wandler Austauschen
- Hoher Ölstand Ölstand korrigieren.

7. Geräusche im Vorwärts- und - Schlechte Ausrichtung des Wandlergruppe und Gehäuse neu
Rückwärtsgang Wandlergehäuses oder Wandlers korrekt einrichten
mit dem Motor
- Beschädigte Zahnräder Zahnräder ersetzen
- Beschädigte Wandlerschaufel Wandler ersetzen.

8. Kein Antrieb in Gängen - Fehlender Druck Siehe “Fehlender Öldruck”


- Gebrochene Antriebswelle Austauschen
- Gebrochene Membrane Austauschen
- Ausfall des Elektriksystems Reparieren.

9. Schlechtes Inchingverhalten - Blockiertes Ventil Reparieren oder ersetzen.

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Defauts de fonctionnement pour toutes les vitesse

F Problemes Causes Remedes


1. Pression d’huile basse - Vanne régulatrice bloquée Nettoyer et polir la vanne
- Fuite interne Remplacer les bagues de tenue
défectueuses
- Niveau d’huile bas Ajouter de l’huile
- Pompe défectueuse Remplacer la pompe
- Filtre d’aspiration ecrassée Remplacer
- Commande Inching mal reglée Regler la commande correctement.

2. Manque de pression huile - Fuite interne Remplacer les pièces défectueuses


- Pompe endommagée Remplacer la pompe
- Vanne régulatrice défectueuse Nettoyer et polir la vanne.

3. Embrayage violent - Haute pression de la vanne Nettoyer et polir


régulatrice bloquée
- Ralenti trop élevé Regler
- Vanne modulatrice défectueuse Réviser
- Vanne antichock mal calibrée ou Calibrer ou remplacer la vanne
bloquée
- Corps étrangers ou impurités Demonter et nettoyer
dans le distributeur

4. Embrayage lent - Pression basse des embrayages Voir chapitre “Pression d’huile basse”
- Ralenti trop bas Régler
- Vanne modulatrice défectueuse Réviser
- Vanne antichock mal calibrée ou Calibrer ou emplacer
bloquée
- Impurités dans le distributeur Nettoyer.

5. Pression haute - Vanne régulatrice bloquée Nettoyer et polir.

6. Température d’huile élevée - Ligne de refroidissement Remplacer les pièces


défectueuse défectueuse
- Entranglement dans la ligne de Remettre la ligne en place
refroidissement
- Radiateur défectueux Remplacer
- Convertisseur endommagé Remplacer
- Niveau d’huile trop haut Régler le niveau.

7. Bruits en Marche Avant ou arrière - Mauvais alignement du carter Aligner le groupe du convertisseur
avec le convertisseur ou du et le corps
convertisseur avec le moteur
- Engrenage endommagés Remplacer les engrenages
endommagés
- Pales du convertisseur Remplacer le convertisseur.
endommagés

8. Pas de mouvement du véhicule - Manque de pression Voir chapitre “Manque pression huile”
direction vitesses enclenchées - Arbre entrée cassé Remplacer
- Plateau d’entraînement du Remplacer
convertisseur cassé
- Panne sur l’installation électrique Reparer

9. Mauvais fonctionnement Inching -Vanne coincée Reparer ou remplacer.

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Anomalie di funzionamento a marce innestate


Marcia Avanti e Retromarcia
Running faults with gears engaged
Forward and Reverse Gear
6
Funktionsstörungen bei eingelegtem gang
Vorwärts- und Rückwärtsgang
Anomalies de fonctionnement avec marches mises
Marche Avant et Marche Arrière

I Problemi Cause Rimedi

1. La frizione fa resistenza o non - Dischi frizione svergolati Sostituire le parti difettose


stacca (il carrello si muove in Folle) - Guasti meccanici Sostituire le parti difettose
- Assenza di gioco nel pacco Aumentare il gioco secondo speci-
frizione fiche
- Elettrovalvola inceppata Riparare o sostituire
- Selettore bloccato Pulire e lucidare
- Guasto elettrico Riparare
- Impurità o corpi estranei nel distri- Smontare e pulire.
butore

2. La frizione non si innesta (il car- - Bassa pressione Vedere “Pressione olio bassa”
rello non si muove) - Elettrovalvola inceppata Riparare o sostituire
- Selettore bloccato Pulire e lucidare
- Guasto elettrico Riparare
- Impurità o corpi estranei nel distri- Smontare e pulire.
butore

3. Il carrello si muove debolmente - Bassa pressione Vedere “Pressione olio bassa”


o non si muove - Anelli di tenuta consumati o rotti Sostituire le parti difettose.

GB Problems Causes Remedies

1. The clutch drags or does not - Warped clutch disks Replace the faulty parts
release (the truck moves at idle) - Mechanical failures Replace the faulty parts
- Absence of clearance in the Increase the clearance as per
clutch pack descriptions
- Sticking electrovalve Repair or replace
- Sticking selector Clean and polish
- Electric failure Repair
- Impurity or foreign particles in the Disassemble and clean.
distributor

2. The clutch does not engage - Low pressure See “Low oil pressure”
(the truck does not move) - Locked electrovalve Repair or replace
- Sticking selector Clean and polish
- Electric failure Repair
- Impurity or foreign particles in the Disassemble and clean.
distributor

3. The truck does not move or it - Low pressure See “Low oil pressure”
moves weakly - Broken or worn seal rings Replace the faulty parts.

159
TXL 15/25

Funktionsstörungen bei eingelegtem gang


Vorwärts- und Rückwärtsgang
Anomalies de fonctionnement avec marches mises
Marche Avant et Marche Arrière

D Probleme Ursachen Abhife


1. Die Kupplung rupft oder löst sich - Verzogene Kupplungsscheiben Defekte Teile austauschen
nicht. Fahrzeug bewegt sich im - Mechanischer Fehler Defekte Teile austauschen
Leerlauf - Fehlendes Spiel im Spiel gemäß Beschreibung
Kupplungspaket erhöhen
- Festsitzendes Elektroventil Reparieren oder ersetzen
- Elektrikausfall Reparieren
- Schmutz im Verteiler Demontieren und reinigen
- Blockierter Wahlschalter Reinigen.

2. Kupplung wurde beaufschlagt - Niedriger Druck Siehe “Zu niedriger Öldruck”


Fahrzeug bewegt sich nicht - Blociertes Elektroventil Reparieren oder austauschen
- Elektrikausfall Reparieren
- Schmutz im Verteiler Demontieren und reinigen.

3. Fahrzeug bewegt sich nicht - Niedriger Druck Siehe “Zu niedriger Öldruck”
oder nur wenig - Geborchene oder verschlissene Defekte Teile austauschen.
Dichtringe

F Problemes Causes Remedes


1. L’embrayage resiste ou ne - Disques de l’embrayage Remplacer les pièces défectueuses
s’enclenche pas. (Le chariot endommagés
bouge au Point Mort). - Pannes mécaniques Remplacer les pièces défectueuses
- Absence de jeu dans le bloc Augementer le jeu suivant les
embrayage normes
- Electrovannes bloquée Reparer ou remplacer
- Sélecteur bloquée Nettoyer et polir
- Panne électrique Reparer
- Corps étrangers ou impuretés Demonter et nettoyer
dans le distributeur

2. L’embrayage n’embrayage pas - Pression basse Voir chapitre “Basse pression d’huile”
(le chariot ne bouge pas) - Electrovanne bloquée Reparer or remplacer
- Sélecteur bloquée Nettoyer et polir
- Panne électrique Reparare
- Corps étranger ou impuretés Demonter et nettoyer.
dans le distributeur

3. Le chariot ne bouge pas - Pression basse Voir chapitre “Basse pression d’huile”
- Bagues de tenue usées ou Remplacer les pièces défectueuses.
cassées

160
TXL 15/25

Problemi vari
Further problems
Sonstige probleme
Problemes divers
6
I Problemi Cause Rimedi
1. Rumore idraulico o ronzio di - Aria nel circuito idraulico o basso Controllare il livello olio e aggiun-
valvola livello olio gerne se manca. Far girare il moto-
re a 1200 giri al minuto per elimina-
re l’aria

2. Rumore di ingranaggi in Marcia - Denti di ingranaggi rotti, incrinati Sostituire le parti difettose
Avanti e Retromarcia o usurati
- Cuscinetti usurati o danneggiati Sostituire.

GB Problems Causes Remedies


1. Hydraulic noises or valve hums - Air in the hydraulic circuit or low Check the oil level and add if failing.
oil level Make the engine run at 1200 r.p.m.
to eliminate the air.

2. Noises in Forward and Reverse - Broken, cracked or worn gear Replace the damaged parts
Gear teeth
- Worn or damaged bearings Replace.

D Probleme Ursachen Abhife


1. Hydraulik-oder Ventilgeräusche - Luft im Hydraulikkreislauf oder Entlüften und Ölstand korrigieren
niedriger Ölstand Motor mit 1200 UpM laufe lassen,
um die Luft zu beseitigen

2. Getriebegeräusche im - Gebrochene, gerissene oder Defekte Teile austauschen


Vorwärtsgang und Rückwärtsgang verschlissene Zähne
- Verschlissene oder beschädigte Austauschen.
Lager

F Problemes Causes Remedes


1. Bruit hydraulique ou - Air dans le circuit hydraulique ou Contrôler le niveau d’huile et en
bourdonnement d’une niveau d’huile trop bas ajuouter le cas échéant. Faire tourner
électrovanne le moteur à 1200 tours minute pour
éliminer l’air

2. Bruit de l’engrenage en Marche - Dents cassées, felées ou usées Remplacer les pièces défectueuses
Avant, et Marche Arrière sur l’engrenage
- Coussinets usés ou détériorés Remplacer.

161
TXL 15/25

Cattivo funzionamento in Folle


Bad working in idle
Schlechter leerlaufbetrieb
Mauvais fonctionnement au Point Mort

I Problemi Cause Rimedi


1. Trascinamento in avanti o in - Dischi della frizione svergolati o Sostituire le parti difettose
Retromarcia guasti meccanici della frizione

2. La Marcia Avanti o Retromarcia - Guasto elettrico Riparare


rimane innestata - Elettrovalvola inceppata Riparare o sostituire
- Selettore bloccato Pulire e lucidare
- Impurità o copri estranei nel Smontare e pulire.
distributore

GB Problems Causes Remedies


1. Truck moving Forward and - Warped clutch plates or clutch Replace the faulty parts
Reverse Gears at idle mechanical failure

2. The Forward and Reverse Gears - Electric breakdown Repair


remain engaged - Sticking electrovalve Repair or replace
- Sticking selector Clean and polish
- Impurities or foreign bodies in valve Dismantle and clean.

D Probleme Ursachen Abhife


1. Fahrzeug bewegt sich im Leerlauf - Verformte Kupplungslamellen Defekte Teile ersetzen.
vorwärts und Rückwärtsgang

2. Vorwärtsgang und Rückwärtsgang - Stromausfall Reparieren


bleibt eingeschaltet - Festsitzendes Elektroventil Reparieren oder ersetzen
- Blockierter Wahlschalter Reinigen
- Verunreinigungen oder Ausbauen und reinigen.
Fremdkörper im Verteiler

F Problemes Causes Remedes


1. Entraînement en Avant ou en - Disques de embrayage détériorés Remplacer les pièces défectueuses.
Marche Arrière ou pannes mécaniques de
l’embrayage

2. La Marche Avant ou Marche - Electrovanne bloquée Reparer ou remplacer


Arrière reste embrayée - Sélecteur bloqué Nettoyer et polir
- Panne électrique Reparer
- Corps étrangers ou impuretés Démonter et nettoyer.
dans le distributeur

162
TXL 15/25

Surriscaldamento della trasmissione


Transmission overheating
Getribeüberhitzung
Surcharge de la transmission
6
I Problemi Cause Rimedi

Surriscaldamento - Radiatore troppo piccolo o Tutte le linee olio esterne ed il


passaggio olio inadeguati radiatore devono permettere il libe-
ro passaggio dell’olio ed aver una
capacità di scambio adeguata
- Radiatore difettoso Sostituire
- Convertitore danneggiato Sostituire
- Livello olio non corretto Ripristinare livello
- Filtro aspirazione intasato Pulire
- Uso improprio o scorretto della Non usare la macchina in stallo
macchina prolungato
- Pressione della pompa bassa, Controllare le pressioni della
pompa usurata o danneggiata trasmissione. Ispezionare il gruppo
della pompa e verificare se le pres-
sioni sono basse. Sostituire il grup-
po della pompa se usurato o
danneggiato
- Frizioni che slittano Controllare gli anelli di tenuta e le
pressioni
- Bassa pressione Vedere “Pressione olio bassa”
- Olio emulsionato Controllare tipo di olio e livello
- Sensore di temperatura difettoso Sostituire.

GB Problems Causes Remedies


Overheating - Too small cooler or oil hoses All the external oil lines and the
cooler must allow the passage of
the oil and have an adequate
exchange capacity
- Faulty cooler Replace
- Damaged converter Replace
- Low oil level Restore the level
- Obstructed suction filter Clean
- Improper use of equipment Do not use the engine in extended
stall
- Low pump pressure, pump worn Check the pressures. Inspect the
or damaged pump if pressures are low. Replace
the pump if worn or damaged
- Slipping clutches Check the seal rings and pressures
- Low pressure See “Low oil pressure”
- Emulsified oil Check the type of oil or low oil level
- Faulty temperature sensor Replace.

163
TXL 15/25

Getriebeüberhitzung
Surcharge de la transmission

D Probleme Ursachen Abhife


Überhitzung - Zu kleiner Kühler oder Alle externen Ölleitungen und der
Verbindungsschläuche (Rohre) Kühler müssen genügend große
Querschnitte aufweisen, und der
Kühler eine genügend große
Kühlleistung
- Beschädigter Kühler Austauschen
- Beschädigter Wandler Austauschen
- Flascher Ölstand Ölstand korrigieren
- Blockierter Saugfilter Reinigen
- Falsch eingestellter Motor oder Eistellung nach Vorschrift korrigieren
zu langes Fahren im Getriebe nicht länger als 10 Sek.
Festbremspunkt festbremsen
- Niedriger Pumpendruck Drücke prüfen. Bei niedrigen Drücken,
Drücken,Pumpengruppe unter-
suchen. Verschlissene oder be-
schädigte Pumpengruppe ersetzen
- Rutschende Kupplungen Dichtringe und Druck prüfen
- Niedriger Druck Siehe “Zu niedriger Öldruck”
- Schäumendes Öl Öl nach Vorschrift tauschen
- Defekter Temperaturfühler Austauschen.

F Problemes Causes Remedes


Surcharge - Radiateur trop petit ou passages Toutes les conduites d’huile
d’huile inadéquats extérieures et le radiateur doivent
permettre le libre passage d’huile
et avoir une capacité d’échange
appropriée
- Radiateur ecrassée Remplacer
- Convertisseur endommagé Remplacer
- Niveau d’huile incorrect Rectifier le niveau d’huile
- Filtre d’aspiration bouché Nettoyer
- Utilisation incorrecte du véhicule Ne pas utiliser le véhicule
- Basse pression de la pompe Contrôler la pression de la
transmission
- Pompe usée ou endommagée Contrôler le groupe de la pompe
dans le cas où les pressions sont
trop basses. Remplacer le groupe
pompe si celui-ci est usé ou
endommagé
- Embrayages qui patinent Contrôler les bagues de tenue et
les pressions
- Basse pression Voir chapitre “Basse pression de
l’huile”
- Huile “émultionée” Contrôler le type d’huile
- Sonde de température Remplacer.
défectueuse

164
TXL 15/25

ATTREZZI SPECIALI - DISEGNI


SPECIFIC TOOLS - DRAWINGS
SPEZIALWERKZEUG - ZEICHNUNG
OUTILS SPECIAUX - PLAN
7
INDICE / INDEX / INHALTSVERZEICHNIS / INDEX

Disegno Denominazione pag.


Drawing. Description page
Zeichnung Beschreibung Seite
Plan Designation pag.

3VT00293 Attrezzo per bloccaggio e sbloccaggio ghiera mozzo ruota 166


Retaining ring in the clutch to release/look the wheel hub
Haltering in der Kupplung zum Öffnen/Anziehen der Nutmutte
Outil pour blocage et deblocage de frette moyeu de la roue.
4A42440/1 Attrezzo per posizionamento assiale pignone conico 167
Pipe for bevel pinion assembly
Rohr für Montage des Kegelritzel
Outil pour positionnement axial de pignon conique.
4A42440/2 Attrezzo per bloccaggio e sbloccaggio ghiera pignone conico 168
Retaining ring in the clutch to release/look the slotted nut
Haltering in der kupplung zum offnen/anziehen der Nutmutte
Outil pour blocage et deblocage de frette de pignon conique.
48A11850 Attrezzo per smontaggio e montaggio anello elastico 169
Holder for compress the platespring to assembly or deassembly the snap ring
Halter zum Niederdrücken der Flachfeder, damit Sicherungsring montiert oder
entferntwerden kann
Outil pour démontage et montage de segment.
48A12093 Punzone per montaggio anello di tenuta 170
Bolt to assemble shaft seal
Bolzen zur Montage von Wellendichtring
Poinçon pour montage bague d’étanchéité.
48A12125 Punzone per montaggio anello di tenuta 171
Bolt to assemble shaft seal
Bolzen zur Montage von Wellendichtring
Poinçon pour montage bague d’étanchéité.
4902058 Punzone per piantaggio anello di tenuta su carter 172
Bolt for assembly a shaft seal
Bolzen zur Montage von Wellendichtring
Poinçon pour positionnement de bague d’étanchéité sur carter.
4902081 Punzone per montaggio anello di tenuta 173
Bolt to assemble shaft seal
Bolzen zur Montage von Wellendichtring
Poinçon pour montage bague d’étanchéité.
4902836 Chiave per chiusura ghiera pignone 174
Slotted nut spanner for bevel pinion
Nutmutterschlüssel für kegelritzel
Clef de fermeture de frette de pignon.

165
TXL 15/25

Ø 82

Ø 68
27

ZONA PER MARCATURA

37
N. ATTREZZO 3VT00293
DIS. ELEMENTO _______

12,70
12,70

7,5 6.3
d

b
c

MODIFICHE

Tolleranze generali per dimensioni di parti lavorate DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
senza indicazioni a disegno: secondo tab. UNI 7226-73
FORI H13
Proteggere le filettature dalla cementazione
ALBERI h13
QUOTE LINEARI J/I13
GHIERA
ANGOLI ± 30' ELEMENTO DIS. N Raggi e smussi non quotati = 0.5
FILETTATURE 6H/6g

ATTREZZATURA
CAD
DRAWING
Chiave per montaggio ghiera NO HANDLING
GRAZIANO Trasmissioni S.p.A.
WITHOUT CAD SYSTEM
10090 Cascine Vica, RIVOLI (TO)
Macchina operatrice N. Op.N.
Disegnato Scala
1:1 Foglio Dis. N
Visto Data
1/1 3VT00293

166
TXL 15/25

-0,02
Ø 80 -0,04

2 x 30°
0,8
2
sm
204 - 0,5
0

2 x 30°
45°
18

sm
2
0,8

Ø 60 ~

Ø 90 -0,072
-0,094
X 0,01

3,2 0,8

1 C40 bon
d

b
c

N.Part Denom.particolare Quant. Materiale o normale Trattamamento Dimens. MODIFICHE

Tolleranze generali per dimensioni di parti lavorate DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
senza indicazioni a disegno: secondo tab. UNI 7226-73
FORI H13
ALBERI h13
Proteggere le filettature dalla cementazione
QUOTE LINEARI J/I13
ANGOLI ± 30' ELEMENTO DIS. N Raggi e smussi non quotati = 0.5
FILETTATURE 6H/6g

ATTREZZATURA
CAD
DRAWING
Attrezzo per posizionamento assiale pignone conico NO HANDLING
GRAZIANO Trasmissioni S.p.A.
WITHOUT CAD SYSTEM
10090 Cascine Vica, RIVOLI (TO)
Macchina operatrice N. Op.N.
Disegnato Scala
1:2 Foglio Dis. N
Visto Data
12/01/88 4A42440/1

167
168
57° 57°

2
sm

2
sm
Ø 82
Ø 142

n. 3 fori su Ø 112
2
Ø 10 H7 sm


12

12

2
sm
20 n. 3 spine cilindriche Ø 10 L= 55mm
c
d
b
a

MODIFICHE

Tolleranze generali per dimensioni di parti lavorate DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
senza indicazioni a disegno: secondo tab. UNI 7226-73
FORI H13
ALBERI h13
Proteggere le filettature dalla cementazione
QUOTE LINEARI J/I13
ANGOLI ± 30' ELEMENTO DIS. N Raggi e smussi non quotati = 0.5
FILETTATURE 6H/6g

ATTREZZATURA
CAD
Attrezzo per bloccaggio e sbloccaggio ghiera DRAWING
GRAZIANO Trasmissioni S.p.A. NO HANDLING
WITHOUT CAD SYSTEM
10090 Cascine Vica, RIVOLI (TO) pignone conico
Macchina operatrice N. Op.N.
Disegnato Scala Foglio Dis. N
1:2
TXL 15/25

Visto Data 4A42440/2


TXL 15/25

110
Ø 15

30°

30
5

=
40
=

Ø 73

Ø 85

12,5
Smussare
d

b
c

MODIFICHE

Tolleranze generali per dimensioni di parti lavorate DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
senza indicazioni a disegno: secondo tab. UNI 7226-73
FORI H13
ALBERI h13
Proteggere le filettature dalla cementazione
QUOTE LINEARI J/I13
ANGOLI ± 30' ELEMENTO DIS. N Raggi e smussi non quotati = 0.5
FILETTATURE 6H/6g

ATTREZZATURA
CAD
DRAWING
Attrezzo per smontaggio e montaggio anello elastico NO HANDLING
GRAZIANO Trasmissioni S.p.A.
WITHOUT CAD SYSTEM
10090 Cascine Vica, RIVOLI (TO)
Macchina operatrice N. Op.N.
Disegnato Scala
1:1 Foglio Dis. N
Visto Data
12/06/92 48A11850

169
TXL 15/25

R.40 sferico

Ø 120

Ø 80

30°
R2

6
30

R10 Ø 80 zigrinato
5

15°

180
129

50
+0.1
+0.2
16

R2

Ø 60 +0.1
+0.2

Ø 70,5 Marcare N. dis. "48A12093"


e cod. elemento "3.21119.3"
Ø 90,5

6.3

Punzone 1 C40 Bon.


d

b
a
c

N.Part Denom.particolare Quant Materiale o normale Trattam. Dimens. MODIFICHE

Tolleranze generali per DENOMINAZIONE ELEMENTO Tolleranze di forma e posiz


dimensioni di parti
lavorate senza indicazioni secondo tab. UNI 7226-73
a disegno:
Proteggere le filettature
FORI H13 Gruppo ruota dx e sx dalla cementazione
presente disegno a norma delle vigenti leggi

ALBERI h13
QUOTE LINEARI J/j13
E'vietato riprodurre o comunicare a terzi il

ELEMENTO DIS. N∞ Raggi e smussi non


ANGOLI ±30'
FILETTATURE 6H/6g 3.21119.3 quotati = 0.5

GRAZIANO Trasmissioni S.p.A. ATTREZZATURA


CAD
Punzone per piantaggio guarnizione 70218 DRAWING
NO HANDLING
WITHOUT CAD SYSTEM
STABILIMENTO DI BARI
Macchina operatrice BANCO DI MONTAGGIO N∞ GT Op.N∞

Disegnato CAPORALE Scala


1:2 Foglio Dis. N∞

Visto Data
11/05/00 1/1 48A12093

170
TXL 15/25

Ø 100

Ø 35
r 25 sferico Flammato

R5

20
6
Ø 35 zig.

R5

150
120

Ø 46

45°
8
10

Ø 20
Marcare N. dis. "48A12125"
e cod. elemento "3210723" Ø 36 h11 Lucidato con tela

6,3

Punzone 1 C40 BON


d

b
c

N.Part Denom.particolare Quant. Materiale o normale Trattamamento Dimens. MODIFICHE

Tolleranze generali per dimensioni di parti lavorate DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
senza indicazioni a disegno: secondo tab. UNI 7226-73
FORI H13
Proteggere le filettature dalla cementazione
ALBERI h13
QUOTE LINEARI J/I13
Trasmissione ad una velocità TXL25
ANGOLI ± 30' ELEMENTO DIS. N Raggi e smussi non quotati = 0.5
FILETTATURE 6H/6g 3.21072.3
ATTREZZATURA
CAD
DRAWING
Attrezzo per piantaggio guarnizione 71448 NO HANDLING
GRAZIANO Trasmissioni S.p.A.
WITHOUT CAD SYSTEM
10090 Cascine Vica, RIVOLI (TO)
Macchina operatrice N. Op.N.
Disegnato Scala
1:1 Foglio Dis. N
Visto Data
28/01/93 48A12125

171
TXL 15/25

Ø 45
Ø 40
Indurire Ø 20
r 40 sferico

02 4902058/2

10
60 Tratto Zigrinato
110
180

160
45°

r3
Sm 2
60
18

Sm 1
Ø 31,3
Sm 1x 30° Ø 39,5 Lucidare
Ø 60 Sm 2
5

Filo superiore banco


22

Ø 40

Ø 79
01 4902058/1

Ø 125

01 Base 1 C40 Bon.


02 Punzone 1 C40 Bon.
d

b
c

N.Part Denom.particolare Quant. Materiale o normale Trattamamento Dimens. MODIFICHE

Tolleranze generali per dimensioni di parti lavorate DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
senza indicazioni a disegno: secondo tab. UNI 7226-73
FORI H13
ALBERI h13
Proteggere le filettature dalla cementazione
QUOTE LINEARI J/I13
ANGOLI ± 30' ELEMENTO DIS. N Raggi e smussi non quotati = 0.5
FILETTATURE 6H/6g

ATTREZZATURA
CAD
DRAWING
Punzone per piantaggio anello di tenuta su carter NO HANDLING
GRAZIANO Trasmissioni S.p.A.
WITHOUT CAD SYSTEM
10090 Cascine Vica, RIVOLI (TO)
Macchina operatrice N. Op.N.
Disegnato Scala
1:2 Foglio Dis. N
Visto Data
1/1 4902058

172
TXL 15/25

Ø 40

r 40 sferico

10
80 Tratto Zigrinato
130

100
r6
Sm
2
5

r0
13

,5
ma
x
1,5
1,5

Sm
Sm

Ø 25
r1
,5

- 0,2
Ø 60 0
Lucidato
- 0,1
Ø 80 - 0,2

Ø 90

6,3

Punzone 1 C40 bon Brunito


d

b
c

N.Part Denom.particolare Quant. Materiale o normale Trattamamento Dimens. MODIFICHE

Tolleranze generali per dimensioni di parti lavorate DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
senza indicazioni a disegno: secondo tab. UNI 7226-73
FORI H13
ALBERI h13
Proteggere le filettature dalla cementazione
QUOTE LINEARI J/I13
ANGOLI ± 30' ELEMENTO DIS. N Raggi e smussi non quotati = 0.5
FILETTATURE 6H/6g

ATTREZZATURA
CAD
DRAWING
Punzone per montaggio anello di tenuta NO HANDLING
GRAZIANO Trasmissioni S.p.A.
WITHOUT CAD SYSTEM
10090 Cascine Vica, RIVOLI (TO)
Macchina operatrice N. Op.N.
Disegnato Scala
1:1 Foglio Dis. N
Visto Data
1/1 4902081

173
174
20 15 5
60 °

r4
60°

Ø 70

Ø 20
Ø 30

Ø 47,5
17 B B

-0,2
Sm 2x45° 7 -0,3

Testa con esagono incassato


ricavato da vite S.T.E.I. M20

12,5 3,2
c
d
b
a

1 38 NCD 4 Bon
Indurire sulla parte annerita N.Part Denom.particolare Quant. Materiale o normale Trattamamento Dimens. MODIFICHE

Tolleranze generali per dimensioni di parti lavorate DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
senza indicazioni a disegno: secondo tab. UNI 7226-73
FORI H13
ALBERI h13
Proteggere le filettature dalla cementazione
QUOTE LINEARI J/I13
r4 r4 ANGOLI ± 30' ELEMENTO DIS. N Raggi e smussi non quotati = 0.5
FILETTATURE 6H/6g

vista B ATTREZZATURA
CAD
DRAWING
Chiave per chiusura ghiera pignone NO HANDLING
GRAZIANO Trasmissioni S.p.A.
WITHOUT CAD SYSTEM
1 Sm 10090 Cascine Vica, RIVOLI (TO)
Sm 1
Macchina operatrice N. Op.N.
Disegnato Scala Foglio Dis. N
1:1
1/1
TXL 15/25

Visto Data 4902836


TXL 15/25

ATTREZZI SPECIALI - DISEGNI


SPECIFIC TOOLS - DRAWINGS
SPEZIALWERKZEUG - ZEICHNUNG 7
OUTILS SPECIAUX - PLAN

INDICE / INDEX / INHALTSVERZEICHNIS / INDEX

Réf. MANITOU . . . . .Code

823 402 . . . . . . . . .4903030


823 370 . . . . . . . . .48A11850
823 371 . . . . . . . . .4902403/1
823 372 . . . . . . . . .4902403/2
823 373 . . . . . . . . .4902404
823 374 . . . . . . . . .4902082
823 375 . . . . . . . . .4A42440/1
823 376 . . . . . . . . .4902058
823 377 . . . . . . . . .4902107
823 378 . . . . . . . . .4902836
823 379 . . . . . . . . .4A42440/2
823 380 . . . . . . . . .4902081
823 381 . . . . . . . . .4902076
823 382 . . . . . . . . .48A12093
823 383 . . . . . . . . .48A12125
823 384 . . . . . . . . .3VT00293
823 385 . . . . . . . . .3.16475.3

822 142 . . . . . . . . .3.17113.3

175
TXL 15/25

I I dati contenuti in questa pubblicazione potrebbero risultare non aggiornati in consequen-


za di modifiche adottate dal Costruttore, in qualunque momento, per ragioni di natura
tecnica o commerciale nonché per adattamento ai requisiti di legge nei diversi Paesi.
Descrizioni e fotografie possono riferirsi ad equipaggiamenti non di serie.

GB The data in this edition may prove not to be up to date due to modification made by the
manufacturer, which may become necessary for technical or commercial reasons, as well
as meeting legal requirements of various countries.
Descriptions and photos might refer to non-serial equipment.

D Die in dieser Ausgabe enthaltenen Daten mögen nicht dem neuesten Stand entsprechen,
da Änderungen aus technischen oder wirtschaftlichen Gesichtspunkten sowie gesetzli-
chen Vorschriften unterschiedlicher Länder jederzeit durchgeführt werden können.

F Les données figurant dans cette publication sont forunies à titre indicatif, suite à des
modifications apportées par le constructeur à n’importe quel moment, pour des raisons
de genre technique ou commercial, ainsi que pour une adaption due aux lois des dif-
férents pays.
Les descriptions et les photos peuvent se référer à des équipements hors série.

MANUALE NORME DI RIPARAZIONI TXL 15/25 3ª edizione rev. a


Aggiornato il 15-11-2004
Realization: Studio ELLETec - Torino.
GEAR BOX DISASSEMBLY/
TRANSMISSION
20-3-19 EN

16 / 01 / 2006
MANUALE NORME DI RIPARAZIONI
REPAIR INSTRUCTIONS
REPARATURANLEITUNG
NORMES DE REPARATION

TXL 30 / ST

3
TXL 30/ST

I PREFAZIONE

Il presente manuale, destinato alla clientela ed al personale addetto alla manutenzione, contiene le infor-
mazioni e istruzioni per la manutenzione e la riparazione della trasmissione GRAZIANO Trasmissioni.
È tassativamente raccomandato ai meccanici di leggere attentamente le istruzioni riprese nel presente
manuale, al fine di familiarizzarsi con i vari elementi della trasmissione, con il funzionamento delle parti,
con la procedura da adottarsi, per la ricerca di guasti e delle messe a punto da effettuare; i meccanici
sono inoltre invitati a riferirsi al presente manuale ogni volta che eseguiranno operazioni di manutenzione
o di riparazione.
Nel caso che si necessiti di pezzi per la riparazione o la sostituzione di elementi, si dovranno utilizzare
soltanto pezzi approvati per GRAZIANO Trasmissioni, cioè i pezzi indicati nella nomenclatura dei pezzi
di ricambio in vigore. L’impiego di pezzi approssimativamente equivalenti o non approvati può portare
pregiudizio al funzionamento ed alle prestazioni del materiale. GRAZIANO Trasmissioni Equipment
Company non garantisce i pezzi utilizzati per la riparazione o la sostituzione che non siano quelli da lei
forniti o approvati; inoltre la sua garanzia non interverrà in caso di incidenti provocati dall’impiego di tali
pezzi.
Importante:
Ad ogni ordine di pezzi, indicare al concessionario il numero di serie ed il numero della
trasmissione.

GB FOREWORD

This manual has been prepared to provide the customer and the maintenance personnel with information
and instructions on the maintenance and repair of the transmission GRAZIANO Trasmissioni.

In order to become familiar with the various parts of the transmission, its principle of operation, trouble
shooting and adjustments, it is important for the mechanic to study the instructiotns of in this manual
carefully and use it as a reference when performing maintenance and repair operations.
Whenever repair or replacement of component parts is required, only GRAZIANO Trasmissioni appro-
ved spares as listed in the applicable spare catalogue should be used. Use of “will-fit” or non-approved
parts may endanger proper operation and performance of the equipment.
GRAZIANO Trasmissioni Equipment Company does not warrant repair or replacement not original parts;
nor failures resulting from the use thereof, which are not supplied by or approved by the GRAZIANO
Trasmissioni Equipment Company.
Important:
Always furnish the Distributor with the transmission serial and model number when ordering
parts.

D VORWORT
Diese Handbuch soll dem Kunden und dem Wartungspersonal zur Information und Hilfestellung in Bezug
auf Wartung und Instandsetzung des GRAZIANO Trasmissioni -Getriebes dienen.
Der Aufwand für die regelmässige Wartung und Überprüfung des Ölstandes und der Einstellungen zahlt
sich durch störungsfreien Betrieb aus. Es ist zu empfehlen, dass die Mechaniker sich mit dem Handbuch
und der Funktion des Getriebes vertraut machen, sowie die Anweisungen befolgen. Bei der Instandsetzung
oder dem Austausch von Einzelteilen müssen ausschliesslich GRAZIANO Trasmissioni -Originalteile
verwendet werden, die im Ersatzteilverzeichnis aufgeführt sind.
Bei Verwendung von Nicht- GRAZIANO Trasmissioni -Originalteilen ist die optimale Funktion nicht
gewährleistet. Fernerhin erlischt jeglicher Garantieanspruch.
Wichtig:
Bei der Bestellung von Ersatzteilen bitten wir Gerätetyp und Seriennummer des Getriebes
anzugeben. Technische Änderungen vorbehalten.

iii
TXL 30/ST

F PREFACE

Ce manuel, destiné à la clientèle et au personnel préposé à l’entretien, contient tous les renseignements
et les instructions pour l’entretien et la réparation de la transmission GRAZIANO Trasmissioni.
C’est rigoureusement récommandé aux mécaniciens de lire soigneusement les instructions reprises dans
ce manuel, pour mieux comprendre les plusieurs éléments qui composent la transmission, le fonctionne-
ment del pièces, la procédure plus propre à suivre, pour la recherche de dérangements et des mises au
point à effectuer; en outre, les mécaniciens sont invités à consulter ce manuel en vue de chaque opéra-
tion d’entretien ou de réparation. Pour éventuelles réparations ou substitutions d’éléments, on devra utili-
ser uniquement des pièces approuvées pour GRAZIANO Trasmissioni, c’est à dire les pièces indiquées
dans la nomenclature des pièces de rechange en vigueur.
L’emploi de pièces approximativement équivalentes ou pas approuvées, peut compromettre le fonction-
nement et les performances du matériel. GRAZIANO Trasmissioni Equipment Company ne garanti
pas les pièces utilisées pour la réparation ou la substitution qui ne soient pas celles par elle fournies ou
approuvées; en outre, sa garantie n’est pas valable en cas d’incidents causés de l’emploi de ces pièces.
Important:
Dans chaque ordre de pièces, indiquer au concessionaire le numéro de série et le numéro de la
transmission.

iv
TXL 30/ST

INDICE I

///
! NORME DI SICUREZZA ix

DATI TECNICI 1
1 Trasmissione TXL 30/ST 1
Schema elettrico della trasmissione 3
Schema cinematico della trasmissione 4
Descrizione generale della trasmissione 5
Viste generali TXL 30/ST 10
Sezione generale 12
CIRCUITO IDRAULICO DELLA TRASMISSIONE - DISTRIB. SUPERMODULATO 14
2 Schema circuito idraulico 19
Schema A - Cambio in Folle 21
Schema B - Retromarcia, Carrello avviato 23
Schema C - Retromarcia in Inching 25
SMONTAGGIO E MONTAGGIO TRASMISSIONE 26
3 Istruzioni generali
Conservazione ed utilizzo del prodotto
26
30
Attrezzi speciali 32
Smontaggio e montaggio trasmissione 35
Revisione scatola Convertitore 37
Smontaggio e rimontaggio distributore Supermodulato 41
Smontaggio e rimontaggio gruppi ruote - 1ª Versione 56
Sostituzione ganasce 57
Registrazione accoppiamento ganasce 62
Smontaggio mozzi ruote 64
Smontaggio Freni 65
Rimontaggio gruppi ruote - 1ª Versione 67
Rimontaggio Freni 68
Rimontaggio mozzi ruote - Norme registrazione cuscinetti 70
Smontaggio e rimontaggio gruppi ruote - 2ª Versione 74
Rimontaggio mozzi ruote 77
Norme registrazione cuscinetti 78
Smontaggio trasmissione 81
Revisione pompa olio e coperchio trasmissione 83
Revisione frizioni 88
Revisione Differenziale 96
Rimont. differenziale e posizionamento coppia conica con relative registrazioni 102
Rimontaggio trasmissione 108
Controllo dentatura coppia conica 113
Comando azionamento inching schema di registrazione 119
TIPO OLIO 120
4 DATI ACCOPPIAMENTO MOTORE - Istruzioni di montaggio 121
Accoppiamento motore con P. d. F. 122
Controllo accoppiamento motore-cambio 125
DATI TECNICI - PRELIEVO PRESSIONE Distributore Supermodulato 126
RODAGGIO 128
5 MANUTENZIONE PERIODICA 129
RICERCA DIFETTI DI FUNZIONAMENTO 131
6 A - Indicazioni generali
B - Indicazioni di intervento
131
131
C - Diagnostica 135
Difetti di funzionamento comuni a tutte le marce 137
Anomalie di funzionamento a marce innestate 141
Problemi vari 143
Cattivo funzionamento in Folle 144
Surriscaldamento della trasmissione 145
ATTREZZI SPECIALI - DISEGNI 147
7

v
TXL 30/ST

GB INDEX

///
! SAFETY RULES.................................................................................................................................................................................... xi

TECHNICAL DATA - TRANSMISSION TXL 30/ST........................................................................................................... 1


1 Transmission TXL 30/ST....................................................................................................................................................... 1
Circuitry........................................................................................................................................................................................... 3
Kinematic diagram of the transmission...................................................................................................................... 4
General description............................................................................................................................................................................. 5
TXL 30/ST General views ................................................................................................................................................... 10
TXL 30 - TXL 30/ST General section............................................................................................................................ 12
TRANSMISSION HYDRAULIC SYSTEM - SUPERMODULATING DISTRIBUTOR.................................... 15
2 Hydraulic diagram - Supermodulating Distributor...............................................................................................
SCHEME A of hydraulic diagram - Gear in neutral position - Supermodulating Distrib.............
19
21
SCHEME B of hydraulic diagram - Reverse gear, Started lift truck - Supermod. Distrib........... 23
SCHEME C of hydraulic diagram - Inching Reverse gear - Supermodulating Distrib.................. 25
DISASSEMBLING AND RE-ASSEMBLING OF TRANSMISSION ....................................................................... 27
3 General instructions................................................................................................................................................................ 27
Storage and service instructions ......................................................................................................................... 30
Specific tools ................................................................................................................................................................... 32
Disassembling and assembling transmission......................................................................................................... 35
Converter case overhauling .................................................................................................................................... 37
Dismantling and re-assembling of Supermodulating Distributor............................................................... 41
Dismantling and re-assembling Wheel hubs - Brakes (1st Version).......................................................... 56
Shoes replacement ...................................................................................................................................................... 57
Shoes setting procedure .......................................................................................................................................... 62
Brakes disassembly ..................................................................................................................................................... 65
Wheel assembly re-assembling - (1st Version) ............................................................................................ 67
Brake reassembly .......................................................................................................................................................... 68
Wheel hubs reassembling - Bearings adjustment specifications ................................................... 70
Dismantling and re-assembling Wheel hubs - Brakes (2nd Version)........................................................ 74
Wheel hubs reassembling ........................................................................................................................................ 77
Bearings adjustment specifications .................................................................................................................. 78
Dismantle transmission ........................................................................................................................................................ 81
Oil pump and transmission cover overhaul .................................................................................................. 83
Clutches overhauling ................................................................................................................................................... 88
Differential overhauling .............................................................................................................................................. 96
Differential reassembly and bevel gear set positioning with relevant adjustment ................ 102
Transmission reassembly .................................................................................................................................................... 108
Bevel pinion-and-ring gear set inspection .................................................................................................... 113
Control inching - assy ................................................................................................................................................ 119
OIL SPECIFICATIONS...................................................................................................................................................................... 120
4 DATA FOR COUPLING TO ENGINE - Assembling instructions........................................................................... 121
Engine with P. T. O. coupling............................................................................................................................................ 122
Engine gearbox coupling check-up............................................................................................................................... 124
TECHNICAL DATA - Supermodulating Distributor pressure measurement................................................... 126
RUNNING-IN ......................................................................................................................................................................................... 128
5 PERIODIC SERVICING ................................................................................................................................................................... 129
TROUBLE SHOOTING PROCEDURE ................................................................................................................................... 132
6 A- General information...........................................................................................................................................................132
B- Problems hints..................................................................................................................................................................... 132
C- Diagnosis................................................................................................................................................................................ 135
Common running faults in all gears.................................................................................................................... 138
Running faults with gears engaged.................................................................................................................... 141
Further problems............................................................................................................................................................ 143
Fault finding in bad working in idle...................................................................................................................... 144
Transmission overheating.......................................................................................................................................... 145

7 SPECIFIC TOOLS - DRAWINGS................................................................................................................................................ 147

vi
TXL 30/ST

INHALTSVERZEICHNIS D

///
! SICHERHEITS VORSCHRIFTEN................................................................................................................................................. xiii

TECHNISCHE DATEN ....................................................................................................................................................................... 2


1 Getriebe TXL 30/ ST ................................................................................................................................................................. 2
Schaltplan....................................................................................................................................................................................... 3
Kinematikdiagramm des Getriebes................................................................................................................................ 4
Allgemeine Beschreibung................................................................................................................................................................ 5
Generelle Ansicht TXL 30/ST............................................................................................................................................. 10
Allgemeine Hinweise TXL 30/ ST...................................................................................................................................... 12
GETRIEBE-HYDRAULIKSYSTEM - STEUERBLOCK SUPERMODULIERT.................................................... 16
2 Hydraulikdiagramm - Steuerblock Supermoduliert.............................................................................................. 19
SCHEMA A Hydraulikdiagramm - Getriebe in neutralstellung - Steuerblock Supermod............ 21
SCHEMA B Hydraulikdiagramm - Getriebe in Rkw., Fahrzustand - Steuerblock Supermod... 23
SCHEMA C Hydraulikdiagramm - Getriebe in Rkw. Inching - Steuerblock Supermoduliert.... 25
GETRIEBE DEMONTAGE UND MONTAGE.......................................................................................................................... 28
3 Haupt instruktionnen............................................................................................................................................................... 28
Lager- und Service Hinweise ............................................................................................................................................ 31
Montagewerkzeug ................................................................................................................................................................... 32
Getriebe Demontage und Montage............................................................................................................................... 35
Überholung Wandlergehäuse ................................................................................................................................. 37
Demontage und Zusammenbau Steuerblock Supermoduliert..................................................................... 41
Bremstrommel Demontage und montage (1. Version)....................................................................................... 56
Austausch Backen ........................................................................................................................................................ 57
Einstellung der Backen-Zufügung ....................................................................................................................... 63
Ausbau Radnaben ......................................................................................................................................................... 64
Bremsendemontage ..................................................................................................................................................... 65
Bremsgruppe Montage - 1. Version ................................................................................................................... 67
Zusammensetzen der Bremse ............................................................................................................................... 68
Einbau Bremstrommel - Vorschriften für Lagermontage ...................................................................... 71
Bremstrommel Demontage und montage (2. Version)....................................................................................... 74
Einbau Bremstrommel ................................................................................................................................................ 77
Vorschriften für Lagermontage .............................................................................................................................. 79
Getriebe Demontage............................................................................................................................................................... 81
Ausprfüng der Ölpumpe und des Deckels ..................................................................................................... 83
Ausprüfung der Kupplungen ................................................................................................................................... 88
Ausprüfung der Differential ...................................................................................................................................... 96
Montageeinstellvorschrift für Kegelradsatz mit Differential ................................................................. 103
Getriebe montage..................................................................................................................................................................... 108
Tragbildkontrolle der Kegelräder und Fehlersuche ................................................................................... 113
Inching- Antrieb Einstellplan ................................................................................................................................... 119
ÖLSPEZIFIKATION ............................................................................................................................................................................. 120
4 EINBAUANWEISUNG ....................................................................................................................................................................... 121
Einbau-Motor mit Nebenabtrieb ..................................................................................................................................... 122
Rundlaufkontrolle ..................................................................................................................................................................... 125
TECHNISCHE DATEN - Druckmessung Steuerblock Supermoduliert............................................................... 126
INBETRIEBNAHME ............................................................................................................................................................................. 128
5 REGELMÄßIGE WARTUNG .......................................................................................................................................................... 130
FEHLERSUCHE..................................................................................................................................................................................... 133
6 A- Allgemeines............................................................................................................................................................................ 133
B- Schadenssuche bzw. -Behebung............................................................................................................................ 133
C- Untersuchung....................................................................................................................................................................... 136
Gilt für alle funktionsstörungen............................................................................................................................... 139
Funktionsstörungen bei eingelegtem gang.................................................................................................... 142
Sonstige probleme......................................................................................................................................................... 143
Schlechter leerlaufbetrieb......................................................................................................................................... 144
Getribeüberhitzung......................................................................................................................................................... 146

7 SPEZIALWERKZEUG - ZEICHNUNG ..................................................................................................................................... 147

vii
TXL 30/ST

F INDEX

///
! NORMES DE SURETE...................................................................................................................................................................... xv

DONNEES TECHNIQUES .............................................................................................................................................................. 2


1 Transmission TXL 30/ST ......................................................................................................................................................
Schéma électrique ..................................................................................................................................................................
2
3
Schéma cinématique de la transmission.................................................................................................................... 4
Description générale........................................................................................................................................................................... 5
Vues générales TXL 30/ST.................................................................................................................................................. 10
Section générale TXL 30/ST.............................................................................................................................................. 12
CIRCUIT HYDRAULIQUE DE LA TRANSMISSION - DISTRIBUTEUR SUPERMODULE....................... 17
2 Schéma du circuit hydraulique - Distributeur Supermodulé.......................................................................... 19
SCHEMA A du circuit hydraulique - Boîte de vitesses au point mort - Distrib. Supermod....... 21
SCHEMA B du circuit hydraulique - M. Arrière, Chariot en marche - Distrib. Supermod.......... 23
SCHEMA C du circuit hydraulique - M. Arrière en Inching - Distrib. Supermod.............................. 25
DEMONTAGE ET MONTAGE DE LA TRANSMISSION................................................................................................. 26
3 Généralites..................................................................................................................................................................................... 29
Conservation et utilisation du produit ......................................................................................................................... 31
Outils spéciaux............................................................................................................................................................................ 32
Démontage et rémontage de la Transmission......................................................................................................... 35
Révision boîte Convertisseur ................................................................................................................................... 37
Démontage et rémontage Distributeur Supermodulé........................................................................................ 41
Démontage et rémontage des moyeux de roues - Freins. (1ère Version)................................................ 56
Substitution des mâchoires ..................................................................................................................................... 57
Enregistrement accouplement mâchoires ..................................................................................................... 63
Démontage des moyeux de roues ...................................................................................................................... 64
Démontage des freins ................................................................................................................................................. 65
Remontage des groupe des roues - (1ère Version) ................................................................................... 67
Remontage des freins ................................................................................................................................................. 68
Rémontage des moyeux de roues - Normes de réglage des roulements ................................. 71
Démontage et rémontage des moyeux de roues - Freins. (2ème Version).............................................. 74
Rémontage des moyeux de roues ...................................................................................................................... 77
Normes de réglage des roulements ................................................................................................................... 79
Démontage de la Transmission......................................................................................................................................... 81
Révision de la pompe à huile et du couvercle de la transmission .................................................. 83
Révision des embrayages ......................................................................................................................................... 88
Révision des Differentiel ............................................................................................................................................ 96
Re-montage du différentiel et positionnement du couple conique selon leurs réglages relatifs 103
Rémontage de la Transmission ........................................................................................................................................ 108
Contrôle denture couple conique ....................................................................................................................... 113
Commande actionnement inching schéma d’enregistrement .......................................................... 119
TYPE HUILE............................................................................................................................................................................................. 120
4 DONNEES D’ACCOUPLEMENT MOTEUR - Mode de montage........................................................................... 121
Accouplement moteur avec P. d. F................................................................................................................................ 122
Contrôle accouplement moteur-boîte.......................................................................................................................... 125
DONNEES TECHNIQUES - Prelevement de pression Distributeur Supermodulé...................................... 126
RODAGE..................................................................................................................................................................................................... 128
5 ENTRETIEN PERIODIQUE.............................................................................................................................................................. 129
RECHERCHE DE PANNES DE FONCTIONNEMENT.................................................................................................... 134
6 A- Généralites.............................................................................................................................................................................. 134
B- Indications d’intervention............................................................................................................................................... 134
C- Diagnostic................................................................................................................................................................................ 136
Defauts de fonctionnement pour toutes les vitesse.................................................................................. 140
Anomalies de fonctionnement avec marches mises................................................................................ 142
Problemes divers............................................................................................................................................................. 143
Mauvais fonctionnement au point mort............................................................................................................. 144
Surcharge de la transmission................................................................................................................................... 146
OUTILS SPECIAUX - PLAN............................................................................................................................................................. 147
7
viii
TXL 30/ST

I NORME DI SICUREZZA
//////
!

