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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
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
- 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
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
COOLING CIRCUIT
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
6
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
8
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
10
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
12
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
14
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
16
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
17
CHARACTERISTICS OF MASTS WITH ROLLERS
CD 15 P
CD 18 P
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
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
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
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
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
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
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
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
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
COOLING CIRCUIT
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
30
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
32
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
34
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
36
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
38
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
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
40
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA dB
(accordng to standard prEN 12053: 1995)
. Overhead guard
41
CHARACTERISTICS OF MASTS WITH ROLLERS
CG 15 P
CG 18 P
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
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
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
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
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
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
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
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
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
*: 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
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
*: 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
TRANSMISSION
TRANSMISSION OIL FILTER CARTRIDGE
Part number: 822270
Change: 500 H
53
LUBRICANTS AND FUEL
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
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
*: 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
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
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
*: 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
TRANSMISSION
TRANSMISSION OIL FILTER CARTRIDGE
Part number: 822045
Change: 500 H
57
LUBRICANTS AND FUEL
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
TABLE OF CONTENTS
CONTENTS PAGE
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.
Thermostat (7)
Fig. 1
9. The following symbols appear throughout this Worshop Manual. They tell you the type of service
operation or step to perform.
APPEARANCE
1. MODELS 4LC1 AND 4LB1 AND 4LE1
Fig. 2
Fig. 3
6 GENERAL INFORMATION
Fig. 4
Fig. 5
GENERAL INFORMATION 7
Engine model(s)
4LB1 4LB1T
Item
Compression ratio 22 : 1
Generator output (V – A) * 12 – 20
Engine model(s)
4LC1 4LE1
Item
Lubricant capacity: In total lit (qts) * About 7.3 (7.7) About 8.7 (9.2)
Generator output (V – A) * 12 – 20
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
A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
GENERAL INFORMATION 11
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
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.
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
Fig. 12
GENERAL INFORMATION 13
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
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
4.2 - 5.6
(30.4 - 40.5)
9.5 - 11.5
(68.7 - 83.2)
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
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
( 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)
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;
nozzle holder
Gasket; headcover
(※)Sealant should not be
Corrugated applied.
washer
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
Fig. 19
20 GENERAL INFORMATION
Engine oil
1 Oil pan Cylinder block Not provided TB1207C
(10W-30)
Engine oil
2 Rocker bracket Cylinder head Provided TB1207C
(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
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
4. INJECTION TIMING
Note:
Take care to avoid entry of dust or foreign particles into
the pump interior when the timing adjustment is made.
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
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)
6. FUEL SYSTEM
Fuel Filter Replacement
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
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
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;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 5W–20
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
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
(14) (11)
(16)
(17)
(15)
(18)
Fig. 38
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
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
Shim
* Stud
Cylinder block
Fig. 42
ENGINE 31
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
(14)
(1)
(3)
(2)
(5)
(18)
(17)
(7)
(4) (16)
(15)
(6)
Fig. 45
34 ENGINE
(20) (13)
Do not pull out
this bolt.
※
(9)
(12)
(21)
(10)
Rear
(19)
(11)
(8)
Fig. 46
ENGINE 35
(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
Valve (7)
Hot plug
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
Pin
Bearing
Lock nut
Idle gear (2)
Sleeve (4)
Thrust collar
Crankshaft
Key
Crank gear
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
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.)
Cap (2)
Bearing (3)
Fig. 54
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
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
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)
Fig. 61
If the measured values exceed the maximum grinding
allowance, the cylinder body must be replaced.
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.
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)
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.
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.
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
Fig. 75
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
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.
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
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
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
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)
Fig. 93
52 ENGINE
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)
mm (in.)
Standard
Rocker Arm Bushing 11.960 – 11.980
Inside Diameter (0.4709 – 0.4717)
mm (in.)
Standard Limit
Rocker Arm Bushing
0.005 – 0.045 0.2
and Rocker Arm
(0.0002 – 0.0018) (0.0079)
Shaft Clearance
Fig. 98
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)
Fig. 100
54 ENGINE
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)
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
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) —
Fig. 106
ENGINE 57
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
Fig. 111
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the
ring gear must be replaced.
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
Valve (2)
Hot plug
Fig. 116
Important Operations
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
Painted potion
Fig. 119
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)
Piston (1)
Bush (2)
Piston pin (3)
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.
Front mark
Engine
front
direction
Isuzu mark
Cylinder
number
stamped side
Fig. 125
62 ENGINE
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
(2) (9)
(13)
※
(10)
(1)
(12)
(3)
(11)
(14)
Fig. 128
ENGINE 65
(8)
(19)
(20)
(18)
(17) (4)
(5)
(15)
(20)
(6)
(7)
(16)
Fig. 129
66 ENGINE
(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.
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.
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.
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
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
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
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.
Fig. 152
ENGINE 73
Push rod
Install the push rods.
Fig. 154
Oil gallery
Fig. 155
74 ENGINE
Front hanger
Fig. 156
ENGINE 75
(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
(10) (11)
(17)
(12)
(16)
(9)
(16) (13)
(14)
Fig. 158
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.)
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
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
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
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)
Fig. 170
80 ENGINE
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.)