! ATTENZIONE A QUESTO SIMBOLO !


Questo simbolo di avvertimento segnala messaggi importanti che interessano la vostra sicurezza.
Leggete attentamente le norme di sicurezza riportate ed attenetevi alle precauzioni consigliate al fine di
evitare pericoli potenziali e salvaguardare la vostra salute ed incolumità personale.

EVITARE GLI INCIDENTI


La maggior parte degli incidenti ed infortuni che si verificano nelle officine sono causati dalla
mancata osservanza di qualche semplice e fondamentale regola di prudenza e sicurezza.
Per questa ragione nella maggior parte dei casi essi possono essere evitati: basta prevederne le
possibili cause ed agire di conseguenza con la necessaria cautela e prudenza.
Con qualsiasi tipo di macchina, per quanto ben progettata e costruita, non è possibile esclu-
dere in assoluto ogni eventualità di incidente.
Un meccanico attento e prudente è la migliore garanzia contro gli incidenti.
Lʼosservanza scrupolosa di una sola ed elementare norma di sicurezza sarebbe già sufficiente ad
evitare molti infortuni gravi.

PERICOLO! Non eseguire mai alcun intervento di pulizia, lubrificazione o manutenzione con il motore
in moto.

NORME DI SICUREZZA
GENERALITÀ

! Seguire attentamente le procedure di manutenzione e di riparazione prescritte.

! Non indossare anelli, orologi da polso, gioielli, capi di vestiario slacciati o penzolanti quali ad
esempio: cravatte, indumenti strappati, sciarpe, giacche sbottonate o bluse con chiusura a
lampo aperte che possono impigliarsi nelle parti in movimento. Si consiglia invece di usare capi
appropriati ai fini antinfortunistici, ad esempio: scarpe antiscivolo, guanti, occhiali di sicurezza,
elmetti, ecc.

Non eseguire alcun intervento assistenziale sulla macchina con persone sul sedile conduttore,
!
salvo che siano operatori abilitati e coadiuvino all’operazione da svolgere.

Non far funzionare la macchina od usare i relativi attrezzi da altra posizione che non sia quella a
! sedere del posto di guida.

Non eseguire mai alcun intervento sulla macchina quando il motore è in moto, salvo che ciò
!
risulti prescritto.

Arrestare il motore ed accertarsi che non vi sia più pressione prima di staccare tubazioni,
! cappellotti, coperchi, valvole, etc.

! Tutti gli interventi assistenziali devono essere eseguiti con la massima cura ed attenzione.

Scollegare le batterie ed etichettare tutti i comandi per segnalare che un intervento è in corso.
! Bloccare la macchina e ogni attrezzatura che deve essere sollevata.

ix
TXL 30/ST

\\\\\\\ !

I freni sono inattivi quando vengono rilasciati manualmente per interventi assistenziali: in tali casi
! occorre provvedere a mantenere il controllo della macchina mediante opportuni bloccaggi o
simili.

Dovendo sollevare o trasportare delle parti pesanti, servirsi di paranchi e simili di adeguata
! capacità.

! Prestare particolare attenzione alla presenza di persone nelle vicinanze.

! Non versare mai benzina o gasolio in recipienti aperti, ampi e bassi.

Non utilizzare mai benzina, gasolio od altri liquidi infiammabili come detergenti: ricorrere invece ai
!
solventi commerciali ininfiammabili e non tossici.

Impiegando aria compressa per la pulizia dei particolari, proteggersi con occhiali aventi ripari
! laterali.

! Limitare la pressione ad un massimo di 2,1 bar secondo le norme vigenti locali o nazionali.

Non servirsi di fiamme come mezzo di illuminazione quando si procede ad operazioni o si ricer-
! cano perdite sulla macchina.

Spostarsi con ogni cautela quando si debbano eseguire lavori sotto la macchina, indossare gli
! equipaggiamenti di sicurezza previsti: elmetti, occhiali e scarpe speciali.

La zona dove si svolgono operazioni di manutenzione deve essere tenuta sempre PULITA ed
! ASCIUTTA. Eliminare immediatamente eventuali pozze d’acqua o macchie d’olio.

In caso di avaria il carrello può essere trainato per distanze inferiori a 2 km a velocità non
! superiore a 10 km/h. Non è consentito accendere il motore del veicolo in fase di rimorchio,
questo potrebbe causare danno alla trasmissione.

x
TXL 30/ST

GB SAFETY RULES
//////
!

! WATCH FOR THIS SIGN !


This sign identify important messages devoted to your safety.
Read carefully safety rules reported here and follow with the greatest care all recommended sugge-
stion to avoid potential dangers and protect your health and personal safety.

AVOID CAUSALITIES

Most of all injuries and accidents that are encountered in workshops are caused by disre-
garding some simple and basic caution and safety rule.
For this reason most of these events can be avoided. To anticipate possible causes will suffice and
acting accordingly with proper care and caution.
Each kind of operating machine, even if correctly planned and assembled, cannot be absolutely safe.
A cautious and careful operator is the best warrant against injuries.
Following scrupulously safety rule will be sufficient to prevent many dangerous injuries.

DANGER! Don’t clean, lubricate or service with engine running.

SAFETY RULES
GENERAL

! Follow strictly directions reported for servicing and repair operations.

Don’t wear rings, wrist watches, loose clothes, i.e.: neckties, torn clothing, scarves, unbuttoned
! jackets or overall with open zip that could be entangled in moving parts.
It is recommended use of proper accident preventing clothing, i.e.: anti-slip shoes, gloves, gog-
gles helmets, etc.

Don’t start any servicing operation on machine with anyone on driver seat, except for authorized
! operator that cooperate for the work to be done.

Don’t operate machine or use relevant equipment from position other than driver’s seat.
!
! Don’t service machine with engine running, if not specified by repair instructions.

Stop engine and make sure there is no pressure when disconnecting piping, caps, covers,
! valves, etc.

! All servicing operations must be performed with best attention and care.

Disconnect batteries and mark all controls to point out that servicing operations are on course.
! Block machine, all equipment must be lifted up, and mechanically secured accordingly, with the
appropriate device.

Brakes are inoperative when hand released for servicing operations: in such a condition machine
! control should be provided by proper blocks or similar equipment.

Should heavy components be displaced or moved, use proper hoist or similar equipment.
!

xi
TXL 30/ST

\\\\\\\ !

! Care for people near operation areas.

! Never pour gasoline or diesel fuel in open, large and low vessels.

Never use gasoline, diesel fuel or other inflammable fluids as detergent. Use only commer-
! cial non toxic, uninflammable cleaning compounds.

! When using compressed air for cleaning purposes wear goggles with side shields.

! Pressure must be limited to 2.1 bar max., according current safety rules.

! Never use free flame for illumination when operations are devoted to repair or locate leaks.

Caution when repair shall be carried out working under machine, wear safety equipment:
! helmets, goggles and safety shoes.

Area where servicing operations are carried out must be always kept CLEAN and DRY.
! Clean and dry immediately any oil or water puddle.

In case of problem, towing of vehicle is only allowed for a distance of less than 2 km with
! maximum towing speed of 10 km/h. It is not possible to start the engine through towing
the vehicle, this can cause damage to the transmission.

xii
TXL 30/ST

D SICHERHEITS VORSCHRIFTEN
//////
!

! BEACHTE DIESES ZEICHEN !


Dieses Zeichen bedeutet wichtige Information bezüglich Sicherheit. Lese und Beachte unbedingt
die Sicherheitsbestimmungen die hier beschrieben sind und folge mit größter Aufmerksamkeit allen
Anweisungen um potentielle Gefahren zu vermeiden sowie zum Schutz von Gesundheit und persönli-
cher Sicherheit.

VERMEIDE KAUSALITÄTEN

Die meisten Unfälle und Verwundungen in Werkstätten entstehen durch Ignoranz und Nichtbeachtung
der einfachsten und grundlegenden Vorsichts- und Sicherheitsbestimmungen.
Die meisten dieser Vorkommnisse können vermieden werden. Durch Abschätzung möglicher
Gefahren kann entsprechend verfahren werden und richtiges Verhalten vermeidet Gefahr.
Jede Art von Maschine, selbst wenn richtig geplant und gebaut, kann nicht absolut sicher sein.
Ein Verantwortungsvoller und Sicherheitsbewußter Fahrer ist die beste Garantie gegen Unfälle.
Die strikte Anwendung einfacher elementarer Sicherheitsregeln ist ausreichend um viele gefährliche
Unfälle zu vermeiden.

GEFAHR! Alle Reinigungs-Abschmier-oder Service Arbeiten sollen nicht bei Laufendem Motor
vorgenommen werden.

SICHERHEITS BESTIMMUNGEN
GENERELL

! Folge strikt den Anweisungen für Service - und Reparaturarbeiten.

Trage keine Ringe, Armbanduhren, lose Kleidung, wie zum Beispiel Krawatten, zerrissene Kleidung,
! Schales, ungeknöpfte Jacken oder Overalls mit offenem Reißverschluß welche durch rotierende /
bewegte Teile erfasst werden können.

Beginne keine Service Arbeiten, wenn jemand im Fahrersitz ist, Ausnahme nach Absprache
! für Funktionen zur Durchführung einer Arbeit.

! Bewege keine Maschine oder Komponenten von einer Position anders als vom Fahrersitz.

Führe keine Service Arbeiten durch wenn der Motor läuft, es sei denn es ist in den
! Reparaturanweisungen spezifiziert.

Stelle den Motor ab und stelle sicher, daß kein Druck vorhanden ist wenn Rohre, Schläuche,
! Kappen, Deckel, Ventile oder ähnliches abgeschraubt wird.

Alle Service Operationen müssen mit der größtmöglichen Aufmerksamkeit und Vorsicht
! ausgeführt werden.

Trenne Batterie Verbindungen und markiere alle Kontroll Instrumente um anzuzeigen, daß Service
! Arbeiten ausgeführt werden.

Blockiere die Maschine, alle Anbauten müssen in oberste Stellung gebracht werden und
! mechanisch gesichert mit den entsprechenden Stützen.

xiii
TXL 30/ST

\\\\\\\ !

Bremsen sind nicht in Funktion wenn durch Hand freigegeben für Service arbeiten. In diesem
! Zustand muß die Maschine durch entsprechende vorgeschriebene Keile oder Blöcke gesichert
sein.

Zum Bewegen von schweren Teilen wenn erforderlich, muß das entsprechende Hebezeug
! verwendet werden.

! Vorsicht für Leute die in unmittelbarer Umgebung arbeiten.

! Benütze und fülle niemals Benzin oder Diesel in offenen großen und niedrigen Behältern.

Benütze niemals Benzin, Diesel oder andere entzündbare Flüssigkeiten als Reinigungsmittel,
! benütze nur kommerzielle, ungiftige, nichtbrennbare Reinigungsmittel.

! Bei Benützung von Druckluft zur Reinigung trage Schutzbrille mit Seitenschutz.

Druck muß reduziert sein auf 2,1 bar Maximum, entsprechend der momentanen
! Sicherheitsvorschriften.

Benütze niemals eine offene Flamme zur Beleuchtung wenn Arbeiten notwendig sind um
! Leckagen zu finden oder zu Reparieren.

Vorsicht wenn Arbeiten unter der Maschine notwendig sind, trage Sicherheitskleidung wie Helm,
! Sicherheitsbrille und Sicherheitsschuhe.

Der Arbeitsplatz wo Service Arbeiten durchgeführt werden muß immer sauber und trocken sein.
! Beseitige unmittelbar Öl oder Wasser Pfützen.

Im Schadensfall darf Fahrzeug über eine Stecke von weniger als 2 km mit einer maximalen
! Geschwindigkeit von 10 km/h abgeschleppt werden.
Durch Schleppen des Fahrzeuges kann der Motor nicht angeworfen werden.
Jeder Anschleppversuch kann Schäden im Getriebe hervorrufen und muß deshalb
unterbleiben.

xiv
TXL 30/ST

F NORMES DE SURETE
//////
!

ATTENTION A CE SYMBOL !
!
Ce symbol d’avertissement signale des messages importants concernants votre sûreté. Lire soigneuse-
ment les normes de sûreté mentionnées et se conformer aux précautions conseillées au but d’éviter dan-
gers éventuels et sauvegarder votre santé et votre sûreté personnelles.

EVITER LES ACCIDENTS

Les accidents les plus fréquents dans les usines se vérifient à cause de la manquée observation de
quelques simples et fondamentales règles de prudence et sûreté.
Pour cette raison presque toujours est possible de les éviter: il suffit prévoir les causes possibles et
agir par conséquent avec la prudence nécessaire.
Pour tous les modèles de machine, même si bien projetée et construite, il n’est pas possible
d’exclure du tout les éventualités d’accident.
Un mécanicien diligent et prudent est la meilleure garantie contre les accidents.
L’observation scrupuleuse d’une seule et élementaire norme de sûreté serait déjà suffisante à éviter
beaucoup d’accidents graves.

DANGER! Ne jamais exécuter aucune intervention de nettoyage, lubrification ou entretien à


moteur en marche.

NORMES DE SURETE
GENERALITES

! Suivre soigneusement les procédures d’entretien et de réparation prescrittes.

Ne pas mettre de bagues, montres, bijoux, pièces déboutonnés ou pendillantes, par


! exemple: cravates, vêtements déchirés, écharpes, vestes déboutonnées ou blouses avec
charnieres ouvertes qui peuvent s’accrocher dans les parties en mouvement.
Il est conseillé plutôt d’ utiliser des pièces appropriées anti-accidents, par exemple chaussures
antiglisse, gants, lunettes de sûreté, casques, etc.

N’exécuter aucune intervention d’assistance sur la machine avec des personnes à la place du
! conducteur à moins qu’ils soyent des opérateurs certifiés coadjuvants à l’opération à effectuer.

Ne pas actionner la machine ou utiliser les relatifs outils d’une position différente de la place du
! conducteur.

! Ne jamais exécuter aucune intervention sur la machine à moteur en marche si non demandé.

Arrêter le moteur et s’assurer qu’il n’y a plus de pression avant de détacher tuyauteries,
! capuchons, couvercles, soupapes, etc.

! Toutes les interventions d’assistance doivent être effectuées avec le plus grand soin et attention.

Disjoindre les batteries et étiquetter toutes les commandes pour signaler qu’une intervention est
! en cours. Bloquer la machine et tous les outillages qui doivent être soulevés.

xv
TXL 30/ST

\\\\\\\ !

! Les freins sont inactifs quand on les rêlache manuelment à cause d’interventions d’assistance:
dans ces cas il faut s’occuper de maintenir le contrôle de la machine au moyen d’ opportuns
blocages ou similaires.

Pour soulever ou transporter des parties lourdes se servir de palans et similaires d’adéquate
! capacité.

! Faire beaucoup d’attention à la présence de personnes dans les voisinages.

! Ne jamais verser d’essence ou gaz-oil dans des récipients ouverts, amples et bas.

Ne jamais utiliser d’essence, gaz-oil ou autres liquides inflammables comme détergents: utiliser
! plutôt des solvants commerciaux ni inflammables ni toxiques.

En employant de l’air comprimé pour le nettoyage des éléments, se protéger par des lunettes
! avec protection de chaque côté.

! Limiter la pression à un maximum de 2,1 bar selon les lois en vigueur du lieu ou nationales.

Ne pas se servir de flammes comme moyen d’éclairage quand on procède à opérations ou on


! recherche des pertes sur la machine.

Se déplacer avec beaucoup de prudence quand on doit exécuter des travaux sous la machine,
! utiliser les équipements de sûreté prévus: casques, lunettes et chaussures spéciales.

La zone ou se déroulent les opérations d’entretien doit être tenue toujours propre et seche.
! Éliminer immédiatement éventuelles flaques d’eau ou taches d’huile.

En cas de panne, le chariot, peut être traîné pour des distances inférieures à 2 km et une
! vitesse non supérieure à 10 km/h. La mise en marche du véhicule est interdite en phase de
remolque: cela pourrait provoquear un dommage à la transmission.

xvi
TXL 30/ST

DATI TECNICI
TECHNICAL DATA
TECHNISCHE DATEN
DONNEES TECHNIQUES
1

Trasmissione TXL 30/ST I

Frizioni cambio powershift: pressione di comando min. 8,5 bar, max. 9,5 bar
Convertitore: ■ pressione ingresso min. 4 bar, max. 5 bar
■ pressione uscita min. 2 bar, max. 3 bar
Lubrificazione: pressione lubrificazione 0,8 ÷ 1 bar
Nota: i dati riportati sono riferiti alla trasmissione in condizioni di temperatura di regime (100°C)
e regime motore di circa 2.000 giri al minuto e comunque prossimo al regime massimo.
Temperatura: ■ funzionamento di regime: 80 - 100°C
■ picco: 120°C

Tipo, qualità d’olio e quantità: Vedere pag. 120


Filtro olio: ■ filtro in aspirazione alla pompa a rete grado di filtraggio
25 µm.
Impianto elettrico: ■ tensione: 12 V C.C. (24 V C.C.)
■ potenza: 26 W

Transmission TXL 30/ST GB

Powershift transmission clutches: operational pressure min. 8.5 bar, max 9.5 bar
Converter: input pressure min. 4 bar, max. 5 bar

■ output pressure min. 2 bar, max. 3 bar

Lubrication: pressure 0.8 - 1 bar


Note: the above mentioned data refer to an operative temperature of 100°C and a engine speed
of about 2000 r.p.m.
Temperature: ■ normal operation: 80 - 100°C
■ peak: 120°C

Oil type, quality and quantity: see page 120


Oil filter: ■ pump mesh intake filter, filtering capacity 25 µm

Electrical installation: ■ voltage: 12 V d.c. (24 V d.c.)


■ power: 26 W

1
TXL 30/ST

TECHNISCHE DATEN
DONNEES TECHNIQUES

D Getriebe TXL 30/ST


Lastschaltgetriebe-Kupplungen: Betriebsdruck min. 8,5 bar, max. 9,5 bar
Drehmomentwandler: ■ Eingangsdruck min. 4 bar, max. 5 bar
■ Ausgangsdruck min. 2 bar, max. 3 bar

Schmierung: Druck 0,8 - 1 bar


Anmerkung: obige Daten beziehen sich auf eine Getriebeöltemperatur von 100°C
und eine Motordrehzahl ~ 2000 U/min.
Temperatur: ■ normale Betrebsbedingunge: 80 - 100°C
■ max.: 120°C

Ölsorte, Ölqualität und Ölmenge: Siehe Seite 120


Ölfilter: ■ Pumpenansaug-Siebfilter Filterfeinheit 25 µm
Elektrische Installation: ■ Spannung: 12 V Gleichstrom (24 V Gleichstrom)
■ Leistung: 26 W

F Transmission TXL 30/ST


Embrayages: pression de commande 8,5 bar mini, 9,5 bar maxi
Convertisseur: ■pression d’entrée 4 bar mini, 5 bar maxi
■ pression sortie 2 bar mini, 3 bar maxi

Lubrification: pression 0,8 à 1 bar


Note: les données susmentionnées se rapportent à la transmission utilisée dans des conditions
de température normales (100°C) et à un régime moteur maxi de 2000 tr/min.
Température: ■ fonctionnement en régime constant 80 - 100°C
■ en charge: 120°C

Type d’huile, genre et quantité: voir page 120


Filtre à huile: ■ filtre à tamis monté sur l’aspiration de la pompe, degré

de filtration 25 µm
Equipment électrique: ■ Tension: 12 V C.C. (24 V C.C.)
■ Puissance: 26 W

2
TXL 30/ST

Schema elettrico
Circuitry
Schaltplan
Schéma électrique
1
Distributore supermodulato
Supermodulating distributor
Steuerblock supermoduliert
Distributeur supermodulé
2

1
Marcia Avanti Retromarcia -
Forward Clutch Reverse Clutch
+
Vorwärts Rückwärts
Marche Avant Marche Arrière

3 3

5 Marcia Avanti
Forward Clutch
Vorwärts
Marche Avant

Retromarcia
Reverse Clutch
Rückwärts
4 Marche Arrière

I 1 -Commutatore D 1 - Schalter
2 -Fusibile 2 - Sicherung
3 -Lampadina 3 - Kontrolleuchte
4 -Distributore 4 - Steuerblock
5 -Elettrovalvola 5 - Magnetventil
Tensione 12/24 V CC/DC Spannung 12/24 V CC/DC
Potenza 26 W Leistung 26 W
GB 1 - Commutator F 1 - Commutateur
2 - Fuse 2 - Fusible
3 - Electric Bulb 3 - Ampoule
4 - Valves body 4 - Distributeur
5 - Solenoid valve 5 - Electrovannes
Voltage 12/24 V CC/DC Tension 12/24 V CC/DC
Power 26 W Puissance 26 W

3
TXL 30/ST

Schema cinematico della trasmissione


Kinematic diagram of the transmission
Kinematikdiagramm des Getriebes
Schéma cinematique de la transmission

Presa di Forza
Power take off
Nebenabtrieb
Prise de force

Freno
Brake
Bremse
Frein

Entrata
Input
Eingang
Entrée

Pompa
Pump
Pumpe
Pompe

4
TXL 30/ST

I Descrizione generale
La trasmissione è dotata di convertitore monostadio con ruota libera per ottenere i massimi ren-
dimenti con bassi rapporti di slittamento. Ha due frizioni idrauliche (una avanti, una indietro) a
1
dischi multipli in bagno d’olio con ingranaggi sempre in presa, aventi rapporti uguali per l’avanti e per
l’indietro.
La selezione del senso di marcia è ottenuta per mezzo di selettori idraulici servocomandati elettri-
camente.

GB General description
The transmission is equipped with a single-stage converter with free wheel. Thus a high efficiency
over the whole range of operation is achieved. It has two hydraulic clutches (one for Forward Gear
and one for Reverse Gear) with multiple wet disks, while the constant mesh gears have the same
ratio in Forward and Reverse Gear. The selection of direction is effected by hydraulic selectors,
which are controlled electrically.

D Allgemeine Beschreibung
Das Getriebe ist mit einem eistufigen Wandler mit Leitradfreilauf ausgerüstet. Damit wird ein hoher
Wirkungsgrad über den gesamten Betriebsbereich erreicht. Es hat zwei hydraulische Lamellen
Kupplungen (eine für den Vorwärtsgang und eine für den Rückwärtsgang), wobei die ständig im
Eingriff befindlichen Zahnräder für Vorwärts- und Rückwärtsgang dasselbe Übersetzungsverhältnis
haben.
Die Schaltung erfolgt über elektrisch betätigte Magnetventile.
F Description générale
La transmission est munie de converisseur monoétage avec une roue libre permettant d’obtenir
des rendements à bas rapport de glissement. Elle est munie de 2 embrayages hydrauliques (l’une
pour Marche Avant, l’autre pour Marche Arrière) à disques multiples submergés dans l’huile, les
engrenages toujours actifs, ayant les mêmes rapports avant er arrière. Des sélecteurs hydrauliques
commandés électriquement permettent de sélectionner le sens de marche.

I Accoppiamento al motore
Un accoppiamento al motore mediante piatto flessibile collega direttamente il convertitore di cop-
pia con il volano motore (vedi pag. 122).

GB Connection engine - converter


The converter is connected to the engine flywheel via flexible drive plate (see page 122 ).

D Verbindung Motor - Wandler


Der Drehmomentwandler wird mit einer axial-elastischen Membrane am Motorschwungrad
angeflanscht (siehe Seite 122).

F Accouplement au moteur
Un accouplement à plateau élastique relie directement le convertisseur de couple au volant-
moteur (voir page 122).

5
TXL 30/ST

I Convertitore di coppia
Il convertitore monostadio è studiato per ottenere la massima flessibilità e le massime prestazioni in
accoppiamento al motore termico. Esso è in grado di trasmettere coppie ben superiori a quelle forni-
te dal motore e di conseguenza garantisce la massima affidabilità. La pompa-convertitore solidale al
carter convertitore viene quindi messa in rotazione generando all’interno dello stesso una circolazione
di olio atta a trascinare la turbina ed a trasmettere quindi il moto agli ingranaggi della trasmissione
come illustrato negli schemi.
GB Torque converter
The single-stage converter has been designed to obtain maximum flexibility when being connected to
different engines with different performances. It is able to transmit considerable torque and guarantees
maximum reliability. The converter-pump, integral with the converter housing, rotates generating suffi-
cient fluid flow inside the converter to drive the turbine and transmit drive to the transmission gears as
shown in the diagrams

D Drehmomentwandler
Der einstufige Drehmomentwandler ist so ausgelegt, daß größtmögliche Flexibilität beim Anbau an
verschiedene Motoren unterschiedlicher Leistung gegeben ist.
Die Wandlerpumpe drückt innerhalb des Drehmomentwandlers durch Rotation die Wandlerflüsauf die
Wandlerturbine. Die dadurch die nachfolgenden Zahnräder antreibt, wie im Systemschema gezeigt.

F Convertisseur de couple
Le convertisseur mono-étage à roue libre est conçu pour obtenir une souplesse, et des perfor-
mances optimales dans son accouplement au moteur thermique. Cet organe, qui permet de tran-
smettre des couples supérieurs à ceux fournis par le moteur, garantit donc une fiabilité maximale.
La pompe du convertisseur, solidaire au carter convertisseur commence à glisser et provoque à
l’interieur un flux d’huile qui entraîne la turbine et transmet le mouvement aux engrenages de la tran-
smission (voir schémas).

Schemi Convertitore di coppia - TXL 30/ST


Converter schemas - TXL 30/ST
Schaltpläne Drehmomentumwandler - TXL30/ST
Schémas Covertissueur de couple - TXL30/ST

Marcia Avanti Retromarcia


Forward Gear Reverse Gear
Vorwärtsgang Rückwärtsgang
Marche Avant Marche Arrière

6
TXL 30/ST

I Funzionamento
1) Cambio di marcia: un selettore idraulico elettropilotato provvede a comandare l’inserimento della
frizione prescelta, mentre una valvola modulatrice regolano la salita della pressione alla frizione in
1
modo graduale, permettendo cambi di direzione, di velocità e avviamenti graduali senza urti.
2) Inching control: la pressione di comando delle marce può essere regolata tra zero ed il valore
massimo permettendo così di modulare la coppia trasmessa dalla frizione con conseguente per-
fetta regolazione dell’avviamento del carrello; l’Inching control agisce su tutte le marce.
3) Capacità: la coppia dinamica trasmissibile dalle frizioni risulta superiore a quella in ingresso al
cambio dopo il convertitore e questo garantisce la vita delle stesse.

GB Operation
1) Gear shifting: an electrically actuated solenoid controls the corresponding valve for releasing oil
pressure on the clutch piston, while an valve regulate the pressure increase to the clutch gradually,
allowing direction changes and soft gear shifts.
2) Inching control: the Inching valve, which is actuated mechanically, allows truck movement at a very
low speed with constant speed of the engine. Inching control works on drive off.
3) Capacity: the dynamic torque transmissible by the clutches is higher than the transmission input
torque after the converter. Thus a long service life of the clutches is guaranteed.

D Arbeitsweise
1) Gangwechsel: Ein elektrisch erregter Magnet steuert das entsprechende Ventil zur Beaufschlagung
der gewünschten Kupplung. Ein Modulationsventil regeln den zur Kupplung ansteigenden Druck
und ermöglichen, daß der Fahrtrichtungswechsel und das Anfahren sanft erfolgen.
2) Inching: Das Inchventil, das für mechanische Betätigung ausgelegt ist, ermöglicht ein Fahren mit
geringster Geschwindigkeit bei konstanter Motordrehzahl. Ein Ventil für hydraulische Betätigung
kann angebaut werden. In jedem Gang ist Inching möglich.
3) Leistungsfähigkeit: Das von den Kupplungen übertagbare dynamische Drehmoment ist höher
als das Getriebeeingangsmoment nach dem Wandler. Dadurch wird eine lange Lebensdauer der
Kupplungen sichergestellt.

F Fonctionnement
1) Changement de vitesses: un sélecteur hydraulique électro-piloté commande l’embrayage choisi,
alors qu’ une vanne régulatrice règlent l’augmentation de la pression à l’embrayage graduellement,
en permettant changements de direction, de vitesse et démarrages graduels et sans chocs.
2) Contrôle de l’Inching: la pression de commande des marches peut être reglée entre zéro et la
valeur maxi, en permettant ainsi de moduler le couple transmis par l’embrayage avec conséquent
réglage parfait de l’avancement du chariot; contrôle de l’Inching agit sur toutes les marches.
3) Capacité: le couple dynamique transmissible par les embrayages résulte supérieur à celui en
entrée à la boîte après le convertisseur, en assurant ainsi la vie des mêmes.

7
TXL 30/ST

I Frizioni
Sono ad azionamento idraulico. La trasmissione del moto avviene tramite 6 dischi (12 super-
fici di attrito attive) a lubrificazione e raffreddamento forzati. Oltre ad una elevata capacità di
coppia trasmissibile statica e dinamica, dispongono di una elevata capacità di assorbimento
di energia cinetica durante i cambi di marce. L’impacchettamento delle frizioni viene effettua-
to dallo spostamento assiale di un pistone sotto la spinta di olio in pressione, mentre il ritorno
del pistone, e quindi di distacco dei dischi, è assicurato da una molla.

GB Clutches
These are hydraulically operated. The drive is transmitted via force-lubricated, force-cooled
plates (12 active friction surfaces). In addition to high static and dynamic transmissible torque
capacity, they also have a high kinetic energy absorption capacity during gearchanges. Clutch
engagement is through piston displaced axially under fluid pressure. A spring pushes the
piston back and the plates are then released.

D Kupplungen
Sie werden hydraulisch beaufschlagt. Die zwangsgeschmierten und gekühlten 6 Lamellen (12
Reibflächen) sind für die Übertragung der holen statischen und dynamischen Drehmomente
ausgelegt.
Die Kupplungen werden durch Druckkolben mit Druckflüssigkeit geschlossen und durch
Federkraft wieder geöffnet.

F Embrayages
Seulement hydrauliques. La transmission du mouvement est assurée par 6 disques (12 sur-
faces de friction actives), à graissage et refroidissement forcés. En plus d’une capacité éle-
vée de couple statique et dynamique transmissible, les embrayages possèdent une capacité
également élevée d’absorption d’énergie cinétique, pendant les changements de marche.
L’empaquetage des embrayages est réalisé par déplacement axial d’un piston sous la pous-
sée de l’huile sous pression, alors que le retour au repos du piston et des disques est assuré
par un ressort.

I Presa di forza
È azionata direttamente dal motore termico e da una catena silenziosa. Alla presa di forza è
flangiata la pompa idraulica per l’impianto idraulico di sollevamento e di sterzatura.

GB Power take-off
It is driven by the thermic motor and by a silent chain. The rotating direction as well as the
speed corresponds to that of the engine. The hydraulic pump for the lifting and steering
system is flanged to the PTO.

D Nebenabtrieb (PTO)
Er wird über die Wärmerkraftmaschine und über eine geräuscharme Zahnkette angetrieben.
Die Drehzahl, sowie die Drehrichtung entsprechen denen des Motors. Die Hydraulikpumpe für
das Hub- und Lenksystem kann an den Nebenabtrieb angeflanscht werden.

F Prise de force
Elle est actionnée directement par le moteur termique et par une chaîne silencieuse. A la prise
de force est bridée la pompe hydraulique pour l’installation hydraulique de soulèvement et de
coup de volant.

8
TXL 30/ST

I Pompa
Una pompa olio a ingranaggi con velocità di rotazione pari a quella del motore è montata
coassiale all’albero di ingresso. L’aspirazione dell’olio dalla coppa avviene tramite condotto
1
ricavato nella fusione del carter con filtro a rete.

GB Pump
A gear oil pump that rotates at the same speed as the engine, is mounted coaxially with the
direct drive shaft. Oil is sucked from the sump via a duct in the transmission case casting, and
passes through a mesh filter.

D Pumpe
Koaxial (hinter dem Nebenabtrieb) ist eine Zahnradpumpe angebracht, die über den Wandler
und einer Welle in abhängigkeit der Motordrehzahl angetrieben wird. Die Ölansaugung vom
Sumpf erfolgt über einen Filter.

F Pompe
Une pompe à huile à engrenages à vitesse de rotation égale à celle du moteur est montée
coaxialement sur l’arbre d’entrée. L’aspiration de l’huile dans le carter est assurée par un con-
duit venu de fonderie du carter de transmission, avec filtre à tamis.

I Distributore di comando e controllo


Il distributore è situato esternamente sul carter della trasmissione. Riceve la portata di olio
dalla pompa e incorpora dispositivi che controllano il flusso e la pressione della medesima
per il corretto funzionamento del convertitore, delle frizioni e della lubrificazione. È dotato di
valvola modulatrice, che permettono cambi di direzione e avviamenti graduali senza urti.

GB Control distributor
The distributor is situated on the outside of the transmission case. It receives the oil delivered
by the pump and incorporates devices that control the flow and pressure of the oil to ensure
that the converter, the clutches and the lubrication system all operate correctly. It is provided
with a modulator valve, which ensure gradual, shock-free gear changes and start-ups.

D Getriebesteuerung
Das Steuerventil ist außen seitlich am Getriebegehäuse angebracht. Es leitet den Ölstrom
von der Pumpe über einen Filter. Es hat Meßstellen für Ölfluß und Drücke, damit der korrekte
Betrieb des Wandlers, der Schaltkupplungen, der Inchsteuerung und des Schmiersystems
kontrolliert werden kann. Es ist mit einem Modulations, welche Fahrtrichtungswechsel und
Anfahren ohne Stöße ermöglichen.

F Distributeur de commande et de contrôle


Le distributeur est placé extérieurement au carter de la transmission. Il reçoit le débit d’huile
de la pompe par le filtre et incorpore des dispositifs qui contrôlent le flux et les pressions du
fluide pour assurer un fonctionnement correct du convertisseur, des embrayages, du contrôle
de l’Inching et de la lubrification. Il est équipé d’une vanne modulatrice, qui permettent des chan-
gements de direction et démarrages graduels et sans chocs.

9
TXL 30/ST

Viste generali TXL 30 / ST


TXL 30 / ST General views
Generelle Ansicht TXL 30 / ST
Vues générales TXL 30 / ST

H M G P

D U D

I A. Tappo intr. olio cambio D A. Getriebeöleinfüllstutzen


B. Elettrodistributore Marcia Avanti B. Solenoid Vorwärtsgang
C. Elettrodistributore Retromarcia C. Solenoid Rückwärtsgang
D. Tappi scarico olio D. Ölablaßschraube
E. Filtro olio E. Ölfilter
F. Tappo riemp. livello olio ponte F. Einfüllstutzen - Ölstand Achse
G. Comando Inching meccanico G. Mechanische Inchsteuerung
H. Convertitore H. Wandler
L. Asta livello olio con sfiato L. Ölpeilstab - Entlüfter
M.Ritorno scambiatore M.Vom Kühler
N. Mandata scambiatore N. Zum Kühler
P. Comando azionamento inching (optional) P. Inching steuerwerk (auf Wunsch)
R. Asta livello olio suppl. (optional) R. Zusatzbügel Ölstand (auf Wunsch)
S. Distributore Supermodulato S. Steuerblock Supermoduliert
T. Pressostato (optional) T. Druckfuehler (auf Wunsch)
U. Interruttore termom. 125° ± 3°C U. Temperaturfühler 125° ± 3°C
V. Presa di forza V. Nebenabtrieb
Z. Comando Inching idraulico Z. Hydraulische inchsteuerung

GB A. Filler plug, gear box oil F A. Bouchon de remplissage huile boîte de vitesses
B. Forward gear solenoid valve B. Electrovanne Marche Avant
C. Reverse gear solenoid valve C. Electrovanne Marche Arrière
D. Oil drain plugs D. Bouchons de vidange huile
E. Oil filter E. Filtre à huile
F. Drive axle oil level plug F. Bouchon de remplissage - niveau huile pont
G. Mechanical Inching control G. Commande Inching mécanique
H. Converter H. Convertisseur
L. Dipstick with breather L. Jauge huile avec reniflard
M.Exchanger return M.Retour échangeur
N. Exchanger delivery N. Alimentation échangeur
P. Inching drive control (optional) P. Commande d’action inching (opcional)
R. Additional oil level rod (optional) R. Jauge niveau huile supplémentaire (en option)
S. Supermodulating Distributor S. Distributeur Supermodule
T. Pressure switch (optional) T. Pressostat (en option)
U. Temp. switch 125° ± 3°C U. Interrupteur thermométrique 125° ± 3°C
V. Power take-off V. Prise de force
Z. Hydraulic Inching control Z. Commande Inching hydraulique

10
TXL 30/ST

Viste generali TXL 30 / ST


TXL 30 / ST General views
Generelle Ansicht TXL 30 / ST
Vues générales TXL 30 / ST
1
S P L V R

E T A

B
Z C

F
E MA

11
TXL 30/ST

Sezione generale TXL 30 / ST


TXL 30 / ST General section
Allgemeine Hinweise TXL 30 / ST
Section générale TXL 30 / ST

14 2
11
3
1 17
4 5 16
13

10 9 8 6 7

I 1. Convertitore GB 1. Converter D 1. Drehmomentwandler


2. Ingranaggio condotto P. d. F. 2. Gear driven by power take-off 2. Nebenabtriebszahnrad getrieben
3. Presa di forza 3. Power take-off 3. Nebenabtrieb
4. Pompa trasmissione 4. Pump 4. Pumpe
5. Frizione Marcia Avanti 5. Forward clutch 5. Kupplung für Vorwärtsfahrt
6. Frizione di Retromarcia 6. Reverse clutch 6. Kupplung für Rückwärtsfahrt
7. Ingranaggio trascinamento pignone 7. Pinion drive gear 7. Kegelritzelantriebszahnrad
8. Pignone 8. Pinion Gear 8. Antriebsrad
9. Ingranaggio conduttore P. d. F. 9. Driving gear, for power take-off 9. Nebenabtriebszahnrad treibend
10. Albero turbina 10. Turbine shaft 10. Turbinenwelle
11. Catena 11. Chain 11. Kette
12. Gruppo Freno 12. Brake Assembly 12. Bremsgruppe
13. Differenziale 13. Differential Unit 13. Differential
14. Scatola Convertitore 14. Converter case 14. Wandlergehäuse
15. Gruppo ruota 15. Wheel Assembly 15. Achsgruppe
16. Valvola sicurezza lubrificazione 16. Lubrication safety valve 16. Schmierdruckventil
17. Distributore con comando inching 17. Distributor with Hydraulic Inching 17. Steuerblock Hydraulische
idraulico control inchsteuerung

12
TXL 30/ST

Sezione generale TXL 30 / ST


TXL 30 / ST General section
Allgemeine Hinweise TXL 30 / ST
Section générale TXL 30 / ST
1

12 15

13

F 1. Convertisseur
2. Engrenage conduit P. d. F.
3. Prise de force
4. Pompe transmission
5. Embrayage de Marche Avant
6. Embrayage de Marche Arrière
7. Engrenage traînement de pignon
8. Pignon
9. Engrenage conducteur P. d. F.
10. Arbre turbine
11. Chaîne
12. Groupe freinage
13. Différentiel
14. Boîte Convertisseur
15. Groupe pont
16. Vanne de sûreté de graissage
17. Distributeur avec Commande Inching
hydraulique

13
TXL 30/ST

CIRCUITO IDRAULICO DELLA TRASMISSIONE - DISTRIBUTORE SUPERMODULATO


2 TRANSMISSION HYDRAULIC SYSTEM - SUPERMODULATING DISTRIBUTOR
GETRIEBE-HYDRAULIKSYSTEM - STEUERBLOCK SUPERMODULIERT
CIRCUIT HYDRAULIQUE DE LA TRANSMISSION - DISTRIBUTEUR SUPERMODULE

I Il corretto funzionamento di tutta la trasmissione è essenzialmente affidato ai vari organi costituenti il


circuito idraulico che provvedono a:
- Garantire una determinata pressione all’interno del convertitore.
- Garantire un continuo ricambio dell’olio nel convertitore ed al suo raffreddamento mediante lo scam-
biatore di calore.
- Fornire olio in pressione al pacco frizione di trasmissioni MA e RM.
- Lubrificare i dischi della frizione di trasmissione MA e RM.
Le principali parti costituenti l’impianto idraulico sono:
a. POMPA OLIO DELLA TRASMISSIONE
Una pompa olio del tipo a dentatura interna è montata internamente alla trasmissione ed ha una
velocità di rotazione pari a quella del motore. L’aspirazione dell’olio dalla coppa avviene tramite un
condotto con filtro a rete.
b. FILTRO OLIO
Montato sul condotto di aspirazione della pompa assicura il filtraggio dell’olio destinato ai vari orga-
ni, con una capacità di 25 micron.
c. CONVERTITORE IDRODINAMICO DI COPPIA
Montato fra il motore e l’inversore, permette mediante l’azione dinamica di un fluido (olio) di molti-
plicare la coppia in uscita dal motore, adeguandola alle richieste di lavoro del carrello.
d. SCAMBIATORE DI CALORE
Situato sul condotto in uscita al convertitore provvede ad asportare il calore sviluppatosi durante il
funzionamento del cambio.
e. INVERSORE
Il gruppo di inversione è costituito da due pacchi di frizioni a dischi multipli in bagno di olio coman-
date idraulicamente mediante l’azionamento dell’elettrovalvole.
f. GRUPPO DISTRIBUTORE SUPERMODULATO
È montato all’esterno della scatola cambio, ed in esso sono incorporati:
Valvola massima pressione
Tale valvola ha il compito di controllare il valore della pressione di impacco delle frizioni di tra-
smissione.
Valvola modulatrice
Posta sul circuito d’alimentazione delle frizioni ha il compito di controllare l’incremento del valore
della pressione di impacco, allo scopo di ottenere un graduale impaccamento della frizione inte-
ressata all’atto del comando indipendentemente dalla rapidità della manovra.
Valvola Inching
Ha il compito di parzializzare la pressione di impacco frizioni e di disimpegnare gradualmente la
frizione innestata. Viene quindi ridotta in modo continuo e senza cambiare regime del motore, la
velocità di marcia fino al punto di poter avanzare con il veicolo in modo lentissimo.
Elettrodistributore selettore
Situato sui condotti di alimentazione dei pacchi frizione, permette di inviare l’olio alle marce o di
lasciarlo defluire in scarico.
Valvola sicurezza convertitore
Posta sul circuito del convertitore provvede a regolarne la pressione in ingresso e a salvaguardar-
lo da accidentali aumenti di pressione.
Valvola sicurezza lubrificazione
Situata sul circuito di lubrificazione provvede a controllare in tale circuito eventuali aumenti di
pressione.

14
TXL 30/ST

TRANSMISSION HYDRAULIC SYSTEM - SUPERMODULATING DISTRIBUTOR


2
GB The whole transmission system relies for its trouble-free operation on the various components of the
hydraulic system which perform the following functions:
- Ensure a given pressure inside the converter.
- Ensure a continuous exchange of converter oil and cooling through heat exchanger.
- Provide oil pressure to forward and reverse clutch pack.
- Lubricate clutch plates.
The main components of the hydraulic system are:
a. TRANSMISSION OIL PUMP
An internal-tooth oil pump is fitted inside the transmission and has the same speed as the engi-
ne. Oil suction from the sump is through a line incorporating a gauze filter.
b. OIL FILTER
Fitted in the inlet duct, it filters the oil for various utilities. Its net size is 25 micron.
c. HYDRAULIC TORQUE CONVERTER
Fitted between engine and reverser the converter uses the dynamic action of the oil to multiply
engine output torque in line with truck work requirements.
d. HEAT EXCHANGER
Located on circuit in exit at the converter the exchanger dissipates the heat produced during
gearbox operation.
e. REVERSER
The reverser unit consists of two oil bath, multiplate clutch packs controlled hydraulically throu-
gh the electrovalves.
f. SUPERMODULATING VALVE BLOCK
This unit is fitted on the gearbox and incorporates:
Max pressure valve (regulator)
This valve regulates clutch pressure.
Modulating valve
Located on the clutch supply circuit, this valve controls the increase in clutch pressure so that
the clutch in question is fed gradually regardless of speed of manoeuvre.
Inching valve
It cloke clutch pack pressure and gradually disengages the engaged clutch. Running speed is
constantly reduced without changing engine speed so that the vehicle can be moved forward
very slowly.
Electrodistributor selector
Situated on the feeding ducts of the clutch units, allows to convey oil to gears and to let it flow
to exhaust.
Converter safety valve
Located on converter inlet line, this valve settles the input pressure and protects the converter
from accidental over pressure.
Lubrication safety valve
Located on the lubrication circuit this valve checks increases in pressure in this circuit.

15
TXL 30/ST

GETRIEBE HYDRAULIK SYSTEM - STEUERBLOCK SUPERMODULIERT

D Die einwandreie Funktion des Getriebes ist von dem Hydraulik-Kreislauf abhängig, der folgendes
gewährleistet:
- Wandlerdruck.
- Ständiger Ölkühlkreislauf.
- Druckölbereitstellung und Schmierung für die Vorwärtsgang-und Rückwärtsgangkupplung.
Folgend die für das Hydrauliksystem erforderlichen Bauelemente:
a. ZAHNRADPUMPE
Die Pumpe ist als Innenzahnradpumpe ausgeführt und ist Motordrehzahl abhängig. Die
Ölansaugung vom Sumpf erfolgt über einer Filter.
b. ÖLFILTER
Der Ölfilter ist in der Absaugungsleitung der Pumpe eingebaut und sichert das Filtern des Öls
für die unterschiedlichen Elemente, mit einer Kapazität 25 Mikron zu.
c. HYDRODYNAMISCHER DREHMOMENTWANDLER
Ist zwischen Motor und Wenedegetriebe eingebaut, vervielfacht über die mit der Wandlerpumpe
und der Betriebsflüssigkeit (Öl) erzeugten Flüssigkeitsstrom angetriebene Turbine und dem
Reaktionsglied das Motordrehmoment. Der Drehmomentwandler gewährleistet eine stoßfreies
beschleunigen und selbsttätige Anpassung an die Belastung.
d. KÜHLER
Der Anschluss für den Kühler ist in der Zuleitung des Wandlers installiert.
e. WENDEGETRIEBE
Der Fahrtrichtungswechsel wird durch 2 im Ölbad laufende Lamellenpakete, die über ein
Elektromagnetventil hydraulisch beaufschlagt werden und dessen verbundenen Zahnräder
b.z.w. Wendezahnrad durchgeführt.
f. GETRIEBESTEUERUNG SUPERMODULIERT
Die Steuerung ist oben auf dem Getriebegehäuse montiert mit folgenden Funktionen:
Hauptdruckbegrenzungsventil
Dieses Ventil regelt den Druck in den Lamellenkupplungen mit Überdruckabsicherung.
Modulationsventil
Dieses Ventil reguliert drehzahlabhängige Druckschwankungen im Druckaufbau für die
Kupplungen.
Inchventil
Über ein Pedal oder Bremsylinder (bei hydraulischer Ausführung) steuert dieses Ventil stu-
fenlos den Anpressdruck im Kupplungslamellenpaket, damit das Fahrzeug unabhängig von der
Motordrehzahl mit geringer Geschwindigkeit (kriechen) gefahren werden kann.
Elektrowählschieber
Auf den Versorgungsleitungen der Kupplungsblöcke angebracht, ermöglicht er, das Öl an die
Gänge oder in den Abluß zu leiten.
Wandlerdruckbegrenzungsventil
Absicherung vom Wandler gegen Überdruck.
Schmierdruckventil
Überdruck- und Druckhalteventil für das Ölschmiersystem.

16
TXL 30/ST

CIRCUIT HYDRAULIQUE DE LA TRANSMISSION - DISTRIBUTEUR SUPERMODULE


2
F Le bon fonctionnement de toute la transmission est dû aux organes constituant le circuit hydraulique
qui doivent:
- Garantir une pression déterminée à l’intérieur du convertisseur.
- Garantir le renouvellement de l’huile du convertisseur de façon continue et son refroidissement par
l’échangeur de température.
- Fournir de l’huile sous pression au piston de l’embrayage marche avant ou Marche Arrière.
- Lubrifier les disques de l’embrayage.
Les parties principales de l’equipement hydraulique sont:

a. LA POMPE A HUILE DE LA TRANSMISSION


Une pompe à huile, du type à denture intérieure, est montée dans la transmission. Sa vitesse de
rotation est égale à celle du moteur. L’aspiration de l’huile se vérifie par un conduit avec filtre.
b. FILTRE A HUILE
Etant monté sur le conduit d’aspiration de la pompe, il permet une filtration adéquate de l’huile
destinée aux différents groupes, sa capacité est de 25 microns.
c. CONVERTISSEUR DE COUPLE HYDRAULIQUE
Monté entre le moteur et l’inverseur, il permet par l’action dynamique d’un fluide (I’huile) de multi-
plier le couple à la sortie du moteur en l’adaptant aux demandes de travail du chariot.
d. ECHANGEUR DE TEMPERATURE
Situé sur le conduit de sortie du convertisseur il pourvoit à retirer la chaleur qui se crée lors du
fonctionnement de la boîte de vitesse.
e. INVERSEUR
Le groupe d’inversion est constitué de deux paquets d’embrayages à disques multiples, à bains
d’huile, commandés hydrauliquement par des électrovannes.
f. LE GROUPE DISTRIBUTEUR SUPERMODULE
Monté à l’extérieur de la boîte, il comprend:
Vanne de pression maxi
Elle doit contrôler la valeur de la pression de blocage des embrayages de la transmission (tarée à
11- 13 bar).
Vanne modulatrice
Placée sur le circuit d’alimentation des embrayages, elle doit contrôler l’augmentation de la pres-
sion dans le but d’obtenir une application progressive de l’embrayage intéressé indépendamment
de la rapidité de la manoeuvre.
Vanne d’Inching
Elle a la charge de partialiser la pression de blocage des embrayages et de dégager ainsi les
disques graduellement et donc de réduire de façon continue, sans changer le régime moteur, la
vitesse de marche jusqu’au point de pouvoir avancer très lentement.
Electrodistributeur sélecteur
Placé sur les conduits d’alimentation des packs embrayage, permet d’envoyer l’huile aux mar-
ches.
Vanne de sûreté du convertisseur
Elle est placée sur le conduit à l’entrée du convertisseur en règlant la pression d’entrée et le pro-
tège contre les variations excessives de pression.
Vanne de sûreté de graissage
Située sur le circuit de graissage, elle amortit la pression excessive dans ce circuit.

17
TXL 30/ST

Descrizione circuito idraulico - Distributore Supermodulato


Hydraulic diagram description - Supermodulating Distributor
Beschreibung Hydraulikschema - Steuerblock Supermoduliert
Schéma du circuit hydraulique - Distributeur Supermodulé

I 1 - FILTRO DI ASPIRAZIONE
2 - POMPA
3 - VALVOLA MAX. PRESSIONE
4 - VALVOLA MODULATRICE
5 - STROZZATURA
6 - CONVERTITORE DI COPPIA
7 - SCAMBIATORE DI CALORE
8 - VALVOLA DI SICUREZZA CONVERTITORE
9 - VALVOLA INCHING
10 - VALVOLA MARCIA AVANTI E RETROMARCIA
11 - VALVOLA DI SICUREZZA LUBRIFICAZIONE

GB 1 - SUCTION FILTER
2 - PUMP
3 - SHIFT PRESSURE VALVE
4 - PRESSURE CONTROL VALVE
5 - ORIFICE
6 - TORQUE CONVERTER
7 - HEAT EXCHANGER (COOLER)
8 - CONVERTER SAFETY VALVE
9 - INCHING VALVEL
10 - FORWARD AND REVERSE SPEED VALVEL
11 - LUBRICATION SAFETY VALVE

D 1 - SAUGFILTER
2 - PUMPE
3 - SCHALTDRUCKVENTIL
4 - MODULATIONSVENTIL
5 - DROSSELVENTIL
6 - DREHMOMENTWANDLER
7 - KÜHLER
8 - WANDLERDRUCKBEGRENZUNGSVENTIL
9 - INCHVENTIL
10 - VORWÄRTS- UND RÜCKWÄRTSGANGVENTIL
11 - SCHMIERDRUCKVENTIL

F 1 - FILTRE D’ASPIRATION
2 - POMPE
3 - VANNE DE PRESSION MAXI
4 - VANNE MODULATRICE
5 - ETRANGLEMENT
6 - CONVERTISSEUR DE COUPLE
7 - ECHANGEUR DE CHALEUR
8 - VANNE DE SECURITE CONVERTISSEUR
9 - VANNE INCHING
10 - VANNE DE MARCHE AVANT ET MARCHE ARRIERE
11 - VANNE DE SECURITE LUBRIFICATION

18
TXL 30/ST

Schema circuito idraulico - Distributore Supermodulato


Hydraulic diagram - Supermodulating Distributor
Hydraulikdiagramm - Steuerblock Supermoduliert
Schéma du circuit hydraulique - Distributeur Supermodulé
2

LUBRIFICAZIONE
LUBRICATION
2.5 bar SCHMIERUNG
11 LUBRIFICATION
CADUTA DI PRESSIONE 1,5 bar max.

CHUTE DE PRESSION 1,5 bar maxi.


PRESSURE DROP 1.5 bar max.
DRUCKABFALL 1,5 bar max.

MARCIA AVANTI
10 FORWARD GEAR
VORWÄRTSGANG
MARCHE AVANT

RETROMARCIA
REVERSE GEAR
RÜCKWÄRTSGANG
MARCHE ARRIERE

8
7 4

5 3

CORPO
CORPODISTRIBUTORE
DISTRIBUTORE
CONTROL VALVE BLOCK
BODY VALVES
1 STEUERBLOCK
CORPS DISTRIBUTEUR

19
TXL 30/ST

Distributore Supermodulato - Cambio in folle / SCHEMA A


Supermodulating Distributor - Gear in neutral position / SCHEME A
Steuerblock Supermoduliert - Getriebe in Neutralstellung / SCHEMA A
Distributeur Supermodulé - BoÎte de vitesses au point mort / SCHEMA A

I Condizione di folle
L’olio aspirato dalla pompa viene inviato, dopo essere stato filtrato, alla valvola di massima
pressione e, tramite la strozzatura (5), al convertitore. Da quest’ultimo dopo aver attraversato
lo scambiatore, tramite il circuito di lubrificazione, raggiunge i pacchi frizione marcia avanti e
retromarcia e dopo averli attraversati cade liberamente nella coppa.
La vena d’olio che è regolata dalla valvola principale, viene mandata in scarico tramite la selet-
trice.
L’olio che arriva in eccesso alla valvola principale alimenta il convertitore, la cui pressione è
regolata dalla valvola di max. pressione covertitore che devia il flusso eccedente al circuito di
lubrificazione.

GB Neutral position
The oil sucked by the pump, after filtration, is conducted to the pressure control valve and the,
by way of the orifice (5), to the converter. From there, after having passed through cooler, the
oil reaches the clutch for forward and reverse Gear through the lubrification circuit and then
oil sump.
The oil flow, regulated by the main valve, is conveyed to exhaust by the selection valve.
The exceeding oil reaching the main valve feeds the converter. The converter pressure is regu-
lated by the converter pressure control valve that diverts the exceeding flow to the lubrication
circuit.

D Neutralstellung
Das von der Pumpe angesaugte Öl wird durch den Filter zum Hauptdruckventil und zum
Vorwärtsgang- und Rückwärtsgangventil geleitet. Gleichzeitig wird das Öl von der Pumpe
über eine Drossel (5) zum Wandler durch den Kühler zur Schmierung der Kupplungen für den
Vorwärtsgang und den Rückwärtsgang und zurück in den Ölsumpf geleitet.
Der Ölfluß, der vom Hauptventil reguliert wird, wird durch den Wählschieber zum Abfluß gelei-
tet.
Das überschüssige Öl, das am Hauptventil ankommt, versorgt den Umwandler, dessen Druck
vom Ventil für den Umwandlerhöchstdruck reguliert wird. Dieses leitet den überschüssigen
Ölstrom zum Schmierkreislauf.

F Au point mort
L’huile aspirée par la pompe est envoyée, une fois filtrée, à la vanne de pression maxi et par
l’étranglement (5), au convertisseur. Après avoir passé l’échangeur, par le circuit de lubrifica-
tion elle arrive aux packs d’embrayages marche avant et marche arrière et, une fois passés,
elle tombe librement dans le carter.
L’huile dosée par la vanne principale est envoyée en vidange par la sélectrice.
L’huile qui arrive en excès à la vanne principale ravitaille le convertisseur la pression auquel est
réglée par la vanne de pression maxi convertisseur qui pousse le flux excédant au circuit de
lubrification.

20
TXL 30/ST

SCHEMA A circuito idraulico - Distributore Supermodulato


SCHEME A of hydraulic diagram - Supermodulating Distributor
SCHEMA A Hydraulikdiagramm - Steuerblock Supermoduliert
SCHEMA A du circuit hydraulique - Distributeur Supermodulé
2

LUBRIFICAZIONE
LUBRICATION
2.5 bar SCHMIERUNG
11 LUBRIFICATION
CADUTA DI PRESSIONE 1,5 bar max.

CHUTE DE PRESSION 1,5 bar maxi.


PRESSURE DROP 1.5 bar max.
DRUCKABFALL 1,5 bar max.

MARCIA AVANTI
10 FORWARD GEAR
VORWÄRTSGANG
MARCHE
MARCIAAVANT
AVANTI
FORWARD GEAR
RETROMARCIA
VORWÄRTSGANG
REVERSE
MARCHEGEAR
AVANT
RÜCKWÄRTSGANG
MARCHE ARRIERE
RETROMARCIA
REVERSE GEAR
8 RÜCKWÄRTSGANG
MARCHE ARRIERE
7 4

6
Scarico
Exhaust
5 Entlastung
Echappement

Principale impacco frizioni


Clutch pressure
5 3 Kupplungsdruck
Principal groupe embrayages

9
Entrata convertitore
Converter inlet
Wandlereingang
2 Entrée convertisseur

CORPO DISTRIBUTORE Entrata scambiatore


CONTROL VALVE BLOCK
1 Exchanger inlet
STEUERBLOCK Eingang Austausches
CORPS DISTRIBUTEUR
Entrée échangeur

Lubrificazione
Lubrication
Schmierung
Graissage

21
TXL 30/ST

Distributore Supermodulato - Retromarcia, Carrello avviato / SCHEMA B


Supermodulating Distributor - Reverse gear, Started lift truck / SCHEME B
Steuerblock Supermoduliert - Getriebe in Rückwärtsgang, Fahrzustand / SCHEMA B
Distributeur Supermodulé - Marche arrière, Chariot en marche / SCHEMA B

I Marcia
Si ha durante questa fase l’alimentazione delle frizioni alla massima pressione. Tale valore
viene regolato dalla valvola (3).

GB Running
During this stage the clutches are supplied at maximum pressure. This value is regulated by
valve (3).

D Gang
Während dieser Phase hat man im Ölzufuhrkreis für die Kupplungen den höchsten Druck.
Dieser Wert wird vom Ventil (3) geregelt.

F Marche
Pendant cette opération l’alimentation des embrayages est à la pression maxi. Cette valeur
est reglée par la vanne (3).

22
TXL 30/ST

SCHEMA B circuito idraulico - Distributore Supermodulato


SCHEME B of hydraulic diagram - Supermodulating Distributor
SCHEMA B Hydraulikdiagramm - Steuerblock Supermoduliert
SCHEMA B du circuit hydraulique - Distributeur Supermodulé
2

LUBRIFICAZIONE
LUBRICATION
SCHMIERUNG
2.5 bar LUBRIFICATION
11
CADUTA DI PRESSIONE 1,5 bar max.

CHUTE DE PRESSION 1,5 bar maxi.


PRESSURE DROP 1.5 bar max.
DRUCKABFALL 1,5 bar max.

MARCIA AVANTI
10 FORWARD GEAR
VORWÄRTSGANG
MARCHE AVANT

RETROMARCIA
REVERSE GEAR
RÜCKWÄRTSGANG
MARCHE ARRIERE

8
7 4

6
Scarico
Exhaust
5 Entlastung
Echappement

Principale impacco frizioni


Clutch pressure
5 3 Kupplungsdruck
Principal groupe embrayages

9
Entrata convertitore
Converter inlet
Wandlereingang
2 Entrée convertisseur

CORPO DISTRIBUTORE
CONTROL VALVE BLOCK Entrata scambiatore
1 Exchanger inlet
STEUERBLOCK
CORPS DISTRIBUTEUR
Eingang Austausches
Entrée échangeur

Lubrificazione
Lubrication
Schmierung
Graissage

23
TXL 30/ST

Distributore Supermodulato - Retromarcia in Inching / SCHEMA C


Supermodulating Distributor - Inching reverse gear / SCHEME C
Steuerblock Supermoduliert - Getriebe in Rückwärtsgang Inching / SCHEMA C
Distributeur Supermodulé - Marche Arrière en Inching / SCHEMA C

I Manovra Inching
La manovra del pedale Inching attuata per abbinare piccoli accostamenti del carrello con
elevato regime di rotazione motore parzializza l’alimentazione della frizione interessata, ridu-
cendo la pressione di lavoro e quindi la coppia trasmessa.

GB Inching manoeuver
The Inching control allows precise movement of the vehicle, irrespective of engine speed. The
oil feed to the clutch is controlled, lowering the operating pressure, allowing slipping to occur
according to pedal position.

D Inchbetätigung
Durch Betätigung des Inchpedals, wird der Druck der jeweils beaufschlagten Kupplung so
gesteuert, dass mit dem Stapler eine Kriechfahrt durchgeführt und stufenlos variiert werden.

F Manoeuvre Inching
La manoeuvre de la pédale Inching réalisée pour jumeler petits rapprochements du chariot à
régime de rotation moteur élevé, partialise l’alimentation de l’embrayage intéressé en rédui-
sant la pression de travail et donc le couple transmis.

24
TXL 30/ST

SCHEMA C circuito idraulico - Distributore Supermodulato


SCHEME C of hydraulic diagram - Supermodulating Distributor
SCHEMA C Hydraulikdiagramm - Steuerblock Supermoduliert
SCHEMA C du circuit hydraulique - Distributeur Supermodulé
2

LUBRIFICAZIONE
LUBRICATION
SCHMIERUNG
2.5 bar LUBRIFICATION
11
CADUTA DI PRESSIONE 1,5 bar max.

CHUTE DE PRESSION 1,5 bar maxi.


PRESSURE DROP 1.5 bar max.
DRUCKABFALL 1,5 bar max.

MARCIA AVANTI
10 FORWARD GEAR
VORWÄRTSGANG
MARCHE AVANT

RETROMARCIA
REVERSE GEAR
RÜCKWÄRTSGANG
MARCHE ARRIERE

8
7 4

6
Scarico
Exhaust
5 Entlastung
Echappement

Principale impacco frizioni


Clutch pressure
5 3 Kupplungsdruck
Principal groupe embrayages

9
Entrata convertitore
Converter inlet
Wandlereingang
2 Entrée convertisseur

CORPO DISTRIBUTORE
CONTROL VALVE BLOCK Entrata scambiatore
1 Exchanger inlet
STEUERBLOCK
CORPS DISTRIBUTEUR
Eingang Austausches
Entrée échangeur

Lubrificazione
Lubrication
Schmierung
Graissage

Inching

25
TXL 30/ST

I SMONTAGGIO E MONTAGGIO TRASMISSIONE - ISTRUZIONI GENERALI

3 Istruzioni generali
Prima di iniziare il lavoro di smontaggio e montaggio della trasmissione bisogna tener presente i seguenti punti:
1) Si raccomanda la massima pulizia durante il lavoro sulla trasmissione, per cui prima del montaggio tutti i
componenti devono essere accuratamente puliti.
2) Il luogo dove dovrà essere effettuato il lavoro dovrà essere privo di polvere e pulito al massimo.
3) Assicurarsi che si abbiano a disposizione tutti gli attrezzi necessari, ed in particolare quelli riportati in questo
manuale. Particolari non perfettamente montati possono infatti provocare gravi danni nella trasmissione,
come anche trucioli o corpi estranei.
4) Durante la revisione della trasmissione si consiglia di sostituire con pezzi nuovi le seguenti parti:
anelli di tenuta olio, guarnizioni, fasce elastiche ed eventuali particolari danneggiati durante lo smontaggio.
5) Nel caso di rotture all’interno della trasmissione, tutti i condotti, le scatole e lo scambiatore di calore devono
essere accuratamente puliti per evitare danni provocati dai residui rimasti nel circuito.

SPESSORI DI REGISTRO
Ad ogni registrazione selezionare gli spessori di registro misurandoli uno ad uno con micrometro e sommando
successivamente i valori rilevati: non fidarsi dell’erronea misurazione del pacco completo oppure del valore
nominale indicato per ciascun anello.
GUARNIZIONI DI TENUTA PER ALBERI ROTANTI
Per il corretto montaggio delle guarnizioni di tenuta per alberi rotanti, attenersi alle seguenti avvertenze:
▲ prima del montaggio, mantenere le guarnizioni a bagno per almeno mezz’ora nello stesso olio di cui faranno
tenuta;
▲ pulire accuratamente lʼalbero ed assicurarsi che la superficie di lavoro dello stesso non risulti danneggiata;
▲ orientare il labbro di tenuta verso il fluido; nel caso di labbro idrodinamico le rigature devono
risultare orientate in modo che, considerando il senso di rotazione dell’albero, tendano a
riportare il fluido verso l’interno del mezzo di tenuta;
▲ spalmare sul labbro di tenuta un velo di lubrificante (l’olio è da preferire al grasso) e riempire
con grasso il vano tra labbro di tenuta e labbro parapolvere delle guarnizioni a doppio labbro;
▲ introdurre la guarnizione nella relativa sede pressandola oppure impiegando un punzone con superficie di
contatto piana, evitare in modo assoluto di colpirla con martello o mazzuolo;
▲ durante il piantaggio, assicurarsi che la guarnizione venga introdotta perpendicolarmente
rispetto alla sede ed, a piantaggio ultimato, accertarsi che, nei casi richiesti, risulti a contatto
dello spallamento;
▲ ad evitare che il labbro di tenuta della guarnizione possa venire danneggiato dall’albero, inter-
porre una protezione adeguata durante il montaggio delle due parti.

GUARNIZIONI TOROIDALI O-RING


Lubrificare le guarnizioni O-RING prima di inserirle nelle rispettive sedi per evitare che, duran-
te la fase di montaggio, rotolino su se stesse ed assumano una posizione attorcigliata che ne
pregiudicherebbe la tenuta.
MASTICI DI TENUTA
Sulle superfici da accoppiare applicare il mastice di tenuta LOCTITE 510 o similare.
Prima di procedere all’ applicazione del mastice, preparare le superfici nel modo seguente:
▲ asportare eventuali incrostazioni mediante spazzola metallica;
▲ sgrassare accuratamente le superfici.

CUSCINETTI
Nel montaggio dei cuscinetti è consigliabile:
▲ riscaldarli ad 80-90° C prima di montarli sui rispettivi alberi;
▲ raffreddarli prima di inserirli nelle relative sedi con piantaggio esterno.

SPINE ELASTICHE
Al montaggio delle spine elastiche a tubo spaccato assicurarsi che l’intaglio delle stesse sia orientato nel
senso dello sforzo, sollecitante la spina.
Le spine elastiche a spirale invece non necessitano di alcun orientamento di montaggio.

IMPORTANTE: L’eliminazione fisica dei materiali usurati e sostituiti deve avvenire nel
rispetto delle leggi locali vigenti.
26
TXL 30/ST

DISASSEMBLING AND RE-ASSEMBLING OF TRANSMISSION - GENERAL INSTRUCTIONS


3
GB General instructions
Prior to starting work on the dismantling or assembing of the transmission, bear in mind the following points:
1) When working on the transmission observe high standards of cleanliness. All parts should be cleaned
throughly prior to assembly.
2) The location where the work is to be carried out should be dust-free clean.
3) Make sure that all the necessary tools are available, particularly those mentioned in this manual. Parts fitted
incorrectly can cause serious damage to the transmission, in the same way as metal chips or foreign
bodies.
4) During the transmission overhaul, you are advised tu substitute the following with new parts: oil sealing
rings, gaskets, retaining rings and any parts damaged during dismantling.
5) If breakage occurs inside the transmission, all lines, casing and heat echanger should be cleaned thoroughly
to prevent damage caused by residues left inside the system.

SHIMS
All adjustments shall be carried out after all adjustment shims have been selected measuring them one by
one with a micrometer gauge and, then, summing up all values measured; don’t trust incorrect measure-
ment of pack as a unit or sum of nominal value printed on each shim.

SEALS FOR REVOLVING SHAFTS


Proceed as follows for proper fitting of captioned seals:
▲ prior assembly, seals should be kept, for at least half an hour, in a bath with the same oil to be sealed;
▲ clean thoroughly shaft and make that working surface be not damaged;
▲ position sealing lip against the fluid to be sealed; in case of hydrodynamic lip lines should be oriented so
as that, considering direction of revolving shaft, they lead fluid inside of sealing means;
▲ smear sealing lip with a film of lubricant (oil is better than grease) and fill up with grease the space
between sealing lip and dust shield lip, if using double sealing lip type seals;
▲ press seal in relevant seat or use a proper fitter with flat contact surface; never use hammer or mallet to
mount seal;
▲ when press fitting seal make sure that it be correctly driven in relevant seat, i.e., perpendicular with res-
pect to its seat, as fitting is completed make sure, if required, that seal itself be in contact with relevant
shoulder;
▲ to prevent damage of seal lip when inserting shaft, duly protect component during assembly.

O-RING SEALS
Lubricate O-RING seals at assembly to prevent twisting that would impair correct sealing.

SEALING COMPOUNDS
For matching surfaces identified by X use compound LOCTITE 510 or similar one.
Clean matching surface as follows prior, smearing compound:
▲ remove old deposits using a metal brush;
▲ degrease surfaces by one the following cleaners: trichloroethylene, kerosene or a warm water and
soda solution.

BEARINGS
When assembling them it is advisable to proceed as follows:
▲ heat them at 80 to 90 °C before fitting on relevant shafts;
▲ cool them before inserting in relevant external seats.

SPRING PINS
When using split pins be sure that lengthwise cleft be positioned toward stress on pin.
Coil pins don’t require specific position.

IMPORTANT: Dispose of worn and replaced materials according to local regulation.

27
TXL 30/ST

D GETRIEBE DEMONTAGE UND MONTAGE - HAUPT INSTRUKTIONEN

Algemeine anweisungen
Von dem Ein- oder Ausbau der Kraftübertragung müssen folgende punkte beachtet werden:
1) Sauberkeit ist für die Arbeit an der Kraftübertragung sehr wichtig, deshalb müssen alle Teile vor
dem Einbau sorgfältig gereinigt werden.
2) Der dafür vorgesehene Arbeitsplatz muß staubfrei und gereinigt sein.
3) Prüfen, ob die notwendigen und in diesem Handbuch beschrieben Werkzeuge verfügbar sind. Nicht
einwandfrei eingebaute Teile, sowie Spähne und Fremdkörper können schwere Schäden im Getriebe
verursachen.
4) Bei der Wartung der Getriebe wird empfohlen, folgende Teile durch neue zu ersetzen: Alle
Dichtungen und eventuell die Teile, die beim Ausbau beschädigt worden sind.
5) Bei Defekten Getrieben müssen alle Leitungen, das Gehäuse und der Wärmetauscher sorgfältig
gereinigt werden, damit Schäden durch zurückgebliebene Fremdkörper vermieden werden.

AUSGLEICHSSCHEIBEN
Alle Einstellungen sollen vorgenommen werden, nachdem alle Ausgleichsscheiben, gemes-
sen mit einem Mikrometer, auf die benötigte Distanz zusammengestellt wurden. Vertraue
nie möglichen inkorrekten Messungen eines Paketes als ganzes, oder der Angabe eines nominellen Wertes,
angegeben auf den Ausgleichsscheiben.

DICHTUNGEN FÜR DREHENDE WELLEN


Für richtigen Einbau beachte folgende Schritte:
▲ Vor dem Einbau sollte die Dichtung mindestens eine halbe Stunde im selben Öl gelegen haben das
auch abgedichtetwerden soll.
▲ Reinige die Welle und stelle sicher, daß die Dichtfläche nicht beschädigt ist.
▲ Die Dichtlippe muß immer in Richtung der abzudichtenden Flüssigkeit eingebaut werden. Bei
Verwendung von Labyrinthdichtungen müssen die Rillen unter Beachtung der Drehrichtung der Welle so
eingebaut werden , daß das rücklaufende Öl immer in Richtung der abzudichtenden Seite fließt.
▲ Schmiere die Dichtlippe mit einem Film Öl ein und fülle den Raum zwischen Dichtlippe und
Staubdichtung mit Fett, wenn Doppel-Dichtringe verwendet werden.
▲ Presse die Dichtung in den entsprechenden Sitz oder benütze ein entsprechendes Montage
Werkzeug, niemals Hammer oder Dorn zur Montage benutzen.
▲ Bei der Montage beachten und sicherstellen, daß die Dichtung richtig im dafür vorgesehenen Platz
sitzt. Überprüfe, daß die Dichtung richtig an der Dichtfläche arbeitet.
▲ Um Beschädigungen der Dichtlippe zu vermeiden bei der Montage der Welle, schütze das Teil so
gut wie möglich.

O-RING DICHTUNGEN
Der O-Ring soll vor Montage eingeölt werden um ein Verdrehen und dadurch Leckagen zu vermeiden.

DICHTUNGS - MITTEL
Für Rontaktflächen bezeichnet mit X sollten nur folgende Mittel verwendet werden: LOCTITE 510.
Reinige die Kontaktflächen wie folgt vor Anwendung von Dichtmittel:
▲ Reinige Kontaktflächen von altem Dichtmittel Entfette Kontaktflächen mit:
▲ Trichloräthylene, Benzin oder warmem Wasser mit Soda Lösung.

LAGER
Bei der Lagermontage soll wie folgt verfahren werden:
▲ Erwärmung auf 80 bis 90 Grad Celsius für Montage auf Welle Kühlung vor Einbau in entsprechenden Sitz.

FEDERSTIFTE
Bei Verwendung von Spannstiften soll die Öffnung in Richtung Kraftwirkung eingebaut werden.
Federstifte erfordern keine spezifische Richtung.

HAUPTSACHE: die Elimination der ausgelaufenen und erneuerten Stoffe muß entsprechend
der örtlichen geltenden Gesetze zustande kommen.

28
TXL 30/ST

DEMONTAGE ET MONTAGE DE LA TRANSMISSION - GENERALITES

F Généralites
3
Avant de démonter ou de monter la bôite de vitesse il faut tenir compte des éléments suivants:
1) On recommande le maximum de propreté et de soin pendant l’intervention, c’est pour cette raison
qu’avant le montage tous les composants devront être soigneusement nettoyés.
2) L’endroit où l’on effectue le travail doit être propre et sans poussière.
3) Vérifier que tous les accessoires dont on a besoin sont disponibles et particulièrement ceux qui sont
mentionnés dans ce manuel. Des pièces mal montées peuvent en effet causer des dommages
importants dans la transmission.
4) Pendant la révision de la transmission nous vous conseillons de remplacer les pièces suivantes:
joints étanchéite d’huile, joints elastiques, joints toriques et toutes les pièces qui ont été éventuellement
déteriorées pendant le démontage.
5) En cas de rupture à l’intérieur de la transmission, tous les conduits, les carters et l’échangeur de chaleur
doivent être bien nettoyés afin d’éviter des dommages provoqués par des résidus restés dans le circuit.
CALES DE REGLAGE
A chaque réglage sélectionner les cales de réglage en les mesurant un à un par micromètre et en aditionnant
par la suite les valeurs relevées: ne pas compter sur l’erronée mesurage du paquet complet ou de la valeur
nominale indiquée pour chaque bague.
JOINTS D’ETANCHEITE POUR ARBRES ROULANTS
Pour un correct montage des joints d’étanchéité pour arbres roulants s’en tenir aux instructions suivates:
▲ avant le montage, maintenir les joints à bain pour au moins une demi-heure dans le même huile dont ils
feront étanchéité;
▲ nettoyer soigneusement l’arbre et s’assurer que la surface de travail du même ne pas résulte endommagée;
▲ orienter le bord d’étanchéité vers le fluide; si le bord est hydrodynamique les rayures doivent
être orientées de façon que, tenu compte du sens de rotation de l’arbre, elles tendent à reporter le fluide
vers l’intérieur du moyen d’étanchéité;
▲ étaler sur le bord d’étanchéité un voile de lubrifiant (l’huile est à préférer au gras) et remplir
avec du gras le siège entre le bord d’étanchéité et le bord parapoussière des joints à bord double;
▲ introduire le joint dans le relatif siège en le pressant ou en utilisant un poinçon avec une
surface de contact plane, éviter absolument de le frapper par marteau ou massette;
▲ pendant le plantage, s’assurer que le joint soit introduit perpendiculaire par rapport au
siège et, à plantage achevé, s’assurer que, dans les cas demandés, il résulte à contact de
l’épaulement;
▲ afin d’éviter que le bord d’étanchéité du joint soit endommagé par l’arbre, interposer une
protection appropriée pendant le montage des deux parts.
JOINTS TOROIDALS O-RING
Lubrifier les joints O-RING avant de les insérer dans les respectifs sièges afin d’éviter
que, pendant la phase de montage, ils roulent sur eux-mêmes et assument une position
enroulée qui serait nocive pour son étanchéité.
PATES A JOINT
Sur les surfaces qu’il faut accoupler appliquer la pâte à joint LOCTITE 510 ou similaires.
Avant de procéder à l’application de la pâte à joint, préparer les surfaces de cette façon:
▲ emporter éventuelles incrustations par une brosse métallique;
▲ dégraisser soigneusement les surfaces.
ROULEMENTS
Pendant le montage des roulements il est conseillable:
▲ les chauffer à 80-90°C avant de les monter sur les respectifs arbres;
▲ les refroidir avant de les insérer dans les sièges relatifs par plantage extérieur.
GOUPILLES ELASTIQUES
Au montage des goupilles élastiques à tuyau fendu s’assurer que l’entaille des mêmes soit orienté vers l’ef-
fort, en activant la goupille.
Pour les goupilles élastiques à spiral au contraire il ne faut pas d’orientation de montage.

IMPORTANT: L’ èlimination physique des vieux matériaux ou de ceux qui ont ètè remplacés doit
être faite dans le respect des lois en vigueur.

29
TXL 30/ST

ISTRUZIONI GENERALI / Conservazione ed utilizzo del prodotto


GENERAL INSTRUCTIONS / Storage and service instructions
HAUPT INSTRUKTIONEN / Lager- und Service Hinweise
GENERALITES / Conservation et utilisation du produit

I Per garantire la corretta conservazione, manipolazione ed utilizzo del prodotto occorre attenersi alle
seguenti istruzioni:

TEMPERATURA AMBIENTE

• di immagazzinamento - 40 + 60° C
• di lavoro - 30 + 60° C

Durante la manipolazione del prodotto evitare urti che potrebbero danneggiare componenti ester-
! ni ed interni.

In caso di fermate prolungate prima dell’installazione o del riavviamento assicurarsi che il prodotto
! non abbia subito danni.

! Non sottoporre i componenti elettrici a tensioni incompatibili con le loro caratteristiche

Non utilizzare mai benzina, gasolio o altri liquidi infiammabili come detergenti: ricorrere invece ai
! solventi commerciali ininfiammabili e non tossici.

! In caso di arresto e di abbandono del veicolo assicurarsi che il freno di stazionamento sia inserito.

Il mancato rispetto di queste istruzioni oppure l’uso non corretto del prodotto può
produrre danni a cose o persone.

GB In order to assure the right condition, handling and utilization of the product, perform the following
instruction:

TEMPERATURE CONDITIONS

• Storage - 40 + 60° C
• Working - 30 + 60° C

During the handling of the product avoid any collision in order not to damage the external and
! internal components.

In case of long inactivity of the product, before installing or starting, beware that the product has
! not suffered any damage.

! Do not energize the electrical components with incompatible voltage.

Never use petrol, solvents or other inflammable fluids, use only approved commercial solvents
! that are both non-inflammable and not-toxic.

! In case of stopping and before living the vehicle, make sure the parking brake is engaged.

Failing to follow these instructions or an unproper use of the product may result in harm to per-
sons and objects damages.

30
TXL 30/ST

HAUPT INSTRUKTIONEN / Lager- und Service Hinweise


GENERALITES / Conservation et utilisation du produit 3
D Um die angemessene Lagerung, Behandlung und Verwendung der Produkte zu garantieren, müssen
folgende Hinweise beachtet werden:

TEMPERATURBEDINGUNGEN

• Bei Lagerung - 40 + 60° C


• Im Einsatz - 30 + 60° C

! Innere und äußere Beschädigungen sind zu vermeiden

ßei Längerer Lagerung des Produktes, muß sichergestellt sein, daß keine Beschädigung auf-
! getreten ist.

! Elektrische Komponenten sind nur mit der vorgeschriebenen Spannung zu belasten.

Niemals Benzin, Lösungsmittel oder entflammbare Flüssigkeiten verwenden.


! Handelsübliche, nicht ent-flammbare und ungiftige Reinigungsmittel benützen.

! Beim Abstellen und vor dem Verlassen des Fahrzeuges ist die Parkbremse zu betätigen.

Durch Nichtbeachtung dieser Instruktionen oder einer ungeeigneten Verwendung dieses


Produktes kann Gefahr für Menschen oder Sachschaden an Objekten entstehen.

F Pour garantir une correcte conservation, manipulation et utilisation du produit, il faut s’en tenir aux
instructions suivantes:

TEMPERATURE AMBIANTE

• Stockage - 40 + 60°C
• de travail - 30 + 60°C

Pendant la manipulation du produit éviter les coups qui pourraient endommager les components
! extérieurs et intérieurs.

En cas d’arrêts prolongés avant de l’installation ou du redémarrage s’assurer que le produit ne


! soit pas endommagé.

! Ne pas soumettre les éléments électriques à tensions incompatibles avec leurs caractéristiques.

Ne jamais utliser de l‘essence, gas-oil ou des autres liquides inflammables comme détergents:
! utiliser plutôt des solvents commerciaux ni inflammables ni toxiques.

! En cas d’arrêt et d’abandon du vehicule s’assurer que le frein de stationnement soit inséré.

Le manqué respect des instructions ou un usage pas approprié du produit peut provoquer des
dommages à choses ou personnes.

31
TXL 30/ST

SMONTAGGIO E MONTAGGIO TRASMISSIONE - Attrezzi speciali


DISASSEMBLING AND RE-ASSEMBLING OF TRANSMISSION - Specific tools
GETRIEBE DEMONTAGE UND MONTAGE - Montagewerkzeug
DEMONTAGE ET MONTAGE DE LA TRANSMISSION - Outils spéciaux

1 - Punzone per piantaggio cuscinetto a sfere


Bearing fitting tool
Bolzen für Montage von Rilenkugellager
Poinçon pour positionnement roulement à billes
2 - Attrezzo per montaggio anello Q-Ring
Tool for Q-Ring assembly
Werkzeug für die Montage des Q-Rings
Outil pour montage bague Q-Ring
3 - Attrezzatura per la scomposizione dei pacchi frizione
Fixture for diassembling of clutch plates
Werkzeug zur Demontage der Kupplungslamellen
Outillage pour démontage des packs embrayage
4 - Punzone per piantaggio cuscinetto
Bearing fitting tool
Bolzen für Montage von Lager
Poinçon pour positionnement roulement
5 - Punzone per piantaggio cuscinetto
Bearing fitting tool
Bolzen für Montage von Lager
Poinçon pour positionnement roulement
6 - Punzone per piantaggio cuscinetto
Bearing fitting tool
Bolzen für Montage von Lager
Poinçon pour positionnement roulement
7 - Punzone per piantaggio cuscinetto
Bearing fitting tool
Bolzen für Montage von Lager
Poinçon pour positionnement roulement
8 - Chiave per chiusura ghiera manicotto mozzo ruota (1a versione) vedere pagina 34
Spanner for slotted nut of wheel hub spindle (1st version) see page 34
Schlüssel zum Festziehen Nutmutter Muffe Radnabe (1. Version) Siehe Seite 34
Clé de fermeture de frette manchon moyeu de la roue (1ère version) voir page 34
9 - Chiave bloccaggio ghiera registrazione cuscinetto mozzo (2 a versione) vedere pagina 34
Locking spanner for slotted nut of hub bearing adjusting (2nd version) see page 34
Feststellschlüssel Einstellnutmutter Lager Radnabe (2. Version) Siehe Seite 34
Clé de blocage frette réglage roulement moyeu de la roue (2 ème version) voir page 34
10 - Punzone per piantaggio guarnizione di tenuta su manicotto ponte (1a versione) vedere pag. 34
Forcing seal ring tool on spindle of axle (1st version) see page 34 Siehe Seite 34
Bolzen für Montage von Dichtring an der Muffe der Achse (1. Version)
Poinçon pour positionnement bague d’étanchéité sur manchon pont (1ère version) voir page 34
11 - Punzone per piantaggio guarnizione di tenuta su manicotto ponte (1a versione) vedere pag. 34
Forcing seal ring tool on spindle of axle (1st version) see page 34 Siehe Seite 34
Bolzen für Montage von Dichtring an der Muffe der Achse (1. Version)
Poinçon pour positionnement bague d’étanchéité sur manchon pont (1ère version) voir page 34
12 - Chiave bloccaggio ghiera registrazione differenziale vedere pag. 34
Locking spanner for slotted nut of Differential see page 34
Feststellschlüssel Einstellnutmutter Differential Siehe Seite 34
Clé de fermeture de frette réglage Différentiel voir page 34
13 - Punzone per piantaggio guarnizione di tenuta su manicotto ponte (2a versione) vedere pag. 34
Forcing seal ring tool on spindle of axle (2nd version) see page 34
Bolzen für Montage von Dichtring an der Muffe der Achse (2. Version) Siehe Seite 34
Poinçon pour positionnement bague d’étanchéité sur manchon pont (2 ème version) voir page 34
14 - Punzone per piantaggio guarnizione di tenuta su manicotto ponte (2a versione) vedere pag. 34
Forcing seal ring tool on spindle of axle (2nd version) see page 34
Bolzen für Montage von Dichtring an der Muffe der Achse (2. Version) Siehe Seite 34
Poinçon pour positionnement bague d’étanchéité sur manchon pont (2 ème version) voir page 34

32
TXL 30/ST

Attrezzi / Tools / Werkzeug / Outils


3
1 2 3

4902166

48A17092 PTO SAE "A"


48A17127 SAE "A"-"B"

4A41377

4 5 6 7

4902648 4902174 4902172 4902302

33
TXL 30/ST

SMONTAGGIO E MONTAGGIO PONTE - Attrezzi speciali


DISASSEMBLING AND RE-ASSEMBLING OF AXLE - Specific tools
ACHSE DEMONTAGE UND MONTAGE - Montagewerkzeug
DEMONTAGE ET MONTAGE DE PONT - Outils

12 13 14

48A19118

48A19394

48A19120

10 9

48A19119

8 12.7
0m
m

48A13533

11

48A13164

"
3/4

48A13511
48A12542

34
TXL 30/ST

Smontaggio e montaggio trasmissione


Dismantle and assemble transmission
Getriebe Demontage und Montage
Demontage et montage de la transmission
3

! SICUREZZA GENERALE !
Prima di eseguire qualsiasi intervento di riparazione, predisporre le adeguate misure di
I
sicurezza indicate nel capitolo “Norme di sicurezza” e rispettare le leggi vigenti in materia di sicu-
rezza nei posti di lavoro.

! GENERAL SAFETY !
GBBefore undertaking any repair, follow safety rules indicated in chapter “Safety rules” in accor-
dance with specific local regulation about safety on work places.

!
ALLGEMEINE SICHERHEIT !
Vor jeder Ausbesserung vorbereiten die Sicherheitsmaßnahme, die im Kapitel “Sicherheit
D
sbestimmungen” angegeben sind und achten die besonderen Gesetze über die Sicherheit im
Arbeitsplätze.

!
SURETE GENERALE !
F Avant d’effectuer toute intervention de réparation, préparer les mesures de sûreté les plus
adéquates, indiquées au chapitre “Normes de sûreté” et respecter les réglementations en vigueur
en matière de sûreté sur les lieux de travail.

I Scarico olio: Scaricare l’olio attraverso il tappo


(a), della scatola ponte ed i tappi (b), della scatola
presa di forza e della scatola trasmissione.
GB Oil draining: Drain oil through plug (a) of axle
casing and plugs (b) of PTO case and transmission
case.
D Ölablassen: Schrauben (a) Achsgehäuse, Schrauben
(b) PTO- und Getriebegehäuse.
a
F Dégorgement huile: Dégorger l’huile par le bou-
chon (a), du carter pont et les bouchons (b), du 1
carter prise de force et du carter transmission.

b
b
1a

35
TXL 30/ST

I In figura è rappresentato il filtro posto sull’ aspi-


razione della pompa. È opportuno ad intervalli
prefissati (vedi manutenzione periodica) o in occa-
sione di una revisione esso venga sostituito com-
pleto di anello di tenuta O-RING.
GB The picture shows the filter placed on the pump
suction duct. This filter, compulsorily with the plug
o.ring, must be replaced at recommended inter-
vals ( see maintenance operation ) or whenever an
overhaul is performed.
2 D In der Abbildung ist der Filter auf der
Pumpenabsaugung dargestellt. Der Filter ist nach
festgelegten Zeitabständen (s. dazu die regelmässi-
ge Wartungsaktivitäten) oder bei einer Überholung
mit Dichtring O-RING komplett auszutauschen.
F La figure représente le filtre placé sur l’aspiration
de la pompe. À intervalles planifiés (voir main-
tenance périodique) ou en cas de révision, il est
conseillé de remplacer le filtre et son joint torique.

I Stacco convertitore
Rimuovere il convertitore sfilandolo assialmente.
GB Torque converter removal
Remove converter unit by pulling it in axial direc-
tion.
D Wandler waagerecht abziehen
Wandler in Achsenrichtung abziehen.
F Détachement du convertisseur
Détacher le convertisseur en l’enlevant axialement.
3

I Stacco scatola convertitore


Togliere le viti di fissaggio scatola convertitore.
GB Removal of torque converter case
Remove the screws securing the converter.
D Wandler waagerecht herausziehen
Schrauben des wandlergetriebegehäuses entfer-
nen.
F Détachement du carter convertisseur
Desserrer les vis de fixation du carter convertis-
4 seur.

I Sfilare la scatola convertitore.