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
Valve
opening
pressure Rocker arm
Crankshaft Timing gear
4.5kg/cm2 bracket
(64.0 PSI)
Rocker arm
Oil pump
Injection pump
Strainer Piston
Piston
pin boss
Oil pan
Fig. 179
LUBRICATING SYSTEM 85
OIL PUMP
Roter; inner
O-ring (common)
Fig. 180
SECTION 4
COOLING SYSTEM
TABLE OF CONTENTS
CONTENTS PAGE
Cylinder block
Water pump ( bypass circuit)
Radiator
Fig. 181
COOLING SYSTEM 89
WATER PUMP
DISASSEMBLY
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)
THERMOSTAT
Inspection and replacement
Replace the thermostat when there is wear, damages or
any other defects found.
Wooden piece
Fig. 188
MEMO
FUEL SYSTEM 93
SECTION 5
FUEL SYSTEM
TABLE OF CONTENTS
CONTENTS PAGE
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.
A Governor shaft
Link plate
Set spring
Control link
Governor cover
Injection pump
Guide lever
Main spring lever
Floating lever
B Tensioner lever
Camshaft
Angleich
Flyweight
Shifter
Fig. 190
96 FUEL SYSTEM
Start spring
Control link
Set spring
Snap pin
Guide lever
Floating lever
Link plate
A
Cap nut Guide piece
Shifter
Setscrew
Shaft (floating)
O-ring Tensioner
lever
Lever;
Bracket; start spring main spring
Idle spring
Sleeve
Lever bush B
Fig. 191
FUEL SYSTEM 97
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
Control lever
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
[Stop] [Operate]
Governor cover
22° 22°
Return spring
(Bent-up part) Governor
Thrust
washer Z
Fig. 195
mm (in.)
(When assembling temporarily)
“A” dimension
Governor 2 – 3 (0.0787 – 0.0118)
lever
Tensioner lever
Washer
Idle spring
Washer
Snap ring
Fig. 196
FUEL SYSTEM 101
Nut; setscrew
Fig. 197
102 FUEL SYSTEM
Set spring
Guide piece
Start spring
Guide lever
Snap pin
Plug
Floating lever
Shaft;
floatong lever
Fig. 198
Injection pipe
Leak off pipe
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
Starter does not run Starter runs but does Engine starts but
not start does not run
continuously.
Check battery
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 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
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)
Uneven OK
Defective OK
(Adjust)
(Repair or
replace)
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
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
Check nozzle
Check valve
clearance and
Defective OK cam lift
(Repair or
replace)
Abnormal OK
(Adjust or
Check injection
replace)
timing
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
Check if fuel used is of Check fuel for water Check nozzle Air cleaner clogged
inferior quality mixing
Check if engine oil is too Check injection timing Check air hose for crash
much Check injection timing
Over-discharge of battery
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
Low
Recharging
Recharge impossible
Oil pressure too low Oil consumption too much Oil consumption too much
Check oil level Check for oil leakage Check for oil leakage
High OK
(See “Overheat”) Defective OK Poor quality OK
(Repair or replace) (Change to specified oil)
Engine knocking
Low OK Defective OK
(Repair or replace)
To fuel system
Note: Fuel used is of poor quality.
SECTION 7
SPECIAL TOOLS
The alphanumeric codes in parentheses “( )” are part numbers assigned by special tool manufacturers.
No. Illustration Part Number Part Name Page
5-8840-9016-0
3. Nozzle tester 24
(J-28829)
5-8840-9015-0
4. Oil filter wrench —
(JKM-9004)
5-8840-9018-0
7. Piston ring compressor —
(J-8037)
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
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
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
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
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
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
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
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
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
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
TABLE OF CONTENTS
ITEM PAGE
1
GENERAL INFORMATION
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.
16
17 The "* Repair Kit" indicates that a repair
kit is available.
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
8. The following symbols appear throughout this Workshop Manual. They tell you the type of service
operation or step to perform.
4
GENERAL INFORMATION
5
GENERAL INFORMATION
Engine Model
4JG2
Item
Specifications marked with an asterisk (*) will vary according to engine application.
6
GENERAL INFORMATION
Bolt No mark
Diameter ×
pitch (mm)
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
A bolt with an asterisk (*) is used for female screws of soft material such as cast iron.
8
GENERAL INFORMATION
Snug torque
A B
9
GENERAL INFORMATION
A B C D
Coinciding line G
B
F
10
GENERAL INFORMATION
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)
4.5 – 5.5
60 – 75° 60 – 75°
(33 – 40/44 – 54)
Apply engine oil to thread portion
11
GENERAL INFORMATION
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
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)
(PKL)
1.0 – 1.5
(7 – 11/10 – 15) 9.5– 11.5
(69 – 83/93 – 113)
13
GENERAL INFORMATION
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
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
(10 – 17/14 – 24)
6.7 – 8.7
(49 – 63/66 – 86)
16
GENERAL INFORMATION
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
MODEL IDENTIFICATION
LUBRICATING SYSTEM
20
MAINTENANCE
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.