GB Remove the converter case.

D Wandlergetriebegehäuse abziehen.

F Enlever le carter convertisseur.

36
TXL 30/ST

Revisione scatola Convertitore


Converter case overhauling
Überholung Wandlergehäuse
Révision boîte Convertisseur
3
I Sganciare l’anello elastico ritegno ingranaggio con-
dotto.

GB Unhook lock ring retaining driven gear.

D Haltesprengring des angetriebenen Rades


aushaken.

F Décroicher le segment de retenue engrenage con-


duit.

I Sollevare l’ingranaggio condotto con opportuna


leva e rimuovere la catena.
GB Lift driven gear by proper lever and remove chain.

D Das angetriebene Rad mit einem geeigneten


Hebel anheben und die Kette entfernen.

F Soulever l’engrenage conduit par opportun levier


et enlever la chaîne.

I Allentare le viti fissaggio coperchio fermo cusci-


netto ingranaggio conduttore.

GB Release screws securing cover retaining driving


gear bearing.

D Deckelbefestigungsschrauben Lagerhalterung
Antriebsrad lockern.

F Desserrer les vis de fixation du couvercle fermetu-


re roulement engrenage conducteur.
8

I Rimuovere l’ingranaggio condotto e l’ingranaggio


conduttore completi di cuscinetti.
GB Remove driving and driven gears, complete with
bearings.

D Das angetriebene Rad und das Antriebsrad kom-


plett mit Lagern entfernen.

F Enlever l’engrenage conduit et l’engrenage con-


ducteur complets de roulements.
9

37
TXL 30/ST

I Togliere gli anelli elastici ritegno cuscinetti rispet-


tivamente sull’ingranaggio condotto e sull’ingra-
naggio conduttore. Pulire perfettamente tutti i par-
ticolari, verificarli, sostituirli secondo necessità.

GB Remove bearing lock rings, respectively on driving


and driven gears. Clean thoroughly all componen-
ts, check and replace as required.

D Haltesprengringe Lager bzw. am getriebenen und


Antriebsrad entfernen. Alle Bauteile vollständig
reinigen, prüfen, falls erforderlich ersetzen.
10
F Enlever les segments de retenue des roulements
respectivement sur l’engrenage conduit et sur
l’engrenage conducteur. Nettoyer soigneusement
tous les composants, les vérifier et substituer
selon nécessité.

I Nell’ eventuale sostituzione dell’ anello Q-Ring


dell’ ingranaggio conduttore e dell’ ingranaggio
condotto, utilizzare per il montaggio l’attrezzo
speciale:
48A17127 per TXL30/ST SAE “A” e SAE “B”
48A17092 per TXL30/ST PTO SAE “A”.

GB Should the replacement of the Q-Ring fitted on


the driving and driven gears be necessary, use
specific tool:
11 48A17127 for TXL30/ST SAE “A” and SAE “B”
48A17092 for TXL30/ST PTO SAE “A”.

D Wenn man den Q-Ring im Antriebszahnrad und im


Abtriebszahnrad erneuern möchte, mub man für
die Montage das spezielle Werkzeug verwenden,
d.h.:

48A17127 für TXL30/ST SAE “A” e SAE “B”


48A17092 für TXL30/ST PTO SAE “A”.

F En cas de remplacement,de bague Q-Ring aussi


bien sur l’engrenage conducteur que sur l’engre-
nage conduit, pour le montage il faut utiliser l’outil
spécial:
12
48A17127 pour TXL30/ST SAE “A” et SAE “B”
48A17192 pour TXL30/ST PTO SAE “A”.

38
TXL 30/ST

I Sostituire la guarnizione di tenuta sulla scatola del


convertitore mediante attrezzo appropriato.
Nota: la guarnizione deve essere lubrificata prima
3
del montaggio seguendo le relative istruzioni
generali.

GB Replace the seal on converter case by using a


proper installer.
Note: Lubricate the seal prior installation following
specific general instructions.

D Dichtring-Ausbau nur mit geeignetem Werkzeug. 13


Beachte: der Dichtring muss für die vorgeschrei-
benen Öle geeignet sein.

F Substituer le joint d’étancheité sur le carter con-


vertisseur par opportun outil.
Note: le joint doit être lubrifié avant le montage en
suivant tout les reinsegnements.

I Rimontare il cuscinetto sull’ingranaggio condotto e


sull’ingranaggio conduttore e i relativi anelli elastici
di ritegno.
Reinserire in sede sulla scatola convertitore, il
complessivo ingranaggio conduttore e ingranaggio
condotto.
Montare e fissare il coperchio fermo cuscinetto,
applicare il frenafiletti medio sulle viti fissaggio e
bloccarle con una coppia di serraggio di 3 Nm.

GB Refit bearings on driving and driven gears and


relevand lock rings.
Refit driving and driven gear assembly in relevant
14
seats on converter case.
Install and secure the bearing retaining cover,
smear a medium locking compound on screws
and tighten with a torque of 3 Nm.

D Das Lager und die jeweiligen Haltesprengringe


wieder auf das angetriebene und das Antriebsrad
montieren.
Die Baugruppe angetriebenes und Antriebsrad
wieder in ihren Sitz auf dem Konvertergehäuse
einsetzen.
Den Deckel Lagerhalterung einbauen und befe-
stigen, mittlere Gewindedichtmasse auf die
Befestigungsschrauben auftragen und mit einem
Anziehdrehmoment von 3 Nm festziehen.

F Remonter le roulement sur l’engrenage conduit


et sur l’engrenage conducteur et les segments de
retenue correspondants.
Réinserer dans son siège sur le carter convertisseur
l’engrenage conducteur et l’engrenage conduit
complets.
Monter et fixer le couvercle de fermeture du rou-
lement, appliquer le frein à filets moyen sur les vis
de fixation et les bloquer à un couple de serrage de
3 Nm.

39
TXL 30/ST

I Montare la catena sull’ingranaggio condotto e con-


duttore.

GB Assemble chain on drive and driven gears.

D Die Kette auf die Abtriebswelle und die


Antriebswelle montieren.

F Monter la chaîne sur l’engrenage conduit et con-


ducteur.

15

I Inserire nella propria sede l’anello elastico di rite-


gno ingranaggio condotto.

GB Insert into its seat the lock ring retaining driven


gear.

D Den Haltesprengring der Abtriebswelle in seinen


Sitz einführen.

F Monter dans son propre siège le segment de rete-


nue engrenage conduit.
16

40
TXL 30/ST

Smontaggio e rimontaggio Distributore Supermodulato


Dismantling and re-assembling of Supermodulating Distributor
Demontage und Zusammenbau Steuerblock Supermoduliert
3
Démontage et rémontage Distributeur Supermodulé

I Smontaggio comando azionamento inching (a


secondo della versione):

GB Removal of the inching control mechanism


(according to various configuration)

D Demontage des Inching-Hydraulik-Befehls (je


nach Version):

F Démontage commande actionnement inching


(selon la version):
17

I Sganciare la molla dai perni.

GB Unhook the spring from pin

D Feder von den Stiften entriegeln.

F Décrocher le ressort des pivots.

18

I Stacco distributore
Sbloccare e svitare le viti di fissaggio e smontare
il distributore completo.
Rimuovere la guarnizione di tenuta in carta.

GB Distributor removal
Unscrew the fixing screws and dismantle the
complete distributor.
Remove the paper gasket

D Ausbau Steuerblock
Zwölf Befestigungsschrauben lösen und 19
Steuerblock komplett abheben.
Entfernen der Dichtung.

F Détachement du distributeur
Débloquer et desserrer les vis de fixation, puis
déposer le distributeur complet.
Enlever le joint d’étanchéité en papier

41
TXL 30/ST

Revisione distributore Supermodulato


Supermodulating distributor overhauling
Nachprüfung Steuerblock Supermoduliert
Révision du distributeur Supermodulé

Inching Idraulico Inching Meccanlco


fig. 20 INCHING IDRAULICO
Hydraulic Inching
INCHING MECCANICO
Mechanical Inching
HYDRAULIC INCHING
Hydraulisches Inching MECHANICAL INCHING
Mechanisches Inching
HYDRAULIK INCHING
Inching Hidraulique Inching Mecanique
MECHANISCHES INCHING

I Nella figura sono individuabili, i quattro assi del D Das Bild zeigt die 4 Schaltebenen des
distributore: Steuerblocks:
1) asse selettrice avanti-indietro 1) Schaltmagnetventile für den Vorwärts-und
2) asse Inching control Rückwärtsgang
3) asse valvola principale - valvola convertitore 2) Inchkolben
4) asse valvola modulatrice 3) Achse Hauptventil - Umwandlerventil
4) Modulatorachse.
GB The figure shows from top to bottom the four
distributor axis: F Dans la figure on peut voir, les quatre axes du
1) forward-reverse shifting axle distributeur:
2) Inching control axle 1) axe sélecteur avant-arrière
3) main valve - converter valve axle 2) axe contrôle Inching
4) Modulating Axle. 3) axe vanne convertisseur et vanne principale
4) axe vanne modulatrice

I Smontaggio asse selettrice avanti-indietro


Svitare il dado di fissaggio elettrovalvola.

GB Disassembly of forward-reverse shifting shaft


Undo nut securing electrovalve.

D Ausbau Wechselachse vor-zurück


Die Befestigungsmutter Magnetventil abschrau-
ben.

F Démontage de l’axe sélecteur avant-arrière


21
Dévisser l’ecrou de fixation électrovanne.

42
TXL 30/ST

I Estrarre le elettrovalvole complete di anelli di


tenuta O-Ring.
Controllare i componenti, l’integrità della parti e
3
l’eventuale impurità (in presenza di residui metal-
lici sostituire l’elettrovalvola completa).
Pulire perfettamente tutti i particolari, in caso di
usura, sostituire.
Riassemblare i componenti bloccando la ghiera
del solenoide alla coppia di 1 daNm.
22
GB Remove the electrovalves complete with O-Rings.
Check components, clean full each component,
replace if required (if there are metallic residues,
replace the electrovalve complete).
Reassemble components locking solenoid nut
with a torque of 1 daNm.

D Magnetventile komplett mit O-Dichtringen herau-


sziehen.
Die Bauteile, die Unversehrtheit der Einzelteile
und eventuelle Unreinheiten kontrollieren
(falls Metallreste vorhanden sein sollten, das
Magnetventil komplett ersetzen).
Alle Bestandteile sorgfältig reinigen; im Falle von
Verschleiß ersetzen.
Die Bestandteile wieder zusammensetzen,
dabei die Nutmutter des Solenoids mit einem
Drehmoment von 1 Nm festziehen.

F Extraire les électrovannes complètes des segmen-


ts de retenue O-Ring.
Contrôler les composants, que toutes les parties
ne soient pas endommagées et les impurétés
éventuelles (en cas de résidus métalliques, rem-
placer l’électrovanne complète).
Nettoyer soigneusement tout les composants et,
en cas d’usure, substituer.
Réassembler les composants en bloquant la frette
au couple de 1 daNm.

I Smontaggio Asse Inching - Versione Comando


Meccanico 23
Svitare le quattro viti di fissaggio coperchio.

GB Inching Axle dismantling - Mechanical Inching


Version
Undo the four screws securing cover.

D Ausbau Inching-Achse - Version mechanische


Schaltung
Die vier Befestigungsschrauben des Deckels
abschrauben.

F Démontage Axe Inching - Version Commande


Mécanique
Dévisser les quatre vis de fixation du couvercle.

43
TXL 30/ST

I Sfilare i componenti asse Inching.


24
GB Remove Inching control components.

D Die Bauteile Achse Inching herausziehen.

F Enlever les composants de l’axe Inching.

I N. B.: Per lo smontaggio dell’asse Inching non è


necessario smontare il dado di regolazione: nel
caso si rendesse necessario, svitare il dado com-
pleto e relativa rosetta di tenuta.

GB Note: To dismantle Inching axle it isn’t necessary


to dismantle regulating nut: if required, unscrew
nut complete and relevant rubber seal.

D Hinweis: Für den Ausbau der Inching-Achse


ist es nicht erforderlich, die Einstellmutter abzu-
bauen: falls es aber notwendig sein sollte, muß
25 die komplette Mutter mit Dichtscheibe herausge-
schraubt werden.

F Note: Pour le démontage de l’axe Inching


démonter l’écrou de réglage n’est pas nécessaire:
si nécessaire, dévisser l’écrou complet et la ron-
delle de retenue.

ATTENZIONE! Per non pregiudicare il corret-


! to funzionamento dell’asse Inching, non mano-
mettere e non smontare il tappo di regolazione
dal dado.

WARNING! To not prejudice right working of


! Inching axle, don’t tamper and don’t dismantle
regulating plug of nut.

ACHTUNG! Um das korrekte Funktionieren


! der Inching-Achse nicht zu beeinträchtigen,
den Einstellverschluß nicht verändern und
25a nicht von der Mutter abbauen.

ATTENTION! Ne pas compromettre le fon-


! ctionnement correct de l’axe Inching, ne pas
toucher le bouchon de réglage de l’écrou.

44
TXL 30/ST

GB
Rimuovere e sostituire la guarnizione O-Ring (a).

Remove and replace O-Ring seal (a).


3
D Den Dichtungs-O-Ring (a) entfernen und ersetzen.
a
F Enlever et remplacer le joint O-Ring (a).

26

I Pulire perfettamente tutti i particolari, verificarli,


sostituirli secondo necessità.

GB
Clean full each component, check them, replace if
required.

Alle Bestandteile sorgfältig reinigen, prüfen, bei


F
Bedarf ersetzen.

Nettoyer soigneusement tout les composants,


F
vérifier et, si nécessaire, remplacer.

27

I Smontaggio asse valvola principale - valvola


convertitore
Svitare il tappo ed estrarre il pistoncino della val-
vola di regolazione della pressione convertitore
con relativa molla ed eventuali spessori di rego-
lazione.

GB Dismantling of main valve - converter valve


axle
Unscrew plug and remove small piston of conver-
ter pressure regulating valve with relevant spring
and possible shims. 28
D Zerlegen Achse Hauptventil - Umwandlerventil
Verschluß abschrauben und den Steuerkolben des
Konverter-Druckregelventils mit entsprechender
Feder und eventuellen Einstellscheiben heraus-
ziehen.

F Démontage axe vanne principale - vanne


Convertisseur
Dévisser le bouchon et extraire le petit piston de la
vanne de réglage de la pression du convertisseur
avec relatif ressort et cales de réglage éventuels.

45
TXL 30/ST

I Svitare il tappo posteriore, estrarre il pistoncino


29 della valvola di pressione principale con relativa
molla ed eventuali spessori di regolazione.

GB Undo rear plug, extract small piston from main


pressure valve with relevant spring and shims.

D Den hinteren Verschluß abschrauben und den


Kolben des Hauptdruckventils mit entsprechender
Feder und Einstellscheibe herausziehen.

F Dévisser le bouchon postérieur, extraire le petit


piston de la vanne de pression principale avec
relatif ressort et cale de réglage.

I Per rimuovere la boccola centrale dell’asse, allen-


30 tare la vite posta sotto il distributore.
GB To remove central bush of axle, undo screw placed
under distributor.

D Um die mittlere Buchse der Achse zu entfernen,


die Schraube unter dem Verteiler lockern.

F Pour enlever la douille centrale de l’axe, desserrer


la vis placée sous le distributeur.

I Componenti asse valvola convertitore - valvola


31 principale
Pulire perfettamente tutti i particolari, verificarli,
sostituirli secondo necessità.

GB Components of converter valve - main valve axle


Clean full each component, check them, replace if
required.

D Bauteile Achse Wandlerventil - Hauptventil


Alle Bestandteile sorgfältig reinigen, prüfen, bei
Bedarf ersetzen.

F Composants axe vanne convertisseur - vanne


principale
Nettoyer soigneusement tout les composants, véri-
fier et, si nécessaire, remplacer.

46
TXL 30/ST

I Smontaggio e rimontaggio Asse Modulatrice


Premere la bussola e sganciare l’anello elastico
anteriore.
3
GB Dismantling and re-assembling Modulating Axle
Push bushing and unhook front lock ring.

D Ausbau und Einbau Modulatorachse


Auf die Buchse drücken und den vorderen
Sprengring aushaken.
32
F Démontage et rémontage Axe Modulatrice
Pousser la douille et décrocher le segment de
retenue.

I Estrarre la bussola e rimuovere la guarnizione O-


Ring. 33
GB Extract bushing and remove O-Ring seal.

D Die Buchse herausziehen und Die O-Ring-


Dichtung entfernen.

F Extraire la douille et enlever le joint O-Ring.

I Sfilare il pistone e le due molle.

GB Remove piston and the two springs.

D Den Kolben und die beiden Federn herausziehen.

F Dévisser le piston et les deux ressorts.

34

I Sganciare l’anello elastico posteriore, rimuo-


vere la guarnizione O-Ring e il coperchio Asse
Modulatrice.

GB Unhook rear lock ring, remove O-Ring seal and


Modulating Axle cover.

D Den hinteren Sprengring aushaken, die O-Ring-


Dichtung und den Deckel Modulatorachse entfer-
nen.

F Décrocher le segment de retenue postérieur,


enlever le joint O-Ring et le couvercle Axe 35
Modulatrice.

47
TXL 30/ST

I Componenti Asse Valvola Modulatrice


36 Pulire perfettamente tutti i particolari, verificarli,
sostituirli secondo necessità.
GB Components of Modulating Valve Axle
Clean full each component, check them, replace if
required.
D Bestandteile Achse Modulatorventil
Alle Bestandteile sorgfältig reinigen, prüfen, bei
Bedarf ersetzen.
F Composants Axe Vanne Modulatrice
Nettoyer soigneusement tout les composants,
vérifier et, si nécessaire, remplacer.

I Particolare attenzione si dovrà dedicare alla bus-


37 37a sola completa:
svitare il tappo, controllare l’interno della stessa e
sulla sfera che non vi siano impurità, pulire perfet-
tamente e rimontare.

GB Special care is required for bushing complete:


unscrew plug, check inside of the same and on
the ball that there aren’t impurities, clean full and
reassemble.

D Besondere Aufmerksamkeit muß der kompletten


Buchse gewidmet werden:
Den Verschluß abschrauben, das innere dersel-
ben sowie die Kugel kontrollieren, damit keine
Unreinheiten vorhanden sind, vollkommen reinigen
und wieder einsetzen.

F Prêter beaucoup d’attention à la douille complète:


dévisser le bouchon, en contrôler la partie
intérieure et pue sur la bille il n’y pas d’impurétés,
nettoyer parfaitement et remonter.

I Montare nella propria sede la guarnizione O-Ring,


38 inserire il coperchio e nel posizionarlo prestare
attenzione a non superare la battuta dell’anello
elastico.

GB Assemble the O-Ring seal into its seat, insert


cover and positionning it, take care not to overtake
lock ring seat.

D Die O-Ring-Dichtung in ihren Sitz einbauen, den


Deckel einsetzen und bei der Positionierung darauf
achten, daß der Anschlag nicht überschritten wird,
um eine eventuelle Beschädigung des O-Rings
und des Sprengrings zu vermeiden.

F Monter le joint O-Ring dans son propre siège,


insérer le couvercle et, en le positionnant, faire
attention à ne pas dépasser anneau de sûreté du
segment de retenue.

48
TXL 30/ST

GB
Inserire l’anello elastico.

Insert lock ring.


3
D Den Sprengring einführen.

F Insérer le segment de retenue.

39

I Rimontare le molle e il pistone.

GB Reassemble springs and piston.

D Die Federn und den Kolben wieder einbauen.

F Remonter le ressort et le piston.

40

I Montare nella propria sede la guarnizione O-Ring.

GB Assemble into its seat O-Ring seal.

D Die O-Ring-Dichtung in ihren Sitz einbauen.

F Monter dans son propre siège le joint O-Ring.

41

I Infilare la bussola completa, avendo cura di non


danneggiare la guarnizione O-Ring, premere la
bussola e inserire l’anello elastico.

GB Assemble the bushing complete, taking care not


to damage the O-Ring seal, push bushing and
insert lock ring.

D Die komplette Buchse einsetzen, dabei darauf


achten, den O-Ring nicht zu beschädigen, die
Buchse eindrücken und den Sprengring einsetzen.

F Insérer la douille coplète, en ayant soin de ne pas 42


endommager le joint O-Ring, pousser la douille et
insérer le segment de retenue.

49
TXL 30/ST

I Rimontaggio Asse Valvola Principale - Valvola


43 Convertitore
- Posizionare la boccola centrale (a);
- umettare la vite di fermo (b) con Loctite 242;
- bloccare la boccola;
- rimontare lo spessore di regolazione (c);
- infilare molla e pistoncino Valvola di Pressione
Principale (d);
- serrare il tappo con rosetta di tenuta (e).
Procedere in modo analogo per il montaggio nella
parte anteriore della valvola convertitore (fig.43b).

GB Reassembling of Main Valve - Converter Valve


Axle
43a
- Position the central bushing (a):
- smear locking screw (b) with Loctite 242;
c - lock bushing;
e - reassemble shims (c);
- insert spring and small piston of Main Pressure
Valve (d);
a b - lock plug with rubber seal (e).
d
Follow the same procedure to assemble front part
of converter valve (fig. 43b).

D Wiedereinbau Achse Hauptventil -


Wandlerventil
- Die mittlere Buchse einsetzen (a);
43b c
- die Halteschraube (b) mit Loctite 242 benetzen;
- die Buchse befestigen;
e - die Einstellscheiben wieder einbauen (c);
d - die Feder und den Kolben Hauptdruckventil
einführen (d);
- den Verschluß mit Scheibe festziehen (e).
In analoger Weise für den Einbau des vorderen
Teils des Wandlerventils vorgehen (Abb. 43b).

F Rémontage Axe Vanne Principale - Vanne


Convertisseur
- Placer la douille centrale (a);
- humecter la vis de fermeture (b) avec Loctite 242;
- bloquer la douille;
- Remonter la cale de réglage (c);
- Insérer le ressort et le petit piston vanne de
pression principale (d);
- Serrer le bouchon en se servant d’une rondelle
de sûreté (e).
Procéder de manière analogue pour le montage
dans la partie antérieure de la vanne convertisseur
(fig. 43b).
50
TXL 30/ST

I Rimontaggio Asse Inching - Versione Comando


Meccanico
Rimontare il dado di regolazione con la relativa
3
rosetta di tenuta e serrare.
GB Reassembling Inching Axle - Mechanical Drive
Version
Reassemble regulating nut with relevant rubber
seal and lock.

D Einbau Inching-Achse - Version mechanische


Schaltung 44
Die Einstellmutter mit der entsprechenden
Dichtscheibe einbauen und festziehen.

F Rémontage Axe Inching - Version Commande


Mecanique
Remonter l’écrou de réglage en se servant de la
rondelle de retenue correspondant et serrer.

! ATTENZIONE !
I Per non pregiudicare il corretto funzionamento
dell’asse Inching, non manomettere il tappo di
regolazione del dado.

! WARNING !
GB To not prejudice right working of Inching axle,
don’t tamper and don’t dismantle regulating
plug of nut.

! ACHTUNG ! 44a
D Um den korrekten Betrieb der Inching-Achse
nicht zu beeinträchtigen, den Einstellstopfen
der Mutter nicht verletzen.

! ATTENTION !
F Ne pas compromettre le fonctionnement cor-
rect de l’axe Inching, ne pas toucher le bou-
chon de réglage de l’écrou.

I Inserire i componenti Asse Inching.


GB
Insert components of Inching Axle.
D
Die Bestandteile der Inching-Achse einführen.
F Insérer les composants de l’axe Inching.

45

51
TXL 30/ST

I Umettare le quattro viti con Loctite 242 e bloccare


alla coppia di 0,5 daNm il coperchio.

GB Smear the four screws with Loctite 242 and lock


the cover with a torque of 0.5 daNm.

D Die vier Schrauben mit Loctite 242 benetzen und


mit einem Drehmoment von 0,5 daNm den Deckel
festziehen.

F Humecter les quatre vis avec Loctite 242 et blo-


quer le couvercle au couple de 0,5 daNm.
46

I Smontaggio Asse Inching - Versione Comando


Idraulico
Svitare le quattro viti di fissaggio corpo Inching al
distributore.
GB Inching Axle Dismantling - Hydraulic Inching
Version
Undo fixing screws of Inching body to distributor.

D Ausbau Inching-Achse - Version hydraulische


Schaltung
47 Die vier Befestigungsschrauben Körper Inching am
Verteiler abschrauben.

F Démontage Axe Inching - Versión Commande


Hydraulique
Dévisser les quatre vis de fixation corps Inching au
distributeur.

I Sfilare i componenti asse Inching.


IMPORTANTE: Il comando Inching idraulico
non è revisionabile, in caso di usura o malfun-
zionamento, sostituire.

GB Remove components of Inching axle.


IMPORTANT: The inching control assy is not
repairable. In case of wear or malfunction a
new assy must be fitted.

D Die Bauteile der Inching-Achse herausziehen.


48
HAUPTSACHE: Der Inching-Hydraulik-Befehl
kann nicht instandgesetzt werden: beim
Verschleiss oder Störung austauschen

F Enlever les composants de l’axe Inching.


IMPORTANT: La commande Inching
hydraulique ne peut pas être inspectée, en
cas d’usure ou de mauvais fonctionnement, la
remplacer.

48a

52
TXL 30/ST

I N. B.: Per lo smontaggio dell’asse Inching non è


necessario smontare il dado di regolazione: nel
caso si rendesse necessario, svitare il dado com-
3
pleto e relativa rosetta di tenuta.
GB Note: To dismantle Inching axle it isn’t necessary
to dismantle regulating nut: if required, unscrew
nut complete and relevant rubber seal.
D Hinweis: Für den Ausbau der Inching-Achse ist es
nicht erforderlich, die Einstellmutter abzubauen:
falls es aber notwendig sein sollte, muß die kom-
plette Mutter mit Dichtscheibe herausgeschraubt
werden.
49
F Note: Pour le démontage de l’axe Inching démon-
ter l’écrou de réglage n’est pas nécessaire: si
nécessaire, dévisser l’écrou complet et la rondelle
de retenue.

ATTENZIONE! Per non pregiudicare il corretto


! funzionamento dell’asse Inching, non manomet-
tere e non smontare il tappo di regolazione dal
dado.
WARNING! To not prejudice right working of
! Inching axle, don’t tamper and don’t dismantle
regulating plug of nut.
ACHTUNG! Um das korrekte Funktionieren
! der Inching-Achse nicht zu beeinträchtigen,
den Einstellverschluß nicht verändern und
nicht von der Mutter abbauen.
ATTENTION! Ne pas compromettre le fon- 49a
ctionnement correct de l’axe Inching, ne pas
! toucher le bouchon de réglage de l’écrou.

I Pulire perfettamente tutti i particolari, verificarli,


sostituirli secondo necessità. 50
GB Clean full each component, check them, replace if
required.

D Alle Bestandteile sorgfältig reinigen, prüfen, bei


Bedarf ersetzen.

F Nettoyer soigneusement tout les composants, véri-


fier et, si nécessaire, remplacer.

I Rimuovere e sostituire la guarnizione O-Ring (a).

GB Remove and replace O-Ring seal (a).

D Den Dichtungs-O-Ring (a) entfernen und ersetzen.


a
F Enlever et remplacer le joint O-Ring (a).

51

53
TXL 30/ST

I Rimontaggio Asse Inching - Versione Comando


Idraulico
Rimontare il dado di regolazione con la relativa
rosetta di tenuta e serrare.

GB Reassembling Inching Axle - Hydraulic Drive


Version
Reassemble regulating nut with relevant securing
washer and lock.

D Einbau Inching-Achse - Version hydraulische


52 Steuerung
Die Einstellmutter mit der entsprechenden
Dichtscheibe einbauen und festziehen.

F Rémontage Axe Inching - Version Commande


Hydraulique
Remonter l’écrou de réglage en se servant de la
rondelle de retenue correspondant et serrer.

! ATTENZIONE !
I Per non pregiudicare il corretto funzionamento
dell’asse Inching, non manomettere il tappo di
regolazione del dado.

! WARNING !
GB To not prejudice right working of Inching axle,
don’t tamper and don’t dismantle regulating
plug of nut.

52a ! ACHTUNG !
D Um den korrekten Betrieb der Inching-Achse
nicht zu beeinträchtigen, den Einstellstopfen
der Mutter nicht verletzen.

! ATTENTION !
F Ne pas compromettre le fonctionnement cor-
rect de l’axe Inching, ne pas toucher le bou-
chon de réglage de l’écrou.

I Inserire i componenti Asse Inching.

GB Insert components of Inching Axle.

D Die Bestandteile der Inching-Achse einführen.

F Insérer les composants de l’Axe Inching.

53

54
TXL 30/ST

I Umettare le quattro viti con Loctite 242 e bloccare


alla coppia di 0,5 daNm il corpo Inching al distri-
butore.
54 3
GB Smear the four screws with Loctite 242 and lock
Inching body to distributor with a torque of 0.5
daNm.

D Die vier Schrauben mit Loctite 242 benetzen


und mit einem Drehmoment von 0,5 daNm den
Inching-Körper am Verteiler festziehen.

F Humecter les quatre vis par Loctite 242 et bloquer


au couple de 0,5 daNm le corps Inching au distri-
buteur.

I Rimontaggio selettrice avanti - indietro


Infilare l’elettrovalvola con le relative guarnizioni
(opportunamente lubrificate).
Bloccare il dado alla coppia di serraggio di ~ 7
daNm.

GB Re-assembling of front - back selection valve


Insert electrovalve with relevant seals (righting
smeared).
Lock nut with a torque of ~ 7 daNm.

D Einbau Wechselvorrichtung vor-zurück 55


Das Magnetventil mit den entsprechenden
Dichtungen (angemessenen geschmiert) einführen.

F Rémontage Selectrice avant - arrière


Enfiler l’électrovanne et les relatifs joints (oppor-
tunément lubrifiés).
Bloquer l’écrou au couple de serrage de ~ 7
daNm.

I Verificare le condizioni della valvola sicurezza della


lubrificazione e relativa tenuta su base appoggio
distributore.

GB Check conditions of safety valve of lubrication


system and relevant seat on distributor adaptor.

D Überprüfen des Sichermeits ventils des Ölsystems


und der Dichtung im Steuergerät.

F Vérifier les conditions de la vanne de sûreté du


graissage et relative étancheité sur base d’appui
distributeur. 56

55
TXL 30/ST

Smontaggio e Rimontaggio gruppi ruote - 1ª Versione


Wheel assembly dismantling and re-assembling - 1st Version
Bremsgruppe Demontage und Montage - 1. Version
Démontage et Remontage des groupe des roues - 1 ère Version

! ATTENZIONE ! ! ACHTUNG !
Maneggiare tutti i particolari con opportuni Schwere Teile nur mit geeignetem Hebe-und
mezzi e con grande attenzione. Non mettere Transportwerkzeug transportieren.
le mani e le dita tra un pezzo e l’altro Vorsicht auf Hände und Finger

! WARNING ! ! ATTENTION !
Manipuler tout les composants par oppor-
Handle all heavy parts with the appropriate
tuns outils et avec beaucoup d’attention.
equipment and with the utmost care. Never
Ne jamais glisser les mains ou les doigts entre
put your hands and fingers in between parts
les différents éléments

I Svitare le due viti fissaggio tamburo freno al mozzo


56 ruota.
Sfilare il tamburo freno. Verificare il diametro e lo
stato di usura dei rivestimenti ganasce freno.
GB Undo screws securing brake drum to wheel hub.
Remove brake. Check diameter and wear condi-
tions of shoes lining.
D Befestigungsschrauben lösen und entfernen.
Bremstrommel abziehen und Trommel innen kon-
trollieren.
F Dévisser les deux vis de fixation du tambour du
frein au moyeu de la roue.
Enlever le tambour du frein. Vérifier le diamètre et
l’état d’usure des revêtements des mâchoires du
frein.

I Smontaggio semiassi
57 Svitare le viti fissaggio semiassi al mozzo ruota
GB Wheel shaft disassembly
Undo screws securing shaft to wheel hub on both
side.
D Ausbau Achswelle
Befestigungsschrauben au beiden Sieten lösen
und entfernen,.

F Démontage des demi-axes


Dévisser les vis de fixation des demi-axes au
moyeu de la roue.

I Svitare le due viti di fissaggio, sbloccare e sfilare il


semiasse.

GB Unscrew the two fixing screws, unlock and remove


the half shaft.

D Die beiden Befestigungsschrauben abschrauben,


die Achswelle freilegen und herausziehen.

F Dévisser les deux vis de fixation, débloquer et


enlever le demi-essieu.

58 58a

56
TXL 30/ST

I IMPORTANTE: Usare esclusivamente ricambi


originali
Sostituzione ganasce
3
Sganciare la molla richiamo ganasce lato disposi-
tivo ripresa automatica gioco.

GB IMPORTANT: Use only genuine spare parts


Shoes replacement
Unhook shoe return spring on automatic brake
clereance take-up device side. 59
D HAUPTSACHE: Ausschliesslich Original-
Ersatzteile verwenden
Austausch Backen
Die Rückholfeder Bremsbacken auf der Seite auto-
matische Spieleinstellvorrichtung aushaken.

F IMPORTANT: Utiliser exclusivement les


pièces de rechange originales
Substitution des mâchoires
Décrocher le ressort de rappel des mâchoires côté
dispositif de reprise automatique du jeu.

I Sganciare le due molle richiamo ganasce lato cilin-


dretto. 60
GB Unhook the two shoe return spring on side of
wheel brake cylinder.

D Untere Haltefedern Lösen.

F Décrocher les deux ressorts de rappel des mâchoi-


res côté petit cylindre.

I Sfilare le molle ritegno ganasce, staccare ganasce,


fulcro rinvio, comando freno a mano e cavo della leva.
Nell’eventualità di sostituzione del cavo freno a
mano togliere la rosetta a forcella per appoggio di
reazione molla ritorno cavo.

GB Remove brake shoes retaining springs, brake


shoes, return fulcrum, hand brake drive and lever
cable.
Should hand control cable be replaced, remove
fork washer backing cable return spring.

D Die Haltefedern Bremsbacken herauziehen, 61 61a


die Bremsbacken, Umlenkdrehbolzen,
Handbremsensteuerung und Hebelkabel abziehen.
Beim Entfernen des Handbremsseiles.

F Enlever les ressorts de retenue des mâchoires,


détacher les mâchoires, le pivot de renvoi, la
commande du frein à main et le cåble du levier.
En cas de substitution du câble du frein à main,
enlever la rondelle à fourche pour appui de réac-
tion du ressort de retour du câble.
57
TXL 30/ST

I In caso di sostituzione del cilindro freno, svitare


a le due viti (a) di fermo piastrina aggancio molla
a richiamo ganasce.
Svitare lo spurgo olio freno (b), il raccordo (c) e le
due viti (d) di tenuta cilindretto poste dietro il piat-
to freno, con relative rosette (vedi fig. 62a).

GB Should brake cylinder be replaced, undo the two


screws (a) retaining small plate of spring hooking
of shoes return.
Unscrew brake oil bleeder (b), connector (c) and
62 the two screws (d) retaining small cylinder placed
behind brake plate, with relevant washers (see fig.
62a).

D Bei einem Austausch des Bremszylinders die


beiden Halteschrauben (a) der Einhakplatte
Rückholfeder Bremsbacken anschrauben.
Ölauslaßschraube Bremse (b), Anschlußstück (c)
und die beiden Schrauben (d) der Zylinderdichtung
hinter der Bremsplatte mit den jeweiligen
Unterlegscheiben abschrauben (siehe Abb. 62a).

F En cas de substitution du cylindre du frein, dévis-


ser les deux vis (a) de férmeture de la plaque
d’accrocage du ressort de rappel des mâchoires.
Dévisser le vidange d’huile du frein (b), le raccor-
dement (c) et les deux vis d’étanchéité (d) du petit
cylindre placées derrière le plateau du frein, avec
les relatives rondelles (voir fig. 62a).

c
b
d

fig. 62a

58
TXL 30/ST

I IMPORTANTE: Non smontare il cilindro freno


per ripararlo; se è malfunzionante, sostituirlo
completo.
3
GB IMPORTANT: Don’t dismantle the brake cylin-
der to repair it, in case of malfunction, change.

D HAUPTSACHE: Die Bremszylinder nicht zer-


legen, um sie zu reparieren; sollte sie schlecht
funktionieren, muß sie ausgetauscht werden.

F IMPORTANT: Ne pas démonter le cylindre du


frein pour le réparer; en cas de fonctionnement
mauvais, remplacer.

I - Posizionare il cilindro freno nella relativa sede


(fig.62a);
- avvitare le due viti (d) con rosette alla coppia di
2,0 ÷ 2,5 daNm;
- montare e avvitare lo spurgo olio (b) alla coppia
di 0,4 ÷ 0,6 daNm;
- montare e avvitare il raccordo (c) con guarnizione di
rame alla coppia di 3,0 ÷ 3,6 daNm;
- rimontare la piastrina aggancio molle e avvitare 63
le viti (a) con rosette alla coppia di 2,0 ÷ 2,5
daNm.

GB - Position brake cylinder into relevant seat (fig.62a); a


- screw in the two screws (d) with washers with a a
torque of 2.0 ÷ 2.5 daNm;
- mount and screw in oil bleeder (b) with a torque
of 0.4 ÷ 0.6 daNm;
- mount and screw connector (c) with copper seal
with a torque of 3.0 ÷ 3.6 daNm;
- reassemble small plate hooking springs and
screw in the screws (a) with washers with a torque
of 2.0 ÷ 2.5 daNm. 64
D - Den Bremszylinder in seinen Sitz einsetzen
(Abb.62a), die beiden Schrauben (d) mit
Unterlegscheiben mit einem Drehmoment von
2,0 ÷ 2,5 daNm festziehen;
- den Ölauslaß (b) einsetzen und mit einem
Drehmoment von 0,4 ÷ 0,6 daNm festziehen, das
Anschlußstück (c) mit Kupferdichtung mit einem
Drehmoment von 3,0 ÷ 3,6 daNm festziehen;
- die Einhakplatte Federn wieder einbauen und die
Schrauben (a) mit Unterlegscheiben mit einem
Drehmoment von 2,0 ÷ 2,5 daNm festziehen.

F - Placer le cylindre du frein dans son siège (fig.62a)


- visser les deux vis (d) avec rondelles au couple
de 2,0 ÷ 2,5 daNm;
- monter et visser le vidange d’huile (b) au couple
de 0,4 ÷ 0,6 daNm;
- monter et visser le raccordement (c) avec joint en
cuivre au couple de 3,0 ÷ 3,6 daNm;
- remonter la plaque d’accrochage des ressorts et
visser les vis (a) avec rondelles au couple de
2,0 ÷ 2,5 daNm.

59
TXL 30/ST

I In caso di sostituzione del registro automatico,


avvitare e chiudere la vite con relative rosette alla
coppia di 9 ÷ 10 daNm.
IMPORTANTE: Non smontare il registro
automatico per ripararlo; se è malfunzionante,
sostituire.
GB Should automatic adjusting be replaced, screw in
and lock screw with relevant washers with a torque
of 9 ÷ 10 daNm.
IMPORTANT: Don’t dismantle the automatic
65 adjusting to repair it, in case of malfunction,
changed.
D Bei einem Austausch der automatischen
65a Einstellung, die Schraube mit entsprechender
Unterlegscheibe mit einem Drehmoment von 9 ÷
10 daNm festziehen.
HAUPTSACHE : Die Automatikeinstellung
nicht zerlegen, um sie zu reparieren; sollte sie
schlecht funktionieren, muß sie ausgetauscht
werden.
F En cas de sustitution du registre automatique,
visser et fermer la vis avec les relatifs rondelles au
couple de 9 ÷ 10 daNm.
IMPORTANT: Ne pas démonter le registre
automatique pour le réparer; en cas de fonc-
tionnement mauvais, remplacer.

I Prima del montaggio delle ganasce registrare lar-


65b ghezza “a” dell’autoregistro a 81±0,5 mm per freno
310x60 (per freni con dimensioni diverse vedere la
tabella), intervenendo in uguale misura su entrambi
i registri.

GB Before mounting the shoes adjust width “a” at


81±0.5 mm for brake size 310x60. Be careful to
operate evenly on both adjusting screws. For other
brake sizes, please refer to the table underneath.
a
D Vor der Montage der Backen, die Breite des
Registers auf 81±0.5 mm bei Bremse 310x60 mm
einstellen (bei Bremsen mit unterschiedlichen
Abmessungen s. Tabelle), wobei man gleichmässig
Dimensioni freno auf beiden Registern eingreifft.
Brake size
a Bremsabemessungen F Avant le démontage des mâchoires, insérer la
Dimension frein largeur “a” dans l’autoregistre à 81±0.5 mm pour
54 170 x 40 le frein 310x60 (pour freins ayant des dimensions
différentes, voir tableau), en intervenant identique-
60 200 x 40 ment dans les deux registres.
60/79 203 x 40/60
79 230 x 50
85 245 x 60
79 250 x 45/50
84/80 270 x 60
81±05 310 x 60

60
TXL 30/ST

I Rimontare la ganascia destra, agganciare il flessi-


bile comando freno a mano sulla leva e inserire la
molla di ritegno.
3
GB Refit right shoe, hook brake hand control cable on
lever and insert retaining spring.

D Die rechte Bremsbacke wieder einbauen, den


Schlauch Steuerung Handbremse auf dem Hebel
einhaken und die Haltefeder einführen.

F Remonter la mâchoire droite, accrocher le flexible


de la commande du frein à main sur le levier et 66
insérer le ressort de retenue.

I Montare la ganascia sinistra e la molla di ritegno


inserendo il fulcro rinvio comando freno a mano. 67
GB Refit left shoe and retaining spring fitting in the
strut of hand brake control.

D Die linke Bremsbacke und die Haltefeder ein-


bauen, dabei den Umlenkdrehbolzen Steuerung
Handbremse einführen.

F Monter la mâchoire gauche et le ressort de rete-


nue en insérant le pivot de renvoi de la commande
du frein à main.

I Agganciare le due molle richiamo ganasce lato


cilindretto. 68
GB Hook the two shoe return spring on side of wheel
brake cylinder.

D Montage Haltefedern Lösen.

F Accrocher les deux ressorts de rappel des mâchoi-


res côté petit cylindre.

I Agganciare la molla richiamo ganasce lato disposi-


tivo ripresa automatica gioco (A).
GB Hook shoe return spring on automatic brake cle-
reance take-up device side (A).
D Die Rückholfeder Bremsbacken auf der Seite auto-
matische Spieleinstellvorrichtung aushaken (A).

F Accrocher le ressort de rappel des mâchoires côté


dispositif de reprise automatique du jeu (A).

69

61
TXL 30/ST

Dimensioni freno Quota di Preregistrazione I Registrazione accoppiamento ganasce


Brake size Presetting width - Assicurarsi che il freno a mano o i cavi siano a
Bremsabemessungen Voreinstellungsgrad
Dimensions frein Côte de Pré-enregistrement riposo
- Misurare il diametro delle ganasce e quello dei
170 x 40 169,2 - 0.2
tamburi. Il gioco corretto è di 1,2-1,8 mm, per
200 x 40 199 - 0.4 freno 310x60 (per freni con dimensioni diverse
vedere la tabella)
203 x 40/60 201.8 +/- 0.2
Se da correggere intervenire in maniera uguale
230 x 50 228.7 +/- 0.2 sui 2 registri laterali .
245 x 60 243.6 +/- 0.3 Nota bene: la precisa registrazione del gioco
tamburo/ganasce è determinante ai fini del corret-
250 x 45/50 248.6 +/- 0.3 to funzionamento dell’autoregistro (A).
270 x 60 268.6 +/- 0.3 ATTENZIONE! Un gioco eccessivamente ampio
310 x 60 308.5+/- 0.3
! può danneggiare irrimediabilmente l’autoregistro
Colludo del funzionamento del freno
Effettuare 10 frenate moderate (non frena-
te d’emergenza) sia in marcia avanti che in
retromarcia alla velocità di circa 10 Km/h.
Questa manovra permette l’assestamento dell’au-
toregistro e di verificare l’efficacia dei freni.
Tamburo fig. 70
Drum
Trommel
Tambour GB Shoes setting procedure.
- Release the parking brake and relieve the cables
tension.
- Measure the diameter of the shoes and of the
drum. The correct gap is 1,2-1,8, for brake
310x60 (for different brake size see table); If not
within limit adjust it acting evenly on both adju-
sting wheels (A).
A Remark: Precise adjustment of the brake shoes
diameter is vital to the correct functioning of the
automatic adjuster.
WARNING! A too small diameter could damage
! permanently the automatic adjuster.

Check the brake efficiency


Gioco Gioco
Gap Gap Carry out approximately 10 braking moderate
Spiels Spiels manoeuvres ( no emergency braking ) at a speed
Jeu Jeu of 10 Km/h forth and back. This will ideally set the
Ø DI PREREGISTRAZIONE automatic adjuster and enable to check the brake
PRESETTING efficiency.
VOREINSTELLUNGSGRAD
DI PRE-ENREGISTREMENT

62
TXL 30/ST

D Einstellung der Backen-Zufügung


- Sich vergewissern, dass die Handbreme bzw. die
Kabel auf Ruheposition sind
Dimensioni freno
Brake size
Bremsabemessungen
Dimensions frein
Quota di Preregistrazione
Presetting width
Voreinstellungsgrad
Côte de Pré-enregistrement
3
- Den Durchmesser der Backen und der Trommeln 170 x 40 169,2 - 0.2
messen. Das richtige Speil beträgt 1,2-1,8 mm, 200 x 40 199 - 0.4
bei einer Bremse von 310x60 mm (bei Bremsen
mit unterschiedlichen Abmessungen s. Tabelle). 203 x 40/60 201.8 +/- 0.2
Beim Eingriff, beide seitliche Register gleichmäs- 230 x 50 228.7 +/- 0.2
sig einstellen.
245 x 60 243.6 +/- 0.3
Anm.: Die genaue Einstellung des Spiels Trommel
/ Backen ist massgebend für die korrekte Funktion 250 x 45/50 248.6 +/- 0.3
des Registers (A). 270 x 60 268.6 +/- 0.3

ACHTUNG! Ein zu grosses Spiel kann den 310 x 60 308.5+/- 0.3


! Register beschädigen.

Die Bremsefunktion auf Richtigkeit prüfen:


10 mässige Bremsungen (keine Not-Bremsung)
sowohl beim Vorwärtsgang als auch beim
Rückwärtsgang bei einer Geschwindigkeit von ca.
10 Km/h durchführen. Durch diese Manöver ist es Tamburo fig. 70
möglich, den Register zu richten und die Wirkung Drum
der Bremsen zu prüfen. Trommel
Tambour

F Enregistrement accouplement mâchoires


- S’assurer que le frein à main ou que les câbles
ne soient pas en fonction.
- Mesurer le diamètre des mâchoires et celui des
tambours. Le jeu correct doit être de 1,2-1,8 mm,
pour le frein 310x60 (pour freins ayant des dimen- A
sions différentes, voir tableau). Si une correction
est nécessaire, intervenir identiquement sur les
deux registres latéraux.
N.B.: le bon enregistrement du jeu tambour/
mâchoires est déterminant pour le bon fonction-
nement de l’auto-registre (A).
Gioco Gioco
ATTENTION! Un jeu excessif peut endommager Gap Gap
! definitivement l’auto-registre. Spiels
Jeu
Spiels
Jeu
Ø DI PREREGISTRAZIONE
Vérification du fonctionnement du frein: PRESETTING
Effectuer 10 freinades modérées (non pas des VOREINSTELLUNGSGRAD
freinades d’urgence) que ce soit en marche avant DI PRE-ENREGISTREMENT
et en marche arrière à la vitesse de 10km/H envi-
ron. Cette manoeuvre permet la bonne mise en
place de l’auto-registre et de vérifier l’efficacité
des freins.

63
TXL 30/ST

I Smontaggio mozzi ruote:


71 Raddrizzare l’aletta della rosetta di bloccaggio
sulla ghiera fissaggio mozzo ruota.

GB Wheel hub dismantly


Straighten up the tab of the locking washer.

D Ausbau Radnaben
Sicherungsnase auf der Ringmutter der Radnabe
aufbiegen.

F Démontage des moyeux des roues


Soulever l’entaille de blocage sur le collier de fixa-
tion du moyeu de la roue.

I Sbloccare e svitare completamente la ghiera fis-


72 saggio mozzo ruota (con attrezzo speciale dis.
48A13164).

GB Undo and unscrew completely ring nut securing


wheel hub (with special tool dwg. 48A13164).

D Ringmutter entfernen (mit spezial Werkzeung


48A13164).

F Débloquer et dévisser complètement le collier de


fixation du moyeu de la roue (par outil spécial plan
48A13164).

I Sfilare la rosetta di sicurezza, distanziale, cuscinet-


73 to e mozzo ruota.

GB Remove the tab washer, distance washer, bearing


and hub.

D Entferne die Sicherungsscheibe, Distanzscheibe,


Lager und Radnabe.

F Enlever la rondelle de blocage, l’entretoise, le rou-


lement et le moyeu de la roue

I Sbloccare la pista interna del cuscinetto interno


74 ruota.
Nota: con l’estrattore agganciare il bordo pista
interna cuscinetto per non danneggiare l’anello
tenuta.

GB Pull out the inner race of wheel inner bearing.


Note: hook up spacer edge with puller to prevent
damage on seal.

D Innenring des inneren Kegelrollenlagers abziehen.


Anmerkung: Beachte, daß der Dichtring nicht
beschädigt wird.

F Débloquer la piste intérieure du roulement intérieur


de la roue.
Note: par l’extracteur accrocher le bord de la piste
intérieure du roulement afin de ne pas endomma-
ger la bague d’étanchéité.
64
TXL 30/ST

I Smontaggio freni
Per lo smontaggio freni eseguire la procedura da punto 59 a 65, pag. 57 - 58 - 59 - 60. 3
GB Brakes disassembly
To disassemble brakes follow the procedure from step 59 to 65, page 57 - 58 - 59 - 60.

D Bremsendemontage
Für den Bremsendemontage das Verfahren von Punkt 59 bis 65 aus Seite 57 - 58 - 59 - 60 ausführen.

F Démontage des freins


Pour le démontage des freins suivre la procédure de point 59 à 65, pages 57 - 58 - 59 - 60.

I Nell’eventualità di sostituzione del cavo freno a


mano togliere la rosetta a forcella per appoggio di 75
reazione molla ritorno cavo.

GB Should hand control cable be replaced. remove


fork washer backing cable return spring.

D Beim Entfernen des Handbremsseiles.

F En cas de substitution du câble du frein à main


enlever la rondelle à fourche pour appui de réac-
tion du ressort de retour du câble.

I Svitare viti fissaggio piatto freno al supporto attac-


co al telaio e sfilarlo.
Nota: procedere in modo analogo per il freno sul
lato opposto.
D Undo screws securing brake back plate to frame
mounting support and remove it.
Note: same procedure should be followed for
brake on the opposite side.

GB Lösen der Befestigungsschrauben der Bremse


vom Achsgehäuse.
76
Anmerkung: Dasselbe muß auch auf der anderen
Seite erfolgen.

F Dévisser les vis de fixation du plateau du frein au


support de raccordement au cadre et l’enlever.
Note: Procéder à la même façon pour le frein du
côté opposé.

65
TXL 30/ST

I Smontaggio supporti attacco telaio


Sbloccare il supporto attacco al telaio.

GB Frame mount support disassembly


Release frame mount support.

D Demontage Flansch für Achsbefestigung


Entfernen Achsbefestigungflansch.

F Démontage des supports de raccordement du


cadre
Débloquer le support de raccordement au cadre.

77

I Sfilare il supporto attacco al telaio.


Nota: procedere in modo analogo per il supporto
sul lato opposto.

GB Remove frame mount support.


Note: same procedure should be followed for sup-
port on opposite side.

D Demontage Achsbefestigungsflansch.
Anmerkung: Auf der anderen Achsseite den sel-
ben vorgang wiederholen.
78
F Enlever le support de raccordement au cadre.
Note: Procéder de manière analogue pour le sup-
port du côté opposé.

66
TXL 30/ST

Rimontaggio gruppi ruote - 1ª Versione


Wheel assembly re-assembling - 1st Version
Bremsgruppe Montage - 1. Version
Remontage des groupe des roues - 1 ère Version
3
I In caso di smontaggio o sostituzione del manicot-
to, umettare i piani di contatto con “Loctite 510”.
Applicare frenafiletti medio sulle viti di fissaggio
manicotto; avvitare e bloccare le viti complete di
rosetta alla coppia di 266÷294 Nm

GB In case of spindle installation, the mating area has


to be smeared with “loctite 510”. Coat the screws
with medium grade fastener. Fit the washer and
tighten to torque of 266÷294 Nm.

D Bei Demontage oder Austausch der Muffe, die


Kontaktflächen mit “Loctite 510” benetzen. Eine mittle-
79
re Gewindesicherung auf den Befestigungsschrauben
der Muffe aufbringen; die Schrauben komplett mit
Federscheibe bei einem Drehmoment von 266 bis 294
Nm festziehen und spannen.

F En cas de démontage ou remplacement du


fourreau,induire les surfaces de contact de “Loctite
510”. Appliquer le frein-filets moyen sur les vis de
fixation du fourreau; visser et bloquer les vis avec
rondelle èlastique et serrer au couple de 266÷294
Nm.

I Rimontaggio supporti attacco telaio


Togliere l’anello O-Ring di tenuta a grasso e sosti-
tuirlo.

GB Frame mount support reassembly


Remove grease seal and replace.

D Montage Achsbefestigungsflansch
Dichtring entfernen.

F Remontage des supports de raccordement du


cadre 80
Enlever la bague O-Ring d’étanchéité à graisse et
substituer.

I Lubrificare con Molikote P40 il manicotto del


ponte e installare il supporto attacco telaio.
Verificare che la rotazione sia libera, esente da
attriti o giochi.

GB Lubricate with Molikote P40 axle sleeve and install


frame mount support. Check that support rotation
be smooth and free from friction or play.

D 5t Molikote P40 d5e Brückenmuffe schmieren und


den Halter zum Rahmenanschluss installieren.
Prüfen, dass die Drehung frei erfolgt und weder
Reibung noch Spiele vorhanden sind. 81

F Lubrifier avec Molikote P40 le manchon du pont


et installer le support de raccordement du cadre.
Vérifier que la rotation soie exempt de frottements
ou jeux.

67
TXL 30/ST

I Rimontare il piatto freno, applicare frenafiletti


medio sulle viti di fissaggio al supporto attacco
telaio.
Avvitare e bloccare le viti M14x1,5x35 alla coppia
di 18,1 ÷ 20 daNm.
GB Remount brake back plate, smear medium locking
compound on screws fixing plate to frame mount
support.
Tighten screws M14x1.5x35 with a torque of 18.1
÷ 20 daNm.
82 D Montage Bremsplatte. Befestigungsschrauben mit
Loctite 242 sichern.
Schrauben M14x1.5x35 mit einem Drehmoment
18.1 ÷ 20 daNm.

F Remonter le plateau du frein, appliquer le frein-à-


filets moyen sur les vis de fixation au support de
raccordement du cadre.
Visser et bloquer les vis M14x1.5x35 au couple de
18.1 ÷ 20 daNm.

I Rimontaggio freni
Per il rimontaggio freni eseguire la procedura da punto 62 a 70, da pag. 58 - 62.

GB Brake reassembly
To reassemble brakes follow the procedure from step 62 to 70, from page 58 to 62.

D Zusammensetzen der Bremse


Für den Wiedereinbau das Verfahren von Punkt 62 bis 70 aus Seite 58 bis 63 ausführen.

F Remontage des freins


Pour le rémontage des freins suivre la procédure de point 62 à 70, de pages 58 à 63.

68
TXL 30/ST

I Umettare con olio l’anello di tenuta (a) prima del


montaggio, e utilizzare l’attrezzo speciale dis.
48A13533 per il montaggio.
3
N. B.: Rispettare la quota di montaggio per evitare
eventuali danneggiamenti dell’anello di tenuta, vedi
figura 84.
Spiantare e sostituire l’ anello di tenuta (b) sul mani-
cotto del ponte; umettare con olio prima del mon-
taggio, e utilizzare l’attrezzo speciale dis. 48A12542
per il montaggio, vedi figura 84a.
83
GB Apply oil to the shaft seal (a) before wheel hub
assembly, by using special tool dwg. 48A13533 for
assembly.
Note: Respect assembling quota to avoid possible
damage to seal ring, see figure 84. a
Remove and replace seal ring (b) on spindle of
axle; apply oil to the shaft ring before wheel hub 48A13533
assembly, by using special tool dwg. 48A12542 for
assembly, see figure 84a.

D Vor dem Einbau den Dichtring (a) mit Öl benetzen,


mit spezial Werkzeung 48A13533.
Hinweis: Das Einbaumaß beachten, um eventuel-
le Beschädigungen des Dichtrings zu vermeiden,
(siehe Abb. 84).
Den Haltering (b) auf der Brückenmuffe entfernen
und austauschen. Vor der Montage mit Öl benetzen
und für die Montage das Speziellwerkzeug nach 0,5 mm
Zchn. 48A12542 verwenden, (siehe Abb. 84a).

F Humecter par huile la bague d’étanchéité (a) avant 84


le montage, et utiliser outil spécial plan 48A13533
pour le montage.
Note: Respecter la partie de montage afin d’évi-
ter des endommagements éventuels de la bague
d’étanchéité voir figure 84.
Enlever et remplacer la bague d’étanchéité (b) sur
le manchon du pont; humecter par huile avant le b
montage, et utiliser outil spécial plan 48A12542
pour le montage voir figure 84a. 48A12542

0,7 mm

84a

69
TXL 30/ST

Rimontaggio mozzi ruote


Wheel hubs reassembling

I Norme registrazione cuscinetti


1) Lavare i cuscinetti con petrolio caldo ed asciu-
garli con aria compressa e lubrificarli immergen-
b
doli in grasso fuso.
2) Montare i cuscinetti con relativo mozzo dopo
averne riempito di grasso (del tipo FIAT MR2 o
similari) ogni cavità interna (a).
Attenzione! L’eccesso di grasso può causare il
! rovesciamento del labbro della guarnizione (b).
Montare la rondella dentata e quindi avvitare la
ghiera.
3) Ruotare e martellare il mozzo per favorire l’as-
sestamento dei rulli conici sulle piste e, nel frat-
tempo, serrare la ghiera progressivamente fino
alla coppia di serraggio di 14,7 daNm.
4) Allentare la ghiera e quindi riavvitarla successi-
vamente incrementando progressivamente la cop- a
pia di serraggio fino al valore di 1 daNm.
5) Riallentare la ghiera in modo da assicurare un
85
gioco max. sui cuscinetti di 0,05 mm, corrispon-
dente a circa 1/32 di giro della ghiera. Fermare
quindi la ghiera come indicato al punto 6.
6) A registrazione avvenuta assicurare la ghiera
ripiegando uno dei lobi della rosetta di sicurezza
in uno degli intagli della ghiera (vedere foto 87).
Se ciò non fosse possibilile continuare ad avvitare
la ghiera fino a raggiungere la posizione di mon-
taggio.

GB Bearings adjustment specifications


1) Wash the bearings with hot petroleum and dry
them lubricate them by immersion in melted grea-
se. 86
2) Assemble the bearings with the related hub,
after filling with grease (FIAT MR2 or similar) each
internal cavity (a).
Attention! Too much grease can cause the over-
! turning of the lip of the seal (b). Assemble the
toothed washer and the screw the ring nut.
3) Rotated and hammer the hub to make easier
the bedding of the conical rollers on the tracks,
and at the same time screw gradually the ring nut
to the driving torque of 14.7 daNm.
4) Loosen the ring nut and then screw it increasing
gradually the driving torque to 1 daNm.
5) Loosen again the ring nut in a way to assure a
max. play on the bearings of 0.05 mm, correspon- 87
dent to about 1/32 of turn of the ring nut. Lock
then the ring nut in the way explained in step 6.
6) If no tab mates the slot, tighten slightly the nut
to match the nearest tab (see photo 87).
70
TXL 30/ST

Einbau Bremstrommel
Rémontage des moyeux des roues 3
D Vorschriften für Lagermontage
1) Reinige die Lager mit entsprechenden
Reinigungsmitteln und schmiere sie mit geeigne- b
tem Lagerfett.
2) Montiere die Lager mit der Radnabe, die vorher
mit Fett (Fiat MR 2 oder vergleichbaires Fett) gefüllt
wurden.
Achtung! Zuviel Fett kann die Wellendichtringfunktion
! beeinträchtigen.
3) Drehe die Radnabe einige Male, um einen
guten Sitz der Kugelrollenlager zu glewährleisten.
Gleichzeitiges Anziehen der Ringmutter bis zu
einem Drehmoment von 14,7 daNm.
4) Löse die Ringmutter und erhöhe das
Anziehdrehmoment um weitere 1 daNm.
5) Löse die Mutter nochmals um ein max.
Lagerspiel von 0,05 mm (entsprechend 1/32
Umdrehung der Ringmutter) sicher zustellen. a
6) Drehe die Ringmutter in eine Position, in der die
85
Nase des Sicherungsringes umgelegt werden kann
(Siehe Foto 87).

F Normes de réglage des roulements


1) Laver les roulements par pétrole chaud et les
sécher à l’air comprimé et les lubrifier en les trem-
pant dans du gras fondu.
2) Monter les roulements avec le relatif moyeu
après avoir graissée (modèle FIAT MR2 ou similai-
res) chaque cavité intérieure (a).
Attention! L’eccès de gras peut provoquer le ren-
! versement du bord du joint (b).
Monter la rondelle dentée et puis visser le collier. 86
3) Tourner et marteler le moyeu pour faciliter la
mise en état des rouleaux coniques sur les pistes
et, entre-temps, serrer le collier progressivement
jusqu’au couple de serrage de 14,7 daNm.
4) Desserrer le collier et puis le revisser par la suite
en augmentant progressivement le couple de ser-
rage jusqu’à la valeur de 1 daNm.
5) Redesserrer le collier de façon à garantir un jeu
maxi de 0,05 mm sur les roulements, correspon-
dant à 1/32 environ de tour du collier; Ensuite fixer
le collier comme indiqué au point 6.
6) A réglage effectué, assurer le collier en repliant
l’un des lobes de la rondelle de blocage dans l’un
des entailles du collier. Si cela n’était pas possible, 87
continuer à visser le collier jusqu’à arriver à la posi-
tion de montage (voir photo 87).

71
TXL 30/ST

I Rimontaggio semiassi
Infilare il semiasse facendo attenzione a non dan-
neggiare l’anello di tenuta, come indicato.

GB Wheel shaft reassembly


Install the half shaft, taking care not to damage the
seal ring.

D Montage Achswelle
Montiere die Achswelle. Vorsicht, daß der
Dichtring nicht beschädigt wird.
88
F Remontage des demi-axes
Monter le demi-essieu en faisant attention à ne pas
endommager pas la bague d’étanchéité, comme
indiqué.

I Applicare frenafiletti Loctite 242 o similare, avvita-


re e bloccare le due viti alla coppia di serraggio di
0,8 ÷ 0,9 daNm.

GB Apply Loctite 242 or similar to the bolts and lock


with a torque of 0.8 ÷ 0.9 daNm.

D Gewindedichtmasse Loctite 242 oder ähnliches


auftragen, die beiden Schrauben anschrauben und
mit einem Anziehdrehmoment von 0,8 ÷ 0,9 daNm
festziehen.
89 F Appliquer le frein à filets Loctite 242 ou similaires,
visser et bloquer les deux vis bloquer au couple de
serrage 0,8 ÷ 0,9 daNm.

I Applicare frenafiletti, avvitare e bloccare le dodici


viti complete di rosetta elastica alla coppia di ser-
raggio di 13 ÷ 13,6 daNm.

GB Screw in twelve bolts with spring washer and


tighten with 13 ÷ 13.6 daNm.

D Schraube die 12 Schrauben mit Federring ein und


ziehe an mit einem Drehmoment von 13 ÷ 13,6
daNm.

90 F Appliquer le frein-à-filets, visser et bloquer les


douze vis complètes de rondelle-ressort au couple
de serrage 13 ÷ 13,6 daNm.

72
TXL 30/ST

I Montare il tamburo freni, umettare la filettatura


delle due viti con Loctite 242 e avvitare le due viti
alla coppia di serraggio di 0,8 ÷ 0,9 daNm.
3
N. B.: assicurarsi che non ci sia strisciamento
delle ganasce del freno sul tamburo.

GB Install the brake drum using Loctite 242 for the


two fixing bolts and screw in with a torque of 0.8 ÷
0.9 daNm.
Note: Make sure that the brake shoes are not in
contact with the drum. 91
D Die Bremstrommel einbauen, das Gewinde
der beiden Schrauben mit Loctite 242 benet-
zen und die beiden Schrauben mit einem
Anziehdrehmoment von 0,8 ÷ 0,9 daNm festziehen.
Hinweis: Sicherstellen, daß bei der Montage
die Bremsschuhe keinen Kontakt mit der
Bremstrommel haben.

F Monter le tambour du frein, humecter le filetage


des deux vis par Loctite 242 et visser les deux vis
au couple de serrage 0,8 ÷ 0,9 daNm.
Note: s’assurer qu’il n’y a pas de frottement des
mâchoires du frein sur le tambour.

73
TXL 30/ST

Smontaggio e Rimontaggio gruppi ruote - 2ª Versione


Wheel assembly dismantling and re-assembling - 2nd Version
Bremsgruppe Demontage und Montage - 2. Version
Démontage et Remontage des groupe des roues - 1 ème Version

! ATTENZIONE ! ! ACHTUNG !
Maneggiare tutti i particolari con opportuni Schwere Teile nur mit geeignetem Hebe-und
mezzi e con grande attenzione. Non mettere Transportwerkzeug transportieren.
le mani e le dita tra un pezzo e l’altro Vorsicht auf Hände und Finger

! WARNING ! ! ATTENTION !
Manipuler tout les composants par oppor-
Handle all heavy parts with the appropriate
tuns outils et avec beaucoup d’attention.
equipment and with the utmost care. Never
Ne jamais glisser les mains ou les doigts entre
put your hands and fingers in between parts
les différents éléments

I Svitare le due viti fissaggio tamburo freno al mozzo


92 ruota.
Sfilare il tamburo freno. Verificare il diametro e lo
stato di usura dei rivestimenti ganasce freno.
Nota: per la sostituzione delle ganasce o per la
revisione del freno, vedere manuale specifico.

GB Undo screws securing brake drum to wheel hub.


Remove brake. Check diameter and wear condi-
tions of shoes lining.
Note: Please refer to specific manufacturer instruc-
tion to overhaul brake or to replace the shoes.
D Befestigungsschrauben lösen und entfernen.
Bremstrommel abziehen und Trommel innen kon-
trollieren.
Hinweis: Zum Austauschen der Backen oder
Überholung der Bremse, s. das spezifische
Handbuch.
F Dévisser les deux vis de fixation du tambour du
frein au moyeu de la roue.
Enlever le tambour du frein. Vérifier le diamètre et
l’état d’usure des revêtements des mâchoires du
frein.
Note: pour la substitution des mâchoires ou pour
la révision du frein, voir manuel spécifique.

I Smontaggio semiassi
93 Svitare le viti fissaggio semiassi al mozzo ruota,
sbloccare e sfilare il semiasse.
GB Wheel shaft disassembly
Undo screws securing shaft to wheel hub on both
side, unlock and remove the half shaft.

D Ausbau Achswelle
Befestigungsschrauben au beiden Sieten lösen
und entfernen, die Achswelle freilegen und herau-
sziehen.

F Démontage des demi-axes


Dévisser les vis de fixation des demi-axes au
moyeu de la roue, débloquer et enlever le demi-
essieu.

74
TXL 30/ST

GB
Spiantare la spina elastica di fermo ghiera.

Remove the spring pin holding the nut.


3
D Die Spannhülse zur Festhalten der Nutmutter
herausziehen.

F Retirer la goupille élastique d’arrêt du collier.

94

I Sbloccare e svitare completamente la ghiera fis-


saggio mozzo ruota (con attrezzo speciale dis.
48A19119).
Sfilare il cuscinetto e mozzo ruota.

GB Unscrew completely ring nut securing wheel hub


(with special tool dwg. 48A19119).
Remove the bearing and hub.

D Ringmutter entfernen (mit spezial Werkzeung


48A19119). 95
Entferne die Lager und Radnabe.

F Débloquer et dévisser complètement le collier de


fixation du moyeu de la roue (par outil spécial plan
48A19119).
Enlever le roulement et le moyeu de la roue.

I Con l’estrattore sbloccare la pista interna del


cuscinetto interno ruota.

GB Pull out the inner race of wheel inner bearing.

D Innenring des inneren Kegelrollenlagers abziehen.

F Débloquer la piste intérieure du roulement intérieur


de la roue.

96

I Rimuovere l’anello di tenuta con distanziale (a).

Remove the lip seal with spacer (a).


GB
a
D Den Haltring mit Distanzscheibe (a) entfernen.

F Retirer la bague d’étanchéité et l’entretoise (a).

97

75
TXL 30/ST

I Smontaggio freno completo


Svitare le viti fissaggio piatto freno al supporto
attacco al telaio e sfilarlo.
Nota: procedere in modo analogo per il freno sul
lato opposto
GB Complete brake dismantly
Undo screws securing brake back plate to frame
mounting support and remove it.
Note: same procedure should be followed for
brake on the opposite side.
98
D Bremsedemontage komplett
Lösen der Befestigungsschrauben der Bremse
vom Achsgehäuse.
Anmerkung: Dasselbe muß auch auf der anderen
Seite erfolgen.
F Démontage du frein complet
Dévisser les vis de fixation du plat du frein au sup-
port de raccordement au cadre et l’enlever.
Note: procéder de maniere analogue pour le frein
du côté opposé.

I Smontaggio supporti attacco telaio e manicotto


Per lo smontaggio eseguire la procedura da punto 77 - 78, pag. 66.
Per il rimontaggio da punto 80 - 81, pag. 67.
GB Frame mount supports and spindle disassembly
To disassemble follow the procedure from step 77 to 78, page 66.
To reassemble from step 80 - 81, page 67.
D Demontage Flansch für Rahmen- und Muffebefestigung.
Für den Demontage das Verfahren von Punkt 77 bis 78 aus Seite 66.
Für den Wiedereinbau das Verfahren von Punkt 80 bis 81 Seite 67.
F Démontage des supports de raccordement du cadre et du fourreau
Pour le démontage suivre la procédure de point 77 à 78, pages 66.
Pour le rémontage de point 80 à 81, pages 67.

I Rimontaggio freno completo


Rimontare il piatto freno, applicare frenafiletti
medio sulle viti di fissaggio al supporto attacco
telaio; avvitare e bloccarle alla coppia di serraggio
18,1 ÷ 20 daNm.
GB Brake reassembly
Remount brake back plate, smear medium locking
compound on screws fixing plate to frame mount
support; screw in and lock with a torque of 18.1 ÷
20 daNm.
99 D Zusammensetzen der Bremse
Montage Bremsplatte. Befestigungsschrauben
mit Loctite 242 sichern. Anschrauben und mit
einem Anziehdrehmoment von 18.1 ÷ 20 daNm
festziehen.
F Remontage du frein complet
Remonter le plat du frein, appliquer le frein-à-filets
moyen sur les vis de fixation au support de raccor-
dement du cadre, visser et bloquer au couple de
serrage de 18.1 ÷ 20 daNm.

76
TXL 30/ST

Rimontaggio mozzi ruote


Wheel hubs reassembling
Einbau Bremstrommel
Rémontage des moyeux des roues
3
I Qualora si renda necessario sostituire i cuscinetti
del mozzo ruota occorre utilizzare ricambi originali
per garantire la funzionalità del sistema.

GB Should hub bearings be replaced use genuine


spare parts only to warrant trouble free operations
of the whole system.
D
Kegelrollenlager kontrollieren und bei Bedart erset-
zen.

F S’il était nécessaire substituer les roulements du


moyeu de la roue, il faudrait utiliser des relais 100
authentiques afin de garantir le bon fonctionne-
ment du système.

I Umettare con olio l’anello di tenuta (a) prima del


montaggio sul distanziale (b), con attrezzo specia- 101
le dis. 48A19120.
N. B.: Rispettare la quota di montaggio per evitare
eventuali danneggiamenti dell’anello di tenuta:

GB Apply oil to the seal ring (a) before assembly on


spacer (b), by using special tool dwg. 48A19120.
Note: Respect assembling quota to avoid possible
damage to seal ring.

D Dichtring mit Öl einreiben und mit vorgeschriebe- 48A19120/01


nem Werkzeug montieren, mit spezial Werkzeung
48A19120.
48A19120/02
Hinweis: Das Einbaumaß beachten, um eventuelle
0,5 mm

Beschädigungen des Dichtrings zu vermeiden.

F Humecter par huile la bague d’étanchéité (a) avant a


le montage sur entretoise (b) par outil approprié
plan 48A19120. b
Note: Respecter la partie de montage afin d’évi-
ter des endommagements éventuels de la bague
d’étanchéité

I Montare il distanziale completo di anello di tenu-


ta, sul manicotto mozzo ruota e calettare l’anello
interno del cuscinetto.

GB Mount spacer lip seal complete on wheel hub slee-


ve and mount inner race of bearing.

D Montage Zwischenring und Dichtring.


Kegellagerinnenring mit Buchse montieren.

F Emboîter l’entretoise complet de la bague d’étan-


chéité sur le manchon du moyeu de la roue et 101a
emboîter la bague intérieure du roulement.

77
TXL 30/ST

I Spiantare e sostituire l’ anello di tenuta (c) sul mani-


101b c cotto del ponte; umettare con olio prima del mon-
taggio, e utilizzare l’attrezzo speciale dis. 48A19394
48A19394 per il montaggio.
N. B.: Rispettare la quota di montaggio per evitare
eventuali danneggiamenti dell’anello di tenuta, vedi
figura 101b.

GB Remove and replace seal ring (c) on spindle of


axle; apply oil to the shaft ring before wheel hub
assembly, by using special tool dwg. 48A19394 for
assembly.
21,5 mm
Note: Respect assembling quota to avoid possible
damage to seal ring, see figure 101b.

I Norme registrazione cuscinetti


102 1) Montare i cuscinetti con relativo mozzo dopo
b averne riempito di grasso (del tipo FIAT MR2 o
similari) ogni cavità interna (a).
Attenzione! L’eccesso di grasso può causare il
! rovesciamento del labbro della guarnizione (b).
Quindi avvitare la ghiera.
2) Ruotare e martellare il mozzo per favorire l’as-
sestamento dei rulli conici sulle piste e, nel frat-
tempo, serrare la ghiera con attrezzo 48A19119
progressivamente fino alla coppia di serraggio di
147 Nm.
3) Allentare la ghiera e quindi riavvitarla suc-
cessivamente portandosi in condizioni di gioco
“ZERO”.
4) A registrazione avvenuta assicurare la ghiera
con la spina elastica. Se cio’ non fosse possibile,
ruotare la ghiera in senso orario fino alla cava piu’
a vicina in modo da poter inserire la spina elastica.
Il precarico assiale ottenuto sara’ 0.00-0.10 mm.

GB Bearings adjustment specifications


1) Assemble the bearings with the related hub,
after filling with grease (FIAT MR2 or similar) each
internal cavity (a).
Attention! Too much grease can cause the over-
! turning of the lip of the seal (b). Assemble the
toothed washer and the screw the ring nut.
2) Rotated and hammer the hub to make easier
the bedding of the conical rollers on the tracks,
and at the same time with tool 48A19119 screw
gradually the ring nut to the driving torque of 147
102a Nm.
3) Loosen the ring nut and then screw it until the
“ZERO CLEARANCE” condition..
4) After the adjustment, lock the ring nut by means
of the pin. If this is not possible, rotated the ring
nut clockwise until the nest slot, then fit the pin.
The preload must be in the range of 0.00-0.10
mm.

78
TXL 30/ST

Den Haltering (c) auf der Brückenmuffe entfernen


3
D
und austauschen. Vor der Montage mit Öl benetzen c 101b
und für die Montage das Speziellwerkzeug nach
Zchn. 48A19394 verwenden. 48A19394
Hinweis: Das Einbaumaß beachten, um eventuel-
le Beschädigungen des Dichtrings zu vermeiden,
(siehe Abb. 101b).

F Enlever et remplacer la bague d’étanchéité (c) sur


le manchon du pont; humecter par huile avant le
montage, et utiliser outil spécial plan 48A19394
pour le montage.
21,5 mm
Note: Respecter la partie de montage afin d’évi-
ter des endommagements éventuels de la bague
d’étanchéité voir figure 101b.

D Vorschriften für Lagermontage


1) Die Lager mit der Radnabe montieren, nachdem b
jeder Hohlraum (a) mit Fett (vom Typ Fiat MR 2 o.
ä.) gefüllt wurde.
Achtung! Zuviel Fett kann dazu führen, dass die
! Dichtungskante (b) kippt.
Dann die Ringmutter drehen.
2) die Radnabe drehen, um einen guten Sitz der
Kugelrollenlager auf den Laufbahnen zu gewährlei-
sten und gleichzeitig die Ringmutter mit Werkzeug
48A19119 bis zu einem Drehmoment von 147 Nm
fortschreitend anziehen.
3) Die Ringmutter lösen und danach nochmals
anziehen, wobei sie auf einem Zustand vom
“NULL”-Spiel gebracht wird.
4) Nach erfolgter Einstellung, die Ringmutter mit
Spannhülse sichern. Ist das nicht möglich, die
Ringmutter im Uhrzeigersinn bis zum nächsten
Einschnitt drehen, so daß die Spannhülse eingeführt a
werden kann.
Die axiale Vorspannung beträgt 0.00-0.10 mm. 102
F Normes de réglage des roulements
1) Monter les roulements avec le relatif moyeu
après avoir graissée (modèle FIAT MR2 ou similai-
res) chaque cavité intérieure (a).
Attention! L’eccès de gras peut provoquer le ren-
! versement du bord du joint (b).
Puis visser le collier.
2) Tourner et marteler le moyeu pour faciliter la
bonne mise en place des rouleaux coniques sur les
pistes et, entre-temps, serrer le collier à l’aide de
l’outil 48A19119 progressivement jusqu’au couple
de serrage de 147 Nm.
3) Dévisser légèrement le collier, puis le revisser 102a
jusqu’à ce qu’il soit en condition de jeu égal à
“ZÉRO”.
4) Une fois le réglage effectué, bloquer le collier
avec la goupille élastique. Si cela n’est pas possible,
tourner le collier dans le sens des aiguilles d’une
montre jusqu’à la cavité la plus proche de manière à
ce qu’elle pénètre dans la goupille élastique.
La précharge axiale obtenue sera de 0.00-0.10 mm.
79
TXL 30/ST

I Rimontaggio semiassi
Infilare il semiasse facendo attenzione a non dan-
neggiare l’anello di tenuta (a), come indicato.

GB Wheel shaft reassembly


Install the half shaft, taking care not to damage the
seal ring (a).

D Montage Achswelle
Montiere die Achswelle. Vorsicht, daß der
Dichtring (a) nicht beschädigt wird.
103 a
F Remontage des demi-axes
Monter le demi-essieu en faisant attention à ne pas
endommager pas la bague d’étanchéité (a), comme
indiqué.

I Applicare frenafiletti, avvitare e bloccare le 10 viti


alla coppia di serraggio di 13 ÷ 13,6 daNm.

GB Screw in 10 bolts and tighten with 13 ÷ 13.6


daNm.

D Schraube die 10 Schrauben ein und ziehe an mit


einem Drehmoment von 13 ÷ 13,6 daNm.

F Appliquer le frein-à-filets, visser et bloquer les 10


vis au couple de serrage 13 ÷ 13,6 daNm.
104

I Montare il tamburo freni, umettare la filettatura


delle due viti con Loctite 242 e avvitare le due viti
alla coppia di serraggio di 1,9 ÷ 2,1 daNm.
N. B.: assicurarsi che non ci sia strisciamento
delle ganasce del freno sul tamburo.

GB Install the brake drum using Loctite 242 for the


two fixing bolts and screw in with a torque of 1.9 ÷
2.1 daNm.
Note: Make sure that the brake shoes are not in
105 contact with the drum.

D Die Bremstrommel einbauen, das Gewinde


der beiden Schrauben mit Loctite 242 benet-
zen und die beiden Schrauben mit einem
Anziehdrehmoment von 1.9 ÷ 2.1 daNm festziehen.
Hinweis: Sicherstellen, daß bei der Montage
die Bremsschuhe keinen Kontakt mit der
Bremstrommel haben.

F Monter le tambour du frein, humecter le filetage


des deux vis par Loctite 242 et visser les deux vis
au couple de serrage 1.9 ÷ 2.1 daNm.
Note: s’assurer qu’il n’y a pas de frottement des
mâchoires du frein sur le tambour.

80
TXL 30/ST

Smontaggio trasmissione
Dismantle transmission
Getriebe Demontage
Demontage de la transmission
3
I Per la revisione della trasmissione, si può proce-
dere rimuovendo i gruppi ruota completi o revisio-
nando gli stessi, come descritto precedentemente
Per rimuovere i gruppi ruota completi, sbloccare
e svitare le viti di fissaggio manicotti al gruppo
centrale.

GB The wheel side assays can be removed complete,


if necessary.
To remove them, undo the screws holding the
spindle to rear case.
106
D Zur Überholung des Antriebs kann man wie folgt
vorgehen: die Rädergruppen komplett ausbauen
oder sie überprüfen, wie vorher beschrieben.
Um die Rädergruppen komplett auszubauen,
die Befestigungsschrauben der Muffen in der
Zentraleinheit lösen.

F Pour la révision de la transmission, il est possible


de procéder ainsi: enlever les groupes roue en
entier ou bien les contrôler, comme décrit pré-
cédemment.
Pour enlever les groupes roue en entier, débloquer
et dévisser les vis de fixation des fourreaux au
groupe central.

I Smontaggio Coperchio trasmissione


- Svitare le viti fissaggio coperchio albero pignone 107
conico.
- Staccare il coperchio albero pignone conico e
sfilarlo.

GB Transmission cover Dismatling


- To unscrew and remove screws securing the
bevel pinion cover.
- Remove bevel pinion cover.

D Deckel des Getriebes Demontage


- Entfernen Befestigungsschraüben vom Ritzel
deckel.
- Ausbaü Ritzeldeckel.
F Démontage Couvercle de la transmission
- Dévisser les vis de fixation du couvercle de l’ar-
bre pignon conique.
- Détacher le couvercle de l’arbre pignon conique et
l’enlever.

81
TXL 30/ST

I Sollevare le acciaccature della ghiera pignone


conico.

GB Lift up notches on bevel pinion ring nut collar.

D Sicherungsnase des Sicherungsbleches zurück-


biegen.

F Soulever les entailles de la frette du pignon coni-


que.

108

I Allentare la ghiera dopo aver impacchettato le due


frizioni con aria compressa.

GB Undo ring nut after both clutches have been pac-


ked up with compressed air.

D Nach dem Paketieren der beiden Kupplungen mit


Druckluft die Nutmutter lockern.

F Desserrer la frette après avoir empaquetés les


deux embrayages avec de l’air comprimé.
109

I Svitare e rimuovere le viti fissaggio coperchio tra-


smissione.

GB Release and remove screws securing transmission


cover.

D Befestigungsschraüben des Getriebegehäuse-


deckels entfernen.

F Dévisser et enlever les vis de fixation du couvercle


de la transmission.
110

I Staccare il coperchio completo di pompa olio dalla


scatola trasmissione.

GB Remove the cover, complete with oil pump, from


transmission case.

D Abban des Getriebegehäusedeckels komplett mit


ölpumpe vom Getriebegehäuse.

F Détacher le couvercle complet de pompe à huile


du carter transmission.
111

82
TXL 30/ST

Revisione pompa olio e coperchio trasmissione


Oil pump and transmission cover overhaul
Ausprfüng der Ölpumpe und des Deckels
Révision de la pompe à huile et du couvercle de la transmission
3
I Svitare le viti ritegno pompa e estrarre la pompa
completa.

GB Undo screws retaining pump and remove the


pump complete.

D Befestigungsschrauben der ölpumpe lösen und


entfernen. Ausbau ölpumpe

F Dévisser les vis de retenue de la pompe et extraire


la pompe complète.
112

I Smontare la pompa. Pulire perfettamente tutti i


particolari, controllare le usure degli stessi e delle
relative sedi di lavoro.

GB Disassermble the pump. Clean full all components,


check wear of parts and of relevant seats.

D Demontage der ölpumpe. Alle Teile säubern und


über prüfen.
F Démonter la pompe. Nettoyer soigneusement tous
les composants, contrôler les usures des mêmes
et des relatifs sièges de travail. 113

I Controllare il cuscinetto sul corpo pompa e sosti


tuirlo all’occorrenza.

GB Check bearing, on pump shell, and replace, if


required

D Überprüfen von Lager und ölpumpen gehäuse.

F Côntroler le roulement sur le corps pompe et, si


nécessaire, le substituer.

114

83
TXL 30/ST

I Rimontare la pompa inserendo gli ingranaggi con-


dotto e conduttore nel corpo pompa e quindi il
coperchio pompa-manicotto statore avendo cura
di non danneggiare la boccola sull’ingranaggio
conduttore.

GB Reassemble the pump unit, fit driving and driven


gears set in pump shell, then, the pump cover sta-
tor sleeve, take care to avoid damage on driving
gear bushing

D Ritzel und Hohlrad ins Pumpengehäuse montieren


115 Leitradträger in Pumpe komplett elnsetzen Vorsicht
bei der Montage, daß die Buchse im Ritzel nicht
beschädigt wird.

F Remonter la pompe en insérant les engrenages


conduit et conducteur dans le corps pompe. puis
le couvercle pompe-manchon stator en ayant soin
de ne pas endommager la boucle sur l’engrenage
conducteur.

I Con un appropriato attrezzo sfilare la guarnizione


dalla sede uscita presa di forza e quindi spiantare
l’astuccio a rullini.

GB Use a proper tool to remove seal from P.T.O. outlet


seat, then, remove needle roller casing.

D Dichtring mit Werkzeug aus PTO - Sitzt heraus-


ziehen. Nadellager entfernen.

F Par opportun outil enlever le joint du siège de la


sortie de la prise de force et donc arracher l’étui à
116 petits rouleaux.

I Con un appropriato punzone spiantare la pista


117 esterna del cuscinetto pignone conico.

GB Remove the outer race, of bevel pinion bearing, by


a driff punch.

D Lageraussenring mit Werkzeug Herrausschlagen

F Par un opportun poinçon arracher la piste extérieu-


re du roulement pignon conique.

84
TXL 30/ST

I Nel caso di sostituzione dei cuscinetti conici,


spiantare le piste esterne con normale estrattore e
rimontare a caldo o con opportuno attrezzo.
3
GB If the tapered bearings have to be replaced, remo-
ve the outer race them with a normal extractor and
re-assemble hot or with the appropriate tool.

D Falls Kegelrollenlager getauscht werden muß,


Lager mit 2-armigen Abzieher abziehen. Bei
Montage den Kegelradinnenring im Ofen
erwärmen. 118
F En cas de remplacement des roulements
coniques, les enlever la piste extérieure à l’aide
d’un extracteur normal, puis les remonter à chaud
ou avec un outil approprié.

I Rimontare l’astuccio a rullini, la guarnizione di


tenuta e la pista esterna del cuscinetto pignone
conico.
Avvertenza: la forza da esercitare sugli astucci
a rullini per introdurli nelle loro sedi deve essere
applicata, senza urti, sul bordo della faccia stam-
pigliata mediante un tampone appropriato agente
sull’astuccio ed accuratamente centrato sulla
sede.

GB Refit needle roller casing, seal and outer race of


bevel pinion bearing. 119
Note: the press fitting strength exerted to drive
needle roller casings, in relevant seats, should be
applied evenly and bumpless, on the marked side,
by a proper tool resting on the casing and suitably
aligned to seat.

D Montage Nadellager, Dichtring und Aussenring


vom Kegelrollenlager.
Beachte: Nadellager mit geeignetem Werkzeug in
die vorgesehene markierte Lage einpresse.

F Remonter I’étui à petits rouleaux, le joint d’étan-


chéité et la piste extérieure du roulement pignon
conique.
Note: la force à exercer sur les étuis à petits rou-
leaux pour les introduire dans leurs sièges doit
être appliquée, sans chocs, sur le bord de la figure
marquée par un tampon approprié qui agit sur
l’étui et soigneusement centré sur le siège.

85
TXL 30/ST

I Rimontare la pompa su coperchio trasmissione,


applicare il frenafiletti medio sulle viti e bloccare
con una coppia di serraggio di 2,3 ÷ 2,5 daNm.

GB Reinstall pump on transmission cover, smear


medium locking compound on screws.
Tighten with a torque of 2.3 to 2.5 daNm.

D Leitradträger und Pumpe komplett montieren.


Befestigungsschrauben mit Loctite Medium ein-
setzen und mit einem Drehmoment von 2,3 ÷ 2,5
daNm anziehen.
120
F Remonter la pompe sur le couvercle de la tran-
smission, appliquer le frein à filets moyen sur les
vis et bloquer à un couple de serrage de 2,3 ÷ 2,5
daNm.

I Smontaggio trasmissione
Sfilare il gruppo frizione superiore completo.

GB Transmission disassembly
Pull out the upper clutch unit complete.

D Getriebedemontage
Die obere Kupplungsgruppe komplett herausneh-
men.

F Démontage de la transmission
121 enlever le groupe embrayage supérieur complet.

I Sfilare il gruppo frizione inferiore completo.

GB Pull out the lower clutch unit complete.

D Die untere Kupplungsgruppe komplett heraus-neh-


men.

F Enlever le groupe embrayage inférieur complet.

122

86
TXL 30/ST

I Sfilare il distanziale e gli spessori di registrazione del


precarico dei cuscinetti del pignone conico.
Svitare le 3 viti di fissaggio e rimuovere il riparo
3
ingranaggio.
Estrarre l’ingranaggio condotto dall’albero pigno-
ne conico.

GB Remove the spacer and bearing pre-load adjust-


ment shims of bevel pinion.
Unscrew the 3 retaining screws and remove the
gear guard.
Pull out the driven gear on bevel pinion.
123

D Zwischenscheibe und Lagereinstellscheiben von


der Ritzelwelle obziehen.
Die drei Befestigungsschrauben lösen und die
Schutzabdeckung des Zahnrads entfernen.
Zahnrad von der Ritzelwelle abziehen.

F Enlever l’entretoise et les cales de réglage du pré-


charge des roulements du pignon conique.
Dévisser les vis de retenue et enlever la protection
engranage.
Extraire l’engrenage conduit de l’arbre pignon
conique.

87
TXL 30/ST

Revisione frizioni
Clutches overhauling
Ausprüfung der Kupplungen
Révision des embrayages

I Sganciare e sfilare con particolare attenzione gli


anelli di tenuta dall’albero frizione.
GB Unhook and remove, with particular care, rings
from clutch shaft.

D Die Dichtringe mit besonderer Vorsicht aushaken


und von der Kupplungswelle abziehen.

F Décrocher et enlever avec soin particulier les


bagues d’étanchéité de l’arbre embrayage
124

I Spiantare il cuscinetto dall’albero lato ingranaggio


sempre in presa.
GB Remove bearing from shaft on constant mesh gear
side.

D Lagerinnenring mit zwei Montagehebeleisen


abdrücken.

F Arracher le roulement de l’arbre côté engrenage


toujours en prise.
125

I Estrarre la pista interna del cuscinetto e le ralle di


spallamento ingranaggio.
GB Remove bearing inner race and thrust washers of
gear.

D Die Außenspur des Lagers und die Paßstücke des


Zahnrades abziehen.

F Extraire la piste intérieure du roulement et les cra-


paudines d’épaulement de l’engrenage.

126

88
TXL 30/ST

I Togliere l’ingranaggio e le relative gabbie a rulli


e distanziale unitamente alle ralle di spallamento
lato interno.
3
GB Remove gear and relevant roller cages along and
spacer with inner thrust washers.

D Zahnrad und entsprechende Rollenkäfige und


Abstandstück zusammen mit den Paßstücken
Innenseite entfernen.

F Enlever l’engrenage et les relatives cages à rou-


leaux de concert aux crapaudines d’épaulement
du côté intérieur.

127

I Rimuovere dalla sede l’anello elastico di ritegno


disco di reazione inserendo, tramite uno dei fori,
un cacciavite e premere verso l’ esterno, contem-
poraneamente con un altro cacciavite sganciare
l’anello elastico di ritegno ed estrarre il tutto.

GB Remove from its seat the circlip which holds the


reaction plate. The circlip must be pressed upwards
with a screwdriver fitted in one of the holes of the
clutch housing.
Simultaneously with another screw driver pry the
circlip out, then remove all the components of the 128
clutch pack.

D Um den Sprengring, der die Reaktionsscheibe hal-


tet, zu entfernen, einen Schraubendreher verwen-
den.
Nach auben drücken und gleichzeitig mit einem
anderem Schraubendreher den Sprengring abhän-
gen und die Teile herausziehen.

F Enlever du siège la bague de retenue du disque


de réaction en insérant, à travers l’un des trous,
un tournevis et pousset vers l’extérieur; en même
temps, à l’aide d’un autre tournevis, décrocher la
bague de retenue et extraire le tout.

I Sfilare dalla campana i dischi e i controdischi fri-


zione.

GB Pull out driving and driven disks from clutch bell


housing.

D Deck-lnnen- und Außenlamellen herausnehmen.

F Enlever de la cloche les disques et les contredi-


sques de I‘embrayage.