21
MAINTENANCE
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)
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)
1 Thermostat
2 Agitating Rod
3 Wooden Piece
24
MAINTENANCE
25
MAINTENANCE
INJECTION TIMING
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
27
MAINTENANCE
RECOMMENDED LUBRICANTS
ENGINE TYPE TYPES OF LUBRICANTS
Diesel engine oil
Without turbocharger
CC or CD grade
[Single grade]
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 20, 20W ;;;;;;;;;;;;;;;;;;;;
SAE 40, 50
;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
SAE 10W
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; SAE 30
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;
28
MAINTENANCE
3
19
2
17
18
19
20
14
15 10 5
13
12 11
1 6
7
9
8
16
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 )
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.
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 )
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
36
ENGINE ASSEMBLY ( 1 )
37
ENGINE ASSEMBLY ( 1 )
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
38
ENGINE ASSEMBLY ( 1 )
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 )
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
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
44
ENGINE ASSEMBLY ( 1 )
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
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.
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 )
3
2
1
Disassembly Steps
▲ 1. Camshaft timing gear 3. Feather key
▲ 2. Thrust plate 4. Camshaft
47
ENGINE ASSEMBLY ( 1 )
Important Operations
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
49
ENGINE ASSEMBLY ( 2 )
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.
Note:
If the cylinder head lower face is reground, valve
depression must be checked.
50
ENGINE ASSEMBLY ( 2 )
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)
51
ENGINE ASSEMBLY ( 2 )
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.
52
ENGINE ASSEMBLY ( 2 )
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.
53
ENGINE ASSEMBLY ( 2 )
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)
55
ENGINE ASSEMBLY ( 2 )
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.
Note:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
56
ENGINE ASSEMBLY ( 2 )
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)
57
ENGINE ASSEMBLY ( 2 )
58
ENGINE ASSEMBLY ( 2 )
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.
59
ENGINE ASSEMBLY ( 2 )
60
ENGINE ASSEMBLY ( 2 )
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 )
1
2
62
ENGINE ASSEMBLY ( 2 )
WARNING:
DRY ICE MUST BE USED WITH GREAT CARE. CARE-
LESS HANDLING OF DRY ICE CAN RESULT IN SEVERE
FROSTBITE.
63
ENGINE ASSEMBLY ( 2 )
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.
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 )
65
ENGINE ASSEMBLY ( 2 )
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.
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)
67
ENGINE ASSEMBLY ( 2 )
68
ENGINE ASSEMBLY ( 2 )
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.
70
ENGINE ASSEMBLY ( 2 )
71
ENGINE ASSEMBLY ( 2 )
72
ENGINE ASSEMBLY ( 2 )
73
ENGINE ASSEMBLY ( 2 )
74
ENGINE ASSEMBLY ( 2 )
75
ENGINE ASSEMBLY ( 2 )
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.
76
ENGINE ASSEMBLY ( 2 )
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 )
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)
79
ENGINE ASSEMBLY ( 2 )
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 )
81
ENGINE ASSEMBLY ( 2 )
82
ENGINE ASSEMBLY ( 2 )
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
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
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 )
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.
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.
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.
92
ENGINE ASSEMBLY ( 3 )
2
3
4
Reassembly Steps
1. Camshaft 3. Thrust plate
2. Feather key ▲ 4. Camshaft timing gear
93
ENGINE ASSEMBLY ( 3 )
Important Operations
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 )
98
ENGINE ASSEMBLY ( 3 )
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.
99
ENGINE ASSEMBLY ( 3 )
1 2 3 4 5
100
ENGINE ASSEMBLY ( 3 )
1
1
101
ENGINE ASSEMBLY ( 3 )
102
ENGINE ASSEMBLY ( 3 )
Note:
Take care not to damage the O-rings when tightening
the oil pipe bolts.
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)
2
7
3
104
ENGINE ASSEMBLY ( 3 )
105
ENGINE ASSEMBLY ( 3 )
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.
107
ENGINE ASSEMBLY ( 3 )
108
ENGINE ASSEMBLY ( 3 )
1
2
7 4
5
16
10
9
12
14
11
13
15
F06E100046
109
ENGINE ASSEMBLY ( 3 )
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)
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
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 )
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
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
013E100005
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 )
1. Intake Manifold
Install the intake manifold gasket with the end hav-
ing the sharp corners facing the front of the engine.
114
ENGINE ASSEMBLY ( 3 )
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)
115
ENGINE ASSEMBLY ( 3 )
116
LUBRICATING SYSTEM
SECTION 6
LUBRICATING SYSTEM
TABLE OF CONTENTS
ITEM PAGE
117
LUBRICATING SYSTEM
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
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 strainer
Oil pan
119
LUBRICATING SYSTEM
OIL PUMP
120
LUBRICATING SYSTEM
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
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis-
covered during inspection.
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
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
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)
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
129
COOLING SYSTEM
Item
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
134
COOLING SYSTEM
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.
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
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.
1 Thermostat
2 Agitating Rod
3 Wooden Piece
138
FUEL SYSTEM
SECTION 8
FUEL SYSTEM
TABLE OF CONTENTS
ITEM PAGE
139
FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW
Fuel cut
solenoid
Injection nozzle
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
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
;À@;À@;À@
041ET003 041ET004
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
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
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is
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)
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
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)
148
FUEL SYSTEM
1 6 ± 4°
°
35.5±5 Full-speed
Idling
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
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)
Number of poles 4
Brush length
Standard mm(in.) 16.5 (0.65)
Limit mm(in.) 13.0 (0.51)
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.