129

89
TXL 30/ST

! ATTENZIONE !
Impiegare gli utensili adatti.
NON USARE MAI DITA O MANI
o attrezzi non idonei

! WARNING !
Use the proper tools.
NEVER USE FINGERS OR HANDS
or incorrect tools

! ACHTUNG !
Schwere Teile nur mit geeignetem Hebe-und
Transportwerkzeug transportieren.
Vorsicht auf Hände und Finger

! ATTENTION !
Utiliser les outils appropriés.
130 NE JAMAIS UTILISER DE DOIGTS OU MAINS
ou d’outils pas appropriés

I Mediante appropriato attrezzo (4A41377) compri-


131 mere la molla di reazione per estrarre l’anello elasti-
co di ritegno.

GB Compress the reaction spring by a proper tool


(4A41377) and pull out the retaining ring.
D Feder über Halteblech mit Spezialwerkzeug
(4A41377) niederdrücken, bis Sicherungsring frei
ist. Sicherungsring lösen. Spezialwerkzeug an den
Muttern lösen und entfernen.

F Par opportun outil (4A41377) comprimer le ressort


de réaction afin d’extraire le segment de retenue.

I Sfilare lo scodellino e la molla.

GB Remove cup and spring.

D Sicherungsring, Halteblech und Feder herausneh-


men

F Enlever le petit bol et le ressort.

132

90
TXL 30/ST

I Sfilare lo stantuffo dalla campana frizione median-


te immissione aria compressa nel condotto della
marcia.
3
Pulire perfettamente tutti i particolari, verificarli,
sostituirli secondo necessità e rimontarli previa
lubrificazione degli anelli di tenuta.

GB Push out piston from clutch bell housing by injec-


ting compressed air into ducting. Clean full all
components, check, replace as required and reas-
samble after O-Rings have been duly lubricated.
133
D Den Kolben von der Kupplungsglocke durch
Druckluftzufuhr in der Gangschaltungsleitung
abnehmen.
Alle Bauteile vollständig reinigen, prüfen, falls
erforderlich ersetzen und nach der Schmierung
der Dichtringe wieder einbauen.

F Enlever le piston de la cloche de l‘embrayage par


introduction d‘air comprimé dans le conduit de la
marche.
Nettoyer soigneusement tous les composants,
les vérifier, les substituer selon nécessité et les
remonter après lubrification des bagues d’étan-
chéité.

I Sostituire l’anello di tenuta esterno e quello inter-


no dello stantuffo. Lubrificarli secondo istruzioni.

GB Replace the outer and inner seal rings of piston.


Lubricate O-Rings according to instructions.

D O-Ringe von Kolben und Welle entfernen.

F Substituer la bague d’étanchéité extérieure et la


bague intérieure du piston. Les lubrifier en suivant
les instructions.
134

I Inserire lo stantuffo, la molla di reazione e lo sco-


dellino appoggio molla nella campana frizione.

GB Insert piston, reaction spring and relevant seat cup


into clutch bell housing.

D O-Ringe prüfen, Kolben in Rückwärtsgangkupplung


einsetzen. Feder, Halteblech und Sicherungsring
einlegen.

F Insérer le piston, le ressort de réaction et le petit bol


d‘appui du ressort dans la cloche embrayage.
135

91
TXL 30/ST

! ATTENZIONE !
Impiegare gli utensili adatti.
NON USARE MAI DITA O MANI
o attrezzi non idonei

! WARNING !
Use the proper tools.
NEVER USE FINGERS OR HANDS
or incorrect tools

! ACHTUNG !
Schwere Teile nur mit geeignetem Hebe-und
Transportwerkzeug transportieren.
Vorsicht auf Hände und Finger
136
! ATTENTION !
Utiliser les outils appropriés.
NE JAMAIS UTILISER DE DOIGTS OU MAINS
ou d’outils pas appropriés

I Comprimere la molla di reazione ed inserire l’anello


136a elastico di ritegno molla nella sede sull’albero.

GB Compress the reaction spring and insert the retai-


ning spring into the seat on shaft.

D Mit Sonderwerkzeug Feder niederdrücken und


Sicherungsring sichern.

F Comprimer le ressort de réaction et insérer le seg-


ment de retenue du ressort au siège sur l’arbre.

I Rimontare nella campana i 6 dischi (b) e i 6 con-


trodischi (a) frizione;
Avvertenza: nella sequenza di montaggio del
pacco frizione occorre inserire a contatto dello
stantuffo un controdisco in acciaio (a).

GB Remount the 6 clutch driving (b) and the 6 driven


disks (a);
Note: when packing clutch disk bear in mind that
a steeldriven disk (a) must face the piston.

137 D 6 Außen (b)- und 6 Innenlamellen einlegen (a);


Hinweis: bei der Einbausequenz des
Kupplungsblocks muß eine Stahlaußenlamelle (a)
in Kontakt mit dem Kolben eingelegt werden.
a b
F Remonter dans la cloche les 6 disques (b) et les 6
contredisques embrayage (a);
Note: dans la séquence de montage du pack
embrayage il faut insérer au contact du piston un
contredisque en acier (a).

92
TXL 30/ST

I Posizionare come da foto 138 il disco di reazione


completo di anello elastico, successivamente pre-
mere sull’ anello in modo che vada a inserirsi nella
3
propria sede, foto 139 e 140.
Avvertenza: controllare il gioco come da figura
141 e verificarlo in tre punti equidistanti a 120°.

GB Fit the circlip on the reaction plate, then insert the


assy as shown in photo 138, then press on the cir-
clip in order to fit it in its seat, photo 139 and 140.
Note: check clereance as figure 141 and verify it 138
in three points, every 120°.

D Die Reaktionsscheibe mit dem Sprengring wie im


Bild 138 stellen, dann auf den Ring drücken um
ihn in seinem Sitz zu stecken. Bild 139 und 140.
Hinweis: Das Spiel wie in Abbildung 141 darge-
stellt kontrollieren und an drei abstandsgleichen
Punkten von 120° messen.

F Placer, comme la photo 138 le montre, le disque


de réaction complet de bague de retenue; par la
suite, pousser sur la bague de maniere qu’elle se
place dans son propre siège, photo 139 et 140. 139
Note: contrôler le jeu selon la figure 141 et le véri-
fier en trois points se trouvant tous à une distance
de 120°.

140

141

93
TXL 30/ST

I Inserire le ralle di spallamento delle gabbie a rulli


dell’ingranaggio lato interno.

GB Insert thrust washers of gear roller cages on inner


side.

D Die Paßstücke der Rollenkäfige des Zahnrades


Innenseite einführen.

F Insérer les crapaudines d’épaulement des cages à


rouleaux de l’engrenage côté intérieur.

142

I Montare le gabbie a rulli con relativo distanziale e


l’ingranaggio centrando il mozzetto sulla dentatura
dei dischi frizione.

GB Mount roller cages with relevant spacer and gear


positioning the hub true on toothing of clutch
disks.

D Rollenkäfige mit jeweiligen Abstandstücken


und das Rad einbauen, dabei die Nabe auf der
Verzahnung der Kupplungsscheibe zentrieren.

F Monter les cages à rouleaux avec entretoise cor-


respondant et l’engrenage en centrant le petit
moyeu sur la denture des disques embrayage.

143

I Montare le ralle di spallamento e la pista interna


cuscinetto lato ingranaggio.

GB Mount thrust washers and bearing inner race on


gear side.

D Montage Anlaufscheibe und Innenring des


Rollenlagers auf der Abtriebsseite .

F Monter le crapaudine d’épaulement et la piste


intérieure du roulement côté engrenage.

144

94
TXL 30/ST

I Verificare il gioco tra ingranaggio e ralla (vedi figu-


ra 145). 3
GB Verify clereance between gear and thrust washer
(see fig. 145).

D Das Spiel zwischen Zahnrad und Paßstück prüfen


(siehe Abb. 145).

F Vérifier le jeu entre engrenage et rapaudine (voir


figure 145).

145

I Montare il cuscinetto sull’albero lato ingranaggio


sempre in presa.

GB Mount bearing on shaft, constant mesh gear side.

D Abtriebsseiting Rollenlager montieren.

F Monter le roulement sur l’arbre côté engrenage


toujours en prise.

146

I Montare gli anelli tenuta nelle proprie sedi.


Nota: dopo l’installazione degli anelli occorre
spalmarli di grasso in modo da poterli centrare e
fermare in sede durante l’inserimento degli alberi
evitando avarie e danneggiamenti.

GB Mount rings in relevant seats.


Note: smear cast rings with grease, after installa-
tion, to keep them centered and steady in relevant
seat when shafts are inserted, so as to prevent fai-
lures or damages.
147
D Montage Graugusskolbenring.
Beachte: Kolbenring mit Fett einschmieren und
in die vorgesehene nut einführendabei ist auf ord-
nungsgemässen Sitzt zu achten.

F Monter les bagues d’étanchéité dans leurs sieges.


Note: après l’installation des bagues, il faut les
étaler de graisse afin de pouvoir les center et blo-
quer au siège pendant l’introduction des arbres en
évitant pannes ou endommangements.

95
TXL 30/ST

Revisione Differenziale
Differential overhauling
Ausprüfung der Differential
Révision des Differentiel

I Spiantare la spina elastica di fermo ghiera e con


attrezzo 48A19118 svitare la ghiera.

GB Remove the spring pin holding the nut and unscrew


the nut with tool 48A19118

D Die Spannhülse zur Festhalten der Nutmutter


herausziehen und mit Werkzeug 48A19118 die
Nutmutter ausschrauben.

F Enlever la goupille élastique d’arrêt du collier à l’ai-


de de l’outil 48A19118 et devisser le collier.
148

I Smontaggio scatola centrale


Smontare il coperchio rimuovendo le viti di fissag-
gio al corpo centrale.

GB Central case diisassembly


Undo screws fixing cover to central casing and
remover cover.

D Demontage des mittleren Gehäuses.


Achsdeckel entfernen, wobei die
Befestigungsschrauben am mittleren Gehäuse
entfernet werden.
149
F Démontage du carter central
Démonter le couvercle en enlevant les vis de fixa-
tion au corps central.

I Svitare e rimuovere le viti di fissaggio dei cappelli


supporto differenziale dopo aver contrassegnato
la posizione dei cappelli per il rimontaggio.

GB Undo and remove screws securing differential


support caps, mind to mark reference for reas-
sembly.

D Die Befestigungsschrauben der


Differentialträgerdeckel abschrauben und entfer-
nen, dabei die Position der Deckel für den
Wiedereinbau markieren.
150
F Dévisser et enlever les vis de fixation des cha-
peaux de support différentiel après a voir marquée
la position des chapeaux pour le remontage.

96
TXL 30/ST

GB
Togliere i cappelli del supporto differenziale.

Take off caps.


3
D Halbschalen entfernen.

F Enlever les chapeaux du support différentiel.

151

I Sfilare il differenziale completo.

GB Remove differential unit complete.

D Differential komplett mit Einstellscheiben


aüsbauen.

F Enlever le différentiel complet.

152

I Sfilare il pignone conico completo di gabbia rulli


del cuscinetto sottotesta e distanziale.

GB Take off bevel pinion complete with roller cage, of


pinion under head bearing, and spacer.

D Kegelradwelle mit Kegellager herausziehen.

F Enlever le pignon conique complet de cage rou-


leaux du roulement sous- tête et entretoise.

153

97
TXL 30/ST

I Smontaggio e revisione complessivo differen-


ziale
Le gabbie rulli dei cuscinetti differenziale si posso-
no estrarre mediante un appropriato estrattore.

GB Differential unit disassembly and overhauling


Roller cages of differential bearing can be taken
off by a proper puller.

D Differentialdemontage, überprüfung, überho-


lung
Das kegelrollenlager des Differentials muß mit
einer Abziehvorrichtung entfernt werden.

F Démontage et révision du différentiel global


On peut extraire les cages rouleaux des roulemen-
ts du différentiel par un extracteur approprié.

154

I Svitare e rimuovere le viti fissaggio corona e sfilar-


la dalla scatola.

GB Undo and remove screws securing the ring gear


and pull it out from casing

D Lösen und entfernen der Befestigungsschraüben


für das kegelrad.

F Dévisser et enlever les vis de fixation de la couron-


ne et l’enlever du carter.

155

I Contrassegnare le semiscatole per l’accoppia-


mento al rimontaggio.

GB Mark both half-casings for reference at reassem-


bly.

D Markieren der beiden Differentialgehäuse hälften.

F Marquer les demi-carters pour l’accouplement au


remontage.

156

98
TXL 30/ST

I Smontare le semiscatole differenziale rimuovendo


le viti di unione. 3
GB Separate differential half casings by undoing the
fixing screws.

D Lösen und entfernen der Differential gehäuse-


schrauben.
F Démonter les deml-carters différentiel en enlevant
les vis d’union.

157

I Visionare i componenti del differenziale. Pulire


perfettamente tutti i particolari. verificarli, sostituir-
li secondo necessità.
GB Check differential components. Clean thoroughly
all parts, check and replace as required.

D Überprüfen der Differential-komponenten, säu-


bern, beurteilen und wenn notwendig ersetzen.

F Contrôler les composants du différentiel. Nettoyer


soigneusement tous les composants, les vérifier et
substituer si nécessaire. 158

I Rimontare il differenziale posizionando i compo-


nenti nelle relative sedi.

GB Remount differential positioning components in


relevant seats.

D Differential mit den zusammengehöringen kompo-


nenten zusammen füger.
F Remonter le différentiel en plaçant les composants
dans les relatifs sièges.

159

99
TXL 30/ST

I Rimontare la gabbia rulli del cuscinetto differen-


ziale a caldo o con un’appropriata attrezzatura.
Applicare frenafiletti medio sulle viti fissaggio
semiscatole.

GB Use a suitable equipment to heat differential


bearing roller cage and install in its seat. Smear
medium locking compound on screws fixing half-
casing.

D Montieren des kegelrollenlagers. Die Differentialge


hauseschrauben mit Loctite 242 sichern.

F Remonter la cage rouleaux du roulement du


différentiel à chaud ou par outillage approprié.
Appliquer le frein-à-filets moyen sur les vis de fixa-
tion de demi-carters.

160

I Bloccare le viti con una coppia di serraggio di


7,5 ÷ 8,3 daNm.

GB Tighten screws with a torque of 7.5 to 8.3 daNm.

D Befestigungsschrauben mit 7,5 bis 8,3 daNm


anziehen.

F Bloquer les vis à un couple de serrage de 7,5 ÷ 8,3


daNm.

161

I Rimontare la gabbia rulli, del cuscinetto lato coro-


na a caldo con un’appropiata attrezzatura.

GB Heat up, by proper equipment, and refit roller cage


of bearing on ring gear side.

D Montieren des kegelrollenlagers out der kagelrad-


seite.

F Remonter la cage rouleaux du roulement côté


couronne à chaud par outillage approprié.

162

100
TXL 30/ST

I Nel caso di sostituzione della coppia conica, ap-


plicare frenafiletti medio sulle viti fissaggio corona
conica e bloccarle con una coppia di serraggio di
3
21 ÷ 23 daNm.

GB Should bevel gear set be replaced it is necessary


to smear medium locking compound on screws
fixing the ring gear and tighten them with torque
of 21 to 23 daNm.

D Die Befestigungsschrauben für das Kegelrad


müssen mit Loctite 242 gesichert werden.
Das Schraubenanzieh drehmoment ist 21 bis 23
Nm.

F En cas de substitution du couple conique. appli-


quer le frein à filets moyen sur les vis de fixation
de la couronne conique et les bloquer à un couple
de serrage de 21 ÷ 23 daNm.
163

I Revisione della scatola centrale


Estrarre i cuscinetti dalle sedi sulla scatola e
rimontare quelli nuovi.

GB Central case overhaul


Pull out bearings from relevant seats on case and
refit new ones.

D Überholung vom Getriebegehäuse


Ausbau der Wälzlager aus dem Gehäuse und
Montage der neuen.

F Révision du carter central


Extraire les roulements des sièges sur le carter et
remonter ceux neufs.

164

I Montare la pista interna del cuscinetto, sottotesta


sul pignone, a caldo o con opportuno punzone.
Inserire la nuova guarnizione OR sul pignone.

GB Fit inner bearing race, under head of pinion, using


proper heating equipment of a specific installer.
Fit a new OR on the pinion shaft.

D Innenring des kegelrollenlagers auf die Ritzelwelle


montieren.
Die neue Dichtung OR auf das Ritzel einbauten.
165
F Monter la piste intérieure du roulement sous-tête
sur le pignon, à chaud ou par poinçon approprié.
Mettre le nouveau joint torique OR sur le pignon.

101
TXL 30/ST

I Rimontaggio differenziale e posizionamento


coppia conica con relative registrazioni:
COPPIA CONICA
1) Posizionamento pignone (fig. 166)
DETERMINAZIONE SPESSORE ANELLI DI
REGISTRO:
- Rilevare la quota A (nel caso non fosse stampi-
A gliata sul supporto) misurando la distanza tra
l’asse del differenziale e la sede del cuscinetto
pignone conico.
166 Esempio: quota A rilevata 190,47 mm
- Determinare la quota B effettiva sommando
algebricalmente la correzione K stampigliata in
testa al pignone alla quota B teorica.
Esempio: B = 149,50; correzione indicata (in
fig. 166a decimi): -1, la quota B effettiva risul-
terà 149,50-0,1=149,40.
- Determinare la quota C rilevando lo spessore di
testa del cuscinetto pignone completo.
Esempio: quota C rilevata 36,6 mm
- Effettuare quindi la somma delle quote B e C.
La misura risultante dovrà essere sottratta alla
S

quota A e la differenza ottenuta sarà il valore


dello spessore S da inserire sotto il cuscinetto
del pignone.
Esempio: S = A - [(B±K)+C]
(190.50)

S = 190,5[(149,50±K)+36,6]
A

B = quota da correggere secondo quanto


K
riportato sulla testa del pignone
K = correzione riportata sulla testa del pignone.

GB Differential reassembly and bevel gear set


positioning with relevant adjustment:
BEVEL GEAR
1) Positioning bevel pinion (fig. 166)
COMPUTING SHIMS THICKNESS:
(36.6)
C

- Record dimension A (if not printed on housing)


housing measure from differential center line to
distance seat of bevel pinion bearing.
e. g.: recorded dimension A = 190.47 mm
- Determine true dimension B algebrically adding
the correction factor
printed on pinion head to theoretical dimension B.
e. g.: B = 149.50 mm; correction shown (in tenth
of millimeter) = -1, true dimension B will
be: 149.50-0.1=149.40 mm
- Determine dimension C measuring thickness of
the pinion head bearing assy.
e. g.: dimension C = 36.6 mm
- Add dimensions B and C. Resulting value
(149.50)

must of S shim thickness to be fitted under the


B

pinion bearing.
e. g.: S = A - [(B±K)+C]
S = 190,5[(149,50±K)+36,6]
B = dimension to be rectified according to value
reported on pinion head.
K = correction value reported on pinion head.

102
TXL 30/ST

D Wiedermontage vom Differentialgetriebe und


Positionierung von Kegelradpaarung mit den
entsprechenden Einstellungen:
KEGELRÄDERPAARUNG
3
1) Kegelritzeleinstellung (Abb. 167)
ERMITTLUNG DER STÄRKE DER EINSTELLRINGE:
- Maß (A) (falls nicht im Gehäuse eingraviert) durch
Messen von der Mitte vom Differential zur Anlage
des Kegelrollenlageraußenriges ermitteln;
A
Beispiel: ermitteltes Maß A 190,47 mm
- Ist-Maß (B) durch die algebraische Summe des
auf der Stirnseite vom Kegelritzel eingeprägten 166
Berichtigungswerts K und vom theoretischen Maß.
Beispiel: B = 149,50; angegebene Berichtigung
(in Zehnteln): -1, das Ist-Maß
beträgt 149,50-0,1=149,40.
- Maß (C) durch Messen der Stärke des komplet- fig. 166a
ten Ritzellagerkopfes ermitteln.
Beispiel: ermitteltes Maß 36,6 mm
- Die Summe der Masse B und C berechnen.
Das sich daraus ergebende Maß ist vom Maß
A abzuziehen und die Differenz entspricht dem
Wert der Stärke S, die unter den Ritzellager hin-
zuzufügen ist.

S
Beispiel: S = A – [(B±K)+C]
S = 190,5 [(149,50±K)+36,6]
B = zu berichtigende Maß anhand der Vorgabe auf
der Stirnseite des Ritzels

(190.50)
K = Berichtigungswert auf der Stirnseite des Ritzels.

A
F Re-montage du différentiel et positionnement K
du couple conique selon leurs réglages relatifs:
COUPLE CONIQUE
1) Positionnement pignon (fig. 166)
DETERMINATION ÉPAISSEUR BAGUES
D’ÉTANCHÉITÉ DE RÉGLAGE :
- Relever la cote A (dans le cas où elle ne serait
pas gravée sur le support) en mesurant la distance
entre l’axe du différentiel et le siège du roulement
(36.6)
C

pignon conique.
Exemple: cote A relevée 190,47 mm
- Déterminer la cote B effective en additionnant
algébriquement la correction K gravée sur la tête
du pignon à la cote B théorique.
Exemple: B = 149,50; correction indiquée (en
dizième): -1, la cote B effective
deviendra 149,50-0,1=149,40.
- Déterminer la cote C en relevant l’épaisseur de la
tête du roulement pignon complet.
Exemple: cote C relevée 36,6 mm
- Effectuer ensuite la somme des cotes B et C.
La mesure obtenue doit être soustraite à la
(149.50)

cote A et la différence obtenue est la valeur


B

de l’épaisseur S qui doit être insérée sous le


roulement du pignon.
Exemple: S = A - [(B±K)+C]
S = 190,5[(149,50±K)+36,6]
B = cote à corriger selon ce qui est reporté sur la
tête du pignon
K = correction reportée sur la tête du pignon.
103
TXL 30/ST

I Prima di posizionare lo spessore S montare la


guarnizione (opportunamente lubrificata con
grasso) e piantare la pista esterna del cuscinetto
sottotesta.
GB Prior positioning shim S, mont the seal (suitably
greased) and fit outer race of pinion underhead
bearing.
D Bevor die Einstellscheibe S montiert wird, wird der
Radialwellendichtring mit Fett in das Achsgehäuse
eingesetzt.
167
F Avant de positionner la cale S, monter le joint
(opportunément graissé) et planter la piste
extérieure du roulement sous-tête.

I Inserire il pignone in sede nella scatola.

GB Insert pinion in its seat with housing.

D Kegelritzel ins Achsgehäuse einschieben.

F Insérer le pignon au siège dans le carter.

168

I Rimontaggio trasmissione
Calettare l’ingranaggio sullo scanalato del pignone
conico e inserire il distanziale.
Posizionare il riparo ingranaggio, umettare il filetto
con “Loctite 242” le 3 viti, avvitare e bloccare alla
coppia di serraggio 9,5÷10,5 Nm.
GB Transmission reassembly
Fit gear on pinion splined shaft and fit spacer.
Fit the guard. Smear the 3 holding screws with
medium grade fastener, and tighten at the torque
169 of 9,5÷10,5 Nm.
D Getriebe montage
Montage des Abtriebszahnrades und Montage
Zwischenring.
Die Schutzabdeckung Zahnrad positionieren, die
Gewinde mit “Loctite 242” benetzen, festziehen
und bei einem Drehmoment von 9,5 bis 10,5 Nm
blockieren.
F Remontage de la transmission
Emboîter l’engrenage sur le rainé du pignon coni-
que et Insérer I’entretoise.
Positionner la protection engrenage, induire d’un
trait de “Loctite 242” les 3 vis, visser et bloquer au
couple 9,5÷10,5 Nm.
104
TXL 30/ST

I Sostituire gli anelli O-Ring sui condotti di mandata


olio. 3
GB Replace O-Ring seals on oil delivery ducts.

D O-RINGE aus Ölzuführung entfernen.

F Substituer les bagues O-Ring sur les conduits


d’envoi d’huile..

170

I Rimontare il gruppo frizione inferiore completo.

GB Refit lower clutch assembly complete.

D Montage Vorwärts Kupplung.

F Remonter le groupe embrayage inférieur complet

171a

I Rimontare il gruppo frizione superiore completo.

GB Refit upper clutch assembly complete.

D Montage Vorwärts Kupplung.


F Remonter le groupe embrayage supérieur com-
plet.

171b

I Applicare sigillante sulla facciata d’appoggio e


rimontare il coperchio trasmissione completo di
pompa olio, applicare il frenafiletti medio e blocca-
re le viti fissaggio complete di rosetta elastica con
una coppia di serraggio di 62 ÷ 69 Nm.

GB Smear sealing compound on contact surface and


reassembly transmission cover complete with oil
pump, smear medium screw locking compound
and lock with a tightening torque of 62 to 69 Nm.

D Montage Ölpumpe. Befestigungsschraube mit 62


bis 69 Nm anziehen.
172
Dichtflächen mit Dichtungsmasse einschmieren.

F Cacheter la façade d’appui et remonter le couver-


cle de la transmission complet de pomp à huile,
appliquer le frein à filets moyen et bloquer les vis
de fixation à un couple de serrage de 62 ÷ 69 Nm.

105
TXL 30/ST

I - Misurare gli spessori di registro del precarico


cuscinetti pignone opportunamente maggiorati in
modo da non avere precarico.
- Inserire i distanziali, quindi piantare l’anello
interno del cuscinetto coda pignone e avvitare la
ghiera.
- Bloccare la ghiera mediante impacchettamento
delle frizioni con aria compressa.
Coppia di serraggio 66,5 ÷ 73,5 daNm.
- Rilevare la coppia passiva del sistema senza pre-
carico dei cuscinetti pignone.
173
GB - Measure shim thickness for pre-load of pinion
bearings, said value should be suitably increased
so as to have no pre-load.
- Insert spacers, then, fit bearing inner race on
pinion shaft and screw in ring nut.
- Pack up clutches by compressed air.
Lock nut with a torque of 66.5 to 73.5 daNm.
- Check system passive torque less pinion bearing
pre-load.

D - Dicke der Einstellscheibe für die kegelritzellage-


rung festlegen.
- Abstandsring, dann Innenring des
Kegelrollenlagers auf die Ritzelwelle scheiben und
die Ringmutter anziehen.
- Die Kupplungspakete mit Preßluft auf
Lamellenspiel prüfen und Mutter mit einem
Drehmoment von 66,5 bis 73,5 daNm anziehen.
- Überprüfen des Durcsdreh-Drehmoments.

F - Mésurer les cales de réglage du pré-charge des


roulements du pignon opportunément majorés de
manière à ne pas avoir pré-charge.
- Insérer les entretoises donc planter la bague
intérieure du roulement de queue pignon et visser
la frette.
- Bloquer la frette par empaquetage des embra-
yages avec air comprimé.
Couple de serrage 66,5 ÷ 73,5 daNm.
- Relever le couple passif du système sans pré-char-
ge des roulements du pignon.

106
TXL 30/ST

I Rilevare il gioco assiale, spiantare l’anello interno


del cuscinetto di coda pignone; sfilare il distan-
ziale, e variare lo spessore eliminando totalmente
3
il gioco fino ad ottenere un precarico di 0,05 mm.
Rimontare il tutto, bloccare la ghiera alla prescritta
coppia di serraggio, controllare che l’incremento
di coppia di rotolamento sia compresa fra 1,5 e
4,0 Nm rispetto alla coppia passiva precedente-
mente rilevata.
Acciaccare la ghiera.

GB Check end play, remove inner race of bearing fit- 174


ted on pinion shaft; remove spacer, vary thickness
to eliminate the whole play and reach a pre-load
of 0.05 mm. Reassembly all components, lock ring
nut at the specified torque, check that increasing
of revolving torque be included within 1.5 to 4.0
Nm than the passive torque that was previously
checked.
Notch ring nut collar.

D Überprüfen des Lagerspiels. Entfernen des


Innenringes vom Kegelrollenlagers und ersetzen der
Einstellscheibe durch eine Scheibendicke, die eine
Vorspannung von 0,05 mm ergibt.
Montieren der Einzelteile und Ringmutter anziehen.
Durchdrehmoment und Lagerspiel kontrollieren.
Sichern der Ringmutter durch Umlegen des
Sicherungsbleches.

F Relever le jeu axial, arracher la bague intérieure


du roulement de queue pignon; enlever l’entretoi-
se et varier la cale en éliminant le jeu complète-
ment jusqu’à obtenir un pré-charge de 0,05 mm.
Remonter le tout, bloquer la frette au couple de
serrage prescrit, contrôler que l’augmentation du
couple de roulement soie comprise entre 1,5 et
4,0 Nm par rapport au couple passif précédem-
ment relevé.
Entrailler la frette.

I Sostituire la guarnizione OR e montare il coper-


chio, applicare frenafiletti medio sulle viti fissaggio
e bloccare.

GB Replace O-Ring and mount cover, smear medium


screw locking compound and tighten.

D Die Dichtung OR ersetzen und Deckel montie-


ren. Eine mittlere Gewindesicherung auf den
Befestigungsschrauben aufbringen und spannen.

F Remplacer joint OR et monter le couvercle, appli-


quer le frein-à-filets moyen sur les vis de fixation et 175
bloquer.

107
TXL 30/ST

I 2) Registrazione coppia conica


- Montare sul corpo centrale il differenziale com-
pleto di corona e di cuscinetti. Avvitare parzial-
mente le ghiere con attrezzo 48A19118.
- Montare i due cappelli e serrare le quattro viti
(umettare con “Loctite 242” o similari) di fissag-
gio alla coppia di 132÷146 Nm.
- Avvitare progressivamente le ghiere (a) ruotando
contemporaneamente il differenziale per garan-
tire l’assestamento e l’eliminazione dei giochi
176 nei cuscinetti.
- Appoggiare un comparatore al corpo centrale
e verificare il gioco assiale del differenziale che
dovrà risultare uguale a 0 mm
fig. 176a - Avvitare ulteriormente entrambe le ghiere (a) di
una tacca.
- Bloccando la rotazione del pignone rilevare infi-
ne il gioco frai i denti di pignone e corona che
deve essere: 0,18 ÷ 0,23 mm
- Se ciò non dovesse risultare, allentare una ghie-
ra ed avvitare l’altra della stessa quantità, fino
ad ottenere il gioco richiesto.
- Spalmare alcuni denti della corona conica con
ossido di piombo e ruotare la corona nei due
sensi. La rotazione deve avvenire non sotto cari-
co e la zona di contatto dovrà risultare conforme
a quella indicata (fig. 180).
- Se ciò non avvenisse occorrerà aumentare o
diminuire lo spessore di registro per spostare
il pignone conico ed agire poi sulle ghiere per
ripristinare il corretto gioco fra i denti spostando
la corona conica.
- Bisognerà in questo caso verificare nuovamente
il precarico dei cuscinetti pignone, il precarico
a a dei cuscinetti supporto differenziale e gioco fra i
denti pignone/corona.
Nota: se il dente di arresto della spina di fissaggio
ghiere non coincidesse con una tacca della
ghiera, avvitare ulteriormente quest’ultima.
A montaggio e registrazione ultimate verificare
che:
- il precarico dei cuscinetti a rulli conici del pigno-
ne sia: 0,15 ÷ 0,40 Nm;
- il gioco normale fra i fianchi dei denti di pignone
e corona sia: 0,18 ÷ 0,23 mm;
- il precarico dei cuscinetti a rulli conici di suppor-
to del differenziale risulti 0,25 ÷ 0,40 Nm;
- la zona di contatto fra i fianchi dei denti di
177 pignone e corona a vuoto sia come indicato
nel paragrafo controllo dentatura coppia conica
pag. 113.

108
TXL 30/ST

GB 2) Adjustment of bevel gear set


- Mount differential assy, complete with ring gear
and bearings, on central body. Screw in partially
3
ring nuts.
- Mount caps. Smear the 4 fixing screws with
medium grade fastener ( loctite 242 )and tighten
them at the torque of 132 to 146 Nm.
- Tighten up progressively ring nuts (a) and, at the
same time, rotate differential unit to set bearing
eliminating bearing play, until end play is com-
pletely taken up. 176
- Rest a dial gauge on central body and check that
differential end play be equal to 0 mm
- Block rotation of pinion and, then, check that
backlash between ring gear (a) and pinion be of fig. 176a
0.18 to 0.23 mm
- Should this value not be approached, release
ring nut on one side and tighten the other of the
same amount up to reach the specified value.
- Smear some teeth of ring gear with red lead
and rotate ring gear in both directions. Rotation
should be performed with no load and contact
area be as shown (fig. 180).
- Should this result not be approached it is neces-
sary increase or reduce thickness of adjustment
shim to displace bevel pinion and act on ring
nuts to reset backlash displacing ring gear.
- Readjust end play of pinion bearings and of dif-
ferential support bearings. Finally readjust back-
lash of ring gear-and-pinion teeth. Check again
the contact area pattern.
Note: should lug of lock plate not match with slot
of nut, ring nut must be tightened slightly more.
As assembling and adjustment have been
completed, check that: a a
- pinion taper roller bearings preload be of 0,15 to
0,40 Nm;
- pinion-ring gear backlash be of 0.18 to 0.23 mm;
- differential support taper roller bearing preload be
of 0,25 to 0,40 Nm;
- contatct area of unloaded pinion-ring gear teeth
be as shown in the bevel pinion-and-ring gear
set inspection page 113.

177

109
TXL 30/ST

D 2) Einstellung vom Kegelradpaar:


- Differential mit Kegelrad komplett und
Kegelrollenlager in die Halbschalen vom
Differentialgehäuse einbauen. Teilweise
Nutmuttern mit Werkzeug 48A19118 einschrau-
ben.
- Spannhalbschalen montieren und die 4
Befestigungsschrauben (mit “Loctite 242” o.ä.
benetzen) mit einem Drehmoment von 132 bis
146 Nm anziehen.
176 - Die Nutmutter (a) beim gleichzeitigen Drehen
des Differential fortschreiten anziehen, um die
Setzung sicherzustellen und die Lagerspiele zu
beseitigen.
fig. 176a - Eine Meßuhr am Differentialgehäuse auflegen
und das Axialspiel des Differentials messen. Das
Differentialspiel soll 0 mm betragen.
- Beide Nutmutter (a) um einen Einschnitt weiter-
drehen.
- Die Ritzeldrehung blockieren und das Spiel
zwischen den Ritzelzähnen und –kranz messen:
das Spiel soll 0,18 bis 0,23 mm betragen.
- Sollte das Spiel von 0,18 bis 0,23 mm nicht stim-
men müssen, eine Nutmutter losmachen und die
andere um den gleichen Maß anziehen, bis das
Flankenspiel erreicht wird.
- Einige Zähne vom Tellerrad mit Bleiasche ein-
streichen und das Kegelrad in beide Richtungen
durchdrehen. Das Drehen darf nicht unter
Belastung erfolgen und die Kontaktfläche soll
dem B (Abb. 180) entsprechen.
- Andererseits muß die Stärke des Distanzringes
im Kegelritzel je nach Bedarf stärker oder
schwächer ausgeführt werden und dann auf den
a a Nutmuttern das korrekte Spiel zwischen den
Zähnen durch Versetzung des Tellerrads wieder
eingeführt werden.
- Dafür muß die Vorspannung der Kegelrollenlager,
die Vorspannung der Differentiallager und das
Spiel unter den Zähnen Ritzel/Kranz neu geprüft
werden.
Vermerk: Sollte die Nase vom Sicherungsblech
und die Nut der Mutter nicht ganz übe-
rein stimmen wird die Nutmutter nach-
gezogen.
Folgende Maße und Einstellungen müssen
nach der Montage gemessen bzw. geprüft
werden:
- Die Vorspannung der Kegelrollenlager am Ritzel
177 soll 0,15 bis 0,40 Nm betragen;
- Das Nenn-Flankenspiel der Kegelräder 0,18 bis
0,23 mm;
- Die Vorspannung der Kegelrollenlager 0,25 bis
0,40 Nm;
- Die Kontaktfläche zwischen den Flanken der
Ritzelverzahnung und Kranz beim Leerlauf
wie im Abschnitt “Kontrolle der Verzahnung
Kegelräderpaarung” Seite 113 dargestellt.

110
TXL 30/ST

F 2) Réglage couple conique


- Monter, sur le support, le différentiel complet de
sa couronne et de ses roulements. Visser partiel-
3
lement les colliers à l’aide de l’outil 48A19118.
-Monter les deux couvercles et serrer les quatre
vis (induire de “Loctite 242” ou similaires) de
fixation au couple de 132÷146 Nm.
- Visser progressivement les colliers (a) en tour-
nant en même temps le différentiel, et ceci pour
garantir la bonne mise en place et l’élimination
des jeux entre les roulements.
176
- Poser un comparateur sur la caisse du dif-
férentiel et vérifier le jeu axial du différentiel qui
devrait être égal à 0 mm
- Revisser les colliers (a) d’un cran. fig. 176a
- Enfin, en bloquant la rotation du pignon, relever
le jeu entre les dents du pignon et la couronne,
celui-ci doit être de: 0,18 ÷ 0,23 mm
- S’il ne correspond pas, dévisser légèrement un
des colliers et visser l’autre de la même quantité
afin d’obtenir le jeu voulu.
- Enduire quelques dents de la couronne conique
d’oxyde de plomb et faire tourner la couronne
dans les deux sens. La rotation doit être
effectuée sans charge et la zone de contact doit
être conforme à celle indiquée (fig. 180).
- Si cela ne correspond pas, il faut augmenter ou
diminuer l’épaisseur de réglage afin de déplacer
le pignon conique et d’agir sur les colliers, et
ceci pour rétablir le bon jeu entre les dents.
- Il faut alors vérifier la précharge des roulements
pignon, la précharge des roulements support
du différentiel et le jeu entre les dents pipgnon/
couronne.
Remarque: si la dent d’arrêt de la goupille de a a
fixation du collier ne coincide pas à un cran du
collier, visser encore.
Pendant le montage et le réglage, vérifier
encore que:
- la précharge des roulements coniques du pignon
soit de: 0,15 ÷ 0,40 Nm;
- le jeu normal entre les flancs des dents du
pignon et la couronne soit de: 0,18 ÷ 0,23 mm;
- la précharge des roulements coniques du sup-
port du différentiel soit de: 0,25 ÷ 0,40 Nm;
- la zone de contact entre les flancs des dents du
pignon et la couronne à vide soit comme indi-
qué dans le paragraphe contrôle denture couple
conique p. 113. 177

111
TXL 30/ST

I Rimontaggio complessivo differenziale-corona


conica
Montare il differenziale completo sui relativi sup-
porti, posizionare i cappelli secondo i riferimenti
dello smontaggio precedente, applicare il frena-
filetti medio alle viti di fissaggio e bloccare alla
coppia di 132 ÷ 146 Nm.

GB Differential reassembly
Mount differenhal unit on relevant support, position
caps according to reference marked at disassembly.
178 Smear medium screw locking compound and lock
with a torque of 132 to 146 Nm.

D Differential Montage
Differential Montage und richtige Lage überprüfen.
Schrauben mit Sicherungsmittel einseken und mit
132 bis 146 Nm anziehen.

F Remontage global différentiel-couronne coni-


que
Monter le différentiel complet sur les relatifs sup-
ports, positionner les chapeaux selon les référen-
ces du démontage precédent, appliquer le frein à
filets moyen aux vis de fixation et bloquer au cou-
ple de 132 ÷ 146 Nm.

I Verificare il gioco normale tra i fianchi di pignone e


corona conica che dovrà risultare uguale a 0,18 ÷
0,23 mm. Se non rientra nei suddetti valori occor-
re intervenire allentando e serrando di uguale
misura le ghiere di registro (fig. 167a).

GB Check for backlash between pinion and ring gear.


It must be within 0.18 to 0.23 mm Should it be
outside said value, operate on both ring nuts by
slackening one and tightening the otherof the
same angle (notches quantity), (fig.167a).
179 D Das normale Zahnspiel zwischen den Flanken von
Kegelrad und Ritzel überprüfen. Es soll zwischen
0,18 und 0,23 mm liegen. Sollte dieser Wert nicht
erreicht werden, dann müssen die Einstellscheiben
(Bild 167a) gleichmässig gelöst und angezogen
werden.

F Vérifier le jeu normal entre les flancs du pignon et


la couronne conique qui doit être compris entre
0,18 et 0,23 mm. S’il ne rentre pas dans ces
valeurs, il faut intervenir en modifiant opportuné-
ment la cale (figure 167a).

112
TXL 30/ST

Controllo dentatura coppia conica


Bevel pinion-and-ring gear set inspection
Tragbildkontrolle der Kegelräder und Fehlersuche
3
Contrôle denture couple conique

I Spalmare di minio alcuni denti della corona, farli impegnare più volte con il pignone in modo da eviden-
ziare il contatto dei fianchi. Sui denti della nuova corona sono visibili segni di contatto che sono riferiti
al contatto ottimale ottenuto al tester e, pertanto un corretto posizionamento assiale del pignone evi-
denzierà una rimarcatura del contatto esistente.

GB Spread red lead on some tooth of ring gear, mesh gears in both directions many times, so to make
evident tooth contact. Proper and correct tooth contact is visible on ring gear and said marks indicate
the optimum contact approached on a tester, therefore, a proper axial position of pinion will emphasize
remarking of previous contact.

D Mit roter Retuschlertusche einen Zahn des kegelrades beidseitig einschmieren, Kegelrad durchdrehen
und Tragbild auf den Zähnen des Kegelritzels auf beiden Seiten Tragbild überprüfen Das optimale
Tragbild ist im Anhang dargestellt.

F Etaler de minium quelques dents de la couronne, Ies faire agir plus d’une fois avec le pignon afin de
mettre en évidence le contacts de flancs. Sur les dents de la nouvelle couronne on peut remarquer des
traces visibles traces de contact qui sont rapportées au contact optlmal obtenu au tester et donc un
correct positionnement axial du pignon mettra en évidence un remarquable contact existent.

I Zona di contatto della dentatura della coppia


conica 180a
La zona di contatto dovrà risultare come indicato
in figura.
Contatto corretto
La distanza del pignone dal centro corona è esat-
ta.

GB Bevel drive tooth contact


Tooth contact should be as shown in the figure.
Correct contact Fianco concavo (corona)
Concave side (crown wheel)
Distance of pinion from ring gear centerlines is Schubflanke (konkav) (Zahnkranz)
correct. Coté concave (couronne)

D Tragbilder des Kegel- Tellerradantriebes


Das Tragbild muß dem Bild entsprechen.
Ideales Tragbild 180b
(d. h., die Ritzeldistanz stimmt).

F Zone de contact de la denture du couple coni-


que
La zone de contact devra resulter comme indiqué
sur la figure.
Bon contact
La distance du pignon du centre est exacte.
Fianco convesso (corona)
Convex side (crown wheel)
Zugflanke (konkav) (Zahnkranz)
Coté convexe (couronne)

113
TXL 30/ST

I Contatto errato
181a La distanza del pignone dal centro corona deve
essere diminuita.
GB Incorrect tooth contact
Distance of pinion from ring gear centerline must
be reduced.
D Ritzeldistanz
Muß kleiner werden.
F Contact errone
Fianco concavo (corona) La distance du pignon du centre couronne doit
Concave side (crown wheel) être diminuée.
Schubflanke (konkav) (Zahnkranz)
Coté concave (couronne)

181c
181b

(—)
Fianco convesso (corona)
Convex side (crown wheel)
Zugflanke (konkav) (Zahnkranz)
Coté convexe (couronne)

I Contatto errato
182a La distanza del pignone dal centro corona deve
essere aumentata.
GB Incorrect tooth contact
Distance of pinion from ring gear centerline must
be increased.

D Ritzeldistanz
Muß größer werden.

F Contact errone
Fianco concavo (corona) La distance du pignon du centre couronne doit
Concave side (crown wheel) être augmentée.
Schubflanke (konkav) (Zahnkranz)
Coté concave (couronne)

182c
182b

(+)
Fianco convesso (corona)
Convex side (crown wheel)
Zugflanke (konkav) (Zahnkranz)
Coté convexe (couronne)

114
TXL 30/ST

GB
Inserire la spina elastica di fermo ghiera.

Fit the spring pin to lock the nut.


3
D Eine Spannhülse zur Muttersicherung einführen.

F Mettre la goupille élastique d’arrêt du collier.

183

I Applicare sigillante sul bordo scatola e montare il


coperchio scatola ponte.
Applicare frenafiletti sulle viti fissaggio coperchio
e bloccare complete di rosetta, con una coppia di
serraggio di 47,5 ÷ 52,5 Nm.

GB Spread sealing compound on housing edge and


mount cover.
Smear medium locking compound on cover
screws and lock washer complete, with a tighte-
ning torque of 47.5 to 52.5 Nm.
184
D Dichtflächen mit Dichtmittel einschmieren.
Schrauben mit Sicherungsmittel einsetzen und mit
47,5 bis 52,5 Nm anziehen.

F Cacheter le bord du carter et monter le couvercle


du carter pont.
Appliquer le frein-à-filets sur les vis de fixation du
couvercle et bloquer complet de rondelle, à un
couple de serrage de 47,5 ÷ 52,5 Nm.

I Rimontare i gruppi ruota, umettare i piani di con-


tatto con “Loctite 510”; Applicare frenafiletti medio
sulle viti di fissaggio manicotto; avvitare e bloccare
le viti complete di rosetta alla coppia di 266 ÷ 294
Nm.

GB Install the wheel assies , smear the butting, faces


moistening by means “loctite 510”. Coat the
screws with medium grade fastener. Fit the washer
and tighten to torque of 266÷294 Nm.

D Die Radgruppen wiedermontieren, die Kontaktflächen


mit “Loctite 510” benetzen; mittlere Gewindesicherung
185
auf den Befestigungsschrauben der Muffe aufbringen;
die Schrauben komplett mit Federscheibe bei einem
Drehmoment von 266 bis 294 Nm festziehen und
spannen.

F Remonter les groupes roue, induire les surfaces


de contact de “Loctite 510”; Appliquer le frein-filet
moyen sur les vis de fixation du fourreau; visser et
bloquer les vis et leur collier au couple 266 ÷ 294
Nm.

115
TXL 30/ST

I Rimontaggio carter convertitore


Applicare sigillante sul bordo del coperchio sca-
tola presa di forza.
Montare il carter convertitore, spalmare le viti con
frenafiletti medio e bloccarle con una coppia di
serraggio di 62 ÷ 69 Nm.
GB Converter carter reassembly
Spread sealing compound on P.T.O. cover edge.
Mount converter carter, smear medium locking
compound on fixing screws and lock with a tor-
186 que of 62 to 69 Nm.
D Wandlergehäuse montage
Wandlergehäuseflache mit Dichtmasse einsch-
mieren.
Das Konvertergehäuse einbauen, die Schrauben
mit mittlerer Gewindedichtmasse bestreichen und
mit einem Anziehdrehmoment von 62 ÷ 69 Nm
festziehen.
F Remontage du carter convertisseur
Cacheter le bord du couvercle du carter prise de
force.
Monter le carter convertisseur, étaler les vis avec
un frein à filets moyen et les bloquer à un couple
de serrage de 62 ÷ 69 Nm.

I Calettare il convertitore sull’albero d’ingresso.


GB Fit converter unit on input shaft.
D Wandler montieren.
F Emboîter le convertisseur sur l’arbre d’entrée.

187

I Installare e serrare il filtro posto sull’aspirazione


della pompa.

GB Install and tighten the filter placed on the pump


intake.

D Filter einbauen.

F Installer et serrer le filtre placé côté aspiration de


la pompe.

188

116
TXL 30/ST

I Dopo aver interposto la guarnizione in carta mon-


tare il distributore, spalmare il frenafiletti medio
sulle viti fissaggio e bloccarle con una coppia di
3
serraggio di 22 ÷ 24 Nm a partire dal centro verso
l’esterno.

GB After having placed the paper gasket in position, fit


the distributor, smear medium locking compound
on fixing screws, lock with a torque of 22 to 24 Nm
from center to esternal side.

D Flachdichtung mit Fett anbringen,Montage 189


Seuergerät. Befestigungsschrauben mit
Sicherungsmittel einseken und mit 22 bis 24 Nm
Vom Zentrum nach Aussen anziehen.

F Après avoir mis en place le joint en papier, monter


le distributeur, étaler le frein-à-filets moyen sur les
vis de fixation et les bloquer à un couple de serra-
ge de 22 ÷ 24 Nm du centre vers l’extérieur.

I Montaggio comando azionamento inching


(a secondo della versione): a
Nel caso di smontaggio o sostituzione dei perni (a)
per molla e del perno per leva, al montaggio bloc-
care alla coppia di serraggio di 22 ÷ 24 Nm i perni
per molla.
Nell’ eventuale sostituzione del kit perni e della c
leva completa, al montaggio umettare con grasso;
controllare che la rotella (b) e la leva (c) girino libe-
ramente sul proprio perno.
Montare il supporto completo sul distributore,
spalmare il frenafiletti medio sulle tre viti di fissag- a b 190
gio e bloccarle con una coppia di serraggio di 22 ÷
24 Nm, e agganciare la molla (d) sui perni.
Per la registrazione e i giochi vedere disegno pag.
119.
d
GB Inching control assay assemly (accordino to
configuration)
The spring hooking pins (a) must be tightened to
a torque of 22 ÷ 24 daNm. If a new pin/lever kit
is fitted coat all the parts with grease, check both
wheel (b) and lever (c) must be rotate freely on their
own center pivot.
Fit the support assay to the valve control and 191
tighten the screws to the torque of 22 ÷ 24 daNm.
Hook the spring (d) to pins.
Refer to picture for end play adjustement page
119.

117
TXL 30/ST

D Montage des Inching-Antriebs (je nach der


a Version):
Bei Demontage oder Austauschen der Federstifte
oder de Heberstifte, sind die Federstifte bei der
Montage mit einem Anzugsmoment vom 22 ÷ 24
Nm zu spanne.
c Bei dem Austausch des Stiftsatzes und des kom-
pletten Hebels, bei der Montage mit Fett benet-
zen; überprüfen, dass die Rolle und das Hebel um
den eigenen Stift frei drehen können.
Der komplette Halter auf den Verteiler montieren,
190 a b die gewindesicherung auftragen und bei einem
Anzugsmoment von 22 ÷ 24 Nm spannen, der
Feder auf den Stiften anhacken.
Für die Einstellung und zulaessige Spiele s. Bild
seite 199.
d F Montage commande actionnement inching
(selon la version):
En cas de démontage ou de remplacement des
pivots (a) pour le ressort ou des pivots pour le
levier, pendant le montage, serrer les pivots pour
ressort au couple de 22 ÷ 24 Nm.
Pour l’èventuel remplacement du kit entier pivots
et celui du levier, pendant le montage graisser
191 légèrement; contrôler que la roue (b) et le levier (c)
tournent librement sur leur pivot.
Monter le support complet sur le distributeur,
ètaler le frein-filets moyen sur les trois vis de fixa-
tion et les serrer au couple de 22 ÷ 24 Nm, enfin,
accrocher le ressort (d) sur les pivots.
Pour l’enregistrement et le jeu, voir dessin page
119.

118
TXL 30/ST

Comando azionamento inching schema di registrazione


Control inching - assy
Inching- Antrieb Einstellplan
Commande actionnement inching schéma d’enregistrement
3

30 13°
6 1

100 38 INGOMBRO MAX.

Sezione "A-A" 23.4 OVERALL DIMENSION


X.
Section MA RSA
RSA ROKE CO E
3 CO T OK
A X. S STR
M A
2 02

0.2-0.6 42° 25°


GIOCO BAUDEN
CLEARANCE FINE CORSA

137
STROKE RETAINER
5

11 4

52.5
7

9
0.1-0.3
GIOCO 8
CLEARANCE
12 1
A
6 10 20 Corsa
1
03 Stroke
03

45.5`0.2 Rif. alla vite


Ref. to the screw
DADO ESAGONALE BASSO M8
12 NUT
SPINA EL. SPACCATA ∅3.5X20
11
LOCK PIN
VITE T.E. M8x20
10
SCREW
SPINA EL. SPACCATA n3X16
9 Motore spento = max. 90 N - Motore acceso = max. 90 N
LOCK PIN
ROTELLA Corsa = 22 mm
2 8 02
WHEEL
PERNO PER ROTELLA
2 7 PIVOT
PERNO MOLLA N
1 6 C.S. 24.15
Nm . 75
PIN FOR SPRING 21.85 = max
25° eso
PERNO LEVA acc
2 5 otore
KNUCKLE PIN
N -M
. 90
max
MOLLA AZIONAMENTO INCHING
4 INCHING REACTION SPRING to =
en
sp mm
ore
Mot
LEVA COMPLETA
2 3 23.4
LEVER ASSY orsa =
C
SUPPORTO PER LEVA
2 SUPPORT FOR LEVER
STAFFA DI REAZIONE
1 REACTION BRACKET
I carichi citati possono accettare il richiamo
di un BAUDEN avendo un attrito di max. 25 N.
POS
DENOMINAZIONE
DENOMINATION NOTE

- LA ROTELLA E LA LEVA DEVONO GIRARE LIBERAMENTE SUL PROPRIO PERNO


BOTH WEEL AND LEVER MUST BE ROTATE FREELY ON THEIR OWN CENTER PIVOT
2 - UMETTARE DI GRASSO AL MONTAGGIO
DURING THE ASSEMBLY MOISTEN BY GREASE
1 - UMETTARE LA FILETTATURA CON LOCTITE 242 O SIMILARI
THREADS MOISTENING BY MEANS OF LOCTITE 242 OR SIMILAR

fig. 192

119
TXL 30/ST

TIPO OLIO
4 OIL SPECIFICATIONS
ÖLSPEZIFIKATION
TYPE HUILE

I Tipo olio trasmissione:


Appartenente alla classe ATF e rispondente alle specifiche DEXRON II D oppure TYPE “A” SUFFIX
A della General Motors oppure C3 della Detroit Diesel Allison (per esempio MOBIL ATF 220 e FIAT
TUTELA GI/A e GI/M) oppure corrispondente alle specifiche MIL-L2104B e API CC (per esempio
MOBIL DELVAC 1110) o specifiche MIL-L2104C e API CD (per esempio MOBIL DELVAC 1310) nella
gradazione 10W20.
Quantità: 1° riempimento ~ 10 lt; cambio olio ~ 9 lt.
Tipo olio ponte: Secondo specifiche MIL-L2105B oppure API GL5 nella gradazione SAE90 o 80W90.
Quantità: cambio olio ~ 6 lt.
Circuito frenante più Inching idraulico: Secondo specifiche: SAE J1703, FMVSS 116 DOT 3, LUNA
DOT 3 AB, FORD SAM 6C 9101A, ISO 4925.

GB Transmission oil specification:


ATF oils corresponding to specifications DEXRON II D or TYPE “A” SUFFIX A of General Motors or
C3 of Detroit Diesel Allison (e.g. MOBIL ATF 220 and FIAT TUTELA GI/A and GI/M) or corresponding
to specifications MIL-L2104B and API CC (e.g. MOBIL DELVAC 1110) or to the specifications MIL-
L2104C and API CD (e.g. MOBIL DELVAC 1310) viscosity 10W20.
Quantity: 1st filling of ~ 10 liters; oil change of ~ 9 liters.
Axle oil specifications: By specifications: MIL-L2105B or API GL5 in the gradation SAE90 or 80W90.
Quantity: oil change of ~ 6 liters.
Brake circuit plus hydraulic Inching: By specifications: SAE J1703, FMVSS 116 DOT 3, LUNA DOT 3
AB, FORD SAM 6C 9101A, ISO 4925.

D Getriebe Ölspezifikation
ATF-Öle entsprechend den Spezifikationen DEXRON II D oder TYP “A” SUFFIX A von General Motors
oder C3 von Detroit Diesel Allison (z.B. MOBIL ATF 220 und FIAT TUTELA GI/A und GI/M) oder
entsprechend den Spezifikationen MIL-L2104B und API CC (z.B. MOBIL DELVAC 1110) oder den
Spezifikationen AIL-L2104C und API CD (z.B. MOBIL DELVAC 1310) Viskosität 10W20.
Bedarf: 1° Öl-Füllung ~ 10 Lt; Ölwechsel ~ 9 Lt.
Oelachse Typ: Bei Spezifikationen: MIL-L2105B oder API GL5 in der Gradation SAE90 oder 80W90.
Bedarf: Ölwechsel ~ 6 Lt.
Bremskreis plus Hydraulisches Inching: Bei Spezifikationen: SAE J1703, FMVSS 116 DOT 3, LUNA DOT
3 AB, FORD SAM 6C 9101A, ISO 4925.

F Transmission type huile


Appartenante à la classe ATF et correspondante aux spécifiques DEXTRON II D ou TYPE “A” SUFFIX
A de la General Motors ou C3 de la Detroit Diesel Allison (par example MOBIL ATF 220 et FIAT
TUTELA GI/A et GI/M) ou correspondante aux spécifiques MIL-L2104B et API CC (par examble
MOBIL DELVAC 1110) ou spécifiques MIL-L2104C et API CD (par example MOBIL DELVAC 1310)
dans la gradation 10W20.
Quantité: 1ére remplissage ~ 10 litres; changement d’huile ~ 9 litres.
Type huile pont: Selon spécifiques: MIL-L2105B ou API GL5 dans la gradation SAE90 ou 80W90.
Quantité: changement d’huile ~ 6 litres.
Circuit freinant plus Inching hydraulique: Selon spécifiques: SAE J1703, FMVSS 116 DOT 3, LUNA
DOT 3 AB, FORD SAM 6C 9101A, ISO 4925.

120
TXL 30/ST

DATI ACCOPPIAMENTO MOTORE


DATA FOR COUPLING TO ENGINE
EINBAUANWEISUNG
DONNEES D’ACCOUPLEMENT MOTEUR
4
I Istruzioni di montaggio
a. Montare il piatto flessibile sul convertitore con l’anello di rinforzo dal lato volano. Verificare la
concentricità dei fori esterni delle viti con il codolino del convertitore entro 0,38 mm (lettura
totale comparatore). Coppia di serraggio delle viti M10 × 18 : 47,5/52,5 Nm.
b. Montare convertitore sul volano. Verificare la concentricità del mozzo anteriore del convertitore
(diam. 55 mm) rispetto al carter coprivolano. La coppia di serraggio delle viti dipende dalla qua-
lità delle stesse.
c. Applicazione: la concentricità deve essere mantenuta entro 0,30 mm (lettura totale comparatore).
Dimensione consigliata del centraggio su carter coprivolano SAE 3 Ø 409,58 F8.

GB Assembling instructions
a. Assemble drive plate to converter with reinforcemente plate on flywheel side. Ensure that con-
centricity of outer bolt circle with converter pilot be within 0.38 mm (0.15 in) T.I.R. (Total Indicator
Reading). Torque M10 × 18 bolts to 47.5/52.5 Nm (0.34 - 0.38 Ibs. ft).
b. Assemble converter to flywheel. Maintain concentricity of hub (diameter 55 mm) to flywheel
housing. Tighten bolts to torque depending on quality of the bolts.
c. Field service: concentricity must be maintained within 0.30 mm (0.012 in) T.I.R. Recommended
gauge size of flywheel housing SAE 3 Ø 409.58 F8 U.D. (16.125 in).

D Einbauanweisung
a. Die Antriebsmembrane an den Wandler -mit dem Verstärkungsblech auf der Schwungradseite -
anbauen. Die Rundlauftoleranz des äußeren Lochkreises zur Wandlerzentrierung 19.037/19.012
min. beträgt 0,38 mm (0,15”) T.I.R. Schrauben M10 × 18 mit 47,5/52,5 Nm (0,34 - 0,38 Ibs. ft)
anziehen.
b. Anbau Wandler and Schwungrad. Konzentrische Ausrichtung 55 mm Durchmesser Nabe und
Schwungradgehäuse herstellen. Vorzugsweise durch Verwendung einer geeigneten Vorrichtung
Schrauben auf ein diesen Schrauben entsprechendes Drehmoment anziehen.
c. Toleranzvorschrift: Die Rundlaufungenauigkeit von der Wandlernabe zu der Zentrierung am
Schwungradgehäuse darf max. 0,30 mm betragen. Normal wird ein SAE
3 Schwungradgehäuse verwendet mit einem Zentrierdurchmesser von
409,58 mm F8.

F Mode de montage
a. Monter le plateau flexible sur le convertisseur avec l’anneau de renforcement , du côté du volant.
Vérifier la bonne concentricité des trous extérieurs des vis avec l’ergot du convertisseur, maxi.
0.38 mm (lecture totale du comparateur). Couple de serrage des vis M10 x 18 : 47,5/52,5 Nm
b. Monter le convertisseur sur le volant, fixer le convertisseur au plateau d’entraînement. Vérifier la
concentricité du moyeu antérieur du convertisseur (diam. 55 mm) par rapport au carter couvre-
volant. Le couple de serrage des vis dépend de la qualité desmêmes.
c. Application: la concentricité doit être maintenue dans 0,30 mm (lecture total comparateur).
Dimension conseillée du centrage sur carter couvre-volant SAE 3 Ø 409,58 F8.

121
TXL 30/ST

Accoppiamento motore con P. d. F.


Engine with P. T. O. coupling
Einbau-Motor mit Nebenabtrieb
Accouplement moteur avec P. d. F.

1 - Piatto di trascinamento convertitore


Converter drive plate
Wandlerantriebsmembrane
Plateau d’entraînement du convertisseur
2 - Anello di rinforzo
Converter reinforcing plate
Wandlerverstärkungsblech
Bague de renfort
3 - Viti di unione del piatto di trascinamento al convertitore
Bolts - drive plate to converter
Schrauben - Verbindung Antriebsmembrane mit Wandler
Vis d’union du plateau d’entraînement au convertisseur
4 - Rondella elastica
Spring washer
Federring
Rondelle elastique
5 - Viti di unione del piatto di trascinamento al volano - fornite dal cliente
Bolts - drive plate to flywheel - supplied by customer
Schrauben - Verbindung Antriebsmembrane mit Schwungrad - Kundenbeistellung
Vis d’union du plateau d’entraînement au volant - fournies du client
6 - Rondella speciale (vedi pag. 124)
Special washer (see page 124)
Spewialscheibe (Siehe Seite 124)
Rondelle spéciale (voir page 124)

0
A Dimensione foro su volano (consigliata): ∅ 19,063 + 0,025
0
Suggested dimension for flywheel hole: ∅ 19.063 + 0.025
0
Maß für Zentrierung im Schwungrad: ∅ 19,063 + 0,025
0
Dimension du trou sur le volant (conseillée): ∅ 19,063 + 0,025

Codolo / Pilot / Führungszapfen / Queue : ∅ 19,037 - 0,025

+ 0,020
A Dimensione foro su volano (consigliata): ∅ 20 + 0,041
+ 0.020
Suggested dimension for flywheel hole: ∅ 20 + 0.041
+ 0,020
Maß für Zentrierung im Schwungrad: ∅ 20 + 0,041
+ 0,020
Dimension du trou sur le volant (conseillée): ∅ 20 + 0,041
- 0,007
Codolo / Pilot / Führungszapfen / Queue: ∅ 20 - 0,040

122
TXL 30/ST

Schema accoppiamento motore con P. d. F.


Engine with P. T. O. coupling diagram
Einbau-Schema Motor mit Nebenabtrieb
4
Schéma d’accouplement moteur avec P. d. F.

159 +0,3
- 0,93

66,5±0,5 92,5

VOLANO 6 5
FLYWHEEL 2
SCHWUNGRAD
VOLANT

r3 MIMIMO
MINIMUM 1
MINIMUM

4
3

2
∅ 232

123
TXL 30/ST

Rondella speciale per fissaggio piatto-volano


Special washer to fix drive plate to flywheel
Spezialscheibe zur Befestigung von der Membrane an das Schwungrad
Rondelle spéciale pour fixer le plateau au volant
17 +0.50

15° 15°
0

+0.30
9 - 0.20

R5 R5

1.5
Disegno N°
Drawing Nr. 3.16475.3
1.5
Zeichnung Nr.
Plan N.
∅ 24±0.65

∅ 13±0.27

15°
15°

R5

1.5
R5

Disegno N°
Drawing Nr. 3.17113.3 2.5±0.22
Zeichnung Nr.
Plan N.
∅10.2 +0.20
0

15°
15°
∅22

R5
1.5

R5
Disegno N° 2
Drawing Nr. 3.20489.3
Zeichnung Nr.
Plan N.
124
TXL 30/ST

Controllo accoppiamento motore-cambio


Engine gearbox coupling check-up
Rundlaufkontrolle
Contrôle accouplement moteur-boîte
4
D

01

2 QUOTA MINIMA
MIN DIMENSION
MINDESTABSTAND
PART MIMINIMUM

PIANO DI APPOGGIO PIATTO DI TRASCINAMENTO


LEVEL TO PLACE DRIVE PLATE
EBENE ZUR BEFESTIGUNG DER MITNEHMERSCHEIBE
PLAN D' APPUI DU PLATEU D' ENTRAINEMENT

B
01 APPLICAZIONE FLANGIA SAE 3 E 4
66.5±0.5 SAE 3 AND 4 FLANGE APPLICATION
VERWENDUNG VON FLANSCH SAE 3 UND 4
APPLICATION BRIDE SAE 3 ET 4

Comparatore montato sul coprivolano Comparatore montato sul volano


Dial gauge mounted on flywheel cover Dial gauge mounted on flywheel
Rundlauftoleranzen Radrundlauftoleranzen
Comparateur monté sur le couvre-volant Comparateur monté sur le volant
Lettura totale Lettura totale
Total reading Total reading
A Ablesung Total ≤ 0,1 mm C Ablesung Total ≤ 0,23 ÷ 0,25
Lecture totale Lecture totale
Lettura totale Lettura totale
Total reading Total reading
B Ablesung Total ≤ 0,2 mm D Ablesung Total ≤ 0,23 ÷ 0,25
Lecture totale Lecture totale

125
TXL 30/ST

DATI TECNICI - Prelievo pressione Distributore Supermodulato


TECHNICAL DATA - Supermodulating Distributor pressure measurement
TECHNISCHE DATEN - Druckmessung Steuerblock Supermoduliert
DONNEES TECHNIQUES - Prelevement de pression Distributeur Supermodulé

D
C
6
20
5 max. pressione pressione zero
2 max. pressure corsa zero pressure
max. Druck stroke Drucklos
max. pression Hub pression zéro
course

Diagramma intervento pressione - Corsa Inching meccanico


Pressure operating time diagram - Mechanical Inching travel
Diagramm Inchdruck - Hub mechanisches inchen
Diagramme d’intervention pression - Course Inching mécanique

Pressione / Pressure / Druk / Pression


Pressione 0.5 ÷ 0.7 max
P./ P. / D. / P. max
Pressure / Druk / Pression
bar
Coppia frenante (intervento freno)
Apply brakes (brake operating time)
Bremsdrehmoment (Bremseinsatz)
Couple de frein (intervention frein)

Corsa / Stroke / Hub / Course


0 2 5 10 15 18 20 mm

F
F / F / K /F = 13 +20 Kg

126
TXL 30/ST

I Prelievo pressione distributore supermodulato


1
2
-
-
Presa pressione principale M10x1
Presa pressione convertitore M10x1
4
3 - Presa pressione Retromarcia TXL 30/ST M10x1
4 - Presa pressione Marcia Avanti TXL 30/ST M10x1
5 - Pressione lubrificazione
6 - Spurgo olio freni nching
A - elettrovalvola MARCIA AVANTI
B - elettrovalvola RETROMARCIA.
C - Inching idraulico.
D - Inching meccanico.
Nel caso le viti di fissaggio del distributore al cambio dovessero essere utilizzate per ancorarvi altri
elementi occorrerà darne comunicazione a GRAZIANO Trasmissioni S.p.A. (Ufficio Tecnico Progetti)
per benestare. In ogni caso le viti dovranno essere chiuse alla coppia di serraggio di 1,9 ÷ 2,1 daNm.

GB Supermodulating distributor pressure measurement


1 - Main pressure intake M10x1
2 - Converter pressure intake M10x1
3 - TXL 30/ST Reverse pressure intake M10x1
4 - TXL 30/ST Forward pressure intake M10x1
5 - Lubrication pressure
6 - Inching brake oil bleeder vent
A - REVERSE electrovalve
B - FORWARD electrovalve.
C - Hydraulic Inching.
D - Mechanical Inching.
If the fixing bolts of the control valve on the transmission are used to locate other elements, please
contact GRAZIANO Trasmissioni S.p.A. (Projects Technical Office) for approval. Bolts have to be
tightened with torque of 1.9 ÷ 2.1 Nm.

D Druckmessung Steuerblock Supermoduliert


1 - Hauptdruckmeßstelle M10x1
2 - Wandlerdruckmeßstelle M10x1
3 - Kupplungsdruck Rückwärtsgang M10x1 - TXL 30/ST
4 - Kupplungsdruck Vorwärtsgang M10x1 -TXL 30/ST
5 - Schmierdruck
6 - Bremsölentlüftungsventil
A - Elektroventil Vorwärtsgang
B - Elektroventil Rückwärtsgang.
C - Hydraulisches Inching.
D - Mechanisches Inching.
Werden die Befestigungsschrauben des Steuerblocks am Getriebe zur Befestigung anderer Teile
verwendet, erfordert dies die Freigabe durch GRAZIANO Trasmissioni S.p.A. Anzugsmoment der
Schrauben: 1,9 ÷ 2,1 daNm.

F Prélèvement de pression distributeur supermodulé


1 - Prise de pression principale M10x1
2 - Prise de pression convertisseur M10x1
3 - Prise de pression Marche Arrière TXL 30/ST M10x1
4 - Prise de pression Marche Avant TXL 30/ST M10x1
5 - Pression lubrification
6 - Vidange huile freins
A - Electrovanne ARRIERE
B - Electrovanne AVANT.
C - Inching hydraulique.
D - Inching mecanique.
Si les vis de serrage du distributeur sur la transmission sont utilisées pour y fixer des autres éléments,
il faut le communiquer à GRAZIANO Trasmissioni S.p.A. (Bureau Technique Projets) pour l’approba-
tion. En tout cas les vis doivent être serrées à la couple de serrage de 1,9 ÷ 2,1 daNm.

127
TXL 30/ST

RODAGGIO

5 RUNNING-IN
INBETRIEBNAHME
RODAGE

I Trasmissione idraulica
Il periodo di rodaggio è di 60-80 ore, durante le quali è necessario seguire le seguenti prescrizioni:
ispezionare frequentemente la trasmissione assicurandosi che non esistano perdite di olio.
Ogni 10 ore
Controllare il livello olio nella trasmissione ed eventualmente rabboccare. Il controllo del livello olio deve
essere effettuato con motore al minimo, olio caldo e cambio in Folle (40°C minimo).
Al termine del periodo di rodaggio
a. sostituire l’olio
b. sostituire il filtro dell’olio
Le suddette norme devono essere osservate anche dopo una revisione della trasmissione idraulica.

GB Hydraulic transmission
The running-in time is 60-80 hrs., during which it is necessary to perform the following operations:
check the transmission frequently to make sure that there are no oil leaks.
Every 10 hrs.
Check the oil level in the transmission and, if required, top up (for oil brand pls. refer to the supply
list). Oil level check must be performed at engine idle speed, transmission in neutral and with oil at
rated temperature (minimum 40°C).
At the end of the running-in period
a. change the oil
b. replace the oil filter
Above rules must be observed even after an overhaul of the hydraulic transmission.

D Hydraulikgetriebe
Die Einlaufzeit beträgt 60-80 Stunden, während der die folgenden Maßnahmen durchzuführen sind:
Getriebe mehrfach prüfen und sicherstellen, daß keine Leckagen auftreten.
Alle 10 Stunden
Getriebeölstand prüfen und gegebenenfalls nachfüllen. Die Ölstandskontrolle muß bei Motorleerlauf,
Getriebe in Neutral und betriebswarmem Öl erfolgen (Mindesten 40°C).
Am Ende der Einlaufphase
a. Ölwechsel
b. Filter wechseln
Die obigen Regeln müssen auch nach einer Überholung des hydraulischen Getriebes befolgt werden.

F Transmission hydraulique
La période de rodage est de 60-80 heures, pendant lesquelles il faut suivre les prescriptions suivan-
tes: inspecter souvent la transmission pour s’assurer qu’il n’y a pas de pertes d’huile.
Toutes les 10 heures
Contrôler le niveau d’huile dans la transmission et éventuellement en ajouter. Le contrôle du niveau
d’huile doit être effectué avec le moteur au ralenti, l’huile chaude et la bôite au Point Mort (minimum
40°C).
A la fin de la période de rodage
a. remplacer l’huile
b. remplacer le filtre à l’huile
Les susmentionées normes doivent être oservées aussi bien après une révision de la transmission
hydraulique.

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MANUTENZIONE PERIODICA
PERIODIC SERVICING
5
I Ogni 200 ore:
Trasmissione idraulica: verificare il livello olio con l’astina e se necessario aggiungerne.
Il controllo deve essere effettuato con il motore al minimo, olio caldo e
cambio in Folle (40°C minimo).
Ogni 500 ore:
Filtro olio cambio: sostituire la cartuccia filtrante e guarnizione OR sul tappo.
Nota: ogni due sostituzioni della cartuccia occorre sostituire l’olio della tra-
smissione. La sostituzione dell’olio deve essere fatta non oltre 1 anno oppure
1000 ore.
Freni : Almeno ogni 500 ore sia i registri laterali che le boccole di scorrimento
dell’autoregistro devono essere ingrassate con grasso resistente alle alte tem-
perature. Si raccomanda di controllare anche le condizioni delle ganasce e la
tenuta dei cilindri e che i tappi di tenuta siano efficienti.
Si raccomanda inoltre di assicurasi che il vano freno sia ben stagno, se si deve
lavare con idropulitrice
Incernieramenti: Ingrassare gli incernieramenti supporti di attacco telaio.

Ogni 1500 ore:


Ponte: sostituire olio.

GB Every 200 hrs.:


Transmission: check oil level with oil dipsticks. If necessary, top up through the inlet plug. The oil
level check must be performed with engine at idle speed, transmission in neutral
and oil at operating temperature (minimum 40°C).
Every 500 hrs.:
Transmission oil filter: change the filtering cartridge and o-ring on plug.
Note: As two cartridges have been replaced it is necessary to replace
transmission oil, drain thru plug. When oil is renewed clean also oil suction
filter. Oil replacement should be performed not over a year or 1000 hours.

Brake At least every 500 hours the automatic adjuster bolt threads and sliding
bushes are to be greased with heat resistance grease. Also the cylinders
and shoe lining must be inspected, check also for plugs installation, if
missing or loose must be replaced.
Care must be taken for water tightness of the brake compartment if steam
cleaner has to be used.
Henges: Grease the frame mount support.

Every 500 hrs.:


Axle: oil change.

129
TXL 30/ST

REGELMÄßIGE WARTUNG
ENTRETIEN PERIODIQUE

D Alle 200 Stunden:


Getriebe: Prüfen Sie den Ölstand mit den Peilstäben.
Die Ölstandsprüfung muß bei Motorleerlauf, in Getriebeneutralstellung und bei
betriebswarmem Öl durchgeführt werden.
Hinweis: Bei Motorstillstand kann der Ölstand im Getriebe steigen (Rücklauf aus
Rohrleitungen und Wandler). (Mindestens 40°C).
Alle 500 Stunden:
Öl ablassen: Filter wechseln. Neues Öl einfüllen. Ölstand wie oben beschrieben kontrollieren.
Anmerkung: Der Ölwechsel muß mindestens 1 mal jährlich oder alle 500 Stunden
maximal durchgeführt werden. Beschädigte Filter dürfen nicht wieder verwendet
werden. Getriebeölmenge: 10 Liter.
Bremsen: Sowohl die seitlichen Register als auch die Schiebebuchsen des Registers sind
wenigstens alle 500 Betriebsstunden mit Hochtemperaturfett aufgetragen werden.
Es wird empfohlen, auch die Backen und die Zylinderdichtung zu prüfen, und dass
die Dichtungsstopfen ausreichend sind. Bitte prüfen, dass der Bremsraum dicht ist,
wenn mit Hydroreiniger zu waschen ist.
Träger: Schierung der Trägerbefestigung.

F Tous les 200 heures:


Transmission hydraulique: vérifier le niveau de l’huile par la fauge et, si nécessaire, en ajouter. Le
contrôle doit être effectué avec le moteur au ralenti, l’huile chaude et la
bôite au Point Mort (minimum 40°C).
Toutes les 500 heures:
Remplacement du filtre à huile: substituer la cartouche de filtrage et son joint torique.
Remarque: toutes les deux substitutions de la cartouche, il faut
remplacer l’huile de la transmission; pour déverser l’huile, enlever le
bouchon au moment du vidange, nettoyer le filtre d’aspiration de la
pompe. Effectuer le vidange chaque année au moins ou 1000 heures.
Freins : Toutes les 500 heures, au moins, les registres latéraux et les guides
de coulissement de l’auto-registre doivent être graissés avec de la
graisse résistante aux hautes températures. Il est recommandé de
contrôler aussi l’ètat des mâchoires et la résistance des vérins, et
enfin que les bouchons d’ètanchéité soient encore efficaces.
En outre, ilest recommandé de vérifier que l’espace du frein soit
bien ètanche si le lavage avec un hydro-nettoyeur s’avère nécessai-
re.
Supports: Graissage charnières support de raccordement du cadre.

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TXL 30/ST

RICERCA DIFETTI DI FUNZIONAMENTO


TROUBLESHOOTING PROCEDURE
FEHLERSUCHE
RECHERCHE DE PANNES DE FONCTIONNEMENT
6
I A. Indicazioni generali
Prima della localizzazione dei guasti della trasmissione occorre fare quanto segue:
• Controllare il livello dell’olio e le condizioni dell’olio. Vedere sezione manutenzione per dettagli.
• Controllare la trasmissione, radiatore dell’olio e linee degli scambiatori di calore dell’olio per dan-
neggiamenti o perdite. Rimediare ad ogni problema.
• Controllare che la causa del problema non sia il motore e/o il gruppo ponte.
Fare tutti i controlli di pressione alla temperatura di funzionamento normale. I misuratori di pressio-
ne usati devono aver un campo di misura di 0 - 15 bar e devono essere precisi.
Attenzione: mai mantenere in stallo la trasmissione per più di 10 secondi con regime motore
! elevato. Mettere in Folle e lasciar raffreddare la trasmissione. La mancanza di questa precauzio-
ne può causare seri danni alla trasmissione.

B. Indicazioni di intervento
Durante la ricerca dei guasti inserire ogni posizione del selettore per stabilire quando si verifica-
no i problemi o i rumori. Determinare quali parti sono in movimento. Questo servirà come punto
di riferimento per individuare la causa. Utilizzare le seguenti informazioni come guida in caso di
problemi.
Convertitore
Alcuni problemi di trasmissione sono legati al convertitore. Controllare e/o sostituire il converti-
tore nei casi seguenti:
• accelerazione debole con velocità massima ridotta e surriscaldamento (velocità di stallo
normale): indica che la ruota libera dello statore si è bloccata.
• Un suono metallico proveniente dal convetitore indica un danneggiamento delle palette del
convertitore.
• Una notevole caduta della velocità di stallo indica che la ruota libera del convertitore non è in
presa.
Frizioni
Controllare e/o sostituire le frizioni qualora si verifichino i seguenti inconvenienti.
• Alta velocità di stallo. Ciò può indicare che la frizione slitta. La frizione che slitta generalmente
stride.
Nota: la frizione che slitta normalmente si surriscalda. Questo può produrre lo svergolamento dei
dischi. In caso di forte surriscaldamento i dischi possono saldarsi insieme. Questo può cau-
sare un arresto nella trasmissione se un’altra frizione viene innestata.
• Il movimento del carrello con Marcia in Folle può indicare danneggiamento della frizione
(Svergolamento dei dischi).

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TXL 30/ST

TROUBLESHOOTING PROCEDURE

GB A. General information
Before locating any fault, it is necessary to act as follows:
• check oil level and oil condition. For details, pls. see servicing section.
• Check transmission, oil cooler and oil cooler pipes to find any damage or leak. Repair if necessary.
• Make sure that the problem is not due to the engine and/or to the axle assy.
Proceed on all pressure checks at normal working temperature. The pressure gauges must have a
range of 0-15 bar and must be accurate.
Warning: never stall converter for more than 10 seconds with high engine r.p.m.. Select neutral
! and let transmission cool. Failure of this precaution can cause serious damage to the transmission.

B. Problems hints
During the diagnosis, switch the selector into all positions and try to find out in which position
the problems or noises appear. Determine which parts are in motion. This will be a useful point
to determinate the cause. Use the following as a guide in case of problems.
Converter
Some transmission problems are related to the converter. Check and/or replace the converter in
the following cases:
• weak acceleration with reduced max. speed and overheating (normal stall speed): it can indicate
that the one way clutch wheel is sticking.
• A metallic noise from the converter can indicate converter vane damage.
• Increased stall speed may indicate that the one way clutch is broken.
Clutches
Check and/or replace the clutches if the following abnormalties appear.
• High stall speed. This can indicate that the clutch is slipping. A slipping clutch generally squeals.
Note: generally a slipping clutch overheats. This can cause the disks to warp. In case of
overheating, the disks can stick together. This can stall the transmission if another clutch is
engaged.
• If the truck moves in neutral this can indicate clutch damage. Clutch plates warped.

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TXL 30/ST

FEHLERSUCHE

6
D A. Allgemeines
Vor der Lokalisierung eines Fehler ist folgendes erforderlich:
• Ölstand und Ölzustand prüfen. Einselheiten gemäß Abschnitt “Wartung”.
• Getriebe, Ölkühler und Verrohrung auf Beschädigung oder Leckage prüfen. Falls notwendig,
reparieren.
• Prüfen, ob Fehler durch Motor und/oder Achsbaugruppe verursacht ist.
Alle Druckprüfungen sind bei normaler Betriebstemperatur vorzunehmen. Die Manometer müs-
sen einen Meßbereich von 0 - 15 bar haben.

Achtung: Getriebe niemals mehr als 10 sec. festbremsen mit hoher Drehzahl. Mißachtung die-
! ser Anweisung kann schwere Schäden im Getriebe hervorrufen.

B. Schadenssuche bzw. -Behebung


Bei der Fehlersuche Wahlschalter in alle Stellungen schalten und versuchen herauszufinden, in
welcher Stellung die Probleme oder Geräusche auftreten.
Wandler
Einige Getriebeprobleme können vom Wandler verursacht werden.
• Schlechte Beschleunigung bei verringerter Höchstgeschwindigkeit und Überhitzung (normale
Festbremsdrehzahl). Dies zeigt an, daß sich bei höherer Fahrgeschwindigkeit das Leitrad nicht
löst. Der Freilauf blockiert.
• Ein metallisches Geräusch im Wandler zeigt eine Wandler-Schaufelbeschädigung an.
• Eine zu hohe Festbremsdrehzahl kann bedeuten, daß sich das in diesem Betriebsbereich
normalerweise feststehende Leitrad dreht. Der Leitradfreilauf hat keine Klemmwirkung mehr.
Schaltkupplungen.
Überprüfen und wenn erforderlich, austauschen. Folgendes Symptom kann einen Austausch
erforderlich machen:
• Zu hohe Festbremsdrehzahl. Dies kann anzeigen, daß die Kupplung rutscht. Schleifgeräusch.
Anmerkung: Im allgemeinen wird eine rutschende Kupplung zu heiß. Dies kann zur Vermormung
der Lamellen führen. Bei sehr starker Überhitzung können die Lamellen zusammen-
schweißen. Dies kann zu einer Blockierung des Getriebes führen, falls eine andere
Kupplung schaltet.
• Bewegt sich das Fahrzeug in Neutralstellung, so kann dies auf verschweißte Lamellen
hindeuten.

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TXL 30/ST

RECHERCHE DE PANNES DE FONCTIONNEMENT

F A. Généralites
Avant de localiser les pannes de la transmission il faut effectuer les opérations suivantes:
• Contrôler le niveau et l’état de l’huile. Reportez vous au chapitre entretien pour avoir plus de détails.
• Contrôler la transmission, le radiateur d’huile et lignes des échangeurs de chaleur de l’huile pour les
pannes ou les pertes. Résoudre chaque problème.
• Contrôler que la cause de la panne ne soit pas imputable au moteur et/ou au groupe pont.
Faire tous les contrôles de pression à la température de fonctionnement normale. Les dispositifs de
mesure pour la pression doivent posséder une plage de mesure de 0 à 15 bar et doivent être précis.
Attention: il ne faut pas mantenir le régime max. de la transmission pendant plus de 10 seconds
! avec régime-moteur élevée. Mettre au Point Mort et laisser refroidir la transmission, dans le cas
contraire on peut causer d’importants à la transmission.

B. Indications d’intervention
Pendant la recherche de la panne, enclencher toutes les positions du sélecteur afin de localiser les
problèmes ou des bruits anormaux. Déterminer quels sont les éléments qui sont en mouvement, ce
qui servira comme point de repère pour identifier la cause. Employez à titre indicatif les renseignements
suivants en cas de problème.
Convertisseur
Quelques problèmes de transmission sont liés au convertisseur. Contrôler et/ou remplacer le
convertisseur dans les cas suivantes:
• faible accéleration, la vitesse maximum est réduite, et surchauffe du moteur (vitesse normale).
Cet état indique que la roue libre du stator est bloquée.
• Un bruit métallique qui provient du convertisseur indique une déterioration des pales du convertisseur.
• Une baisse de vitesse important du régime max. indique que la roue libre du convertisseur n’èst
pas en prise.
Embrayages:
Contrôler et/ou remplacer les embrayages quand on a les inconvenients suivants:
• vitesse élévée du régime. Ceci peut indiquer que l’embrayage patine. Un embrayage qui patine
pent produire un sifflement.
Remarque: L’embrayage qui patine en général surchauffe. Ceci peut provoquer une déformation
des disques. Dans le cas de surchauffe importante, les disques peuvent se souder
entre eux. Ceci peut provoquer un blocage dans la transmission si un autre embrayage
est embrayé.
• Le mouvement du chariot au Point Mort est conséquent à une détérioration des embrayages
(déformatiotion des disques).

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TXL 30/ST

C. Diagnostica
C. Diagnosis
C. Untersuchung
C. Diagnostic
6
I Problemi Cause Rimedi
PERDITE

1. Perdite della pompa dalla guar- - Guarnizione difettosa Sostituire


nizione dell’albero d’uscita o - Cattivo allineamento Correggere
dall’albero della P.d.F. - Albero danneggiato Sostituire.

2. Perdite tra l’esterno della guar- - Sede danneggiata Applicare sigillante sul diam. ester-
nizione e la sua sede no della guarnizione sostituendola.

3. Perdite dalle guarnizioni di - Allentamento viti di unione Stringere bene le viti.


unione carter

4. Perdite dai tappi scarico olio - Danneggiamento guarnizione in Sostituire.


rame

5. Perdita d’olio non localizzabile - Perdite d’olio dal radiatore o dal Sostituire componenti del circuito
sulla trasmissione circuito di raffreddamento olio difettosi.

6. Fuoriuscita olio dallo sfiato - Livello olio alto o basso Correggere livello olio

GB Problems Causes Remedies


LEAKS

1. Pump output shaft gasket or - Faulty gasket Replace


PTO shaft leaks - Bad alignement Rectify
- Damaged shaft Replace.

2. Leaks between the outside of - Damaged seal seat in housing Change seal and apply sealant on
the gasket and its seating the outside diameter.

3. Leaks from the case sealing - Fixing screws loosened Tighten the screws.
gasket

4. Leaks from the drain plug - Copper gasket damaged Replace.

5. Not easy to locate oil leaks on - Oil leaks from the cooler or from Replace the faulty cooler or the faulty
the transmission the oil cooling circuit components of the circuit.

6. Oil leaks from the breather - High or low oil level Rectify the oil level.

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TXL 30/ST

C. Diagnostica
C. Inspection
C. Untersuchung
C. Diagnostic

D Probleme Ursachen Abhife


UNDICHTIGKEIT

1. Pumpenabtriebswellen dichtung - Fehlerhafte Dichtung Austauschen


oder Nebenabtriebswellendich- - Schlechte Ausrichtung Korrigieren
tung undicht - Beschädigte Welle Ersetzen.

2. Leckage zwischen äußerer - Aufnahmebohrung für Dichtung Dichtung tauschen. Dichtmasse


Dichtung und Gehäuse Gehäuse beschädigt auf den Außendurchmesser der
Dichtung aufrbingen.

3. Undichtigkeit am Zwischen- - Verbindungsschrauben lösen sich Anziehen.


gehäuse

4. Undichter Ablaß - Kupferdichtung beschädigt Austauschen.

5. Nicht leicht zu lokalisierende - Ölleckage vom Kühler oder vom Fehlerhaften Kühler oder defekte
Ölleckagen am Getriebe Ölkühlkreislauf Teile des Kreislaufs ersetzen.

6. Ölausfluß vom Entlüfter - Zu hoher Ölstand Ölstand korrigieren.

F Problemes Causes Remedes


FUITES

1. Fuite de la pompe, du joint de - Joint déféctueux Remplacer


l’arbre de sortie ou de l’arbre de - Mauvais alignement Corrigere
la prise de force - Arbre endommagé Remplacer.

2. Fuites entre l’extérieur du joint - Siège endommagé Remplacer le joint.


et son siège

3. Fuites aux joints de jonction au - Desserage des vis de jonction Bien serrer les vis.

4. Fuites aux bouchons de vidange - Joint en cuivre endommagé Remplacer.


d’huile

5. Fuite d’huile non localisée sur la - Pertes d’huile du radiateur ou du Remplacer le radiateur ou la pièce
transmission circuit de refroidissement défectueuse du circuit.

6. Sortie d’huile du reniflard - Niveau d’huile trop haut ou bas Corriger le niveau d’huile.

136
TXL 30/ST

Difetti di funzionamento comuni a tutte le marce


Common running faults in all gears
Gilt für alle funktionsstörungen
Defauts de fonctionnement pour toutes les vitesse
6
I Problemi Cause Rimedi

1. Pressione olio bassa - Valvola regolatrice bloccata Pulire e lucidare la valvola


- Perdita interna Sostituire gli anelli di tenuta diffettosi
- Livello olio basso Aggiungere olio
- Pompa difettosa Sostituire la pompa
- Filtro d’aspirazione intasato Sostituire
- Comando Inching sregolato Regolare correttamente.

2. Mancanza di pressione olio - Perdita interna Sostituire le parti difettose


- Pompa danneggiata Sostituire la pompa
- Valvola regolatrice difettosa Pulire e lucidare la valvola.

3. Innesto violento - Alta pressione valvola regolatrice Pulire e lucidare


bloccata
- Minimo motore troppo alto Regolare
- Valvola modulatrice difettosa Revisionare
- Valvola antishock starata o bloccata Tarare o sostituire
- Impurità o corpi estranei nel Smontare e pulire.
distributore

4. Innesto lento - Bassa pressione alle frizioni Vedere “Pressione olio bassa”
- Minimo motore troppo basso Regolare
- Valvola modulatrice difettosa Revisionare
- Valvola antishock starata o bloccata Tarare o sostituire.

5. Alta pressione - Valvola regolatrice bloccata Pulire e lucidare.

6. Temperatura dell’olio alta - Linea di raffreddamento difettosa Sostituire le parti difettose


- Strozzatura nella linea di raffred- Rimuovere
damento
- Radiatore difettoso Sostituire
- Convertitore danneggiato Sostituire
- Livello olio alto Ripristinare livello.

7. Rumorosità con la Marcia Avanti - Cattivo allineamento del carter Allineare il gruppo del convertitore
e Retromarcia convertitore o del convertitore e il corpo
con il motore
- Ingranaggi danneggiati Sostituire
- Danneggiamento palette Sostituire convertitore.
convertitore

8. Assenza di movimento con le - Mancanza pressione Vedi “Mancanza pressione olio”


marce inserite - Albero d’ingresso rotto Sostituire
- Piatto di trascinamento converti- Sostituire
tore rotto
- Guasto all’impianto elettrico Riparare.

9. Cattivo funzionamento Inching - Valvola inceppata Riparare o sostituire.

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TXL 30/ST

Common running faults in all gears

GB Problems Causes Remedies


1. Low oil pressure - Regulating valve sticked Clean and polish the valve
- Internal leakage Replace the faulty seal rings
- Low oil level Add oil
- Faulty pump Replace the pump
- Suction filter clogged Replace
- Misadjusted Inching control Adjust.

2. No oil pressure - Internal leakage Replace the faulty parts


- Damaged pump Replace the pump
- Damage in the regulating valve Clean and polish the valve.

3. Hard clutch engagement - Locked high pressure, regulating Clean and polish
valve
- Engine idling speed too high Rectify
- Faulty modulating valve Overhaul
- Sticking or unset anti-shock valve Reset or replace
- Impurity or foreign particles in Disassemble and clean.
the distributor

4. Slow clutch engagement - Low clutch pressure See “Low oil pressure”
- Too low idling speed engine Adjust
- Faulty modulating valve Overhaul
- Sticking or unset anti-shock valve Reset or replace.

5. High pressure - Sticking regulating valve Clean and polish.

6. High oil temperature - Faulty cooling circuit Replace the faulty parts
- Choke in the cooling circuit Remove
- Faulty cooler Replace
- Damaged converter Replace
- High oil level Restore the level.

7. Noises in Forward and Reverse - Bad alignment of the converter Align the converter group and the
housing or of the converter with case
the engine
- Damaged gears Replace the damaged gears
- Damaged converter vane Replace the converter.

8. No drive when gears are - Pressure lack See “Oil pressure lack”
engaged - Broken input shaft Replace
- Broken converter drive plate Replace
- Failure of the electric system Repair.

9. Bad Inching working - Sticking valve Repair or replace.

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TXL 30/ST

Gilt für alle funktionsstörungen

6
D Probleme Ursachen Abhife
1. Zu niedriger Öldruck - Regelventil blockiert Ventil reinigen
- Innere Leckage Defekte Dichtringe austauschen
- Niedriger Ölstand Öl auffüllen
- Pumpenfehler Pumpe austauschen
- Saugfilter verstopft Austauschen
- Falsch eingestellte Inchsteuerung Korrigieren.

2. Fehlender Öldruck - Innere Leckage Defekte Teile ersetzen


- Pumpenfehler Pumpe austauschen
- Verschmutztes Ventil reinigen.