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
14. Retainer
15. Clutch Roller
Remove the retainer and clutch roller from the
starter housing.
157
ENGINE ELECTRICALS
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.
158
ENGINE ELECTRICALS
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.
160
ENGINE ELECTRICALS
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
3. Clutch Roller
4. Retainer
Apply a coat of engine oil to the clutch roller and the
retainer.
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.
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
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
Brush length
Standard mm(in.) 14.5 (0.57)
Limit mm(in.) 7.5 (0.30)
Shaft diameter
Front mm(in.) 15.0 (0.59)
Rear mm(in.) 12.0 (0.47)
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
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
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
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is dis-
covered during inspection.
Ball Bearing
Check that the ball bearings rotate smoothly.
If the ball bearings are noisy, they must be replaced.
170
ENGINE ELECTRICALS
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
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
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)
BRUSH
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
176
TROUBLESHOOTING
SECTION 10
TROUBLESHOOTING
TABLE OF CONTENTS
ITEM PAGE
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
NG NG
Neutral switch (If so equipped) Defective neutral switch Replace the neutral switch
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
OK
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
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
OK
180
TROUBLESHOOTING
1. HARD STARTING
3. ENGINE TURNS OVER BUT DOES NOT START
NG Defective fuel cut solenoid valve NG Replace the fuel cut solenoid
(VE pump) valve
NG NG
Fuel Fuel tank is empty Fill the fuel tank
OK
OK
NG Fuel filter overflow valve does NG Repair or replace the fuel filter
Fuel filter
not close overflow valve
OK
NG NG
Fuel system Air in the fuel system Bleed the air from the fuel system
181
TROUBLESHOOTING
1. HARD STARTING
3. ENGINE TURNS OVER BUT DOES NOT START
FUEL IS BEING DELIVERED TO THE INJECTION PUMP
OK
OK
182
TROUBLESHOOTING
2. UNSTABLE IDLING
NG NG
Idling system Idling improperly adjusted Adjust the idling
OK
OK
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
183
TROUBLESHOOTING
2. UNSTABLE IDLING
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 NG
Worn cam disc (VE pump only) Replace the cam disc
184
TROUBLESHOOTING
2. UNSTABLE IDLING
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
OK
NG NG
Fuel Water particles in the fuel Replace the fuel
OK
OK
OK
NG NG
Injection nozzle Injection nozzle sticking Replace the injection nozzle
OK
186
TROUBLESHOOTING
3. INSUFFICIENT POWER
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
Weak governor spring Replace the governor spring
187
TROUBLESHOOTING
3. INSUFFICIENT POWER
NG NG
Injection pump Worn plunger Replace the plunger assembly
NG NG
Worn camshaft (In-line pump only) Replace the camshaft
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
OK
NG NG
Valve spring Valve spring weak or broken Replace the valve spring
188
TROUBLESHOOTING
3. INSUFFICIENT POWER
NG NG
Exhaust system Exhaust pipe clogged Clean the exhaust pipe
OK
189
TROUBLESHOOTING
OK
OK
NG NG
Idling speed Poorly adjusted idling speed Adjust the idling speed
OK
OK
OK
OK
190
TROUBLESHOOTING
OK
NG NG
Valve spring Valve spring weak or broken Replace the valve spring
191
TROUBLESHOOTING
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
OK
OK
192
TROUBLESHOOTING
6. OVERHEATING
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
OK
OK
NG NG
Water pump Defective water pump Repair or replace the water pump
OK
OK
NG NG
Thermostat Defective thermostat Replace the thermostat
193
TROUBLESHOOTING
6. OVERHEATING
OK
194
TROUBLESHOOTING
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
OK
OK
195
TROUBLESHOOTING
OK
OK
OK
NG NG
Excessive injection volume Adjust the injection volume
196
TROUBLESHOOTING
OK
OK
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
OK
NG NG
Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing
197
TROUBLESHOOTING
OK
198
TROUBLESHOOTING
NG NG
Fuel Fuel unsuitable Replace the fuel
OK
OK
OK
OK
199
TROUBLESHOOTING
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
OK
OK
200
TROUBLESHOOTING
OK
NG NG
Rocker arm Damaged rocker arm Replace the rocker arm
OK
NG NG
Flywheel Loose flywheel bolts Retighten the flywheel bolts
OK
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
201
TROUBLESHOOTING
MEMO
202
SPECIAL TOOL LIST
SECTION 11
203
SPECIAL TOOL LIST
44
3 9-8523-1423-0 Valve Spring Compressor
89
67
6 5-8840-2038-0 Camshaft Bearing Replacer
68
204
SPECIAL TOOL LIST
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
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
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
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
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
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
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
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
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
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)
CONTENTS
TIGHTENING TORQUE
ET-2
TROUBLE DIAGNOSES AND CORRECTIONS
CANNOT CRANK
ENGINE OR SLOW
CRANKING
ET-3
TROUBLE DIAGNOSES AND CORRECTIONS
ET-4
TROUBLE DIAGNOSES AND CORRECTIONS
IMPROPER ENGINE
IDLING
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
WARNING
RETIGHTENING MANIFOLD
NUTS
ET-9
ENGINE TUNE-UP
WARNING
CHECKING ENGINE
COMPRESSION PRESSURE
ET-10
ENGINE TUNE-UP
CHECKING CARBURETOR
IGNITION AND FUEL
SYSTEM
CLEANING OR REPLACING AIR
CLEANING FILTER
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
ET-13
ENGINE TUNE-UP
ET-14
ENGINE TUNE-UP
ET-15
ENGINE TUNE-UP
ET-16
ENGINE TUNE-UP
ET-17
SPECIAL SERVICE TOOL
ET-18
ET-19
ENGINE FUEL
(EF)
CONTENTS
CARBURETOR
GOVERNOR
EF-2
TROUBLE DIAGNOSES AND CORRECTIONS
EF-3
TROUBLE DIAGNOSES AND CORRECTIONS
AUTO-CHOKE MECHANISM
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
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)
CONTENTS
GENERAL SPECIFICATIONS
TIGHTENING TORQUE
TIGHTENING TORQUE
LC-2
TROUBLE DIAGNOSES AND CORRECTIONS
LC-3
TROUBLE DIAGNOSES AND CORRECTIONS
LC-4
ENGINE LUBRICATION SYSTEM
Oil pan
Oil strainer
Oil pump
Oil filter
LC-5
ENGINE LUBRICATION SYSTEM
OIL PUMP
REMOVAL
INSPECTION
INSTALLATION
LC-6
ENGINE LUBRICATION SYSTEM
LC-7
ENGINE COOLING SYSTEM
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)
CONTENTS
STARTER MOTOR
EE-2
SERVICE DATA AND SPECIFICATIONS
DISTRIBUTOR
SPARK PLUG
EE-3
BATTERY
BATTERY
WARNING
CHECKING SPECIFIC GRAVITY
EE-4
BATTERY
WARNING
EE-5
STARTING SYSTEM
STARTING SYSTEM
WARNING
WIRING DIAGRAM
EE-6
STARTING SYSTEM
EE-7
STARTING SYSTEM
STARTER MOTOR
REDUCTION GEAR TYPE
EE-8
STARTING SYSTEM
INSPECTION
EE-9
STARTING SYSTEM
ASSEMBLY
EE-10
STARTING SYSTEM
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)
CONTENTS
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
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
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
CYLINDER BLOCK
EM-14
INSPECTION AND REPAIR
EM-15
INSPECTION AND REPAIR
PISTON PIN
PISTON RINGS
CONNECTING RODS
EM-16
INSPECTION AND REPAIR
EM-17
INSPECTION AND REPAIR
CRANKSHAFT
INSPECTION
EM-18
INSPECTION AND REPAIR
EM-19
INSPECTION AND REPAIR
VALVE TIMING
CAM BUSHING
EM-20
INSPECTION AND REPAIR
PUSH RODS
TIMING SPROCKET
ROCKER SHAFT
VALVE ROCKER MECHANISM
VALVE LIFTERS
EM-21
INSPECTION AND REPAIR / ENGINE ASSEMBLY
MEASURING RUNOUT
ENGINE ASSEMBLY
PRECAUTIONS
PISTON AND CONNECTING RODS
ASSEMBLY
EM-22
ENGINE ASSEMBLY
ASSEMBLING OF ENGINE
EM-23
ENGINE ASSEMBLY
INSTALLING CRANKSHAFT
INSTALLING REAR OIL SEAL RETAINER
INSTALLING PISTONS
EM-24
ENGINE ASSEMBLY
INSTALLING CAMSHAFT
INSTALLING TIMING CHAIN TENSIONER
EM-25
ENGINE ASSEMBLY
EM-26
ENGINE ASSEMBLY
OTHER PARTS
INSTALLING DISTRIBUTOR
EM-27
ENGINE ASSEMBLY
EM-28
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
1 – DIAGRAM
Valve
Gas
inlet
Gas
outlet
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
6
5. Remove valve spring.
7
9. Cutaway shows assembly of valve spring, valve
seat, valve operating pin, seal retaining washer and
"O" ring seal.
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).
9
17. Place the body with the filter side up, as shown in
the photo, on a flat surface.
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.
11
25. Valve seat shown with aluminium side up ready to
be placed on jet.
12
29. With spring in place, lift it slightly to assure free-
dom of travel.
13
33. With 2 opposite screws in "Fuel In" cover, lower
cover on to gasket and start two screws in their
threads.
14
37. Remove cover and diaphragm assy.
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
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.
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
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.
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.
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.
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.
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.
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
Replace filter X X X X
GENERAL MAINTENANCE
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
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
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.
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
10
5 – TECHNICAL SHEET
- 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
11
12
LPG CARBURETION SYSTEM
12-8-20 EN
23 / 03 / 2006
2
TABLE OF CONTENTS
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
5
3 - MACHINE COMPONENT LAYOUT
C13 Bottle
(13kg of gas)
Carburettor
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)
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
///////
!
PERICOLO! Non eseguire mai alcun intervento di pulizia, lubrificazione o manutenzione con
il motore in moto.
NORME DI SICUREZZA
GENERALITÀ
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.
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.
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.
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
///////
!
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.