3. Rupfende Kupplung - Blockierter Hauptdruck, Regelvenil Reinigen


- Defektes Modulationsventil Überholen / Ersetzen
- Blockiertes oder falsch eingestelltes Einstellen oder austauschen
Anti-Schock-Ventil
- Schmutz oder Fremdkörper im Demontieren und reinigen.
Verteiler

4. Verzögertes Einschalten der - Niedriger Kupplungsdruck Siehe “Zu niedriger Öldruck”


Kupplung - Zu niedrige Leerlaufdrehzahl Motor Korrigieren
- Defektes Modulationsventil Überholen
- Blockiertes oder falsch eingestelltes Einstellen oder austauschen
Anti-Schock-Ventil
- Schmutz im Verteiler Reinigen.

5. Zu hoher Druck - Festsitzendes Regelventil Reinigen.

6. Hohe Öltemperatur - Defekter Kühlerkreis Defekte Teile austauschen


- Drossel im Kühlkreislauf Entfernen
- Defekter Kühler Austauschen
- Beschädigter Wandler Austauschen
- Hoher Ölstand Ölstand korrigieren.

7. Geräusche im Vorwärts- und - Schlechte Ausrichtung des Wandlergruppe und Gehäuse neu
Rückwärtsgang Wandlergehäuses oder Wandlers korrekt einrichten
mit dem Motor
- Beschädigte Zahnräder Zahnräder ersetzen
- Beschädigte Wandlerschaufel Wandler ersetzen.

8. Kein Antrieb in Gängen - Fehlender Druck Siehe “Fehlender Öldruck”


- Gebrochene Antriebswelle Austauschen
- Gebrochene Membrane Austauschen
- Ausfall des Elektriksystems Reparieren.

9. Schlechtes Inchingverhalten - Blockiertes Ventil Reparieren oder ersetzen.

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TXL 30/ST

Defauts de fonctionnement pour toutes les vitesse

F Problemes Causes Remedes


1. Pression d’huile basse - Vanne régulatrice bloquée Nettoyer et polir la vanne
- Fuite interne Remplacer les bagues de tenue
défectueuses
- Niveau d’huile bas Ajouter de l’huile
- Pompe défectueuse Remplacer la pompe
- Filtre d’aspiration ecrassée Remplacer
- Commande Inching mal reglée Regler la commande correctement.

2. Manque de pression huile - Fuite interne Remplacer les pièces défectueuses


- Pompe endommagée Remplacer la pompe
- Vanne régulatrice défectueuse Nettoyer et polir la vanne.

3. Embrayage violent - Haute pression de la vanne Nettoyer et polir


régulatrice bloquée
- Ralenti trop élevé Regler
- Vanne modulatrice défectueuse Réviser
- Vanne antichock mal calibrée ou Calibrer ou remplacer la vanne
bloquée
- Corps étrangers ou impurités Demonter et nettoyer
dans le distributeur

4. Embrayage lent - Pression basse des embrayages Voir chapitre “Pression d’huile basse”
- Ralenti trop bas Régler
- Vanne modulatrice défectueuse Réviser
- Vanne antichock mal calibrée ou Calibrer ou emplacer
bloquée
- Impurités dans le distributeur Nettoyer.

5. Pression haute - Vanne régulatrice bloquée Nettoyer et polir.

6. Température d’huile élevée - Ligne de refroidissement Remplacer les pièces


défectueuse défectueuse
- Entranglement dans la ligne de Remettre la ligne en place
refroidissement
- Radiateur défectueux Remplacer
- Convertisseur endommagé Remplacer
- Niveau d’huile trop haut Régler le niveau.

7. Bruits en Marche Avant ou arrière - Mauvais alignement du carter Aligner le groupe du convertisseur
avec le convertisseur ou du et le corps
convertisseur avec le moteur
- Engrenage endommagés Remplacer les engrenages
endommagés
- Pales du convertisseur Remplacer le convertisseur.
endommagés

8. Pas de mouvement du véhicule - Manque de pression Voir chapitre “Manque pression huile”
direction vitesses enclenchées - Arbre entrée cassé Remplacer
- Plateau d’entraînement du Remplacer
convertisseur cassé
- Panne sur l’installation électrique Reparer

9. Mauvais fonctionnement Inching -Vanne coincée Reparer ou remplacer.

140
TXL 30/ST

Anomalie di funzionamento a marce innestate


Marcia Avanti e Retromarcia
Running faults with gears engaged
Forward and Reverse Gear
6
Funktionsstörungen bei eingelegtem gang
Vorwärts- und Rückwärtsgang
Anomalies de fonctionnement avec marches mises
Marche Avant et Marche Arrière

I Problemi Cause Rimedi

1. La frizione fa resistenza o non - Dischi frizione svergolati Sostituire le parti difettose


stacca (il carrello si muove in Folle) - Guasti meccanici Sostituire le parti difettose
- Assenza di gioco nel pacco Aumentare il gioco secondo speci-
frizione fiche
- Elettrovalvola inceppata Riparare o sostituire
- Selettore bloccato Pulire e lucidare
- Guasto elettrico Riparare
- Impurità o corpi estranei nel distri- Smontare e pulire.
butore

2. La frizione non si innesta (il car- - Bassa pressione Vedere “Pressione olio bassa”
rello non si muove) - Elettrovalvola inceppata Riparare o sostituire
- Selettore bloccato Pulire e lucidare
- Guasto elettrico Riparare
- Impurità o corpi estranei nel distri- Smontare e pulire.
butore

3. Il carrello si muove debolmente - Bassa pressione Vedere “Pressione olio bassa”


o non si muove - Anelli di tenuta consumati o rotti Sostituire le parti difettose.

GB Problems Causes Remedies

1. The clutch drags or does not - Warped clutch disks Replace the faulty parts
release (the truck moves at idle) - Mechanical failures Replace the faulty parts
- Absence of clearance in the Increase the clearance as per
clutch pack descriptions
- Sticking electrovalve Repair or replace
- Sticking selector Clean and polish
- Electric failure Repair
- Impurity or foreign particles in the Disassemble and clean.
distributor

2. The clutch does not engage - Low pressure See “Low oil pressure”
(the truck does not move) - Locked electrovalve Repair or replace
- Sticking selector Clean and polish
- Electric failure Repair
- Impurity or foreign particles in the Disassemble and clean.
distributor

3. The truck does not move or it - Low pressure See “Low oil pressure”
moves weakly - Broken or worn seal rings Replace the faulty parts.

141
TXL 30/ST

Funktionsstörungen bei eingelegtem gang


Vorwärts- und Rückwärtsgang
Anomalies de fonctionnement avec marches mises
Marche Avant et Marche Arrière

D Probleme Ursachen Abhife


1. Die Kupplung rupft oder löst sich - Verzogene Kupplungsscheiben Defekte Teile austauschen
nicht. Fahrzeug bewegt sich im - Mechanischer Fehler Defekte Teile austauschen
Leerlauf - Fehlendes Spiel im Spiel gemäß Beschreibung
Kupplungspaket erhöhen
- Festsitzendes Elektroventil Reparieren oder ersetzen
- Elektrikausfall Reparieren
- Schmutz im Verteiler Demontieren und reinigen
- Blockierter Wahlschalter Reinigen.

2. Kupplung wurde beaufschlagt - Niedriger Druck Siehe “Zu niedriger Öldruck”


Fahrzeug bewegt sich nicht - Blociertes Elektroventil Reparieren oder austauschen
- Elektrikausfall Reparieren
- Schmutz im Verteiler Demontieren und reinigen.

3. Fahrzeug bewegt sich nicht - Niedriger Druck Siehe “Zu niedriger Öldruck”
oder nur wenig - Geborchene oder verschlissene Defekte Teile austauschen.
Dichtringe

F Problemes Causes Remedes


1. L’embrayage resiste ou ne - Disques de l’embrayage Remplacer les pièces défectueuses
s’enclenche pas. (Le chariot endommagés
bouge au Point Mort). - Pannes mécaniques Remplacer les pièces défectueuses
- Absence de jeu dans le bloc Augementer le jeu suivant les
embrayage normes
- Electrovannes bloquée Reparer ou remplacer
- Sélecteur bloquée Nettoyer et polir
- Panne électrique Reparer
- Corps étrangers ou impuretés Demonter et nettoyer
dans le distributeur

2. L’embrayage n’embrayage pas - Pression basse Voir chapitre “Basse pression d’huile”
(le chariot ne bouge pas) - Electrovanne bloquée Reparer or remplacer
- Sélecteur bloquée Nettoyer et polir
- Panne électrique Reparare
- Corps étranger ou impuretés Demonter et nettoyer.
dans le distributeur

3. Le chariot ne bouge pas - Pression basse Voir chapitre “Basse pression d’huile”
- Bagues de tenue usées ou Remplacer les pièces défectueuses.
cassées

142
TXL 30/ST

Problemi vari
Further problems
Sonstige probleme
Problemes divers
6
I Problemi Cause Rimedi
1. Rumore idraulico o ronzio di - Aria nel circuito idraulico o basso Controllare il livello olio e aggiun-
valvola livello olio gerne se manca. Far girare il moto-
re a 1200 giri al minuto per elimina-
re l’aria

2. Rumore di ingranaggi in Marcia - Denti di ingranaggi rotti, incrinati Sostituire le parti difettose
Avanti e Retromarcia o usurati
- Cuscinetti usurati o danneggiati Sostituire.

GB Problems Causes Remedies


1. Hydraulic noises or valve hums - Air in the hydraulic circuit or low Check the oil level and add if failing.
oil level Make the engine run at 1200 r.p.m.
to eliminate the air.

2. Noises in Forward and Reverse - Broken, cracked or worn gear Replace the damaged parts
Gear teeth
- Worn or damaged bearings Replace.

D Probleme Ursachen Abhife


1. Hydraulik-oder Ventilgeräusche - Luft im Hydraulikkreislauf oder Entlüften und Ölstand korrigieren
niedriger Ölstand Motor mit 1200 UpM laufe lassen,
um die Luft zu beseitigen

2. Getriebegeräusche im - Gebrochene, gerissene oder Defekte Teile austauschen


Vorwärtsgang und Rückwärtsgang verschlissene Zähne
- Verschlissene oder beschädigte Austauschen.
Lager

F Problemes Causes Remedes


1. Bruit hydraulique ou - Air dans le circuit hydraulique ou Contrôler le niveau d’huile et en
bourdonnement d’une niveau d’huile trop bas ajuouter le cas échéant. Faire tourner
électrovanne le moteur à 1200 tours minute pour
éliminer l’air

2. Bruit de l’engrenage en Marche - Dents cassées, felées ou usées Remplacer les pièces défectueuses
Avant, et Marche Arrière sur l’engrenage
- Coussinets usés ou détériorés Remplacer.

143
TXL 30/ST

Cattivo funzionamento in Folle


Bad working in idle
Schlechter leerlaufbetrieb
Mauvais fonctionnement au Point Mort

I Problemi Cause Rimedi


1. Trascinamento in avanti o in - Dischi della frizione svergolati o Sostituire le parti difettose
Retromarcia guasti meccanici della frizione

2. La Marcia Avanti o Retromarcia - Guasto elettrico Riparare


rimane innestata - Elettrovalvola inceppata Riparare o sostituire
- Selettore bloccato Pulire e lucidare
- Impurità o copri estranei nel Smontare e pulire.
distributore

GB Problems Causes Remedies


1. Truck moving Forward and - Warped clutch plates or clutch Replace the faulty parts
Reverse Gears at idle mechanical failure

2. The Forward and Reverse Gears - Electric breakdown Repair


remain engaged - Sticking electrovalve Repair or replace
- Sticking selector Clean and polish
- Impurities or foreign bodies in valve Dismantle and clean.

D Probleme Ursachen Abhife


1. Fahrzeug bewegt sich im Leerlauf - Verformte Kupplungslamellen Defekte Teile ersetzen.
vorwärts und Rückwärtsgang

2. Vorwärtsgang und Rückwärtsgang - Stromausfall Reparieren


bleibt eingeschaltet - Festsitzendes Elektroventil Reparieren oder ersetzen
- Blockierter Wahlschalter Reinigen
- Verunreinigungen oder Ausbauen und reinigen.
Fremdkörper im Verteiler

F Problemes Causes Remedes


1. Entraînement en Avant ou en - Disques de embrayage détériorés Remplacer les pièces défectueuses.
Marche Arrière ou pannes mécaniques de
l’embrayage

2. La Marche Avant ou Marche - Electrovanne bloquée Reparer ou remplacer


Arrière reste embrayée - Sélecteur bloqué Nettoyer et polir
- Panne électrique Reparer
- Corps étrangers ou impuretés Démonter et nettoyer.
dans le distributeur

144
TXL 30/ST

Surriscaldamento della trasmissione


Transmission overheating
Getribeüberhitzung
Surcharge de la transmission
6
I Problemi Cause Rimedi

Surriscaldamento - Radiatore troppo piccolo o Tutte le linee olio esterne ed il


passaggio olio inadeguati radiatore devono permettere il libe-
ro passaggio dell’olio ed aver una
capacità di scambio adeguata
- Radiatore difettoso Sostituire
- Convertitore danneggiato Sostituire
- Livello olio non corretto Ripristinare livello
- Filtro aspirazione intasato Pulire
- Uso improprio o scorretto della Non usare la macchina in stallo
macchina prolungato
- Pressione della pompa bassa, Controllare le pressioni della
pompa usurata o danneggiata trasmissione. Ispezionare il gruppo
della pompa e verificare se le pres-
sioni sono basse. Sostituire il grup-
po della pompa se usurato o
danneggiato
- Frizioni che slittano Controllare gli anelli di tenuta e le
pressioni
- Bassa pressione Vedere “Pressione olio bassa”
- Olio emulsionato Controllare tipo di olio e livello
- Sensore di temperatura difettoso Sostituire.

GB Problems Causes Remedies


Overheating - Too small cooler or oil hoses All the external oil lines and the
cooler must allow the passage of
the oil and have an adequate
exchange capacity
- Faulty cooler Replace
- Damaged converter Replace
- Low oil level Restore the level
- Obstructed suction filter Clean
- Improper use of equipment Do not use the engine in extended
stall
- Low pump pressure, pump worn Check the pressures. Inspect the
or damaged pump if pressures are low. Replace
the pump if worn or damaged
- Slipping clutches Check the seal rings and pressures
- Low pressure See “Low oil pressure”
- Emulsified oil Check the type of oil or low oil level
- Faulty temperature sensor Replace.

145
TXL 30/ST

Getriebeüberhitzung
Surcharge de la transmission

D Probleme Ursachen Abhife


Überhitzung - Zu kleiner Kühler oder Alle externen Ölleitungen und der
Verbindungsschläuche (Rohre) Kühler müssen genügend große
Querschnitte aufweisen, und der
Kühler eine genügend große
Kühlleistung
- Beschädigter Kühler Austauschen
- Beschädigter Wandler Austauschen
- Flascher Ölstand Ölstand korrigieren
- Blockierter Saugfilter Reinigen
- Falsch eingestellter Motor oder Eistellung nach Vorschrift korrigieren
zu langes Fahren im Getriebe nicht länger als 10 Sek.
Festbremspunkt festbremsen
- Niedriger Pumpendruck Drücke prüfen. Bei niedrigen Drücken,
Drücken,Pumpengruppe unter-
suchen. Verschlissene oder be-
schädigte Pumpengruppe ersetzen
- Rutschende Kupplungen Dichtringe und Druck prüfen
- Niedriger Druck Siehe “Zu niedriger Öldruck”
- Schäumendes Öl Öl nach Vorschrift tauschen
- Defekter Temperaturfühler Austauschen.

F Problemes Causes Remedes


Surcharge - Radiateur trop petit ou passages Toutes les conduites d’huile
d’huile inadéquats extérieures et le radiateur doivent
permettre le libre passage d’huile
et avoir une capacité d’échange
appropriée
- Radiateur ecrassée Remplacer
- Convertisseur endommagé Remplacer
- Niveau d’huile incorrect Rectifier le niveau d’huile
- Filtre d’aspiration bouché Nettoyer
- Utilisation incorrecte du véhicule Ne pas utiliser le véhicule
- Basse pression de la pompe Contrôler la pression de la
transmission
- Pompe usée ou endommagée Contrôler le groupe de la pompe
dans le cas où les pressions sont
trop basses. Remplacer le groupe
pompe si celui-ci est usé ou
endommagé
- Embrayages qui patinent Contrôler les bagues de tenue et
les pressions
- Basse pression Voir chapitre “Basse pression de
l’huile”
- Huile “émultionée” Contrôler le type d’huile
- Sonde de température Remplacer.
défectueuse

146
TXL 30/ST

ATTREZZI SPECIALI - DISEGNI


SPECIFIC TOOLS - DRAWINGS
SPEZIALWERKZEUG - ZEICHNUNG
OUTILS SPECIAUX - PLAN
7
INDICE / INDEX / INHALTSVERZEICHNIS / INDEX

Disegno Denominazione pag.


Drawing. Description page
Zeichnung Beschreibung Seite
Plan Designation pag.

4A41377/00 Attrezzatura per la scomposizione dei pacchi frizione 148


Fixture for diassembling of clutch plates 149
Werkzeug zur Demontage der Kupplungslamellen
Outillage pour démontage des packs embrayage
48A17092/00 Attrezzo per montaggio anello Q-Ring PTO SAE “A” 150
Q-Ring assembling tool PTO SAE “A” 151
Werkzeug für die Montage des Q-Rings PTO SAE “A”
Outil pour montage bague Q-Ring PTO SAE “A”
48A17127/00 Attrezzo per montaggio anello Q-Ring SAE “A” -”B” 152
Q-Ring assembling tool SAE “A” -”B” 153
Werkzeug für die Montage des Q-Rings SAE “A” -”B”
Outil pour montage bague Q-Ring SAE “A” -”B”
48A19118 Chiave bloccaggio ghiera registrazione differenziale 154
Locking spanner for slotted nut of Differential
Feststellschlüssel Einstellnutmutter Differential
Clé de fermeture de frette réglage Différentiel
48A19119 Chiave bloccaggio ghiera registrazione cuscinetto mozzo (2a versione) 155
Locking spanner for slotted nut of hub bearing adjusting (2nd version)
Feststellschlüssel Einstellnutmutter Lager Radnabe (2. Version)
Clé de blocage frette réglage roulement moyeu de la roue (2 ème version)
48A19120/00 Punzone per piantaggio guarnizione di tenuta su manicotto ponte (2a versione) 156
Forcing seal ring tool on spindle of axle (2nd version)
Bolzen für Montage von Dichtring an der Muffe der Achse (2. Version)
Poinçon pour positionnement bague d’étanchéité sur manchon pont (2 ème version)
48A19394 Punzone per piantaggio guarnizione di tenuta su manicotto ponte (2a versione) 157
Forcing seal ring tool on spindle of axle (2nd version)
Bolzen für Montage von Dichtring an der Muffe der Achse (2. Version)
Poinçon pour positionnement bague d’étanchéité sur manchon pont (2 ème version)

147
TXL 30/ST

Attrezzatura per la scomposizione dei pacchi frizione


Fixture for diassembling of clutch plates
Werkzeug zur Demontage der Kupplungslamellen
Outillage pour démontage des packs embrayage

∅ 8 x 130

Acciaccare
Notch
Sichem

∅ 22 x 250

Saldature 3x3
Weldings
Schweinßnaht
Soudures

01

02

Barra Filettata M12 L = 240 mm


Thread Rod
Gewindestange Attrezzo 4A41377/00
Barre Taraudee Tool
Werkzeug
Outil

Scala : 1:2.5

148
TXL 30/ST

Attrezzo / Tool / Werkzeug / Outil 4A41377/01

22
40 sm 2x45 8 12
= = 01

65
15
45
30

3x30
180

122
80
66
=
Saldature 3x3
14

Weldings
Schweinßnaht 7 30'

118
Soudures

25
Soldaduras

Scala : 1:2,5

Attrezzo / Tool / Werkzeug / Outil 4A41377/02

20
sm 2x45
=
40
=
02 12
50

Saldature 3x3
Weldings sm 1
Schweinßnaht
Soudures
Soldaduras
sm 1
=
150
110

180
=
M12

Scala : 1:2,5

149
TXL 30/ST

Attrezzo per montaggio anello Q-Ring PTO SAE “A”


Q-Ring assembling tool PTO SAE “A”
Werkzeug für die Montage des Q-Rings PTO SAE “A”
Outil pour montage bague Q-Ring PTO SAE “A”

3
N

3/N CACCIASPINA 1 UNI 7502 ∅5


2 BASE 1 ALLUMINIO
1 PUNZONE 1 ALLUMINIO
N.Part Denom.particolare Quant Materiale o normale Trattam. Dimens.

ELEMENTO DIS. N. 3350283

Scala : 1:2
Attrezzo / Tool / Werkzeug / Outil 48A17092/00

150
TXL 30/ST

Attrezzo / Tool / Werkzeug / Outil 48A17092/01

∅ 145

∅ 95.2
15

2x45
88

∅ 132.7+0.1

Quantita' Mater.
*ZONA PER MARCATURA 1 ALLUMINIO
3.2 N. ATTREZZO 48A17092/1 1 N.Dis. Trattam.
DIS.ELEMENTO 335028 -
Scala : 1:2

Attrezzo / Tool / Werkzeug / Outil 48A17092/02

∅ 95

∅ 54.2
1.6

R20
15
65

R20
85

13
1.6

15

R20
7.8

∅ 129.7
1.6

∅ 132.5+0.1
3.2 1.6

Quantita' Mater.
*ZONA PER MARCATURA 1 ALLUMINIO
N. ATTREZZO 48A17092/2 2 N.Dis. Trattam.
DIS.ELEMENTO 335028 -

Scala : 1:2

151
TXL 30/ST

Attrezzo per montaggio anello Q-Ring SAE “A” -”B”


Q-Ring assembling tool SAE “A” -”B”
Werkzeug für die Montage des Q-Rings SAE “A” -”B”
Outil pour montage bague Q-Ring SAE “A” -”B”

3
N

3/N CACCIASPINA 1 UNI 7502 ∅5


2 BASE 1 ALLUMINIO
1 PUNZONE 1 ALLUMINIO
N.Part Denom.particolare Quant Materiale o normale Trattam. Dimens.

ELEMENTO DIS. N. 3289943-3289933-3290003

Attrezzo / Tool / Werkzeug / Outil 48A17127/00 Scala : 1:2

152
TXL 30/ST

Attrezzo / Tool / Werkzeug / Outil 48A17127/01

∅ 140

∅ 95.2

15
85

∅ 126.2+0.1

Quantita' Mater.
*ZONA PER MARCATURA 1 ALLUMINIO
N. ATTREZZO 48A17127/1 1 N.Dis. Trattam.
3.2
DIS.ELEMENTO 328993-94
329000 -

Scala : 1:2

Attrezzo / Tool / Werkzeug / Outil 48A17127/02

∅ 95

R15
15

R15
75
15

R15
7.7

∅ 54.2
∅ 123
1.6

∅ 126+0.1

Quantita' Mater.
*ZONA PER MARCATURA 1 ALLUMINIO 3.2 1.6
N. ATTREZZO 48A17127/2 2 N.Dis. Trattam.
DIS.ELEMENTO 328993-94
329000 -

Scala : 1:2

153
TXL 30/ST

45° 45°
33
7.5
R1
7±0.10 (N.8 POS.) 1
45°

45°

Ø 106

Ø 112

Ø 125
Ø 126

Ø 64

Ø 74

Ø 85
10
sm.10X45° 6.3
12.7 Saldare elettricamente 50
Chiave 1 39NiCrMo3 Bon.

b
a
c
N.Part Denom.particolare Quant Materiale o normale Trattam. Dimens. MODIFICHE
Tolleranze generali per
dimensioni di parti DENOMINAZIONE ELEMENTO Tolleranze di forma e posiz
lavorate senza indicazioni secondo tab. UNI 7226-73
a disegno:
Proteggere le filettature
FORI
ALBERI
H13
h13
Trasmissione TXL30/ST dalla cementazione
QUOTE LINEARI J/j13
ZONA PER MARCATURA ANGOLI ±30'
ELEMENTO DIS. N°
3.35338.3 Raggi e smussi non
FILETTATURE 6H/6g quotati = 0.5

presente disegno a norma delle vigenti leggi


N° ATTREZZO 48A19118

E' vietato riprodurre o comunicare a terzi il


ATTREZZATURA
DIS.ELEMENTO 3.35338.3
Chiave a settore per CAD
DRAWING
GRAZIANO Trasmissioni S.p.A.
Ghiera dis.3352013 (M100x1.5) NO HANDLING
WITHOUT CAD SYSTEM
BARI
N° GT OP.N°
Macchina operatrice MONTAGGIO
Disegnato
CAPORALE Scala Foglio DIS. N°
Visto Data 1di1 48A19118

154
18/09/03
155
Saldare elettricamente
b 30
7 a
48°
48°

6± 0.10 (N.8 POS.)


48°
sm1X45°

48°
R5
Ø 42
Ø 32

Ø 95

Ø 85

Ø 80

24°
sm1X45°
12.7

48
°

°
48
10X45° 48°
15
160.00
6.3
b Tubo Fe360
a Chiave 1 39NiCrMo3 Bon.

b
c

a
N.Part Denom.particolare Quant. Materiale o normale Trattam. Dimens. MODIFICHE
Tolleranze generali per
dimensioni di parti DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
lavorate senza indicazioni secondo tab. UNI 7226-73
ZONA PER MARCATURA a disegno:
FORI H13 Trasmissione TXL30/ST Proteggere le filettature dalla cementazione
N° ATTREZZO 48A19119 ALBERI
QUOTE LINEARI J/j13
h13
ELEMENTO DIS. N. Raggi e smussi non quotati = 0.5
DIS.ELEMENTO 3.35338.3 ANGOLI ±30'
3.35338.3

presente disegno a norma delle vigenti leggi


FILETTATURE 6H/6g

E' vietato riprodurre o comunicare a terzi il


ATTREZZATURA
Chiave a settori per CAD
DRAWING
GRAZIANO Trasmissioni S.p.A.
Ghiera dis. 3352023 (M80x1.5) NO HANDLING
BARI WITHOUT CAD SYSTEM
Macchina operatrice MONTAGGIO N. GT OP.N.
TXL 30/ST

Disegnato Scala Foglio Dis. N


CAPORALE
Visto Data
18/09/03 1di1 48A19119
TXL 30/ST

105 Proteggere dalla cmt


50
R 10
26
6
10

R 10
Ø 50 ZIGRINATO
82 (Tratto zigrinato)
181

ZONA PER MARCATURA


N° ATTREZZO 48A19120/1
DIS.ELEMENTO 3353383 1
Ø4

2
45°
+0.05
+0.10
+0.10
+0.05

60
58

11
16
2

205
18

0.8
0.8

6.3 0.8

13 (Quota elemento)
Ø 30 H7
Ø 105.5`0.10
PART.N. Quantita' Materiale
Ø 112`0.10 1 1 18NiCrMo5
N. DISEGNO Trattamento
Ø 118`0.10
48A19120/1 cmt/tmp HRC60`2

Quota di montaggio 0.5


Ø 150
Ø 91 -0.05
-0.10
Ø 30 G6
15°

0.8
5

2 Base 1 18NiCrMo5 cmt/tmp


1 Punzone 1 18NiCrMo5

b
a
c
cmt/tmp
ZONA PER MARCATURA
45

N° ATTREZZO 48A19120/2 N.Part Denom.particolare Quant. Materiale o normale Trattam. Dimens. MODIFICHE
DIS.ELEMENTO 3353383
Tolleranze generali per
DENOMINAZIONE ELEMENTO Tolleranze di forma e posizione
80

dimensioni di parti
lavorate senza indicazioni secondo tab. UNI 7226-73
a disegno:

19.5
FORI
ALBERI
H13
h13
Trasmissione TXL30/ST Proteggere le filettature dalla cementazione
QUOTE LINEARI J/j13
ANGOLI ±30' ELEMENTO DIS. N° 3.35338.3 Raggi e smussi non quotati = 0.5
FILETTATURE 6H/6g

presente disegno a norma delle vigenti leggi


E' vietato riprodurre o comunicare a terzi il
ATTREZZATURA Punzone per piantaggio CAD
Ø 150 DRAWING
6.3 0.8 guarn. (3352113) su dist. (3352003)
GRAZIANO Trasmissioni S.p.A. NO HANDLING
WITHOUT CAD SYSTEM
BARI
Macchina operatrice N. GT OP.N.
PART.N. Quantita' Materiale
MONTAGGIO
2 1 18NiCrMo5 Disegnato
CAPORALE Scala Foglio DIS. N.
N. DISEGNO Trattamento
Visto Data 1di1 48A19120

156
48A19120/2 cmt/tmp HRC60`2 18/09/03
157
∅ 110
∅ 50
Proteggere dalla cmt
R 10
26
6

ZONA PER MARCATURA


N° ATTREZZO 48A19394
DIS.ELEMENTO 3353383
R 10
∅ 50 (ZIGRINATO)
184
135

R 10

21.5`0.05
6.3 0.8
0.8
42.5

Punzone 1 18NiCrMo5 cmt/tmp HRC 60`2

b
a
c
0.8 N.Part Denom.particolare Quant Materiale o normale Trattam. Dimens. MODIFICHE
Tolleranze generali per DENOMINAZIONE ELEMENTO Tolleranze di forma e posiz
dimensioni di parti
lavorate senza indicazioni secondo tab. UNI 7226-73
a disegno:

11
Proteggere le filettature
ASSALE TXL30/ST
∅ 30
FORI H13
ALBERI h13 dalla cementazione
QUOTE LINEARI J/j13
ELEMENTO DIS. N. Raggi e smussi non
ANGOLI `30'
3353383

presente disegno a norma delle vigenti leggi


FILETTATURE 6H/6g quotati = 0.5

E' vietato riprodurre o comunicare a terzi il


ATTREZZATURA
∅ 42 -0.05
Punzone per piantaggio

0.8
-0.10 CAD
DRAWING
GRAZIANO Trasmissioni S.p.A.
anello di tenuta dis.71482 su NO HANDLING
WITHOUT CAD SYSTEM
∅ 55 -0.05
-0.10 BARI manicotto scatola ponte
Macchina operatrice MONTAGGIO N. GT OP.N.
Disegnato Scala Foglio DIS. N.
∅ 77 CAPORALE
48A19394
TXL 30/ST

Visto Data
11/02/04 1di1
TXL 30/ST

ATTREZZI SPECIALI - DISEGNI


SPECIFIC TOOLS - DRAWINGS
SPEZIALWERKZEUG - ZEICHNUNG 7
OUTILS SPECIAUX - PLAN

INDICE / INDEX / INHALTSVERZEICHNIS / INDEX

Réf. MANITOU . . . . .Code

823 386 . . . . . . . . .4902166


823 387 . . . . . . . . .48A17092
823 388 . . . . . . . . .48A17127
823 389 . . . . . . . . .4A41377
823 390 . . . . . . . . .4902648
823 391 . . . . . . . . .4902174
823 392 . . . . . . . . .4902172
823 393 . . . . . . . . .4902302
823 394 . . . . . . . . .48A19118
823 395 . . . . . . . . .48A19120
823 396 . . . . . . . . .48A19394
823 397 . . . . . . . . .48A13164
823 398 . . . . . . . . .48A13511
823 399 . . . . . . . . .48A19119
823 400 . . . . . . . . .48A13533
823 401 . . . . . . . . .48A12542

823 385 . . . . . . . . .3.16475.3


822 142 . . . . . . . . .3.17113.3
822 321 . . . . . . . . .3.20489.3

158
TXL 30/ST

I I dati contenuti in questa pubblicazione potrebbero risultare non aggiornati in consequen-


za di modifiche adottate dal Costruttore, in qualunque momento, per ragioni di natura
tecnica o commerciale nonché per adattamento ai requisiti di legge nei diversi Paesi.
Descrizioni e fotografie possono riferirsi ad equipaggiamenti non di serie.

GB The data in this edition may prove not to be up to date due to modification made by the
manufacturer, which may become necessary for technical or commercial reasons, as well
as meeting legal requirements of various countries.
Descriptions and photos might refer to non-serial equipment.

D Die in dieser Ausgabe enthaltenen Daten mögen nicht dem neuesten Stand entsprechen,
da Änderungen aus technischen oder wirtschaftlichen Gesichtspunkten sowie gesetzli-
chen Vorschriften unterschiedlicher Länder jederzeit durchgeführt werden können.

F Les données figurant dans cette publication sont forunies à titre indicatif, suite à des
modifications apportées par le constructeur à n’importe quel moment, pour des raisons
de genre technique ou commercial, ainsi que pour une adaption due aux lois des dif-
férents pays.
Les descriptions et les photos peuvent se référer à des équipements hors série.

158
GROUP 70

HYDRAULIC
HYDRAULIC DIAGRAM

70-6-M128 EN

06 / 02 / 2006
CONTENTS

– HYDRAULIC DIAGRAM

CD 15/18/20/25/30/35 P
CG 15/18/20/25/30/35 P ............................... 4

3
HYDRAULIC DIAGRAM

CS Safety valve

D Valve bank 3 sections


EA Attachment section
EE Inlet section
EI Tilting section
EL Lifting section

P Hydraulic pump
PD Steering pump

VAP Control valve


VD Steering cylinder
VI Tilting cylinder DE
VL Lifting cylinder DE

4
HYDRAULIC DIAGRAM

VL

VL VL
VD

VI VI

PD CS

A1 B2 A2

EE EL EI EA

2 2 2
T

185 bar

1 1 1

LS
L T R

EF P
D
VAP A3 B3

P T

5
GROUP 80

ELECTRICITY
ELECTRIC DIAGRAM

80-6-M128 EN

28 / 02 / 2006
CONTENTS

- INSTRUMENT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

- GAS ENGINE DIAGRAM (For CG 15/18/20/25/30/35 P) . . . . . . . . . . . . . . . . 8

- DIESEL ENGINE DIAGRAM (For CD 15/18/20/25/30/35 P) . . . . . . . . . . . . . 12

3
INSTRUMENT DIAGRAM

COMPONENTS 15 - Battery negative


16 - Free
R1 - Engine starting relay
R2 - Starting agreement relay COLOUR CODING
R3 - Low beam relay
R4 - High beam relay A : Sky-Blue B : White C : Orange
R5 - Intermittence G : Yellow H : Grey L : Dark-Blue
X4 - Connector 12 + 4 ways M : Brown N : Black R : Red
X5 - Connector 20 + 2 ways S : Pink V : Green Z : Purple
DE1 - Forward / Reverse switch
DE2 - Lighting / Horn switch ROCKER SWITCHES
KEY1 - Ignition switch
STR1 - Water temperature gauge I1 - Headlight
STR2 - Oil temperature gauge I2 - Working light
STR3 - Fuel level gauge I3 - Roof lamp
STR4 - Hour meter I4 - Front wiper
I5 - Rear wiper
X5 CONNECTOR I6 - Electric fan
I7 - Hazard
1 - Low beam
2 - Free FUSES BOX
3 - Slow speed gear solenoid
4 - Night light / Position light F1 - Feeding fuse through ignition switch (15A)
5 - L.H. signal light + Flash light F2 - Front wiper (5A)
6 - R.H. signal light + Flash light F3 - High beam (10A)
7 - Horn F4 - Low beam (10A Maxi)
8 - Direct power supply F12 not under ignition switch F5 - Stop engine / injection pump (7,5A)
9 - Water sedimenter F6 - Electric fan (7,5A)
10 - Forward gear solenoid F7 - Preheating/alternator/cooling fan relay (7,5A)
11 - Reverse gear solenoid / Reverse alarm F8 - Position light + signal light + dashboard light (7,5A)
12 - Roof lamp F9 - Starting relay (15A)
13 - Oil temperature sensor F10 - Working light (15A)
14 - 1st speed electric fan F11 - Gauge + warning light (10A Maxi)
15 - 2nd speed electric fan F12 - Hazard + headlight + direct power supply + cooling
16 - Front wiper fan (7,5A)
17 - Rear wiper F13 - Rear wiper (15A)
18 - Rear working light F14 - Hazard (10A)
19 - Fast speed gear solenoid F15 - Horn + flashing (5A)
20 - Direct power supply (ignition switch) F16 - Forward / reverse switch (10A)
21 - Direct power supply (ignition switch) braking light
22 - High beam

WARNING LIGHT INDICATORS

L1 - Battery charge warning light


L2 - Position light warning light
L3 - Engine oil pressure warning light
L4 - High beam warning light
L5 - Preheating warning light
L6 - Working light warning light
L7 - Water sedimenter warning light
L8 - Signal light warning light
L9 - Fuel reserve warning light
L10 - Parking brake warning light

X4 CONNECTOR

1 - Battery positive / cooling fan


2 - Alternator
3 - Engine oil pressure sender
4 - Glow relay (glow indicator)
5 - Preheating device
6 - Injection pump / Engine stop solenoid
7 - Preheating (ACC) / Alternator / Cooling fan relay
8 - Fuel level sender (fuel level indicator)
9 - Fuel level sender (fuel reserve indicator)
10 - Starter
11 - Water temperature sender
12 - Free
13 - Parking brake sender
14 - Free

4
INSTRUMENT DIAGRAM

RN2.5

RN2.5
RN2.5
R2.5
F11

RN2.5
RN2.5

R2.5
5A

H1.5
V1.5
RN
F14 F12 F15 F3 F4

RN

RN
RN
STR1 10A 10A 10A 15A 15A
STR2 STR3 STR4

VN1.5
BR1.5

HN1.5
A1.5
+ + + +

RG
B B S L L L 000001
VN1.5

RN1.5
S S S L
- - - - HN1.5

GR
HR
HB
BR1.5

G
G

N
N
G
N
R5

BR 1.5
HB L
R3 31 R

RG
RN
C

L
HS 86 30

RN
RN
RN
RN
1 1 3 6

SG

AB
I7 0

N
L1

VN
1
CV1.5 1 1 1 1 1
L3
2 L5 L7 L9 L10 1 N 85
L4 87 87a

HL
2 2 2 2 2 4 2 5 7
HL

RV

H1.5
SN
M
2

GR

GR

SG
LN
LR

N
RN
1
RV
LN L8
SN
HR 2
CV1.5
LR VG 86 30
RN1.5

CV1.5
G

N
Z R4
G

F8

31 A1.5
N

A1.5
85

56 VG
SG

56b HS
LN
7.5A

Z
87 87a

L
G

GB1.5

56a
49a

56d

31b

V1.5
1

R
GB1.5

CV1.5

L
N

L2
2 DE2
-1 3 5 9 11
N

012 V
I1
+7 4 10
M
RN1.5
RN1.5
BG

BR1.5
RN2.5

RN2.5 RN2.5

RN2.5

RN2.5

RN2.5

RN2.5

RN2.5
RN2.5
RN2.5

LN2.5

F16 F10 F2 F13 F6


RN2.5
M4

LN2.5
M4

RB

KEY1 7.5A 10A 10A 10A 10A

RG1.5
SN1.5

RV1.5
P0 1 23

C1.5
B1.5
10 5 6 8 7 3 4 F9
F7 3A CB1.5

CN1.5
CB1.5
20A R1
SR

1 2 86 30
X5 CN1.5

N
HN1.5 1 HN1.5 2
M4

- 3 5 9 11
R6

R2.5 85 HZ 3 HZ 4
G G 0 12
V
I6
B

87
RN2.5

RN2.5

87a LN 5 6 L
L2.5

X4 LN L + 4 10
R6 1 R6 HR Z 7 8 BR1.5
2 HR Z BR1.5 C1.5
F5 F1 BV1.5
M 7.5A 15A RV 9 10 ZB
HL 3 HL 4 M RV ZB BN1.5
AB1.5
CV

MV
RB 5 RB 6 CV CV ZN 11 ZN 12
MV
MV
GV1.5
HB 13 HB 14 HZ

GV
M4 7 8 S S CN1.5 CN1.5
M4
HG
SN 9 SN CB1.5 15 16 BV1.5 1
10 L2.5 CB1.5 BV1.5
ZN BN1.5 17 18 GV1.5 ZB L6 BR1.5
B 11 B 12 BN1.5 GV1.5
ZB ZN 2
LR 13 14 HG 19 20 AB1.5

GV1.5
LR N HG AB1.5
R2

BV1.5
BN1.5
56b
49a

MV
56a

N
31b
AB1.5 21 22

56
N 15 VN1.5

31
F

R
N 16 86 30 AB1.5 VN1.5

N
N

N
I2 - 8 11 I3 - 8 11 I4 - 8 11 I5 - 8 11
85 1 2 1 2 1 2 1 2
87 87a V V V V
DE1
N

BN1.5 + 9 + 9 + 9 + 9
CB1.5
GV RG1.5 MV BR BN RV1.5 BV B1.5
ZN

5
7
GAS ENGINE DIAGRAM (for CG 15/18/20/25/30/35 P)

COMPONENTS X4 CONNECTOR

1 - Distributor 1 - Battery positive / cooling fan


2 - Throttle valve 2 - Alternator
3 - Fuel solenoid 3 - Engine oil pressure sender
4 - Reverse / Forward solenoid 4 - Glow relay (glow indicator)
5 - Reverse alarm 5 - Preheating device
6 - RH reverse light 6 - Injection pump / Engine stop solenoid
7 - LH reverse light 7 - Preheating (ACC) / Alternator / Cooling fan relay
8 - Oil temperature sensor 8 - Fuel level sender (fuel level indicator)
9 - Water temperature sensor 9 - Fuel level sender (fuel reserve indicator)
10 - Roof lamp (option) 10 - Starter
11 - Speed electric fan (option) 11 - Water temperature sender
12 - Rear working light 12 - Free
13 - Flash light 13 - Parking brake sender
14 - Flash light 14 - Free
15 - Horn 15 - Battery negative
16 - Battery negative 16 - Free
17 - RH signal light
18 - LH signal light
19 - High beam
20 - Night light
21 - Low beam
22 - Braking light
23 - Water sedimenter
24 - Foot brake sensor
25 - Connector 20 + 2 ways
26 - Battery
27 - Start motor
28 - Parking brake sensor
29 - Engine oil pressure sensor
30 - Alternator
31 - Fuel level sensor
32 - Connector 12 + 4 ways

COLOUR CODING

A : Sky-Blue B : White C : Orange


G : Yellow H : Grey L : Dark-Blue
M : Brown N : Black R : Red
S : Pink V : Green Z : Purple

X5 CONNECTOR

1 - Low beam
2 - Free
3 - Slow speed gear solenoid
4 - Night light / Position light
5 - L.H. signal light + Flash light
6 - R.H. signal light + Flash light
7 - Horn
8 - Direct power supply F12 not under ignition switch
9 - Water sedimenter
10 - Forward gear solenoid
11 - Reverse gear solenoid / Reverse alarm
12 - Roof lamp
13 - Oil temperature sensor
14 - 1st speed electric fan
15 - 2nd speed electric fan
16 - Front wiper
17 - Rear wiper
18 - Rear working light
19 - Fast speed gear solenoid
20 - Direct power supply (ignition switch)
21 - Direct power supply (ignition switch) braking light
22 - High beam

8
GAS ENGINE DIAGRAM (for CG 15/18/20/25/30/35 P)

5
P

6
1
11
4
7

2 3 10
8 9
4
3

1 2

18
14 13
M
27 23 19
15
26 21 20
17

29 28
30
22
G
31
~
24 12

VN
C2
22
V
21 16
C1 C1 20 C2
16
32 19
25
N NV
15 18
14 17 4 3 2 1
M
13
12
3 1 2 16
15 9 8 7 6 5
V R
11 14
L
10 6 5 4 RB
13 15 14 13 12 11 10
VN H
09 12
R
08 10 9 8 7 Z
11 22 21 20 19 18 17 16
V VR
07 10
L
06 13 12 11 V
09
28 27 26 25 24 23
M
05 08
H
04 16 15 14
B
07
33 32 31 30 29
G A
03 06
R
02
L
05
37 36 35 34
R GN
01 04
03
02
HR
01

9
11
DIESEL ENGINE DIAGRAM (for CD 15/18/20/25/30/35 P)

COMPONENTS C1 CONNECTOR

4 - Reverse / Forward solenoid 1 - Battery positive / cooling fan


5 - Reverse alarm 2 - Alternator
6 - RH reverse light 3 - Engine oil pressure sender
7 - LH reverse light 4 - Glow relay (glow indicator)
8 - Oil temperature sensor 5 - Preheating device
9 - Water temperature sensor 6 - Injection pump / Engine stop solenoid
10 - Roof lamp (option) 7 - Preheating (ACC) / Alternator / Cooling fan relay
11 - Speed electric fan (option) 8 - Fuel level sender (fuel level indicator)
12 - Rear working light 9 - Fuel level sender (fuel reserve indicator)
13 - Flash light 10 - Starter
14 - Flash light 11 - Water temperature sender
15 - Horn 12 - Free
16 - Battery negative 13 - Parking brake sender
17 - RH signal light 14 - Free
18 - LH signal light 15 - Battery negative
19 - High beam 16 - Free
20 - Night light
21 - Low beam
22 - Braking light
23 - Water sedimenter
24 - Foot brake sensor
25 - Connector 20 + 2 ways
26 - Battery
27 - Start motor
28 - Parking brake sensor
29 - Engine oil pressure sensor
30 - Alternator
31 - Fuel level sensor
32 - Connector 12 + 4 ways
33 - Preheating relay
34 - Glowing plug
35 - Injection pump solenoid

COLOUR CODING

A : Sky-Blue B : White C : Orange


G : Yellow H : Grey L : Dark-Blue
M : Brown N : Black R : Red
S : Pink V : Green Z : Purple

C2 CONNECTOR

1 - Low beam
2 - Free
3 - Slow speed gear solenoid
4 - Night light / Position light
5 - L.H. signal light + Flash light
6 - R.H. signal light + Flash light
7 - Horn
8 - Direct power supply F12 not under ignition switch
9 - Water sedimenter
10 - Forward gear solenoid
11 - Reverse gear solenoid / Reverse alarm
12 - Roof lamp
13 - Oil temperature sensor
14 - 1st speed electric fan
15 - 2nd speed electric fan
16 - Front wiper
17 - Rear wiper
18 - Rear working light
19 - Fast speed gear solenoid
20 - Direct power supply (ignition switch)
21 - Direct power supply (ignition switch) braking light
22 - High beam

12
DIESEL ENGINE DIAGRAM (for CD 15/18/20/25/30/35 P)

5
P

11
4
7

10
8 9

18 14 13
M
33 27 24
19 15

34 26 21 20 35
17

28
22
G
31
~
30 29

12
23

C2
VN
22
V 21 16
C1 C1 25 C2
32 20
16 19
N NV 18
15
14 17 4 3 2 1
M
13 3 1 2 16
9 8 7 6 5
12 15
V R
11 14
L 6 5 4 RB 15 14 13 12 11 10
VN
10 H 13
09 12
R
08 10 9 8 7 Z
11
22 21 20 19 18 17 16
V VR
07 10
L
06 13 12 11 V
09
28 27 26 25 24 23
M
H
05 B 08 33 32 31 30 29
G
04 16 15 14 A
07
03 06
R
02
L
05
37 36 35 34
R GN 04
01
03
02
HR
01

13

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