SAFETY RULES
GENERAL
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
\\\\\\\\ !
! 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
///////
!
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
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.
! 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.
xiv
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.
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.
NORMES DE SURETE
GENERALITES
Ne pas actionner la machine ou utiliser les relatifs outils d’une position différente de la
! place du conducteur.
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.
! Ne jamais verser d’essence ou gaz-oil dans des récipients ouverts, amples et bas.
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.
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
1
TXL 15/25
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
3
TXL 15/25
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
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).
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.
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
TXL 15/25
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
F H
Dx Sx
Rh Lh
A
K
11
TXL 15/25
L B C
MAIN
MOD
G
S D M N D
12
TXL 15/25
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
TXL 15/25
Sezione generale
General section
Allgemeine Hinweise
Section générale
1
3 4 8
5 6 7
13 9 13
15
TXL 15/25
16
TXL 15/25
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
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
TXL 15/25
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
TXL 15/25
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
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
20
TXL 15/25
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
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
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
23
TXL 15/25
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
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
25
TXL 15/25
26
TXL 15/25
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
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.
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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:
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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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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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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.
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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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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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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
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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.
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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
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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.
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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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.
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.
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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.
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.
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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
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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 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.
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
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TEMPERATURBEDINGUNGEN
ßei Längerer Lagerung des Produktes, muß sichergestellt sein, daß keine Beschädigung auf-
!
getreten ist.
! Beim Abstellen und vor dem Verlassen des Fahrzeuges ist die Parkbremse zu betätigen.
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.
! 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
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44
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1 2 3A 3B 4
3
5
4902403/1
4A42440/1
6 7 8A 8B 9 10
45
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12 13
48A12093 48A12125
11
3VT00293
46
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! 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.
47
TXL 15/25
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.
48
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2
INCHING IDRAULICO INCHING MECCANICO
HYDRAULIC INCHING MECHANICAL INCHING
3 HYDRAULISCHES INCHING MECHANISCHES INCHING
INCHING HYDRAULIQUE INCHING MECANIQUE
49
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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
50
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51
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14
GB Assembly of Inching:
insert the adjusting shims and spring on the Inching
piston, then fit this fully into its own seating.
54
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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.
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).
55
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56
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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
57
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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.
58
TXL 15/25
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.
28
59
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60
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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
61
TXL 15/25
62
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34
63
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36
64
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65
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44
66
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67
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50
51
68
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69
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55
70
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71
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60
61
72
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! 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.
63
73
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74
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! 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 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
71
76
TXL 15/25
c fig. 73a
b
77
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78
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79
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80
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81
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82
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81
84
83
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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.
84
TXL 15/25
D Montage Achsbefestigungsflansch
Dichtring entfernen.
85
TXL 15/25
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.
86
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87
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88
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Einbau Bremstrommel
Rémontage des moyeux des roues
3
Vorschriften für Lagermontage
b
D
89
TXL 15/25
I Rimontaggio semiassi
Infilare il semiasse facendo attenzione a non dan-
neggiare l’anello di tenuta, come indicato.
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.
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.
91
TXL 15/25
103
105 105a
92
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108
93
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94
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114
95
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117
118
96
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120
97
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123
124
98
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125
99
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128
! 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
100
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101
TXL 15/25
102
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103
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! 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
104
TXL 15/25
105
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Rimontaggio trasmissione
Reassebling transmission
Getriebe Montage
Remontage de la transmission
106
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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.
3
I
letti medio; avvitare e bloccare alla coppia di
4,8 ÷ 5,2 daNm.
109
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155
156
110
TXL 15/25
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
111
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112
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162
113
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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
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169
170
117
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118
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119
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I Contatto errato
177 La distanza del pignone dal centro corona deve
essere diminuita.
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
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
179
121
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182
122
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123
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184
185
124
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125
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126
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127
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193
128
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129
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201
130
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131
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205
210a
133
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134
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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
211a
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D Filter einbauen.
212
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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.
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.
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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)
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.
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).
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1 1.5
4
3
4
3
Zetrierung
Trou
Welle
Arbre
Ø30 +0,022
+0,043
Ø29 g8
Albero
Shaft
Foro
Hole
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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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2 mm QUOTA MINIMA
MIN DIMENSION
MINDESTABSTAND
PART MINIMUM
16.5 ± 0.5
D
B
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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
F / F / K / F max - 12 +2
0 Kg
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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.
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
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.
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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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
F
F / F / K / F max - 13 +20 Kg
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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.
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.
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.
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.
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.
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REGELMÄßIGE WARTUNG
ENTRETIEN PERIODIQUE
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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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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. 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.
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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
2. Perdite tra l’esterno della guar- - Sede danneggiata Applicare sigillante sul diam. ester-
nizione e la sua sede no della guarnizione sostituendola.
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
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
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
5. Nicht leicht zu lokalisierende - Ölleckage vom Kühler oder vom Fehlerhaften Kühler oder defekte
Ölleckagen am Getriebe Ölkühlkreislauf Teile des Kreislaufs ersetzen.
3. Fuites aux joints de jonction au - Desserage des vis de jonction Bien serrer les vis.
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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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.
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
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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.
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.
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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.
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.
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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.
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
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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
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
3. Fahrzeug bewegt sich nicht - Niedriger Druck Siehe “Zu niedriger Öldruck”
oder nur wenig - Geborchene oder verschlissene Defekte Teile austauschen.
Dichtringe
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.
2. Noises in Forward and Reverse - Broken, cracked or worn gear Replace the damaged parts
Gear teeth
- Worn or damaged bearings Replace.
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
162
TXL 15/25
163
TXL 15/25
Getriebeüberhitzung
Surcharge de la transmission
164
TXL 15/25
165
TXL 15/25
Ø 82
Ø 68
27
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
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
3°
12
12
3°
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
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
6.3
b
a
c
ALBERI h13
QUOTE LINEARI J/j13
E'vietato riprodurre o comunicare a terzi il
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
b
c
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
Ø 40
Ø 79
01 4902058/1
Ø 125
b
c
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
b
c
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
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
175
TXL 15/25
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.
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
vi
TXL 30/ST
INHALTSVERZEICHNIS D
///
! SICHERHEITS VORSCHRIFTEN................................................................................................................................................. xiii
vii
TXL 30/ST
F INDEX
///
! NORMES DE SURETE...................................................................................................................................................................... xv
I NORME DI SICUREZZA
//////
!
PERICOLO! Non eseguire mai alcun intervento di pulizia, lubrificazione o manutenzione con il motore
in moto.
NORME DI SICUREZZA
GENERALITÀ
! 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.
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
//////
!
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.
SAFETY RULES
GENERAL
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
\\\\\\\ !
! 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
//////
!
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
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.
! 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.
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.
NORMES DE SURETE
GENERALITES
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.
! 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.
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
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
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
1
TXL 30/ST
TECHNISCHE DATEN
DONNEES TECHNIQUES
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
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).
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).
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.
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.
9
TXL 30/ST
H M G P
D U D
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
E T A
B
Z C
F
E MA
11
TXL 30/ST
14 2
11
3
1 17
4 5 16
13
10 9 8 6 7
12
TXL 30/ST
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
14
TXL 30/ST
15
TXL 30/ST
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
17
TXL 30/ST
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
LUBRIFICAZIONE
LUBRICATION
2.5 bar SCHMIERUNG
11 LUBRIFICATION
CADUTA DI PRESSIONE 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
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
LUBRIFICAZIONE
LUBRICATION
2.5 bar SCHMIERUNG
11 LUBRIFICATION
CADUTA DI PRESSIONE 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
9
Entrata convertitore
Converter inlet
Wandlereingang
2 Entrée convertisseur
Lubrificazione
Lubrication
Schmierung
Graissage
21
TXL 30/ST
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
LUBRIFICAZIONE
LUBRICATION
SCHMIERUNG
2.5 bar LUBRIFICATION
11
CADUTA DI PRESSIONE 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
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
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
LUBRIFICAZIONE
LUBRICATION
SCHMIERUNG
2.5 bar LUBRIFICATION
11
CADUTA DI PRESSIONE 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
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
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.
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
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.
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.
27
TXL 30/ST
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.
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
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
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 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.
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
TEMPERATURBEDINGUNGEN
ßei Längerer Lagerung des Produktes, muß sichergestellt sein, daß keine Beschädigung auf-
! getreten ist.
! Beim Abstellen und vor dem Verlassen des Fahrzeuges ist die Parkbremse zu betätigen.
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.
! 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
32
TXL 30/ST
4902166
4A41377
4 5 6 7
33
TXL 30/ST
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
! 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.
b
b
1a
35
TXL 30/ST
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
D Wandlergetriebegehäuse abziehen.
36
TXL 30/ST
D Deckelbefestigungsschrauben Lagerhalterung
Antriebsrad lockern.
37
TXL 30/ST
38
TXL 30/ST
39
TXL 30/ST
15
40
TXL 30/ST
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
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
42
TXL 30/ST
43
TXL 30/ST
44
TXL 30/ST
GB
Rimuovere e sostituire la guarnizione O-Ring (a).
26
GB
Clean full each component, check them, replace if
required.
27
45
TXL 30/ST
46
TXL 30/ST
34
47
TXL 30/ST
48
TXL 30/ST
GB
Inserire l’anello elastico.
39
40
41
49
TXL 30/ST
! 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.
45
51
TXL 30/ST
48a
52
TXL 30/ST
51
53
TXL 30/ST
! 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.
53
54
TXL 30/ST
55
TXL 30/ST
! 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 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,.
58 58a
56
TXL 30/ST
c
b
d
fig. 62a
58
TXL 30/ST
59
TXL 30/ST
60
TXL 30/ST
69
61
TXL 30/ST
62
TXL 30/ST
63
TXL 30/ST
D Ausbau Radnaben
Sicherungsnase auf der Ringmutter der Radnabe
aufbiegen.
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.
65
TXL 30/ST
77
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
D Montage Achsbefestigungsflansch
Dichtring entfernen.
67
TXL 30/ST
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.
68
TXL 30/ST
0,7 mm
84a
69
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).
71
TXL 30/ST
I Rimontaggio semiassi
Infilare il semiasse facendo attenzione a non dan-
neggiare l’anello di tenuta, come indicato.
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.
72
TXL 30/ST
73
TXL 30/ST
! 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 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.
74
TXL 30/ST
GB
Spiantare la spina elastica di fermo ghiera.
94
96
97
75
TXL 30/ST
76
TXL 30/ST
77
TXL 30/ST
78
TXL 30/ST
I Rimontaggio semiassi
Infilare il semiasse facendo attenzione a non dan-
neggiare l’anello di tenuta (a), come indicato.
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.
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.
81
TXL 30/ST
108
82
TXL 30/ST
114
83
TXL 30/ST
84
TXL 30/ST
85
TXL 30/ST
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.
122
86
TXL 30/ST
87
TXL 30/ST
Revisione frizioni
Clutches overhauling
Ausprüfung der Kupplungen
Révision des embrayages
126
88
TXL 30/ST
127
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
132
90
TXL 30/ST
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
92
TXL 30/ST
140
141
93
TXL 30/ST
142
143
144
94
TXL 30/ST
145
146
95
TXL 30/ST
Revisione Differenziale
Differential overhauling
Ausprüfung der Differential
Révision des Differentiel
96
TXL 30/ST
GB
Togliere i cappelli del supporto differenziale.
151
152
153
97
TXL 30/ST
154
155
156
98
TXL 30/ST
157
159
99
TXL 30/ST
160
161
162
100
TXL 30/ST
164
101
TXL 30/ST
S = 190,5[(149,50±K)+36,6]
A
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
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)
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
170
171a
171b
105
TXL 30/ST
106
TXL 30/ST
107
TXL 30/ST
108
TXL 30/ST
177
109
TXL 30/ST
110
TXL 30/ST
111
TXL 30/ST
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.
112
TXL 30/ST
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.
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.
183
115
TXL 30/ST
187
D Filter einbauen.
188
116
TXL 30/ST
117
TXL 30/ST
118
TXL 30/ST
30 13°
6 1
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
fig. 192
119
TXL 30/ST
TIPO OLIO
4 OIL SPECIFICATIONS
ÖLSPEZIFIKATION
TYPE HUILE
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.
120
TXL 30/ST
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
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
+ 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
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
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
01
2 QUOTA MINIMA
MIN DIMENSION
MINDESTABSTAND
PART MIMINIMUM
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
125
TXL 30/ST
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
F
F / F / K /F = 13 +20 Kg
126
TXL 30/ST
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.
128
TXL 30/ST
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.
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.
129
TXL 30/ST
REGELMÄßIGE WARTUNG
ENTRETIEN PERIODIQUE
130
TXL 30/ST
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).
131
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.
132
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.
133
TXL 30/ST
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).
134
TXL 30/ST
C. Diagnostica
C. Diagnosis
C. Untersuchung
C. Diagnostic
6
I Problemi Cause Rimedi
PERDITE
2. Perdite tra l’esterno della guar- - Sede danneggiata Applicare sigillante sul diam. ester-
nizione e la sua sede no della guarnizione sostituendola.
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
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
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.
135
TXL 30/ST
C. Diagnostica
C. Inspection
C. Untersuchung
C. Diagnostic
5. Nicht leicht zu lokalisierende - Ölleckage vom Kühler oder vom Fehlerhaften Kühler oder defekte
Ölleckagen am Getriebe Ölkühlkreislauf Teile des Kreislaufs ersetzen.
3. Fuites aux joints de jonction au - Desserage des vis de jonction Bien serrer les vis.
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
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.
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
137
TXL 30/ST
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.
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.
138
TXL 30/ST
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.
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.
139
TXL 30/ST
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.
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
140
TXL 30/ST
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
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
3. Fahrzeug bewegt sich nicht - Niedriger Druck Siehe “Zu niedriger Öldruck”
oder nur wenig - Geborchene oder verschlissene Defekte Teile austauschen.
Dichtringe
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.
2. Noises in Forward and Reverse - Broken, cracked or worn gear Replace the damaged parts
Gear teeth
- Worn or damaged bearings Replace.
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
144
TXL 30/ST
145
TXL 30/ST
Getriebeüberhitzung
Surcharge de la transmission
146
TXL 30/ST
147
TXL 30/ST
∅ 8 x 130
Acciaccare
Notch
Sichem
∅ 22 x 250
Saldature 3x3
Weldings
Schweinßnaht
Soudures
01
02
Scala : 1:2.5
148
TXL 30/ST
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
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
3
N
Scala : 1:2
Attrezzo / Tool / Werkzeug / Outil 48A17092/00
150
TXL 30/ST
∅ 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
∅ 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
3
N
152
TXL 30/ST
∅ 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
∅ 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
154
18/09/03
155
Saldare elettricamente
b 30
7 a
48°
48°
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
R 10
Ø 50 ZIGRINATO
82 (Tratto zigrinato)
181
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
0.8
5
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
156
48A19120/2 cmt/tmp HRC60`2 18/09/03
157
∅ 110
∅ 50
Proteggere dalla cmt
R 10
26
6
R 10
21.5`0.05
6.3 0.8
0.8
42.5
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
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
158
TXL 30/ST
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
P Hydraulic pump
PD Steering pump
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
3
INSTRUMENT DIAGRAM
X4 CONNECTOR
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
LN2.5
M4
RB
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
COLOUR CODING
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
COLOUR CODING
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